Yamaha WR450F User Manual

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Page 1

2008

OWNER’S SERVICE MANUAL

MANUEL D’ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGSHANDBUCH

MANUAL DE SERVICIO

DEL PROPIETARIO

WR450F

5TJ-28199-45

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Page 3

WR450F

5TJ-28199-45-E0

2008

OWNER’S SERVICE MANUAL

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Page 5

WR450F

OWNER'S SERVICE MANUAL

1st Edition, October 2007

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan

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FOREWORD

INTRODUCTION

Congratulations on your purchase of a Yamaha WR 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.

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.

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

A NOTE provides key information to make procedures easier or clearer.

IMPORTANT NOTICE

THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may be illegal. Please check local regulations before riding.

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.

5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.

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

7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE 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.

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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.

TO THE NEW OWNER

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.

This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

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.

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.

HOW TO USE THIS MANUAL

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Tuning", "Engine", "Chassis" and "Electrical".

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.

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, stepby-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

•Bearings

Pitting/damage → Replace.

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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 or-

der 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. For jobs requiring more information, the step-by-step format supplements "5" are given in addition to the exploded diagram and job instruction chart.

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols "1" to "7" are used to identify the specifications appearing in the text.

1. With engine mounted

2. Filling fluid

3. Lubricant

4. Special tool

5. Tightening

6. Specified value, Service limit

7. Resistance (Ω), Voltage (V),

Electric current (A) Illustrated symbols "8" to "13" in the exploded diagrams indicate grade of lubricant and location of lubrication point.

8. Apply engine oil

9. Apply molybdenum disulfide oil

10. Apply brake fluid

11. Apply lightweight lithium-soap

base grease

12. Apply molybdenum disulfide

grease

13. Apply silicone grease Illustrated symbols "14" to "15" in the exploded diagrams indicate where to apply a locking agent and where to install new parts.

14. Apply locking agent (LOC-

15. Use new one

TITE

)

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TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

REGULAR INSPECTION AND ADJUSTMENTS

TUNING

ENGINE

CHASSIS

ELECTRICAL

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CONTENTS

CHAPTER 1

GENERAL INFOR-

MATION

DESCRIPTION ................. 1-1

MACHINE

IDENTIFICATION ............. 1-2

INCLUDED PARTS .......... 1-2

IMPORTANT

INFORMATION................. 1-2

CHECKING OF CONNEC-

TION ................................. 1-3

SPECIAL TOOLS............. 1-4

CONTROL FUNCTIONS .. 1-8 MULTI-FUNCTION

DISPLAY ..........................1-9

STARTING AND

BREAK-IN ......................1-14

TORQUE-CHECK

POINTS........................... 1-16

CLEANING AND

STORAGE ...................... 1-17

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICA-

TIONS............................... 2-1

MAINTENANCE

SPECIFICATIONS............ 2-4

TIGHTENING

TORQUES ...................... 2-13

LUBRICATION

DIAGRAMS .................... 2-19

CABLE ROUTING

DIAGRAM....................... 2-21

CHAPTER 3

REGULAR INSPEC-

TION AND AD-

JUSTMENTS

MAINTENANCE

INTERVALS......................3-1

PRE-OPERATION INSPECTION AND

MAINTENANCE................ 3-5

ENGINE ............................3-6

CHASSIS ........................3-17

ELECTRICAL .................3-27

CHAPTER 4

TUNING

ENGINE ............................4-1

CHASSIS ..........................4-5

CHAPTER 5

ENGINE

RADIATOR .......................5-1

CARBURETOR................. 5-4

AIR INDICTOIN

SYSTEM .........................5-13

CAMSHAFTS..................5-15

CYLINDER HEAD...........5-20

VALVES AND VALVE

SPRINGS ........................5-23

CYLINDER AND

PISTON...........................5-27

CLUTCH .........................5-30

OIL FILTER ELEMENT

AND WATER PUMP.......5-34

BALANCER ....................5-38

OIL PUMP.......................5-40

KICK SHAFT AND SHIFT

SHAFT ............................5-43

AC MAGNETO AND

STARTER CLUTCH .......5-48

ENGINE REMOVAL .......5-53

CRANKCASE AND

CRANKSHAFT ...............5-57

TRANSMISSION, SHIFT CAM AND SHIFT

FORK ..............................5-63

CHAPTER 6

CHASSIS

FRONT WHEEL AND

REAR WHEEL ..................6-1

FRONT BRAKE AND

REAR BRAKE ..................6-6

FRONT FORK.................6-16

HANDLEBAR..................6-23

STEERING ......................6-27

SWINGARM ....................6-31

REAR SHOCK

ABSORBER....................6-36

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS AND WIRING DIA-

GRAM ...............................7-1

IGNITION SYSTEM...........7-3

ELECTRIC STARTING

SYSTEM............................7-5

CHARGING SYSTEM .....7-13

THROTTLE POSITION

SENSOR SYSTEM .........7-15

LIGHTING SYSTEM .......7-18

SIGNALING SYSTEM.....7-20

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GENERAL INFORMATION

DESCRIPTION

1. Clutch lever

2. Hot starter lever

3. Engine stop switch

4. Multi-function display

5. Main switch

6. Start switch

7. Front brake lever

8. Throttle grip

9. Radiator cap

10. Fuel tank cap

11. Taillight

12. Kickstarter crank

13. Fuel tank

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

• Designs and specifications are subject to change without notice.

14. Headlight

15. Radiator

16. Coolant drain bolt

17. Rear brake pedal

18. Valve joint

19. Fuel cock

20. Cold starter knob

21. Air cleaner

22. Catch tank

23. Drive chain

24. Shift pedal

25. Oil dipstick

26. Front fork

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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.

VEHICLE IDENTIFICATION NUMBER

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

MACHINE IDENTIFICATION

SPARK PLUG WRENCH

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

2. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" section.

NIPPLE WRENCH

This nipple wrench "1" is used to tighten the spoke.

ENGINE SERIAL NUMBER

The engine serial number "1" is stamped into the elevated part of the right-side of the engine.

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.

INCLUDED PARTS

VALVE JOINT

This valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hose.

In this installation, make sure the arrow faces the fuel tank and also downward.

JET NEEDLE PULL-UP TOOL

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

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly.

• When washing the machine with high pressured water, cover the parts follows. Silencer exhaust port Side cover air intake port Water pump housing hole at the bottom Drain hole on the cylinder head (right side) All electrical components

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.

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CHECKING OF CONNECTION

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.

GASKETS, OIL SEALS AND ORINGS

1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

LOCK WASHERS/PLATES AND COTTER PINS

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.

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 lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

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.

CHECKING OF CONNECTION

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

1. Disconnect:

• Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two or three times.

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

5. If the terminal comes off, bend up the pin "1" and reinsert the terminal into the connector.

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.

6. Connect:

• Connector

The two connectors "click" together.

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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.

• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".

• For others, use part number starting with "90890-".

Tool name/Part number How to use Illustration

Dial gauge and stand YU-3097, 90890-01252 Stand YU-1256

These tools are used to check each part for runout or bent.

Crankshaft installing tool Crankshaft installing pot YU-90050, 90890-01274 Crankshaft installing bolt YU-90050, 90890-01275 Spacer (crankshaft installer) YM-91044, 90890-04081 Adapter (M12) YU-90063, 90890-01278

Piston pin puller set YU-1304, 90890-01304

Radiator cap tester YU-24460-01, 90890-01325 Radiator cap tester adapter YU-33984, 90890-01352

These tools are used to install the crankshaft.

This tool is used to remove the piston pin.

These tools are used for checking the cooling system.

Steering nut wrench YU-33975, 90890-01403

This tool is used when tighten the steering ring nut to specification.

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SPECIAL TOOLS

Tool name/Part number How to use Illustration

Damper rod holder YM-01494, 90890-01494

Use this tool to remove and install the damper rod.

Fork seal driver YM-A0948, 90890-01502

Sheave holder YS-1880-A, 90890-01701

Pocket tester YU-3112-C, 90890-03112

This tool is used when install the fork oil seal.

This tool is used for when loosening or tightening the flywheel magneto securing nut.

Use this tool to inspect the coil resistance, output voltage and amperage.

Timing light YM-33277-A, 90890-03141

Valve spring compressor YM-4019, 90890-04019

This tool is necessary for checking ignition timing.

This tool is needed to remove and install the valve assemblies.

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SPECIAL TOOLS

Tool name/Part number How to use Illustration

Clutch holding tool YM-91042, 90890-04086

This tool is used to hold the clutch when removing or installing the clutch boss securing nut.

Valve guide remover Intake 4.5 mm (0.18 in) Exhaust 5.0 mm (0.20 in) YM-4116, 90890-04116 YM-4097, 90890-04097

Valve guide installer Intake 4.5 mm (0.18 in) Exhaust 5.0 mm (0.20 in) YM-4117, 90890-04117 YM-4098, 90890-04098

Valve guide reamer Intake 4.5 mm (0.18 in) Exhaust 5.0 mm (0.20 in) YM-4118, 90890-04118 YM-4099, 90890-04099

Rotor puller YM-4142, 90890-04142

This tool is needed to remove and install the valve guide.

This tool is needed to install the valve guide.

This tool is needed to rebore the new valve guide.

This tool is used to remove the flywheel magneto.

Crankcase separating tool YU-A9642 90890-04152

These tool is used to remove the crankshaft from either case.

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SPECIAL TOOLS

Tool name/Part number How to use Illustration

Dynamic spark tester YM-34487 Ignition checker 90890-06754

This instrument is necessary for checking the ignition system components.

Vacuum/pressure pump gauge set YB-35956-A, 90890-06756

Digital tachometer YU-39951-B, 90890-06760

YAMAHA Bond No. 1215 (ThreeBond® No. 1215) 90890-85505

This tool is used to check the air induction system.

This tool is needed for observing engine rpm.

This sealant (Bond) is used for crankcase mating surface, etc.

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CONTROL FUNCTIONS

MAIN SWITCH

Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off.

Main switch indicator light

The main switch "1" is equipped with an indicator light "2" to avoid forgetting to turn it off. This light functions as follows.

• It lights up with the main switch "ON".

• It goes out when the engine increases its speed after being started.

• It lights up again when the engine is stopped.

If the indicator light will not light up with the main switch "ON", it shows a lack of the battery voltage. Recharge the battery.

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.

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.

FRONT BRAKE LEVER

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

REAR BRAKE PEDAL

The rear brake pedal "1" is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

ENGINE STOP SWITCH

The engine stop switch "1" is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

START SWITCH

The start switch "1" is located on the right handlebar. Push this switch to crank the engine with the starter.

KICKSTARTER CRANK

Rotate the kickstarter crank "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 kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

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.

FUEL COCK

The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has the three 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. RES: With the lever in this position fuel flows to the carburetor from the reserve section of the fuel tank after the main supply of the fuel has been depleted. Normal riding is possible with the lever is in this position, but it is recommended to add fuel as soon as possible.

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COLD STARTER KNOB

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.

HOT STARTER LEVER

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.

MULTI-FUNCTION DISPLAY

Be sure to stop the machine before making any setting changes to the multi-function display.

The multi-function display is equipped with the following: BASIC MODE:

• Speedometer

•Clock

• Two tripmeters (which shows the distance that has been traveled since it was last set to zero)

RACE MODE:

• Timer (which shows the time that has been accumulated since the start of timer measurement)

• Tripmeter (which shows the accumulated travel distance in timer measurement)

• Change tripmeter digits (capable of change to any given ones)

DESCRIPTION Operation buttons:

1. Select button "SLCT 1"

2. Select button "SLCT 2"

3. Reset button "RST"

Screen display:

4. Tripmeter indicator

5. Tripmeter indicator

6. Timer indicator

7. Clock/Timer

8. Speedometer

9. Odometer/Tripmeter

Setting the time

1. Push the "SLCT1" button for 2 seconds or more to enter the time setting mode.

2. Push the "RST" button to change the display for time indication. The display will change in the following order: Hour → Minute → Second → Hour.

The digits capable of setting go on flashing.

3. Push the "SLCT1" button (plus) or "SLCT2" button (minus) and change the time. A long push on the button will fast-forward the time.

SIDESTAND

This sidestand "1" is used to support only the machine when standing or transporting it.

• Never apply additional force to the sidestand.

• Hold up the sidestand before starting out.

The operation buttons can be pushed in the following two manners: Short push: Push the button. ( ) Long push: Push the button for 2 seconds or more. ( )

BASIC MODE Changing speedometer display (for U.K.)

1. Push the "SLCT2" button for 2 seconds or more to change the speedometer units. The speedometer display will change in the following order: MPH → km/h → MPH.

4. To end the setting, push the "RST" button for 2 seconds or more.

• In a 30-second absence of button

operation, the setting will come to an end with the indicated time.

• To reset the seconds, push the

"SLCT1" button or "SLCT2" button.

Changing odometer and tripmeter A/B (TRIP A/B)

1. Push the "SLCT2" button to change the tripmeter display. The display will change in the following order: Odometer → TRIP A → TRIP B → TRIP A → Odometer.

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To reset the digits, select the tripmeter involved and push the "RST" button for 2 seconds or more.

CHANGEOVER TO BASIC MODE/ RACE MODE

MULTI-FUNCTION DISPLAY

Returning to BASIC MODE from RACE MODE

It is possible to return to BASIC MODE with timer measurement at a stop.

1. Check that the timer is not in operation. If the timer is in operation, stop the timer by pushing the "SLCT1" button and "SLCT2" button at the same time.

2. Push the "SLCT1" button and "SLCT2" button for 2 seconds or more at the same time to change over to BASIC MODE.

When the machine is made ready for a run by manual start, and will start flashing.

2. Start timer measurement by pushing the "RST" button.

3. When stopping timer measurement, pushing the "SLCT1" button and "SLCT2" button at the same time.

If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A).

• Measurement using the timer function can be made in RACE MODE.

• Indicator will light up as an identifier that shows RACE MODE has been selected.

• RACE MODE cannot display the functions as in BASIC MODE.

• Changeover to RACE MODE forces the digits for tripmeter A (TRIP A) in BASIC MODE to be reset.

Changeover from BASIC MODE to RACE MODE

1. Push the "SLCT1" button and

"SLCT2" button for 2 seconds or more at the same time to change over to RACE MODE.

Changeover to RACE MODE will put manual start measurement on standby causing and to flash. (For manual start, refer to "Putting measurement on standby" in "RACE MODE".)

RACE MODE Putting measurement on standby

Starting measurement consists of the following two starts, either of which can be selected.

• Manual start Starting measurement by the rider himself operating the button. (A long push on the "SLCT2" button will put measurement on standby.)

• Auto start Starting timer measurement automatically on detection of the movement of the machine. (A long push on the "SLCT1" button will put measurement on standby.)

