Yamaha YZ450FT user guide

LIT-11626-18-44

YZ450FT

5XD-28199-11

OWNER’S SERVICE MANUAL

EC010000

YZ450FT

OWNER’S SERVICE MANUAL

©2004 by Yamaha Motor Corporation, U.S.A.

1st Edition, June 2004
All rights reserved. Any reprinting or
unauthorized use without the written

permission of Yamaha Motor Corporation

U.S.A. is expressly prohibited.

Printed in Japan

P/N. LIT-11626-18-44

EC020000

INTRODUCTION

Congratulations on your purchase of a
Yamaha YZ series. This model is the 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.

OTE:

As improvements are made on this model,
some data in this manual may become out­dated. If you have any questions, please con­sult your Yamaha dealer.

WARNING

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

IMPORTANT NOTICE

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

SAFETY INFORMATION

1. THIS MACHINE IS TO BE OPERATED
BY AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this
machine at maximum power until you
are totally familiar with its character­istics.

2. THIS MACHINE IS DESIGNED TO BE
RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this
machine.

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

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

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

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

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

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

9. THE ENGINE, EXHAUST PIPE, MUF­FLER, AND OIL TANK WILL BE VERY
HOT AFTER THE ENGINE HAS BEEN
RUN.
Be careful not to touch them or to
allow any clothing item to contact
them during inspection or repair.

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

EC050000

TO THE NEW OWNER

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

OTE:

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

EC060000

NOTICE

Some data in this manual may become out­dated due to improvements made to this
model in the future. If there is any question
you have regarding this manual or your
machine, please consult your Yamaha
dealer.

EC070001

F.I.M. MACHINE WEIGHTS:

Weights of machines without fuel

The minimum weights for motocross
machines are:

for the class 125 cc ....................... minimum

88 kg (194 lb)

for the class 250 cc ....................... minimum

98 kg (216 lb)

for the class 500 cc ....................... minimum

102 kg (225 lb)
In modifying your machine (e.g., for weight
reduction), take note of the above limits of
weight.

EC080000

WARNING

CAUTION:

HOW TO USE

THIS MANUAL

EC081000

PARTICULARLY IMPORTANT
INFORMATION

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

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

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

NOTE:

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

EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters;

“General Information”, “Specifications”,
“Regular inspection and adjustments”,
“Engine”, “Chassis”, “Electrical” and “Tun-

ing”.

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.

EC083000

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.

EC084002

HOW TO READ DESCRIPTIONS

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

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

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

enclosed by a circle indicates a disassembly step.

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

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

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

of parts, notes in jobs, etc.

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

sary removal job.

6. For jobs requiring more information, the step-by-step format supplements 6 are given in addi-

tion to the exploded diagram and job instruction chart.

12

ILLUSTRATED SYMBOLS

GEN

INFO

34

SPEC

INSP

ADJ

56

CHAS

78

ENG

–+

ELEC

TUN

90

(Refer to the illustration)

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

General information

1

Specifications

2

Regular inspection and adjustments

3

Engine

4

Chassis

5

Electrical

6

Tuning

7

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

With engine mounted

8

Special tool

9

Filling fluid

0

Lubricant

A

Tightening

B

Specified value, Service limit

C

Resistance (Ω), Voltage (V), Electric current (A)

D

AB

T

.

R

.

CD

EF

E

GH

B

IJ

M

M

New

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

Apply engine oil

E

Apply molybdenum disulfide oil

F

Apply lightweight lithium-soap base grease

G

Apply molybdenum disulfide grease

H

Illustrated symbols I to J in the exploded
diagrams indicate where to apply a locking
agent and where to install new parts.

®

Apply locking agent (LOCTITE

I

Use new one

J

)

EC090000

INDEX

GENERAL
INFORMATION

SPECIFICATIONS

REGULAR

GEN

INFO

SPEC

1

2

INSPECTION AND
ADJUSTMENTS

ENGINE

CHASSIS

ELECTRICAL

TUNING

INSP

ADJ

ENG

CHAS

– +

ELEC

TUN

3

4

5

6

7

EC0A0000

CONTENTS

CHAPTER 1

GENERAL INFORMATION

DESCRIPTION
MACHINE IDENTIFICATION
IMPORTANT INFORMATION
CHECKING OF CONNECTION
SPECIAL TOOLS
CONTROL FUNCTIONS
FUEL
STARTING AND BREAK-IN
TORQUE-CHECK POINTS
CLEANING AND STORAGE

........................................................1-13

...........................................1-1

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

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

.................1-6

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

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

....................1-14

......................1-18

...................1-19

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
GENERAL TORQUE
SPECIFICATIONS
DEFINITION OF UNITS
LUBRICATION DIAGRAMS
CABLE ROUTING DIAGRAM

...................................2-18

...........................2-18

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

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

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

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

CHAPTER 3

REGULAR INSPECTION

AND ADJUSTMENTS

MAINTENANCE INTERVALS
PRE-OPERATION INSPECTION
AND MAINTENANCE
ENGINE
CHASSIS
ELECTRICAL

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

.................................................3-24

...........................................3-46

................................3-4

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

CHAPTER 4

ENGINE

SEAT, FUEL TANK
AND SIDE COVERS
EXHAUST PIPE AND SILENCER
RADIATOR
CARBURETOR
CAMSHAFTS
CYLINDER HEAD
VALVES AND VALVE SPRINGS
CYLINDER AND PISTON
CLUTCH
OIL FILTER, WATER PUMP
AND CRANKCASE COVER (RIGHT)
BALANCER
OIL PUMP
KICK AXLE AND SHIFT SHAFT
CDI MAGNETO
ENGINE REMOVAL
CRANKCASE AND CRANKSHAFT
TRANSMISSION, SHIFT CAM
AND SHIFT FORK

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

...........................................4-21

...................................................4-48

.............................................4-62

................................................4-65

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

.............4-3

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

....................................4-29

............4-33

........................4-42

.............4-69

........................................4-76

.................................4-80

...................................4-94

.....4-55

........4-85

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR WHEEL
FRONT BRAKE AND REAR BRAKE
FRONT FORK
HANDLEBAR
STEERING
SWINGARM
REAR SHOCK ABSORBER

..........................................5-26

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

...............................................5-48

.............................................5-53

....................5-61

.......5-1

.....5-10

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS
AND WIRING DIAGRAM
MAP-CONTROLLED CDI UNIT
IGNITION SYSTEM
TPS (THROTTLE POSITION SENSOR)
SYSTEM

.....................................................6-7

...........................6-1

.................6-2

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

CHAPTER 7

TUNING

ENGINE
CHASSIS

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

.................................................7-11

EC100000

GENERAL INFORMATION

EC110000

DESCRIPTION

Clutch lever

1

Hot starter lever

2

Front brake lever

3

Throttle grip

4

Radiator cap

5

Fuel tank cap

6

“ENGINE STOP” button

7

Kick starter

8

Fuel tank

9

Radiator

0

Coolant drain bolt

A

Rear brake pedal

B

Valve joint

C

Fuel cock

D

Cold starter knob

E

Drive chain

F

Air cleaner

G

Shift pedal

H

Oil dipstick

I

Front fork

J

GEN

DESCRIPTION

OTE:

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

• Designs and specifications are subject to
change without notice.

INFO

1

1 - 1

MACHINE IDENTIFICATION

EC120001

MACHINE IDENTIFICATION

There are two significant reasons for knowing
the serial number of your machine:

1. When ordering parts, you can give the

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

2. If your machine is stolen, the authorities will

need the number to search for and identify
your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

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

GEN

INFO

EC123001

ENGINE SERIAL NUMBER

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

EC124000

MODEL LABEL

The model label 1 is affixed to the frame
under the rider’s seat. This information will be
needed to order spare parts.

1 - 2

IMPORTANT INFORMATION

EC130000

IMPORTANT INFORMATION

EC131010

PREPARATION FOR REMOVAL AND
DISASSEMBLY

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

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

• Silencer exhaust port

• Side cover air intake port

• Water pump housing hole at the bottom

• Drain hole on the cylinder head (right

side)

GEN

INFO

2. Use proper tools and cleaning equipment.

Refer to “SPECIAL TOOLS” section.

3. When disassembling the machine, keep

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

4. During the machine disassembly, clean all

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

5. Keep away from fire.

1 - 3

IMPORTANT INFORMATION

EC132000

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine

parts for all replacements. Use oil and/or
grease recommended by Yamaha for
assembly and adjustment.

EC133000

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should

be replaced when an engine is overhauled.
All gasket surfaces, oil seal lips, and O­rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil
seal lips.

GEN

INFO

EC134000

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.

EC135001

BEARINGS AND OIL SEALS

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

with their manufacturer’s marks or numbers
facing outward. (In other words, the
stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of light-weight
lithium base grease to the seal lip(s). Oil
the bearings liberally when installing.

CAUTION:

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

1 - 4

IMPORTANT INFORMATION

EC136000

CIRCLIPS

1. All circlips should be inspected carefully

before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlip 1, make
sure that the sharp-edged corner 2 is posi­tioned opposite to the thrust 3 it receives.
See the sectional view.

Shaft

4

GEN

INFO

1 - 5

CHECKING OF CONNECTION

EC1C0001

CHECKING OF CONNECTION

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

1. Disconnect:

• Connector

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two

or three times.

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

off.

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

1 and reinsert the terminal into the con­nector.

GEN

INFO

6. Connect:

• Connector

OTE:

The two connectors “click” together.

7. Check for continuity with a tester.

OTE:

• If there in no continuity, clean the terminals.

• Be sure to perform the steps 1 to 7 listed

above when checking the wire harness.

• For a field remedy, use a contact revitalizer
available on the market.

• Use the tester on the connector as shown.

1 - 6

GEN

SPECIAL TOOLS

EC140001

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the
correct special tool will help prevent damage caused by the use of improper tools or improvised
techniques. The shape and part number used for the special tool differ by country, so two types are
provided. Refer to the list provided to avoid errors when placing an order.

OTE:

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

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

Part number Tool name/How to use Illustration

YU-1135-A, 90890-01135 Crankcase separating tool

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

YU-1235, 90890-01235 Rotor holding tool

YU-1135-A 90890-01135

YU-1235 90890-01235

INFO

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

YU-3097, 90890-01252
YU-1256

YU-90050, 90890-01274
YU-90050, 90890-01275
YU-91044, 90890-04081
YU-90063, 90890-01278

YU-1304, 90890-01304 Piston pin puller

YU-24460-01, 90890-01325
YU-33984, 90890-01352

YM-1189, 90890-01189 Flywheel puller

Dial gauge and stand
Stand

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

Crankshaft installing tool
Crankshaft installing pot
Crankshaft installing bolt
Spacer (crankshaft installer)
Adapter (M12)
These tools are used to install the crankshaft.

This tool is used to remove the piston pin.

Radiator cap tester
Adapter

These tools are used for checking the cooling sys­tem.

YU-3097
YU-1256

YU-90050
YU-90063
YU-91044

YU-1304 90890-01304

YU-24460-01
YU-33984

YM-1189 90890-01189

90890-01252

90890-01274
90890-01275
90890-01278
90890-04081

90890-01325
90890-01352

This tool is used to remove the flywheel magneto.

1 - 7

SPECIAL TOOLS

Part number Tool name/How to use Illustration

YU-33975, 90890-01403 Ring nut wrench

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

YM-01442, 90890-01442 Fork seal driver

This tool is used when install the fork oil seal.

