Manuel d'utilisation / d'entretien du produit YZ450FT du fabricant Yamaha
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LIT-11626-18-44 YZ450FT 5XD-28199-11 OWNER’S SERVICE MANUAL.
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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.
EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machin es. It represents the highest grade of craftsmanship and reliability that have ma de Yamaha a leader.
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IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for t his machine to be operated on an y public street, road, or highway. Off-road use on pu blic lands may also be illegal. Please check local regula- tions before riding.
6. GASOLINE CAN CAUSE INJURY. If you should swallow so me 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.
EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, opera tion, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your n ew machine.
EC080000 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 instru ctions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
EC083000 MANUAL FORMAT All of the procedures in this manual are org anized in a sequential, step-by-step format. The informa- tion has been complied to p rovide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disa ssembly, repair, assembly, a nd inspection operations.
ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter ’ s number and content.
EC090000 INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 TUNING TUN 7 GEN INFO INSP ADJ – +.
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ...........................................1-1 MACHINE IDENTIFICATION ..................... 1-2 IMPORTANT INFORMATION .................... 1-3 CHECKING OF CONNECTION ................. 1-6 SPECIAL TOOLS .
CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS .................................. 4-1 EXHAUST PIPE AND SILENCER ............. 4-3 RADIATOR .................. ..............................4-5 CARBURETOR ................................. ......... 4-8 CAMSHAFTS .
CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........................... 6-1 MAP-CONTROLLED CDI U NIT ................. 6-2 IGNITION SYSTEM .................................... 6-3 TPS (THROTTLE POSITION SENSOR) SYSTEM ...............
GEN INFO 1 - 1 DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 Hot starter lever 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 “ ENGINE STOP ”.
1 - 2 GEN INFO MACHINE IDENTIFICATION EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you ca n give the number to your Yamaha dealer for positive identification of the model you own.
1 - 3 GEN INFO 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 pres- sured water, cover the parts as follows.
1 - 4 GEN INFO 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.
1 - 5 GEN INFO 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 posi- tioned opposite to the thrust 3 it receives.
1 - 6 GEN INFO 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.
GEN INFO 1 - 7 SPECIAL TOOLS EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and a ssembly. Using the correct special tool will help preve nt damage caused by the use of improper tools or improvised techniques.
GEN INFO 1 - 8 SPECIAL TOOLS YU-33975, 90890-01403 Ring nut wrench This tool is used when tighten the steering ring nut to specification. YU-33975 90890-01403 YM-01442, 90890-01442 Fork seal driver This tool is used when install the fork oil seal.
GEN INFO 1 - 9 SPECIAL TOOLS YM-4117, 90890-04117 YM-4098, 90890-04098 Valve guide installer Intake Exhaust This tool is needed to install the valve guide. YM-4117 YM-4098 90890-04117 90890-04098 YM-4118, 90890-04118 YM-4099, 90890-04099 Valve guide reamer Intake 4.
1 - 10 GEN INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS EC151000 “ ENGINE STOP ” BUTTON The “ ENGINE STOP ” button 1 is located on the left handlebar.
1 - 11 GEN INFO CONTROL FUNCTIONS EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is locate d on the right side of the machine.
1 - 12 GEN INFO CONTROL FUNCTIONS EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. W ARNING • Never apply additional force to the side- stand. • Remove this sidestand befo re starting out.
1 - 13 GEN INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as v alves, piston rings, and exhaust system, etc .
1 - 14 GEN INFO STARTING AND BREAK-IN STARTING AND BREAK-IN W ARNING Never start or run the engine in a closed area. The exhaust fumes are po isonous; they can cause loss of consciousness and death in a very short tim e. Always operate the machine in a well-ventilated area.
1 - 15 GEN INFO STARTING AND BREAK-IN 6. Return the cold starter knob to its original position and run the e ngine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. N OTE: Since this model is equipped with an accelera- tor pump, if the engine is raced (the th rottle opened and closed), the air/fuel mixture will be too rich and the e ngine may stall.
1 - 16 GEN INFO STARTING AND BREAK-IN STARTING A WARM ENGINE Do not operate the cold starter knob an d throt- tle. 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.
1 - 17 GEN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks o n the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation o f the controls and the “ ENGINE STOP ” button.
GEN INFO 1 - 18 TORQUE-CHECK POINTS TORQUE-CHECK POINTS N OTE: Concerning the tightening torque, refer to “ MAINTENANCE SPEC IFICATIONS ” section in the CHAPTER 2.
1 - 19 GEN INFO CLEANING AND STORAGE EC1B000 0 CLEANING AND STORAGE EC1B100 0 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to p revent water from entering.
1 - 20 GEN INFO CLEANING AND STORAGE 8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combi- nation cleaner-waxes, as they may contain abrasives. 9. After completing the above, start the engine and allow it to idle for several min- utes.
SPEC 2 - 1 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 EUR (Except for F) F, CDN Overall length 2,190 mm (86.
SPEC 2 - 2 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.
SPEC 2 - 3 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.
SPEC 2 - 4 MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) ---- Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.
SPEC 2 - 5 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: “ A ” head diameter IN 26.
SPEC 2 - 6 Valve spring: Free length IN 37.03 mm (1.46 in) 36.03 mm (1.42 in) EX 37.68 mm (1.48 in) 36.68 mm (1.44 in) 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.
SPEC 2 - 7 Piston rings: Top ring: Type Barrel ---- Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ---- End gap (installed) 0.20 ~ 0.30 mm (0.008 ~ 0.012 in) 0.55 mm (0.022 in) Side clearance (installed) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.12 mm (0.
SPEC 2 - 8 Clutch: Friction plate thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 2.8 mm (0.110 in) Quantity 9 ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity 8 ---- Warp limit ---- 0.1 mm (0.004 in) Clutch spring free length 47.
SPEC 2 - 9 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) 0.20 mm (0.008 in) Tip clearance “ B ” 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) 0.24 mm (0.009 in) Side clearance 0.
SPEC 2 - 10 Item Standard Lubrication chart: Pressure feed Splashed scavenge Oil strainer Oil pan Oil pump rotor 2 Oil pump rotor 1 Oil tank Oil filter Check ball Cylinder head Crank pin Piston pin Pi.
SPEC 2 - 11 Part to be tightened Thread size Q ’ ty Tightening torque Nm m · kg ft · lb 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.
SPEC 2 - 12 N OTE: - marked portion shall b e checked for torque tighte ning after break-in or before each ra ce. N OTE: *1: Tighten the cylinder hea d 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.
SPEC 2 - 13 EC212201 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.
SPEC 2 - 14 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.
SPEC 2 - 15 N OTE: 1. First, tighten the ring nut approxima tely 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wre nch, then loosen the ring nut one turn. 2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). Part to be tightened Thread size Q ’ ty Tightening torque Nm m · kg ft · lb Handle crown and outer tube M8 × 1.
SPEC 2 - 16 N OTE: - marked portion shall b e checked for torque tighte ning after break-in or before each ra ce. Part to be tightened Thread size Q ’ ty Tightening torque Nm m · kg ft · lb Rear wheel axle and nut M20 × 1.5 1 125 12.5 90 Driven sprocket and wheel hub M8 × 1.
SPEC 2 - 17 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 ~.
SPEC 2 - 18 EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies to rque for standard fasten - ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book.
2 - 19 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake ca mshaft 3 Exhaust camshaft 4 Oil cleaner element 5 Oil pump 6 Main axle 7 Drive axle 7 6 5 4 3 2 1 4 5 A - A D - D .
2 - 20 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Cranksh aft 5 Main axle 6 Drive axle 7 Oil delivery pipe.
2 - 21 SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank brea ther hose 2 Oil tank breather hose 3 Hot starter cable 4 Radiator hose 4 5 Clutch cable 6 Cylinder head breath er hose.
2 - 22 SPEC CABLE ROUTING DIAGRAM Î Fasten the “ ENGINE STOP ” but- ton lead and sub wire ha rness to the frame at the pro tecting t ube for the “ ENG INE STOP ” button lead with a plastic locking tie and cut off the tie end.
2 - 23 SPEC CABLE ROUTING DIAGRAM Û Position the neutral switch lea d, CDI magneto lead an d radiator breather hose at the left of th e frame. B 0 C-C D-D B A A B D D C C F D G F D A G A A F A E A D .
