Сервисный мануал yamaha wr450f на русском

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5TJ-28199-45 WR450F OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH MANUAL DE SERVICIO DEL PROPIETARIO PRINTED IN JAPAN 2007.10-1.6 × 1 CR (E,F,G,S) WR450F PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN 2008 2008[…]

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WR450F 5TJ-28199-45-E0 2008 OW NER’S SERVICE MANUAL[…]

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WR450F OWNER’S SERVICE MANUAL ©2007 by Yamaha Motor Co., Ltd. 1st Edition, October 2007 All rights reserved. Any reprin ting or unauthorized use wi thout the written permission of Yamaha Motor Co., Ltd. is expressly prohib ited. Printed in Japan[…]

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FOREWORD INTRODUCTION Congratul ations on your pu rchase of a Yamaha WR series. This model is the culmination of Yamaha’ s vast ex- perience in the production of paceset- ting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yama- ha a leader. This manual explain s operation, in- spection, basic […]

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TO THE NEW OWNER This manual will provide you with a good basic understanding of fea- tures, operation, and basic mainte- nance and inspection items of this machine. Please read this manual carefully and comple tely before oper- ating your new machine. If you have any questions regarding the ope ra- tion or maintenan ce of your machine, please cons[…]

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HOW TO READ DESCRIPTIONS To help identify parts and clarify pro- cedure steps, there are exploded dia — grams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram «1» is provided for removal and disassembly jobs. 2. Numbers «2» are given in the or- der of the jobs in the exploded di- agram. A […]

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TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 TUNING 4 ENGINE 5 CHASSIS 6 ELECTRICAL 7[…]

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CONTENTS CHAPTER 1 GENERAL INFOR- MATION DESCRIPTION …………….. 1-1 MACHINE IDENTIFICATION …………. 1-2 INCLUDED PARTS ………. 1-2 IMPORTANT INFORMATION…………….. 1-2 CHECKING OF CONNEC- TION …………………………… 1-3 SPECIAL TOOLS …………. 1-4 CONTROL FUNCTIONS .. 1-8 MULTI-FUNCTION DISPLAY ………………[…]

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1-1 DESCRIPTION GENERAL INFORMATION DESCRIPTION • The machine you have purchased may differ slightly from those shown in the following. • Designs and specifications are subject to chang e without notice. 1. Clutch lever 2. Hot starter lever 3. Engine stop switch 4. Multi-function displ ay 5. Main switch 6. Start switch 7. Front brake lever 8. T[…]

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1-2 MACHINE IDENTIFICATION MACHINE IDENTIFICATION There are two signifi cant 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 au- thorities will need the number to search for and identify yo[…]

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1-3 CHECKING OF CONNECTION ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replace- ments. Use oil and/or grease rec- ommended by Yamaha for assembly and adj ustment. GASKETS, OIL SEALS AND O- RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an en- gine is overhauled. Al l gasket sur- faces, oil seal li[…]

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1-4 SPECIAL TOOLS SPECIAL TOOLS The proper spe cial tools are necessary for complet e and accura te tune-up and asse mbly. Using the correct sp ecial tool will help prevent damage caused by the use of improper too ls or improvised techniques . The shape an d part number used fo r the special tool differ by coun try, so two types are provided. Refer[…]

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1-5 SPECIAL TOOLS Damper rod holder YM-01494, 90890-01494 Use this tool to remove and install the damper rod. Fork seal driver YM-A0948, 90890-01502 This tool is used when install th e fork oil seal. Sheave holder YS-1880-A, 90890-01701 This tool is used for when loosening or tightening the flywheel magneto securing nut. Pocket tester YU-3112-C, 90[…]

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1-6 SPECIAL TOOLS Clutch holding tool YM-91042, 90890-04086 This tool is used to hold the clutch when removing or installing th e clutch boss securing nut. Valve guide remover Intake 4.5 mm (0.18 in) Exhaust 5.0 mm (0.20 in) YM-4116, 90890-04116 YM-4097, 90890-04097 This tool is needed to remove and install the valve gui de. Valve guide installer I[…]

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1-8 CONTROL FUNCTIONS CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch po- sitions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch «1» is equipped with an indicator light «2» to avoid forget- ting to tu[…]

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1-9 MULTI-FUNCTION DISPLAY COLD STARTER KNOB When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which i s con- trolled 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 […]

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1-10 MULTI-FUNCTION DISPLAY To reset the digits, se lect the tripme- ter involved and push the «RST» but- ton for 2 seconds or more. CHANGEOVER TO BASIC MODE/ RACE MODE • Measurement using the time r func- tion can be made in RACE MODE. • Indicator will light up as an identifier that shows RACE MODE has been selected. • RACE MODE ca[…]

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1-11 MULTI-FUNCTION DISPLAY If the machine is run while timer mea — surement is not made, n o change will occur to the digit in tripmeter A (TRIP A). 5. To resume the mea surement, again pushing the «SLCT1» button and «SLCT2» button at the same time. Resetting measurement data Resetting can be made in the follow- ing two manners[…]

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1-12 MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. A short push on the button changes the operation in both arrowed directions. A long push on the button changes the operation in the arrowed direction. A long push on the button changes the operation in both arrowed directions. Met[…]

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1-13 MULTI-FUNCTION DISPLAY The following diagram illustrates th e multi-function display rega rding the direction and operation condition in- volved in each of its functions. A. A short push on the button changes the operation i n the ar- rowed direction. B. A short push on the button changes the operation i n both arrowed di rections. C. A long p[…]

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1-14 STARTING AND BREAK-IN STARTING AND BREAK-IN FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Use only unleaded gaso line. The use of leaded g asoline will cause severe damage to the engi ne inter- nal parts such as valv es, piston rings, and exhaust system, etc. If knocking or pingi ng […]

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1-15 STARTING AND BREAK-IN The engine fails to start Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 10 to 20 times to clear the engine. Then, re start the en- gine. Refer to «Restarting an engine after a fall». Observe the fo llowing break-in procedures during ini tial opera tion to ensu[…]

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1-16 TORQUE-CHECK POINTS TORQUE-CHECK POINTS Concerning the tightening torque, refer to «TIGHTENING TORQUES» section in the CHAPTER 2. Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame […]

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1-17 CLEANING AND STORAGE CLEANING AND STORAGE CLEANING Frequent cleaning of your machine will enhance its appe arance, maintain good overall perfo rmance, and ex- tend the life of many components. 1. Before washing the machine, block off the en d of the exhaust pipe to prevent water from enter- ing. A plastic bag secured with a rubber band may be […]

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2-1 GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR450FX (CDN, AUS, NZ) WR450F (EUROPE, ZA) Model code numbe r: 5TJK (CDN) 5TJL (EUROPE) 5TJM (AUS, NZ, ZA) Dimensions: CDN, ZA AUS, NZ EUROPE Overall length 2,175 mm (85.63 in) 2,190 mm (86.22 in) 2,200 mm (86.61 in) Overall width 825 mm (32.48 in) ←← Overall height 1,[…]

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2-2 GENERAL SPECIFICATIONS (Except for CDN) SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher, JASO standard MA Oil capacity: Engine oil Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (includ[…]

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2-3 GENERAL SPECIFICATIONS Chassis: CDN, ZA AUS, NZ EUROPE Frame type Semi double cra- dle ←← Caster angle 27.3 ° 27.0 ° 26.8 ° Trail 117 mm (4.61 in) 116 mm (4.57 in) 115 mm (4.53 in) Tire: Type With tube Size (front) 80/100-21 51M (CDN, ZA) 90/90-21 54R (AUS, N Z, EUROPE) Size (rear) 110/100-18 64M (CDN, Z A) 130/90-18 69R (AUS, NZ, EUROPE[…]

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2-4 MAINTENANCE SPECIFICATIONS MAINTENANCE S PECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit —- 0.05 mm (0.002 in) Cylinder: Bore size 95.00–95.01 mm (3.7402 –3.7406 in) —- Out of round limit —- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) —- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.[…]

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2-5 MAINTENANCE SPECIFICATIONS Valve, valve seat, valve guide: Valve clearance (cold) IN 0.10–0.15 mm (0.0039–0.0059 in ) —- EX 0.20–0.25 mm (0.0079–0.0098 in ) —- Valve dimensions: «A» head diameter (IN) 26.9–27.1 mm (1.0591–1.0669 in) —- «A» head diameter (EX) 27.9–28.1 mm (1.0984–1.1063 in) —- «B&[…]

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2-6 MAINTENANCE SPECIFICATIONS Stem runout limit —- 0.01 mm (0.0004 in) Valve spring: Free length (IN) 39.46 mm (1.55 in) 38.46 mm (1.51 in) Free length (EX) 37.61 mm (1.48 in) 36.61 mm (1.44 in) Set length ( valve closed ) (IN) 27.87 mm (1.10 in) —- Set length ( valve closed ) (EX) 28.38 mm (1.12 in) —- Compressed force (installed) (IN) 13 0[…]

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2-7 MAINTENANCE SPECIFICATIONS 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 (insta lled) 0.030–0.065 mm (0.0012–0.0026 in) 0.12 mm (0.005 in) 2nd ring: Type Taper —- Dimensions (B × T) 1.00 × 3.35 mm […]

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2-8 MAINTENANCE SPECIFICATIONS Clutch: Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110 in) Quantity 8 —- Clutch plate 1 thickness 1.9–2.1 mm (0.075–0.083 in ) —- Quantity 4 —- Warp limit —- 0.1 mm (0.004 in) Clutch plate 2 thickness 1.5–1.7 mm (0.059–0.067 in ) —- Quantity 3 —- Warp limit —- 0.1 mm (0.[…]

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2-9 MAINTENANCE SPECIFICATIONS Lubrication system: Oil filter type Paper type —- Oil pump type Trochoid type —- Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 in) Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009 in) Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.1 7 mm (0.0067 in) Bypass val[…]

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2-10 MAINTENANCE SPECIFICATIONS CHASSIS Item Sta ndard Limit Steering system: Steering bearing type Taper roller bearing —- Front suspension: CDN AUS, NZ, ZA, EUROPE Front fork travel 300 mm (11.8 in) ← —- Fork spring free length 460 mm (18.1 in) ← 455 mm (17.9 in) Spring rate, STD K = 4.5 N/mm (0.459 kg/ mm, 25.7 lb/in) ← —- Optional s[…]

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2-11 MAINTENANCE SPECIFICATIONS ELECTRICAL Drive chain: Type/manufacturer DID520VM/DAIDO —- Number of links 113 links + joint —- Chain slack 48–58 mm (1.9–2.3 in) —- Chain length (15 links) —- 239.3 mm (9.42 in) Front disc brake: Disc outside dia. × Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm (9.84 × 0.10 in) Pad thickness[…]

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2-12 MAINTENANCE SPECIFICATIONS Charging system: System type AC magneto —- Model (stator)/manufacture r 5TJ 50/YAMAHA —- Normal output 14 V/120 W at 5,000 r/min —- Charging coil resistance (color) 0.28 8–0.432 Ω at 20 °C (68 °F) (White– Ground) —- Lighting coil resistance (color) 0.224–0.336 Ω at 20 °C (68 °F) (Yellow– Ground)[…]

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2-13 TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ — marked portion shall be checked for torque ti ghtening after brea k-in or before each race. *1: Tighten the cylinder head bo lts to 30 Nm (3.0 m•kg, 22 ft•l b) in the prop er tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper t[…]