YM-01500, 90890-01500 Cap bolt wrench

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

YM-01501, 90890-01501 Cap bolt ring wrench

YU-33975 90890-01403

YM-01442 90890-01442

YM-01500 90890-01500

YM-01501 90890-01501

GEN

INFO

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

YU-3112-C, 90890-03112 Pocket tester

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

YM-33277-A, 90890-03141 Timing light

This tool is necessary for checking ignition timing.

YM-4019, 90890-04019 Valve spring compressor

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

YM-91042, 90890-04086 Clutch holding tool

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

YM-4116, 90890-04116
YM-4097, 90890-04097

Valve guide remover

Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)

YU-3112-C 90890-03112

YM-33277-A 90890-03141

YM-4019 90890-04019

YM-91042 90890-04086

YM-4116
YM-4097

90890-04116
90890-04097

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

1 - 8

SPECIAL TOOLS

Part number Tool name/How to use Illustration

YM-4117, 90890-04117
YM-4098, 90890-04098

YM-4118, 90890-04118
YM-4099, 90890-04099

YM-34487

90890-06754

ACC-QUICK-GS-KT

90890-85505

Valve guide installer

Intake
Exhaust

This tool is needed to install the valve guide.

Valve guide reamer

Intake 4.5 mm (0.18 in)
Exhaust 5.0 mm (0.20 in)

This tool is needed to rebore the new valve guide.

Dynamic spark tester
Ignition checker

This instrument is necessary for checking the ignition
system components.

Quick gasket
YAMAHA Bond No. 1215



YM-4117
YM-4098

YM-4118
YM-4099

YM-34487 90890-06754

ACC-QUICK-GS-KT 90890-85505

GEN

INFO

90890-04117
90890-04098

90890-04118
90890-04099

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

1 - 9

CONTROL FUNCTIONS

EC150000

CONTROL FUNCTIONS

EC151000

“ENGINE STOP” BUTTON

The “ENGINE STOP” button 1 is located on
the left handlebar. Continue pushing the
“ENGINE STOP” button till the engine comes
to a stop.

EC152000

CLUTCH LEVER

The clutch lever 1 is located on the left 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.

GEN

INFO

1

EC153000

SHIFT PEDAL

The gear ratios of the constant-mesh 4 speed
transmission are ideally spaced. The gears
can be shifted by using the shift pedal 1 on
the left side of the engine.

EC154000

KICK STARTER

Rotate the kick starter 1 away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kick starter so the engine can be
started in any gear if the clutch is disengaged.
In normal practices, however, shift to neutral
before starting.

EC155001

THROTTLE GRIP

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

1 - 10

CONTROL FUNCTIONS

EC156000

FRONT BRAKE LEVER

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

EC157000

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.

GEN

INFO

EC158001

FUEL COCK

The fuel cock supplies fuel from the tank to
carburetor while filtering the fuel. The fuel cock
has the two positions:
OFF: With the lever in this position, fuel will not

flow. Always return the lever to this posi­tion when the engine is not running.

ON: With the lever in this position, fuel flows

to the carburetor. Normal riding is done
with the lever in this position.

COLD STARTER KNOB

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

HOT STARTER LEVER

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

1 - 11

CONTROL FUNCTIONS

EC15R001

DETACHABLE SIDESTAND

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

WARNING

• Never apply additional force to the side­stand.

• Remove this sidestand before starting
out.

EC15F000

VALVE JOINT

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

CAUTION:

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

GEN

INFO

1

SPARK PLUG WRENCH

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

1

NIPPLE WRENCH

This nipple wrench 1 is used to tighten the
spoke.

1 - 12

GEN

FUEL

FUEL

Always use the recommended fuel as stated
below. Also, be sure to use new gasoline the
day of a race.

Recommended fuel:

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

CAUTION:

Use only unleaded gasoline. The use of
leaded gasoline will cause severe damage
to the engine internal parts such as valves,
piston rings, and exhaust system, etc.

OTE:

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

INFO

WARNING

• For refueling, be sure to stop the engine
and use enough care not to spill any fuel.
Also be sure to avoid refueling close to a
fire.

• Refuel after the engine, exhaust pipe, etc.
have cooled off.

1 - 13

STARTING AND BREAK-IN

STARTING AND BREAK-IN

WARNING

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

CAUTION:

• The carburetor on this machine has a
built-in accelerator pump. Therefore,
when starting the engine, do not operate
the throttle or the spark plug will foul.

• Unlike a two-stroke engine, this engine
cannot be kick started when the throttle is
open because the kick starter may kick
back. Also, if the throttle is open the air/
fuel mixture may be too lean for the
engine to start.

• Before starting the machine, perform the
checks in the pre-operation check list.

GEN

INFO

STARTING A COLD ENGINE

1. Inspect the coolant level.

2. Turn the fuel cock to “ON”.

3. Shift the transmission into neutral.

4. Fully open the cold starter knob 1.

5. Kick the kick starter.

WARNING

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

1 - 14

STARTING AND BREAK-IN

6. Return the cold starter knob to its original

position and run the engine at 3,000 ~
5,000 r/min for 1 or 2 minutes.

OTE:

Since this model is equipped with an accelera­tor pump, if the engine is raced (the throttle
opened and closed), the air/fuel mixture will be
too rich and the engine may stall. Also unlike a
two-stroke engine, this model can idle.

CAUTION:

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

GEN

INFO

1 - 15

STARTING AND BREAK-IN

STARTING A WARM ENGINE

Do not operate the cold starter knob and throt­tle. Pull the hot starter lever 1 and start the
engine by kicking the kick starter forcefully with
a firm stroke.
As soon as the engine starts, release the hot
starter lever to close the air passage.

Restarting an engine after a fall

Pull the hot starter lever and start the engine.
As soon as the engine starts, release the hot
starter lever to close the air passage.

The engine fails to start

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

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

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

Air temperature (normal tem­perature) = between 5 °C
(41 °F) and 25 °C (77 °F)

Air temperature = more

Starting a cold engine

than 25 °C (77 °F)

Starting an engine after a long
period of time

Restarting a warm engine None OFF ON

Restarting an engine after a fall None OFF ON

* Operate the throttle grip before kick starting.

GEN

INFO

Throttle

grip oper-

ation*

Open 3

or 4 times

None ON OFF

None ON/OFF OFF

None OFF OFF

None ON OFF

Cold

starter

knob

ON OFF

Hot

starter

lever

CAUTION:

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

1 - 16

STARTING AND BREAK-IN

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” button.
Then, restart the engine and check its
operation within no more than 5 minutes
after it is restarted.

4. Operate the machine in the lower gears at

moderate throttle openings for five to eight
minutes.

5. Check how the engine runs when the

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

6. Restart the engine and check the operation

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

GEN

INFO

CAUTION:

• After the break-in or before each race,
you must check the entire machine for
loose fittings and fasteners as per
“TORQUE-CHECK POINTS”.
Tighten all such fasteners as required.

• When any of the following parts have
been replaced, they must be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in operation is
necessary.
PISTON, RING, VALVES, CAMSHAFTS
AND GEARS:
These parts require about 30 minutes of
break-in operation at half-throttle or less.
Observe the condition of the engine care­fully during operation.

1 - 17

TORQUE-CHECK POINTS

TORQUE-CHECK POINTS

GEN

INFO

Frame construction

Combined seat and tank

Exhaust system

Engine mounting

Steering Steering shaft to

handlebar

Suspension Front Steering shaft to front

fork

Rear For link type

Rear Installation of shock

absorber

Frame to rear frame
Fuel tank to frame

Silencer to rear frame

Frame to engine
Engine bracket to engine
Engine bracket to frame

Steering shaft to frame
Steering shaft to handle crown
Handle crown to handlebar

Front fork to handle crown
Front fork to under bracket

Assembly of links
Link to frame
Link to shock absorber
Link to swingarm

Shock absorber to frame

Rear Installation of

swingarm

Wheel Installation of wheel Front

Rear

Brake Front

Rear

Fuel system

Tightening of pivot shaft

Tightening of front axle
Tightening of axle holder

Tightening of rear axle
Wheel to sprocket

Caliper to front fork
Brake disc to wheel
Tightening of union bolt
Master cylinder to handlebar
Tightening of air bleeder
Tightening of brake hose holder

Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Master cylinder to frame
Tightening of air bleeder
Tightening of brake hose holder

Fuel tank to fuel cock

Lubrication system

Tightening of oil hose clamp

OTE:

Concerning the tightening torque, refer to
“MAINTENANCE SPECIFICATIONS” section
in the CHAPTER 2.

1 - 18

CLEANING AND STORAGE

EC1B0000

CLEANING AND STORAGE

EC1B1000

CLEANING

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

1. Before washing the machine, block off the

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

2. If the engine is excessively greasy, apply

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

3. Rinse the dirt and degreaser off with a gar-

den hose; use only enough pressure to do
the job.

GEN

INFO

CAUTION:

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

4. After the majority of the dirt has been

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

5. Rinse the machine off immediately with

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

6. Immediately after washing, remove excess

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

7. Clean the seat with a vinyl upholstery

cleaner to keep the cover pliable and
glossy.

1 - 19

CLEANING AND STORAGE

8. Automotive wax may be applied to all

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

9. After completing the above, start the

engine and allow it to idle for several min­utes.

EC1B2001

STORAGE

If your machine is to be stored for 60 days or
more, some preventive measures must be
taken to avoid deterioration. After cleaning the
machine thoroughly, prepare it for storage as
follows:

1. Drain the fuel tank, fuel lines, and the car-

buretor float bowl.

2. Remove the spark plug, pour a tablespoon

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

3. Remove the drive chain, clean it thoroughly

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

4. Lubricate all control cables.

5. Block the frame up to raise the wheels off

the ground.

6. Tie a plastic bag over the exhaust pipe out-

let 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.

GEN

INFO

OTE:

Make any necessary repairs before the
machine is stored.

1 - 20

GENERAL SPECIFICATIONS

EC200000

SPECIFICATIONS

EC211000

GENERAL SPECIFICATIONS

Model name: YZ450FT (USA, CDN, AUS, NZ)

YZ450F (EUROPE, ZA)

Model code number: 5XD5 (USA)

5XD6 (EUROPE)
5XD8 (CDN, AUS, NZ, ZA)

Dimensions: USA, ZA,

AUS, NZ

Overall length 2,190 mm

(86.2 in)

Overall width 827 mm

(32.6 in)

Overall height 1,300 mm

(51.2 in)

Seat height 999 mm

(39.3 in)

Wheelbase 1,493 mm

(58.8 in)

Minimum ground clearance 379 mm

(14.9 in)

Dry weight:

Without oil and fuel 100.0 kg (220 lb)

Engine:

Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 449 cm
Bore × stroke 95.0 × 63.4 mm (3.74 × 2.50 in)
Compression ratio 12.3 : 1
Starting system Kick starter

Lubrication system: Dry sump

3

(15.8 Imp oz, 15.2 US oz)

EUR

(Except for F)

2,195 mm
(86.4 in)

← ←

1,302 mm
(51.3 in)

1,001 mm
(39.4 in)

← ←

381 mm
(15.0 in)

SPEC

F, CDN

←

1,303 mm
(51.3 in)

←

←

2

2 - 1

GENERAL SPECIFICATIONS

Oil type or grade:

Engine oil (For USA and CDN)

At 5 °C (40 °F) or higher È
Yamalube 4 (20W-40) or SAE 20W-40 type SG
motor oil (Non-Friction modified)
At 15 °C (60 °F) or lower É
Yamalube 4 (10W-30) or SAE 10W-30 type SG
motor oil (Non-Friction modified) and/or
Yamalube 4-R (15W-50) (Non-Friction modi­fied)

(Except for USA and CDN)

-20-4-101403010502068308640 50

˚CTemp.