Manual start

4. To resume the measurement, again push the "SLCT1" button and "SLCT2" button at the same time.

Auto start

1. Check that changeover has been made to RACE MODE. (Refer to "Changeover from BASIC MODE to RACE MODE".)

2. Make the machine ready for a run by pushing the "SLCT1" button for 2 seconds or more.

When the measurement is made ready for a run by auto start, and

will start flashing. Timer display

will turn on scrolling from left to right.

Initial setting at changeover to RACE MODE will remain for manual start.

1. Check that changeover to RACE MODE has been made. (Refer to "Changeover from BASIC MODE to RACE MODE".)

1-10

3. Run the machine and start timer measurement.

4. To stop timer measurement, pushing the "SLCT1" button and "SLCT2" button at the same time.

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MULTI-FUNCTION DISPLAY

If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A).

5. To resume the measurement, again pushing the "SLCT1" button and "SLCT2" button at the same time.

Resetting measurement data

Resetting can be made in the following two manners. Resetting is possible while timer measurement is made:

• Reset tripmeter A.

Resetting is possible while timer measurement is not made:

• Reset tripmeter A and timer.

• Resetting will reset the timer display and travel distance display and put measurement on standby.

• Auto start attempt will put measurement on standby as such. Likewise, manual start attempt will put measurement on standby as such.

Correcting tripmeter A (TRIP A)

1. Change the travel distance dis-

play by pushing the "SLCT1" button (plus) or "SLCT2" button (minus). A long push on the button will fast-forward the change.

Change can be made any time while timer measurement is or is not being made.

Resetting tripmeter A (TRIP A)

1. Check that the timer is in operation. If the timer is not in operation, start the timer by pushing the "SLCT1" button and "SLCT2" button at the same time.

2. Reset tripmeter A (TRIP A) display by pushing the "RST" button for 2 seconds or more.

If reset, and travel distance display will go on flashing for four seconds.

Resetting tripmeter A (TRIP A) and timer

1. Check that the timer is not in operation. If the timer is in operation, stop it by pushing the "SLCT1" button and "SLCT2" button at the same time.

2. Reset all measured data by pushing the "RST" button for 2 seconds or more.

1-11

Page 22

FUNCTION DIAGRAM

BASIC MODE

A short push on the button changes the operation in the arrowed direction.

A short push on the button changes the operation in both arrowed directions.

A long push on the button changes the operation in the arrowed direction.

A long push on the button changes the operation in both arrowed directions.

Clock

MULTI-FUNCTION DISPLAY

Meter function

Function that can be performed whether the time is or is not in operation.

Extent to which the meter can operate

RACE MODE

Tripmeter

ODO TRIP A TRIP B

ODO

Putting measurement on standby

Manual start

Timer in operation

Reset TRIP A

Correct TRIP A

Speedometer (for U.K.)

km/h MPH

MPH

Auto start

Measurement starts as the machine moves

Timer not in operation

Correct TRIP A

Reset TRIP A & timer

1-12

Page 23

The following diagram illustrates the multi-function display regarding the direction and operation condition involved in each of its functions.

A. A short push on the button

changes the operation in the arrowed direction.

B. A short push on the button

changes the operation in both arrowed directions.

C. A long push on the button

changes the operation in the arrowed direction.

D. A long push on the button

changes the operation in both

arrowed directions. E. Meter function F. Function that can be performed

whether the time is or is not in

operation. G. Extent to which the meter can

operate

1. BASIC MODE

2. Clock

3. Trip meter

4. Speedometer (for U.K.)

5. RACE MODE

6. Putting measurement on stand-

7. Manual start

8. Auto start

9. Measurement starts as the ma-

chine moves

10. Timer in operation

11. Reset TRIP A

12. Correct TRIP A

13. Timer not in operation

14. Reset TRIP A & timer

MULTI-FUNCTION DISPLAY

1-13

Page 24

STARTING AND BREAK-IN

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.

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.

If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.

• 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.

AIR FILTER MAINTENANCE

According to "CLEANING THE AIR FILTER ELEMENT" section in the CHAPTER 3, apply the foam-air-filter oil or its equivalent to the element. (Excess oil in the element may adversely affect engine starting.)

STARTING A COLD ENGINE

This model is equipped with an ignition circuit cut-off system. The engine can be started under the following conditions.

• When the transmission is in neutral.

• When the clutch is disengaged with the transmission in any position. However, it is recommended to shift into neutral before starting the engine.

1. Inspect the coolant level.

2. Turn the fuel cock to "ON".

3. Push on the main switch to "ON".

4. Shift the transmission into neutral.

5. Fully open the cold starter knob

"1".

7. 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.

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.

Do not warm up the engine for extended periods of time.

STARTING A WARM ENGINE

Do not operate the cold starter knob and throttle. Pull the hot starter lever "1" and start the engine by pushing the start switch or by kicking the kickstarter crank forcefully with a firm stroke. As soon as the engine starts, Release the hot starter lever to close the air passage.

HANDLING NOTE

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.

• 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 kickstarter 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.

6. Start the engine by pushing the start switch or by kicking the kickstarter crank.

If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstarter crank.

• If the starter motor will not turn

when pushing the start switch, stop pushing it immediately and kick start the engine in order to avoid the load on the motor.

• Do not open the throttle while

kicking the kickstarter crank. Otherwise, the kickstarter crank may kick back.

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.

1-14

Page 25

STARTING AND BREAK-IN

The engine fails to start

Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 10 to 20 times to clear the engine. Then, restart the engine. Refer to "Restarting an engine after a fall".

Thro

Hot

Cold

ttle

start-

grip

er le-

op-

ver

knob

era-

tion*

Air temperature = less than 5 °C (41 °F)

St ar

Air tempera-

ture = more

than 5 °C (41

°F)

a c

Air tempera-

ture (normal

temperature)

= between 5

°C (41 °F)

and 25 °C

(77 °F)

Air temperature = more than 25 °C (77 °F)

Starting an engine after a long period of time

Restarting a warm engine

Restarting an engine after a fall

* Operate the throttle grip before kick starting.

Ope

n 3

ON OFF

or 4 time

Non

ON OFF

NoneON/

OFF

Non

OFF OFF

Non

ON OFF

Non

OFF ON

Non

OFF ON

OFF

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.

• After the break-in or before each

race, you must check the entire machine for loose fittings and fasteners as per "TORQUECHECK 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.

Observe the following break-in procedures during initial operation to ensure optimum performance and avoid engine damage.

BREAK-IN PROCEDURES

1. Before starting the engine, fill the fuel tank with the fuel.

2. Perform the pre-operation checks on the machine.

3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted.

1-15

Page 26

TORQUE-CHECK POINTS

Frame construction Frame to rear frame

Combined seat and fuel tank Fuel tank to frame

Exhaust system Silencer to rear frame

Engine mounting Frame to engine

Engine bracket to engine

Engine bracket to frame

Steering Steering stem to handlebar Steering stem to frame

Steering stem to upper bracket

Upper bracket to handlebar

Suspension Front Steering stem to front fork Front fork to upper bracket

Front fork to lower bracket

Rear For link type Assembly of links

Link to frame

Link to rear shock absorber

Link to swingarm

Installation of rear shock absorber Rear shock absorber to frame

Installation of swingarm Tightening of pivot shaft

Wheel Installation of wheel Front Tightening of wheel axle

Tightening of axle holder

Rear Tightening of wheel axle

Wheel to rear wheel sprocket

Brake Front Brake caliper to front fork

Brake disc to wheel

Tightening of union bolt

Brake master cylinder to handlebar

Tightening of bleed screw

Tightening of brake hose holder

Rear Brake pedal to frame

Brake disc to wheel

Tightening of union bolt

Brake master cylinder to frame

Tightening of bleed screw

Tightening of brake hose holder

Fuel system Fuel tank to fuel cock

Lubrication system Tightening of oil hose clamp

Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.

1-16

Page 27

CLEANING AND STORAGE

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.

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.

8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleanerwaxes, as they may contain abrasives.

9. After completing the above, start the engine and allow it to idle for several minutes.

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 the ground.

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.

Make any necessary repairs before the machine is stored.

1-17

Page 28

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model name: WR450FX (CDN, AUS, NZ)

WR450F (EUROPE, ZA)

Model code number: 5TJK (CDN)

5TJL (EUROPE)

5TJM (AUS, NZ, ZA)

Dimensions: CDN, ZA AUS, NZ EUROPE

Overall length 2,175 mm (85.63

in)

Overall width 825 mm (32.48 in) ←←

Overall height 1,295 mm (50.98

in)

Seat height 980 mm (38.58 in) 990 mm (38.98 in) ←

Wheelbase 1,485 mm (58.46

in)

Minimum ground clearance 365 mm (14.37 in) 370 mm (14.57 in) 375 mm (14.76 in)

Dry weight:

Without oil and fuel 112.5 kg (248.0 lb)

Engine:

Engine type Liquid cooled 4-stroke, DOHC

Cylinder arrangement Single cylinder, forward inclined

Displacement 449 cm

Bore × stroke 95.0 × 63.4 mm (3.74 × 2.50 in)

Compression ratio 12.3 : 1

Starting system Kick and electric starter

Lubrication system: Dry sump

Oil type or grade:

Engine oil (For CDN)

Yamalube 4, SAE10W30 or SAE20W40

Yamalube 4-R, SAE10W50

API service SG type or higher,

JASO standard MA

(15.8 Imp oz, 15.2 US oz)

2,190 mm (86.22 in)

1,300 mm (51.18 in)

← 1,500 mm (59.06

2,200 mm (86.61 in)

1,305 mm (51.38 in)

in)

2-1

Page 29

GENERAL SPECIFICATIONS

(Except for CDN)

SAE10W30, SAE10W40, SAE15W40,

SAE20W40 or SAE20W50

API service SG type or higher,

JASO standard MA

Oil capacity:

Engine oil

Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt)

With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt)

Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)

Coolant capacity (including all routes): 1.0 L (0.88 Imp qt, 1.06 US qt)

Air filter: Wet type element

Fuel:

Type Premium unleaded gasoline only with a research octane

number of 95 or higher.

Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal)

Reserve 1.1 L (0.24 Imp gal, 0.29 US gal)

Carburetor:

Type FCR-MX39

Manufacturer KEIHIN

Spark plug:

Type/manufacturer CR8E/NGK (resistance type)

Gap 0.7–0.8 mm (0.028–0.031 in)

Clutch type: Wet, multiple-disc

Transmission: CDN, ZA, AUS, NZ EUROPE

Primary reduction system Gear ←

Primary reduction ratio 61/23 (2.652) ←

Secondary reduction system Chain drive ←

Secondary reduction ratio 50/13 (3.846) 47/14(3.357)

Transmission type Constant mesh, 5-speed ←

Operation Left foot operation ←

Gear ratio:

1st 29/12 (2.417) ←

2nd 26/15 (1.733) ←

3rd 21/16 (1.313) ←

4th 21/20 (1.050) ←

5th 21/25 (0.840) ←

2-2

Page 30

GENERAL SPECIFICATIONS

Chassis: CDN, ZA AUS, NZ EUROPE

Frame type Semi double cra-

dle

Caster angle 27.3 ° 27.0 ° 26.8 °

Trail 117 mm (4.61 in) 116 mm (4.57 in) 115 mm (4.53 in)

Tire:

Type With tube

Size (front) 80/100-21 51M (CDN, ZA)

90/90-21 54R (AUS, NZ, EUROPE)

Size (rear) 110/100-18 64M (CDN, ZA)

130/90-18 69R (AUS, NZ, EUROPE)

Tire pressure (front and rear) 100 kPa (1.0 kgf/cm

Brake:

Front brake type Single disc brake

Operation Right hand operation

Rear brake type Single disc brake

Operation Right foot operation

Suspension:

Front suspension Telescopic fork

Rear suspension Swingarm (link type monocross suspension)

Shock absorber:

Front shock absorber Coil spring/oil damper

Rear shock absorber Coil spring/gas, oil damper

Wheel travel:

Front wheel travel 300 mm (11.8 in)

Rear wheel travel 305 mm (12.0 in)

Electrical:

Ignition system CDI

Generator system AC magneto

Battery type YTZ7S (F)

Battery voltage/capacity 12V/6 AH

Specific gravity 1.310

Headlight type: Quartz bulb (halogen)

Bulb wattage × quantity:

Headlight 12 V 35/36.5 W × 1

Taillight 12 V 1.6/0.3 W × 1

←←

, 15 psi)

2-3

Page 31

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.05 mm (0.002

in)

Cylinder:

Bore size 95.00–95.01 mm (3.7402–3.7406 in) ----

Out of round limit ---- 0.05 mm (0.002

in)

Camshaft:

Drive method Chain drive (Left) ----

Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----

Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----

Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003

in)

Cam dimensions

Intake "A" 30.100–30.200 mm (1.1850–1.1890 in) 30.000 mm

(1.1811 in)

Intake "B" 22.450–22.550 mm (0.8839–0.8878 in) 22.350 mm

(0.8799 in)

Exhaust "A" 30.200–30.300 mm (1.1890–1.1929 in) 30.100 mm

(1.1850 in)

Exhaust "B" 22.450–22.550 mm (0.8839–0.8878 in) 22.350 mm

(0.8799 in)

Camshaft runout limit ---- 0.03 mm

(0.0012 in)

Timing chain:

Timing chain type/No. of links 98XRH2010-118M/118 ----

Timing chain adjustment method Automatic ----

2-4

Page 32

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Valve, valve seat, valve guide:

Valve clearance (cold)

IN 0.10–0.15 mm (0.0039–0.0059 in) ----

EX 0.20–0.25 mm (0.0079–0.0098 in) ----

Valve dimensions:

"A" head diameter (IN) 26.9–27.1 mm (1.0591–1.0669 in) ----

"A" head diameter (EX) 27.9–28.1 mm (1.0984–1.1063 in) ----

"B" face width (IN) 2.26 mm (0.089 in) ----

"B" face width (EX) 2.26 mm (0.089 in) ----

"C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630

in)

"C" seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630

in)

"D" margin thickness (IN) 1 mm (0.0394 in) 0.85 mm (0.033

in)

"D" margin thickness (EX) 1 mm (0.0394 in) 0.85 mm (0.033

in)

Stem outside diameter (IN) 4.475–4.490 mm (0.1762–0.1768 in) 4.445 mm

(0.1750 in)

Stem outside diameter (EX) 4.965–4.980 mm (0.1955–0.1961 in) 4.935 mm

(0.1943 in)

Guide inside diameter (IN) 4.500–4.512 mm (0.1772–0.1776 in) 4.550 mm

(0.1791 in)

Guide inside diameter (EX) 5.000–5.012 mm (0.1969–0.1973 in) 5.050 mm

(0.1988 in)

Stem-to-guide clearance (IN) 0.010–0.037 mm (0.0004–0.0015 in) 0.08 mm (0.003

in)