2 - 24 SPEC CABLE ROUTING DIAGRAM 1 CDI unit 2 Hot starter cable 3 Throttle c able (ret urn) 4 Throttle cable (pu ll) 5 Ignition coil 6 Radiator brea ther hose 7 Radiator hose 4 8 Cylinder head breath er hose 9 CDI unit bracket 0 CDI unit band È Pass the hot starter cab le and throttle cables throug h the cable guides.
2 - 25 SPEC CABLE ROUTING DIAGRAM 1 Master cylinder 2 Brake hose holde r 3 Brake hose È Install the brake hose so that its pipe portion directs as sh own and lightly touche s the projec- tion on the ca liper. É Pass the brake ho se into the brake hose holder s.
2 - 26 SPEC CABLE ROUTING DIAGRAM 1 Throttle ca ble 2 Fuel tank brea ther hose 3 Clamp 4 Clutch cable 5 Hot starter cable 6 “ ENGINE STOP ” button lead 7 Brake hose 8 Hose guide È Fasten the “ ENGINE STOP ” but- ton lead to t he handlebar with the plastic band.
3 - 1 INSP ADJ MAINTENANCE INTERVALS EC300000 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a gene ral guide to maintenance an d lubrication.
3 - 2 INSP ADJ MAINTENANCE INTERVALS SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten MUFFLER Inspect and retig hten Clean Replace * Whichever comes first CRANK Inspect and clean CARBURETOR Inspect, adjust an d clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Chain slack: 48 ~ 58 mm (1.
3 - 3 INSP ADJ MAINTENANCE INTERVALS FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER (After rain ride) Inspect and adjus t Lube Molybde.
3 - 4 INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, pra ctice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points.
3 - 5 INSP ADJ EC350000 ENGINE EC351011 COOLANT LEVEL INSPECTION W ARNING Do not remove the radiator cap 1 , drain bolt and hoses when the e ngine and radia- tor are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
3 - 6 INSP ADJ COOLANT REPLACEMENT EC353011 COOLANT REPLACEMENT W ARNING Do not remove the radiator cap when the engine is hot. CAUTION: Take care so that coo lant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine.
3 - 7 INSP ADJ RADIATOR CAP INSPECTION CAUTION: • Do not mix more than on e type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. • Do not use water containing impurities or oil. 7. Install: • Radiator cap Start the engine and warm it up for a sev- eral minutes.
3 - 8 INSP ADJ RADIATOR CAP OPENING PRESSURE INSPECTION/ COOLING SYSTEM INSPECTION EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: • Radiator cap tester 1 and adapter 2 N OTE: Apply water on the radiator cap seal. 3 Radiator ca p 2. Apply the specified pressure.
3 - 9 INSP ADJ CLUTCH ADJUSTMENT N OTE: • Do not apply pressure more than specified pressure. • Radiator should be filled fu lly. 4. Inspect: • Pressure Impossible to maintain the specified pres- sure for 10 seconds → Repair. • Radiator • Radiator hose joint Coolant leakage → Repair or re place.
3 - 10 INSP ADJ THROTTLE CABLE ADJUSTMENT/ THROTTLE LUBRICATION EC35A00 1 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: • Throttle grip free play Throttle grip free play adjustment steps: • Slide the adjuster cover.
3 - 11 INSP ADJ HOT STARTER LEVER ADJUSTMENT/ AIR FILTER CLEANING HOT STARTER LEVER ADJUSTMENT 1. Check: • Hot starter lever free play a Out of specification → Adjust. 2. Adjust: • Hot starter lever free play N OTE: After adjustment, check proper op eration of hot starter.
3 - 12 INSP ADJ AIR FILTER CLEANING 2. Clean: • Air filter element Clean them with solvent. N 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 ele- ment may result in poor starting.
3 - 13 INSP ADJ 7. Install: • Air filter element 1 • Washer • Fitting bolt N OTE: Align the projection a on filter guide with the hole b in air filter case. T R . . 2 Nm (0.2 m · kg, 1.4 ft · lb) ENGINE OIL LEVEL INSPECTION 1. Stand the machine on a level surface.
3 - 14 INSP ADJ ENGINE OIL LEVEL INSPECTION 4. Inspect: • Oil level Oil level should be between maximum a and minimum b marks. Oil level low → Add oil to proper level. N OTE: When inspecting the oil level, do not screw the oil level gauge into the oil tank.
3 - 15 INSP ADJ 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 machin e upright. Then stop the engine and add the oil to the maxi- mum level.
3 - 16 INSP ADJ ENGINE OIL REPLACEMENT 6. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. 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.
3 - 17 INSP ADJ PILOT SCREW ADJUSTMENT 10. Install: • Oil filler plug 11. Inspect: • Engine (for oil leaks) • Oil level Refer to “ ENGINE OIL LEVEL INSPEC- TION ” . 12. Check: • Oil pressure Checking steps: • Slightly loosen the oil gallery bolt 1 .
3 - 18 INSP ADJ IDLE SPEED ADJUSTMENT/ VALVE CLEARANCE ADJUSTMENT EC35M021 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: • Idle speed VALVE CLEARANCE ADJUSTMENT N OTE: • The valve clearance should be adjusted when the engine is cool to th e touch.
3 - 19 INSP ADJ 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.
3 - 20 INSP ADJ VALVE CLEARANCE ADJUSTMENT 5. Adjust: • Valve clearance Adjustment steps: • Loosen the timing cha in tensioner cap bolt. • Remove the timing chain tensioner and camshaft caps. N OTE: Remove the camshaft cap bolts in a criss- cross pattern from the outside working inwards.
3 - 21 INSP ADJ VALVE CLEARANCE ADJUSTMENT • Round off the last digit of the installed pad number to the nearest in crement. 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 N OTE: Pads can only be selected in 0.
3 - 22 INSP ADJ 6. Install: • All removed parts N OTE: Install all removed parts in reversed order of their removal. • Install the timing chain tensioner. Refer to “ CAMSHAFTS ” section in the CHAPTER 4. N OTE: Turn the crankshaft counterclockwise sev- eral turns so that the installed parts settle into the right position.
3 - 23 INSP ADJ VALVE CLEARANCE ADJUSTMENT INTAKE MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 1 65 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 1 55 160 1 65 170 175 180 185 190 195 200 205 210 215 220 225 230 0.
3 - 24 INSP ADJ CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING W ARNING Bleed the brake system if: • The system has been disasse mbled. • A brake hose has been loosened or removed. • The brake fluid is very low.
3 - 25 INSP ADJ FRONT BRAKE ADJUSTMENT 3. Install: • Protector (rear brake) • Reservoir float (front brake) • Diaphragm • Master cylinder cap N OTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours.
3 - 26 INSP ADJ REAR BRAKE ADJUSTMENT/ FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMEN T 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 .
3 - 27 INSP ADJ 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 con- tainer under its end.
3 - 28 INSP ADJ REAR BRAKE PAD INSPECTION AND REPLACEMENT 3. Inspect: • Brake fluid level Refer to “ BRAKE FLUID LEVEL INSPEC- TION ” section. 4. Check: • Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “ BRAKE SYSTEM AIR BLEED- ING ” section.
3 - 29 INSP ADJ REAR BRAKE PAD INSPECTION AND REPLACEMENT • Remove the pad pin 6 and brake p ads 7 . • Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. • Loosen the bleed screw and push the cali- per piston in.
3 - 30 INSP ADJ REAR BRAKE PAD INSULATOR INSPECTION/ BRAKE FLUID LEVEL INSPECTION 3. Inspect: • Brake fluid level Refer to “ BRAKE FLUID LEVEL INSPEC- TION ” section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system.
3 - 31 INSP ADJ SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION EC368000 SPROCKETS INSPECTION 1. Inspect: • Sprocket teeth a Excessive wear → Replace. N 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.
3 - 32 INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT 4. Check: • Drive chain stiffness a Clean and oil the chain and hold as illus- trated. Stiff → Replace drive chain. 5. Install: • Drive chain 1 • Joint 2 • Master link clip 3 CAUTION: Be sure to install the master link c lip to the direction as shown.
3 - 33 INSP ADJ FRONT FORK INSPECTION 3. Adjust: • Drive chain slack Drive chain slack adjustment steps: • Loosen the axle nut 1 a nd locknuts 2 . • Adjust chain slack by turning the adjusters 3 . To tighten → Turn adjuster 3 counter- clockwise.