10W-30

10W-40

15W-40

20W-40

20W-50

API “SG” or higher grade

SPEC

104

122

˚F

Oil capacity:

Engine oil

Periodic oil change 1.0 L (0.88 Imp qt, 1.06 US qt)
With oil filter replacement 1.1 L (0.97 Imp qt, 1.16 US qt)

Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 1.2 L (1.06 Imp qt, 1.27 US qt)
Air filter: Wet type element
Fuel:

Type Premium unleaded gasoline only with a

research octane number of 95 or higher.

Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal)

Carburetor:

Type FCR MX39
Manufacturer KEIHIN

Spark plug:

Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

Clutch type: Wet, multiple-disc

2 - 2

GENERAL SPECIFICATIONS

Transmission:

Primary reduction system Gear
Primary reduction ratio 61/23 (2.652)
Secondary reduction system Chain drive
Secondary reduction ratio 51/14 (3.643)
Transmission type Constant mesh, 4-speed
Operation Left foot operation
Gear ratio: 1st 27/14 (1.929)

2nd 25/16 (1.563)
3rd 23/18 (1.278)
4th 21/20 (1.050)

Chassis:

Frame type Semi double cradle
Caster angle 27.1°
Trail 116 mm (4.57 in) (For USA, ZA, AUS, NZ)

117 mm (4.61 in) (For EUROPE except F)
118 mm (4.65 in) (For F, CDN)

Tire:

Type With tube
Size (front) 80/100-21 51M (For USA, CDN, ZA, AUS, NZ

and F)
80/100-21 51R (For EUROPE except F)

Size (rear) 110/90-19 62M (For USA, CDN, ZA, AUS, NZ

and F)
110/90-19 NHS (For EUROPE except F)

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

Brake:

Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation

Suspension:

Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)

Shock absorber:

Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper

Wheel travel:

Front wheel travel 300 mm (11.8 in)
Rear wheel travel 315 mm (12.4 in)

Electrical:

Ignition system CDI magneto

2

, 15 psi)

SPEC

2 - 3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.05 mm

(0.002 in)

Cylinder:

Bore size 95.00 ~ 95.01 mm

(3.7402 ~ 3.7406 in)

Out of round limit ---- 0.05 mm

Camshaft:

Drive method Chain drive (Left) ---­Camshaft cap inside diameter 22.000 ~ 22.021 mm

(0.8661 ~ 0.8670 in)

Camshaft journal diameter 21.967 ~ 21.980 mm

(0.8648 ~ 0.8654 in)

Shaft-to-cap clearance 0.020 ~ 0.054 mm

(0.0008 ~ 0.0021 in)

Cam dimensions

----

(0.002 in)

----

----

0.08 mm
(0.003 in)

A

B

Intake “A” 31.200 ~ 31.300 mm

(1.2283 ~ 1.2323 in)

“B” 22.550 ~ 22.650 mm

(0.8878 ~ 0.8917 in)

Exhaust “A” 30.950 ~ 31.050 mm

(1.2185 ~ 1.2224 in)

“B” 22.494 ~ 22.594 mm

(0.8856 ~ 0.8895 in)

Camshaft runout limit ---- 0.03 mm

31.100 mm
(1.2244 in)

22.450 mm
(0.8839 in)

30.850 mm
(1.2146 in)

22.394 mm
(0.8817 in)

(0.0012 in)

2 - 4

MAINTENANCE SPECIFICATIONS

SPEC

Item Standard Limit

Cam chain:

Cam chain type/No. of links 98XRH2010-118M/118 ---­Cam chain adjustment method Automatic ----

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in)

EX 0.20 ~ 0.25 mm

(0.0079 ~ 0.0098 in)

Valve dimensions:

----

----

B

A

Head Diameter

Face Width

Seat Width

“A” head diameter IN 26.9 ~ 27.1 mm

C

D

Margin Thickness

----

(1.0591 ~ 1.0669 in)

EX 27.9 ~ 28.1 mm

----

(1.0984 ~ 1.1063 in)

“B” face width IN 2.26 mm (0.089 in) ----

EX 2.26 mm (0.089 in) ----

“C” seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

1.6 mm
(0.0630 in)

1.6 mm
(0.0630 in)

“D” margin thickness IN 1 mm (0.0394 in) 0.85 mm

(0.033 in)

EX 1 mm (0.0394 in) 0.85 mm

(0.033 in)

Stem outside diameter IN 4.475 ~ 4.490 mm

(0.1762 ~ 0.1768 in)

EX 4.965 ~ 4.980 mm

(0.1955 ~ 0.1961 in)

Guide inside diameter IN 4.500 ~ 4.512 mm

(0.1772 ~ 0.1776 in)

EX 5.000 ~ 5.012 mm

(0.1969 ~ 0.1973 in)

Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

EX 0.020 ~ 0.047 mm

(0.0008 ~ 0.0019 in)

4.445 mm
(0.1750 in)

4.935 mm
(0.1943 in)

4.550 mm
(0.1791 in)

5.050 mm
(0.1988 in)

0.08 mm
(0.003 in)

0.10 mm
(0.004 in)

Stem runout limit ---- 0.01 mm

(0.0004 in)

2 - 5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Valve spring:

Free length IN 37.03 mm (1.46 in) 36.03 mm

EX 37.68 mm (1.48 in) 36.68 mm

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

EX 27.38 mm (1.08 in) ----

Compressed force (installed) IN 111.3 ~ 127.9 N at 27.87 mm

(11.3 ~ 13.0 kg at 27.87 mm,

24.91 ~ 28.66 lb at 1.10 in)

EX 127.4 ~ 146.4 N at 27.38 mm

(13.0 ~ 14.9 kg at 27.38 mm,

28.66 ~ 32.85 lb at 1.08 in)

Tilt limit IN ----

EX ----

SPEC

(1.42 in)

(1.44 in)

----

----

2.5°/1.61 mm

(2.5°/0.063 in)

2.5°/1.65 mm

(2.5°/0.065 in)

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

EX Clockwise ----

Piston:

Piston to cylinder clearance 0.040 ~ 0.065 mm

(0.0016 ~ 0.0026 in)

Piston size “D” 94.945 ~ 94.960 mm

(3.738 ~ 3.739 in)

H

D

Measuring point “H” 8 mm (0.315 in) ----
Piston off-set 1 mm (0.0394 in) ---­Piston pin bore inside diameter 18.004 ~ 18.015 mm

(0.7088 ~ 0.7093 in)

Piston pin outside diameter 17.991 ~ 18.000 mm

(0.7083 ~ 0.7087 in)

0.1 mm
(0.004 in)

----

18.045 mm
(0.7104 in)

17.971 mm
(0.7075 in)

2 - 6

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Piston rings:

Top ring:

B

T

Type Barrel ----

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

End gap (installed) 0.20 ~ 0.30 mm

(0.008 ~ 0.012 in)

Side clearance (installed) 0.030 ~ 0.065 mm

(0.0012 ~ 0.0026 in)

2nd ring:

B

T

Type Taper ----

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

End gap (installed) 0.35 ~ 0.50 mm

(0.014 ~ 0.020 in)

Side clearance 0.020 ~ 0.055 mm

(0.0008 ~ 0.0022 in)

Oil ring:

SPEC

0.55 mm
(0.022 in)

0.12 mm
(0.005 in)

0.85 mm
(0.033 in)

0.12 mm
(0.005 in)

B

T

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

End gap (installed) 0.2 ~ 0.5 mm (0.01 ~ 0.02 in) ---­Crankshaft:

Crank width “A” 61.95 ~ 62.00 mm

(2.439 ~ 2.441 in)

Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm

Big end side clearance “D” 0.15 ~ 0.45 mm

(0.0059 ~ 0.0177 in)

Small end free play “F” 0.4 ~ 1.0 mm (0.02 ~ 0.04 in) 2.0 mm

Balancer:

Balancer drive method Gear ----

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

oil

----

(0.002 in)

0.50 mm
(0.02 in)

(0.08 in)

----

2 - 7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Clutch:

Friction plate thickness 2.92 ~ 3.08 mm

(0.115 ~ 0.121 in)

Quantity 9 ----

Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ----

Quantity 8 ----

Warp limit ---- 0.1 mm

Clutch spring free length 47.8 mm (1.88 in) 46.8 mm

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

Kick starter:

Type Ratchet type ----

Carburetor:

I.D. mark 5XD5 50 ---­Main jet (M.J) #165 ---­Main air jet (M.A.J) ø2.0 ----
Jet needle - clip position (J.N) NFLR-4 ---­Cutaway (C.A) 1.5 ---­Pilot jet (P.J) #45 ---­Pilot air jet (P.A.J) #100 ---­Pilot outlet (P.O) ø0.9 ----
Pilot screw (example) (P.S) 1-3/4 ---­Bypass (B.P) ø1.0 ---­Valve seat size (V.S) ø3.8 ----
Starter jet (G.S) #72 ---­Leak jet (Acc. P) #40 ---­Float height (F.H) 8 mm (0.31 in) ---­Engine idle speed 1,900 ~ 2,100 r/min ---­Intake vacuum 28.0 ~ 33.3 kPa

(210 ~ 250 mmHg,

8.27 ~ 9.84 inHg)

Hot starter lever free play 3 ~ 6 mm (0.12 ~ 0.24 in) ----

SPEC

2.8 mm
(0.110 in)

(0.004 in)

(1.84 in)

----

----

(0.002 in)

----

2 - 8

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Lubrication system:

Oil filter type Paper type ---­Oil pump type Trochoid type ---­Tip clearance “A” 0.12 mm or less

(0.0047 in or less)

Tip clearance “B” 0.09 ~ 0.17 mm

(0.0035 ~ 0.0067 in)

Side clearance 0.03 ~ 0.10 mm

(0.0012 ~ 0.0039 in)

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

5.69 ~ 11.38 psi)

Cooling:

Radiator core size

Width 117.8 mm (4.6 in) ----

Height 260 mm (10.2 in) ----

Thickness 32 mm (1.26 in) ----

Radiator cap opening pressure 110 kPa (1.1 kg/cm
Radiator capacity (total) 0.71 L (0.62 Imp qt, 0.75 US qt) ---­Water pump

Type Single-suction centrifugal pump ----

2

, 15.6 psi) ----

SPEC

2

,

0.20 mm
(0.008 in)

0.24 mm
(0.009 in)

0.17 mm
(0.007 in)

----

2 - 9

Lubrication chart:

MAINTENANCE SPECIFICATIONS

Item Standard

SPEC

Main axle

Drive axle

Pressure feed

Splashed scavenge

Transmission gears

Cylinder head

Oil filter

Check ball

Oil pump rotor 1

Oil pump rotor 2

Oil tank

Camshaft

Valve lifter

Piston

Piston pin

Crank pin

Oil strainer

Oil pan

2 - 10

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M6 × 1.0 2 7 0.7 5.1

M8 × 1.25 1 15 1.5 11
(bolt) M10 × 1.25 4 Refer to NOTE.*
(nut) M6 × 1.0 2 10 1.0 7.2

Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Timing chain guide (rear) M6 × 1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8 × 1.25 1 13 1.3 9.4

