Yamaha YZ450FA user guide

q Read this manual carefully before operating this vehicle.

2011

LIT-11626-24-22

OWNER’S SERVICE MANUAL

YZ450FA

33D-28199-11

Q

Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.

YZ450FA

OWNER'S SERVICE MANUAL

©2010 by Yamaha Motor Corporation, U.S.A.

1st Edition, May 2010

All rights reserved.

Any reprinting or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in Japan

P/N. LIT-11626-24-22

INTRODUCTION

Congratulations on your purchase of a Yamaha
YZ series. This model is the culmination of Ya­maha's vast experience in the production of
pacesetting racing machines. It represents the
highest grade of craftsmanship and reliability
that have made Yamaha a leader.
This manual explains operation, inspection, ba­sic maintenance and tuning of your machine. If
you have any questions about this manual or
your machine, please contact your Yamaha
dealer.

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.

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.

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.

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

SAFETY INFORMATION

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 pre­operation 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.
For safety, drain the gasoline from the fuel
tank before transporting the vehicle.

YAMAHA MOTOR CORPORATION, U.S.A.

YZ MOTORCYCLE LIMITED WARRANTY

HOW TO USE THIS MANUAL

FINDING THE REQUIRED PAGE

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

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

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-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.

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 cur-

rent (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 (LOCTITE

15. Use new one

®

)

MEMO

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

REGULAR INSPECTION AND
ADJUSTMENTS

ENGINE

CHASSIS

1

2

3

4

5

FUEL SYSTEM

ELECTRICAL

TUNING

6

7

8

CONTENTS

CHAPTER 1

GENERAL INFORMATION

LOCATION OF IMPORTANT LABELS ..... 1-1

DESCRIPTION ........................................... 1-2

CONSUMER INFORMATION .................... 1-3

FEATURES ................................................ 1-4

INCLUDED PARTS.................................... 1-6

IMPORTANT INFORMATION.................... 1-8

HANDLING THE ELECTRONIC

PARTS ..................................................... 1-10

CHECKING OF CONNECTION ............... 1-10

SPECIAL TOOLS..................................... 1-12

CONTROL FUNCTIONS.......................... 1-17

STARTING AND BREAK-IN.................... 1-19

TORQUE-CHECK POINTS...................... 1-21

CLEANING AND STORAGE ................... 1-22

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS................... 2-1

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

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

LUBRICATION DIAGRAMS .................... 2-21

CABLE ROUTING DIAGRAM.................. 2-23

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

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

PRE-OPERATION INSPECTION AND

MAINTENANCE ......................................... 3-6

ENGINE...................................................... 3-7

CHASSIS.................................................. 3-20

ELECTRICAL........................................... 3-37

TROUBLESHOOTING ............................. 3-39

CHAPTER 4

ENGINE

SEAT AND SIDE COVERS........................ 4-1

EXHAUST PIPE AND SILENCER ............. 4-3

RADIATOR................................................. 4-8

CAMSHAFTS ........................................... 4-12

CYLINDER HEAD .................................... 4-19

VALVES AND VALVE SPRINGS ............ 4-23

CYLINDER AND PISTON ........................ 4-30

CLUTCH................................................... 4-35

OIL FILTER ELEMENT AND

WATER PUMP ......................................... 4-41

BALANCER ............................................. 4-47

OIL PUMP ................................................ 4-51

KICK SHAFT AND SHIFT SHAFT........... 4-55

AC MAGNETO ......................................... 4-62

ENGINE REMOVAL................................. 4-65

CRANKCASE AND CRANKSHAFT........ 4-71

TRANSMISSION, SHIFT CAM AND

SHIFT FORK ............................................ 4-79

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR WHEEL ....... 5-2

FRONT BRAKE AND REAR BRAKE........ 5-9

FRONT FORK .......................................... 5-23

HANDLEBAR........................................... 5-36

STEERING ............................................... 5-42

SWINGARM ............................................. 5-47

REAR SHOCK ABSORBER.................... 5-54

CHAPTER 6

FUEL SYSTEM

FUEL TANK ............................................... 6-2

THROTTLE BODY ..................................... 6-6

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS AND

WIRING DIAGRAM .................................... 7-1

IGNITION SYSTEM.................................... 7-4

THROTTLE POSITION

SENSOR SYSTEM..................................... 7-8

FUEL INJECTION SYSTEM .................... 7-11

FUEL PUMP SYSTEM ............................. 7-44

ELECTRICAL COMPONENTS ................ 7-45

CHAPTER 8

TUNING

CHASSIS.................................................... 8-1

LOCATION OF IMPORTANT LABELS

GENERAL INFORMATION

LOCATION OF IMPORTANT LABELS

Please read the following important labels carefully before operating this vehicle.

1

Premium unleaded
gasoline only.

3FB-2415E-02

WARNING

This unit contains high pressure nitrogen gas.
Mishandling can cause explosion.
Read owner’s manual for instructions.
Do not incinerate, puncture or open.

4AA-22259-80

For use only on a closed course
in sanctioned competition.

This motorcycle does not meet
EPA noise and emissions
standards and is not for general
off-road recreational riding.

17D-2812P-00

1-1

DESCRIPTION

DESCRIPTION

1. Clutch lever

2. Front brake lever

3. Throttle grip

4. Radiator cap

5. Fuel tank cap

6. Engine stop switch

7. Kickstarter crank

8. Fuel tank

9. Radiator

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

• Designs and specifications are subject to change without notice.

10. Coolant drain bolt

11. Rear brake pedal

12. Valve joint

13. Air cleaner

14. Drive chain

15. Shift pedal

16. Oil level check window

17. Starter knob/idle screw

18. Front fork

1-2

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.

CONSUMER INFORMATION

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.

1-3

FEATURES

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti­mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera­ture.Inthe conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustionchamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies by the engine operating
conditions,such as acceleration, deceleration, or operating under a heavy load.Carburetors that me­ter the fuel through the use of jets have been provided with various auxiliary devices, so that an op­timum air fuel ratio can be achieved to accommodate the constant changes in the operating
conditions of the engine.
This model has adopted an electronically controlled fuel injection (FI) system, in place of the conven­tional carburetor system.This system can achieve an optimum air-fuel ratio required by the engine at
all times by using a microprocessor that regulates the fuel injection volume according to the engine
operating conditions detected by various sensors.

1. Fuel injector

2. Throttle position sensor

3. Intake air pressure sensor

4. ECU

5. Fuel pump

6. Intake air temperature sensor

7. Atmospheric pressure sensor

8. Crankshaft position sensor

9. Coolant temperature sensor

10. Ignition coil

11. Condenser

1-4

FEATURES

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kgf/cm ² , 47.0 psi). According­ly,when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus­ing the fuel to be injected into the intake manifold only during the time the passage remains open.
Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater
the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is en­ergized(injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, coolant temperature sensor, atmospheric pressure sensor, lean angle
sensor, crankshaft position sensor, intake air pressure sensor and intake air temperature sensor en­able the ECU to determine the injection duration. The injection timing is determined through the sig­nals from the rankshaft position sensor. As a result, the volume of fuel that is required by the engine
can be supplied at all times in accordance with the driving conditions.

4

11

10

B

9

8

1. Fuel pump

2. Fuel injector

3. ECU

4. Throttle position sensor

5. Coolant temperature sensor

6. Crankshaft position sensor

7. Intake air pressure sensor

8. Throttle body

9. Intake air temperature sensor

10. Air filter case

C

1

A

2

7

5

11. Atmospheric pressure sensor

A. Fuel system
B. Intake system
C. Control system

3

6

1-5

INCLUDED PARTS

INCLUDED PARTS

DETACHABLE SIDESTAND

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

• Never apply additional force to the side-

stand.

• Remove this sidestand before starting out.

VALVE JOINT

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

NIPPLE WRENCH

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

HANDLEBAR PROTECTOR

Install the handlebar protector "1" so that the
mark "a" face forward.

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.

FUEL TANK HOLDING CABLE

The fuel tank holding cable "1" is used to sup­port the fuel tank during maintenance.

1-6

FUEL HOSE JOINT COVER

The fuel hose joint covers "1" are used to pre­vent mud, dust, and other foreign material from
entering the fuel pump when the fuel hose is
disconnected.

COUPLER FOR CONNECTING OPTIONAL
PART

This coupler "1" is used for connection to an op­tional Power Tuner and so on.

INCLUDED PARTS

When no optional parts, etc. are connected,
connect the connection terminal to the orig­inal coupler "2".
Before removing the coupler, thoroughly
wipe off any mud or water stuck to it.

Part name Part number

GYTR Power Tuner 33D-H59C0-V0-00

The GYTR Power Tuner is optional.