3 - 34 INSP ADJ 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 N OTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.
3 - 35 INSP ADJ FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. * For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment.
3 - 36 INSP ADJ REAR SHOCK ABSORBER INSPECTION • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. * For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment.
3 - 37 INSP ADJ 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 .
3 - 38 INSP ADJ REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUN D DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1 . Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.
3 - 39 INSP ADJ REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT EC36c00 0 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.
3 - 40 INSP ADJ EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • High compression damping force By turning the adjuster 1 . Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compres- sion damping force.
3 - 41 INSP ADJ TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION EC36Q00 0 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. N OTE: • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
3 - 42 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: • Bearing free play Exist play → Replace. STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine . 2. Check: • Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and f orth.
3 - 43 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT • Tighten the ring nut 3 using ring nut wrench 4 . N OTE: • Apply the lithium soap base gr ease on the thread of the steering shaft. • Set the torque wrench to the ring nut wrench so that they form a right angle.
3 - 44 INSP ADJ T R . . Steering shaft nut: 145 Nm (14.5 m • kg, 1 05 ft • lb) Handlebar upper holder: 28 Nm (2.8 m • kg, 20 ft • lb) Pinch bolt (handle crown): 23 Nm (2.
3 - 45 INSP ADJ LUBRICATION LUBRICATION To ensure smooth operation of all compo- nents, lubricate your machine during setup, after break-in, and after every race.
3 - 46 INSP ADJ ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/damage → Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.
3 - 47 INSP ADJ IGNITION TIMING CHECK IGNITION TIMING CHECK 1. Remove: • Timing plug 1 2. Attach: • Timing light To the ignition coil lead (orange lead 1 ). Timing light: YM-33277-A/90890-03141 3. Adjust: • Engine idling speed Refer to “ IDLE SPEED ADJUSTMENT ” .
4 - 1 ENG EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS Extent of removal: 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal Extent of removal Order Part name Q’ty Remarks SEAT, FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal Turn the fuel cock to “OFF”.
4 - 2 ENG REMOVAL POINTS Side cover 1. Remove: • Bolt (side cover) • Side cover (left) 1 • Side cover (right) 2 N OTE: Draw the side cover downward to remove it because its claws a are inserted in the air fil- ter case.
4 - 3 ENG EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER È Except for USA Extent of removal: 1 Silencer removal 2 Exhaust pipe removal Extent of removal Order Part name Q ’ ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Side cover (right) Refer to “ SEAT, FUEL TANK AND SIDE COVERS ” section.
4 - 4 ENG EXHAUST PIPE AND SILENCER INSPECTION Exhaust pipe and silencer 1. Inspect: • Gasket 1 Damage → Replace. 1 ASSEMBLY AND INSTALLATION Exhaust pipe and silencer 1.
4 - 5 ENG RADIATOR EC450001 RADIATOR Extent of removal: 1 Radiator removal Extent of removal Order Part name Q ’ ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “ COOLANT REPLACEMENT ” section in the CHAPTER 3. Seat and fuel tank Refer to “ SEAT, FUEL TANK AND SIDE COVERS ” section.
4 - 6 ENG RADIATOR EC456000 HANDLING NOTE W ARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out und er pressure, which could cause serious injury.
4 - 7 ENG RADIATOR 3. Install: • Radiator breather hose 1 • Radiator (right) 2 Refer to “ CABLE ROUTING DIAGRAM ” section in the CHAPT ER 2. T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Install: • Panel 1 • Bolt (radiator panel upper) 2 N OTE: Fit the hook a on the inner side first into the radiator.
4 - 8 ENG CARBURETOR CARBURETOR 5 1 2 6 6 3 9 7 8 4 4 T R . . 3 Nm (0.3 m • kg, 2.2 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.9 ft • Ib) T R . . 11 Nm (1.1 m • kg, 8.0 ft • Ib) T R . . 2 Nm (0.2 m • kg, 1.4 ft • Ib) T R . . 4 Nm (0.4 m • kg, 2.
4 - 9 ENG CARBURETOR CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q ’ ty Remarks CARBURETOR DISASSEMBLY 1 Breather hose 4 2 Valve lever housin.
4 - 10 ENG CARBURETOR Extent of removal Order Part name Q ’ ty Remarks F Main jet 1 G Needle jet 1 H Spacer 1 I Pilot jet 1 J Starter jet 1 K Push rod 1 Pull the push rod.
4 - 11 ENG CARBURETOR EC466020 HANDLING NOTE CAUTION: Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. 1 REMOVAL POINTS Pilot screw 1.
4 - 12 ENG CARBURETOR 2. Inspect: • Main jet 1 • Pilot jet 2 • Needle jet 3 • Starter jet 4 • Pilot air jet 5 • Leak jet 6 Damage → Replace. Contamination → Clean. N OTE: • Use a petroleum based solven t for cleaning. Blow out all passages and jets with com- pressed air.
4 - 13 ENG CARBURETOR EC464511 Float height 1. Measure: • Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: • Hold the carburetor in an upside down position.
4 - 14 ENG Starter plunger 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. Accelerator pump 1. Inspect: • Diaphragm (accelerator pump) 1 • Spring 2 • Cover 3 • O-ring 4 • Push rod 5 Tears (diaphragm)/damage → Replace.
4 - 15 ENG CARBURETOR 3. Install: • Spring 1 1 • Lever 1 2 To lever 2 3 . N OTE: Make sure the spring 1 fits on the stopper a of the lever 2. a 3 1 2 4. Install: • Spring 2 1 To lever 2 2 . 1 2 5. Install: • Push rod link lever assembly 1 N OTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor.
4 - 16 ENG CARBURETOR 8. Install: • Throttle shaft assembly 1 • Plain washer (metal) 2 • Plain washer (resin) 3 • Valve lever 4 N OTE: • Apply the fluorochemical grease on the bear- ings. • Fit the projection a on the throttle shaft assembly into the slot b in the TPS (throttle position sensor).
4 - 17 ENG CARBURETOR 11. Install: • Needle valve 1 • Float 2 • Float pin 3 N OTE: • After installing the needle valve t o the float, install them to the carburetor.
4 - 18 ENG CARBURETOR 14. Install: • Diaphragm (accelerator pump) 1 • Spring 2 • O-ring 3 • Cover 4 • Hose holder (drain hose) 5 • Screw (cover) 6 N OTE: Install the diaphragm (accelerator pump) with its mark a facing the spring.
4 - 19 ENG CARBURETOR Accelerator pump timing adjustment Adjustment steps: N OTE: In order for the throttle valve height a to achieve the specified value, tuck und er the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value.
4 - 20 ENG 4. Tighten: • Screw (air cleaner joint) 1 • Screw (carburetor joint) 2 T R . . 3 Nm (0.3 m · kg, 2.2 ft · lb) T R . . 3 Nm (0.3 m · kg, 2.2 ft · lb) 5. Install: • Throttle cable (pull) 1 • Throttle cable (return) 2 6. Adjust: • Throttle grip free play Refer to “ THROTTLE CABLE ADJUST- MENT ” section in the CHAPTER 3.
4 - 21 ENG CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER Extent of removal: 1 Cylinder head cover removal Extent of removal Order Part name Q ’ ty Remarks CYLINDER HE AD COVER REMOVAL Preparation for removal Seat and fuel tank R efer to “ SEAT, FUEL TANK AND SIDE COVERS ” section.
4 - 22 ENG CAMSHAFTS CAMSHAFTS Extent of removal: 1 Camshaft removal Extent of removal Order Part name Q ’ ty Remarks CAMSHAFTS REMOVAL 1 Timing plug 1 Refer to “ REMOVAL POINTS ” .
4 - 23 ENG CAMSHAFTS REMOVAL POINTS Camshaft 1. Remove: • Timing plug 1 • Straight plug 2 2. Align: •“ I ” mark With stationary po inter. Checking steps: • Turn the crankshaft counterclockwise with a wrench. • Align the “ I ” mark a on the rotor with the stationary pointer b on the crankcase cover.
4 - 24 ENG CAMSHAFTS 6. Remove: • Clips • Exhaust camshaft 1 • Intake camshaft 2 N OTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. 1 2 3 INSPECTION Camshaft 1. Inspect: • Cam lobes Pitting/scratches/blue discoloration → Replace.
4 - 25 ENG CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specificat ion → Measure camshaft journal diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: • Install the camshaft onto the cylinder head.