(bolt) M8 × 1.25 1 24 2.4 17
Silencer M8 × 1.25 2 35 3.5 25
Silencer clamp M8 × 1.25 1 16 1.6 11
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
Clamp (cylinder head side) M5 × 0.8 1 3 0.3 2.2
Clamp (carburetor side) M4 × 0.7 1 3 0.3 2.2
Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Air filter element M6 × 1.0 1 2 0.2 1.4
Radiator panel (upper) M6 × 1.0 2 10 1.0 7.2
Radiator M6 × 1.0 6 10 1.0 7.2
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M10 × 1.0 2 10 1.0 7.2
Impeller M8 × 1.25 1 14 1.4 10
Water pump housing cover M6 × 1.0 3 10 1.0 7.2
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 3 9 0.9 6.5
Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2
Oil filter cover M6 × 1.0 2 10 1.0 7.2
Oil delivery pipe 1 M10 × 1.25 1 20 2.0 14

M8 × 1.25 2 18 1.8 13
Oil delivery pipe 2 M6 × 1.0 1 10 1.0 7.2
Oil hose M6 × 1.0 2 8 0.8 5.8
Oil check bolt M6 × 1.0 1 10 1.0 7.2

Tightening torque

Nm m·kg ft·lb

1

2 - 11

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Oil hose clamp — 220.21.4
Clutch cover M6 × 1.0 7 10 1.0 7.2
Crankcase cover (right) M6 × 1.0 10 10 1.0 7.2
Crankcase cover (left) M6 × 1.0 8 10 1.0 7.2
Crankcase M6 × 1.0 12 12 1.2 8.7
Clutch cable holder M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (crankcase rear) M10 × 1.25 1 20 2.0 14

(crankcase left) M6 × 1.0 1 10 1.0 7.2
Oil drain bolt (frame) M8 × 1.25 1 23 2.3 17
Oil strainer (frame) M14 × 1.5 1 70 7.0 50
Crankcase bearing stopper M6 × 1.0 15 10 1.0 7.2
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kick starter M8 × 1.25 1 33 3.3 24
Screw (kick starter) M6 × 1.0 1 7 0.7 5.1
Primary drive gear M20 × 1.0 1 110 11.0 80
Clutch boss M20 × 1.0 1 75 7.5 54
Clutch cable locknut M8 × 1.25 2 7 0.7 5.1
Push lever M6 × 1.0 1 10 1.0 7.2
Clutch spring M6 × 1.0 6 8 0.8 5.8
Balancer driven gear M14 × 1.0 1 50 5.0 36
Balancer weight plate M6 × 1.0 3 10 1.0 7.2
Drive sprocket M20 × 1.0 1 75 7.5 54
Drive sprocket cover M6 × 1.0 2 8 0.8 5.8
Shift pedal M6 × 1.0 1 12 1.2 8.7
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22

Tightening torque

Nm m·kg ft·lb

OTE:

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

OTE:

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

2 - 12

MAINTENANCE SPECIFICATIONS

EC212201

SPEC

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Taper roller bearing ----

Front suspension: USA, CDN,

AUS, NZ, ZA

EUROPE

Front fork travel 300 mm (11.8 in) ← ---­Fork spring free length 465 mm (18.3 in) ← 460 mm (18.1 in)
Spring rate, STD K = 4.5 N/mm

(0.459 kg/mm,

25.7 lb/in)

K = 4.4 N/mm
(0.449 kg/mm,

25.1 lb/in)

----

Optional spring/spacer Yes ← ---­Oil capacity 445 cm

(15.7 Imp oz,

15.0 US oz)

Oil grade Suspension oil

3

455 cm3

----

(16.0 Imp oz,

15.4 US oz)
← ----

“S1”

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

Rear suspension: USA, CDN,

AUS, NZ, ZA

Shock absorber travel 132 mm

EUROPE

← ----

(5.20 in)

Spring free length 260 mm

← ----

(10.24 in)

Fitting length 248 mm

(9.76 in)

<Min.~Max.> 240.5 ~ 258.5 mm

245 mm

----

(9.65 in)
← ----

(9.47 ~ 10.18 in)

Spring rate, STD K = 52.0 N/mm

(5.30 kg/mm,

296.8 lb/in)

K = 50.0 N/mm
(5.10 kg/mm,

285.6 lb/in)

----

Optional spring Yes ← ---­Enclosed gas pressure 1,000 kPa

(10 kg/cm

2

,

← ----

142 psi)

Swingarm:

Swingarm free play limit

End ---- 1.0 mm (0.04 in)

2 - 13

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Wheel:

Front wheel type Spoke wheel ---­Rear wheel type Spoke wheel ---­Front rim size/material 21 × 1.60/Aluminum ---­Rear rim size/material 19 × 2.15/Aluminum ---­Rim runout limit:

Radial ---- 2.0 mm (0.08 in)
Lateral ---- 2.0 mm (0.08 in)

Drive chain:

Type/manufacturer DID520DMA2 SDH/DAIDO ---­Number of links 115 links + joint ---­Chain slack 48 ~ 58 mm (1.9 ~ 2.3 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 mm

Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ---­Caliper cylinder inside dia. 27.0 mm (1.063 in) × 2 ---­Brake fluid type DOT #4 ----

Rear disc brake:

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

Deflection limit ---- 0.15 mm (0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04 in)
Master cylinder inside dia. 11.0 mm (0.433 in) ---­Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ---­Brake fluid type DOT #4 ----

Brake lever and brake pedal:

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

(vertical height above footrest top)
Clutch lever free play (lever end) 8 ~ 13 mm (0.31 ~ 0.51 in) ---­Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----

5 mm (0.20 in) ----

SPEC

(9.563 in)

(9.84 × 0.10 in)

(9.65 × 0.14 in)

2 - 14

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Handle crown and outer tube M8 × 1.25 4 23 2.3 17
Under bracket and outer tube M8 × 1.25 4 20 2.0 14
Handle crown and steering shaft M24 × 1.0 1 145 14.5 105
Handlebar holder (upper) M8 × 1.25 4 28 2.8 20
Steering ring nut M28 × 1.0 1 Refer to NOTE.
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 protector M6 × 1.0 6 10 1.0 7.2
Protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle cable cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder mounting M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting (nut) M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder mounting M5 × 0.8 2 4 0.4 2.9
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
Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Front brake caliper and front fork M8 × 1.25 2 23 2.3 17
Front brake caliper and brake hose holder M6 × 1.0 1 10 1.0 7.2
Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2
Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 1 105 10.5 75
Front wheel axle holder M8 × 1.25 4 23 2.3 17
Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
Brake pedal mounting M8 × 1.25 1 26 2.6 19
Rear brake master cylinder and frame M6 × 1.0 2 11 1.1 8.0
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22

M6 × 1.0 1 4 0.4 2.9

Tightening torque

Nm m·kg ft·lb

OTE:

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

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

2 - 15

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Rear wheel axle and nut M20 × 1.5 1 125 12.5 90
Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30
Nipple (spoke) — 72 3 0.3 2.2
Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 2 16 1.6 11
Engine mounting:

Engine upper bracket and frame M10 × 1.25 2 55 5.5 40
Engine lower bracket and frame M8 × 1.25 4 34 3.4 24
Engine and engine bracket (front) M10 × 1.25 1 69 6.9 50
Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
Engine and frame (lower) M10 × 1.25 1 69 6.9 50
Engine guard (lower) M8 × 1.25 1 34 3.4 24

Engine skid plate mounting M6 × 1.0 6 10 1.0 7.2
CDI unit bracket mounting M6 × 1.0 1 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 80 8.0 58
Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
Connecting rod and frame M14 × 1.5 1 80 8.0 58
Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
Rear frame and frame (upper) M8 × 1.25 1 32 3.2 23
Rear frame and frame (lower) M8 × 1.25 2 29 2.9 21
Swingarm and brake hose holder M5 × 0.8 4 1 0.1 0.7
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Drive chain tensioner mounting (upper) M8 × 1.25 1 19 1.9 13
Drive chain tensioner mounting (lower) M8 × 1.25 1 20 2.0 14
Chain support and swingarm M6 × 1.0 3 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
Fuel tank mounting M6 × 1.0 2 10 1.0 7.2
Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Seat mounting M8 × 1.25 2 23 2.3 17
Side cover mounting M6 × 1.0 2 7 0.7 5.1
Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
Air scoop and radiator panel (lower) M6 × 1.0 2 6 0.6 4.3
Front fender mounting M6 × 1.0 4 7 0.7 5.1
Rear fender mounting (front) M6 × 1.0 2 7 0.7 5.1
Rear fender mounting (rear) M6 × 1.0 2 12 1.2 8.7
Number plate M6 × 1.0 1 7 0.7 5.1

Tightening torque

Nm m·kg ft·lb

OTE:

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

2 - 16

MAINTENANCE SPECIFICATIONS

EC212300

ELECTRICAL

Item Standard Limit

Ignition system:

Advancer type Electrical ----

C.D.I.:

Magneto-model (stator)/manufacturer 5XD-00/YAMAHA ---­Source coil 1 resistance (color) 720 ~ 1,080 Ω at 20 °C (68 °F)

(Green – Brown)

Source coil 2 resistance (color) 44 ~ 66 Ω at 20 °C (68 °F)

(Black – Pink)

Pickup coil resistance (color) 248 ~ 372 Ω at 20 °C (68 °F)

(White – Red)

CDI unit-model/manufacturer 5XD-50/YAMAHA (For USA)

5XD-60/YAMAHA (Except for
USA)

Ignition coil:

Model/manufacturer 5TA-10/DENSO ---­Minimum spark gap 6 mm (0.24 in) ---­Primary winding resistance 0.08 ~ 0.10 Ω at 20 °C (68 °F) ---­Secondary winding resistance 4.6 ~ 6.8 kΩ at 20 °C (68 °F) ----

SPEC

----

----

----

----

----

Part to be tightened Thread size Q’ty

Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 56 5.6 40
Neutral switch M5 × 0.8 2 4 0.4 2.9

Tightening torque

Nm m·kg ft·lb

2 - 17

GENERAL TORQUE SPECIFICATIONS/

DEFINITION OF UNITS

EC220001

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.

A

(Nut)

B

(Bolt)

Nm m•kg ft•lb

TORQUE

SPECIFICATION

SPEC

A: Distance between flats
B: Outside thread diameter

10 mm
12 mm
14 mm
17 mm
19 mm
22 mm

EC230000

6 mm

8 mm
10 mm
12 mm
14 mm
16 mm

6
15
30
55
85

130

0.6

1.5

3.0

5.5

8.5
13

4.3
11
22
40
61
94

DEFINITION OF UNITS

Unit Read Definition Measure

mm
cm

millimeter
centimeter

kg kilogram 10

N Newton 1 kg × m/sec

Nm
m • kg

Newton meter
Meter kilogram

Pa Pascal N/m

-3

10

meter

-2

meter

10

3

gram Weight

2

Force

N × m
m × kg

2

N/mm Newton per millimeter N/mm Spring rate

L
cm

3

Liter
Cubic centimeter

—
—

r/min Revolution per minute — Engine speed

Length
Length

Torque
Torque

Pressure

Volume or capacity
Volume or capacity

2 - 18

LUBRICATION DIAGRAMS

Oil delivery pipe

1

Intake camshaft

2

Exhaust camshaft

3

Oil cleaner element

4

Oil pump

5

Main axle

6

Drive axle

7

LUBRICATION DIAGRAMS

SPEC

7

6

1

4

2

G

3

4

G

D

A

D

A

D - D

5

A - A

5

2 - 19

Camshaft

1

Connecting rod

2

Oil cleaner element

3

Crankshaft

4

Main axle

5

Drive axle

6

Oil delivery pipe

7

LUBRICATION DIAGRAMS

SPEC

2 - 20

EC240000

CABLE ROUTING DIAGRAM

Fuel tank breather hose

1

Oil tank breather hose

2

Hot starter cable

3

Radiator hose 4

4

Clutch cable

5

Cylinder head breather hose

6

Radiator hose 1

7

Hose guide

8

Brake hose

9

“ENGINE STOP” button lead

0

Clamp

A

Sub wire harness

B

TPS (throttle position sensor)

C

lead
Neutral switch lead

D

Oil hose

E

Û

G

F

D

D-D

C-C

Radiator breather hose

F

CDI magneto lead

G

Carburetor breather hose

H

Overflow hose

I

Insert the end of the fuel tank

È

breather hose into the hole in
the steering shaft cap.
Pass the hot starter cable

É

between the cylinder head
breather hose, oil tank breather
hose and ignition coil, then on
the outside of the left engine
bracket.
Pass the clutch cable through

Ê

the cable guides.