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2-14 TIGHTENING TORQUES 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 bol t M6 × 1.0 1 10 1.0 7.2 Oil pump cove r M4 × 0.7 1 2 0.2 1.4 Oil pump M6 × 1.0 2 10 1.0 7.2 Oil pump drive gear sha ft M6 × 1.0 1 10 1.0 7.2 Engine oil drain bolt (oil filter) M6 ×[…]

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2-15 TIGHTENING TORQUES CHASSIS △ — marked portion shall be checked for torque ti ghtening after brea k-in or before each race. Part to be tightened Thread size Q’ty Tightening torque Nm m•kg ft•lb △ Upper bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Lower bracket and outer tube M8 × 1.25 4 21 2.1 15 △ Upper bracket and steeri […]

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2-16 TIGHTENING TORQUES △ Driven sprocket and wheel hub M8 × 1.25 6 50 5.0 36 △ Nipple (spoke) — 72 3 0.3 2.2 △ Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2 △ Protector and rear brake calip er M6 × 1.0 2 7 0.7 5.1 Chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13 Engine mounting: △ Engine uppe r bracket and frame[…]

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2-17 TIGHTENING TORQUES 1. First, tighten the steering ring nut app roximately 38 Nm (3.8 m•kg, 27 ft•l b) by using the steerin g nut wrench, then loosen the steering ring nut one turn. 2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb). ELECTRICAL Tighten the rotor nut to 65 Nm (6.5 m•k g, 47 ft•lb), loose n and retighten th[…]

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2-18 TIGHTENING TORQUES GENERAL TORQUE SPECIFICA TIONS This chart specifies torque for stan- dard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener as- semblies in a crisscr oss fashion, in progress[…]

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2-19 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Crankshaft 6. Connecting rod A. From cylinder B. To oil tank[…]

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2-20 LUBRICATION DIAGRAMS 1. Intake camshaft 2. Exhaust camshaft A. To main axle B. From oil pump[…]

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2-21 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 1. Fuel tank breather hose 2. Clamp 3. Diode 4. Hot starter cable 5. Throttle position sensor lead 6. Wire harness 7. Hump (frame) 8. Negative battery lead 9. Starter motor lead 10. Neutral switch le ad 11. AC magneto lead 12. Brake hose 13. Rectifier/regulator lead 14. Carburetor breather hose 15. C[…]

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2-22 CABLE ROUTING DIAGRAM C. Fasten the diode (at the mark- ing), throttle cable and hot start- er cable onto the frame. Locate the clamp end facing towa rd the lower right of the frame and with the tie end facing downward . D. Fasten the wire harness, throttle position sensor lead and clutch cable onto the frame. Pass the clamp through the hole i[…]

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2-23 CABLE ROUTING DIAGRAM 1. Throttle cable (pull) 2. Throttle cable (return) 3. Catch tank hose 4. Ignition coil 5. Clamp 6. Air induction hose (air cut-off valve — rear of cylinder he ad) 7. Catch tank breather hose A. Cross the pull and push throttle cables. B. Fasten the catch tank ho se and air induction hose (air cut-off valve-rear of cylind[…]

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2-24 CABLE ROUTING DIAGRAM 1. Brake ma ster cylinder 2. Brake hose holder 3. Brake ho se A. Install the brake hose so that its pipe portion directs as shown and lightly touches the projec- tion on the brake caliper. B. Pass the brake hose into the brake hose holders. C. If the brake hose contacts the spring (rear shock absorber), correct its twist.[…]

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2-25 CABLE ROUTING DIAGRAM 1. Clamp 2. Positive battery lead 3. Battery 4. Negative battery lead 5. Taillight coupler 6. CDI unit coupler (6-pin) 7. CDI unit coupler (3-pin) 8. CDI unit coupler (6-pin) A. Fasten the wire harness to th e upper engine bracket (left side). Locate the clamp end fa cing to- ward the upper side of the frame with the tie […]

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2-26 CABLE ROUTING DIAGRAM E. Connect the wire harness to the starter relay. F. Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightly enough not to crush it. Locate the clamp end facing towa rd the rear of the frame with the tie end facing downward.[…]

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2-27 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clamp 3. Brake ho se 4. Clutch cable 5. Hose guide 6. Main switch coupler 7. Wire harness 8. Headlight coupler 9. Hot starter cable 10. Multi-function displ ay bracket 11. Main switch 12. Upper bracket 13. Clutch switch coupler 14. Engine stop switch coupler 15. Multi-function display cou pler 16. Sta[…]

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2-28 CABLE ROUTING DIAGRAM D. Secure the coupl er by inserting it into the multi-function display bracket. E. Pass the throttle cables, clutch cable and hot starter cable be- tween the upper bracket and multi-function displ ay bracket. F. Fasten the multi-function display leads to the bracket. Cut off the tie end. G. Secure the coupler by pushing i[…]

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3-1 MAINTENANCE INTERVALS REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE IN TERVALS The following schedule is intended as a gen eral guide to maint enance and l ubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual u sage will alter the requ ired maintenance and lubrication intervals. If you are a dou[…]

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3-2 MAINTENANCE INTERVALS CLUTCH Inspect and adjust ●● Insp ect housing, friction plate, clutch plate and spring. Replace ● TRANSMISSION Inspect ● Replace bearing ● SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect ● Inspect wear. ROTOR NUT Retighten ●● MUFFLER Inspect and retighten ●● Clean ● Replace ● CRANK Inspect and clean ●●[…]

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3-3 MAINTENANCE INTERVALS FUEL TANK, COCK Clean and insp ect ●● BRAKES Adjust lever position a nd pedal height ●● Lubricate pivot point ●● Check brake disc surface ●● Check fluid level and leakage ●● Retighten brake d isc bolts, cali- per bolts, master cylinder bolts and union bolts ●● Replace pads ● Replace brake fluid ?[…]

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3-4 MAINTENANCE INTERVALS TIRE, WHEELS Inspect air pressure , wheel run- out, tire wear and spoke loose- ness ●● Retighten sprocke t bolt ●● Inspect bearings ● Replace bearings ● Lubricate ● Lithium ba se grease THROTTLE, CONTROL CABLE Check routing and connectio n ●● Lubricate ●● Yamaha cable lube or SAE 10W-30 motor oil HOT […]

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3-5 PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in goo d operating condition. Before using this machine, ch eck the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Coolant Check that coolant is fill ed up to the ra[…]

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3-6 ENGINE ENGINE REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q’ty Remarks Turn the fuel cock to «OFF». Disconnect the fuel hose. 1S e a t 1 2 Air scoop (left and right) 2 3 Bolt (fuel tank) 2 4 Fuel tank 1 5 Left side cover 1 Open the air filter case cover. 6 Right side cover 1 Refe r to removal section. 7 Headlight[…]

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3-7 ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover «1» Draw the side cover backward to re- move it because its claw «a» is insert- ed in the air filter case.[…]

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3-8 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q’ty Remarks Right side cover Refer to «REMOVING THE SEAT, FUEL TANK AND SIDE COVERS» section. 1 Bolt (silencer clamp) 1 Onl y loosening. 2 Bolt [silencer (front)] 1 3 Bolt [silencer (rear)] 1 4 Collar 1 5 Silencer 1 6 Silencer clamp 1 7 Nut (exhaust pipe) 1 8 Bolt (ex[…]

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3-9 ENGINE CHECKING THE SILENCER AND EXHAUST PIPE 1. Inspect: • Gasket «1» Damage → Replace. INSTALLING THE SILENCER AND EXHAUST PIPE 1. Install: • Gasket • Exhaust pipe «1» • Nut (exhaust pipe) «2» • Bolt (exhaust pipe) «3» First, temporarily tighten the nut (ex- haust pipe), then tighten the bol[…]

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3-10 ENGINE Handling note s of coolant: The coolant is harmful so it should be handled with sp ecial care. • When cool ant splashes to your eye. Thoroughly wash your eye wi th water and see your do ctor. • When cool ant splashes to your clothes. Quickly wash it away with water and then with soap. • When co olant is swallowed . Quickly make hi[…]

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3-11 ENGINE 2. Adjust: • Throttl e grip free play Throttle grip free play adjus tment steps: a. Slide the adjuster cover. b. Loosen the locknut «1». c. Tu rn the adjuster «2» until the specified free play is obtained. d. Tighten the lockn ut. Before adjusting the th rottle cable free play, the engine idle speed should be adjus[…]

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3-12 ENGINE 5. Inspect: • Air filter element Damage → Replace. 6. Apply: • Foam-air-filter oil or equivalent oil to the el ement • Squeeze out the e xcess oil. Ele- ment shoul d be wet but not drip- ping. • Wipe off the oil left on the element surface using a clean dry cloth. (Ex- cess oil in the element may ad- versely affect engine star[…]

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3-13 ENGINE • Do not add any chemical add i- tives or use oils with a grade of CD «a» or higher. • Do not use oi ls labeled «ENERGY CONSERVING II» «b» or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. • Do not allow foreign material to enter the crankcase. 5. Start the en[…]

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3-14 ENGINE ADJUSTING THE PILOT SCREW 1. Adjust: • Pilot screw «1» Adjustme nt steps: To optimize the fuel flo w at a smaller throttle opening, e ach machine’s pilot screw has been individuall y set at the factory. Before adju sting the pilo t screw, turn it in fully and count the number of turns. Record this number as the factory-[…]

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3-15 ENGINE 5. Adjust: • Valve clearance Adjustme nt steps: a. Remove the camshaft (intake and exhaust). Refer to «CAMSHAFTS» section in the CHAPTER 5. b. Remove the valve lifters «1» and the pads «2». • Place a rag in the timing chain space to prevent pads from falling into the crankcase. • Identity each valve l[…]

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3-16 ENGINE INTAKE EXHAUST[…]

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3-17 CHASSIS CLEANING THE SPARK ARRESTER (For USA) • Be sure the exhaust pipe and si- lencer a re cool before cleaning the spark arre ster. • Do not sta rt the engine whe n cleaning the exhaus t system. 1. Remove: • Screw (silencer ca p) «1» 2. Remove: • Bolt (spark arrester) «1» 3. Remove: • Tail pipe «1» ?[…]

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3-18 CHASSIS 2. Remove: • Brake lever cover 3. Adjust: • Brake lever position Brake lever position adjustment steps: a. Loosen the locknut «1». b. Turn the adjusti ng bolt «2» until the lever position «a» is within speci- fied position. c. Ti ghten the locknut. Be sure to tighten the locknut, as it will cause poor […]

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3-19 CHASSIS i. Insta ll the brake caliper «8» and tighten the pad pin «9». j. Insta ll the pad pin plug «10». 3. Inspect: • Brake fluid level Refer to «CHECKING THE BRAKE FLUID LEVEL» section. 4. Check: • Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to «BLEEDING THE […]

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3-20 CHASSIS 3. Inspect: • Brake fluid level Refer to «CHECKING THE BRAKE FLUID LEVEL» section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to «BLEEDING THE HY- DRAULIC BRAKE SYSTEM» sec- tion. CHECKING THE REAR BRAKE PAD INSULATOR 1. Remove: • Brake pad Refer to «CHECKING[…]