Stem-to-guide clearance (EX) 0.020–0.047 mm (0.0008–0.0019 in) 0.10 mm (0.004

in)

2-5

Page 33

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Stem runout limit ---- 0.01 mm

(0.0004 in)

Valve spring:

Free length (IN) 39.46 mm (1.55 in) 38.46 mm (1.51

in)

Free length (EX) 37.61 mm (1.48 in) 36.61 mm (1.44

in)

Set length (valve closed) (IN) 27.87 mm (1.10 in) ----

Set length (valve closed) (EX) 28.38 mm (1.12 in) ----

Compressed force (installed) (IN) 130.2–149.8 N at 27.87 mm (13.28–15.28

kg at 27.87 mm, 29.27–33.68 lb at 1.10 in)

Compressed force (installed) (EX) 123.1–141.7 N at 28.38 mm (12.55–14.45

kg at 28.38 mm, 27.67–31.85 lb at 1.12 in)

Tilt limit* (IN) ---- 2.5°/1.7 mm

Tilt limit* (EX) ---- 2.5°/1.6 mm

----

(2.5°/0.067 in)

(2.5°/0.063 in)

Direction of winding (top view) (IN) Clockwise ----

Direction of winding (top view) (EX) Clockwise ----

Piston:

Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in) 0.1 mm (0.004

in)

Piston size "D" 94.965–94.980 mm (3.7388–3.7394 in) ----

Measuring point "H" 8 mm (0.315 in) ----

Piston off-set 1 mm (0.0394 in) ----

Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in) 18.045 mm

(0.7104 in)

Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in) 17.971 mm

(0.7075 in)

2-6

Page 34

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Piston rings:

Top ring:

Type Barrel ----

Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ----

End gap (installed) 0.20–0.30 mm (0.008–0.012 in) 0.55 mm (0.022

in)

Side clearance (installed) 0.030–0.065 mm (0.0012–0.0026 in) 0.12 mm (0.005

in)

2nd ring:

Type Taper ----

Dimensions (B × T) 1.00 × 3.35 mm (0.04 × 0.13 in) ----

End gap (installed) 0.35–0.50 mm (0.014–0.020 in) 0.85 mm (0.033

in)

Side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005

in)

Oil ring:

Dimensions (B × T) 2.0 × 2.9 mm (0.08 × 0.11 in) ----

End gap (installed) 0.2–0.5 mm (0.01–0.02 in) ----

Crankshaft:

Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ----

Runout limit "C" 0.03 mm (0.0012 in) 0.05 mm (0.002

in)

Big end side clearance "D" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02

in)

Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08

in)

Balancer:

Balancer drive method Gear ----

Air filter oil grade: Foam-air-filter oil or equivalent oil ----

2-7

Page 35

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Clutch:

Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110

in)

Quantity 8 ----

Clutch plate 1 thickness 1.9–2.1 mm (0.075–0.083 in) ----

Quantity 4 ----

Warp limit ---- 0.1 mm (0.004

in)

Clutch plate 2 thickness 1.5–1.7 mm (0.059–0.067 in) ----

Quantity 3 ----

Warp limit ---- 0.1 mm (0.004

in)

Clutch spring free length 50.0 mm (1.97 in) 49.0 mm (1.93

in)

Quantity 6 ----

Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ----

Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ----

Clutch release method Inner push, cam push ----

Shifter:

Shifter type Cam drum and guide bar ----

Guide bar bending limit ---- 0.05 mm (0.002

in)

Kickstarter:

Type Ratchet type ----

Carburetor: CDN, ZA, AUS, NZ EUROPE

I. D. mark 5TJE E0 5TJL L0 ----

Main jet (M.J) #162 #160 ----

Main air jet (M.A.J) ø2.0 ← ----

Jet needle (J.N) NFNT NNHU ----

Cutaway (C.A) 1.5 ← ----

Pilot jet (P.J) #45 #48 ----

Pilot air jet (P.A.J) #70 ← ----

Pilot outlet (P.O) ø0.9 ← ----

Bypass (B.P) ø1.0 ← ----

Valve seat size (V.S) ø3.8 ← ----

Starter jet (G.S) #65 ← ----

Leak jet (Acc.P) #60 ← ----

Float height (F.H) 8 mm (0.31 in) ← ----

Engine idle speed 1,750–1,950 r/min ← ----

Intake vacuum 34.8–40.1 kPa

(261–301 mmHg,

10.28–11.85 inHg)

Hot starter lever free play 3–6 mm (0.12–0.24

in)

← ----

2-8

Page 36

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Lubrication system:

Oil filter type Paper type ----

Oil pump type Trochoid type ----

Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008

in)

Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009

in)

Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm

(0.0067 in)

Bypass valve setting pressure 40–80 kPa (0.4–0.8 kg/cm

psi)

Cooling:

Radiator core size

Width 120.2 mm (4.73 in) ----

Height (Left/Right) 260 mm (10.24 in)/240 mm (9.45 in) ----

Thickness 22 mm (0.87 in) ----

Radiator cap opening pressure 110 kPa (1.1 kg/cm

Radiator capacity (total) 0.57 L (0.50 Imp qt, 0.60 US qt) ----

Water pump

Type Single-suction centrifugal pump ----

, 5.69–11.38

, 15.6 psi) ----

----

2-9

Page 37

MAINTENANCE SPECIFICATIONS

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Taper roller bearing ----

Front suspension: CDN AUS, NZ, ZA, EUROPE

Front fork travel 300 mm (11.8 in) ← ----

Fork spring free length 460 mm (18.1 in) ← 455 mm (17.9

in)

Spring rate, STD K = 4.5 N/mm (0.459 kg/

mm, 25.7 lb/in)

Optional spring/spacer Yes ← ----

Oil capacity 648 cm

21.9 US oz)

Oil level 132 mm (5.20 in) 125 mm (4.92 in) ----

<Min.–Max.> (From top of outer tube with inner tube and damper rod fully compressed without spring.)

Oil grade Suspension oil "S1" ← ----

Inner tube outer diameter 48 mm (1.89 in) ← ----

Front fork top end Zero mm (Zero in) ← ----

Rear suspension: CDN, ZA, AUS, NZ EUROPE

Shock absorber travel 130 mm (5.12 in) ← ----

Spring free length 260 mm (10.24 in) ← ----

Fitting length 252.5 mm (9.94 in) 251.5 mm (9.90 in) ----

<Min.–Max.> 238.5–258.5 mm (9.39–

Spring rate, STD K = 54.0 N/mm (5.50 kg/

Optional spring Yes ← ----

Enclosed gas pressure 1,000 kPa (10 kg/cm

Swingarm:

Swingarm free play limit

End ---- 1.0 mm (0.04

Wheel:

Front wheel type Spoke wheel ----

Rear wheel type Spoke wheel ----

Front rim size/material 21 × 1.60/Aluminum ----

Rear rim size/material 18 × 2.15/Aluminum ----

Rim runout limit:

Radial ---- 2.0 mm (0.08

Lateral ---- 2.0 mm (0.08

95–150 mm (3.74–5.91 in)

10.18 in)

mm, 308.0 lb/in)

142 psi)

(22.8 lmp oz,

← ----

655 cm3 (23.1 lmp oz,

22.1 US oz)

← ----

----

in)

2-10

Page 38

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Drive chain:

Type/manufacturer DID520VM/DAIDO ----

Number of links 113 links + joint ----

Chain slack 48–58 mm (1.9–2.3 in) ----

Chain length (15 links) ---- 239.3 mm

(9.42 in)

Front disc brake:

Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm

(9.84 × 0.10 in)

Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04

in)

Master cylinder inside dia. 11.0 mm (0.433 in) ----

Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ----

Brake fluid type DOT #4 ----

Rear disc brake:

Disc outside dia. × Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm

(9.65 × 0.14 in)

Deflection limit ---- 0.15 mm

(0.006 in)

Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04

in)

Master cylinder inside dia. 11.0 mm (0.433 in) ----

Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----

Brake fluid type DOT #4 ----

Brake lever and brake pedal:

Brake lever position 95 mm (3.74 in) ----

Brake pedal height (vertical height above footrest top)

Clutch lever free play (lever end) 8–13 mm (0.31–0.51 in) ----

Throttle grip free play 3–5 mm (0.12–0.20 in) ----

ELECTRICAL

10 mm (0.39 in) ----

Item Standard Limit

Ignition system:

Advancer type Electrical ----

CDI: CDN, ZA, AUS,NZ EUROPE

Pickup coil resistance (color) 248–372 Ωat 20 °C

(68 °F) (White–Red)

CDI unit-model/manufacturer 5TJ-F0 5TJ-L0 ----

Ignition coil:

Model/manufacturer 5TA-10/DENSO ----

Minimum spark gap 6 mm (0.24 in) ----

Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----

Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----

← ----

2-11

Page 39

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Charging system:

System type AC magneto ----

Model (stator)/manufacturer 5TJ 50/YAMAHA ----

Normal output 14 V/120 W at 5,000 r/min ----

Charging coil resistance (color) 0.288–0.432 Ω at 20 °C (68 °F) (White–

Ground)

Lighting coil resistance (color) 0.224–0.336 Ω at 20 °C (68 °F) (Yellow–

Ground)

Rectifier/regulator:

Regulator type Semiconductor short circuit ----

Model/manufacturer SH770AA/SHINDENGEN ----

Regulated voltage (AC) 12.5–13.5 V ----

Regulated voltage (DC) 14.0–15.0 V ----

Rectifier capacity (AC) 12 A ----

Rectifier capacity (DC) 8 A ----

Electric starting system:

Type Constant mesh ----

Starter motor:

Model/manufacturer 5UM20/YAMAHA ----

Operation voltage 12 V ----

Output 0.48 kW ----

Armature coil resistance 0.0117–0.0143 Ω at 20 °C (68 °F) ----

Brush overall length 7 mm (0.28 in) 3.5 mm (0.14

Brush quantity 2 pcs. ----

Spring force 3.92–5.88 N (400–600 g, 14.1–21.2 oz) ----

Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65

Mica undercut (depth) 1.5 mm (0.06 in) ----

Starter relay:

Model/manufacturer 2768090-A/JIDECO ----

Amperage rating 180 A ----

Coil winding resistance 4.2–4.6 Ω at 20 °C (68 °F) ----

Starting circuit cut-off relay:

Model/manufacturer ACM33221 M06/MATSUSHITA ----

Coil winding resistance 75.69–92.51 Ω at 20 °C (68 °F) ----

Fuse (amperage×quantity):

Main fuse 10 A × 1 ----

Reserve fuse 10 A × 1 ----

----

in)

2-12

Page 40

TIGHTENING TORQUES

ENGINE

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

*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.

Part to be tightened Thread size Q'ty

Spark plug M10S × 1.0 1 13 1.3 9.4

Camshaft cap M6 × 1.0 10 10 1.0 7.2

Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20

Cylinder head (stud bolt) M8 × 1.25 1 15 1.5 11

Cylinder head (bolt) M10 × 1.25 4 Refer to NOTE.*1

Cylinder head (bolt) M6 × 1.0 2 10 1.0 7.2

Cylinder head cover M6 × 1.0 2 10 1.0 7.2

Cylinder M6 × 1.0 1 10 1.0 7.2

Timing chain tensioner M6 × 1.0 2 10 1.0 7.2

Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1

Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2

Exhaust pipe (nut) M8 × 1.25 1 20 2.0 14

Exhaust pipe (bolt) M8 × 1.25 1 20 2.0 14

△ Silencer M8 × 1.25 2 30 3.0 22

Silencer clamp M8 × 1.25 1 16 1.6 11

Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2

Spark arrester M5 × 0.8 4 7 0.7 5.1

Silencer cap M5 × 0.8 6 5 0.5 3.6

Air induction pipe M6 × 1.0 2 10 1.0 7.2

Air cut-off valve assembly and bracket M6 × 1.0 2 10 1.0 7.2

Bracket (air cut-off valve) and frame M6 × 1.0 2 7 0.7 5.1

Carburetor joint M6 × 1.0 3 10 1.0 7.2

Carburetor joint clamp M4 × 0.7 1 3 0.3 2.2

△ Air filter case M6 × 1.0 2 8 0.8 5.8

Air filter joint clamp M6 × 1.0 1 3 0.3 2.2

Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9

Throttle cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9

Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9

Throttle cable (return) M12 × 1.0 1 11 1.1 8.0

Throttle cable cover M5 × 0.8 2 4 0.4 2.9

Hot starter plunger M12 × 1.0 1 2 0.2 1.4

Hot starter cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9

Air filter element M6 × 1.0 1 2 0.2 1.4

Radiator stay M6 × 1.0 6 7 0.7 5.1

Radiator M6 × 1.0 4 10 1.0 7.2

Radiator hose clamp M6 × 1.0 8 2 0.2 1.4

Tightening torque

Nm m•kg ft•lb

2-13

Page 41

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

Radiator pipe 1, 2 M10 × 1.0 2 10 1.0 7.2

Impeller M8 × 1.25 1 14 1.4 10

Water pump housing cover M6 × 1.0 3 10 1.0 7.2

Coolant drain bolt M6 × 1.0 1 10 1.0 7.2

Oil pump cover M4 × 0.7 1 2 0.2 1.4

Oil pump M6 × 1.0 2 10 1.0 7.2

Oil pump drive gear shaft M6 × 1.0 1 10 1.0 7.2

Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2

Oil filter cover M6 × 1.0 2 10 1.0 7.2

Oil check bolt (cylinder head) M6 × 1.0 1 10 1.0 7.2

△ Oil hose clamp — 2 2 0.2 1.4

Crankshaft end accessing screw M27 × 1.5 1 10 1.0 7.2

Timing mark accessing screw M14 × 1.5 1 6 0.6 4.3

Clutch cover M6 × 1.0 7 10 1.0 7.2

Crankcase cover (right) M6 × 1.0 8 10 1.0 7.2

Crankcase cover (right) M6 × 1.0 2 12 1.2 8.7

Crankcase cover (left) M6 × 1.0 8 10 1.0 7.2

Idle gear cover (starter motor) M6 × 1.0 2 10 1.0 7.2

Crankcase M6 × 1.0 12 12 1.2 8.7

Clutch cable holder M6 × 1.0 1 10 1.0 7.2

Oil drain bolt (crankcase right) M6 × 1.25 1 20 2.0 14

Oil drain bolt (crankcase left) M6 × 1.0 1 20 2.0 14

Oil check bolt (crankcase) M6 × 1.0 1 10 1.0 7.2

Oil strainer M6 × 1.0 1 10 1.0 7.2

Crankcase bearing stopper M6 × 1.0 4 14 1.4 10

Crankcase bearing stopper M6 × 1.0 8 10 1.0 7.2

Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2

Ratchet wheel guide M6 × 1.0 2 12 1.2 8.7

Kickstarter crank M8 × 1.25 1 33 3.3 24

Screw (kickstarter crank) M6 × 1.0 1 7 0.7 5.1

Starter clutch M6 × 1.0 6 16 1.6 11

Primary drive gear M20 × 1.0 1 110 11.0 80

Clutch boss M20 × 1.0 1 75 7.5 54

Clutch cable adjust bolt and locknut M8 × 1.0 1 4 0.4 2.9

Clutch spring M6 × 1.0 6 10 1.0 7.2

Balancer M10 × 1.0 1 45 4.5 32

Balancer driven gear M14 × 1.0 1 50 5.0 36

Balancer weight plate M6 × 1.0 3 10 1.0 7.2

Drive sprocket M20 × 1.0 1 75 7.5 54

Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8

Shift pedal M6 × 1.0 1 12 1.2 8.7

Shift guide M6 × 1.0 2 10 1.0 7.2

Stopper lever M6 × 1.0 1 10 1.0 7.2

Segment M8 × 1.25 1 30 3.0 22

Tightening torque

Nm m•kg ft•lb

2-14

Page 42

TIGHTENING TORQUES

CHASSIS

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

Part to be tightened Thread size Q'ty

△ Upper bracket and outer tube M8 × 1.25 4 21 2.1 15

△ Lower bracket and outer tube M8 × 1.25 4 21 2.1 15

△ Upper bracket and steering stem M24 × 1.0 1 145 14.5 105

△ Handlebar holder (upper) M8 × 1.25 4 28 2.8 20

△ Handlebar holder (lower) M12 × 1.25 2 34 3.4 24

△ Steering ring nut M28 × 1.0 1 Refer to NOTE.