E

F

CABLE ROUTING DIAGRAM

Pass the cylinder head breather

Ë

hose on the outside of the radia­tor hose 1 and on the inside of
the radiator pipe (radiator hose

4).
Pass the clutch cable in front of

Ì

the lower radiator mounting boss.
Fasten the “ENGINE STOP” but-

Í

ton lead and sub wire harness to
the frame at the protecting tube
of the sub wire harness with a
plastic locking tie and cut off the
tie end.

0

A

Í

B

B

A

D

Ù

A

SPEC

Î

A

Ï

A

Ð

0

Ñ

B

B

A

Ð

8

Ê

9

Ê

7

Ì

Ë

Ê

6

5

Ê

4

1

È

2

3

É

Ø

×

G

Ö

A

A

Ò

A

Ó

D

D

C

C

C

F

A

Õ

A

Ô

H

I

A

H

E

A

D

Ú

2 - 21

CABLE ROUTING DIAGRAM

SPEC

Fasten the “ENGINE STOP” but-

Î

ton lead and sub wire harness to
the frame at the protecting tube
for the “ENGINE STOP” button
lead with a plastic locking tie and
cut off the tie end.
Fasten the sub wire harness and

Ï

hot starter cable to the frame at
the white tape for the sub wire
harness with a plastic locking tie
and cut off the tie end.
Fasten the sub wire harness to

Ð

the frame with a plastic locking
tie and cut off the tie end.
Pass the sub wire harness

Ñ

between the engine brackets.

Û

G

F

D

D-D

C-C

Make sure that the TPS coupler

Ò

does not go outside the chassis.
Fasten the TPS lead to the

Ó

frame with a plastic band.
Fasten the neutral switch lead

Ô

and oil hose together with a
plastic locking tie and cut off the
tie end.
Fasten the neutral switch lead to

Õ

the frame with a plastic band.
Fasten the neutral switch lead,

Ö

CDI magneto lead and radiator
breather hose to the frame with
a plastic band.

E

F

A

Ù

D

Fasten the neutral switch lead,

×

CDI magneto lead and radiator
breather hose to the frame with
a plastic locking tie and cut off
the tie end.
Pass the neutral switch lead,

Ø

CDI magneto lead and radiator
breather hose between the radi­ator and frame.
Fasten the neutral switch lead

Ù

and CDI magneto lead to the
cable guide at their protecting
tubes with a plastic locking tie
and cut off the tie end.
Pass the carburetor breather

Ú

hoses and overflow hose so that
all there hoses do not contact
the rear shock absorber.

0

A

Í

B

B

A

Î

A

Ï

A

0

Ð

Ñ

B

B

A

Ð

8

Ê

9

Ê

7

Ì

Ë

Ê

6

5

Ê

4

1

È

2

3

É

Ø

×

G

Ö

A

A

Ò

A

Ó

D

D

C

C

C

F

A

Õ

A

Ô

H

I

A

H

E

A

D

Ú

2 - 22

Position the neutral switch lead,

Û

CDI magneto lead and radiator
breather hose at the left of the
frame.

Û

G

F

D

D-D

C-C

CABLE ROUTING DIAGRAM

E

F

D

Ù

A

0

A

Í

B

B

A

Î

A

SPEC

0

B

Ï

A

Ð

Ñ

A

B

Ð

8

Ê

9

Ê

7

Ì

Ë

Ê

6

5

Ê

4

1

È

2

3

É

Ø

×

G

Ö

A

A

Ò

A

Ó

D

D

C

C

C

F

A

Õ

A

Ô

H

I

A

H

E

A

D

Ú

2 - 23

CABLE ROUTING DIAGRAM

SPEC

CDI unit

1

Hot starter cable

2

Throttle cable (return)

3

Throttle cable (pull)

4

Ignition coil

5

Radiator breather hose

6

Radiator hose 4

7

Cylinder head breather hose

8

CDI unit bracket

9

CDI unit band

0

Pass the hot starter cable and

È

throttle cables through the cable
guides.
Pass the hot starter cable over

É

the top radiator mounting boss.
Pass the hot starter cable and

Ê

throttle cables between the radi­ator and frame, then over the
middle radiator mounting boss.
Pass the throttle cables on the

Ë

outside of the ignition coil.
Pass the carburetor breather

Ì

hose (throttle cable cover)
through the hose holder.
Pass the radiator breather hose

Í

at the rear of the radiator, on the
left of the chassis, and then
between the frame and radiator
hose 4.

Ï

1

Insert the CDI unit band over the

Î

CDI unit bracket as far as possi­ble.
First install the CDI unit and CDI

Ï

unit band to the CDI unit
bracket, then the CDI unit
bracket to the frame.

9

Î

8

0

B

6

Í

2

3

4

1

7

A

È

É

B

A

Ì

Ê

5

2 - 24

Ë

CABLE ROUTING DIAGRAM

SPEC

Master cylinder

1

Brake hose holder

2

Brake hose

3

Install the brake hose so that its

È

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

É

brake hose holders.
If the brake hose contacts the

Ê

spring (rear shock absorber),
correct its twist.
Install the brake hose so that its

Ë

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

2 - 25

CABLE ROUTING DIAGRAM

SPEC

Throttle cable

1

Fuel tank breather hose

2

Clamp

3

Clutch cable

4

Hot starter cable

5

“ENGINE STOP” button lead

6

Brake hose

7

Hose guide

8

1

Fasten the “ENGINE STOP” but-

È

ton lead to the handlebar with
the plastic band.
Pass the brake hose in front of

É

the number plate.

2

3

È

A

5

8

6

7

4

É

40˚±10˚

3

6

A

2 - 26

INSP

MAINTENANCE INTERVALS

EC300000

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.

ADJ

Item

ENGINE OIL

Replace

VALVES

Check the valve clearances
Inspect
Replace

VALVE SPRINGS

Inspect
Replace

VALVE LIFTERS

Inspect
Replace

CAMSHAFTS Inspect the camshaft sur-

Inspect
Replace

CAMSHAFT SPROCKETS

Inspect
Replace

PISTON

Inspect
Clean
Replace

PISTON RING

Replace

PISTON PIN

Inspect
Replace

CYLINDER HEAD Inspect carbon deposits

Inspect and clean

CYLINDER

Inspect and clean
Replace

CLUTCH

Inspect and adjust
Replace

TRANSMISSION

Inspect
Replace bearing

After

break-in

Every

race

Every

third

(or

500 km)

Every

fifth

(or

1,000 km)

As re­quired

Remarks

The engine must be cold.
Check the valve seats
and valve stems for wear.

Check the free length and
the tilt.

Check for scratches and
wear.

face.
Inspect the decompres­sion system

Check for wear on the
teeth and for damage.

Inspect crack
Inspect carbon deposits
and eliminate them.

Check ring end gapInspect

and eliminate them.
Change gasket

Inspect score marks
Inspect wear

Inspect housing, friction
plate, clutch plate and
spring

3

3 - 1

MAINTENANCE INTERVALS

INSP

ADJ

Item

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect Inspect wear

ROTOR NUT

Retighten

MUFFLER

Inspect and retighten
Clean
Replace * Whichever comes first

CRANK

Inspect and clean

CARBURETOR

Inspect, adjust and clean

SPARK PLUG

Inspect and clean
Replace

DRIVE CHAIN

Lubricate, slack, alignment
Replace

COOLING SYSTEM

Check coolant level and leakage
Check radiator cap operation
Replace coolant Every two years
Inspect hoses

OUTSIDE NUTS AND BOLTS Refer to “STARTING

Retighten

AIR FILTER

Clean and lubricate
Replace

OIL FILTER

Replace

OIL STRAINER (frame)

Clean

FRAME

Clean and inspect

FUEL TANK, COCK

Clean and inspect

BRAKES

Adjust lever position and pedal height
Lubricate pivot point
Check brake disc surface
Check fluid level and leakage
Retighten brake disc bolts, caliper
bolts, master cylinder bolts and union
bolts
Replace pads
Replace brake fluid Every one year

FRONT FORKS

Inspect and adjust
Replace oil Suspension oil “S1”
Replace oil seal

After

break-in

Every

race

Every

third

(or

500 km)

Every

fifth

(or

1,000 km)

As re­quired

Remarks

Use chain lube
Chain slack: 48 ~ 58 mm

(1.9 ~ 2.3 in)

AND BREAK-IN” section
in the CHAPTER 1.

Use foam air-filter oil or
equivalent oil

3 - 2

MAINTENANCE INTERVALS

INSP

ADJ

Item

FRONT FORK OIL SEAL AND DUST
SEAL

Clean and lube Lithium base grease

PROTECTOR GUIDE

Replace

REAR SHOCK ABSORBER

Inspect and adjust
Lube
Retighten

CHAIN GUARD AND ROLLERS

Inspect

SWINGARM

Inspect, lube and retighten

RELAY ARM, CONNECTING ROD

Inspect, lube and retighten

STEERING HEAD

Inspect free play and retighten
Clean and lube 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

HOT STARTER, CLUTCH LEVER

Inspect free play

After

break-in

Every

race

Every

third

(or

500 km)

Every

fifth

(or

1,000 km)

As re­quired

(After
rain ride)

Remarks

Molybdenum disulfide
grease

Molybdenum disulfide
grease

Molybdenum disulfide
grease

Yamaha cable lube or
SAE 10W-30 motor oil

3 - 3

INSP

PRE-OPERATION INSPECTION AND MAINTENANCE

EC320000

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

Brakes Check the play of front brake and effect of front and rear brake. P.3-24 ~ 30

Chain

Wheels

Steering

Front forks and rear shock
absorber

Cables (wires)

Muffler Check that the muffler is tightly mounted and has no cracks. —
Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-31
Lubrication Check for smooth operation. Lubricate if necessary. P.3-45
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18

Lead connectors

Settings

Check that coolant is filled up to the radiator filler cap.
Check the cooling system for leakage.

Check that a fresh gasoline is filled in the fuel tank. Check the
fuel line for leakage.

Check that the oil level is correct. Check the crankcase and
frame oil line for leakage.

Check that gears can be shifted correctly in order and that the
clutch operates smoothly.

Check that the throttle grip operation and free play are correctly
adjusted. Lubricate the throttle grip and housing, if necessary.

Check chain slack and alignment. Check that the chain is lubri­cated properly.

Check for excessive wear and tire pressure. Check for loose
spokes and have no excessive play.

Check that the handlebar can be turned smoothly and have no
excessive play.

Check that they operate smoothly and there is no oil leakage. P.3-33 ~ 40

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 CDI magneto, CDI unit, and ignition coil are con­nected tightly.