1-7

IMPORTANT INFORMATION

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.
Air duct
Silencer exhaust port
Drain hole on the cylinder head (right side)
Water pump housing hole at the bottom

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.

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

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 O-RINGS

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

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

1-8

IMPORTANT INFORMATION

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.

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.

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

1-9

HANDLING THE ELECTRONIC PARTS

HANDLING THE ELECTRONIC
PARTS

Electronic parts are very sensitive. Handle
with care and do not give impact.

• Mankind has static electricity. It`s voltage
is very high and electronic parts are very
sensitive.

• It is possible that inner small components
of electronic parts are destroyed by static
electricity.

• Do not touch and do not make them dirty.

3. Check:

• All connections

Loose connection → Connect properly.

If the pin "1" on the terminal is flattened, bend it
up.

CHECKING OF CONNECTION

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.

1. Disconnect:

• Lead

• Coupler

• Connector

2. Check:

• Lead

• Coupler

• Connector

Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev­eral times.

If the contact seems not good, pull the terminal
by hand and check its condition.

4. Connect:

• Lead

• Coupler

• Connector

Make sure all connections are tight.

1-10

CHECKING OF CONNECTION

5. Check:

•Continuity

(with the pocket tester)

Pocket tester:

90890-03112

Analog pocket tester:

YU-03112-C

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform
steps (1) to (5).

• As a quick remedy, use a contact revitalizer
available at most part stores.

REMOVING THE QUICK FASTENER

Do not push the center pin with too much
force. Otherwise, the center pin could be
damaged.

To remove a quick fastener, push the center pin
in with a screwdriver, then pull the fastener out.

INSTALLING THE QUICK FASTENER

To install a quick fastener, push its center pin
"a" back so that it protrudes from the fastener
head, then insert the fastener and push the pro­truding pin in until it is flush with the fastener
head.

When you check the voltage or electrical conti­nuity, insert the measuring probe from back
side as you can insert from back side.

1. Probe

2. Coupler

1-11

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 bend.

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.

1-12

SPECIAL TOOLS

Tool name/Part number How to use Illustration

Steering nut wrench
YU-33975, 90890-01403

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

Cap bolt wrench
YM-01500, 90890-01500

Cap bolt ring wrench
YM-01501, 90890-01501

Fork seal driver
YM-A0948, 90890-01502

Spoke nipple wrench
YM-01521, 90890-01521

This tool is used to loosen or
tighten the base valve.

This tool is used to loosen or
tighten the damper assembly.

This tool is used when install
the fork oil seal.

This tool is used to tighten the
spoke.

Pocket tester
YU-03112-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.

1-13

SPECIAL TOOLS

Tool name/Part number How to use Illustration

Pressure gauge.
YU-03153, 90890-03153

This tool is used to measure
the fuel pressure.

FI diagnostic tool
YU-03182, 90890-03182

Fuel pressure adapter
YM-03186, 90890-03186

Test harness S-pressure sen­sor (3P)
YU-03207, 90890-03207

Test harness-speed sensor
(3P)
YU-03208, 90890-03208

This tool is used to check the
fault codes and diagnose any
problems.

This tool is used to attach the
pressure gauge.

This tool is connected be­tween the intake air pressure
sensor and the wire harness
and is used to measure the
voltage.

This tool is connected be­tween the throttle position
sensor and the wire harness
and is used to measure the
voltage.

FI diagnostic tool sub-lead
YU-03212, 90890-03212

Valve guide remover & in­staller set
90890-04016

Valve spring compressor
YM-4019, 90890-04019

This tool is used to connect
the FI diagnostic tool to a bat­tery.

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

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

1-14

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

5.5 mm (0.22 in)
YM-01122

Valve guide installer

5.5 mm (0.22 in)
YM-04015

Valve guide reamer

5.5 mm (0.22 in)
YM-01196

Valve spring compressor at­tachment
YM-04108, 90890-04108

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 needed to remove
and install the valve assem­blies.

Rotor puller
YM-04151, 90890-04151

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.

1-15

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.

Digital tachometer
YU-39951-B, 90890-06760

YAMAHA Bond No. 1215
(ThreeBond
90890-85505

®

No. 1215)

This tool is needed for ob­serving engine rpm.

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

1-16

CONTROL FUNCTIONS

CONTROL FUNCTIONS

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.

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.

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.

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.

1-17

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.

STARTER KNOB/IDLE SCREW

The starter knob/idle screw "1" is used when
starting a cold engine. Pull the starter knob/idle
screw out to open the circuit for starting. When
the engine has warmed up, push it in to close
the circuit.

CONTROL FUNCTIONS

1-18

STARTING AND BREAK-IN

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

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.

Your Yamaha engine has been designed to use
premium unleaded gasoline with a pump oc­tane number [(R+M)/2] of 91 or higher, or a re­search octane number of 95 or higher. If
knocking (or pinging) occurs, use a gasoline of
a different brand.

• 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.

• 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

1. Inspect the coolant level.

2. Shift the transmission into neutral.

3. Pull the starter knob/ idle screw "1" to its full

length.

Use the starter knob/ idle screw below an air
temperature of 15°C (59°F).

Gasohol (For USA and 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

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.

4. Push the kickstarter down lightly with your

foot until resistance is felt.

5. With the throttle fully closed, fold out the

kickstarter lever, move it down lightly with
your foot until the gears engage, and then
push it down smoothly but forcefully.

Do not open the throttle while kicking the
kickstarter crank. Otherwise, the kickstarter
crank may kick back.

If the engine fails to start, give the kickstarter 10
to 20 slow kicks at full throttle in order to clear
the engine of the rich air-fuel mixture retained in
it.

1-19

STARTING AND BREAK-IN

6. When the engine starts running, warm it up
one or two minutes at a steady speed (of
3,000 to 5,000 r/min), and then return the
starter knob/ idle screw to its original posi­tion.

7. Push the engine stop switch "1".

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

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. The ma­chine will now be ready to race.

STARTING A WARM ENGINE

To start a warm engine, make sure that the
starter (choke) knob/idling screw is pushed in
and the throttle is closed, and then start the en­gine by pushing the kickstarter.

If the engine fails to start, give the kickstarter 10
to 20 slow kicks at full throttle in order to clear
the engine of the rich air-fuel mixture retained in
it.

• 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.

1-20

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 pump to fuel tank

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

1-21

CLEANING AND STORAGE

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.

Do not use high-pressure washers or
steam-jet cleaners since they cause water
seepage and deterioration seals.

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
cleaner-waxes, 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. Fill up the fuel tank and add fuel stabilizer (if
available) to prevent the fuel tank from rust­ing and the fuel from deteriorating.

2. Remove the spark plug, pour a tablespoon
of SAE 10W-40 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.

1-22

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Model name: YZ450FA (USA, CDN, AUS)

YZ450F (EUROPE, NZ, ZA)

Model code number: 33D5 (USA,CDN)

33D6 (EUROPE)

33D8 (AUS, NZ, ZA)

Dimensions: USA, CDN EUROPE AUS, NZ, ZA

Overall length 2,193 mm

(86.34 in)

Overall width 825 mm (32.48

in)

Overall height 1,311 mm

(51.61 in)

Seat height 999 mm (39.33

in)

Wheelbase 1,492 mm

(58.74 in)

Minimum ground clearance 383 mm (15.08

in)

Weight:

With oil and fuel 111 kg (245 lb)

Engine:

Engine type Liquid cooled 4-stroke, DOHC

Cylinder arrangement Single cylinder, Backward inclined

Displacement 449.7 cm

Bore × stroke 97.0 × 60.8 mm (3.82 × 2.39 in)

Compression ratio 12.5 : 1

Starting system Kickstarter

3

2,191 mm
(86.26 in)

←←

←←

← 998 mm (39.29

1,487 mm
(58.54 in)

← 384 mm (15.12

(15.8 Imp oz, 15.2 US oz)

2,194 mm
(86.38 in)

in)

←

in)

2

Lubrication system: Dry sump

Oil type or grade:

Engine oil

Recommended brand: YAMALUBE

SAE10W-30, SAE10W-40, SAE10W-50,

SAE15W-40, SAE20W-40 or SAE20W-50

API service SG type or higher,

JASO standard MA

2-1

GENERAL SPECIFICATIONS

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): 1.13 L (0.99 Imp qt, 1.19 US qt)

Air filter: Wet type element

Fuel:

Type Premium unleaded gasoline only.