Front fork and cap bolt M51 × 1.5 2 30 3.0 22

Front fork and base valve M30 × 1.0 2 55 5.5 40

Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21

Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7

△ Front fork and protector M6 × 1.0 6 7 0.7 5.1

△ Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1

Throttle cable cap M5 × 0.8 2 4 0.4 2.9

Clutch lever holder mounting M5 × 0.8 2 4 0.4 2.9

Clutch lever mounting M6 × 1.0 1 4 0.4 2.9

Hot starter lever holder mounting M5 × 0.8 2 4 0.4 2.9

Hot starter lever mounting M5 × 0.8 1 2 0.2 1.4

△ Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5

Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4

Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3

Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3

Brake lever position locknut M6 × 1.0 1 5 0.5 3.6

△ Hose guide (front brake hose) and hose guide bracket M5 × 0.8 1 4 0.4 2.9

△ Hose guide (front brake hose) and under bracket M6 ×1.0 1 4 0.4 2.9

△ Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22

△ Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22

△ Front brake caliper and front fork M8 × 1.25 2 23 2.3 17

△ Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2

△ Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2

△ Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13

△ Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3

△ Front wheel axle and nut M16 × 1.5 1 90 9.0 65

△ Front wheel axle holder M8 × 1.25 4 21 2.1 15

△ Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7

△ Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10

△ Brake pedal mounting M8 × 1.25 1 26 2.6 19

△ Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2

Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4

△ Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22

△ Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22

△ Rear wheel axle and nut M20 × 1.5 1 125 12.5 90

Tightening torque

Nm m•kg ft•lb

2-15

Page 43

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

△ Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36

△ Nipple (spoke) — 72 3 0.3 2.2

△ Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2

△ Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1

Chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13

Engine mounting:

△ Engine upper bracket and frame M10 × 1.25 4 55 5.5 40

△ Engine lower bracket and frame M8 × 1.25 4 34 3.4 24

△ Engine and engine bracket (lower) M10 × 1.25 1 53 5.3 38

△ Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40

△ Engine and frame (lower) M10 × 1.25 1 53 5.3 38

△ Engine guard M6 × 1.0 3 7 0.7 5.1

Regulator mounting M6 × 1.0 2 7 0.7 5.1

△ Pivot shaft and nut M16 × 1.5 1 85 8.5 61

△ Relay arm and swingarm M14 × 1.5 1 70 7.0 50

△ Relay arm and connecting rod M14 × 1.5 1 80 8.0 58

△ Connecting rod and frame M14 × 1.5 1 80 8.0 58

△ Rear shock absorber and frame M10 × 1.25 1 56 5.6 40

△ Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38

△ Rear frame and frame (upper) M8 × 1.25 1 38 3.8 27

△ Rear frame and frame (lower) M8 × 1.25 2 32 3.2 23

△ Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4

Swingarm and patch M4 × 0.7 4 2 0.2 1.4

Drive chain tensioner mounting (upper) M8 × 1.25 1 16 1.6 11

Drive chain tensioner mounting (lower) M8 × 1.25 1 16 1.6 11

Chain support and swingarm M6 × 1.0 3 7 0.7 5.1

Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3

△ Fuel tank mounting M6 × 1.0 2 9 0.9 6.5

△ Fuel tank and fuel cock M6 × 1.0 2 4 0.4 2.9

Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1

Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1

△ Seat mounting M8 × 1.25 2 23 2.3 17

△ Side cover mounting M6 × 1.0 2 7 0.7 5.1

△ Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1

△ Air scoop and radiator panel (lower) M6 × 1.0 2 6 0.6 4.3

△ Front fender mounting M6 × 1.0 4 7 0.7 5.1

△ Rear fender mounting(front) M6 × 1.0 2 7 0.7 5.1

△ Rear fender mounting (rear) M6 × 1.0 2 11 1.1 8.0

Multi-function display bracket mounting M6 × 1.0 2 7 0.7 5.1

Multi-function display mounting M5 × 0.8 2 4 0.4 2.9

Plate 1 and protector M5 × 0.8 2 4 0.4 2.9

Plate 2 and protector — 2 0.5 0.05 0.36

Speed sensor lead holder and under bracket M6 × 1.0 1 13 1.3 9.4

Headlight body and headlight unit — 2 1 0.1 0.7

Tightening torque

Nm m•kg ft•lb

2-16

Page 44

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

△ Headlight mounting (left and right) M6 × 1.0 2 7 0.7 5.1

Taillight mounting — 3 1 0.1 0.7

Taillight lead clamp and rear fender — 3 0.5 0.05 0.36

△ Catch tank (upper) M6 × 1.0 1 16 1.6 11

△ Catch tank (lower) M6 × 1.0 1 7 0.7 5.1

△ Footrest bracket and frame M10 × 1.25 4 55 5.5 40

Sidestand mounting M10 × 1.25 1 25 2.5 18

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

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

ELECTRICAL

Part to be tightened Thread size Q'ty

Stator M5 × 0.8 2 7 0.7 5.1

Holder (AC magneto lead) M5× 0.8 2 10 1.0 7.2

Rotor M12 × 1.25 1 Refer to NOTE.

Neutral switch M5 × 0.8 2 4 0.4 2.9

Starter motor M6 × 1.0 2 10 1.0 7.2

Starter relay terminal M6 × 1.0 2 4 0.4 2.9

Pickup coil M6 × 1.0 2 10 1.0 7.2

Tightening torque

Nm m•kg ft•lb

Tightening torque

Nm m•kg ft•lb

Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m •kg, 47 ft•lb).

2-17

Page 45

TIGHTENING TORQUES

GENERAL TORQUE SPECIFICATIONS

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.

DEFINITION OF UNITS

Unit Read Definition Measure

m•kg

N/mm

r/min

millimeter 10-3 meter Length

centimeter 10-2 meter Length

kilogram 103 gram Weight

Newton 1 kg × m/sec

Newton meter N × m Torque

Meter kilogram m × kg Torque

Pascal N/m

Newton per millimeter N/mm Spring rate

Liter — Volume or capacity

Cubic centimeter — Volume or capacity

Revolution per minute — Engine speed

A. Distance between flats B. Outside thread diameter

TORQUE SPECIFI-

(Nut)

(Bolt

)

Nm m•kg ft•lb

6 mm 6 0.6 4.3

8 mm 15 1.5 11

14 mm10

17 mm12

19 mm14

22 mm16

30 3.0 22

55 5.5 40

85 8.5 61

130 13 94

Force

Pressure

CATION

2-18

Page 46

LUBRICATION DIAGRAMS

1. Oil filter element

2. Oil pump

3. Drive axle

4. Main axle

5. Crankshaft

6. Connecting rod

A. From cylinder B. To oil tank

2-19

Page 47

LUBRICATION DIAGRAMS

1. Intake camshaft

2. Exhaust camshaft

A. To main axle B. From oil pump

2-20

Page 48

CABLE ROUTING DIAGRAM

1. Fuel tank breather hose

2. Clamp

3. Diode

4. Hot starter cable

5. Throttle position sensor lead

6. Wire harness

7. Hump (frame)

8. Negative battery lead

9. Starter motor lead

10. Neutral switch lead

11. AC magneto lead

12. Brake hose

13. Rectifier/regulator lead

14. Carburetor breather hose

15. Carburetor overflow hose

16. Catch tank breather hose

2-21

A. Insert the end of the fuel tank

breather hose into the hole in the steering stem.

B. Fasten the throttle cable, hot

starter cable and rectifier/regulator lead onto the frame. Locate the clamp end facing the lower side of the hot starter cable and cut off the tie end.

Page 49

C. Fasten the diode (at the mark-

ing), throttle cable and hot starter cable onto the frame. Locate the clamp end facing toward the lower right of the frame and with the tie end facing downward.

D. Fasten the wire harness, throttle

position sensor lead and clutch cable onto the frame. Pass the clamp through the hole in the stay (air cut-off valve). Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

E. Fasten the throttle position sen-

sor lead onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

F. Pass the carburetor breather

hoses, carburetor overflow hose and catch tank breather hose between the connecting rod and cross tube (frame).

G. Pass the neutral switch lead on

the inside of the engine bracket.

H. Fasten the neutral switch lead

and AC magneto lead onto the frame. Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame.

I. Fasten the AC magneto lead

and neutral switch lead onto the frame. Locate the clamp end facing toward the rear of the frame and cut off the tie end.

J. Pass the neutral switch lead and

AC magneto lead on the inside of the wire harness.

K. Fasten the AC magneto lead

and neutral switch lead onto the frame.

L. Pass the wire harness through

the cable guide.

M. Locate the couplers in the frame

recess.

N. Pass the carburetor breather

hoses, carburetor overflow hose and catch tank breather hose so that the hoses do not contact the rear shock absorber.

O. Secure the coupler by pushing it

into the hole in the headlight unit.

CABLE ROUTING DIAGRAM

2-22

Page 50

CABLE ROUTING DIAGRAM

1. Throttle cable (pull)

2. Throttle cable (return)

3. Catch tank hose

4. Ignition coil

5. Clamp

6. Air induction hose (air cut-off

valve - rear of cylinder head)

7. Catch tank breather hose

A. Cross the pull and push throttle

cables.

B. Fasten the catch tank hose and

air induction hose (air cut-off valve-rear of cylinder head) onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

C. Fasten the catch tank breather

hose and carburetor breather hoses together.

2-23

D. Pass the carburetor breather

hose (of the throttle cable cover) through the hose holder.

Page 51

CABLE ROUTING DIAGRAM

1. Brake master cylinder

2. Brake hose holder

3. Brake hose

A. Install the brake hose so that its

pipe portion directs as shown and lightly touches the projection on the brake caliper.

B. Pass the brake hose into the

brake hose holders.

C. If the brake hose contacts the

spring (rear shock absorber), correct its twist.

D. Install the brake hose so that its

pipe portion directs as shown and lightly touches the projection on the brake master cylinder.

2-24

Page 52

CABLE ROUTING DIAGRAM

1. Clamp

2. Positive battery lead

3. Battery

4. Negative battery lead

5. Taillight coupler

6. CDI unit coupler (6-pin)

7. CDI unit coupler (3-pin)

8. CDI unit coupler (6-pin)

A. Fasten the wire harness to the

upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame.

2-25

B. Fasten the wire harness to the

upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame. Clamp the wire harness at the marking.

C. Pass the starter motor lead

through the hole in the relay holder.

D. Fit the cover securely.

Page 53

E. Connect the wire harness to the

starter relay.

F. Fasten the catch tank breather

hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightly enough not to crush it. Locate the clamp end facing toward the rear of the frame with the tie end facing downward.

G. Fasten the (three) CDI unit leads

and taillight lead to the rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the tie end.

H. Connect the negative battery

lead to the battery negative terminal.

I. Connect the negative battery

lead to the wire harness.

J. Fasten the wire harness to the

rear frame. Locate the clamp end facing toward the upper side of the frame and the tie end toward the inside of the frame. Clamp the wire harness at the marking.

K. Pass the wire harness, starter

relay lead, starting circuit cut-off relay lead and negative battery lead through the hole in the relay holder.

L. Fasten the (three) CDI unit leads

and taillight lead to the rear frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

M. Fasten the taillight lead to the

rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the tie end.

N. Do not allow the taillight lead to

slacken.

O. Locate the CDI unit lead be-

tween the CDI unit and rear fender.

P. Locate the CDI unit coupler in

the clearance between the upper side of the CDI unit and lower side of the catch tank stay.

Q. Locate the CDI unit lead be-

tween the CDI unit and rear frame.

CABLE ROUTING DIAGRAM

2-26

Page 54

CABLE ROUTING DIAGRAM

1. Throttle cable

2. Clamp

3. Brake hose

4. Clutch cable

5. Hose guide

6. Main switch coupler

7. Wire harness

8. Headlight coupler

9. Hot starter cable

10. Multi-function display bracket

11. Main switch

12. Upper bracket

13. Clutch switch coupler

14. Engine stop switch coupler

15. Multi-function display coupler

16. Start switch coupler

17. Speed sensor coupler

18. Speed sensor lead

2-27

A. Fasten the start switch lead to

the handlebar with the plastic bands.

B. Fasten the engine stop switch

lead and clutch switch lead to the handlebar with the plastic bands.

C. Pass the brake hose through

the hose guides.

Page 55

D. Secure the coupler by inserting

it into the multi-function display bracket.

E. Pass the throttle cables, clutch

cable and hot starter cable between the upper bracket and multi-function display bracket.

F. Fasten the multi-function display

leads to the bracket. Cut off the tie end.

G. Secure the coupler by pushing it

into the hole in the multi-function display bracket.

H. Secure the wire harness clip by

pushing it into the hole in the multi-function display bracket on the inside.

I. Fasten the main switch lead

(wire harness side) to the multifunction display bracket. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

J. Pass the speed sensor lead

through the guide on the outside of the front fork.

CABLE ROUTING DIAGRAM

2-28

Page 56

MAINTENANCE INTERVALS

REGULAR INSPECTION AND ADJUSTMENTS

MAINTENANCE INTERVALS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.

After

Item

ENGINE OIL

Replace ●●

VALVES

Check the valve clearances ●● The engine must be cold.

Inspect ● Check the valve seats and valve

Replace ●

VALVE SPRINGS

Inspect ● Check the free length and the tilt.

Replace ●

VALVE LIFTERS

Inspect ● Check for scratches and wear.

Replace ●

CAMSHAFTS Inspect the camshaft surface.

Inspect ● Inspect the decompression system.

