Yamaha WR450 FZ 2010 Owner's manual
2010
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
q
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
q Lea atentamente este manual antes de utilizar el vehículo.
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUAL DE SERVICIO
DEL PROPIETARI
O
WR450F(Z
5TJ-28199-47
)
Q
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
Q
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit
étre remis avec le véhicule en cas de vente de ce dernier.
Q
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben.
Q
Lea atentamente este manual antes de utilizar el vehículo. Este manual debe acompañar al vehículo si
este se vende.
Read this manual carefully before operating this vehicle.Read this manual carefully before operating this vehicle.
20102010
OWNER’S SERVICE MANUALOWNER’S SERVICE MANUAL
WR450F(Z)WR450F(Z)
5TJ-28199-47-E05TJ-28199-47-E0
WR450F (Z)
OWNER'S SERVICE MANUAL
©2009 by Yamaha Motor Co., Ltd.
1st Edition, July 2009
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
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.
For Canada
The design and manufacture of this
Yamaha machine fully comply with
the emissions standards for clean air
applicable at the date of manufacture.
Yamaha has met these standards
without reducing the performance or
economy of operation of the machine.
To maintain these high standards, it
is important that you and your Yamaha dealer pay close attention to the
recommended maintenance schedules and operating instructions contained within this manual.
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.
IMPORTANT MANUAL
INFORMATION
Particularly important information is
distinguished in this manual by the
following notations.
This is the safety alert symbol. It is
used to alert you to potential personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or
death.
A WARNING indicates a hazardous
situation which, if not avoided,
could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to
avoid damage to the vehicle or other property.
A TIP provides key information to
make procedures easier or clearer.
SAFETY INFORMATION
For Canada
This machine is designed for off-road
use only. 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.
Except for Canada
THIS MACHINE IS DESIGNED
STRICTLY FOR COMPETITION
USE, ONLY ON A CLOSED
COURSE. It is illegal for this machine
to be operated on any public street,
road, or highway. Off-road use on
public lands may also be illegal.
Please check local regulations before
riding.
• 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.
• THIS MACHINE IS DESIGNED TO
BE RIDDEN BY THE OPERATOR
ONLY.
Do not carry passengers on this
machine.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
F.I.M. MACHINE WEIGHTS
(Except for Canada)
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 be-
ginning 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.
HOW TO READ DESCRIPTIONS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal
and disassembly section.
1. An easy-to-see exploded diagram
"1" is provided for removal and
disassembly jobs.
2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes
is presented in an easy-to-read
way by the use of symbol marks
"3". The meanings of the symbol
marks are given on the next page.
4. A job instruction chart "4" accompanies the exploded diagram,
providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements "5" are given in addition
to the exploded diagram and job
instruction chart.
1
2
4
ILLUSTRATED SYMBOLS (Refer to
the illustration)
3
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
5
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
®
)
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
REGULAR INSPECTION AND
ADJUSTMENTS
TUNING
ENGINE
1
2
3
4
5
CHASSIS
ELECTRICAL
6
7
CONTENTS
CHAPTER 1
GENERAL INFOR-
MATION
LOCATION OF
IMPORTANT LABELS ..... 1-1
DESCRIPTION ................. 1-5
CONSUMER
INFORMATION................. 1-6
INCLUDED PARTS .......... 1-6
IMPORTANT
INFORMATION................. 1-6
CHECKING OF
CONNECTION.................. 1-7
SPECIAL TOOLS ............. 1-8
CONTROL
FUNCTIONS ................... 1-12
MULTI-FUNCTION
DISPLAY ........................1-13
STARTING AND
BREAK-IN ......................1-18
TORQUE-CHECK
POINTS........................... 1-20
CLEANING AND
STORAGE ...................... 1-21
CHAPTER 2
SPECIFICATIONS
GENERAL
SPECIFICATIONS............ 2-1
MAINTENANCE
SPECIFICATIONS............ 2-3
TIGHTENING
TORQUES ...................... 2-12
LUBRICATION
DIAGRAMS .................... 2-19
CABLE ROUTING
DIAGRAM....................... 2-21
CHAPTER 3
REGULAR INSPEC-
TION AND AD-
JUSTMENTS
PERIODIC MAINTENANCE
CHART FOR THE EMISSION
CONTROL SYSTEM (For
Canada) ............................ 3-1
GENERAL MAINTENANCE
AND LUBRICATION CHART
(For Canada) .................... 3-2
MAINTENANCE
INTERVALS FOR
COMPETITION USE.........3-3
PRE-OPERATION
INSPECTION AND
MAINTENANCE................ 3-7
ENGINE ............................3-8
CHASSIS ........................3-19
ELECTRICAL .................3-29
CHAPTER 4
TUNING
ENGINE
(Except for Canada) ........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 DIAGRAM...........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
LOCATION OF IMPORTANT LABELS
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS
Please read the following important labels carefully before operating this vehicle.
CANADA
1
Essence super sans
plomb seulement.
3FB-2415E-12
1-1
LOCATION OF IMPORTANT LABELS
EUROPE
1-2
AUS, NZ, ZA
LOCATION OF IMPORTANT LABELS
1-3
LOCATION OF IMPORTANT LABELS
Familiarize yourself with the following pictograms and read the explanatory text.
Read Owner's service manual.
This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate,
puncture or open.
Turn off the main switch after riding to avoid draining the battery.
Use unleaded gasoline only.
Measure tire pressure when tires are cold.
Adjust tire pressure.
Improper tire pressure can cause loss of control.