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

ADJ

P.3-5 ~ 9

P.1-13

P.3-13 ~ 17

P.3-9

P.3-10

P.3-31 ~ 33

P.3-41 ~ 42

P.3-42 ~ 44

—

P.1-6

P.7-1 ~ 21

3 - 4

ENGINE/COOLANT LEVEL INSPECTION

EC350000

ENGINE

EC351011

COOLANT LEVEL INSPECTION

WARNING

Do not remove the radiator cap 1, drain
bolt and hoses when the engine and radia­tor are hot. Scalding hot fluid and steam
may be blown out under pressure, which
could cause serious injury.
When the engine has cooled, place a thick
towel over the radiator cap, slowly rotate
the cap counterclockwise to the detent.
This procedure allows any residual pres­sure to escape. When the hissing sound
has stopped, press down on the cap while
turning counterclockwise and remove it.

INSP

ADJ

CAUTION:

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

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

2. Remove:

• Radiator cap

3. Check:

• Coolant level a

Coolant level low → Add coolant.

Radiator

1

3 - 5

COOLANT REPLACEMENT

EC353011

COOLANT REPLACEMENT

WARNING

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

CAUTION:

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

1. Place a container under the engine.

2. Remove:

• Engine guard 1

• Coolant drain bolt 2

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

• Engine guard

• Bolt (engine guard)

6. Fill:

• Radiator

• Engine

To specified level.

New

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

T

34 Nm (3.4 m · kg, 24 ft · lb)

.

R

.

INSP

ADJ

3 - 6

Recommended coolant:

High quality ethylene glycol
anti-freeze containing anti­corrosion for aluminum engine

Coolant 1 and water (soft water)

mixing ratio:

2

50 %/50 %

Coolant capacity:

1.2 L (1.06 Imp qt, 1.27 US qt)

RADIATOR CAP INSPECTION

CAUTION:

• Do not mix more than one type of ethyl-

ene glycol antifreeze containing corro­sion inhibitors for aluminum engine.

• Do not use water containing impurities or

oil.

Handling notes of coolant:

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

WARNING

• When coolant splashes to your eye.
Thoroughly wash your eye with water
and see your doctor.

• When coolant splashes to your clothes.
Quickly wash it away with water and
then with soap.

• When coolant is swallowed.
Quickly make him vomit and take him
to a doctor.

INSP

ADJ

7. Install:

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

8. Check:

• Coolant level
Coolant level low → Add coolant.

EC355000

RADIATOR CAP INSPECTION

1. Inspect:

• Seal (radiator cap) 1

• Valve and valve seat 2

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

3 - 7

RADIATOR CAP OPENING PRESSURE INSPECTION/

COOLING SYSTEM INSPECTION

EC356001

RADIATOR CAP OPENING PRESSURE
INSPECTION

1. Attach:

• Radiator cap tester 1 and adapter 2

Radiator cap tester:

YU-24460-01/90890-01325

Adapter:

YU-33984/90890-01352

OTE:

Apply water on the radiator cap seal.

Radiator cap

3

2. Apply the specified pressure.

INSP

ADJ

Radiator cap opening pressure:

2

110 kPa (1.1 kg/cm

, 15.6 psi)

3. Inspect:

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

EC357002

COOLING SYSTEM INSPECTION

1. Inspect:

• Coolant level

2. Attach:

• Radiator cap tester 1 and adapter 2

Radiator cap tester:

YU-24460-01/90890-01325

Adapter:

YU-33984/90890-01352

3. Apply the specified pressure.

Standard pressure:

180 kPa (1.8 kg/cm

3 - 8

2

, 25.6 psi)

CLUTCH ADJUSTMENT

OTE:

• Do not apply pressure more than specified
pressure.

• Radiator should be filled fully.

4. Inspect:

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

• Radiator

• Radiator hose joint

Coolant leakage → Repair or replace.

• Radiator hose
Swelling → Replace.

INSP

ADJ

EC359020

CLUTCH ADJUSTMENT

1. Check:

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

Clutch lever free play a:

8 ~ 13 mm (0.31 ~ 0.51 in)

2. Adjust:

• Clutch lever free play

Clutch lever free play adjustment steps:

• Loosen the locknuts 1.

• Adjust the free play by changing their tight-

ening position.

• Tighten the locknut.

Locknut:

T

.

7 Nm (0.7 m • kg, 5.1 ft • lb)

R

.

OTE:

• Make minute adjustment on the lever side

using the adjuster 2.

• After adjustment, check proper operation of
clutch lever.

3 - 9

THROTTLE CABLE ADJUSTMENT/

THROTTLE LUBRICATION

EC35A001

THROTTLE CABLE ADJUSTMENT

1. Check:

• Throttle grip free play a

Out of specification → Adjust.

Throttle grip free play a:

3 ~ 5 mm (0.12 ~ 0.20 in)

2. Adjust:

1

2

• Throttle grip free play

Throttle grip free play adjustment steps:

• Slide the adjuster cover.

• Loosen the locknut 1.

• Turn the adjuster 2 until the specified free

play is obtained.

• Tighten the locknut.

INSP

ADJ

OTE:

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

WARNING

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

THROTTLE LUBRICATION

1. Remove:

• Cover (throttle cable cap) 1

• Cover (grip cap) 2

• Throttle cable cap 3

3 - 10

2. Apply:

• Lithium soap base grease

On the throttle cable end a.

3. Install:

• Throttle cable cap

• Screw (throttle cable cap)

T

4 Nm (0.4 m · kg, 2.9 ft · lb)

.

R

.

• Cover (grip cap)

• Cover (throttle cable cap)

HOT STARTER LEVER ADJUSTMENT/

AIR FILTER CLEANING

HOT STARTER LEVER ADJUSTMENT

1. Check:

• Hot starter lever free play a

Out of specification → Adjust.

Hot starter lever free play a:

3 ~ 6 mm (0.12 ~ 0.24 in)

2. Adjust:

• Hot starter lever free play

Hot starter lever free play adjustment
steps:

• Loosen the locknut 1.

• Turn the adjuster 2 until free play a is

within the specified limits.

• Tighten the locknut.

OTE:

After adjustment, check proper operation of
hot starter.

INSP

ADJ

EC35G040

AIR FILTER CLEANING

OTE:

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

CAUTION:

Never run the engine without the air filter
element in place; this would allow dirt and
dust to enter the engine and cause rapid
wear and possible engine damage.

1. Remove:

• Seat

• Fitting bolt 1

• Washer 2

• Air filter element 3

• Filter guide 4

3 - 11

AIR FILTER CLEANING

2. Clean:

• Air filter element
Clean them with solvent.

OTE:

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

CAUTION:

• Do not twist the element when squeezing
the element.

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

3. Inspect:

• Air filter element

Damage → Replace.

4. Apply:

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

INSP

ADJ

OTE:

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

5. Install:

• Filter guide 1

OTE:

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

3 - 12

6. Apply:

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

ENGINE OIL LEVEL INSPECTION

7. Install:

• Air filter element 1

• Washer

T

2 Nm (0.2 m · kg, 1.4 ft · lb)

.

• Fitting bolt

OTE:

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

ENGINE OIL LEVEL INSPECTION

1. Stand the machine on a level surface.

OTE:

• When checking the oil level make sure that
the machine is upright.

• Place the machine on a suitable stand.

WARNING

Never remove the oil tank cap just after
high speed operation. The heated oil could
spurt out. causing danger. Wait until the oil
cools down to approximately 70 °C (158 °F).

R

.

INSP

ADJ

1

2. Idle the engine more than 3 minutes while

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

3. Remove:

• Oil tank cap 1

3 - 13

ENGINE OIL LEVEL INSPECTION

4. Inspect:

• Oil level

Oil level should be between maximum a
and minimum b marks.

a

b

Oil level low → Add oil to proper level.

OTE:

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

(For USA and CDN)

Recommended oil:

At 5 °C (40 °F) or higher È
Yamalube 4 (20W-40) or SAE
20W-40 type SG motor oil
(Non-Friction modified)
At 15 °C (60 °F) or lower É
Yamalube 4 (10W-30) or SAE
10W-30 type SG motor oil
(Non-Friction modified)
and/or
Yamalube 4-R (15W-50)
(Non-Friction modified)

INSP

ADJ

-20-4-101403010502068308640 50

10W-30

10W-40

15W-40

20W-40

20W-50

104

122

a

b

˚CTemp.

˚F

CAUTION:

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

• Do not allow foreign material to enter the
crankcase.

(Except for USA and CDN)

Recommended oil:

Refer to the following chart for
selection of oils which are
suited to the atmospheric

temperatures.
Recommended engine oil classi­fication:
API STANDARD:

API “SG” or higher grade

(Designed primarily for

motorcycles)

CAUTION:

• Do not add any chemical additives or use
oils with a grade of CD a or higher.

• Do not use oils labeled “ENERGY CON­SERVING II” b or higher. Engine oil also
lubricates the clutch and additives could
cause clutch slippage.

• Do not allow foreign materials to enter the
crankcase.

3 - 14

ENGINE OIL REPLACEMENT

5. Start the engine and let it warm up for sev-

eral minutes.

CAUTION:

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

6. Idle the engine more than 10 seconds

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

7. Install:

• Oil tank cap

ENGINE OIL REPLACEMENT

1. Start the engine and let it warm up for sev-

eral minutes.

2. Stop the engine and place an oil pan under

the drain bolt.

3. Remove:

• Oil tank plug 1

• Oil filler cap 2

• Drain bolt (with gasket) 3

• Oil filter drain bolt (O-ring) 4

• Drain bolt (with gasket) 5

• Drain bolt (with gasket) 6

Drain the crankcase and oil tank (frame)
of its oil.

INSP

ADJ

3 - 15

4. Remove:

• Engine skid plate

• Engine oil hose clamp 1

• Bolt (engine oil hose) 2

• Engine oil hose 3

• Oil strainer (frame) 4

5. Clean:

• Oil strainer (frame)

ENGINE OIL REPLACEMENT

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

oil change, remove the following parts and
reinstall them.

Replacement steps:

• Remove the oil filter cover 1 and oil filter
element 2.

• Check the O-rings 3, if cracked or dam-
aged, replace them with a new one.

• Install the oil filter element and oil filter
cover.

Oil filter cover:

T

.

7. Install:

• Plain washer 1

• Oil strainer (frame) 2

• Engine oil hose 3

• Bolt (engine oil hose) 4

• Engine oil hose clamp 5

• Engine skid plate

8. Install:

• Gaskets

• Oil filter drain bolt

• Drain bolt (crankcase rear)

• Drain bolt (crankcase left)

• Drain bolt (frame)

9. Fill:

• Crankcase

10 Nm (1.0 m • kg, 7.2 ft • lb)

R

.

T

70 Nm (7.0 m · kg, 50 ft · lb)

.

R

.

T

8 Nm (0.8 m · kg, 5.8 ft · lb)

.

R

.

T

2 Nm (0.2 m · kg, 1.4 ft · lb)

.

R

.

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

New

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

T

20 Nm (2.0 m · kg, 14 ft · lb)

.

R

.

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

T

23 Nm (2.3 m · kg, 17 ft · lb)

.

R

.

INSP

ADJ

New

3 - 16

Oil quantity:

Periodic oil change:

1.0 L (0.88 Imp qt, 1.06 US qt)

With oil filter replacement:

1.1 L (0.97 Imp qt, 1.16 US qt)

Total amount:

1.2 L (1.06 Imp qt, 1.27 US qt)

PILOT SCREW ADJUSTMENT

10. Install:

• Oil filler plug

11. Inspect:

• Engine (for oil leaks)

• Oil level

Refer to “ENGINE OIL LEVEL INSPEC­TION”.