4 - 26 ENG CAMSHAFTS Decompression system 1. Check: • Decompression syst em Checking steps: • Check that the decompressor cam 1 moves smoothly. • Check that the decomp ressor lever pin 2 projects from the camshaft.
4 - 27 ENG CAMSHAFTS • Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. N OTE: The camshafts should be installed onto the cylinder head so that the exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the sur- face of the cylinder head.
4 - 28 ENG • With the rod fully wound and the chain ten- sioner UP mark a facing upward, install the gasket 1 and the chain tensioner 2 , and tighten the bolt 3 to the specified torque.
4 - 29 ENG CYLINDER HEAD CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal N OTE: Tighten the cylinder head b olts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening seq uence, remove and retighten the cylinder head bolts to 20 Nm (2.
4 - 30 ENG CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. N OTE: Do not use a sharp instrument to avoid damag- ing or scratching: • Spark plug threads • Valve seats 2.
4 - 31 ENG CYLINDER HEAD ASSEMBLY AND INSTALLATION 1. Install: • Timing chain guide (front) 1 • Dowel pin 2 • Cylinder head gasket 3 • Cylinder head 4 N OTE: While pulling up the timin g chain, install the timing chain guide (front) an d cylinder head.
4 - 32 ENG • Remove the bolts. • Again apply the molybdenum disulfide grease on the t hreads and contact sur- faces of the bolts an d on both contact sur- faces of the plain washers. • Retighten the bolts. N OTE: Tighten the bolts to the specified torque in two or three steps in the pro per tightening sequence as shown.
4 - 33 ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valve removal Extent of removal Order Part name Q ’ ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section.
4 - 34 ENG VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: • Valve lifters 1 • Pads 2 N OTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.
4 - 35 ENG VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: • Stem-to-guide clearance Out of specification → Replace the va lve guide. Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Clearance (stem to guide): Intake: 0.
4 - 36 ENG VALVES AND VALVE SPRINGS Valve guide remover: Intake: 4.5 mm (0.18 in) YM-4116/90890-04116 Exhaust: 5.0 mm (0.20 in) YM-4097/90890-04097 Valve guide installer: Intake: YM-4117/90890-04117 Exhaust: YM-4098/90890-04098 Valve guide reamer: Intake: 4.
4 - 37 ENG VALVES AND VALVE SPRINGS 5. Measure: • Runout (valve stem) Out of specification → Replace. N OTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. 6. Eliminate: • Carbon deposits (from the valve face and valve seat) 7.
4 - 38 ENG VALVES AND VALVE SPRINGS 9. Lap: • Valve face • Valve seat N OTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: • Apply a coarse lapping compound to the valve face.
4 - 39 ENG VALVES AND VALVE SPRINGS Valve spring 1. Measure: • Valve spring free length a Out of specification → Replace. 2. Measure: • Compressed spring force a Out of specification → Replace. b Installed length Free length (valve spring): Intake: 37.
4 - 40 ENG VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION 1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: • Valves 1 • Valve spring seats 2 • Valv.
4 - 41 ENG VALVES AND VALVE SPRINGS 5. Install: • Adjusting pad 1 • Valve lifter 2 N OTE: • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem end. • Valve lifter must turn smoothly when rotated with a finger.
4 - 42 ENG CYLINDER AND PISTON CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder re moval 2 Piston removal Extent of removal Order Part name Q ’ ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section.
4 - 43 ENG CYLINDER AND PISTON REMOVAL POINTS Piston 1. Remove: • Piston pin clips 1 • Piston pin 2 • Piston 3 N OTE: • Put identification marks on each piston head for reference during reinstallation. • Before removing each pist on pin, deburr the clip groove and pin hole area.
4 - 44 ENG CYLINDER AND PISTON Cylinder bore “ C ” 95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in) Taper limit “ T ” 0.05 mm (0.002 in) Out of round “ R ” 0.
4 - 45 ENG CYLINDER AND PISTON Piston ring 1. Measure: • Ring side clearance Use a feeler gauge 1 . Out of specifica tion → Replace the piston and rings as a set. N OTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.
4 - 46 ENG CYLINDER AND PISTON Piston pin 1. Inspect: • Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: • Piston pin-to-piston clearance ASSEMBLY AND INSTALLATION Piston 1. Install: • Piston rings Onto the piston.
4 - 47 ENG CYLINDER AND PISTON 2. Position: • Top ring • 2nd ring • Oil ring Offset the piston ring end gaps as shown. a Top ring end b 2nd ring e nd c Oil ring en d (upper) d Oil ring e Oil ring end (lower) 3. Install: • Piston 1 • Piston pin 2 • Piston pin clips 3 N OTE: • Apply engine oil onto the pisto n pin and pis- ton.
4 - 48 ENG CLUTCH CLUTCH CLUTCH Extent of removal: 1 Push rod and pu sh lever removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housin g removal Extent of removal Order Part name Q ’ ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil.
4 - 49 ENG CLUTCH Extent of removal Order Part name Q ’ ty Remarks 12 Clutch plate 8 13 Friction plate 9 14 Nut 1 Use special tool. Refer to “ REMOVAL POINTS ” .
4 - 50 ENG CLUTCH EC493000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: • Nut 1 • Lock washer 2 • Clutch boss 3 N OTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss.
4 - 51 ENG CLUTCH EC484500 Friction plate 1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four poin ts. EC484600 Clutch plate 1. Measure: • Clutch plate warpage Out of specification → Replace clutch plate as a set.
4 - 52 ENG CLUTCH EC4A500 0 ASSEMBLY AND INSTALLATION Push lever 1. Install: • Push lever 1 • Bolt (push lever) N OTE: • Apply the lithium soap base grease on the oil seal lip. • Apply the engine oil on the push lever. • Fit the seat plate 2 in the groove a of the push lever and tighten the b olt (seat plate).
4 - 53 ENG CLUTCH 3. Bend the lock washer 1 tab. 4. Install: • Friction plate 1 • Clutch plate 2 N OTE: • Install the clutch plates a nd friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
4 - 54 ENG CLUTCH 7. Install: • Pressure plate 1 8. Install: • Clutch spring • Bolt (clutch spring) N OTE: Tighten the bolts in stage, using a crisscross pattern. T R . . 8 Nm (0.8 m · kg, 5.8 ft · lb ) 9. Install: • Gasket (clutch cover) 1 • Dowel pin 2 New 10.
4 - 55 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCA SE COVER (RIGHT) Extent of removal: 1 Oil filter rem.
4 - 56 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal Order Part name Q ’ ty Remarks 7 Oil hose 1 8 Kick starter 1 9 Crankcase cover (right) 1 10 Gasket 1 11 Dowel pin/O-ring 4/2 12 Impeller 1 Refer to “ REMOVAL POINTS ” .
4 - 57 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: • Impeller 1 • Plain washer 2 • Impeller shaft 3 N OTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller.
4 - 58 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4H4600 Bearing 1. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. EC444400 Oil seal 1. Inspect: • Oil seal Wear/damage → Replace. ASSEMBLY AND INSTALLATION EC4G5110 Oil seal 1.
4 - 59 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4G5220 Impeller shaft 1. Install: • Impeller shaft 1 • Plain washer 2 • Impeller 3 N OTE: • Take care so that th e oil seal lip is not dam- aged or the spring does not slip off its posi- tion.
4 - 60 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Kick crank 1. Install: • Kick starter 1 • Plain washer • Bolt (kick starter) N OTE: Install the kick starter so that the kick starter is as vertical as possible with the distance a between the kick starter and th e frame being 5 mm (0.
4 - 61 ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) 2. Install: • Water pump housing 1 • Bolt (water pump housing) 2 • Plain washer 3 • Coolant drain bolt 4 T R . . 10 Nm (1.0 m · kg, 7.2 ft · lb) New T R . . 10 Nm (1.0 m · kg, 7.
4 - 62 ENG BALANCER BALANCER BALANCER Extent of removal: 1 Balancer drive g ear 2 Balancer Extent of removal Order Part name Q ’ ty Remarks BALANCER REMOVAL Preparation for removal Clutch h ousing Refer to “ CLUTCH ” section. Crankcase cover (right) R e f e r to “ OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ” section.
4 - 63 ENG BALANCER REMOVAL POINTS Balancer drive gear and balancer driven gear 1. Straighten the lock washer tab. 2. Loosen: • Nut (primary drive gear) 1 • Nut (balancer) 2 N OTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear 4 .