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3-21 CHASSIS When installing th e drive chain, apply the lithium soap base grease on th e chain joint and O-rings. 7. Install: • Link plate • Press the link plate onto the chain joint using a drive chain riveter «5». • Rivet the end of the chain joint us- ing a drive chai n riveter. • After riveting the chain joint, make sure its […]

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3-22 CHASSIS 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove the air bleed screw «1» and release the internal pressure from the front fork. 3. Install: • Air bleed screw ADJUSTING THE FRONT FORK REBOUND DAMPING FORCE 1. Adjust: • Rebound dampin g force By turning the adjuster «1». • STAND[…]

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3-23 CHASSIS Never attempt to turn the adjuster beyond the maximum or minimum setting. 5. Tighten: •L o c k n u t 6. Install: • Rear frame (upper) • Rear frame (lower) ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE 1. Adjust: • Rebound dampin g force By turning the adjuster «1». • STANDARD POSITION: This is the position[…]

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3-24 CHASSIS CHECKING THE TIRE PRESSURE 1. Measure: • Tire pressure Out of specification → Adjust. • Check the tire while it is cold. • Loose bead stoppers a llow the tire to slip off its position on t he rim when the tire pressure is low. • A tilted tire valve stem indicates that the tire slips off its position on the rim. • If the tir[…]

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3-25 CHASSIS • The handlebar upper holder should be installed with the punched mark «a» forward. • Install the handleb ar so that the marks «b» are in place on both sides. • Install the han dlebar so that the pro- jection «c» of the handlebar upper holder is positioned at the mark on the handlebar a s shown. • […]

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3-26 CHASSIS LUBRI CATION To ensure smooth operation of all components, lubricate your machine during setup, afte r break-in, and after every race. 1. All control cable 2. Clutch lever pivot 3. Shift pedal pivot 4. Footrest pivot 5. Throttle-to-handlebar contact 6. Drive chain 7. Tube guide ca ble winding por- tion 8. Throttle cable end 9. Clutch c[…]

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3-27 ELECTRICAL ELECTRICAL CHECKING THE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode «1» Wear/damage → Replace. • Insulator color «2» Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. When the engine runs for many hours at low speeds, the spark plug […]

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3-28 ELECTRICAL 3. Remove: • Battery band •B a t t e r y 4. Measure: • Battery charge Measurement steps: a. Connect a pocket tester «1» to the battery terminals. • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the vol t- age when the positive terminal is disconnected). • No chargin[…]

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3-29 ELECTRICAL Charging method using a variabl e voltage charger[…]

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3-30 ELECTRICAL Charging method usin g a constant voltage charger[…]

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3-31 ELECTRICAL 6. Install: •B a t t e r y • Battery band 7. Connect: • Battery leads (to the batte ry terminals) First, connect the positiv e lead «1», then the negative lead «2». 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • Battery terminal 10.[…]

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3-32 ELECTRICAL ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (ve rtically) Adjusting steps: a. Turn the adjustin g screw «1» in di- rection «a» or «b». Direction «a» Headlight beam is raised. Direction «b» Headlight beam is lowered.[…]

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4-1 ENGINE TUNING ENGINE CARBURETOR SETTING • The air/fuel mixture will vary de- pending on atmospheric conditi ons. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, hu midity, etc., when adjusting the carburetor. • Perform a test run to check for prop- er engine performance (e.g., throt- tle response[…]

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4-2 ENGINE ADJUSTING THE PILOT JET The richness of the air-fuel mixtu re with the throttle open 1/4 or less can be set by adjusti ng the pilot jet «1». Effects of adjusting the pilot jet (reference) A. Idle B. Fully open 1. #48 2. #42 3. #45 ADJUSTING THE JET NEEDLE GROOVE POSITION Adjusting the jet needl e «1» position affects […]

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4-3 ENGINE CARBURETOR SETTING PARTS Main jet Size Part number (-14943-) Rich #185 4MX-44 #182 4MX-94 #180 4MX-43 #178 4MX-93 #175 4MX-42 #172 4MX-92 #170 4MX-41 #168 4MX-91 #165 4MX-40 (STD) #162 4MX-90 *(STD) Lean #160 4MX-39 Pilot jet Size Part number (-14948-) Rich #55 4MX-09 #52 4MX-08 #50 4MX-07 *(STD) #48 4MX-06 (STD) Lean #45 4MX-05 Jet need[…]

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4-4 ENGINE EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM * This should be taken simply for an example. It is necessary to set the carbureto r while checking the operating conditions of the engine. Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug ↓ Lean mixture Increase main jet cal ibration no. (Gra[…]

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4-5 CHASSIS CHASSIS SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) <Requirement for selection of sec- ondary gear reduction ra tio> • It is generally said that the second- ary gear ratio should be reduced for a longer straight portion of a speed course and should be in creased for a course with many corners. Actual — ly, however, as […]

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4-6 CHASSIS A. Air spring characteristics in relation to oil l evel change B. Load C. Stroke 1. Max. oil level 2. Standard oil level 3. Min. oil level ADJUSTING THE SPRING PRELOAD The spring preload is adjusted by in- stalling the adjustment washer «1 » be- tween the fork spring «2» and damper rod «3». Do not install t[…]

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4-7 CHASSIS 2. Setting of damping force • Change the rebound damping. • Change the compression damp- ing. CHOOSING SET LENGTH 1. Place a stand or bl ock under the engine to put the rear wheel above the floor, and measure the length «a» between the rear wheel axle center and the re ar fender holding bolt. 2. Remove the stand or bl ock […]

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4-8 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure gi ven in the same chart. • Before any change, set t he rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Symptom Section[…]

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4-9 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure gi ven in the same chart. • Adjust the rebound damping in 2-click increments or decrements. • Adjust the low compression damping in 1-click incre[…]

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5-1 RADIATOR ENGINE RADIATOR REMOVING THE RADIATOR Order Part name Q’ty Remarks Drain the coolant. Refer to «CHANGING THE COOLANT» sec — tion in the CHAPTER 3. Seat, fuel tank and left side cover Refer to «REMOVING THE SEAT, FUEL TANK AND SIDE COVERS» section in the CHAPTER 3. Exhaust pipe Refer to «REMOVING THE EXHAUS[…]

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5-2 RADIATOR 11 Pipe 1/O-ring 1/1 12 Catch tank breather hose 1 13 Catch tank 1 Order Part name Q’ty Remarks[…]

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5-3 RADIATOR HANDLING NOTE Do not remove the radiator cap when the engine and ra diator are hot. Scaldi ng hot fluid and ste am may be blown out under pressure, which could ca use serious in jury. When the engin e has cooled, open the radiator cap by th e following procedure: Place a thick rag, like a towel, over the radiator cap, sl owly rotate th[…]

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5-4 CARBURETOR CARBURETOR REMOVING THE CARBURETOR Order Part name Q’ty Remarks Seat and fuel ta nk Refer to «REMOVING THE SEAT, FUEL TANK AND SIDE COVERS» section in the CHAPTER 3. Rear shock absorber Refer to «REAR SHOCK ABSORBER» sec- tion in the CHAPTER 6. 1C l a m p 2 2 Throttle position sensor lead coupler 1 3 Throttle[…]

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5-5 CARBURETOR 13 Bracket (cylinder head breather pipe) 1 14 Carburetor joint 1 Order Part name Q’ty Remarks[…]

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5-6 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q’ty Remarks 1 Carburetor breather hose 4 2 Valve lever housing cover 1 3 Screw (throttle shaft) 1 4 Throttle valve 1 5 Need le holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8S p r i n g 1 9 Diaphragm (accelerator pump) 1 10 Air cut valve cover 1 11 Spring (air cut valve) 1 12 Di[…]

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5-7 CARBURETOR 19 Main jet 1 20 Needle jet 1 21 Spacer 1 22 Pilot jet 1 23 Starter jet 1 24 Push rod 1 Pull the push rod. 25 Throttle shaft assembly 1 26 Push rod link lever assembly 1 27 Pilot air jet 1 28 Cold starter plunger 1 Order Part name Q’ty Remarks[…]

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5-8 CARBURETOR HANDLING NOTE Do not loosen th e screw (throttle position sensor) «1» except when changing the th rottle position sen- sor due to failur e because it will cause a drop in engine pe rfor- mance. REMOVING THE PILOT SCREW 1. Remove: • Pilot screw «1» To optimize th e fuel flow at a small throttle opening, e ach mac[…]

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5-9 CARBURETOR e. If both are fine, adjust the float height by bending th e float tab «b» on the float. f. Recheck the float height. CHECKING THE FLOAT 1. Inspect: • Float «1» Damage → Replace. CHECKING THE STARTER PLUNGER 1. Inspect: • Cold starter plunger «1» • Hot starter plunger «2» Wear/damage ?[…]

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5-10 CARBURETOR • Apply the fluoro chemical grease on the bearings. • Fit the projection «a» on the throttle shaft assembly into the slot «b» in the throttle posit ion sensor. • Make sure the stopper «c» of the spring fits into the recess in the car- buretor . • Turn the throttle shaft assembl y left while hold[…]

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5-11 CARBURETOR 17. Install: • Throttle valve assembly «1» • Screw (throt tle shaft) «2» Install the valve lever rollers «3» into the slits «a» of the throttle valve. 18. Install: • O-ring «1» • Valve lever housing cover «2» • Bolt (valve lever housing cov er) «3» 19. I[…]

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5-12 CARBURETOR 7. Install: • Throttle cable cover «1» • Bolt (thr ottle cable cover) «2» 8. Install: • Throttle po sition sensor lead cou- pler «1» • Clamp «2 » Refer to «CABLE R OUTING DIA- GRAM» section in the CHAPTER 2. 9. Install: • Clamp «1 » Refer to «CABLE R OUTING D[…]

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5-13 AIR INDICTOIN SYSTEM AIR INDICTOIN SYSTEM REMOVING THE AIR INDUCTION SYSTEM Order Part name Q’ty Remarks 1 Bracket 1 2 Air cut-off valve assembly 1 3 Air induction hose (ai r cut-off valve — front of cyl- inder head) 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose (air cut-off valve — rear of cylin- der head) 1 7 Air induction ho[…]

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5-14 AIR INDICTOIN SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: • Operation of air cut valve Pass air through the pipe and check the air cut valve for opera- tion. Does not meet the followi ng con- dition → Replace the air cut val[…]

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5-15 CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q’ty Remarks Seat and fuel ta nk Refer to «REMOVING THE SEAT, FUEL TANK AND SIDE COVERS» section in the CHAPTER 3. Air cut-off valve assembly Refer to «AIR INDUCTION SYSTEM» section. Engine upper bracket (right) Refer to «ENGINE REMOVAL» se […]

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5-16 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q’ty Remarks 1 Timing mark accessing screw 1 Refer to removal section. 2 Crankshaft end accessing screw 1 Refer to removal section. 3 Timing chain tensioner cap bolt 1 Refer to removal section. 4 Timing chain tensioner 1 Refer to removal section. 5 Gasket 1 Refer to removal section. 6 Bolt […]

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5-17 CAMSHAFTS REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw «1» • Crankshaft end accessing screw «2» 2. Align: • T.D.C. mark With align mark. Checking steps: a. Turn the crankshaft counterclock- wise with a wren ch. b. Align the T.D.C. mark «a» on th e rotor with the align mark «b» on […]