Replace ●

CAMSHAFT SPROCKETS

Inspect ● Check for wear on the teeth and for

Replace ●

PISTON

Inspect ●●Inspect crack.

Clean ● Inspect carbon deposits and eliminate

Replace ●

PISTON RING

Inspect ● Check ring end gap.

Replace ●●

PISTON PIN

Inspect ●

Replace ●

CYLINDER HEAD Inspect carbon deposits and eliminate

Inspect and clean ● Change gasket.

CYLINDER

Inspect and clean ● Inspect score marks.

Replace ● Inspect wear.

break-

Every

race

Every

third

(or 500

km)

Every

fifth (or

1,000

km)

As required

Remarks

stems for wear.

damage.

them.

3-1

Page 57

MAINTENANCE INTERVALS

After

Item

CLUTCH

Inspect and adjust ●● Inspect housing, friction plate, clutch

Replace ●

TRANSMISSION

Inspect ●

Replace bearing ●

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect ● Inspect wear.

ROTOR NUT

Retighten ●●

MUFFLER

Inspect and retighten ●●

Clean ●

Replace ●

CRANK

Inspect and clean ●●

CARBURETOR

Inspect, adjust and clean ●●

AIR INDUCTION SYSTEM

Inspect and clean ●● ●●

SPARK PLUG

Inspect and clean ●●

Replace ●

DRIVE CHAIN Use chain lube.

Lubricate, slack, alignment ●● Chain slack: 48–58 mm (1.9–2.3 in)

Replace ●

COOLING SYSTEM

Check coolant level and leakage ●●

Check radiator cap operation ●

Replace coolant ● Every two years

Inspect hoses ●

OUTSIDE NUTS AND BOLTS

Retighten ●● Refer to "STARTING AND BREAK-

AIR FILTER

Clean and lubricate ●● Use foam air-filter oil or equivalent oil.

Replace ●

OIL FILTER

Replace ●●

FRAME

Clean and inspect ●●

break-

Every

race

Every

third

(or 500

km)

Every

fifth (or

1,000

km)

As required

Remarks

plate and spring.

IN" section in the CHAPTER 1.

3-2

Page 58

MAINTENANCE INTERVALS

After

Item

FUEL TANK, COCK

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 ● Every one year

FRONT FORKS

Inspect and adjust ●●

Replace oil ●●Suspension oil "S1"

Replace oil seal ●

FRONT FORK OIL SEAL AND DUST SEAL

Clean and lube ●● Lithium base grease

PROTECTOR GUIDE

Replace ●

REAR SHOCK ABSORBER

Inspect and adjust ●●

Lube ●

Retighten ●●

DRIVE CHAIN GUIDE AND ROLLERS

Inspect ●●

SWINGARM

Inspect, lube and retighten ●● Molybdenum disulfide grease

RELAY ARM, CONNECTING ROD

Inspect, lube and retighten ●● Molybdenum disulfide grease

SIDESTAND

Lubricate ● Lithium base grease

STEERING HEAD

Inspect free play and retighten ●●

Clean and lube ● Lithium base grease

Replace bearing ●

break-

Every

●●

race

Every

third

(or 500

km)

Every

fifth (or

1,000

km)

As required

(After

rain

ride) ● Molybdenum disulfide grease

Remarks

3-3

Page 59

MAINTENANCE INTERVALS

After

Item

TIRE, WHEELS

Inspect air pressure, wheel runout, tire wear and spoke looseness

Retighten sprocket bolt ●●

Inspect bearings ●

Replace bearings ●

Lubricate ● Lithium base grease

THROTTLE, CONTROL CABLE

Check routing and connection ●●

Lubricate ●● Yamaha cable lube or SAE 10W-30

HOT STARTER, CLUTCH LEVER

Inspect free play ●

BATTERY

Check terminal for looseness and corrosion

break-

Every

●●

race

Every

third

(or 500

km)

Every

fifth (or

1,000

km)

As required

●

Remarks

motor oil

3-4

Page 60

PRE-OPERATION INSPECTION AND MAINTENANCE

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

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page

Coolant

Fuel

Engine oil

Gear shifter and clutch

Throttle grip/Housing

Brakes Check the play of front brake and effect of front and rear brake. P.3-17 – 20

Drive chain

Wheels

Steering

Front forks and rear shock absorber

Cables (wires)

Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. P.3-8 – 9

Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-20

Lubrication Check for smooth operation. Lubricate if necessary. P.3-26

Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-16

Lead connectors

Settings

Check that coolant is filled up to the radiator 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 drive chain slack and alignment. Check that the drive 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 AC 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?

P.3-9 – 10

P.1-14

P.3-12 – 13

P.3-10

P.3-10 – 11

P.3-20 – 21

P.3-24

P.3-24 – 25

P.3-21 – 24

—

P.1-3

P.4-1 – 9

3-5

Page 61

ENGINE

REMOVING THE SEAT, FUEL TANK AND SIDE COVERS

ENGINE

Order Part name Q'ty Remarks

Turn the fuel cock to "OFF".

Disconnect the fuel hose.

1Seat 1

2 Air scoop (left and right) 2

3 Bolt (fuel tank) 2

4 Fuel tank 1

5 Left side cover 1 Open the air filter case cover.

6 Right side cover 1 Refer to removal section.

7 Headlight coupler 1

8 Headlight 1

3-6

Page 62

REMOVING THE SIDE COVER

1. Remove:

• Bolt (side cover)

• Right side cover "1"

Draw the side cover backward to remove it because its claw "a" is inserted in the air filter case.

ENGINE

3-7

Page 63

REMOVING THE EXHAUST PIPE AND SILENCER

ENGINE

Order Part name Q'ty Remarks

Right side cover

1 Bolt (silencer clamp) 1 Only loosening.

2 Bolt [silencer (front)] 1

3 Bolt [silencer (rear)] 1

4 Collar 1

5 Silencer 1

6 Silencer clamp 1

7 Nut (exhaust pipe) 1

8 Bolt (exhaust pipe) 1

9 Exhaust pipe 1

10 Gasket 2

Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section.

3-8

Page 64

CHECKING THE SILENCER AND EXHAUST PIPE

1. Inspect:

• Gasket "1"

Damage → Replace.

INSTALLING THE SILENCER AND EXHAUST PIPE

1. Install:

• Gasket

• Exhaust pipe "1"

• Nut (exhaust pipe) "2"

Nut (exhaust pipe):

20 Nm (2.0 m•kg, 14 ft•lb)

• Bolt (exhaust pipe) "3"

Bolt (exhaust pipe):

20 Nm (2.0 m•kg, 14 ft•lb)

First, temporarily tighten the nut (exhaust pipe), then tighten the bolt (exhaust pipe) 13 Nm (1.3 m•kg, 9.4 ft•lb). After that, retighten the nut (exhaust pipe) 20 Nm (2.0 m•kg, 14 ft•lb) and then the bolt (exhaust pipe) 20 Nm (2.0 m•kg, 14 ft•lb).

CHECKING THE COOLANT LEVEL

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.

Hard water or salt water is harmful to the engine parts. You may use distilled water, if you can't get soft water.

ENGINE

Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water.

1. Place a container under the engine.

2. Remove:

• Seat

• Left side cover

3. Remove the catch tank hose from the catch tank and drain the tank of its coolant.

4. Remove:

• Coolant drain bolt "1"

5. Remove:

• Radiator cap Drain the coolant completely.

6. Clean:

• Cooling system Thoroughly flush the cooling system with clean tap water.

7. Install:

• Copper washer

• Coolant drain bolt

Coolant drain bolt:

10 Nm (1.0 m•kg, 7.2 ft•lb)

2. Install:

• Silencer clamp "1"

Silencer clamp:

16 Nm (1.6 m•kg, 11 ft•lb)

• Gasket "2"

• Silencer

• Washer "4"

• Bolt (silencer) "5"

Bolt (silencer):

30 Nm (3.0 m•kg, 22 ft•lb)

1. Place the machine on a level place, and hold it in an upright position.

2. Remove:

• Radiator cap

3. Check:

• Coolant level "a"

Coolant level low → Add coolant.

1. Radiator

CHANGING THE COOLANT

Do not remove the radiator cap when the engine is hot.

8. Fill:

•Radiator

• Engine To specified level.

Recommended coolant:

High quality ethylene glycol anti-freeze containing anti-corrosion

for aluminum engine Coolant "1" and water (soft water) "2" mixing ratio:

50%/50% Coolant capacity:

1.0 L (0.88 Imp qt, 1.06

US qt)

• 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.

3-9

Page 65

Handling notes of coolant:

The coolant is harmful so it should be handled with special care.

• 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.

9. Install:

• Radiator cap

Start the engine and warm it up for a several minutes.

10. Check:

• Coolant level

Coolant level low → Add coolant.

CHECKING THE RADIATOR CAP

1. Inspect:

• Seal (radiator cap) "1"

• Valve and valve seat "2"

Crack/damage → Replace. Exist fur deposits "3" → Clean or replace.

Apply water on the radiator cap seal.

3. Radiator cap

2. Apply the specified pressure.

Radiator cap opening pressure:

110 kPa (1.1 kg/cm2,

15.6 psi)

3. Inspect:

•Pressure Impossible to maintain the specified pressure for 10 seconds → Replace.

CHECKING THE COOLING SYSTEM

1. Inspect:

• Coolant level

2. Attach:

• Radiator cap tester "1" and adapter "2"

Radiator cap tester:

YU-24460-01/90890-

01325 Radiator cap tester adapter:

YU-33984/90890-01352

ENGINE

• Radiator hose joint

Coolant leakage → Repair or replace.

• Radiator hose

Swelling → Replace.

ADJUSTING THE CLUTCH CABLE FREE PLAY

1. Check:

• Clutch lever free play "a"

Out of specification → Adjust.

Clutch lever free play "a" :

8–13 mm (0.31–0.51 in)

2. Adjust:

• Clutch lever free play

Clutch lever free play adjustment steps:

a. Loosen the locknuts "1". b. Turn the adjuster "2" until free

play "a" is within the specified limits.

c. Tighten the locknuts.

Locknut:

4 Nm (0.4 m•kg, 2.9 ft•lb)

• Make minute adjustment on the lever side using the adjuster "3".

• After adjustment, check proper operation of clutch lever.

CHECKING THE RADIATOR CAP OPENING PRESSURE

1. Attach:

• Radiator cap tester "1" and adapter "2"

Radiator cap tester:

YU-24460-01/90890-

01325 Radiator cap tester adapter:

YU-33984/90890-01352

3. Apply the specified pressure.

Standard pressure:

180 kPa (1.8 kg/cm

25.6 psi)

• Do not apply pressure more than specified pressure.

• Radiator should be filled fully.

4. Inspect:

•Pressure

Impossible to maintain the specified pressure for 10 seconds → Repair.

• Radiator

3-10

ADJUSTING THE THROTTLE CABLE FREE PLAY

1. Check:

• Throttle grip free play "a"

Out of specification → Adjust.

Throttle grip free play "a":

3–5 mm (0.12–0.20 in)

Page 66

ENGINE

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.

2. Adjust:

• Throttle grip free play

Throttle grip free play adjustment steps:

a. Slide the adjuster cover. b. Loosen the locknut "1". c. Turn the adjuster "2" until the

specified free play is obtained.

d. Tighten the locknut.

Locknut:

4 Nm (0.4 m•kg, 2.9 ft•lb)

Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

After adjusting the throttle cable free play, start the engine and turn the handlebar to right and left and make sure that the engine idling does not run faster.

3. Install:

• Throttle grip cap

• Screw (throttle grip cap)

Screw (throttle grip cap):

4 Nm (0.4 m•kg, 2.9 ft•lb)

• Cover (grip cap)

• Cover (throttle cable cap)

ADJUSTING THE HOT STARTER LEVER FREE PLAY

1. Check:

• Hot starter lever free play "a"

Out of specification → Adjust.

Hot starter lever free play "a":

3–6 mm (0.12–0.24 in)

2. Adjust:

• Hot starter lever free play

Hot starter lever free play adjustment steps:

a. Loosen the locknut "1". b. Turn the adjuster "2" until free

play "a" is within the specified limits.

c. Tighten the locknut.

Locknut:

4 Nm (0.4 m•kg, 2.9 ft•lb)

1. Open the air filter case cover "1"

Loosen the quick screw "2" and pull on it to open the air filter case cover.

2. Unhook:

•Binder "1"

3. Remove:

• Air filter element "1"

• Air filter guide "2"

LUBRICATING THE THROTTLE

1. Remove:

• Cover (throttle cable cap) "1"

• Cover (grip cap) "2"

• Throttle grip cap "3"

2. Apply:

• Lithium soap base grease On the throttle cable end "a".

After adjustment, check proper operation of hot starter.

CLEANING THE AIR FILTER ELEMENT

Proper air filter maintenance is the biggest key to preventing premature engine wear and damage.

3-11

4. Clean:

• Air filter element Clean them with solvent.

After cleaning, remove the remaining solvent by squeezing the element.

• Do not twist the element when squeezing the element.

• Leaving too much of solvent in the element may result in poor starting.

Page 67

ENGINE

5. Inspect:

• Air filter element

Damage → Replace.

6. Apply:

• Foam-air-filter oil or equivalent oil to the element

• Squeeze out the excess oil. Element should be wet but not dripping.

• Wipe off the oil left on the element surface using a clean dry cloth. (Excess oil in the element may adversely affect engine starting.)

7. Install:

• Air filter guide "1"

• Align the projection "a" on filter guide with the hole "b" in air filter element.

• Apply the lithium soap base grease on the matching surface "c" on air filter element.

CHECKING THE ENGINE OIL LEVEL

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.

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.

3. Remove:

• Oil tank cap 1

(For CDN)

Recommended oil:

Yamalube 4, SAE10W30 or SAE20W40 Yamalube 4-R, SAE10W50 API service SG type or higher, JASO standard MA

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

• Do not allow foreign material to enter the crankcase.

8. Install:

• Air filter element "1"

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

9. Hook:

•Binder "1"

Hook the binder "1" so that it contacts the filter guide projections "a".

4. Inspect:

• Oil level Check that the engine oil is above the level mark "a" and that the oil does not come out when the check bolt "1" is removed. Below the level mark "a"→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.

When inspecting the oil level, do not screw the oil level gauge into the oil tank. Insert the gauge lightly.

(Except for CDN)

Recommended oil:

SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher, JASO standard MA

3-12

Page 68

• 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 material to enter the crankcase.

5. Start the engine and let it warm up

for several minutes.

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

6. Idle the engine more than 10 sec-

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

7. Install:

• Oil tank cap

CHANGING THE ENGINE OIL

1. Start the engine and let it warm up

for several minutes.

2. Stop the engine and place an oil

pan under the drain bolt.