4 - 64 ENG BALANCER ASSEMBLY AND INSTALLATION Balancer, balancer drive gear and balance r driven gear 1. Install: • Balancer 1 N OTE: When installing the balancer shaft, align the center of the balancer shaft weight a along the line connecting the centers of the crank- shaft and balancer shaft.
4 - 65 ENG OIL PUMP OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil pump disassembly Extent of removal Order Part name Q ’ ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Clutch h ousing Refer to “ CLUTCH ” section.
4 - 66 ENG OIL PUMP Extent of removal Order Part name Q ’ ty Remarks 13 Pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1 2.
4 - 67 ENG OIL PUMP INSPECTION Oil pump 1. Inspect: • Oil pump drive gear • Oil pump driven gear • Rotor housing • Oil pump cover Cracks/wear/damage → Replace. 2. Measure: • Tip clearance a Between the inner rotor 1 and the outer rotor 2 .
4 - 68 ENG OIL PUMP 2. Install: • Outer rotor 1 1 N OTE: Apply the engine oil on the outer rotor 1. 3. Install: • Oil pump cover 1 • Screw (oil pump cover) 2 • Pin 3 • Inner rotor 2 4 • Circlip 5 N OTE: • Apply the engine oil on the oil pump d rive shaft end and inner rotor 2.
4 - 69 ENG KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT Extent of removal: 1 Kick axle removal 2 Kick axle disassembly 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q ’ ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to “ OIL PUMP ” section.
4 - 70 ENG KICK AXLE AND SHIFT SHAFT Extent of removal Order Part name Q ’ ty Remarks 13 Roller 1 14 Shift guide 1 Refer to “ REMOVAL POINTS ” . 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt (stopper lever) 1 21 Stopper lever 1 22 Torsion spring 1 23 Segm ent 1 Refer to “ REMOVAL POINTS ” .
4 - 71 ENG KICK AXLE AND SHIFT SHAFT REMOVAL POINTS EC4B310 1 Kick axle assembly 1. Remove: • Kick axle assembly 1 N OTE: Unhook the torsion spring 2 from the hole a in the crankcase.
4 - 72 ENG KICK AXLE AND SHIFT SHAFT EC4B440 0 Shift shaft 1. Inspect: • Shift shaft 1 Bend/damage → Replace. • Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: • Shift guide 1 • Shift lever 2 • Pawl 3 • Pawl pin 4 • Spring 5 Wear/damage → Replace.
4 - 73 ENG KICK AXLE AND SHIFT SHAFT EC4B511 1 Stopper lever 1. Install: • Torsion spring 1 • Stopper lever 2 • Bolt (stopper lever) 3 N OTE: Align the stopper lever roller with the slot on segment. Shift guide and shift lever assembly 1. Install: • Spring 1 • Pawl pin 2 • Pawl 3 To shift lever 4 .
4 - 74 ENG KICK AXLE AND SHIFT SHAFT EC4C5301 Shift shaft 1. Install: • Roller 1 • Collar 2 • Torsion spring 3 • Shift shaft 4 N OTE: Apply the engine oil on the roller and shift shaft.
4 - 75 ENG KICK AXLE AND SHIFT SHAFT 3. Install: • Spring guide 1 N OTE: Slide the spring guide into the kick axle, make sure the groove a in the spring g uide fits on the stopper of the torsion spring.
4 - 76 ENG CDI MAGNETO EC4L0000 CDI MAGNETO Extent of removal: 1 CDI magneto removal Extent of removal Order Part name Q ’ ty Remarks CDI MAGNETO REMOVAL Preparation for removal Seat and fuel tank R efer to “ SEAT, FUEL TANK AND SIDE COVERS ” section.
4 - 77 ENG CDI MAGNETO EC4L3000 REMOVAL POINTS EC4L3101 Rotor 1. Remove: • Nut (rotor) 1 • Plain washer Use the rotor holding tool 2 . 2. Remove: • Rotor 1 Use the flywheel puller 2 . N OTE: When installing the flywheel puller, t urn it counterclockwise.
4 - 78 ENG CDI MAGNETO EC4L5000 ASSEMBLY AND INSTALLATION CDI magneto 1. Install: • Stator 1 • Screw (stator) 2 N OTE: • Apply the sealant to the grommet of the CDI magneto lead. • Tighten the screws using the T30 b it. Quick gasket ® : ACC-QUICK-GS-KT YAMAHA Bond No.
4 - 79 ENG CDI MAGNETO 4. Connect: • CDI magneto lead Refer to “ CABLE ROUTING DIAGRAM ” section in the CHAPT ER 2. 5. Install: • Dowel pin • Gasket [crankcase cover (left)] • Crankcase co.
4 - 80 ENG ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q ’ ty Remarks ENGINE REMOVAL Preparation for removal Hold th e machine by placing the suitable stand under the frame. W ARNING Support the machine securely so there is no danger of i t falling ove r.
4 - 81 ENG ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q ’ ty Remarks 1 Engine skid plate (front) 1 2 Neutral switch 1 3 Oil hose 2 4 Chain cover 1 5 Nut (drive sprocket) 1 Refer to “ REMOVAL POINTS ” .
4 - 82 ENG ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 N OTE: • Straighten the lock washer tab. • Loosen the nut while ap plying the rear brake. 2. Remove: • Drive sprocket 1 • Drive chain 2 N OTE: Remove the drive sprocket toge ther with the drive chain.
4 - 83 ENG ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: • Engine 1 Install the engine from right side. • Pivot shaft 2 • Engine mounting bolt (lower) 3 • E.
4 - 84 ENG ENGINE REMOVAL 2. Install: • Lock washer 1 • Nut (drive sprocket) 2 N OTE: Tighten the nut while applying the re ar brake. New T R . . 75 Nm (7.5 m · kg, 54 ft · lb) 3. Bend the lock washer tab to lock the nut. 4. Install: • Chain guide • Chain cover 1 • Screw (chain cover) 2 2 1 T R .
4 - 85 ENG CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q ’ ty Remarks CRANKCASE SEPARATION Preparation for removal Engine Refer to “ ENGINE REMOVAL ” section.
4 - 86 ENG CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q ’ ty Remarks 10 Crankcase (right) 1 Refer to “ REMOVAL POINTS ” . 11 Crankcase (left) 1 12 Oil strainer 1 13 Oil delivery pipe 2 1 14 Crankshaft 1 U se special tool. Refer to “ REMOVAL POINTS ” .
4 - 87 ENG CRANKCASE AND CRANKSHAFT CRANKCASE BEARING Extent of removal: 1 Crankcase bearing removal Extent of removal Order Part name Q ’ ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to “ TRANSMISSION, SHIFT CAM AND SHIFT FORK ” section.
4 - 88 ENG CRANKCASE AND CRANKSHAFT REMOVAL POINTS Crankcase 1. Separate: • Crankcase (right) • Crankcase (left) Separation steps: • Remove the crankcase bolts, hose guide and clutch cable holder. N OTE: Loosen each bolt 1/4 of a turn at a t ime and after all the bolts are loosen ed, remove them.
4 - 89 ENG CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2 . CAUTION: Do not use a hammer to drive out the crankshaft. Crankshaft bearing 1. Remove: • Bearing 1 N OTE: • Remove the bearing from the crankcase by pressing its inner race.
4 - 90 ENG CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width d Out of specification → Replace. Use the dial gauge and a thickne ss gauge.
4 - 91 ENG CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankshaft bearing 1. Install: • Bearing • Bearing stopper • Bolt (bearing stopper) • Screw (bearing stopper) • Screw [bearing stopper (crankshaft)] 1 To crankcase (left and right).
4 - 92 ENG CRANKCASE AND CRANKSHAFT N OTE: • Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Ope rate the installing tool until the crankshaft botto ms against the bearing. • Before installing the crankshaft, clean the contacting surface of cra nkcase.
4 - 93 ENG CRANKCASE AND CRANKSHAFT 5. Install: • Dowel pin 1 • O-ring 2 • Crankcase (right) To crankcase (left). N OTE: • Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft ham- mer. • When installing the crankcase, the connect- ing rod should be positioned at TDC (top dead center).
4 - 94 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK Extent of removal: 1 Shift fork, shift cam, main axle and drive axle rem.