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[…]

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5-19 CAMSHAFTS Do not turn the cranksha ft during the camshaft insta llation. Damage or improper valve timing will re- sult. d. Install the clips, camshaft caps «4» and bolts (camshaft cap) «5». • Before removing the clip s, cover the cylinder head with a clean rag to prevent the clips from into the cylin- der head cavity. •[…]

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5-20 CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb ) in the proper ti ghtening sequenc e, remove and retighten the cylinder head bolts to 20 Nm (2.0 m•kg , 14 ft•lb) in the prop er tightening sequ ence, and then tighten th e cylinder head bolts further to reach the specif[…]

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5-21 CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • Carbon deposits (from the com- bustion chambers) Use a rounded scraper. Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seats 2. Inspect: • Cylinder head Scratches/damage → Replace. 3. Measure: • Cylinder head warpage Out of specifi[…]

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5-22 CYLINDER HEAD 3. Install: • Bolt (cylinder head) «1» Bolt (cylinder head): 10 Nm (1.0 m•kg, 7.2 ft•lb)[…]

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5-23 VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q’ty Remarks Cylinder head Refer to «CYLINDER HEAD» section. 1 Valve lifter 5 Refer to removal sectio n. 2 Adjusting pad 5 Refer to removal section. 3 Valve cotter 10 Refer to removal section. 4 Valve spring retainer 5 5 Valve[…]

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5-24 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter «1» • Pad «2» Identify each lifter «1» and pad «2» po- sition very carefully so that they can be reinstalled in their original pla ce. 2. Check: • Valve sealing Leakage at the valve seat → In- spect the […]

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5-25 VALVES AND VALVE SPRINGS 4. Measure: • Margin thickness «a» Out of specification → Replace. 5. Measure: • Runout (valve stem) Out of specification → Replace. • 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 th[…]

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5-26 VALVES AND VALVE SPRINGS CHECKING THE VALVE SPRINGS 1. Measure: • Valve spring free length «a» Out of specification → Replace. 2. Measure: • Compressed spring force «a» Out of specification → Replace. b. Installed length 3. Measure: • Spring tilt «a» Out of specification → Replace. CHECKING THE VALVE L[…]

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5-27 CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q’ty Remarks Cylinder head Refer to «CYL INDER HEAD» section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Piston pin clip 2 Refer to removal section. 6 Piston pin 1 Refer to removal section. 7 Piston 1 Refer to removal sectio[…]

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5-28 CYLINDER AND PISTON REMOVING THE PISTON AND PISTON RING 1. Remove: • Piston pin clip «1» • Piston pin «2» • Piston «3» • Put identification marks on each piston head for reference during re- installation. • Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groov[…]

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5-29 CYLINDER AND PISTON 3. Measure: • Ring end gap Out of specification → Replace. You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. CHECKING THE PISTON PIN 1. Inspect: • Piston pin Blue discoloration/gro oves → Re- place, then inspect t[…]

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5-30 CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q’ty Remarks Drain the engine oil . Refer to «CHANGING THE ENGINE OIL» section in the CHAPTER 3. Brake pedal Refer to «ENGINE REMOVAL» section. Clutch cable Disconnect at engine side. 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 5 Pressure plate 1 6 Push […]

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5-31 CLUTCH 14 Nut (clutch boss) 1 Refer to removal section. 15 Lock washer 1 Refer to removal sectio n. 16 Clutch boss 1 Refer to removal section. 17 Thrust washer 1 18 Primary driven gear 1 19 Push lever shaft 1 Order Part name Q’ty Remarks[…]

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5-32 CLUTCH REMOVING THE CLUTCH BOSS 1. Remove: •N u t » 1 » • Lock washer «2» • Clutch boss «3» Straighten the lock washer tab and use the clutch holding tool «4» to hold the clutch boss. A. For USA and CDN B. Except for USA and CDN CHECKING THE CLUTCH HOUSING AND BOSS 1. Inspect: • Clutch housing &q[…]

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5-33 CLUTCH 2. Install: • Lock washer «1» • Nut (clutch boss) «2» Make sure to tighten to specifica- tion; otherw ise, it may damage the other part that is fastened togeth- er. • Install the lock washer with its con- caves fitted over the convexes of the clutch boss. • Use the clutch holding tool «3» to hold th[…]

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5-34 OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q’ty Remarks Right engine guard Refer to «ENGINE REMOVAL» section. Drain the engine oil . Refer to «CHANGING THE ENGINE OIL» section in the CHAPTER 3. Drain the coolant. Refer to «CHAN[…]

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5-35 OIL FILTER ELEMENT AND WATER PUMP 9 Gasket 1 10 Dowel pin/O-ring 3/1 11 Impeller 1 Refer to removal section. 12 Washer 1 Refer to removal section. 13 Impeller shaft 1 Refer to removal section. 14 Oil seal 1 1 Refer to removal sectio n. 15 Oil seal 2 1 Refer to removal sectio n. 16 Bearing 1 Refer to removal section. Order Part name Q’ty R[…]

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5-36 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller «1» • Washer «2» • Impeller shaft «3» Hold the impeller shaft on its width across the flats «a» with spanners, etc. and remove the impeller. REMOVING THE OIL SEAL It is not necessary to disassemble the water pump, u[…]

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5-37 OIL FILTER ELEMENT AND WATER PUMP 2. Install: • Right crankcase cover «1» •B o l t » 2 » •B o l t • Apply the engine oil on the impeller shaft end. • When installing the crankcase cov- er onto the crankca se, be sure that the impeller shaft end «2» aligns with the balancer end slot «3». • Tig[…]

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5-38 BALANCER BALANCER REMOVING THE BALANCER Order Part name Q’ty Remarks Primary driven gear Refer to «CLUTCH» secti on. Right crankcase cover Refer to «OIL FILTER ELEMENT AND WA- TER PUMP» section. Stator Refer to «CDI MAGNETO» section. 1 Nut (balancer) 1 Refer to removal section. 2 Nut (primary drive gear) 1 R […]

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5-39 BALANCER REMOVING THE BALANCER 1. Straighten the lock wa sher tab. 2. Loosen: • Nut (balancer) «1» • Nut (primary drive gear) «2» • Nut (balancer shaft driven gear) «3» Place an aluminum plate «a» b etween the teeth of the balancer shaft drive gear «4» and driven gear «5». CHECK[…]

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5-40 OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q’ty Remarks Primary driven gear Refer to «CLUTCH» section. Right crankcase cover Refer to «OIL FILTER ELEMENT AND WA- TER PUMP» section. 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Dowel pin 2 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor[…]

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5-41 OIL PUMP 15 Oil pump drive shaft 1 16 Rotor housing 1 Order Part name Q’ty Remarks[…]

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5-42 OIL PUMP CHECKING THE OIL PUMP 1. Inspect: • Oil pump drive gear • Oil pump drive shaft • Rotor housing • Oil pump cover Cracks/wear/damage → Replace. 2. Measure: • Tip clearance «a» (between the inner rotor «1» and outer rotor «2») • Side clea rance «b» (between the outer rotor «2&quo[…]

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5-43 KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q’ty Remarks Oil pump Refer to «OIL PUMP» section. 1 Kick idle gear 1 2 Kick shaft assembly 1 Ref er to removal section. 3 Spring guide 1 4 Torsion spring 1 5 Ratch et wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Sh[…]

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5-44 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt (stopper lever) 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section. Order Part name Q’ty Remarks[…]

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5-45 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly «1» Unhook the torsion spring «2» from the hole «a» in the crankcase. REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift gui de «1» • Shift lever assembly «2&qu[…]

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5-46 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Install: • Spring «1» • Pawl pin «2» •P a w l » 3 » To shift lever «4». Apply the engine oil on the spring, pawl pin and p awl. 2. Install: • Shift lever assembly «1» To shift guide «2». 3. Insta[…]

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5-47 KICK SHAFT AND SHIFT SHAFT INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear «1» • Washer «2» • Circlip «3» • Apply the e ngine oil on the kick idle gear inner circumference. • Install the kick idle gear with its de- pressed side «a » toward you.[…]

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5-48 AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q’ty Remarks Drain the engine oil . Refer to «CHANGING THE ENGINE OIL» section in the CHAPTER 3. Seat and fuel ta nk Refer to «REMOVING THE SEAT, FUEL TANK AND SIDE COVERS» section in the CHAPTER 3. Di[…]

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5-49 AC MAGNETO AND STARTER CLUTCH Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten th e rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb). 12 Woodruff key 1 13 Starter clutch assembly co ver 1 Refer to removal section. 14 Starter clutch 1 Refer to removal section. 15 Starter clutch drive gear 1 16 Holder 1 17 Pickup coil 1 1[…]

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5-50 AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR 1. Remove: • Nut (rot or) «1» • Washer Use the sheave holder «2». 2. Remove: • Rotor «1» Use the rotor puller «2». REMOVING THE STARTER CLUTCH 1. Remove: • Starter cl utch a ssembly cover «1» Insert a thin screwdriver or the like under th[…]

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5-51 AC MAGNETO AND STARTER CLUTCH • Pass the AC magneto lead «5» un- der the pickup coil. • Pass the AC magneto lead «4» un- der the holder as shown. • Take care not to catch the AC mag- neto lead between crankcase cover ribs. • Tighten the bolt (stator) usi ng the T25 bit. • Apply the sealant to the grommet of the AC[…]

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5-52 AC MAGNETO AND STARTER CLUTCH Install the co ver (idle gear 1) wi th its mark «a» facing upw ard. 11. Connect: • AC magneto lead Refer to «CABLE R OUTING DIA- GRAM» section in the CHAPTER 2. 12. Install: • Shift pedal «1» • Bolt (shift pedal) When installing the shift pedal onto the shift shaft, be su re tha[…]

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5-53 ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the frame. Refer to «HANDLING NOTE». Drain the engine oil . Refer to «CHANGING THE ENGINE OIL» section in the CHAPTER 3. Seat and fuel ta nk Refer to «REMOVING THE SEAT, FUEL TANK AND[…]

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5-54 ENGINE REMOVAL Ignition coil Disconnect the AC magneto lead. Disconnect the starter motor lead. Refer to «ELECTRIC STARTING SYSTEM» section in the CHAPTER 7. Negative battery lead Disconnect at the engine side. 1 Engine guard 1 2 Neutr al switch 1 3 Drive chain sprocket cover 1 4 Nut (drive sprocket) 1 Ref er to removal section. 5 Lo[…]

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5-55 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: • Nut (drive sprocket) «1» • Lock washer «2» • Straighten the lock washer tab . • Loosen the nut while applyi ng the rear brake. 2. Remove: • Drive sprocket «1» • […]

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5-56 ENGINE REMOVAL 2. Install: • Lock washer «1» • Nut (drive sprocket) «2» Tighten the nut while applying the rear brake. Make sure to tighten to specifica- tion; otherw ise, it may damage the other part that is fastened togeth- er. 3. Bend the lock washer tab to lock the nut. 4. Install: • Drive chain sprocket guide •[…]

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5-57 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q’ty Remarks Engine Refer to «ENGINE REMOVAL» section. Piston Refer to «CYLINDE R AND PISTON» section. Balancer Refer to «BALANCER» section. Kick shaft assembly Refer to «KICK SHAFT AND SHIFT SHAFT» section. Se[…]