Tank capacity 6.2 L (1.40 Imp gal, 1.64 US gal)

Throttle body:

Type 30RA

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:

Primary reduction system Gear

Primary reduction ratio 61/23 (2.652)

Secondary reduction system Chain drive

Secondary reduction ratio 48/13 (3.692) (For USA, CDN)

49/13 (3.769) (For EUROPE, AUS, NZ, ZA)

Transmission type Constant mesh, 5-speed

Operation Left foot operation

Gear ratio:

1st 27/14 (1.929)

2nd 23/15 (1.533)

3rd 23/18 (1.278)

4th 24/22 (1.091)

5th 20/21 (0.952)

2-2

GENERAL SPECIFICATIONS

Chassis: USA, CDN EUROPE AUS, NZ, ZA

Frame type Semi double

cradle

Caster angle 26.9° 26.8° 26.9°

←←

Trail 118.6 mm

(4.67 in)

Tire:

Type With tube

Size (front) 80/100-21 51M

Size (rear) 120/80-19 63M (For USA, CDN, AUS, NZ, ZA)

110/90-19 62M (For 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

117.5 mm
(4.63 in)

2

, 15 psi)

119.0 mm
(4.69 in)

Wheel travel:

Front wheel travel 310 mm (12.2 in)

Rear wheel travel 315 mm (12.4 in) (For USA,CDN)

312 mm (12.3 in) (For EUROPE,AUS,NZ,ZA)

Electrical:

Ignition system TCI

2-3

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.05 mm

(0.002 in)

Cylinder:

Bore size 97.00–97.01 mm (3.8189–3.8193

in)

Out of round limit ---- 0.05 mm

Camshaft:

Drive method Chain drive (Left) ----

----

(0.002 in)

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)

Cam dimensions

Intake "A" 37.750–37.850 mm

(1.4862–1.4902 in)

Intake "B" 28.129–28.229 mm

(1.1074–1.1114 in)

Exhaust "A" 33.540–33.640 mm

(1.3205–1.3244 in)

Exhaust "B" 24.769–24.869 mm

(0.9752–0.9791 in)

----

----

0.08 mm
(0.003 in)

37.650 mm
(1.4823 in)

28.029 mm
(1.1035 in)

33.440 mm
(1.3165 in)

24.669 mm
(0.9712 in)

2-4

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Camshaft runout limit ---- 0.03 mm

(0.0012 in)

Timing chain:

Timing chain type/No. of links 98XRH2010-122M/122 ----

Timing chain adjustment method Automatic ----

Valve, valve seat, valve guide:

Valve clearance (cold)

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

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

Valve dimensions:

"A" head diameter (IN) 35.9–36.1 mm (1.4134–1.4213 in) ----

"A" head diameter (EX) 29.9–30.1 mm (1.1772–1.1850 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)

2-5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

"D" margin thickness (IN) 1.3 mm (0.0512 in) ----

"D" margin thickness (EX) 1.0 mm (0.0394 in) ----

Stem outside diameter (IN) 5.475–5.490 mm (0.2156–0.2161

in)

Stem outside diameter (EX) 5.465–5.480 mm (0.2152–0.2157

in)

Guide inside diameter (IN) 5.500–5.512 mm (0.2165–0.2170

in)

Guide inside diameter (EX) 5.500–5.512 mm (0.2165–0.2170

in)

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

in)

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

in)

Stem runout limit ---- 0.01 mm

Valve seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm

5.445 mm
(0.2144 in)

5.435 mm
(0.2140 in)

5.550 mm
(0.2185 in)

5.550 mm
(0.2185 in)

0.08 mm
(0.003 in)

0.10 mm
(0.004 in)

(0.0004 in)

(0.0630 in)

Valve seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm

(0.0630 in)

Valve spring:

Free length (IN) 40.76 mm (1.60 in) 39.76 mm

(1.57 in)

Free length (EX) 37.01mm (1.46 in) 36.01 mm

(1.42 in)

Set length (valve closed) (IN) 34.78 mm (1.37 in) ----

Set length (valve closed) (EX) 30.83 mm (1.21 in) ----

Compressed force (installed) (IN) 178–204 N at 34.78 mm

(18.2–20.8 kg at 34.78 mm,

40.01–45.86 lb at 1.37 in)

Compressed force (installed) (EX) 124–142 N at 30.83 mm

(12.6–14.5 kg at 30.83 mm,

27.88–31.92 lb at 1.21 in)

----

----

2-6

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Tilt limit* (IN) ---- 2.5°/1.8 mm

(2.5°/0.071
in)

Tilt limit* (EX) ---- 2.5°/1.6 mm

(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)

Piston size "D" 96.965–96.980 mm

(3.8175–3.8181 in)

Measuring point "H" 9.0 mm (0.354 in) ----

Piston off-set Zero mm (Zero in) ----

Piston pin bore inside diameter 18.004–18.015 mm

(0.7088–0.7093 in)

Piston pin outside diameter 17.991–18.000 mm

(0.7083–0.7087 in)

Piston rings:

Top ring:

0.1 mm
(0.004 in)

----

18.045 mm
(0.7104 in)

17.971 mm
(0.7075 in)

Type Barrel ----

Dimensions (B × T) 1.00 × 3.30 mm (0.04 × 0.13 in) ----

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

(0.022 in)

Side clearance (installed) 0.015–0.065 mm (0.0006–0.0026

in)

0.120 mm
(0.0047 in)

2-7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

2nd ring:

Type Taper ----

Dimensions (B × T) 1.00 × 3.10 mm (0.04 × 0.12 in) ----

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

(0.033 in)

Side clearance 0.020–0.060 mm (0.0008–0.0024

in)

Oil ring:

Dimensions (B × T) 1.5 × 2.55 mm (0.06 × 0.10 in) ----

End gap (installed) 0.20–0.50 mm (0.008–0.020 in) ----

Crankshaft:

0.120 mm
(0.0047 in)

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 ----

Clutch:

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

(0.110 in)

Quantity 8 ----

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

Quantity 7 ----

Warp limit ---- 0.1 mm

(0.004 in)

2-8

MAINTENANCE SPECIFICATIONS

Item Standard Limit

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

Kickstarter:

Type Kick and ratchet type ----

Fuel pump:

Fuel pressure 324 kPa (3.24 kg/cm

2

, 46.1 psi) ----

----

(0.002 in)

Fuel injector: ----

Model/manufacturer 1010/DENSO ----

Throttle body: ----

I. D. mark 33D1 00 ----

Manufacturer KEIHIN ----

Throttle position sensor: ----

Throttle position sensor maximum resistance 5 kΩ ----
Throttle position sensor variable resistance 0–2 kΩ (full closed) ----

Throttle position sensor input voltage 4–6 V ----

Fuel injection sensor: ----

Crankshaft position sensor resistance 248–372 Ω ----

Intake air pressure sensor output voltage 3.57–3.71 V at 101.3kPa (1.013

Atmospheric pressure sensor output voltage 3.57–3.71 V at 101.3kPa (1.013

Intake air temperature sensor 5.4–6.6 kΩat 0 °C (32 °F)

Idling condition: ----

2

kg/cm

kg/cm

290–390 Ωat 80 °C (176 °F)

, 14.41 psi)

2

, 14.41 psi)

----

----

----

Engine idle speed 1,900–2,100 r/min ----

Oil temperature 55–65 °C (131–149 °F) ----

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

2-9

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

(0.007 in)

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

5.69–11.38 psi)

Cooling:

Radiator core size

Width 121.4 mm (4.78 in) ----

Height 235 mm (9.25 in) ----

Thickness 28 mm (1.10 in) ----

Radiator cap opening pressure 108–137 kPa (1.08–1.37 kg/cm

15.4–19.5 psi)

Radiator capacity (total) 0.62 L (0.55 Imp qt, 0.66 US qt) ----

2

,

----

2

,

----

Water pump

Type Single-suction centrifugal pump ----

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Taper roller bearing ----

Front suspension:

Front fork travel 310 mm (12.2 in) ← ---­Fork spring free length 470 mm (18.5 in) ← 465 mm

Spring rate, STD K = 4.6 N/mm

Optional spring Yes ← ----

Oil capacity 544 cm

Oil grade Suspension oil "S1" ← ----

USA, CDN

(0.469 kg/mm, 26.3
lb/in)

3

(19.1 lmp

oz, 18.4 US oz)

EUROPE, AUS,

NZ, ZA

(18.3 in)

← ----

← ----

Inner tube outer diameter 48 mm (1.89 in) ← ----
Front fork top end Zero mm (Zero in) ← ----

2-10

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Rear suspension:

Shock absorber travel 132.0 mm (5.20 in) ← ---­Spring free length 260 mm (10.24 in) ← 254.8 mm

Fitting length 252 mm (9.92 in) 253 mm (9.96 in) ----

Preload length

<Min.–Max.> 1.5–18 mm

Spring rate, STD K = 56.0 N/mm (5.7

Optional spring Yes ← ----

Enclosed gas pressure 1,000 kPa (10 kg/

Swingarm:

Swingarm free play limit

End ---- 1.0 mm

Wheel:

Front wheel type Spoke wheel ----

Rear wheel type Spoke wheel ----

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

Rear rim size/material 19 × 2.15/Aluminum ----

Rim runout limit:

Radial ---- 2.0 mm

Lateral ---- 2.0 mm

Drive chain:

Type/manufacturer DID520DMA2 SDH/DAIDO ----

Number of links 113 links + joint ----

Chain slack 50–60 mm (2.0–2.4 in) ----

Chain length (15 links) ---- 242.9 mm

Front disc brake:

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

Pad thickness 4.4 mm (0.17 in) 1.0 mm

Master cylinder inside dia. 9.52 mm (0.375 in) ----

Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ----

Brake fluid type DOT #4 ----

USA, CDN

(0.06–0.71 in)

kg/mm, 319.2 lb/in)

2

, 142 psi)

cm

EUROPE, AUS,

NZ, ZA

(10.03 in)

←

← ----

← ----

(0.04 in)

(0.08 in)

(0.08 in)

(9.563 in)

mm (9.84 ×

0.10 in)

(0.04 in)

2-11

MAINTENANCE SPECIFICATIONS

Item Standard Limit

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) 7–12 mm (0.28–0.47 in) ----

Zero mm (Zero in) ----

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

ELECTRICAL

Item Standard Limit

Ignition system:

Advancer type Electrical ----

AC magneto:

Magneto-model (stator)/manufacturer 33D00/YAMAHA ---­Stator coil resistance (color) 0.60–0.90 Ωat 20 °C (68 °F)

(White–White)

Crankshaft position sensor resistance (color) 248–372 Ωat 20 °C (68 °F)

(Gray–Black)

ECU-model/manufacturer 33D0 (USA, CDN) ----

33D4 (EUROPE) ----

33D6 (AUS, NZ, ZA) ----

Ignition coil:

Model/manufacturer F6T541/MITSUBISHI ----

Minimum spark gap 6 mm (0.24 in) ---­Primary coil resistance 3.57–4.83 Ωat 20 °C (68 °F) ---­Secondary coil resistance 10.71–14.49 kΩat 20 °C (68 °F) ----

----

----

Coolant temperature sensor:

Coolant temperature sensor resistance 2.51–2.78 kΩat 20 °C (68 °F) ----

210–220 kΩat 100 °C (212 °F) ----

2-12

TIGHTENING TORQUES

TIGHTENING TORQUES

ENGINE

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

Part to be tightened Thread size Q'ty

Spark plug M10S × 1.0 1 13 1.3 9.4

Camshaft cap M6 × 1.0 8 10 1.0 7.2

Cylinder head blind plug screw M12 × 1.0 2 28 2.8 20

Oil passage plug M8 × 1.25 1 15 1.5 11

Cylinder head (stud bolt) M6 × 1.0 3 7 0.7 5.1

Cylinder head (bolt) M10 × 1.25 4 Refer to TIP.

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

Cylinder head cover M6 × 1.0 3 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 stopper plate (exhaust side) M6 × 1.0 2 10 1.0 7.2

Exhaust pipe (nut) M6 × 1.0 3 10 1.0 7.2

Exhaust pipe and frame M8 × 1.25 1 20 2.0 14

△ Silencer M8 × 1.25 2 30 3.0 22

Silencer clamp (front) M8 × 1.25 1 12 1.2 8.7

Tightening torque

Nm m•kg ft•lb

*1

Silencer clamp (rear) M8 × 1.25 1 16 1.6 11

Starter knob/Idle screw M12 × 1.0 1 2 0.2 1.4

Throttle body joint M6 × 1.0 2 10 1.0 7.2

Throttle body joint clamp M5 × 0.8 1 3 0.3 2.2

△ Air filter case M6 × 1.0 3 7 0.7 5.1

Air filter case cover M5 × 0.8 2 5 0.5 3.6

Air filter joint clamp M4 × 0.7 1 4 0.4 2.2

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

Throttle cable (pull) M10 × 1.25 1 7 0.7 5.1

Throttle cable (return) M10 × 1.25 1 7 0.7 5.1

Throttle cable cover M5 × 0.8 2 4 0.4 2.9

Air duct M6 × 1.0 3 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

Radiator pipe 1 M6 × 1.0 1 10 1.0 7.2

Radiator pipe 2 M6 × 1.0 1 10 1.0 7.2

Impeller M8 × 1.25 1 14 1.4 10

Water pump housing cover M6 × 1.0 4 10 1.0 7.2

2-13

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

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

Oil filter element cover M6 × 1.0 2 10 1.0 7.2

Oil pressure check bolt M6 × 1.0 2 10 1.0 7.2

Crankshaft end accessing screw M36 × 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

Right crankcase cover M6 × 1.0 9 10 1.0 7.2

Left crankcase cover M6 × 1.0 8 10 1.0 7.2

Crankcase M6 × 1.0 13 12 1.2 8.7

Clutch cable holder M6 × 1.0 2 10 1.0 7.2

Oil drain bolt M8 × 1.25 1 20 2.0 14

Oil drain bolt M8 × 1.25 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

Tightening torque

Nm m•kg ft•lb

Oil nozzle M5 × 0.8 1 8 0.8 5.8

Crankcase bearing stopper M6 × 1.0 8 10 1.0 7.2

Crankcase bearing stopper (crankshaft) M8 × 1.25 4 22 2.2 16

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

Kick shaft 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

Primary drive gear M20 × 1.0 1 100 10.0 72

Clutch boss M20 × 1.0 1 75 7.5 54

Clutch cable locknut M8 × 1.25 1 7 0.7 5.1

Clutch cable adjust bolt and locknut M6 × 0.75 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 shaft driven gear M14 × 1.0 1 50 5.0 36

Balancer weight 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 7 0.7 5.1

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

2-14

TIGHTENING TORQUES

*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 150° in the
proper tightening sequence.

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 upper holder M8 × 1.25 4 28 2.8 20
△ Handlebar lower holder M10 × 1.25 2 34 3.4 24
△ Steering ring nut M28 × 1.0 1 Refer to TIP.

Front fork and damper assembly M51 × 1.5 2 30 3.0 22

Front fork and adjuster M22 × 1.25 2 55 5.5 40

Damper assembly and base valve M42 × 1.5 2 29 2.9 21

Adjuster and damper assembly M12 × 1.25 2 29 2.9 21

Bleed screw (front fork) and base valve M5 × 0.8 2 1 0.1 0.7

△ Front fork and front fork protector M6 × 1.0 6 5 0.5 3.6
△ Front fork protector and brake hose holder M6 × 1.0 2 8 0.8 5.8

Throttle grip cap M5 × 0.8 2 4 0.4 2.9

Clutch lever holder M6 × 1.0 2 5 0.5 3.6

Clutch lever mounting nut M6 × 1.0 1 4 0.4 2.9

Tightening torque

Nm m•kg ft•lb

Clutch lever position lock nut M5 × 0.8 1 5 0.5 3.6

△ 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

△ Cable guide (front brake hose) and under bracket M6 × 1.0 1 4 0.4 2.9
△ Front brake hose union bolt (brake master cylin-

der)

△ Front brake hose union bolt (brake caliper) M10 × 1.25 1 30 3.0 22
△ Front brake caliper and front fork M8 × 1.25 2 28 2.8 20

Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 2 0.2 1.4

△ 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 axle nut M16 × 1.5 1 105 10.5 75

M10 × 1.25 1 30 3.0 22

2-15

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

△ 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
△ Footrest bracket and frame M10 × 1.25 4 55 5.5 40
△ Brake pedal mounting M8 × 1.25 1 26 2.6 19

Brake pedal position locknut M6 × 1.0 1 6 0.6 4.3

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

der)

△ Rear wheel axle and axle nut M22 × 1.5 1 135 13.5 98
△ Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30
△ Nipple (spoke) — 72 3 0.3 2.2
△ Disc cover and rear 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

M10 × 1.25 1 30 3.0 22

Tightening torque

Nm m•kg ft•lb

Drive chain puller adjust bolt and locknut M8 × 1.25 2 21 2.1 15

Engine mounting:

△ Upper engine bracket and frame M8 × 1.25 4 45 4.5 32
△ Front engine bracket and frame M8 × 1.25 4 34 3.4 24
△ Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
△ Engine and engine bracket (upper) M10 × 1.25 2 45 4.5 32
△ Engine and frame (lower) M10 × 1.25 1 53 5.3 38
△ Engine guard M6 × 1.0 1 10 1.0 7.2

Lower engine guard M6 × 1.0 3 10 1.0 7.2

△ 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 shock absorber locknut M60 × 1.5 1 30 3.0 22
△ Rear frame and frame (upper) M8 × 1.25 1 32 3.2 23
△ Rear frame and frame (lower) M8 × 1.25 2 32 3.2 23
△ Swingarm and brake hose holder M5 × 0.8 4 3 0.3 2.2