4 - 95 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS Shift fork, shaft cam and transmission 1. Remove: • Shift forks • Shift cam • Main axle • Drive axle N OTE: • Tap lightly on the transmission drive axle and shift cam with a soft hammer to remove.
4 - 96 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4801 Shift fork, shift cam and segment 1. Inspect: • Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: • Shift cam 1 • Segment 2 Bend/wear/damage → Replace. 3. Check: • Shift fork movement Unsmooth operation → Replace shift fork.
4 - 97 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: • 2nd wheel gear (25T ) 1 • Collar 2 • 3rd wheel gear (23T) 3 • 4th wheel gear (21T) 4 • 1st wheel gear (27T) 5 • O-ring 6 To drive ax le 7 .
4 - 98 ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: • Shift fork 1 (L) 1 • Shift fork 2 (R) 2 • Shift cam 3 To main axle and drive axle. N OTE: • Apply the molybdenum disulfide oil on the shift fork grooves. • Mesh the shift fork #1 (L) with the 3rd pinion gear 4 on the main axle.
5 - 1 CHAS EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL FRONT WHEEL AND REAR WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing re moval 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks FRONT WHEEL REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r.
5 - 2 CHAS EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal Extent of removal Order Part name Q ’ ty Remarks REAR WHEEL REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r.
5 - 3 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 N OTE: Push the wheel forward and re move the drive chain 2 . EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 N OTE: Remove the bearing using a general bearing puller 2 .
5 - 4 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: • Wheel axle bends Out of specification → Replace. Use the dial gauge 1 . N OTE: The bending value is shown by on e half of the dial gauge reading. W ARNING Do not attempt to straighten a bent axle.
5 - 5 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: • Bearing (left) 1 • Spacer 2 • Bearing (right) 3 • Oil seal 4 N OTE: • Apply the lithium soap base g rease on the bearing and oil seal lip when installing.
5 - 6 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: • Wheel axle 1 N OTE: Apply the lithium soap base grease on the wheel axle. 6. Install: • Nut (wheel axle) 1 T R .
5 - 7 CHAS FRONT WHEEL AND REAR WHEEL Rear wheel 1. Install: • Bearing (right) 1 • Circlip 2 • Spacer 3 • Bearing (left) 4 • Oil seal 5 N OTE: • Apply the lithium soap base g rease on the bearing and oil seal lip when installing. • Install the bearing with seal facing outward.
5 - 8 CHAS 4. Install: • Collar 1 N OTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: • Wheel N OTE: Install the brake disc 1 be tween the brake pads 2 correctly. 6. Install: • Drive chain 1 N OTE: Push the wheel 2 forward and install th e drive chain.
5 - 9 CHAS FRONT WHEEL AND REAR WHEEL 9. Adjust: • Drive chain slack a Refer to “ DRIVE CHAIN SLACK ADJUSTMENT ” section in the CHAPTER 3. Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) 10. Tighten: • Nut (wheel axle) 1 • Locknut 2 T R . . 125 Nm (12.
5 - 10 CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Caliper removal 3 Master cylinder removal Extent of removal Order Part name Q ’ ty Remarks FRONT BRAKE REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r.
5 - 11 CHAS EC5A8100 REAR BRAKE Extent of removal: 1 Master cylinder removal 2 Brake ho se removal 3 Caliper removal Extent of removal Order Part name Q ’ ty Remarks REAR BRAKE REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r.
5 - 12 CHAS EC5A8200 CALIPER DISASSEMBLY È Front É Rear Extent of removal: 1 Front caliper disassembly 2 Rear caliper disassembly Extent of removal Order Part name Q ’ ty Remarks CALIPER DISASSEMBLY AB 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Caliper pi ston 2 1 Refer to “ REMOVAL POINTS ” .
5 - 13 CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY È Front É Rear Extent of removal: 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal.
5 - 14 CHAS FRONT BRAKE AND REAR BRAKE EC5A300 0 REMOVAL POINTS Brake fluid 1. Remove: [Front] • Master cylinder cap 1 [Rear] • Master cylinder cap 1 • Protector N OTE: Do not remove the diaphragm. È Front É Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable con- tainer under its end.
5 - 15 CHAS FRONT BRAKE AND REAR BRAKE EC533402 Piston seal kit 1. Remove: • Dust seal 1 • Piston seal 2 N OTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and dust seals. W ARNING Replace the piston seals and dust seals whenever a caliper is disassembl ed.
5 - 16 CHAS 4. Inspect: • Master cylinder piston 1 • Master cylinder cup 2 Wear/damage/score marks → Replace master cylinder kit. È Front É Rear ÈÉ EC534214 Caliper 1. Inspect: • Caliper cylinder inner surface a Wear/score marks → Replace caliper assembly.
5 - 17 CHAS EC5A580 0 Caliper piston 1. Clean: • Caliper • Piston seal • Dust seal • Caliper piston Clean them with brake fluid. 2. Install: • Piston seal 1 • Dust seal 2 W ARNING Always use new piston seals and dust seals. N OTE: Fit the piston seals and dust seals ont o the slot on caliper correctly.
5 - 18 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Caliper 1 • Bolt (caliper) 2 3. Tighten: • Pad pin 3 4. Install: • Pad pin plug 4 T R . . 23 Nm (2.3 m · kg, 17 ft · lb) T R . . 18 Nm (1.8 m · kg, 13 ft · lb) T R . . 3 Nm (0.3 m · kg, 2.
5 - 19 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Caliper 1 • Rear wheel 2 Refer to “ FRONT WHEEL AND REAR WHEEL ” section. 4. Tighten: • Pad pin 3 5. Install: • Pad pin plug 4 Master cylinder kit 1. Clean: • Master cylinder • Master cylinder kit Clean them with brake fluid.
5 - 20 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: [Front] • Master cylinder kit 1 • Plain washer 2 • Circlip 3 • Master cylinder boot 4 To master cylinder 5 . [Rear] • Master cylinder kit 1 • Push rod 2 • Circlip 3 • Master cylinder boot 4 To master cylinder 5 .
5 - 21 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake lever 1 • Bolt (brake lever) 2 • Nut (brake lever) 3 N OTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston.
5 - 22 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: • Pin 1 • Plain washer 2 • Cotter pin 3 N OTE: After installing, check the brake pedal height. Refer to “ REAR BRAKE ADJUSTMENT ” sec- tion in the CHAPTER 3. New Front brake hose 1. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 W ARNING Always use new copper washers.
5 - 23 CHAS FRONT BRAKE AND REAR BRAKE 4. Pass the brake hose through the cable guide 1 . 5. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 W ARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as shown and lightly touches the projection b on the mas ter cylinder.
5 - 24 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder 1 • Screw (brake hose holder) 2 CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist.
5 - 25 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: • Brake system Refer to “ BRAKE SYSTEM AIR BLEED- ING ” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to “ BRAKE FLUID LEVEL INSPEC- TION ” section in the CHAPTER 3.
5 - 26 CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q ’ ty Remarks Preparation for removal FRONT FORK REMOVAL Hold the ma chine by placing the suitable stand under the engi ne. W ARNING Support the machine securely so there is no danger of i t falling ove r.
5 - 27 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper assembly removal Extent of removal Order Part name Q ’ ty Remarks FRONT FORK DISASSEMBLY 1 Adjuster 1 Drain the fork oi l. Use special tool. Refer to “ REMOVAL POINTS ” .
5 - 28 CHAS FRONT FORK EC556000 HANDLING NOTE N OTE: The front fork requires careful attentio n. So it is recommended that the front fork be maintained at the dealers.
5 - 29 CHAS Adjuster 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster 1 3. Remove: • Adjuster 1 N OTE: • While compressing the inner tube 2 , set the cap bolt ring wrench 4 between the inner tube and locknut 3 . • Hold the locknut and remove the adjuster.
5 - 30 CHAS Base valve 1. Remove: • Base valve 1 From damper assembly 2 . N OTE: Hold the damper assembly with th e cap bolt ring wrench 3 and use the cap bolt wrench 4 to remove the base valve. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501 EC554000 INSPECTION Damper assembly 1.
5 - 31 CHAS Base valve 1. Inspect: • Base valve 1 Wear/damage → Replace. Contamination → Clean. • O-ring 2 Wear/damage → Replace. • Bush 3 Wear/damage → Replace base valve . • Spring 4 Damage/fatigue → Replace base valve. • Air bleed screw 5 Wear/damage → Replace base valve .