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5-58 CRANKCASE AND CRANKSHAFT 9 Left crankcase 1 Refer to removal section. 10 Oil strainer 1 11 Balancer shaft 1 Refer to removal section. 12 Crankshaft 1 Refer to removal sectio n. Order Part name Q’ty Remarks[…]

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5-59 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q’ty Remarks Transmission Refer to «TRANSMISSION, SHIFT CAM AND SHIFT FORK» section. Shift cam and shift fork Refer to «TRANSMISSION, SHIFT CAM AND SHIFT FORK» section. 1 Oil seal 3 2 Bearing 10 Refer to remova l section.[…]

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5-60 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase Separation steps: a. Remove the crankcase bolts, hose guide an d clutch cable hold — er. Loosen each bolt 1/4 of a turn at a time and after all the bolts are loos- ened, remove them. b. Remove the right crankcase. • Place the crankcase wi[…]

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5-61 CRANKCASE AND CRANKSHAFT CHECKING THE CRANKSHAFT 1. Measure: • Runout limit «a» • Small end free play limit «b» • Connecting rod big end side clearance «c» • Crank w idth «d» Out of specification → Replace. Use the dial gauge and a thick- ness gauge. CHECKING THE OIL STRAINER 1. Inspect: • Oi[…]

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5-62 CRANKCASE AND CRANKSHAFT 4. Apply: • Sealant On the right crankc ase. Clean the contacting surface of left and right crankcase before applying the sealant. 5. Install: • Dowel pin «1» • O-ring «2» • Right crankcase To left crankcase. • Apply the lithium soap ba se grease on the O-ring. • Fit the right crankca se[…]

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5-63 TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q’ty Remarks Engine Refer to «ENGINE REMOVAL» section. Separate the crankcase. Refer to «CRANKCASE AND CRANK- SHAFT» section. 1 Main axle 1 Refer to remova l section. 2 Drive[…]

Страница 160

5-64 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: • Main axle «1» • Drive axle «2» • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 • Remove assembly with the collar «3» installed to the crankcase. • Remove assembly carefully. Note the position of each part. Pay pa[…]

Страница 161

5-65 TRANSMISSION, SHIFT CAM AND SHIFT FORK • Be sure the circlip sharp-edged cor- ner «a» is po sitioned oppo site side to the washer and gear «b». • Install the circlip with its ends «c» settled evenly on the spline crests. 4. Install: •C o l l a r » 1 » • Apply the lithium soap ba se grease on the […]

Страница 162

6-1 FRONT WHEEL AND REAR WHEEL CHASSIS FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». 1 Bolt (axle holder) 4 Only loosening. 2 Nut (front wheel axle) 1 3 Front wheel axle 1 4 Front wheel 1 5 Speed sensor 1 6 Co[…]

Страница 163

6-2 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». 1 Nut (rear wheel axle) 1 2 Rear whe el axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section. 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8[…]

Страница 164

6-3 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel «1» Push the wheel forward and remove the drive chain «2». REMOVING THE WHEEL BEARING 1. Remove: • Bearing «1» Remove the bearing using a general bearing pu[…]

Страница 165

6-4 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc «1» • Bolt (brake disc) «2» Tighten the bolts in stage, using a crisscross pattern. 3. Install: •C o l l a r » 1 » Apply the lithium soap base grease on the oil seal lip. 4. Install: • Speed sensor «1» • Apply the lithium soap ba se grease on t[…]

Страница 166

6-5 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc «1» • Bolt (brake disc) «2» Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Rear wheel sprocket «1» • Bolt (rear wheel sprocket) «2» • Washer (rear wheel sprocket) «3» • Nut (rear wheel sprocket) «4» […]

Страница 167

6-6 FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». Drain the brake fluid. Refer to removal section. 1 Brake hose hold er (protector) 2 2 Brake hose hold er (brake calipe r) 1 3 Union […]

Страница 168

6-7 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». Rear wheel Refer to «FRONT WHEEL AND REAR WHEEL» section. Drain the brake fluid. Refer to removal section. 1 Brake pedal 1 2 Brake master cylinder 1 3[…]

Страница 169

6-8 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q’ty Remarks A. Front B. Rear AB 1P a d p i n 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Re fer to removal section. 5 Brake caliper piston dust s eal 2 1 Refer to removal section. 6 Brake caliper piston seal 2 1 Refer to removal section.[…]

Страница 170

6-9 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q’ty Remarks A. Front B. Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reserv oir float 1 4 Brake master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers. 6 Washer 1 7 Push rod 1 8 Brake master cylinder kit 1[…]

Страница 171

6-10 FRONT BRAKE AND REAR BRAKE HANDLING NOTE Support the machine securely so there is no dange r of it falling over. DRAINING THE BRAKE FLUID 1. Remove: • Brake master cylinder cap «1» • Protector (rear brake) Do not remove the diaphragm. A. Front B. Rear 2. Connect the transparent hose » 2″ to the bleed screw «1»[…]

Страница 172

6-11 FRONT BRAKE AND REAR BRAKE 4. Inspect: • Brake master cylinder piston «1» • Brake master cylinder cup «2» Wear/damage/score marks → Re- place brake master cylinder kit. A. Front B. Rear CHECKING THE BRAKE CALIPER 1. Inspect: • Brake caliper cylinder inner sur- face «a» Wear/score marks → Replace brake ca[…]

Страница 173

6-12 FRONT BRAKE AND REAR BRAKE 4. Install: • Pad pin plug «4» INSTALLING THE REAR BRAKE CALIPER 1. Install: • Pad support «1» • Brake pad «2» • Pad pin «3» • Install the brake pads with th eir pro- jections «a» into the brake caliper re — cesses «b». • Tempora rily tighten the[…]

Страница 174

6-13 FRONT BRAKE AND REAR BRAKE 2. Install: • Brake lever «1» • Bolt (brake lever) «2» • Nut (brake lever) «3» Apply the silicone grease on the brake lever sliding surface, bolt an d contacting surface of the brake mas- ter cylinder piston. INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washer &[…]

Страница 175

6-14 FRONT BRAKE AND REAR BRAKE 3. Install: • Brake hose hol der «1» • Nut (brake h ose holder) «2» Align the top «a» of the brake hose holder with the paint «b» of the brake hose. 4. Pass the brake hose through the front brake hose guides «1». 5. Install: • Copper washer «1» • Bra[…]

Страница 176

6-15 FRONT BRAKE AND REAR BRAKE 3. Inspect: • Brake fluid level Fluid at lower l evel → Fill up. Refer to «CHECKING THE BRAKE FLUID LEVEL» section in the CHAPTER 3. 4. Install: • Reservoir float (front brake) • Diaphragm • Brake master cylinder cap «1» • Screw (bolt) {brake master cylin- der cap} «2» After […]

Страница 177

6-16 FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». Front wheel Refer to «FRONT WHEEL AND REAR WHEEL» section. Front brake caliper Refer to «FRONT BRAKE AND REAR BRAKE» section. Headlight Handleba[…]

Страница 178

6-17 FRONT FORK DISASSEMBLING THE F RONT FORK Order Part name Q’ty Remarks 1 Front fork cap bolt 1 Refer to removal section. 2 Fork spring 1 Drain the fork oil. 3 Dust seal 1 Refer to removal sectio n. 4 Stopper ring 1 Refer to removal section. 5 Inner tube 1 Refer to removal section. 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal […]

Страница 179

6-18 FRONT FORK HANDLING NOTE Support the machine securely so there is no dange r of it falling over. The front fork requires careful atten- tion. So it is recommended that the front fork be maintained at the deal- ers. To prevent an ac cidental explosion of air, the following instructions should be observed: • The front fork with a built- in pis[…]

Страница 180

6-19 FRONT FORK The bending value is shown by one half of the dial gauge reading. Do not attempt to straighten a bent inner tube as this may dangerous- ly weaken the tube . CHECKING THE OUTER TUBE 1. Inspect: • Outer tub e «1» Score marks/we ar/damage → Re- place. CHECKING THE FRONT FORK CAP BOLT 1. Inspect: • Front fork cap bolt &q[…]

Страница 181

6-20 FRONT FORK 8. Install: • Outer tub e «1» To inner tube «2». 9. Install: • Slide metal » 1″ • Oil seal washer «2» To outer tube slot. Press the slide metal into the outer tube with fork seal driver «3». 10. Install: • Oil seal «1» Press the oil seal into the outer tube with for[…]

Страница 182

6-21 FRONT FORK Be sure to install the spring guide «2» when checking the oil level. Never fail to make the oil level ad- justment between the maximum and minimum level and always ad — just each front fork to the same setting. Uneven adjustmen t can cause poor h andling and loss of stability. 21. Measure: • Distance «a» Out of[…]

Страница 183

6-22 FRONT FORK 3. Adjust: • Front fork top end «a» 4. Tighten: • Pinch bolt (upper bracket) «1» • Pinch bolt (lower bracket) «2» Tighten the lower brac ket to speci- fied torque. If to rqued too much, it may cause the fron t fork to mal- function. 5. Install: • Speed sensor lead «1» • Plate 1 «[…]

Страница 184

6-23 HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q’ty Remarks Headlight 1 Hot starter cable 1 Disconnect at the lever side. 2 Hot start er lever holder 1 3 Clutch cable 1 Disconnect at the lever side. 4 Clutch lever holder 1 Disconnect the clutch switch lead. 5 Engine stop switch 1 Disconnect the engine stop switch lead. 6 Brake[…]

Страница 185

6-24 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER 1. Remove: • Brake master cylinder bracket «1» • Brake master cylinder «2» • Do not let the brake master cylin- der hang on th e brake hose. • Keep the brake master cylin der cap side horizontal to prevent air from coming in. REMOVING THE GRIP 1. Remove: •G r i p «[…]

Страница 186

6-25 HANDLEBAR 5. Install: • Right grip «1» •C o l l a r » 2 » Apply the adhesive o n the tube guide «3». • Before applying the adhesive, wipe off grease or oil on the tube guide surface «a» with a lacquer thinner. • Install the grip to the tube guide so that the grip match mark «b» and tube[…]

Страница 187

6-26 HANDLEBAR 12. Install: • Clutch cable «1» • Hot starter cable «2» Apply the lithium soap base grease on the clutch cable end and hot start- er cable end. 13. Adjust: • Clutch lever free play Refer to «ADJUSTING THE CLUTCH CABLE FREE PLAY» section in the CHAPTER 3. • Hot starter lever free play Refer to &qu[…]

Страница 188

6-27 STEERING STEERING REMOVING THE STEERING Order Part name Q’ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft• lb) Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». Headlight Handlebar Refer[…]

Страница 189

6-28 STEERING 9 Bearing race cover 1 10 Upper bearing 1 11 Lower bearing 1 Refer to removal section. 12 Bearing race 2 Refer to removal sectio n. Order Part name Q’ty Remarks[…]

Страница 190

6-29 STEERING HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE STEERING RING NUT 1. Remove: • Steering ring nut «1» Use the steering nut wrench «2». Support the steering stem so that it may not fall d own. REMOVING THE LOWER BEARING 1. Remove: • Lower bearing «1» Us[…]