Upper drive chain tensioner M8 × 1.25 1 16 1.6 11

Lower drive chain tensioner M8 × 1.25 1 16 1.6 11

Drive chain support and swingarm M6 × 1.0 3 7 0.7 5.1

△ Seal guard and swingarm M5 × 0.8 3 4 0.4 2.9

2-16

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

△ Fuel tank mounting boss and frame M10 × 1.25 1 20 2.0 14
△ Fuel tank (front) M6 × 1.0 2 9 0.9 6.5

Fuel tank bracket (front) M6 × 1.0 4 7 0.7 5.1

△ Fuel tank (rear) M6 × 1.0 2 9 0.9 6.5

Fuel tank bracket (rear) M6 × 1.0 2 7 0.7 5.1

△ Fuel pump M5 × 0.8 6 4 0.4 2.9

Fuel tank side cover M6 × 1.0 4 7 0.7 5.1

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 M8 × 1.25 2 22 2.2 16

△ Side cover M6 × 1.0 4 7 0.7 5.1

Heat protector M5 × 0.8 2 4 0.4 2.9

△ Air scoop and fuel tank M6 × 1.0 2 9 0.9 6.5
△ Air scoop and air duct M6 × 1.0 2 7 0.7 5.1

Radiator and radiator guard M6 × 1.0 2 10 1.0 7.2

△ Air scoop and radiator guard M6 × 1.0 2 7 0.7 5.1
△ Front fender M6 × 1.0 4 10 1.0 7.2

Tightening torque

Nm m•kg ft•lb

△ Rear fender (front) M6 × 1.0 3 7 0.7 5.1
△ Rear fender (rear) M6 × 1.0 2 18 1.8 13
△ Mud flap — 2 1 0.1 0.7
△ Number plate M6 × 1.0 1 7 0.7 5.1

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).

2-17

ELECTRICAL

TIGHTENING TORQUES

Part to be tightened Thread size Q'ty

Stator M5 × 0.8 3 8 0.8 5.8

Rotor M12 × 1.25 1 65 6.5 47

Crankshaft position sensor M6 × 1.0 2 10 1.0 7.2

Throttle position sensor M5 × 0.8 1 3 0.3 2.2

Injector M5 × 0.8 2 3 0.3 2.2

Ignition coil M5 × 0.8 2 4 0.4 2.9

Coolant temperature sensor M10 × 1.25 1 16 1.6 11

Rectifier/regulator M6 × 1.0 2 7 0.7 5.1

Ignition coil bracket M6 × 1.0 2 10 1.0 7.2

Intake air pressure sensor M5 × 0.8 1 5 0.5 3.6

Atmospheric pressure sensor M5 × 0.8 1 4 0.4 2.9

Atmospheric pressure sensor bracket M6 × 1.0 1 7 0.7 5.1

Condenser bracket M6 × 1.0 2 7 0.7 5.1

Ground lead M5 × 0.8 1 4 0.4 2.9

ECU M5 × 0.8 2 4 0.4 2.9

ECU bracket M6 × 1.0 2 7 0.7 5.1

Tightening torque

Nm m•kg ft•lb

2-18

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.

TIGHTENING TORQUES

A. Distance between flats
B. Outside thread diameter

TORQUE SPECIFICA-

A (Nut) B (Bolt)

Nm m•kg ft•lb

10 mm 6 mm 6 0.6 4.3

12 mm 8 mm 15 1.5 11

14 mm 10 mm 30 3.0 22

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13 94

TION

2-19

DEFINITION OF UNITS

Unit Read Definition Measure

mm

cm

kg

N

Nm

m•kg

Pa

N/mm

L

3

cm

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

TIGHTENING TORQUES

2

2

Force

Pressure

2-20

LUBRICATION DIAGRAMS

LUBRICATION DIAGRAMS

2-21

1. Oil strainer

2. Oil check bolt

3. Scavenging pump

4. Oil feed pump

5. Oil filter element

6. Crankshaft

7. Oil nozzle

8. Exhaust camshaft

9. Intake camshaft

10. Main axle

11. Drive axle

12. Oil level check window

13. Oil tank

LUBRICATION DIAGRAMS

2-22

CABLE ROUTING DIAGRAM

CABLE ROUTING DIAGRAM

2-23

CABLE ROUTING DIAGRAM

1. Fuel tank breather hose

2. Coupler for connecting optional part

3. Cylinder head breather hose

4. Hose holder

5. Radiator hose 3

A. Insert the end of the fuel tank breather

hose into the hole in the steering stem.

B. Fit the accessory coupler into the connec-

tor to fasten it to the bracket.

C. Point the end of the cylinder head breather

hose downward.

D. Pass the cylinder head breather hose

through the hose holder, making sure that
the stopper on the hose contacts the hold­er.

E. Route the cylinder head breather hose be-

tween the frame and radiator hose 3, and
to the outside of the AC magneto lead.

2-24

CABLE ROUTING DIAGRAM

F-F

F

A

A

F

B

B

E

100mm

D-D

E

D

D

C

C

C-C

2-25

CABLE ROUTING DIAGRAM

1. Clutch cable

2. Throttle cable (return)

3. Throttle cable (pull)

4. Cable holder

5. Clamp

6. Rectifier/regulator

7. Ignition coil

8. Ignition coil coupler

9. AC magneto coupler

10. Radiator hose 2

11. Ground lead terminal

12. Plug cap

13. Ignition coil bracket

14. Clamp (lock)

15. Clamp (clip)

16. AC magneto lead

17. ECU bracket

A. Pass the clutch cable, throttle cables, and

engine stop switch lead through the cable
holder. Pass the clutch cable through the
lower guide only.

B. Route the engine stop switch lead to the in-

side of the clip.

C. Fasten the rectifier/regulator lead and en-

gine stop switch lead (wire harness end).

D. Insert the projection on the engine stop

switch coupler into the hole in the bracket.

E. Insert the projection on the rectifier/regula-

tor coupler into the hole in the bracket.

F. Position the ignition coil bracket to the out-

side of the ignition coil, and insert the bolts
from the ignition coil side.

G. Fasten the AC magneto lead to the ignition

coil bracket with a plastic locking tie, mak­ing sure to position the tie above the lower
mounting portion of the bracket. Face the
buckle of the plastic locking tie forward,
and then cut off the excess end of the tie.

H. Route the ignition coil lead between the

condenser and the ignition coil.

I. Fit the clip portion of the clamp into the ig-

nition coil bracket and fasten the clutch ca­ble with the locking portion of the clamp.

J. Route the clutch cable to the outside of the

AC magneto lead.

K. Route the throttle cables under radiator

hose 2, making sure not to twist the cables.

L. Route the AC magneto lead to the inside of

the throttle cables and clutch cable.

M. Install the ground lead terminal between

the ECU bracket and the cable holder,
making sure to position the terminal be­tween the stoppers.

N. Push in the spark plug cap completely,

making sure that there is no gap between
the cylinder head cover and the cap.

O. Apply sealant to the slit and inner surface

of the grommet, and then install the grom­met at the position shown.

2-26

CABLE ROUTING DIAGRAM

G

B-B

A

B

F

F

C

D

B

C

D

A-A

A

G

C-C

E

E

E-E

D-D

2-27

CABLE ROUTING DIAGRAM

1. Tension pipe

2. Coolant temperature sensor coupler

3. Front engine bracket

4. Fuel pump coupler

5. Fuel pump

6. Intake air temperature sensor coupler

7. Radiator hose 2

8. Radiator breather hose

9. Radiator hose 1

10. Radiator hose 4

11. Radiator pipe 2

12. Radiator hose 3

13. Cylinder head breather hose

14. Frame

15. ECU (electronic control unit)

16. ECU bracket

17. Main harness

18. AC magneto lead

19. Throttle position sensor lead

20. Condenser lead

21. Coolant temperature sensor lead

22. Ignition coil lead

23. Condenser

A. Fasten the wire harness at the positioning

tape to the ECU bracket with a plastic lock­ing tie. Face the buckle of the plastic lock­ing tie downward, and then cut off the
excess end of the tie.

B. Install the cover onto the wire harness cou-

pler.

C. Route the condenser lead, throttle position

sensor lead, coolant temperature sensor
lead, ignition coil lead, and AC magneto
lead under radiator hose 2.

D. Connect the vacuum hose to the atmo-

spheric pressure sensor, and then fasten
the hose with the clamp. Make sure to face
the moving part of the sensor rearward.

E. After connecting the condenser coupler, in-

stall the coupler cover onto the coupler.

F. After connecting the throttle position sen-

sor coupler, install the coupler cover onto
the coupler.