5 - 32 CHAS FRONT FORK EC554600 Outer tube 1. Inspect: • Outer tube 1 Score marks/wear/damage → Replace. Adjuster 1. Inspect: • Adjuster 1 • O-ring 2 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solven t.
5 - 33 CHAS FRONT FORK 4. After filling, pump the damper assembly 1 slowly up and down (about 200 mm (7.9 in) stroke) several times to bleed the damper assembly of air. N OTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will ca use air to enter.
5 - 34 CHAS FRONT FORK 9. Tighten: • Base valve 1 N OTE: Hold the damper assembly with th e cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve wit h specified torque. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501 T R .
5 - 35 CHAS FRONT FORK 13. Check: • Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Install: • Dust seal 1 • Stopper ring 2 • Oil seal 3 • Oil seal washer 4 • Slide metal 5 To inner tube 6 . N OTE: • Apply the fork oil on the inner tub e.
5 - 36 CHAS FRONT FORK 17. Install: • Slide metal 1 • Oil seal washer 2 To outer tube slot. N OTE: Press the slide metal into the outer tube with fork seal driver 3 . Fork seal driver: YM-01442/90890-01442 18. Install: • Oil seal 1 N OTE: Press the oil seal into the outer t ube with fork seal driver 2 .
5 - 37 CHAS FRONT FORK 21. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 14 to 20. 22. Measure: • Distance a Out of specification → Turn into the lock- nut. Distance a : 19 mm (0.75 in) or more Between damper assembly 1 bottom and locknut 2 bottom.
5 - 38 CHAS FRONT FORK 26. Install: • Push rod 1 • Copper washer 2 • Adjuster 3 To damper as sembly 4 . N OTE: • While compressing the inner tube 5 , set the cap bolt ring wrench 7 between the inner tube and locknut 6 . • Fully finger tighten the adjuster onto the damper asse mbly.
5 - 39 CHAS 29. Install: • Adjuster 1 To inner tube. T R . . 55 Nm (5.5 m · kg, 40 ft · lb) 30. Fill: • Front fork oil 1 From outer tube top. * For EUROPE W ARNING Never fail to make the oil amou nt adjust- ment between the maximum and minimum amount and always adjust each front fork to the same setting.
5 - 40 CHAS 32. Install: • Protector guide 1 Installation 1. Install: • Front fork 1 N OTE: • Temporarily tighten the pinch bo lts (under bracket). • Do not tighten the pinch bolts (handle crown) yet. 2. Tighten: • Damper assembly 1 N OTE: Use the cap bolt ring wrench 2 to tighten the damper assembly with specif ied torque.
5 - 41 CHAS 4. Tighten: • Pinch bolt (handle crown) 1 • Pinch bolt (under bracket) 2 CAUTION: Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. T R . . 23 Nm (2.3 m · kg, 17 ft · lb) T R .
5 - 42 CHAS EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q ’ ty Remarks HANDLEBAR REMOVAL Preparation for removal Number plate Remove th e clamp portion only. 1 Hot starter cable 1 Disconnect at the lever side.
5 - 43 CHAS EC5B300 0 REMOVAL POINTS EC5B310 0 Master cylinder 1. Remove: • Master cylinder bracket 1 • Master cylinder 2 CAUTION: • Do not let the master cylinder hang on the brake hose. • Keep the master cylinder cap side hori- zontal to prevent air from coming in.
5 - 44 CHAS HANDLEBAR EC5B500 0 ASSEMBLY AND INSTALLATION Handlebar 1. Install: • Handlebar 1 • Handlebar holder 2 • Bolt (handlebar holder) 3 N OTE: • The upper handlebar hold er should be installed with the punched mark a forward. • Install the handlebar so th at the marks b are in place on both sides.
5 - 45 CHAS HANDLEBAR 3. Install: • Grip (right) 1 • Collar 2 Apply the adhesive on the tube guide 3 . N OTE: • Before applying the adhesive, wip e off grease or oil on the tube guide surface a with a lacquer thinner. • Install the grip to t he tube guide so that the grip match mark b and tube guide slot c form the angle as shown.
5 - 46 CHAS HANDLEBAR 6. Install: • Throttle cab le cap 1 • Screw (throttle cable cap) 2 W ARNING After tightening the screws, check that the throttle grip 3 moves smoothly. If it does not, retighten the bolts for a djustment. T R . . 4 Nm (0.4 m · kg, 2.
5 - 47 CHAS HANDLEBAR 9. Install: •“ ENGINE STOP ” button 1 • Clutch lever holder 2 • Bolt (clutch lever holder) 3 • Hot starter lever holder 4 • Bolt (hot starter lever holder) 5 • Clamp 6 N OTE: • The “ ENGINE STOP ” button, clutch lever holder and clamp should be installed accord- ing to the dimensions shown.
5 - 48 CHAS EC560000 STEERING Extent of removal: 1 Under bracket removal 2 Bearing removal Extent of removal Order Part name Q ’ ty Remarks STEERING REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r. Preparation for removal Hold th e machine by placing the suitable stand under the engi ne.
5 - 49 CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: • Ring nut 1 Use the ring nut wrench 2 . W ARNING Support the steering sha ft so that it may not fall down. Ring nut wrench: YU-33975/90890-01403 EC563300 Bearing (lower) 1. Remove: • Bearing (lower) 1 Use the floor chisel 2 .
5 - 50 CHAS STEERING Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: • Bearing 1 • Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand.
5 - 51 CHAS 4. Install: • Ring nut 1 Tighten the ring nut using the rin g nut wrench 2 . Refer to “ STEERING HEAD INSPEC- TION AND ADJUSTMENT ” section in the CHAPTER 3. T R . . 7 Nm (0.7 m · kg, 5.1 ft · lb ) 5. Check the steering shaft by turning it lo ck to lock.
5 - 52 CHAS STEERING 9. Install: • Steering shaft cap 1 10. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11. Adjust: • Front fork top end a Front fork top end (standard) a : Zero mm (Zero in) 12.
5 - 53 CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q ’ ty Remarks SWINGARM REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r. Preparation for removal Hold th e machine by placing the suitable stand under the engi ne.
5 - 54 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disasse mbly 2 Connecting rod removal and disassembl y 3 Relay arm removal and disassembly Extent of removal Order Part name Q ’ ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 Refer to “ REMOVAL POINTS ” .
5 - 55 CHAS SWINGARM EC573000 REMOVAL POINTS Cap 1. Remove: • Cap (left) 1 N OTE: Remove with a slotted-head screwdriver inserted under the mark a on the cap (left). EC573200 Bearing 1. Remove: • Bearing 1 N OTE: Install the bearing by pressing its outer race.
5 - 56 CHAS SWINGARM Connecting rod 1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. EC575000 ASSEMBLY AND INSTALLATION Bearing and oil seal 1.
5 - 57 CHAS SWINGARM 3. Install: • Bearing 1 • Oil seal 2 To connecting rod. N OTE: • Apply the molybdenum disu lfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the m anufacture ’ s marks or numbers.
5 - 58 CHAS SWINGARM 3. Install: • Collar 1 To connecting rod 2 . N OTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Plain washer 3 • Nut (connecting rod) 4 To relay arm 5 .
5 - 59 CHAS SWINGARM 8. Install: • Bolt (connecting rod) 1 • Plain washer 2 • Nut (connecting rod) 3 N OTE: • Apply the molybdenum disu lfide grease on the bolt.
5 - 60 CHAS 13. Install: • Bolt [chain tensioner (lower)] 1 • Plain washer 2 • Collar 3 • Chain tensioner 4 • Nut [chain tensioner (lower)] 5 T R . . 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: • Chain support 1 • Support cover 2 • Bolt {chain support [ = 50 mm (1.
5 - 61 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER Extent of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal Order Part name Q ’ ty Remarks REAR SHOCK ABSORBER REMOVAL W ARNING Support the machine securely so there is no danger of i t falling ove r.
5 - 62 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ’ ty Remarks 9 Spring guide (upper) 1 10 Spring (rear shock absorber) 1 11 Bearing 2 Refer to “ REMOVAL POINTS ” .
5 - 63 CHAS EC586000 HANDLING NOTE W ARNING This shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the follow- ing information before handling the shock absorber.
5 - 64 CHAS EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: • Stopper ring (upper bearing) 1 N OTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: • Upper bearing 1 N OTE: Remove the bearing by pressing its outer race.