3. Remove:

• Engine guard "1"

• Oil tank plug "2"

• Oil filler cap "3"

• Drain bolt (with gasket) "4"

• Oil filter drain bolt (O-ring) "5"

• Drain bolt (with gasket) "6"

Drain the crankcase and oil tank of its oil.

4. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them.

Replacement steps:

a. Remove the oil filter element cov-

er "1" and oil filter element "2".

b. Check the O-rings "3", if cracked

or damaged, replace them with a new one.

c. Install the oil filter element and oil

filter element cover.

Oil filter element cover:

10 Nm (1.0 m•kg, 7.2 ft•lb)

5. Install:

• Gaskets

• Oil filter drain bolt

Oil filter drain bolt:

10 Nm (1.0 m•kg, 7.2 ft•lb)

• Drain bolt (right crankcase)

Drain bolt (right crankcase):

20 Nm (2.0 m•kg, 14 ft•lb)

• Drain bolt (left crankcase)

Drain bolt (left crankcase):

20 Nm (2.0 m•kg, 14 ft•lb)

ENGINE

Oil quantity:

Periodic oil change:

0.95 L (0.84 Imp qt,

1.00 US qt) With oil filter replacement:

1.0 L (0.88 Imp qt, 1.06

US qt)

Total amount:

1.2 L (1.06 Imp qt, 1.27

US qt)

7. Install:

• Oil filler cap "1"

8. Inspect:

• Engine (for oil leaks)

• Oil level Refer to "CHECKING THE ENGINE OIL LEVEL".

CHECKING THE OIL PRESSURE

1. Check:

• Oil pressure

Checking steps:

a. Slightly loosen the oil pressure

check bolt "1".

b. Start the engine and keep it idling

until oil starts to seep from the oil pressure check bolt. If no oil comes out after one minute, turn the engine off so it will not seize.

c. Check oil passages and oil pump

for damage or leakage.

d. Start the engine after solving the

problem(s) and recheck the oil pressure.

e. Tighten the oil pressure check

bolt.

Oil pressure check bolt:

10 Nm (1.0 m•kg, 7.2 ft•lb)

6. Fill:

• Engine oil

3-13

Page 69

ENGINE

ADJUSTING THE PILOT SCREW

1. Adjust:

• Pilot screw "1"

Adjustment steps:

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.

a. Turn in the pilot screw until it is

lightly seated.

b. Turn out the pilot screw by the

factory-set number of turns.

Pilot screw (example):

2 turns out (For EUROPE)

ADJUSTING THE VALVE CLEARANCE

• 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.

4. Check:

• Valve clearance

Out of specification → Adjust.

Valve clearance (cold):

Intake valve:

0.10–0.15 mm (0.0039–0.0059 in)

Exhaust valve:

0.20–0.25 mm (0.0079–0.0098 in)

Checking steps:

a. Turn the crankshaft counterclock-

wise with a wrench.

b. 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.

ADJUSTING THE ENGINE IDLING SPEED

1. Start the engine and thoroughly warm it up.

2. Adjust:

• Engine idling speed

Adjustment steps:

a. Turn the throttle stop screw "1"

until the specified engine idling speed.

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".

1. Remove:

•Seat

•Fuel tank Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section.

2. Remove:

• Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section in the CHAPTER 5.

• Spark plug

• Engine upper bracket

• Cylinder head cover Refer to "CAMSHAFTS" section in the CHAPTER 5.

3. Remove:

• Timing mark accessing screw "1"

• Crankshaft end accessing screw "2"

• O-ring

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.

c. Measure the valve clearance "e"

using a feeler gauge "1".

Record the measured reading if the clearance is incorrect.

Engine idling speed:

1,750–1,950 r/min

3-14

Page 70

ENGINE

h. Install the timing chain tensioner.

Refer to "CAMSHAFTS" section in the CHAPTER 5.

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

5. Adjust:

• Valve clearance

Adjustment steps:

a. Remove the camshaft (intake and

exhaust). Refer to "CAMSHAFTS" section in the CHAPTER 5.

b. Remove the valve lifters "1" and

the pads "2".

• 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.

d. Round off the last digit of the in-

stalled pad number to the nearest increment.

Last digit of pad

number

0, 1 or 2 0

4, 5 or 6 5

8 or 9 10

EXAMPLE:

Installed pad number = 148 Rounded off value = 150

Pads can only be selected in 0.05 mm increments.

e. 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.

Use the new pad number only as a guide when verifying the valve clearance adjustment.

Rounded valve

i. Recheck the valve clearance. j. If the clearance is still incorrect,

repeat all the clearance adjustment steps until the specified clearance is obtained.

6. Install:

• All removed parts

Install all removed parts in reversed order of their removal.

c. Select the proper pad using the

pad selecting table.

Pad Availabili-

Pad range

No.

120–

No. 240

The thickness "a" of each pad is indicated in hundredths of millimeters on the pad upper surface.

1.20

mm–

2.40 mm

ty: 25 incre-

ments

Pads are avail-

able in 0.05 mm

increments

f. Install the new pads "3" and the

valve lifters "4".

• 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.

g. Install the camshafts (exhaust

and intake). Refer to "CAMSHAFTS" section in the CHAPTER 5.

Bolt (camshaft cap):

10 Nm (1.0 m•kg, 7.2 ft•lb)

3-15

Page 71

INTAKE

ENGINE

EXHAUST

3-16

Page 72

CHASSIS

CLEANING THE SPARK ARRESTER (For USA)

• Be sure the exhaust pipe and silencer are cool before cleaning the spark arrester.

• Do not start the engine when cleaning the exhaust system.

1. Remove:

• Screw (silencer cap) "1"

2. Remove:

• Bolt (spark arrester) "1"

3. Remove:

• Tail pipe "1"

• Gasket (tail pipe) "2"

• Spark arrester "3"

Pull the spark arrester out of the silencer.

• Gasket (spark arrester) "4"

6. Install:

• Silencer cap

Silencer cap:

5 Nm (0.5 m•kg, 3.6 ft•lb)

First tighten the two screws "a" located horizontally apart, and then tighten the others.

CHASSIS

BLEEDING THE HYDRAULIC BRAKE SYSTEM

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.

1. Remove:

• Brake master cylinder cap

• Diaphragm

• Reservoir float (front brake)

• Protector (rear brake)

2. Bleed:

•Brake fluid

A. Front B. Rear

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)

i. Repeat steps (e) to (h) until of the

air bubbles have been removed from the system.

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.

j. Add brake fluid to the level line on

the reservoir.

4. Clean:

• Spark arrester Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits.

5. Install:

• Gasket (spark arrester)

• Spark arrester Insert the spark arrester into the silencer and align the bolt holes.

• Gasket (tail pipe)

• Bolt (spark arrester)

Bolt (spark arrester):

7 Nm (0.7 m•kg, 5.1 ft•lb)

Air bleeding steps:

a. Add proper brake fluid to the res-

ervoir.

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".

3-17

Check the operation of the brake after bleeding the brake system.

3. Install:

• Protector (rear brake)

• Reservoir float (front brake)

• Diaphragm

• Brake master cylinder cap

ADJUSTING THE FRONT BRAKE

1. Check:

• Brake lever position "a"

Brake lever position "a":

Standard posi-

tion

95 mm (3.74 in)

Extent of ad-

justment

76–97 mm

(2.99–3.82 in)

Page 73

Pedal height adjustment steps:

a. Loosen the locknut "1". b. Turn the adjusting nut "2" until the

pedal height "a" is within specified height.

c. Tighten the locknut.

CHASSIS

2. Remove:

• Brake lever cover

3. Adjust:

• Brake lever position

Brake lever position adjustment steps:

a. Loosen the locknut "1". b. Turn the adjusting bolt "2" until the

lever position "a" is within specified position.

c. Tighten the locknut.

Locknut:

5 Nm (0.5 m •kg, 3.6 ft•lb)

Be sure to tighten the locknut, as it will cause poor brake performance.

• Adjust the pedal height between the maximum "A" and the minimum "B" 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.

b. Loosen the pad pin "2". c. Remove the brake caliper "3"

from the front fork.

d. Remove the pad pin and brake

pads "4".

e. Connect the transparent hose "5"

to the bleed screw "6" and place the suitable container under its end.

4. Install:

• Brake lever cover

ADJUSTING THE REAR BRAKE

1. Check:

• Brake pedal height "a"

Out of specification → Adjust.

Brake pedal height "a":

10 mm (0.39 in)

2. Adjust:

• Brake pedal height

CHECKING AND REPLACING THE FRONT BRAKE PADS

1. Inspect:

• Brake pad thickness "a"

Out of specification → Replace as a set.

Brake pad thickness:

4.4 mm (0.17 in) <Limit>: 1.0 mm (0.04 in)

2. Replace:

•Brake pad

Brake pad replacement steps:

a. Remove the pad pin plug "1".

f. Loosen the bleed screw and push

the brake caliper piston in.

Do not reuse the drained brake fluid.

g. Tighten the bleed screw.

Bleed screw:

6 Nm (0.6 m•kg, 4.3 ft•lb)

h. Install the brake pads "7" and pad

pin.

• Install the brake pads with their projections "a" into the brake caliper recesses "b".

• Temporarily tighten the pad pin at this point.

3-18

Page 74

i. Install the brake caliper "8" and

tighten the pad pin "9".

Bolt (brake caliper):

23 Nm (2.3 m•kg, 17 ft•lb)

Pad pin:

18 Nm (1.8 m•kg, 13 ft•lb)

j. Install the pad pin plug "10".

Pad pin plug:

3 Nm (0.3 m•kg, 2.2 ft•lb)

2. Replace:

•Brake pad

Brake pad replacement steps:

a. Remove the protector "1" and pad

pin plug "2".

b. Loosen the pad pin "3". c. Remove the rear wheel "4" and

brake caliper "5". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 6.

CHASSIS

Do not reuse the drained brake fluid.

g. Tighten the bleed screw.

Bleed screw:

6 Nm (0.6 m•kg, 4.3 ft•lb)

h. Install the brake pad "10" and pad

pin "11".

• Install the brake pads with their projections "a" into the brake caliper recesses "b".

• Temporarily tighten the pad pin at this point.

i. Install the brake caliper "12" and

rear wheel "13". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 6.

j. Tighten the pad pin "14".

Pad pin:

18 Nm (1.8 m•kg, 13 ft•lb)

3. Inspect:

• Brake fluid level Refer to "CHECKING THE BRAKE FLUID LEVEL" section.

4. Check:

• Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" section.

CHECKING AND REPLACING THE REAR BRAKE PADS

1. Inspect:

• Brake pad thickness "a" Out of specification → Replace as a set.

Brake pad thickness:

6.4 mm (0.25 in) <Limit>: 1.0 mm (0.04 in)

d. Remove the pad pin "6" and brake

pads "7".

e. Connect the transparent hose "8"

to the bleed screw "9" and place the suitable container under its end.

f. Loosen the bleed screw and push

the brake caliper piston in.

k. Install the pad pin plug "15" and

protector "16".

Pad pin plug:

3 Nm (0.3 m•kg, 2.2 ft•lb)

Bolt (protector):

7 Nm (0.7 m•kg, 5.1 ft•lb)

3-19

Page 75

3. Inspect:

• Brake fluid level Refer to "CHECKING THE BRAKE FLUID LEVEL" section.

4. Check:

• Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" section.

CHECKING THE REAR BRAKE PAD INSULATOR

1. Remove:

• Brake pad Refer to "CHECKING AND REPLACING THE REAR BRAKE PADS" section.

2. Inspect:

• Rear brake pad insulator "1" Damage → Replace.

a. Lower level A. Front B. Rear

CHECKING THE SPROCKET

1. Inspect:

• Sprocket teeth "a"

Excessive wear → Replace.

Replace the drive sprocket, rear wheel sprocket and drive chain as a set.

CHASSIS

3. Clean:

• Drive chain Brush off as much dirt as possible. Then clean the drive chain using the chain cleaner.

This machine has a drive chain with small rubber O-rings "1" between the side plates. Steam cleaning, high-pressure washes, certain solvent and kerosene can damage these O-rings.

CHECKING THE BRAKE FLUID LEVEL

1. Place the brake master cylinder so that its top is in a horizontal position.

2. Inspect:

• Brake fluid level

Fluid at lower level → Fill up.

Recommended brake fluid:

DOT #4

• 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 con-

taminants do not enter master cylinder when refilling.

• Clean up spilled fluid immediate-

ly to avoid erosion of painted surfaces or plastic parts.

CHECKING THE DRIVE CHAIN

1. Measure:

• Drive chain length (15 links) "a"

Out of specification → Replace.

Drive chain length (15 links):

<Limit>: 239.3 mm (9.42 in)

• 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 "16" as shown.

• Perform this measurement at two or three different places.

2. Remove:

• Drive chain "1"

4. Inspect:

• O-ring "1" (drive chain)

Damage → Replace the drive chain.

•Roller "2"

• Side plate "3"

Damage/wear → Replace the drive chain.

5. Check:

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

Remove the drive chain using a drive chain cutter "2".

3-20

6. Install:

• Chain joint "1"

• O-ring "2"

• Drive chain "3"

• Link plate "4"

Page 76

When installing the drive chain, apply the lithium soap base grease on the chain joint and O-rings.

7. Install:

• Link plate

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 the drive chain slack with the rear wheel in this "tight chain" position.

CHASSIS

e. Tighten the locknuts.

Locknut:

19 Nm (1.9 m•kg, 13 ft•lb)

CHECKING THE FRONT FORK

1. Inspect:

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

• Press the link plate onto the chain joint using a drive chain riveter "5".

• Rivet the end of the chain joint using a drive chain riveter.

• After riveting the chain joint, make sure its movement is smooth.

8. Lubricate:

• Drive chain

Drive chain lubricant:

SAE 10W-30 motor oil or suitable chain lubricants

3. Adjust:

• Drive chain slack

Drive chain slack adjustment steps:

a. Loosen the axle nut "1" and lock-

nuts "2".

b. Adjust the drive chain slack by

turning the adjusters "3".

To tighten→Turn the adjuster "3"

counterclockwise.

To loosen→Turn the adjuster "3"

clockwise and push wheel forward.

c. Turn each adjuster exactly the

same amount to maintain correct axle alignment. (There are marks "a" on each side of the drive chain puller alignment.)

CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL

1. Remove:

•Protector

• Dust seal "1"

Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.

2. Clean:

• Dust seal "a"

• Oil seal "b"

ADJUSTING THE DRIVE CHAIN SLACK

1. Elevate the rear wheel by placing

the suitable stand under the engine.

2. Check:

• Drive chain slack "a"

Above the seal guard installation bolt. Out of specification → Adjust.

Drive chain slack:

48–58 mm (1.9–2.3 in)

Turn the adjuster so that the drive chain is in line with the sprocket, as viewed from the rear.

Too small drive chain slack will overload the engine and other vital parts; keep the slack within the specified limits.

d. Tighten the axle nut while pushing

down the drive chain.