G. Fasten the AC magneto lead, condenser

lead, throttle position sensor lead, coolant
temperature sensor lead, and ignition coil
lead to the frame with the plastic band,
making sure to position the band between
the ignition coil bracket and the tension
pipe. Face the buckle of the plastic band to
the right with the end pointing rearward.

H. Point the end of the vacuum hose rear-

ward.

I. Fit the bracket into the hole in the rubber

portion of the condenser.

J. Fasten the radiator breather hose to the

frame with the plastic band, making sure to
position the band above the front engine
bracket. Face the buckle of the plastic band
outward with the end pointing rearward.

K. After connecting the coolant temperature

sensor coupler, install the coupler cover
onto the coupler.

L. Route the radiator breather hose between

the down tubes.

M. Fasten the fuel hose and fuel pump lead

with the plastic band, making sure to posi­tion the band between the bend in the fuel
hose protector and the end of the protector.
Point the end of the plastic band upward.

N. Insert the projection on the joint coupler

into the hole in the bracket, and then install
the coupler cover onto the coupler.

O. Route the atmospheric pressure sensor

lead, intake air pressure sensor lead, in­take air temperature sensor lead, fuel injec­tor lead, and fuel pump lead above radiator
hose 2. Position the joint coupler above ra­diator hose 2.

P. Route the radiator breather hose to the in-

side of radiator hose 1 and the front engine
bracket.

Q. Hose installation position (1.3–3.3 mm,

0.05–0.13 in)

R. Clip installation position (0–2.0 mm, 0–0.08

in)

S. Install the washer so that it contacts the

bolt head.

T. Install the collar so that the flange on the

collar contacts the ECU bracket.

2-28

CABLE ROUTING DIAGRAM

2-29

CABLE ROUTING DIAGRAM

1. Ignition coil coupler

2. Coolant temperature sensor lead

3. Atmospheric pressure sensor coupler

4. Intake air temperature sensor lead

5. Clamp

6. Intake air pressure sensor coupler

7. Cover

8 Fuel hose

9. Fuel pump lead

10. Fuel injector coupler

11. Throttle body

12. High tension code

13. Throttle cable

14. AC magneto lead

A. Route the fuel pump lead to the outside of

the fuel hose and above the cover.

B. Route the spark plug wire between the

throttle cables and the throttle body. When
installing the air filter, be sure not to pinch
the spark plug wire.

C. Route the AC magneto lead to the inside of

the throttle cables.

2-30

CABLE ROUTING DIAGRAM

2-31

CABLE ROUTING DIAGRAM

1. Brake master cylinder

2. Brake hose holder

3. Brake hose

A. Install the brake hose so that its pipe por-

tion 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 por-

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

2-32

CABLE ROUTING DIAGRAM

2-33

CABLE ROUTING DIAGRAM

1. Throttle cable

2. Clutch cable

3. Clamp

4. Engine stop switch lead

5. Hose guide

6. Main harness

A. Route the clutch cable to the rear of the

number plate band.

B. Fasten the engine stop switch lead to the

handlebar.

C. Route the brake hose to the front of the

number plate.

D. Pass the clutch cable through the cable

guide on the number plate.

2-34

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.

•Periodic inspection is essential in making full use of the machine performance. The service life of

the parts varies substantially according to the environment in which the machine runs (e.g., rain,
dirt, etc.). Therefore, earlier inspection is required by reference to the list below.

Every

Item

ENGINE OIL

Replace ●●

VALVES

Check the valve
clearances

Inspect ● Check the valve seats

Replace ●

VALVE SPRINGS

Inspect ● Check the free length

Replace ●

VALVE LIFTERS

After

break-in

●● The engine must be cold.

race

(about

2.5

hours)

Every

third

(about

7.5

hours)

Every

fifth

(about

12.5

hours)

As re­quired

Remarks

and valve stems for
wear.

and the tilt.

Inspect ● Check for scratches and

wear.

Replace ●

CAMSHAFTS Inspect the camshaft sur-

face.

Inspect ● Inspect the decompres-

sion system.

Replace ●

CAMSHAFT SPROCK­ETS

Inspect ● Check for wear on the

teeth and for damage.

Replace ●

3-1

MAINTENANCE INTERVALS

Every

Item

PISTON

Inspect ● Inspect crack.
Clean ● Inspect carbon deposits

Replace ●●Replace the piston, pis-

PISTON RING

Inspect ● Check ring end gap.
Replace ●●Replace the piston, pis-

PISTON PIN

After

break-in

race

(about

2.5

hours)

Every

third

(about

7.5

hours)

Every

fifth

(about

12.5

hours)

As re­quired

Remarks

and eliminate them.

ton pin, piston pin clip,
and piston ring all as a
set.

ton pin, piston pin clip,
and piston ring all as a
set.

3

Inspect ●
Replace ●●Replace the piston, pis-

ton pin, piston pin clip,
and piston ring all as a
set.

CYLINDER HEAD Inspect carbon deposits

and eliminate them.

Inspect and clean ● Change gasket.

CYLINDER

Inspect and clean ● Inspect score marks.
Replace ● Inspect wear.

CLUTCH

Inspect and adjust ●● Inspect housing, friction

plate, clutch plate and
spring.

Replace ●

TRANSMISSION

Inspect ●
Replace bearing ●

SHIFT FORK, SHIFT
CAM, GUIDE BAR

Inspect ● Inspect wear.

ROTOR NUT

Retighten ●●

3-2

MAINTENANCE INTERVALS

Every

Item

EXHAUST PIPE, SI­LENCER, PROTEC­TOR

Inspect and retighten ●●
Clean ●

Replace fiver ●●*

CRANK

Inspect and clean ●●

THROTTLE BODY

Inspect ●

SPARK PLUG

Inspect and clean ●●
Replace ●

DRIVE CHAIN Use chain lube.

After

break-in

race

(about

2.5

hours)

Every

third

(about

7.5

hours)

Every

fifth

(about

12.5

hours)

As re­quired

Remarks

* When the exhaust
sound becomes louder
or when a performance
drop is felt.

Lubricate, slack,
alignment

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

AIR FILTER

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

Replace ●

●● Chain slack: 50–60 mm

(2.0–2.4 in)

●●

●

AND BREAK-IN" section
in the CHAPTER 1.

equivalent oil.

OIL FILTER

Replace ●●

3-3

MAINTENANCE INTERVALS

Every

Item

ENGINE GUARD

Replace ● Breakage

FRAME

Clean and inspect ●●

FUEL TANK, FUEL
PUMP

inspect ●●

FUEL HOSE

Inspect ●
Replace ● Every four years

BRAKES

Adjust lever position
and pedal height

Lubricate pivot point ●●

After

break-in

●●

race

(about

2.5

hours)

Every

third

(about

7.5

hours)

Every

fifth

(about

12.5

hours)

As re­quired

Remarks

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 ●

3-4

MAINTENANCE INTERVALS

Every

Item

REAR SHOCK AB­SORBER

Inspect and adjust ●●

Lube ●
Retighten ●●

DRIVE CHAIN GUIDE
AND ROLLERS

Inspect ●●

SWINGARM

Inspect, lube and re-

tighten

RELAY ARM, CON­NECTING ROD

Inspect, lube and re-

tighten

STEERING HEAD

After

break-in

●● Molybdenum disulfide

●● Molybdenum disulfide

race

(about

2.5

hours)

Every

third

(about

7.5

hours)

Every

fifth

(about

12.5

hours)

As re­quired

(After

rain

ride) ●

Remarks

Molybdenum disulfide
grease

grease

grease

Inspect free play and
retighten

Clean and lube ● Lithium base grease
Replace bearing ●

TIRE, WHEELS

Inspect air pressure,
wheel run-out, 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-40 motor oil

3-5

PRE-OPERATION INSPECTION AND MAINTENANCE

PRE-OPERATION INSPECTION AND MAINTENANCE

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

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page

Coolant

Fuel

Engine oil

Gear shifter and clutch

Throttle grip/Housing

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.

P.3-7 – 9

P.1-19

P.3-13 – 15

P.3-9 – 10

P.3-10 – 11

Brakes

Drive chain

Wheels

Steering

Front forks and rear
shock absorber

Cables (wires)

Exhaust pipe

Rear wheel sprocket

Lubrication Check for smooth operation. Lubricate if necessary. P.3-35 – 36

Bolts and nuts

Lead connectors

Check the play of front brake and effect of front and
rear brake.

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 exhaust pipe is tightly mounted and
has no cracks.

Check that the rear wheel sprocket tightening bolt is
not loose.

Check the chassis and engine for loose bolts and
nuts.

Check that the AC magneto, ECU and ignition coil are
connected tightly.

P.3-20 – 25

P.3-25 – 27

P.3-32 – 33

P.3-33 – 34

P.3-27 – 32

—

P.4-3 – 7

P.3-25

P.1-21

P.1-10 – 11

Settings

Is the machine set suitably for the condition of the rac­ing course and weather or by taking into account the
results of test runs before racing? Are inspection and
maintenance completely done?