12. Check:

• Oil pressure

Checking steps:

• Slightly loosen the oil gallery bolt 1.

• Start the engine and keep it idling until oil

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

• Check oil passages, oil filter and oil pump
for damage or leakage.

• Start the engine after solving the prob­lem(s) and recheck the oil pressure.

• Tighten the oil gallery bolt to specification.

INSP

ADJ

Oil gallery bolt:

T

.

10 Nm (1.0 m • kg, 7.2 ft • lb)

R

.

PILOT SCREW ADJUSTMENT

1. Adjust:

• Pilot screw 1

Adjusting steps:

OTE:

To optimize the fuel flow at a smaller throttle
opening, each machine’s pilot screw has
been individually set at the factory. Before
adjusting the pilot screw, turn it in fully and
count the number of turns. Record this num­ber as the factory-set number of turns out.

• Turn in the pilot screw until it is lightly
seated.

• Turn out the pilot screw by the factory-set
number of turns.

3 - 17

Pilot screw:

1-3/4 turns out (example)

c

2

IDLE SPEED ADJUSTMENT/

VALVE CLEARANCE ADJUSTMENT

EC35M021

IDLE SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up.

2. Adjust:

• Idle speed

Adjustment steps:

• Adjust the pilot screw.
Refer to “PILOT SCREW ADJUSTMENT”
section.

• Turn the throttle stop screw 1 until the
specified engine idling speed.

OTE:

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

INSP

ADJ

To increase idle speed →

Turn the throttle stop screw 1 in a.

To decrease idle speed →

Turn the throttle stop screw 1 out b.

Engine idling speed:

1,900 ~ 2,100 r/min

VALVE CLEARANCE ADJUSTMENT

OTE:

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

• The piston must be at Top Dead Center
(T.D.C.) on compression stroke to check or
adjust the valve clearance.

1. Remove:

• Seat

• Fuel tank

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

2. Remove:

• Carburetor
Refer to “CARBURETOR” section in the
CHAPTER 4.

• Spark plug

• Engine stay (upper)

• Cylinder head cover

Refer to “CAMSHAFTS” section in the
CHAPTER 4.

3 - 18

VALVE CLEARANCE ADJUSTMENT

3. Remove:

• Timing plug 1

• Straight plug 2

• O-ring

4. Check:

• Valve clearance
Out of specification → Adjust.

Valve clearance (cold):
Intake valve:

0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)

Exhaust valve:

0.20 ~ 0.25 mm
(0.0079 ~ 0.0098 in)

INSP

ADJ

Checking steps:

• Turn the crankshaft counterclockwise with
a wrench.

• Align the T.D.C. mark a on the rotor with
the align mark b on the crankcase cover
when piston is at T.D.C. on compression
stroke.

OTE:

In order to be sure that the piston is at Top
Dead Center, the punch mark c on the
exhaust camshaft and the punch mark d on
the intake camshaft must align with the cyl­inder head surface, as shown in the illustra­tion.

• Measure the valve clearance e using a
feeler gauge 1.

OTE:

Record the measured reading if the clear­ance is incorrect.

3 - 19

VALVE CLEARANCE ADJUSTMENT

INSP

ADJ

1

3

2

5. Adjust:

• Valve clearance

Adjustment steps:

• Loosen the timing chain tensioner cap
bolt.

• Remove the timing chain tensioner and
camshaft caps.

OTE:

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

• Remove the camshaft (exhaust 1 and
intake 2).

OTE:

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

• Remove the valve lifters 4 and the pads

5.

OTE:

• Place a rag in the timing chain space to
prevent pads from falling into the crank­case.

• Identity each valve lifter and pad position
very carefully so that they can be rein­stalled in their original place.

• Select the proper pad using the pad
selecting table.

Pad range

No. 120

~

No. 240

OTE:

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

1.20 mm
~

2.40 mm

Pad Availability:

25 increments

Pads are available

in 0.05 mm incre-

ments

3 - 20

VALVE CLEARANCE ADJUSTMENT

• Round off the last digit of the installed pad
number to the nearest increment.

INSP

ADJ

Last digit of pad

number

Rounded value

0, 1 or 2 0

4, 5 or 6 5

8 or 9 10

EXAMPLE:

Installed pad number = 148
Rounded off value = 150

OTE:

Pads can only be selected in 0.05 mm incre­ments.

• Locate the rounded-off value and the mea­sured valve clearance in the chart “PAD
SELECTION TABLE”. The field where
these two coordinates intersect shows the
new pad number to use.

OTE:

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

• Install the new pads 6 and the valve lift-
ers 7.

OTE:

• Apply the engine oil on the valve lifters.

• Apply the molybdenum disulfide oil on the

valve stem ends.

• Valve lifter must turn smoothly when
rotated with a finger.

• Be careful to reinstall valve lifters and
pads in their original place.

• Install the camshafts (exhaust and intake),
the timing chain and the camshaft caps.
Refer to “CAMSHAFTS” section in the
CHAPTER 4.

Bolt (camshaft cap):

T

.

10 Nm (1.0 m • kg, 7.2 ft • lb)

R

.

3 - 21

VALVE CLEARANCE ADJUSTMENT

• Install the timing chain tensioner.
Refer to “CAMSHAFTS” section in the
CHAPTER 4.

OTE:

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

• Recheck the valve clearance.

• If the clearance is still incorrect, repeat all

the clearance adjustment steps until the
specified clearance is obtained.

6. Install:

• All removed parts

OTE:

Install all removed parts in reversed order of
their removal.

INSP

ADJ

3 - 22

INTAKE

VALVE CLEARANCE ADJUSTMENT

INSP

ADJ

MEASURED

CLEARANCE

0.00 ~ 0.04 120 125 130 135 140 145 150 155

0.05 ~ 0.09

0.10 ~ 0.15

0.16 ~ 0.20 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.21 ~ 0.25 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.26 ~ 0.30 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.31 ~ 0.35 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.36 ~ 0.40 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.41 ~ 0.45 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.46 ~ 0.50 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.51 ~ 0.55 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.56 ~ 0.60 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.61 ~ 0.65 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.66 ~ 0.70 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.71 ~ 0.75 180 185 190 195 200 205 210 215 220 225 230 235 240

0.76 ~ 0.80 185 190 195 200 205 210 215 220 225 230 235 240

0.81 ~ 0.85 190 195 200 205 210 215 220 225 230 235 240

0.86 ~ 0.90 195 200 205 210 215 220 225 230 235 240

0.91 ~ 0.95 200 205 210 215 220 225 230 235 240

0.96 ~ 1.00 205 210 215 220 225 230 235 240

1.01 ~ 1.05 210 215 220 225 230 235 240

1.06 ~ 1.10 215 220 225 230 235 240

1.11 ~ 1.15 220 225 230 235 240

1.16 ~ 1.20 225 230 235 240

1.21 ~ 1.25 230 235 240

1.26 ~ 1.30 235 240

1.31 ~ 1.35 240

120 125 130 135 140 145 150 155 160 165 170

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

INSTALLED PAD NUMBER

175 180 185 190 195 200 205 210 215 220 225 230 235 240

160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

STANDARD CLEARANCE

VALVE CLEARANCE (cold):

0.10 ~ 0.15 mm

Example: Installed is 175

Measured clearance is 0.22 mm

Replace 175 pad with 185 pad

Pad number: (example)
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm

EXHAUST

MEASURED

CLEARANCE

0.00 ~ 0.04 120 125 130 135 140 145

0.05 ~ 0.09

0.10 ~ 0.14

0.15 ~ 0.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

0.20 ~ 0.25

0.26 ~ 0.30 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.31 ~ 0.35 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.36 ~ 0.40 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.41 ~ 0.45 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.46 ~ 0.50 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.51 ~ 0.55 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.56 ~ 0.60 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.61 ~ 0.65 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.66 ~ 0.70 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.71 ~ 0.75 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.76 ~ 0.80 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.81 ~ 0.85 180 185 190 195 200 205 210 215 220 225 230 235 240

0.86 ~ 0.90 185 190 195 200 205 210 215 220 225 230 235 240

0.91 ~ 0.95 190 195 200 205 210 215 220 225 230 235 240

0.96 ~ 1.00 195 200 205 210 215 220 225 230 235 240

1.01 ~ 1.05 200 205 210 215 220 225 230 235 240

1.06 ~ 1.10 205 210 215 220 225 230 235 240

1.11 ~ 1.15 210 215 220 225 230 235 240

1.16 ~ 1.20 215 220 225 230 235 240

1.21 ~ 1.25 220 225 230 235 240

1.26 ~ 1.30 225 230 235 240

1.31 ~ 1.35 230 235 240

1.36 ~ 1.40 235 240

1.41 ~ 1.45 240

120 125 130 135 140 145 150 155 160 165 170

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

INSTALLED PAD NUMBER

175 180 185 190 195 200 205 210 215 220 225 230 235 240

150 155 160 165 170 175 180 185 190 195 200 205 210 215 220

STANDARD CLEARANCE

VALVE CLEARANCE (cold):

0.20 ~ 0.25 mm

Example: Installed is 175

Measured clearance is 0.32 mm

Replace 175 pad with 185 pad

Pad number: (example)
Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm

3 - 23

È

É

CHASSIS/BRAKE SYSTEM AIR BLEEDING

EC360000

CHASSIS

EC361012

BRAKE SYSTEM AIR BLEEDING

WARNING

Bleed the brake system if:

• The system has been disassembled.

• A brake hose has been loosened or

removed.

• The brake fluid is very low.

• The brake operation is faulty.

A dangerous loss of braking performance
may occur if the brake system is not prop­erly bled.

1. Remove:

• Master cylinder cap

• Diaphragm

• Reservoir float (front brake)

• Protector (rear brake)

2. Bleed:

• Brake fluid

Front

È

Rear

É

INSP

ADJ

Air bleeding steps:

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

spill any fluid or allow the reservoir to
overflow.

c. Connect the clear plastic tube 2 tightly

to the caliper bleed screw 1.

d. Place the other end of the tube into a

container.

e. Slowly apply the brake lever or pedal

several times.

f. Pull the lever in or push down on the

pedal. Hold the lever or pedal in position.

g. Loosen the bleed screw and allow the

lever or pedal to travel towards its limit.

h. Tighten the bleed screw when the lever

or pedal limit has been reached; then
release the lever or pedal.

Bleed screw:

T

.

6 Nm (0.6 m • kg, 4.3 ft • lb)

R

.

3 - 24

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

bubbles have been removed from the
system.

FRONT BRAKE ADJUSTMENT

OTE:

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

j. Add brake fluid to the level line on the

reservoir.

WARNING

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

3. Install:

• Protector (rear brake)

• Reservoir float (front brake)

• Diaphragm

• Master cylinder cap

INSP

ADJ

EC362040

FRONT BRAKE ADJUSTMENT

1. Check:

• Brake lever position a

Brake lever position a:

Standard position Extent of adjustment

95 mm (3.74 in)

76 ~ 97 mm

(2.99 ~ 3.82 in)

2. Remove:

• Lever cover

3. Adjust:

• Brake lever position

Brake lever position adjustment steps:

• Loosen the locknut 1.

• Turn the adjusting bolt 2 until the lever

position a is within specified position.

• Tighten the locknut.