Axle nut:

125 Nm (12.5 m•kg, 90 ft•lb)

3-21

• Clean the dust seal and oil seal after every run.

• Apply the lithium soap base grease on the inner tube.

RELIEVING THE FRONT FORK INTERNAL PRESSURE

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

Page 77

CHASSIS

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.

3. Install:

• Air bleed screw

Air bleed screw:

1 Nm (0.1 m•kg, 0.7 ft•lb)

ADJUSTING THE FRONT FORK REBOUND DAMPING FORCE

1. Adjust:

• Rebound damping force By turning the adjuster "1".

Stiffer "a" → Increase the re-

bound damping force. (Turn the adjuster "1" in.)

Softer "b" → Decrease the re-

bound damping force. (Turn the adjuster "1" out.)

Extent of adjustment:

Maximum Minimum

Fully turned in position

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position.

Standard position:

8 clicks out

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

20 clicks out (from maximum position)

Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

ADJUSTING THE FRONT FORK COMPRESSION DAMPING FORCE

1. Remove:

• Rubber cap

2. Adjust:

• Compression damping force By turning the adjuster "1".

Stiffer "a" → Increase the com-

pression damping force. (Turn the adjuster "1" in.)

Softer "b" → Decrease the com-

pression damping force. (Turn the adjuster "1" out.)

Extent of adjustment:

Maximum Minimum

Fully turned in position

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position.

Standard position:

9 clicks out

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

Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

3. Install:

• Rubber cap

20 clicks out (from maximum position)

CHECKING THE REAR SHOCK ABSORBER

1. Inspect:

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

ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD

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

2. Remove:

• Rear frame

3. Loosen:

• Locknut "1"

4. Adjust:

• Spring preload By turning the adjuster "2".

Stiffer → Increase the spring pre-

load. (Turn the adjuster "2" in.)

Softer → Decrease the spring pre-

load. (Turn the adjuster "2" out.)

Spring length (installed) "a":

Standard

length

252.5 mm (9.94 in) * 251.5 mm (9.90 in)

* For EUROPE

• 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.

Extent of ad-

justment

238.5–258.5 mm (9.39–10.18 in)

3-22

Page 78

Never attempt to turn the adjuster beyond the maximum or minimum setting.

5. Tighten:

•Locknut

6. Install:

• Rear frame (upper)

Rear frame (upper):

38 Nm (3.8 m•kg, 27 ft•lb)

• Rear frame (lower)

Rear frame (lower):

32 Nm (3.2 m•kg, 23 ft•lb)

ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE

1. Adjust:

• Rebound damping force By turning the adjuster "1".

Stiffer "a" → Increase the re-

bound damping force. (Turn the adjuster "1" in.)

Softer "b" → Decrease the re-

bound damping force. (Turn the adjuster "1" out.)

Standard position:

About 11 clicks out

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

ADJUSTING THE REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE

1. Adjust:

• 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 Minimum

Fully turned in position

20 clicks out (from maximum position)

CHASSIS

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

ADJUSTING THE REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE

1. Adjust:

• 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 Minimum

Fully turned in position

2 turns out (from maximum position)

Extent of adjustment:

Maximum Minimum

Fully turned in 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.)

20 clicks out (from maximum position)

Standard position:

About 8 clicks out * About 9 clicks out ** About 11 clicks out

* For AUS, NZ and ZA ** For EUROPE

3-23

• 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 1-1/8 turns out * About 1-1/4 turns out

* For AUS, NZ and ZA

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

Page 79

CHASSIS

CHECKING THE TIRE PRESSURE

1. Measure:

• Tire pressure

Out of specification → Adjust.

Standard tire pressure:

100 kPa (1.0 kgf/cm 15 psi)

• 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.

CHECKING THE WHEELS

1. Inspect:

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

2. Inspect:

• Bearing free play Exist play → Replace.

CHECKING AND ADJUSTING THE STEERING HEAD

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

2. Check:

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

c. Loosen the steering ring nut "1"

using the steering nut wrench "2".

Steering nut wrench:

YU-33975/90890-01403

d. Tighten the steering ring nut "3"

using steering nut wrench "4".

• Apply the lithium soap base grease on the thread of the steering stem.

• Set the torque wrench to the steering nut wrench so that they form a right angle.

Steering nut wrench:

YU-33975/90890-01403

Steering ring nut (initial tightening):

38 Nm (3.8 m•kg, 27 ft•lb)

CHECKING AND TIGHTENING THE SPOKES

1. Inspect:

• Spokes "1"

Bend/damage → Replace. Loose spoke → Retighten.

2. Tighten:

• Spokes

Spokes:

3 Nm (0.3 m•kg, 2.2 ft•lb)

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

3. Check:

• Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut.

4. Adjust:

• Steering ring nut

Steering ring nut adjustment steps:

a. Remove the headlight. b. Remove the handlebar and upper

bracket.

e. Loosen the steering ring nut one

turn.

f. Retighten the steering ring nut us-

ing the steering nut wrench.

Avoid over-tightening.

Steering ring nut (final tightening):

7 Nm (0.7 m•kg, 5.1 ft•lb)

g. Check the steering stem by turn-

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

h. Install the washer "5", upper

bracket "6", washer "7", steering stem nut "8", handlebar "9", handlebar upper holder "10" and headlight "11".

3-24

Page 80

• The handlebar upper holder 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 upper holder is positioned at the mark on the handlebar as shown.

• Insert the end of the fuel breather hose "12" into the hole in the steering stem.

First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.

Steering stem nut:

145 Nm (14.5 m•kg, 105 ft•lb)

Handlebar upper holder:

28 Nm (2.8 m•kg, 20

ft•lb) Pinch bolt (upper bracket):

21 Nm (2.1 m•kg, 15

ft•lb) Headlight:

7 Nm (0.7 m•kg, 5.1

ft•lb)

CHASSIS

3-25

Page 81

LUBRICATION

CHASSIS

To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race.

1. All control cable

2. Clutch lever pivot

3. Shift pedal pivot

4. Footrest pivot

5. Throttle-to-handlebar contact

6. Drive chain

7. Tube guide cable winding portion

8. Throttle cable end

9. Clutch cable end

10. Hot starter cable end

A. Use Yamaha cable lube or

equivalent on these areas.

B. Use SAE 10W-30 motor oil or

suitable chain lubricants.

C. Lubricate the following areas

with high quality, lightweight lithium-soap base grease.

Wipe off any excess grease, and avoid getting grease on the brake discs.

3-26

Page 82

ELECTRICAL

CHECKING THE SPARK PLUG

1. Remove:

• Spark plug

2. Inspect:

• Electrode "1"

Wear/damage → Replace.

• Insulator color "2" Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.

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.

CHECKING THE IGNITION TIMING

1. Remove:

• Timing mark accessing screw "1"

2. Attach:

• Timing light

• Inductive tachometer To the ignition coil lead (orange lead"1").

Timing light:

YM-33277-A/9089003141

• Charge batteries in a well-ventilated area.

• Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).

• DO NOT SMOKE when charging or handling batteries.

• KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.

• Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.

FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL

• Skin — Wash with water.

• Eyes — Flush with water for 15 minutes and get immediate medical attention.

INTERNAL

• Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

3. Measure:

• Plug gap "a" Use a wire gauge or thickness gauge. Out of specification → Regap.

Spark plug gap:

0.7–0.8 mm (0.028–

0.031 in)

4. Clean the plug with a spark plug cleaner if necessary.

5. Tighten:

• Spark plug

Spark plug:

13 Nm (1.3 m•kg, 9.4 ft•lb)

• Before installing a spark plug, clean

the gasket surface and plug surface.

• Finger-tighten "a" the spark plug

before torquing to specification "b".

3. Adjust:

• Engine idling speed Refer to "ADJUSTING THE ENGINE IDLING SPEED" section.

4. Check:

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

5. Install:

• Timing mark accessing screw

CHECKING AND CHARGING THE BATTERY

Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures:

• Wear protective eye gear when handling or working near batteries.

Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.

1. Remove:

• Seat

2. Disconnect:

• Battery leads (from the battery terminals)

First, disconnect the negative battery lead "1", and then the positive battery lead "2".

3-27

Page 83

3. Remove:

• Battery band

•Battery

4. Measure:

• Battery charge

Measurement steps:

a. Connect a pocket tester "1" to the

battery terminals.

Tester positive probe → battery

positive terminal

Tester negative probe → battery

negative terminal

• The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).

• No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery,

as shown in the charts and the following example.

Example

Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20–30%

A. Relationship between the

open-circuit voltage and the charging time at 20 °C (68 °F) (These values vary with the temperature, the condition of the battery plates, and the

electrolyte level.) B. Open-circuit voltage C. Charging time (hours) D. Time (minutes) E. Charging condition of the bat-

tery F. Ambient temperature 20 °C

(68 °F) a. Charging b. Check the open-circuit volt-

age

5. Charge:

•Battery (refer to the appropriate charging method illustration)

Do not quick charge a battery.

• Never remove the MF battery sealing caps.

• Do not use a high-rate battery charger since it forces a highamperage current into the battery quickly and can cause battery overheating and battery plate damage.

• If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.

• When charging a battery, be sure to remove it from the machine. (If charging has to be done with the battery mounted on the machine, disconnect the negative battery lead from the battery terminal.)

ELECTRICAL

• To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.

• Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.

• Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.

• If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!

• As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

3-28

Page 84

Charging method using a variable voltage charger

ELECTRICAL

3-29

Page 85

Charging method using a constant voltage charger

ELECTRICAL

3-30

Page 86

ELECTRICAL

6. Install:

•Battery

• Battery band

7. Connect:

• Battery leads (to the battery terminals)

First, connect the positive lead "1", then the negative lead "2".

8. Check:

• Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly.

9. Lubricate:

• Battery terminal

Recommended lubricant:

Lithium soap base grease

10. Install:

• Seat

CHECKING THE FUSE

To avoid a short circuit, always set the main switch to "OFF" when checking or replacing a fuse.

1. Remove:

• Seat

• Fuse cover

2. Check:

• Continuity

Checking steps:

a. Remove the fuse "1". b. Connect the pocket tester to the

fuse and check the continuity.

Set the pocket tester selector to " Ω× 1".

Pocket tester:

YU-3112-C/9089003112

2. Reserve fuse

c. If the pocket tester indicates " ∞",

replace the fuse.

3. Replace:

• Blown fuse

Replacement steps:

a. Set the main switch to "OFF". b. Install a new fuse of the correct

amperage.

c. Set on the switches to verify if the

electrical circuit is operational.

d. If the fuse immediately blows

again, check the electrical circuit.

Items Amperage

rating

Main fuse 10 A 1

Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the starting and ignition systems to malfunction and could possibly cause a fire.

4. Install:

• Fuse cover

•Seat

REPLACING THE HEADLIGHT BULBS

1. Remove:

• Headlight Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section.

Q'ty

2. Remove:

• Headlight bulb holder cover "1"

3. Remove:

• Headlight bulb holder "1"

Remove the headlight bulb holder by pushing it in and turning it counterclockwise.

4. Remove:

• Headlight bulb

Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb unit it has cooled down.

5. Install:

• Headlight bulb

Avoid touching the glass part of the headlight bulb to keep it free form oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

6. Install:

• Headlight bulb holder

7. Install:

• Headlight bulb holder cover

8. Install:

• Headlight

Headlight:

7 Nm (0.7 m•kg, 5.1 ft•lb)

Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section.

3-31

Page 87

ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:

• Headlight beam (vertically)

Adjusting steps:

a. Turn the adjusting screw "1" in di-

rection "a" or "b".

Direction "a" Headlight beam is

raised.

Direction "b" Headlight beam is

lowered.

ELECTRICAL

3-32

Page 88

ENGINE

TUNING

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.

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.

• 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.

• After installing the carburetor, check that the throttle operates correctly and opens and closes smoothly.

ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS

Air

Hu-

pres-

tem

midi-

High High

Low Low

The air density (i.e., concentration of oxygen in the air) determines the richness or leanness of the air/fuel mixture.

• 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.

EFFECT OF SETTING PARTS IN RELATION TO THROTTLE VALVE OPENING

sure

(alti-

tude)

Low

(high)

High

(low)

Mix-

ture

Rich-erLean-

Lean-erRich-

Set-

ting

CONSTRUCTION OF CARBURETOR AND SETTING PARTS

The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing machines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor.

1. Jet needle

2. Pilot air jet

3. Needle jet

4. Main jet

5. Pilot jet

ADJUSTING THE MAIN JET

The richness of the air-fuel mixture at full throttle can be set by changing the main jet "1".

Standard main jet

* For EUROPE

#162 * #160

• 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.

A. Closed B. Fully open

1. Pilot jet

2. Throttle valve cutaway

3. Jet needle

4. Main jet

4-1

If the air-fuel mixture is too rich or too lean, the engine power will drop, resulting in poor acceleration.

Effects of changing the main jet (reference)

A. Idle B. Fully open

1. #165

2. #160

3. #162

Page 89

ENGINE

ADJUSTING THE PILOT JET

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

* For EUROPE

Effects of adjusting the pilot jet (reference)

A. Idle B. Fully open

1. #48

2. #42

3. #45

ADJUSTING THE JET NEEDLE GROOVE POSITION

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. 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 posi-

tion

#45 * #48

No.4

groove

Effects of changing the jet needle groove position (reference)

A. Idle B. Fully open

1. No.5 groove

2. No.3 groove

3. No.4 groove

ADJUSTING THE JET NEEDLE

The jet needle is adjusted by changing it.

Supplied jet needle

*For EUROPE

The jet needle setting parts, having the same taper angle, are available in different straight portion diameters.

a. Diameter of the straight por-

tion

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.

A. Idle B. Fully open

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.