Страница 191

6-30 STEERING 6. Install: • Washer «1» 7. Install: • Front fork «1» • Upper bracket «2» • Main switch «3» • Front brake hose guide bracket «4» • Temporarily tighten the p inch bolts (lower brack et). • Do not tighten the pinch bolts (up- per bracket) yet. 8. Install: • Guide (speed s[…]

Страница 192

6-31 SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». Brake hose holder Refer to «FRONT BRAKE AND REAR BRAKE» section. Rear brake caliper Refer to «FRONT BRAKE AND REAR BRAKE» section. Bolt (brake pedal) […]

Страница 193

6-32 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q’ty Remarks 1 Cap 2 Refer to removal section. 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refer to remova l section.[…]

Страница 194

6-33 SWINGARM HANDLING NOTE Support the machine securely so there is no dange r of it falling over. REMOVING THE CAP 1. Remove: • Left cap «1» Remove with a slotted-head screw- driver inserted under the mark » a» on the left cap. REMOVING THE BEARING 1. Remove: • Bearing «1» Remove the bearing by pressing its outer[…]

Страница 195

6-34 SWINGARM INSTALLING THE SWINGARM 1. Install: • Bushing «1» • Thrust bearing «2» • Oil seal «3» •C o l l a r » 4 » To swingarm «5» Apply the molybdenum disulfide grease on the bushin gs, thrust bear- ings, oil seal lips and contact surfaces of the collar and thrust b earing. 2. Install: […]

Страница 196

6-35 SWINGARM 10. Tighten: • Nut (connecting rod) «1» 11. Tighten: • Nut (relay arm) «1» 12. Install: •C a p » 1 » Install the right cap with its mark «a» facing forward. 13. Install: • Bolt (lower chain tensioner) «1» • Washer «2» •C o l l a r » 3 » • Lower chain t[…]

Страница 197

6-36 REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q’ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to «HANDLING NOTE». Seat and side cover Refer to «REMOVING THE SEAT, FUEL TANK AND SIDE COVERS» section in the CHAPTER 3. Silencer Refer to «R[…]

Страница 198

6-37 REAR SHOCK ABSORBER 1 Locking tie 4 2 Taillight coupler 1 3 CDI unit coupler 3 4 Plastic band 1 5 Clamp (air filter joint) 1 Only loosening. 6R e a r f r a m e 1 7 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm. 8 Bolt (rear shock absorber-frame) 1 9 Rear shock absorber 1 10 Locknut 1 Only l oosening. 11 Adjuster 1 Only loosen ing. 1[…]

Страница 199

6-38 REAR SHOCK ABSORBER HANDLING NOTE • Support the machin e securely so there is no danger of it falling over. • This rear s hock absorber is pro- vided with a separate type tank filled with high- pressure nitro- gen gas. To pr event the danger of explosion, read and u nder- stand the follow ing information before handli ng the shock ab- sorb[…]

Страница 200

6-39 REAR SHOCK ABSORBER 3. Install: • Lower bearing «1» Install the bearing by pressing it on the side having the manufacture’ s marks or numbers. INSTALLING THE SPRING (REAR SHOCK ABSORBER) 1. Install: • Spring «1» • Upper spring guide «2» • Lower spring guide «3» 2. Tighten: •A d j u s t e r[…]

Страница 201

6-40 REAR SHOCK ABSORBER 7. Tighten: • Screw (air filter joint) «1» 8. Install: • Plastic band • Taillight coupler • Locking tie Screw (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb)[…]

Страница 202

7-1 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1. Headlight 2. Multi-function displ ay 3. Engine stop switch 4. Clutch switch 5. Diode 6. Starter relay diode 7. Throttle position sensor 8. Starter relay 9. Fuse 10. Starting circuit cut-off relay 11. CDI unit 12. Taillight 13. N[…]

Страница 203

7-2 ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM 1. Headlight 2. Multi-function displ ay 3. Engine stop switch 4. Clutch switch 5. Diode 6. Starter relay diode 7. Throttle position sensor 8. Starter relay 9. Fuse 10. Starting circuit cut-off relay 11. CDI unit 12. Taillight 13. Neutral switch 14. Starter motor 15. AC magneto 16. Re ctifi[…]

Страница 204

7-3 IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfuncti oning engine being attributable to igni tion system failure and for checking the spa rk plug which will not spark. *1 marked: Refer to «CHECKING TH E FUSE» section in the CHAPTER 3. *2 marked: Refer to «CHECKING […]

Страница 205

7-4 IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition co il cap. 3. Connect the dynamic spark tester «1» (ignition ch ecker «2») as shown. • Ignition coil «3» • Spark plug «4» A. For USA and CDN B. Except for USA and CDN 4. Kick the kickstarter crank. 5[…]

Страница 206

7-5 ELECTRIC STARTING SYSTEM 4. Inspect: • Sealed portion of ignition coil «a» • Spark plug terminal pin «b» • Threaded portion of sp ark plug «c» Wear → Replace. CHECKING THE AC MAGNETO 1. Inspect: • Pickup coil resistance Out of specification → Replace. CHECKING THE NEUTRAL SWITCH 1. Inspect: • Neutral […]

Страница 207

7-6 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the fo llowing inspection steps. *1 marked: Refer to «CHECKING TH E FUSE» section in the CHAPTER 3. *2 marked: Refer to «CHECKING AND CHARGIN G THE BATTERY» section in the CHAPTER 3. *3 marked: Refer to «CHECKING THE MAIN SWITCH» s[…]

Страница 208

7-7 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/short-circuit → Repai r or replace. CHECKING THE STARTER MOTOR OPERATION 1. Connect the posi tive battery ter- minal «1» and starter motor lead «2» with a jumper lead » 3″. Not oper[…]

Страница 209

7-8 ELECTRIC STARTING SYSTEM 2. Inspect: • Rubber part «a» Tears/damage → Replace.[…]

Страница 210

7-9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q’ty Remarks Exhaust pipe Refer to «REMOVING THE EXHAUST PIPE AND SILENCER» section in the CHAPTER 3. 1 Starter motor 1[…]

Страница 211

7-10 ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q’ty Remarks 1 Starter motor front cover 1 2 Washer (starter motor front cover) 1 3 Washer 1 4 Circlip 1 5O — r i n g 1 6 Starter motor yoke 1 7 Armature assembly 1 8 Starter motor rear cover 1 9 Brush 2 10 Brush spring 2[…]

Страница 212

7-11 ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit san dpa- per. 2. Measure: • Commutator diameter «a» Out of specification → Replace the starter motor. 3. Measure: • Mica undercut «a» Out of specification → Scrape the mica to the prope r measureme[…]

Страница 213

7-12 ELECTRIC STARTING SYSTEM • For installation, align the proj ec- tions on the washer with the slots in the front cover. • Align the match mark «a» on the starter motor yoke with the match mark «b» on the starter motor front cover. 5. Install: •B o l t » 1 » • O-ring «2» Apply the lithium soap base[…]

Страница 214

7-13 CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the followin g inspection steps. *1 marked: Refer to «CHECKING TH E FUSE» section in the CHAPTER 3. *2 marked: Refer to «CHECKING AND CHARGIN G THE BATTERY» section in the CHAPTER 3. • Remove the following p arts before i nspection. 1. Sea[…]

Страница 215

7-14 CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/short-circuit → Repai r or replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Chargin g voltage Out of specification → If no failure is found in checking the source coil resistance, replace th[…]

Страница 216

7-15 THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position senso r will not operate, use the follo wing inspection steps. Use the following special to ols in this inspection. Check entire ignition system for connection. No good → Repai r or replace. OK ↓ Check throttle position sen sor.(Thrott[…]

Страница 217

7-16 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE Do not loosen th e screw (throttle position sensor) «1» except when changing the th rottle position sen- sor due to failur e because it will cause a drop in engine pe rfor- mance. CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/s[…]

Страница 218

7-17 THROTTLE POSITION SENSOR SYSTEM Measure the output voltage accurate- ly with a digital e lectronic voltmeter that gives an easy reading of a small voltage. 10. Put the aligning marks «a» on the throttle position sensor and car- buretor. 11. Stop the engine. 12. Remove the carburetor. 13. Tighten: • Screw (throttle position sensor) […]

Страница 219

7-18 LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to th e following flow chart when inspect ing the lighting system for possible problems. • Remove the following p arts before i nspection. 1. Seat 2. Fuel tank 3. Left side cover • Use the following special to ols in this inspection. Check the bulb and bulb socket. No goo d → Rep lac[…]

Страница 220

7-19 LIGHTING SYSTEM CHECKING THE TAILLIGHT (LEDs) 1. Disconnect the taillight coupler. 2. Connect two jumper leads «1» from the battery terminals to the respective coupler terminal as shown. 3. Check: • LED (for proper operation) Does not light → Replace the tail — light assemb ly. • A wire that is used as a jumper lead must have a[…]

Страница 221

7-20 SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate , use the following inspection steps. *1 marked: Refer to «CHECKING AND CHARGIN G THE BATTERY» section in the CHAPTER 3. • Remove the following p arts before i nspection. 1. Headlight • Use the following special to ols in this inspection. *1 Ch[…]

Страница 222

7-21 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads con nection Rust/dust/looseness/short-circuit → Repai r or replace. CHECKING THE MULTI-FUNCTION DISPLAY INPUT VOLTAGE 1. Disconne ct the multi-function dis- play coupler. 2. Set the main switch to «ON». 3. Measure: • Multi-function displa[…]

Yamaha WR450F (2012) — page 1

q Read this manual carefull y before operating this vehic le. O WNER’S MANU AL WR450F 1DX-28199-E1 U1DXE1_Hyoshi.indd 1 2012/08/08 17:42:00 …

Yamaha WR450F (2012) — page 2

Q Read thi s ma nu al c aref ull y b ef ore ope rati ng t his vehi c le. Thi s ma nu al s houl d st a y wi th t his vehi c le i f it is sol d. EAU46090 U1DXE1_Hyoshi.indd 2 2012/08/08 17:42:01 …

Yamaha WR450F (2012) — page 3

INTRODUCTION EAU10102 Welcome to the Yamaha world of mot orcycling! As the owner of the WR450F, you are benefiting from Ya maha’s vast experience and newes t technology regarding the de- sign and manufacture of high-qualit y products, which have e arned Yamaha a reputation for dependabilit y. Please take the time to read this manual t horoughly, …

Yamaha WR450F (2012) — page 4

IMPORTANT MANUAL INFORMATION EAU10133 Particularly important informatio n is distingui shed in this manual by the following notations: *Product and specifications are subject to change without notice. This is the saf ety alert symbol. It is us ed to alert yo u to potential per sonal injury hazar ds. Obe y all safet y messages that fo llow thi s sym …

Yamaha WR450F (2012) — page 5

IMPORTANT MANUAL INFORMATION EAU10200 WR450F O WNER’S MANU AL ©2012 b y Y amaha Motor Co., Ltd. 1st edition, J uly 2012 All rights reserved. Any repr inting or unauthorized use without the written permission of Y amaha Motor Co., Ltd. is expressl y prohibited. Printed in Japan. 1DX-9-E1.book 2 ページ ２０ １２年７月３ １日　火曜? …

Yamaha WR450F (2012) — page 6

TABLE OF CONTENTS SAFETY INFORMATION ……………. .. 1-1 DESCRIPTION …………. ……….. ………. 2-1 Left view ………… ………….. ………….. .. 2-1 Right view …………. ………….. …………. 2-2 Controls and instrument s …………. …. 2-3 INSTRUMENT AND CONTROL FUNCTIONS …………… ………….. ….. …