Locknut:

T

.

5 Nm (0.5 m • kg, 3.6 ft • lb)

R

.

3 - 25

CAUTION:

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

4. Install:

• Lever cover

REAR BRAKE ADJUSTMENT/

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

EC364002

REAR BRAKE ADJUSTMENT

1. Check:

• Brake pedal height a

Out of specification → Adjust.

Brake pedal height a:

5 mm (0.20 in)

2. Adjust:

• Brake pedal height

Pedal height adjustment steps:

• Loosen the locknut 1.

• Turn the adjusting nut 2 until the pedal

height a is within specified height.

• Tighten the locknut.

INSP

ADJ

ÈÉ

WARNING

• Adjust the pedal height between the
maximum È and the minimum É as
shown. (In this adjustment, the bolt
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.

EC365080

FRONT BRAKE PAD INSPECTION AND
REPLACEMENT

1. Inspect:

• Brake pad thickness a

Out of specification → Replace as a set.

Brake pad thickness a:

Standard <Limit>

3

3 - 26

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

2. Replace:

• Brake pad

Brake pad replacement steps:

• Remove the pad pin plug 1.

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

• Loosen the pad pin 2.

• Remove the caliper 3 from the front fork.

• Remove the pad pin and brake pads 4.

• Connect the transparent hose 5 to the

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

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

CAUTION:

Do not reuse the drained brake fluid.

• Tighten the bleed screw.

Bleed screw:

T

.

• Install the brake pads 7 and pad pin.

OTE:

• Install the brake pads with their projections

a into the caliper recesses b.

• Temporarily tighten the pad pin at this
point.

6 Nm (0.6 m • kg, 4.3 ft • lb)

R

.

INSP

ADJ

• Install the caliper 8 and tighten the pad
pin 9.

Bolt (caliper):

T

.

23 Nm (2.3 m • kg, 17 ft • lb)

R

.

Pad pin:

18 Nm (1.8 m • kg, 13 ft • lb)

3 - 27

REAR BRAKE PAD INSPECTION AND REPLACEMENT

• Install the pad pin plug 0.

Pad pin plug:

T

.

3. Inspect:

• Brake fluid level

4. Check:

• Brake lever operation

3 Nm (0.3 m • kg, 2.2 ft • lb)

R

.

Refer to “BRAKE FLUID LEVEL INSPEC­TION” section.

A softy or spongy feeling → Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED­ING” section.

INSP

ADJ

EC366060

REAR BRAKE PAD INSPECTION AND
REPLACEMENT

1. Inspect:

• Brake pad thickness a

Out of specification → Replace as a set.

Brake pad thickness a:

Standard <Limit>

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

2. Replace:

• Brake pad

Brake pad replacement steps:

• Remove the protector 1 and pad pin plug

2.

• Loosen the pad pin 3.

• Remove the rear wheel 4 and caliper 5.

Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.

3 - 28

REAR BRAKE PAD INSPECTION AND REPLACEMENT

• Remove the pad pin 6 and brake pads 7.

• Connect the transparent hose 8 to the

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

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

CAUTION:

Do not reuse the drained brake fluid.

• Tighten the bleed screw.

Bleed screw:

T

.

• Install the brake pad 0 and pad pin A.

OTE:

• Install the brake pads with their projections

a into the caliper recesses b.

• Temporarily tighten the pad pin at this
point.

6 Nm (0.6 m • kg, 4.3 ft • lb)

R

.

INSP

ADJ

• Install the caliper B and rear wheel C.
Refer to “FRONT WHEEL AND REAR
WHEEL” section in the CHAPTER 5.

• Tighten the pad pin D.

Pad pin:

T

.

18 Nm (1.8 m • kg, 13 ft • lb)

R

.

• Install the pad pin plug E and protector
F.

Pad pin plug:

T

.

3 Nm (0.3 m • kg, 2.2 ft • lb)

R

.

Bolt (protector):

7 Nm (0.7 m • kg, 5.1 ft • lb)

3 - 29

REAR BRAKE PAD INSULATOR INSPECTION/

BRAKE FLUID LEVEL INSPECTION

3. Inspect:

• Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC­TION” section.

4. Check:

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

EC36b000

REAR BRAKE PAD INSULATOR
INSPECTION

1. Remove:

• Brake pad
Refer to “REAR BRAKE PAD INSPEC­TION AND REPLACEMENT” section.

2. Inspect:

• Rear brake pad insulator 1
Damage → Replace.

INSP

ADJ

ÈÉ

EC367001

BRAKE FLUID LEVEL INSPECTION

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

2. Inspect:

• Brake fluid level

Fluid at lower level → Fill up.

Lower level

a

Front

È

Rear

É

Recommended brake fluid:

DOT #4

WARNING

• Use only designated quality brake fluid to

avoid poor brake performance.

• Refill with same type and brand of brake

fluid; mixing fluids could result in poor
brake performance.

• Be sure that water or other contaminants

do not enter master cylinder when refill­ing.

• Clean up spilled fluid immediately to

avoid erosion of painted surfaces or plas­tic parts.

3 - 30

SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION

EC368000

SPROCKETS INSPECTION

1. Inspect:

• Sprocket teeth a

Excessive wear → Replace.

OTE:

Replace the drive, driven sprockets and drive
chain as a set.

DRIVE CHAIN INSPECTION

1. Measure:

• Drive chain length (15 links) a

Out of specification → Replace.

Drive chain length (15 links):

<Limit>: 242.9 mm (9.563 in)

OTE:

• While measuring the drive chain length, push

down on the drive chain to increase its ten­sion.

• Measure the length between drive chain

roller 1 and F as shown.

• Perform this measurement at two or three

different places.

INSP

ADJ

3 - 31

2. Remove:

• Master link clip

• Joint 1

• Drive chain 2

3. Clean:

• Drive chain

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

DRIVE CHAIN SLACK ADJUSTMENT

4. Check:

• Drive chain stiffness a

Clean and oil the chain and hold as illus­trated.
Stiff → Replace drive chain.

5. Install:

• Drive chain 1

• Joint 2

• Master link clip 3

CAUTION:

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

INSP

ADJ

New

Turning direction

a

6. Lubricate:

• Drive chain

Drive chain lubricant:

SAE 10W-30 motor oil or
suitable chain lubricants

DRIVE CHAIN SLACK ADJUSTMENT

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

2. Check:

• Drive chain slack a

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

Drive chain slack:

48 ~ 58 mm (1.9 ~ 2.3 in)

OTE:

Before checking and/or adjusting, rotate the
rear wheel through several revolutions and
check the slack several times to find the tight­est point. Check and/or adjust chain slack with
rear wheel in this “tight chain” position.

3 - 32

FRONT FORK INSPECTION

3. Adjust:

• Drive chain slack

Drive chain slack adjustment steps:

• Loosen the axle nut 1 and locknuts 2.

• Adjust chain slack by turning the adjusters

3.

To tighten →Turn adjuster 3 counter-

clockwise.

To loosen →Turn adjuster 3 clockwise

and push wheel forward.

• Turn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks a on each side of chain
puller alignment.)

OTE:

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

INSP

ADJ

CAUTION:

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

• Tighten the axle nut while pushing down
the drive chain.

Axle nut:

T

.

125 Nm (12.5 m • kg, 90 ft • lb)

R

.

• Tighten the locknuts.

Locknut:

T

EC36C000

.

16 Nm (1.6 m • kg, 11 ft • lb)

R

.

FRONT FORK INSPECTION

1. Inspect:

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

3 - 33

FRONT FORK OIL SEAL AND DUST SEAL CLEANING/

FRONT FORK INTERNAL PRESSURE RELIEVING/

FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT

EC36D001

FRONT FORK OIL SEAL AND DUST SEAL
CLEANING

1. Remove:

• Protector

• Dust seal 1

OTE:

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

OTE:

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

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

INSP

ADJ

FRONT FORK INTERNAL PRESSURE
RELIEVING

OTE:

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 suit-

able 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

T

1 Nm (0.1 m · kg, 0.7 ft · lb)

.

R

.

EC36H002

FRONT FORK REBOUND DAMPING FORCE
ADJUSTMENT

1. Adjust:

• Rebound damping force

By turning the adjuster 1.

3 - 34

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.)

FRONT FORK COMPRESSION DAMPING FORCE

ADJUSTMENT

Extent of adjustment:

Maximum Minimum

INSP

ADJ

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:

13 clicks out
*14 clicks out

* For EUROPE

CAUTION:

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

WARNING

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

20 clicks out (from
maximum position)

EC36J001

FRONT FORK COMPRESSION DAMPING
FORCE ADJUSTMENT

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.)

3 - 35

REAR SHOCK ABSORBER INSPECTION

Extent of adjustment:

Maximum Minimum

INSP

ADJ

Fully turned in
position

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

Standard position:

8 clicks out
*11 clicks out

* For EUROPE

CAUTION:

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

WARNING

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

20 clicks out
(from maximum
position)

EC36K000

REAR SHOCK ABSORBER INSPECTION

1. Inspect:

• Swingarm smooth action

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

3 - 36

REAR SHOCK ABSORBER SPRING PRELOAD

ADJUSTMENT

REAR SHOCK ABSORBER SPRING
PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suit-

able stand under the engine.

2. Remove:

• Rear frame

3. Loosen:

• Locknut 1

4. Adjust:

• Spring preload

By turning the adjuster 2.

Stiffer →Increase the spring preload.

(Turn the adjuster 2 in.)

Softer →Decrease the spring preload.

(Turn the adjuster 2 out.)

Spring length (installed) a:

INSP

ADJ

Standard length Extent of adjustment

248 mm (9.76 in)
*245 mm (9.65 in)

240.5 ~ 258.5 mm
(9.47 ~ 10.18 in)

* For EUROPE

OTE:

• Be sure to remove all dirt and mud from
around the locknut and adjuster before
adjustment.

• The length of the spring (installed) changes

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

CAUTION:

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

5. Tighten:

• Locknut

6. Install:

• Rear frame (upper)

T

32 Nm (3.2 m · kg, 23 ft · lb)

.

R

.

• Rear frame (lower)

T

29 Nm (2.9 m · kg, 21 ft · lb)

.

R

.

3 - 37

REAR SHOCK ABSORBER REBOUND

DAMPING FORCE ADJUSTMENT

EC36N014

REAR SHOCK ABSORBER REBOUND
DAMPING FORCE ADJUSTMENT

1. Adjust:

• Rebound damping force

By turning the adjuster 1.

Stiffer a →Increase the rebound damp-

ing force. (Turn the adjuster

in.)

1

Softer b →Decrease the rebound damp-

ing force. (Turn the adjuster

out.)

1

Extent of adjustment:

Maximum Minimum

INSP

ADJ

Fully turned in
position

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

Standard position:

About 12 clicks out
*About 13 clicks out

20 clicks out
(from maximum
position)

* For EUROPE

CAUTION:

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

3 - 38

REAR SHOCK ABSORBER LOW COMPRESSION

DAMPING FORCE ADJUSTMENT

EC36c000

REAR SHOCK ABSORBER LOW
COMPRESSION DAMPING FORCE
ADJUSTMENT

1. Adjust:

• Low compression damping force

By turning the adjuster 1.

Stiffer a →Increase the low compres-

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

Softer b →Decrease the low compres-

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

Extent of adjustment:

Maximum Minimum

1

b

a

INSP

ADJ

a

b

Fully turned in
position

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

Standard position:

About 13 clicks out

20 clicks out
(from maximum
position)

CAUTION:

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

3 - 39