GDDSQ * GDDUQ

ADJUSTING THE LEAK JET (ADJUSTING THE ACCELERATOR PUMP)

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. When the engine breathes hard in quick throttle opening, select a leak jet having lower calibrating No. than standard to enrich the mixture. <Example> #60 → #55

2. When 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> #60 → #65

Standard leak jet #60

4-2

Page 90

ENGINE

CARBURETOR SETTING PARTS

Part

Main jet Size

Rich #185 4MX-44

#182 4MX-94

#180 4MX-43

#178 4MX-93

#175 4MX-42

#172 4MX-92

#170 4MX-41

#168 4MX-91

#165 4MX-40

(STD) #162 4MX-90

*(STD) Lean #160 4MX-39

Pilot jet Size

Rich #55 4MX-09

#52 4MX-08

#50 4MX-07

*(STD) #48 4MX-06

(STD) Lean #45 4MX-05

Jet needle Size

Rich GDDUM 5TJ-9M

GDDUN 5TJ-9N

GDDUP 5TJ-9P

GDDUQ 5TJ-91

GDDUR 5TJ-9R

GDDUS 5TJ-9S

Lean GDDUT 5TJ-9T

Rich GDDSM 5TJ-AM

GDDSN 5TJ-AN

GDDSP 5TJ-AP

GDDSQ 5TJ-A1

GDDSR 5TJ-AR

GDDSS 5TJ-AS

Lean GDDST 5TJ-AT

number

(-14943-)

Part

number

(-14948-)

Part

number

(-14916-)

Leak jet Size

Rich #35 4JT-01

#40 4JT-03

#45 4JT-05

#50 4JT-07

#55 4JT-09

(STD) #60 4JT-11

Lean #65 4JT-13

* For EUROPE

Part

number

(-1494F-)

4-3

Page 91

EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM

Symptom Setting Checking

At full throttle

Hard breathing

Increase main jet calibration no. (Gradual-

ly) Shearing noise Whitish spark plug

↓

Lean mixture

At full throttle

Speed pick-up stops

Decrease main jet calibration no. (Gradual-

ly) Slow speed pick-up Slow response Sooty spark plug

↓

Rich mixture

Lean mixture Lower jet needle clip position. (1 groove

down)

Rich mixture Raise jet needle clip position. (1 groove up)

1/4–3/4 throttle

Hard breathing

Lower jet needle clip position. (1 groove

down) Lack of speed

1/4–1/2 throttle

Raise jet needle clip position. (1 groove up) Slow speed pick-up Poor acceleration

Closed to 1/4 throttle

Use jet needle with a smaller diameter. Slow-speed-circuit passage Hard breathing Speed down

Closed to 1/4 throttle

Poor acceleration

Poor response in the low to intermediate speeds

Use jet needle with a larger diameter.

Raise jet needle clip position. (1 groove up)

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.

ENGINE

Discoloration of spark plug → If tan color, it

is in good condition.

If cannot be corrected:

Clogged float valve seat Clogged fuel hose

Clogged fuel cock Check that the accelerator pump operates smoothly.

Discoloration of spark plug → If tan color, it

is in good condition. If cannot be corrected:

Clogged air filter

Fuel overflow from carburetor

Groove 1 Groove 2 Groove 3 Groove 4 Groove 5 Groove 6 Groove 7

Jet needle

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).

Clogged → Clean. Overflow from carburetor

Check air filter for fouling. Check that the accelerator pump operates smoothly.

Clip

Leaner

(Standard)

Richer

* This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine.

4-4

Page 92

CHASSIS

SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET)

Secondary reduction ratio =

Number of rear wheel sprocket teeth/Number of drive sprocket teeth

50/13 Standard secondary reduction ratio

* For EUROPE

• 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.

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.

(3.846) * 47/14 (3.357)

DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS

Part

name

Drive sprocket "1"

(STD) 13T 9383E-13233

** (STD) ** 14T 5NG-17460-00

* For AUS and NZ ** For EUROPE

Part

name

Rear wheel sprocket "2"

** (STD) ** 47T 1C3-25447-00

(STD) 50T 5TJ-25450-80

* (STD) * 50T 1C3-25450-00

* For AUS and NZ ** For EUROPE

TIRE PRESSURE

Tire pressure should be adjust to suit the road surface condition of the circuit.

Size Part number

* 14T 9383E-14215

Size Part number

48T 5GS-25448-50

* 48T 1C3-25448-00

* 49T 1C3-25449-00

* 51T 1C3-25451-00

52T 5TJ-25452-80

* 52T 1C3-25452-00

Standard tire pressure:

100 kPa (1.0 kgf/cm 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/

, 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/cm

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 characteris-

tics

• Change the fork oil level.

2. Setting of spring preload

• Change the spring.

• Install the adjustment washer.

3. Setting of damping force

• Change the compression damp-

ing.

• Change the rebound damping.

The spring acts on the load and the damping force acts on the cushion travel speed.

CHANGE IN LEVEL AND CHARACTERISTICS OF FORK OIL

Damping characteristic near the final stroke can be changed by changing the fork oil amount.

Adjust the oil level in 5 mm (0.2 in) increments or decrements. Too low oil level 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 high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated performance and characteristics. Therefore, adjust the front fork within the specified range.

, 15–18 psi)

4-5

Page 93

CHASSIS

Standard oil level:

132 mm (5.20 in) *125 mm (4.92 in)

Extent of adjustment:

95–150 mm (3.74–5.91 in) From top of outer tube with inner tube and damper rod fully compressed without spring.

* For AUS, NZ , ZA and EUROPE

A. Air spring characteristics in

relation to oil level change B. Load C. Stroke

1. Max. oil level

2. Standard oil level

3. Min. oil level

ADJUSTING THE SPRING PRELOAD

The spring preload is adjusted by installing the adjustment washer "1" between the fork spring "2" and damper rod "3".

Standard washer quantity:

Zero adjustment washers

Extent of adjustment:

Zero–2 adjustment washers

A. Load B. Fork stroke

1. Without adjustment washer (standard)

2. 1 adjustment washer

3. 2 adjustment washers

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

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

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

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.

2. Use of stiff spring

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

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

FRONT FORK SETTING PARTS

• Adjustment washer "1"

TYPE (thick-

ness)

T = 2.3 mm (0.09

in)

• Front fork spring "2"

SPRI

TYPE

SOFT

STD 0.459 5TJ-L0 —

STIFF 0.469 5TJ-60 |-||

The I.D. mark (slits) "a" is proved on the end of the spring.

When using a spring with a spring rate of 0.469 kg/mm, do not install two or more adjustment washers for each front fork.

RATE

0.408 5TJ-00 |

0.418 5TJ-10 ||

0.428 5TJ-20 |||

0.438 5TJ-30 ||||

0.449 5TJ-40 |||||

PART NUMBER

5XE-23364-00

SPRING

PART

NUMBER

(-23141-)

MARK

I.D.

(slits)

Do not install three or more adjustment washers for each front fork.

Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

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.

4-6

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.

• Change the spring.

Page 94

CHASSIS

2. Setting of damping force

• Change the rebound damping.

• Change the compression damping.

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.

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.

REAR SHOCK ABSORBER SETTING PARTS

• Rear shock spring "1"

I.D.

SPRI

FRE

E LEN GTH

260

SPRIN

G PART NUM-

BER (-

22212-)

COLOR/

Yellow/

SPR ING

RAT

4.3 5UN-00 Brown/1 260

4.5 5UN-10 Green/1 260

4.7 5UN-20 Red/1 260

4.9 5UN-30 Black/1 260

5.1 5UN-40 Blue/1 260

5.3 5UN-50

5.5 5UN-60 Pink/1 260

STI

5.7 5UN-70 White/1 260

POINT

The I.D. color "a" is marked at the end of the spring.

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)

• 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.

When using a rear shock absorber 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:

488.5 mm (19.23 in)

• Extent of adjustment (spring length)

SPRING FREE

LENGTH

260 mm (10.24

in)

EXTENT OF AD-

JUSTMENT "b"

238.5–258.5

mm (9.39–10.18

in)

4-7

Page 95

CHASSIS

SUSPENSION SETTING (FRONT FORK)

• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to

the adjustment procedure given in the same chart.

• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).

Section

Symptom

Stiff over entire range

Unsmooth movement over entire range

Poor initial movement

Soft over entire range, bottoming out

Stiff toward stroke end

Soft toward stroke end, bottoming out

Stiff initial movement

Low front, tending to lower front posture

"Obtrusive" front, tending to upper front posture

Jump

○○○

○○○○

○○

○ Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in).

○ Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).

○○○○Compression damping

Large

gap

Medi-

Small

gap

○

○○

Check Adjust

Compression damping Turn adjuster counterclockwise (about 2 clicks) to

decrease damping.

Oil level (oil amount) Decrease oil level by about 5–10 mm (0.2–0.4 in).

Spring Replace with soft spring.

Outer tube Check for any bends, dents, and other noticeable

Inner tube

Under bracket tightening torque

Rebound damping Turn adjuster counterclockwise (about 2 clicks) to

Oil seal Apply grease in oil seal wall.

Compression damping Turn adjuster clockwise (about 2 clicks) to in-

Oil level (oil amount) Increase oil level by about 5–10 mm (0.2–0.4 in).

Spring Replace with stiff spring.

Compression damping Turn adjuster clockwise (about 2 clicks) to in-

Rebound damping Turn adjuster counterclockwise (about 2 clicks) to

Balance with rear end Set sunken length for 95–100 mm (3.7–3.9 in)

Oil level (oil amount) Increase oil level by about 5 mm (0.2 in).

Compression damping Turn adjuster counterclockwise (about 2 clicks) to

Balance with rear end Set sunken length for 90–95 mm (3.5–3.7 in)

Spring Replace with soft spring.

Oil level (oil amount) Decrease oil level by about 5–10 mm (0.2–0.4 in).

scars, etc. If any, replace affected parts.

Retighten to specified torque.

decrease damping.

crease damping.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

crease damping.

decrease damping.

when one passenger is astride seat (lower rear posture).

decrease damping.

when one passenger is astride seat (upper rear posture).

4-8

Page 96

CHASSIS

SUSPENSION SETTING (REAR SHOCK ABSORBER)

• 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

Heavy and dragging ○○

Poor road gripping ○

Bottoming out ○○

Bouncing ○○

Stiff travel ○○

Jump

Large

gap

Medi-

Small

gap

○○

Check Adjust

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 in-

crease damping.

Low compression damping

Spring Replace with stiff spring.

Rebound damping Turn adjuster counterclockwise (about 2 clicks) to

Spring Replace with soft spring.

Rebound damping Turn adjuster counterclockwise (about 2 clicks) to

Low compression damping

High compression damping

Spring set length Set sunken length for 90–100 mm (3.5–3.9 in)

Spring Replace with soft spring.

High compression damping

Spring set length Set sunken length for 90–100 mm (3.5–3.9 in)

Spring Replace with stiff spring.

Rebound damping Turn adjuster clockwise (about 2 clicks) to in-

Spring Replace with soft spring.

High compression damping

Spring set length Set sunken length for 90–100 mm (3.5–3.9 in)

Spring Replace with soft spring.

Turn adjuster clockwise (about 1 click) to increase damping.

decrease damping.

Turn adjuster clockwise (about 1 clicks) to increase damping.

Turn adjuster clockwise (about 1/6 turn) to increase damping.

when one passenger is astride seat.

Turn adjuster clockwise (about 1/6 turn) to increase damping.

when one passenger in astride seat.

crease damping.

Turn adjuster counterclockwise (about 1/6 turn) to decrease damping.

when one passenger is astride seat.

4-9

Page 97

ENGINE

RADIATOR

REMOVING THE RADIATOR

RADIATOR

Order Part name Q'ty Remarks

Drain the coolant.

Seat, fuel tank and left side cover

Exhaust pipe

1 Radiator guard 2

2 Radiator hose clamp 8

3 Right radiator 1

4 Radiator hose 2 1

5 Radiator hose 3 1

6 Radiator hose 4 1

7 Pipe 2/O-ring 1/1

8 Catch tank hose 1

9 Left radiator 1

10 Radiator hose 1 1

Refer to "CHANGING THE COOLANT" section in the CHAPTER 3.

Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 3.

Refer to "REMOVING THE EXHAUST PIPE AND SILENCER" section in the CHAPTER 3.

5-1

Page 98

RADIATOR

Order Part name Q'ty Remarks

11 Pipe 1/O-ring 1/1

12 Catch tank breather hose 1

13 Catch tank 1

5-2

Page 99

RADIATOR

HANDLING NOTE

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.

CHECKING THE RADIATOR

1. Inspect:

• Radiator core "1"

Obstruction → Blow out with compressed air through rear of the radiator. Bent fin → Repair/replace.

INSTALLING THE RADIATOR

1. Install:

• Pipe 1 "1"

Pipe 1:

10 Nm (1.0 m•kg, 7.2 ft•lb)

2. Install:

• Radiator hose 2 "1"

Radiator hose 2:

2 Nm (0.2 m•kg, 1.4 ft•lb)

• Left radiator "2"

Left radiator:

10 Nm (1.0 m•kg, 7.2 ft•lb)

3. Install:

• Catch tank hose "1"

• Right radiator "2"

Right radiator:

10 Nm (1.0 m•kg, 7.2 ft•lb)

Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER

5. Install:

• Catch tank "1"

• Bolt (catch tank) "2"

Bolt (catch tank):

7 Nm (0.7 m•kg, 5.1 ft•lb)

• Bolt (catch tank) "3"

Bolt (catch tank):

16 Nm (1.6 m•kg, 11 ft•lb)

• Catch tank hose "4"

• Catch tank breather hose "5" Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER

• Radiator hose 1 "2"

Radiator hose 1:

2 Nm (0.2 m•kg, 1.4 ft•lb)

• Pipe 2 "3"

Pipe 2:

10 Nm (1.0 m•kg, 7.2 ft•lb)

• Radiator hose 3 "4"

Radiator hose 3:

2 Nm (0.2 m•kg, 1.4 ft•lb)

• Radiator hose 4 "5"

Radiator hose 4:

2 Nm (0.2 m•kg, 1.4 ft•lb)

4. Install:

• Radiator guard "1"

First fit the inner hook portion "a" and then the outer one "b" onto the radiator.

5-3

Page 100

CARBURETOR

REMOVING THE CARBURETOR

CARBURETOR

Order Part name Q'ty Remarks

Refer to "REMOVING THE SEAT, FUEL

Seat and fuel tank

Rear shock absorber

1Clamp 2

2 Throttle position sensor lead coupler 1

3 Throttle cable cover 1

4 Throttle cable 2

5 Clamp (air filter joint) 1 Loosen the screw (air filter joint).

6 Clamp (carburetor joint) 1 Loosen the screws (carburetor joint).

7 Hot starter plunger 1

8 Carburetor 1

9 Cylinder head breather pipe 1

10 Cylinder head breather hose 1 1

11 Cylinder head breather hose 2 1

12 Cylinder head breather hose 3 1

TANK AND SIDE COVERS" section in the CHAPTER 3.

Refer to "REAR SHOCK ABSORBER" section in the CHAPTER 6.

5-4

Yamaha WR450F User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SPECIFICATIONS

TUNING

ENGINE

CHASSIS

ELECTRICAL

DESCRIPTION

MACHINE IDENTIFICATION

INCLUDED PARTS

IMPORTANT INFORMATION

CHECKING OF CONNECTION

SPECIAL TOOLS

CONTROL FUNCTIONS

MULTI-FUNCTION DISPLAY

STARTING AND BREAK-IN

TORQUE-CHECK POINTS

CLEANING AND STORAGE

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

TIGHTENING TORQUES

LUBRICATION DIAGRAMS

CABLE ROUTING DIAGRAM

MAINTENANCE INTERVALS

PRE-OPERATION INSPECTION AND MAINTENANCE

ENGINE

CHASSIS

ELECTRICAL

ENGINE

CHASSIS

RADIATOR

CARBURETOR