Yamaha WR450F (2012) — page 7

TABLE OF CONTENTS Checking the steering ………………. 6-30 Checking the wheel bearings ……. 6-30 Battery ………. ………….. …………… … 6-30 Replacing the fuse …………………… 6-32 Replacing the headli ght bulb …….. 6-32 Tail/brake light ………………… ……… 6-34 Replacing a turn signal light bulb … …

Yamaha WR450F (2012) — page 8

1-1 1 SAFETY INFORMATION EAU53004 Be a Responsi ble Owner As the vehicle’s owner, you are respon- sible for the safe and proper operation of your motorcycle. Motorcycles are single-track vehicles. Their safe use and operation are de- pendent upon the use of proper riding techniques as well as the expertise of the operator. Every operator should k …

Yamaha WR450F (2012) — page 9

1-2 1 SAFETY INFORMATION motorist’s blind spot. • Never maintain a motorcycle without proper knowledge. Con- tact an authorized motorcycle dealer to inform you on basic motorcycle maintenance. Cer- tain maintenance can only be carried out by certified staff.  Many accidents involve inexperi- enced operators. • Make sure that you are qua li …

Yamaha WR450F (2012) — page 10

1-3 SAFETY INFORMATION 1 unable to save yourself. Also, deadly levels of carbon monoxide can linger for hours or days in enclosed or poorly ventilated areas. If you experience any symptoms of carbon monoxide poison- ing, leave the area immediately, get fresh air, and SEEK MEDICAL TREAT- MENT.  Do not run engine indoors. Even if you try to ventil …

Yamaha WR450F (2012) — page 11

1-4 1 SAFETY INFORMATION mended by Yamaha, even if sold and installed by a Yamaha dealer. Aftermarket Parts , Accessories, and Modifications While you may find aftermarket prod- ucts similar in design and quality to genuine Yamaha accessories, recog- nize that some aftermarket accessories or modifications are not suitable be- cause of potential saf …

Yamaha WR450F (2012) — page 12

1-5 SAFETY INFORMATION 1 tie-downs or suitable straps t hat are attached to solid parts of the motorcycle, such as the frame or upper front fork triple clamp (and not, for example, to rubber-mount- ed handlebars or turn signals, or parts that could break). Choose the location for the straps carefully so the straps will not rub against painted surfa …

Yamaha WR450F (2012) — page 13

2-1 1 2 DESCRI PTION EAU10410 Left view 12 1, 2 3 4, 5 6 7 8 10 9 11 1. F ront f ork compression damping force adjusting screw (page 3-14) 2. Bleed screw (page 3-15) 3. Star ter knob (page 3-12) 4. Batter y (page 6-30) 5. Main fuse (page 6-32) 6. Air filter element (page 6-14) 7. Engine oil check bolt (page 6-8) 8. Shift pedal (page 3-8) 9. Engine …

Yamaha WR450F (2012) — page 14

DESCRIPTION 2-2 1 2 3 4 5 6 7 8 9 EAU10420 Right view 1, 2 3 5 7 8 11 6 10 12 9 4 1. Shock absorber assemb ly comp ression damping force adjusting screw (f or slow compre ssion damping) (page 3-16) 2. Shock absorber assemb ly compression damping force adjusting nut (for f ast compression damping) (page 3-16) 3. Kickstarter (page 3-12) 4. Fuel tank …

Yamaha WR450F (2012) — page 15

DESCRI PTION 2-3 2 3 4 5 6 7 8 9 EAU10430 Controls and instruments 12 3 4 5 6 8 7 1. Clutch lev er (page 3-8) 2. Left handlebar switches (page 3-7) 3. Multi-function display (page 3-2) 4. Main switch (page 3-1) 5. F ront brake fluid reservoir (page 6-23) 6. Right handlebar switches (page 3-7) 7. Brake le ver (page 3-8) 8. Throttle grip (page 6-17) …

Yamaha WR450F (2012) — page 16

3-1 1 2 3 4 5 6 7 8 9 INSTRUMENT AND CONTROL FUNCTIONS EAU10451 Main switch The main switch controls the ignit ion and lighting systems. The various main switch positions are described below. EAU52430 ON All electrical circui ts are supplied with power; the meter lighting , taillight, li- cense plate light and auxiliary light come on, and the engin …

Yamaha WR450F (2012) — page 17

INSTRUMENT AND CONTROL FUNCTIONS 3-2 2 3 4 5 6 7 8 9 EAU11080 High beam indicator light “ ” This indicator light comes on when the high beam of the headlight is switched on. EAU52390 Fuel level warning light “ ” This warning light comes on when the fuel level drops below approximately 3.0 L (0.79 US gal, 0.66 Imp.gal). When this occurs, ref …

Yamaha WR450F (2012) — page 18

INSTRUMENT AND CONTROL FUNCTIONS 3-3 1 2 3 4 5 6 7 8 9 TIP  The multi-function display can be set to the basic mode or the mea- surement mode.  Tripmeter A will automatically re- set to zero when changing from the basic mode to the measure- ment mode or vice versa. Basic mode:  a speedometer  an odometer  two tripmeters (which show t …

Yamaha WR450F (2012) — page 19

INSTRUMENT AND CONTROL FUNCTIONS 3-4 2 3 4 5 6 7 8 9 TIP Indicator “ ” comes on when tripmeter A is selected, and indicator “ ” comes on when tripmeter B is selected. To reset a tripmeter, select it by push- ing the “SLCT 2” button, and then push the “RST” button for at least one sec- ond. Clock The clock displays when the main swit …

Yamaha WR450F (2012) — page 20

INSTRUMENT AND CONTROL FUNCTIONS 3-5 1 2 3 4 5 6 7 8 9 TIP Starting measurement consists of the following two starts, either of which can be selected.  Manual start Starting measurement by the rider himself operating the button. (A long push on the “SLCT 2” button will put measurement on standby.)  Auto start Starting timer measurement au …

Yamaha WR450F (2012) — page 21

INSTRUMENT AND CONTROL FUNCTIONS 3-6 2 3 4 5 6 7 8 9 ton together again. TIP The stopwatch will continue counting when the vehicle is stopped. To stop and/or resume counting, repeat steps 3 and 4. Measurement mode (for ca librating the distance- compensation tripme- ter’s reading) The distance-compensation tripmeter is a feature intended to provi …

Yamaha WR450F (2012) — page 22

INSTRUMENT AND CONTROL FUNCTIONS 3-7 1 2 3 4 5 6 7 8 9 EAU1234B Handlebar switches Left Right EAU12400 Dimmer switch “ / ” Set this switch to “ ” for the high beam and to “ ” for the low beam. EAU12460 Turn signal switch “ / ” To signal a right-hand turn, push this switch to “ ”. To signal a left-hand turn, push this switch to ? …

Yamaha WR450F (2012) — page 23

INSTRUMENT AND CONTROL FUNCTIONS 3-8 2 3 4 5 6 7 8 9 EAU12820 Clutch lever The clutch lever is located at the lef t handlebar grip. To disengage the clutch, pull the lever toward the handle- bar grip. To engage the clutch, release the lever. The lever should be pulled rapidly and released slowly for smooth clutch operation. The clutch lever is equi …

Yamaha WR450F (2012) — page 24

INSTRUMENT AND CONTROL FUNCTIONS 3-9 1 2 3 4 5 6 7 8 9 3. While holding the lever pushed away from the throttle grip, turn the adjusting bolt in direction (a) to in- crease the distance, and in direc- tion (b) to decrease it. 4. Tighten the locknut. 5. Slide the rubber cover to its origi- nal position. EAU12941 Brake pedal The brake pedal is on the …

Yamaha WR450F (2012) — page 25

INSTRUMENT AND CONTROL FUNCTIONS 3-10 2 3 4 5 6 7 8 9 EAU13212 Fuel Make sure there is sufficient gasoline in the tank. W ARNING EWA10881 Gasoline and gasoline vapors are extremely flammable. To avoid fires and explosions and to reduce the risk of injury when refueling, follow these instructions. 1. Before refueling, turn off the en- gine and be su …

Yamaha WR450F (2012) — page 26

INSTRUMENT AND CONTROL FUNCTIONS 3-11 1 2 3 4 5 6 7 8 9 spark plug life and reduce maintenance costs. EAU41360 Fuel tank breather hose Before operating the motorcycle:  Check the fuel tank breather hose connection.  Check the fuel tank breather hose for cracks or damage, and replace it if damaged.  Make sure that the end of the fuel tank b …

Yamaha WR450F (2012) — page 27

INSTRUMENT AND CONTROL FUNCTIONS 3-12 2 3 4 5 6 7 8 9 converter. EAU53230 Starter knob Starting a cold engine requires a richer air-fuel mixture, which is supplied by the starter. Move the knob in direction (a) to turn on the starter. Move the knob in direction (b) to turn off the starter. EAU13650 Kickstarter To start the engine, fold out the kick …

Yamaha WR450F (2012) — page 28

INSTRUMENT AND CONTROL FUNCTIONS 3-13 1 2 3 4 5 6 7 8 9 EAU53100 Steering lock To lock the stee ring 1. Turn the handlebar all the way to the left. 2. Insert the key into the steering lock under the steering head pipe, and then turn it 1/2 turn in either dir ec- tion. 3. Check that the steering is locked, and then remove the key from the lock. To u …

Yamaha WR450F (2012) — page 29

INSTRUMENT AND CONTROL FUNCTIONS 3-14 2 3 4 5 6 7 8 9 To instal l the se at 1. Fit the slot in the seat onto the pro- jection on the fuel tank. 2. Place the seat in the original posi- tion, and then tighten the bolts. TIP Make sure that the seat is p roperly se- cured before riding. EAU52450 Adjusting the front fork W ARNING EWA10180 Always adjust …

Yamaha WR450F (2012) — page 30

INSTRUMENT AND CONTROL FUNCTIONS 3-15 1 2 3 4 5 6 7 8 9 each fork leg in direction (b). TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above spec- ifications due to small differences in production, the actual number of clicks always represents the entire adjusting range. To obtain a precise …

Yamaha WR450F (2012) — page 31

INSTRUMENT AND CONTROL FUNCTIONS 3-16 2 3 4 5 6 7 8 9 3. Install the bleed screws. 4. Lower the front wheel so that it is on the ground, and then put the sidestand down. EAU52892 Adjusting the shock absorber assembly This shock absorber assembly is equipped with a spring preload adjust- ing ring, a rebound damping force ad- justing screw, a compres …

Yamaha WR450F (2012) — page 32

INSTRUMENT AND CONTROL FUNCTIONS 3-17 1 2 3 4 5 6 7 8 9 Compression damping force Compression damping force (for fast compression damping) To increase the compression damping force and thereby harden the compres- sion damping, turn the adjusting bolt in direction (a). To decrease the compres- sion damping force and thereby soften the compression da …

Yamaha WR450F (2012) — page 33

INSTRUMENT AND CONTROL FUNCTIONS 3-18 2 3 4 5 6 7 8 9 visable to check the actual total number of clicks or turns of each damping force adjusting mechanism. This adjustment range may not exactly match the spec- ifications listed due to small d ifferences in production. W ARNING EWA10221 This shock absorber assembly con- tains highly pressurized nit …