Loss of control can result in severe injury or death.
1-4
DESCRIPTION
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
1-5
CONSUMER INFORMATION
CONSUMER INFORMATION
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.
ENGINE SERIAL NUMBER
The engine serial number "1" is
stamped into the elevated part of the
right-side of the engine.
A. Left
B. Right
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.
SPARK PLUG WRENCH
This spark plug wrench "1" is used to
remove and install the spark plug.
DRIVE CHAIN SPROCKET GUIDE
(For EUROPE)
Use the drive chain sprocket guide
"1" when installing the included drive
sprockt (13T).
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
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.
VEHICLE EMISSION CONTROL
INFORMATION LABEL (For
Canada)
The Vehicle Emission Control Information label "1" is affixed at the location in the illustration. This label
shows specifications related to exhaust emissions as required by federal law, state law and Environment
Canada.
NIPPLE WRENCH
This nipple wrench "1" is used to
tighten the spoke.
2. Use proper tools and cleaning
equipment. Refer to "SPECIAL
TOOLS" section.
JET NEEDLE PULL-UP TOOL
(Except for Canada)
The jet needle pull-up tool "1" is used
to pull the jet needle out of the carburetor.
1-6
CHECKING OF CONNECTION
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.
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.
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.
6. Connect:
• Connector
The two connectors "click" together.
5. Keep away from fire.
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.
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.
7. Check for continuity with a tester.
• If there in no continuity, clean the
terminals.
• Be sure to perform the steps 1 to 7
listed above when checking the
wire harness.
• For a field remedy, use a contact revitalizer available on the market.
• Use the tester on the connector as
shown.
1-7
SPECIAL TOOLS
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.
1-8
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
Spoke nipple wrench
YM-01521, 90980-01521
Sheave holder
YS-1880-A, 90890-01701
This tool is used when install the fork
oil seal.
This tool is used to tighten the
spoke.
This tool is used for when loosening
or tightening the flywheel magneto
securing nut.
Pocket tester
YU-3112-C, 90890-03112
Timing light
YM-33277-A, 90890-03141
Use this tool to inspect the coil resistance, output voltage and amperage.
This tool is necessary for checking
ignition timing.
1-9
SPECIAL TOOLS
Tool name/Part number How to use Illustration
Valve spring compressor
YM-4019, 90890-04019
This tool is needed to remove and
install the valve assemblies.
Clutch holding tool
YM-91042, 90890-04086
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
This tool is used to hold the clutch
when removing or installing the
clutch boss securing nut.
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.
Rotor puller
YM-4142, 90890-04142
Crankcase separating tool
YU-A9642
90890-04152
This tool is used to remove the flywheel magneto.
These tool is used to remove the
crankshaft from either case.
1-10
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 (Three-
®
No. 1215)
Bond
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.
1-11
CONTROL FUNCTIONS
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.
1-12
MULTI-FUNCTION DISPLAY
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
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.
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.
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. ( )
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.
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.
1-13
MULTI-FUNCTION DISPLAY
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.
To reset the digits, select the tripmeter involved and push the "RST" button for 2 seconds or more.
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.
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
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".)
CHANGEOVER TO BASIC MODE/
RACE MODE
• 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".)
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).
4. To resume the measurement,
again push the "SLCT1" button
and "SLCT2" button at the same
time.
1-14
MULTI-FUNCTION DISPLAY
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.
3. Run the machine and start timer
measurement.
4. To stop timer measurement,
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 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.
Correcting tripmeter A (TRIP A)
1. Change the travel distance display 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.
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 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.
• Resetting will reset the timer display
and travel distance display and put
measurement on standby.
• Auto start attempt will put measure-
ment on standby as such. Likewise,
manual start attempt will put measurement on standby as such.
1-15
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
1-16
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
MULTI-FUNCTION DISPLAY
1. BASIC MODE
2. Clock
3. Trip meter
4. Speedometer (for U.K.)
5. RACE MODE
6. Putting measurement on standby
7. Manual start
8. Auto start
9. Measurement starts as the machine moves
10. Timer in operation
11. Reset TRIP A
12. Correct TRIP A
13. Timer not in operation
14. Reset TRIP A & timer
1-17
STARTING AND BREAK-IN
STARTING AND BREAK-IN
FUEL
Always use the recommended fuel as
stated below. Also, be sure to use
new gasoline.
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.
Gasohol (For Canada)
There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing
ethanol can be used if the ethanol
content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can
cause damage to the fuel system or
vehicle performance problems.
HANDLING NOTE
• 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.
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".
• 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.
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.
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.
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.
1-18
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.
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-
start-
grip
er le-
er
op-
ver
knob
era-
tion*
Air temperature = less
than 5 °C (41
°F)
St
ar
Air tempera-
ti
ture = more
n
than 5 °C (41
g
°F)
a
c
Air tempera-
ol
ture (normal
d
temperature)
e
= between 5
n
°C (41 °F)
gi
and 25 °C
n
(77 °F)
e
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
s
Non
ON OFF
e
NoneON/
OFF
Non
OFF OFF
e
Non
ON OFF
e
Non
OFF ON
e
Non
OFF ON
e
OFF
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.
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.
After the break-in or before each
ride, you must check the entire machine for loose fittings and fasteners as per "TORQUE-CHECK
POINTS". Tighten all such fasteners as required.
Observe the following break-in
procedures during initial operation
to ensure optimum performance
and avoid engine damage.
1-19
TORQUE-CHECK POINTS
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.
1-20
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