3-6

P.8-1 – 7

ENGINE

ENGINE

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.

CHANGING THE COOLANT

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

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:

• Coolant drain bolt "1"

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

3. Remove:

•Radiator cap
Drain the coolant completely.

4. Clean:

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

5. Install:

• Copper washer

• Coolant drain bolt

Coolant drain bolt:

10 Nm (1.0 m•kg, 7.2 ft•lb)

6. Fill:

•Radiator

•Engine
To specified level.

Recommended coolant:

High quality ethylene glycol anti­freeze containing anti-corrosion

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

50%/50%
Coolant capacity:

1.13 L (0.99 Imp qt, 1.19 US qt)

3-7

• Do not mix more than one type of ethylene
glycol antifreeze containing corrosion in­hibitors for aluminum engine.

• Do not use water containing impurities or
oil.

Handling notes of coolant:

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

• 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.

ENGINE

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.

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

Apply water on the radiator cap seal.

7. Install:

•Radiator cap

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

8. Check:

• Coolant level

Coolant level low → Add coolant.

3. Radiator cap

2. Apply the specified pressure.

Radiator cap opening pressure:

108–137 kPa (1.08–1.37 kg/cm

15.4–19.5 psi)

3. Inspect:

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

3-8

2

,

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

3. Apply the specified pressure.

Standard pressure:

196 kPa (1.96 kg/cm

• Do not apply pressure more than specified
pressure.

• Radiator should be filled fully.

2

, 27.9 psi)

ENGINE

c. Tighten the locknuts.

Locknut:

5 Nm (0.5 m•kg, 3.6 ft•lb)

2. Adjust:

• Clutch cable free play
Refer to "ADJUSTING THE CLUTCH CA­BLE FREE PLAY".

ADJUSTING THE CLUTCH CABLE FREE
PLAY

1. Check:

• Clutch lever free play "a"
Out of specification → Adjust.

Clutch lever free play "a" :

7–12 mm (0.28–0.47 in)

4. Inspect:

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

•Radiator

• Radiator hose joint
Coolant leakage → Repair or replace.

• Radiator hose
Swelling → Replace.

ADJUSTING THE CLUTCH LEVER
POSITION

1. Adjust:

• Clutch lever position

Clutch lever position adjustment steps:

a. Loosen the locknuts "1".
b. Turn the adjusting bolt "2" until the clutch le-

ver position "a" is in the desiered position.

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)

3-9

• Before adjustment, expose the adjuster by
moving the boot "3" and cap "4" away.

• Make minute adjustment on the lever side us­ing the adjuster "5".

• After adjustment, check proper operation of
clutch lever.

3. Install:

•Cap "1"

• Boot "2"

ENGINE

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.

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.

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)

LUBRICATING THE THROTTLE

1. Remove:

• Cover (throttle cable cap) "1"

• Cover (grip cap) "2"

• Throttle grip cap "3"

3-10

2. Apply:

• Lithium soap base grease

On the throttle cable end "a".

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)

CHECKING THE THROTTLE VALVE PULLY
COVER DRAIN HOSE

ENGINE

3. Remove:

• Mounting bolt for air filter case cover

4. Loosen and release the binder "1" and lift
the air filter case lid.

Hold the air filter case lid by the use of the bind­er.

Drain the water that stays in the throttle valve
pulley cover after a machine wash or a rainy
weather ride.

1. Drain the water by picking up the flat portion
of the lower end "a" of the drain hose.

CLEANING THE AIR FILTER ELEMENT

1. Remove:

• Seat

2. Remove the fuel tank bolt (front) "1" and lift
the fuel tank.

Hold the fuel tank in position by the use of the
fuel tank holding cable "2".

5. Remove:

• Air filter guide

• Air filter element "1"

Do not remove the thin sheet (air filter ele­ment 2) “2” under the air filter element un­less it is dirty. It is there to prevent foreign
matter from dropping into the throttle body.
If the thin sheet must be removed for clean­ing, lift it carefully to avoid loosening the
dirt, and then temporarily block the throttle
body opening with a clean, lint-free cloth.

3-11

ENGINE

6. 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 ele-

ment may result in poor starting.

b. Clean the air filter element 2 with solvent.

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

Do not twist the element when squeezing
the element.

c. Inspect the air filter element 2.

Damage → Replace.

d. Install the air filter element 2.

10.Install:

• Air filter element "1"

• Air filter guide "2"

• Binder

7. Inspect:

• Air filter element

Damage → Replace.

8. Apply:

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

Oil application quantify:

35 g

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

9. If the thin sheet (air filter element 2) is dirty
with mud etc., clean the thin sheet (air filter
element 2) by the following steps.

Cleaning steps:

a. Remove the air filter element 2 "1".

11.Install:

• Mounting bolt for air filter case cover

Mounting bolt for air filter case cov­er:

4 Nm (0.4 m•kg, 2.9 ft•lb)

12.Install:

• Fuel tank bolt (front)

Fuel tank bolt (front):

9 Nm (0.9 m•kg, 6.5 ft•lb)

CHECKING THE THROTTLE BODY JOINT

1. Remove:

•Seat

• Air scoop (left/right)

• Fuel tank

• Air filter

2. Check:

• Throttle body joint "1"

Cracks/damage → Replace.

3-12

3. Install:

• Air filter

• Fuel tank

• Air scoop (left/right)

• Seat

CHECKING THE FUEL LINE

1. Remove:

• Seat

• Fuel tank

• Air scoop (left/right)

• Air filter case

•Cover

2. Check:

• Fuel hose "1"
Cracks/damage → Replace.
Loose connection → Reconnect.

ENGINE

3. Inspect:

• Oil level
Make sure that the engine oil level is be­tween the maximum level line "a" and mini­mum level line "b" shown for the oil level
check window.
Above the upper limit "a"→ Check that no oil
comes out when the check bolt "1" for the oil
quantity upper limit is removed.
If any engine oil comes out, drain it until its
last drop is out.
Below the level mark "b" → Add sufficient oil
and idle run the engine, and after stopping
the engine, recheck through the oil inspec­tion window that the oil is at the specified
level.

• Check the oil quantity within 5 minutes after
the engine is shut off. Over 5 minutes, idle the
engine again and recheck the oil quantity.

• Do not leave the check bolt for the oil quantity
upper limit removed. Otherwise, the oil level
drops with time in the engine, allowing the oil
to flow out.

3. Install:

•Cover

• Air filter case

• Air scoop (left/right)

• Fuel tank

• Seat

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.

2. Start the engine, warm it up for 2–3 minutes

at engine idling speed, and then stop the en­gine and wait approximately 1 minute.

• Engine oil also luburicates the clutch and
the wrong oil types or additives could
cause clutch slippage. Therefore, do not
add any chemical additives or use engine
oils with a grade of CD or higher and do
not use oils labeled "ENERGY CONSERV­ING II".

• Do not allow foreign material to enter the
crankcase.

3-13

ENGINE

Recommended brand: YAMALUBE
Recommended engine oil type

SAE10W-30, SAE 10W-40,
SAE10W-50, SAE 15W-40, SAE
20W-40 or SAE 20W-50

Recommended engine oil grade

API service SG type or higher,
JASO standard MA

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:

• Oil filler cap "1"

• Drain bolt (with gasket) "2"

• Drain bolt (with gasket) "3"
Drain the engine oil.

Replacement steps:

a. Remove the oil filter element cover "1" and

oil filter element "2".

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

aged, replace them with a new one.

c. Install the oil filter element and oil filter ele-

ment cover.

Oil filter element cover:

10 Nm (1.0 m•kg, 7.2 ft•lb)

5. Install:

• Gaskets

• Oil drain bolt (oil pan)

Oil drain bolt (oil pan):

20 Nm (2.0 m•kg, 14 ft•lb)

• Oil drain bolt (oil tank)

Oil drain bolt (oil tank):

20 Nm (2.0 m•kg, 14 ft•lb)

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

6. Fill:

• Engine oil

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)

3-14

ENGINE

7. Install:

• Oil filler cap

8. Inspect:

• Engine (for oil leaks)

•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 dam-

age 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)

2. Use a temperature probe tester "1" and con­tact it to the drain bolt thread.

Oil temperature:

55.0–65.0 °C (131–149°F)

3. Adjust:

• Engine idling speed

Adjustment steps:

a. Turn the starter knob/idle screw "1" until the

specified engine idling speed.

Using the digital tachometer, measure the en­gine speed with the detector "c" pinched in the
high tension cord "2" of the ignition coil.