5 - 65 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: • Upper bearing 1 N OTE: Install the bearing paralle l until the stopper ring groove appears by pressing its outer race.
5 - 66 CHAS REAR SHOCK ABSORBER 2. Tighten: • Adjuster 1 3. Adjust: • Spring length (installed) a * For EUROPE N OTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the ad juster. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting.
5 - 67 CHAS REAR SHOCK ABSORBER 2. Install: • Bush 1 • Collar 2 • Dust seal 3 N OTE: • Apply the molybdenum disu lfide grease on the bearing. • Apply the lithium soap base g rease on the bush, collars and dust seals. • Install the dust seals with their lips facing out- ward.
6 - 1 –+ ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 “ ENGINE STOP ” button 2 TPS (throttle positio n sensor) 3 Neutral switch 4 CDI magneto 5 Ignition coil 6 Spark plug 7 CDI unit COLOR CODE B .
– + ELEC 6 - 2 MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the YZ450F. The microcomputer in the CDI unit detects the e ngine speed and throttle position, thus det ermining the optimum ignition timing th rough the entire operating range.
– + ELEC 6 - 3 IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of th e malfunctioning engine being attributa ble to ignition system failure and for ch ecking the spark plug wh ich will not spark.
6 - 4 – + ELEC IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (igni- tion checker 2 ) as shown. • Ignition coil 3 • Spark plug 4 È For USA and CDN É Except for USA and CDN 4.
6 - 5 – + ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Remove the ignition coil cap. 2. Inspect: • Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester ( – ) lead → Black lead 2 Primary coil resistance Tester selector position 0.
6 - 6 – + ELEC IGNITION SYSTEM 2. Inspect: • Source coil 1 resistan ce Out of specification → Replace. 3. Inspect: • Source coil 2 resistan ce Out of specification → Replace.
– + ELEC 6 - 7 TPS (THROTTLE POSITION SENSOR) SYSTEM EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM INSPECTION STEPS If the TPS will not operate, use the follo wing inspection steps. *marked: Refer to “ IGNITION SYSTEM ” section. N OTE: Use the following special tools in this inspect ion.
6 - 8 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM HANDLING NOTE CAUTION: Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance.
6 - 9 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 3. Inspect: • TPS coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position . Out of specification → Replace.
6 - 10 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 4. Adjust: • Idle speed Refer to “ IDLE SPEED ADJUSTMENT ” section in the CHAPT ER 3. 5. Insert the thin electric conductors 2 (lead) into the TPS coupler 1 , as sho wn, and connect the tester to them.
6 - 11 – + ELEC TPS (THROTTLE POSITION SENSOR) SYSTEM 8. Tighten: • Screw (TPS) 1 9. Stop the engine. 1 EC694000 TPS INPUT VOLTAGE INSPECTION 1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: • TPS input voltage Out of specification → Replace the CDI unit.
7 - 1 TUN EC700000 TUNING EC710000 ENGINE Carburetor setting • The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is nec- essary to take into consideration the air pres- sure, ambient temperature, humidity, etc., when adjusting the carburetor.
7 - 2 TUN CAUTION: • The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor.
7 - 3 TUN SETTING Effects of the setting parts on the throttle valve opening 1 Pilot screw /pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet È Closed É Fully open 1/2 3/4 1/4 1/8 1 2 3 4 ÈÉ Main system The FLATCR carburetor has a primary main jet.
7 - 4 TUN SETTING Pilot system The FLATCR carburetor is manufactured with a pilot screw. The pilot screw adjustment ranges from fully closed throttle to 1/4 open throttle. Main jet adjustment The richness of the air-fuel mixture at full throt- tle can be set by changing the main jet 1 .
7 - 5 TUN SETTING Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1 . Turning in the p ilot screw will make the mixture lean at low speeds, and turning it out will enrich it.
7 - 6 TUN SETTING Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjust- ing the pilot jet 1 .
7 - 7 TUN Jet needle adjustment The jet needle is adjusted by changing it. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper sta rting positions. <Example> NFLR - 4 Clip position Diameter a of straight portio n b Reference needle c 0.
7 - 8 TUN Leak jet adjustment (accelerator pump adjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump.
7 - 9 TUN SETTING Carburetor setting parts Part name Size Part number Main jet Rich (STD) Lean #178 #175 #172 #170 #168 #165 #162 #160 #158 #155 #152 4MX-14943-93 4MX-14943-42 4MX-14943-92 4MX-14943-4.
7 - 10 TUN Examples of carburetor setting depending on symptom This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the eng ine. Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug Lean mixture Increase main jet calibration no.
7 - 11 TUN EC720000 CHASSIS EC71P00 2 Selection of the secondary reduction ratio (Sprocket) <Requirement for selection of secondary gear reduction ratio> • It is generally said that the secondary gear ratio should be re duced for a longer str aight portion of a speed co urse and should be increased for a course with many corners.
7 - 12 TUN SETTING EC72N000 Drive and driven sprockets setting pa rts Part name Size Part number Drive sprocket 1 (STD) 14T 9383E-14215 Driven sprocket 2 (STD) 47T 48T 49T 50T 51T 52T 1C3-25447-00 1C3.
7 - 13 TUN SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider ’ s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics • Change the fork oil amount.
7 - 14 TUN SETTING EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the spacer 2 and fork spring 3 . CAUTION: Do not install three or more adjustment washers for each front fork. W ARNING Always adjust each front fork to the same setting.
7 - 15 TUN 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface o r in a vibrating handlebar. To set a stiff spring: • Change the rebound damping.
7 - 16 TUN EC72P00 0 Front fork setting parts • Adjustment wa sher 1 • Front fork spring 2 * For EUROPE N OTE: The I.D. mark (slits) a is proved on the end of the spring. TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 1C3-23364-00 TYPE SPRING RATE SPRING PART NUMBER I.
7 - 17 TUN EC72C001 Choosing set length 1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length a between the rear wheel axle center and the rear fender hold- ing bolt.
7 - 18 TUN SETTING EC72G00 1 Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 ~ 100 mm (3.5 ~ 3.9 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load.
7 - 19 TUN SETTING EC72Q00 0 Rear shock absorber setting parts • Rear shock spri ng 1 [Equal pitch spring] *For EUROPE [Unequal pitch spring] N OTE: • The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres- sion.
7 - 20 TUN SETTING EC72H002 Suspension setting • Front fork N OTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adju stment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.
7 - 21 TUN SETTING • Rear shock absorber N OTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adju stment procedure given in the same chart. • Adjust the rebound damping in 2-click incre ments or decrements.
PRINTED IN JAPAN 2004.06-1.9 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN.
Un point important après l'achat de l'appareil (ou même avant l'achat) est de lire le manuel d'utilisation. Nous devons le faire pour quelques raisons simples:
Si vous n'avez pas encore acheté Yamaha YZ450FT c'est un bon moment pour vous familiariser avec les données de base sur le produit. Consulter d'abord les pages initiales du manuel d'utilisation, que vous trouverez ci-dessus. Vous devriez y trouver les données techniques les plus importants du Yamaha YZ450FT - de cette manière, vous pouvez vérifier si l'équipement répond à vos besoins. Explorant les pages suivantes du manuel d'utilisation Yamaha YZ450FT, vous apprendrez toutes les caractéristiques du produit et des informations sur son fonctionnement. Les informations sur le Yamaha YZ450FT va certainement vous aider à prendre une décision concernant l'achat.
Dans une situation où vous avez déjà le Yamaha YZ450FT, mais vous avez pas encore lu le manuel d'utilisation, vous devez le faire pour les raisons décrites ci-dessus,. Vous saurez alors si vous avez correctement utilisé les fonctions disponibles, et si vous avez commis des erreurs qui peuvent réduire la durée de vie du Yamaha YZ450FT.
Cependant, l'un des rôles les plus importants pour l'utilisateur joués par les manuels d'utilisateur est d'aider à résoudre les problèmes concernant le Yamaha YZ450FT. Presque toujours, vous y trouverez Troubleshooting, soit les pannes et les défaillances les plus fréquentes de l'apparei Yamaha YZ450FT ainsi que les instructions sur la façon de les résoudre. Même si vous ne parvenez pas à résoudre le problème, le manuel d‘utilisation va vous montrer le chemin d'une nouvelle procédure – le contact avec le centre de service à la clientèle ou le service le plus proche.