ADJUSTING THE ENGINE IDLING SPEED

• Because the air pressure is lower at high alti­tudes, the air-fuel mixture will become richer.
If the engine idling speed is low, turn the start­er (choke) knob/idling screw a few clicks
counterclockwise to increase the idling speed.

• Before adjusting the engine idling speed,
make sure that the compression pressure is
within specification and that the air filter ele­ment is not clogged.

• Adjust the engine idling speed with the starter
(choke) knob/idling screw pushed in com­pletely.

Digital tachometer:

YU-39951-B/90890-06760

To increase the engine idling speed→Turn

the starter (choke) knob/idling screw
counterclockwise "a".

To decrease the engine idling speed →

Turn the starter (choke) knob/idling
screw clockwise "b".

Engine idling speed:

1,900–2,100 r/min

1. Start the engine and warm it up until the en-

gine oil has reached the specified tempera­ture.

3-15

ADJUSTING THE VALVE CLEARANCE

• This section is intended for those who have
basic knowledge and skill concerning the ser­vicing of Yamaha motorcycles (e.g., Yamaha
dealers, service engineers, etc.) Those who
have little knowledge and skill concerning ser­vicing are requested not to undertake inspec­tion, adjustment, disassembly, or reassembly
only by reference to this manual. It may lead
to servicing trouble and mechanical damage.

• The valve clearance should be adjusted when
the engine is cool to the touch.

ENGINE

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 counterclockwise with a

wrench.

b. Align the alignment mark "a" on the rotor

with the alignment mark "b" on the crank­case cover.

1. Remove:

• Seat
Refer to "SEAT AND SIDE COVERS" sec­tion in the CHAPTER 4.

• Fuel tank
Refer to "FUEL TANK" section in the CHAP­TER 6.

2. Remove:

• Spark plug

• Cylinder head cover
Refer to "CAMSHAFTS" section in the
CHAPTER 4.

3. Remove:

• Timing mark accessing screw "1"

• Crankshaft end accessing screw "2"

• O-ring

Make sure that the alignment mark "c" on the
exhaust camshaft sprocket and the alignment
mark "d" on the intake camshaft sprocket are
aligned with the edge of the cylinder head.

3-16

c. Measure the valve clearance "e" using a

feeler gauge "1".

Record the measured reading if the clearance
is incorrect.

ENGINE

c. Select the proper pad using the pad select-

ing table.

Pad range

No.

120–No.

240

1.20

mm–2.40

mm

Pad Availability: 25

increments

Pads are available in

0.05 mm increments

5. Adjust:

• Valve clearance

Adjustment steps:

a. Remove the camshaft (intake and exhaust).

Refer to "CAMSHAFTS" section in the
CHAPTER 4.

b. Remove the valve lifter "1" and the valve pad

"2" with a valve lapper "3".

• 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.

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

d. Round off the last digit of the installed 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

Rounded valve

Pads can only be selected in 0.05 mm incre­ments.

e. Locate the rounded-off value and the mea-

sured valve clearance in the chart "PAD SE­LECTION TABLE". The field where these
two coordinates intersect shows the new
pad number to use.

3-17

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

f. Install the new pads "4" and the valve lifters

"5".

• 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.

ENGINE

g. Install the camshafts (exhaust and intake).

Refer to "CAMSHAFTS" section in the
CHAPTER 4.

3-18

INTAKE

ENGINE

EXHAUST

3-19

CHASSIS

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

Air bleeding steps:

a. Add proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to spill

any fluid or allow the reservoir to overflow.

c. Connect the clear plastic tube "2" tightly to

the caliper bleed screw "1".

d. Place the other end of the tube into a con-

tainer.

e. Slowly apply the brake lever or pedal sever-

al 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 bub-

bles 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 reser-

voir.

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"

A. Front
B. Rear

3-20

Brake lever position "a":

Standard position Extent of adjustment

95 mm (3.74 in)

86–105 mm

(3.39–4.13 in)

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 po-

sition "a" is within specified position.

c. Tighten the locknut.

Locknut:

5 Nm (0.5 m •kg, 3.6 ft•lb)

2. Adjust:

• Brake pedal height

Pedal height adjustment steps:

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

height "a" is within specified height.

• 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.

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

4. Install:

• Brake lever cover

ADJUSTING THE REAR BRAKE

1. Check:

• Brake pedal height "a"

Out of specification → Adjust.

Brake pedal height "a":

0 mm (0.0 in)

c. Tighten the locknut.

Locknut:

6Nm (0.6 m •kg, 4.3 ft•lb)

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

3-21

CHASSIS

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".

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.

f. Loosen the bleed screw and push the brake

caliper piston in.

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

fork.

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.

3-22

i. Install the brake caliper "8" and tighten the

pad pin "9".

Bolt (brake caliper):

28 Nm (2.8 m•kg, 20 ft•lb)

Pad pin:

18 Nm (1.8 m•kg, 13 ft•lb)

j. Install the pad pin plug "10".

Pad pin plug:

2 Nm (0.2 m•kg, 1.4 ft•lb)

CHASSIS

2. Replace:

•Brake pad

Brake pad replacement steps:

a. Remove the protector "1" and pad pin plug

"2".

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)

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 5.

d. Remove the pad pin "6" and brake pads "7".

3-23

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.

Do not reuse the drained brake fluid.

g. Tighten the bleed screw.

Bleed screw:

6 Nm (0.6 m•kg, 4.3 ft•lb)

CHASSIS

k. Install the pad pin plug "15" and protector

"16".

Pad pin plug:

2 Nm (0.2 m•kg, 1.4 ft•lb)

Bolt (protector):

7 Nm (0.7 m•kg, 5.1 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 5.

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 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.

3-24

CHASSIS

2. Inspect:

• Rear brake pad insulator "1"

Damage → Replace.

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 contaminants

do not enter master cylinder when refill­ing.

• Clean up spilled fluid immediately to avoid

erosion of painted surfaces or plastic
parts.

CHECKING THE SPROCKET

1. Inspect:

• Sprocket teeth "a"

Excessive wear → Replace.

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

CHECKING THE DRIVE CHAIN

1. Measure:

• Drive chain length (15 links) "a"

Out of specification → Replace.

Drive chain length (15 links):

<Limit>: 242.9 mm (9.563 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.

a. Lower level
A. Front
B. Rear

3-25

2. Remove:

• Master link clip

• Joint "1"

• Drive chain "2"

CHASSIS

Be sure to install the master link clip to the
direction as shown.

3. Clean:

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

4. Check:

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

a. Turning direction

6. Lubricate:

• Drive chain

Drive chain lubricant:

SAE 10W-40 motor oil or suitable
chain lubricants

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:

50–60 mm (2.0–2.4 in)

5. Install:

• Drive chain "1"

• Joint "2"

• Master link clip "3"

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.

3-26

3. Adjust:

• Drive chain slack

Drive chain slack adjustment steps:

a. Loosen the axle nut "1" and locknuts "2".
b. Adjust the drive chain slack by turning the

adjusters "3".

To tighten → Turn the adjuster "3" counter-

clockwise.

To loosen → Turn the adjuster "3" clock-

wise 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.) NOTICE: Improper drive

chain slack will overload the engine as­well as other vital parts of the motorcycle
and can lead to chain slippage or break­age. To prevent this from occurring, keep
the drive chain slack within the specified
limits.

CHASSIS

A. Right
B. Left

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

d. Tighten the axle nut while pushing down the

drive chain.

Axle nut:

135 Nm (13.5 m•kg, 98 ft•lb)

e. Tighten the locknuts.

Locknut:

21 Nm (2.1 m•kg, 15 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.

CHECKING THE FRONT FORK
PROTECTOR GUIDE

1. Inspect:

• Protector guide "1"
Out of specification → Replacet.

The protector guide reaches the limit of its use
when it is worn down to the same height "a" as
of the outer tube circumference.

3-27

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"

CHASSIS

ADJUSTING THE FRONT FORK REBOUND
DAMPING FORCE

1. Adjust:

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

Stiffer "a" → Increase the rebound damp-

ing force. (Turn the adjuster "1" in.)

Softer "b" → Decrease the rebound damp-

ing force. (Turn the adjuster "1" out.)

Extent of adjustment:

• 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.

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)

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:

10 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.

20 clicks out (from
maximum position)

3-28

CHASSIS

ADJUSTING THE FRONT FORK
COMPRESSION DAMPING FORCE

1. Adjust:

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

Stiffer "a" → Increase the compression

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

Softer "b" → Decrease the compression

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

Extent of adjustment:

Maximum Minimum

Fully turned in posi­tion

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. Measure:

• Spring fitting length

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

Standard position:

13 clicks out
* 12 clicks out

* Except for USA and CDN

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.

Standard fitting length:

I.D. MARK/ Q'TY Length

White/1 252 mm (9.92 in)

*253 mm (9.96 in)

*Except for USA and CDN

3-29