Yamaha WR450F (2012) — page 34

INSTRUMENT AND CONTROL FUNCTIONS 3-19 1 2 3 4 5 6 7 8 9 Yamaha de aler rep air it if it do es not function properly. EAU52861 Ignition circuit cut-off system The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions.  It prevents starting when the t rans- mission is in …

Yamaha WR450F (2012) — page 35

INSTRUMENT AND CONTROL FUNCTIONS 3-20 2 3 4 5 6 7 8 9 With the engine turned off: 1. Mov e the sidestand down. 2. Make sure that the engine stop s witch is set to “ 3. Push the main switch to “ON”. 4. Shift the transmission into the neutral position. 5. Push the star t switch. Does the engine start? With the engine still running: 6. Mov e the …

Yamaha WR450F (2012) — page 36

4-1 1 2 3 4 5 6 7 8 9 FOR YOUR SAFETY – PRE-OPERATION CHECKS EAU15596 Inspect your vehicle each time you use it to make sure the vehi cle is in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in the Owner ’s Manual. W ARNING EWA11151 Failure to inspect or maintain the vehicle properly in …

Yamaha WR450F (2012) — page 37

FOR YOUR SAFETY – PRE-OPERATION CHECKS 4-2 2 3 4 5 6 7 8 9 Rear brake • Check operation. • If soft or spongy , have Y amaha dealer bleed h ydraulic system. • Check brak e pads f or wear . • Replace if necessar y . • Check fluid le v el in reser voir . • If necessar y , add specified brak e fluid to specified le vel. • Check h ydraul …

Yamaha WR450F (2012) — page 38

FOR YOUR SAFETY – PRE-OPERATION CHECKS 4-3 1 2 3 4 5 6 7 8 9 Chassis fasteners • Make sure that all nuts, bolts and scre ws are properly tightened. • Tighten if necessar y . — Instruments, lights, signals and switches • Check operation. • Correct if necessar y . — Sidestand switch • Check operation of ignition circuit cut-off system …

Yamaha WR450F (2012) — page 39

5-1 2 3 4 5 6 7 8 9 OPERATION AND IMPORT ANT RIDING POINTS EAU15951 Read the Owner’s Manual carefully to become familiar with all controls. If there is a control or function you do not understand, ask your Yamaha dealer. W ARNING EWA10271 Failure to familiarize yourself with the controls can lead to loss of con- trol, which could cause an acciden …

Yamaha WR450F (2012) — page 40

OPERATION AND IMPORTANT RIDING POINTS 5-2 1 2 3 4 5 6 7 8 9 pushed to “ON”, or if a warning light remains on, see page 3-1 for the cor- responding warning light circuit check. 2. Shift the transmission into the neu- tral position. The neutral indicator light should come on. If not, ask a Yamaha dealer to check the elec- trical circuit. 3. Turn …

Yamaha WR450F (2012) — page 41

OPERATION AND IMPORT ANT RIDING POINTS 5-3 2 3 4 5 6 7 8 9 TIP If the engine fails to start, push the main switch to “OFF” and give the kickstarter 10 to 20 slow kicks at full throttle in or- der to clear the engine o f the rich air-fu- el mixture retained in it. EAU52971 Starting a warm engine Follow the same procedure as for start- ing a cold …

Yamaha WR450F (2012) — page 42

OPERATION AND IMPORTANT RIDING POINTS 5-4 1 2 3 4 5 6 7 8 9 the neutral position, do not coast for long periods of time with the engine off, and do not tow the motorcycle for long dis- tances. The transmission is properly lubricated only when the engine is running. Inade- quate lubrication may damage the transmission.  Always use the cl utch whi …

Yamaha WR450F (2012) — page 43

OPERATION AND IMPORT ANT RIDING POINTS 5-5 2 3 4 5 6 7 8 9 5. Start the engine and check the op- eration of the motorcycle through- out its entire operating range. Restart the motorcycle and ride it for about 10 to 15 more minutes. The motorcycle will now be ready to ride normally. After the engine break-in period, thor- oughly check the motorcycle …

Yamaha WR450F (2012) — page 44

6-1 1 2 3 4 5 6 7 8 9 PERIODIC MAINTENANCE AND ADJUSTMENT EAU17244 Periodic inspection, adjustment, and lu- brication will keep your vehicle in the safest and most efficient cond ition pos- sible. Safety is an obligation of the vehi- cle owner/operator. The most important points of vehicle inspection, adjust- ment, and lubrication are explained on …

Yamaha WR450F (2012) — page 45

PERIODIC MAINTENANCE AND ADJUSTMENT 6-2 2 3 4 5 6 7 8 9 EAU17311 Owner’s tool kit The service information included in this manual and the tools provided in the owner’s tool kit are intended to assist you in the performance of preventive maintenance and minor repairs. How- ever, additional tools such as a torque wrench may be necessary to per fo …

Yamaha WR450F (2012) — page 46

PERIODIC MAINTENANCE AND ADJUSTMENT 6-3 1 2 3 4 5 6 7 8 9 EAU52500 TIP  The annual checks must be performed every year, exc ept if a kilometer-based maintenance, or f or the UK, a mileage-based maintenance, is performed instead.  From 7000 km (4200 mi) or 9 months, repeat the maintenance int ervals starting from 3000 km (1 800 mi) or 3 months …

Yamaha WR450F (2012) — page 47

PERIODIC MAINTENANCE AND ADJUSTMENT 6-4 2 3 4 5 6 7 8 9 EAU52581 General maintenance an d lubrication chart NO . ITEM CHECKS AND MAINTENANCE JOBS INITIAL ODOMETER READINGS ANNU A L CHECK 1000 km (600 mi) or 1 month 3000 km (1800 mi) or 3 months 5000 km (3000 mi) or 6 months 1* Air filter element • Clean. • Replace if damaged.  2 Clutch …

Yamaha WR450F (2012) — page 48

PERIODIC MAINTENANCE AND ADJUSTMENT 6-5 1 2 3 4 5 6 7 8 9 12 * Steering bearings • Check bearing play and steering f or roughn ess. • Lubricate with lithium-soap-based grease.  13 * Chassis fasteners • Make sure that all nuts, bolts and scre ws are properly tightened.  14 Brake lever piv ot shaft • Lubricate with silico …

Yamaha WR450F (2012) — page 49

PERIODIC MAINTENANCE AND ADJUSTMENT 6-6 2 3 4 5 6 7 8 9 EAU53210 TIP  The air filter needs more frequent service if y ou are riding in unusually wet or dusty areas.  Hydraulic brake service • Regularly check and, if necessary, correct the bra ke fluid level. • Every two years replace the internal components of t he brake master cylinders …

Yamaha WR450F (2012) — page 50

PERIODIC MAINTENANCE AND ADJUSTMENT 6-7 1 2 3 4 5 6 7 8 9 EAU18751 Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time the panel needs to be removed and installed. EAU52872 Panel A To remove the panel 1. Remove the seat. (See page 3- …

Yamaha WR450F (2012) — page 51

PERIODIC MAINTENANCE AND ADJUSTMENT 6-8 2 3 4 5 6 7 8 9 wire thickness gauge and, if necessary, adjusted to specification. Clean the surface of the spark plug gasket and its mating surface, and then wipe off any grime from t he spark plug threads. TIP If a torque wrench is not available when installing a spark plug, a good estimate of the correct t …

Yamaha WR450F (2012) — page 52

PERIODIC MAINTENANCE AND ADJUSTMENT 6-9 1 2 3 4 5 6 7 8 9 And do not touch the radiator pipe after high-speed operation, otherwise the cooling system is hot and cause burns. Always let the engine oil cool down suffi- ciently before removing the oil tank cap. [EWA16140 ] NOTICE: Do not operate the vehicle until you know that the engine oil l evel is …

Yamaha WR450F (2012) — page 53

PERIODIC MAINTENANCE AND ADJUSTMENT 6-10 2 3 4 5 6 7 8 9 6. Install the engine oil tank cap, and then the check bolt and its gasket. To change the engine oil (with or without oil filter element re place- ment) 1. Place the vehicle on a level sur- face. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place an oil pan un …

Yamaha WR450F (2012) — page 54

PERIODIC MAINTENANCE AND ADJUSTMENT 6-11 1 2 3 4 5 6 7 8 9 TIP Skip steps 8–10 if the oil filter element is not being replaced. 8. Remove the oil filter element cover by removing the bolts. 9. Remove and replace the oil filter element and O-rings. 10. Install the oil filter element cover by installing the bolts, and t hen tight- en the bolts to t …

Yamaha WR450F (2012) — page 55

PERIODIC MAINTENANCE AND ADJUSTMENT 6-12 2 3 4 5 6 7 8 9 mix any chemical additives. Do not use oils with a diesel speci- fication of “CD” or oils of a high- er quality than specified. In addition, do not use oils labeled “ENERGY CONSERV ING II” or higher.  Make sure that no foreign mate- rial enters the crankcase. 13. Start the engine, …

Yamaha WR450F (2012) — page 56

PERIODIC MAINTENANCE AND ADJUSTMENT 6-13 1 2 3 4 5 6 7 8 9 TIP The coolant should be at the bottom of the radiator filler neck. The level will change with variation of engine temper- ature. 3. If the coolant is below the correct coolant level, add coolant, and then install the radiator cap. NOTICE: If coolant is not avail- able, use distilled water …

Yamaha WR450F (2012) — page 57

PERIODIC MAINTENANCE AND ADJUSTMENT 6-14 2 3 4 5 6 7 8 9 into the radiator until it is full. 7. Install the radiator cap, start the engine, let it idle for sever al min- utes, and then turn it off . 8. Remove the radiat or cap to check the coolant level in the radiator. If necessary, add sufficient coolant until it reaches the bottom of the radiato …

Yamaha WR450F (2012) — page 58

PERIODIC MAINTENANCE AND ADJUSTMENT 6-15 1 2 3 4 5 6 7 8 9 with solvent, and then squeeze the remaining solvent out. WARNING! Use only a dedicated parts cleaning solvent. To avoid the risk of fire or explosion, do not use gasoline or solvents with a low flash point. [EWA10431] NOTICE: To avoid damaging the foam material, handle it gently and carefu …

Yamaha WR450F (2012) — page 59

PERIODIC MAINTENANCE AND ADJUSTMENT 6-16 2 3 4 5 6 7 8 9 7. Place the holding clip in the origi- nal position. TIP Hook the holding clip so that it contacts the filter guide projections. 8. Close the air filter case cover, and then tighten the quick fastener screw. To clean the air f ilter check ho se 1. Check the hose at the bottom of the air filt …

Yamaha WR450F (2012) — page 60

PERIODIC MAINTENANCE AND ADJUSTMENT 6-17 1 2 3 4 5 6 7 8 9 EAU52460 Adjusting the engine idling speed The engine idling speed must be checked and, if necessary, adjusted as follows. TIP A digital tachometer is needed to make this adjustment. 1. Position the digital tachometer at the ignition coil, which is located in the spark plug cap. 2. Check th …

Yamaha WR450F (2012) — page 61

PERIODIC MAINTENANCE AND ADJUSTMENT 6-18 2 3 4 5 6 7 8 9 EAU21401 Valve clearance The valve clearance changes wit h use, resulting in improper air-fuel mixture and/or engine noise. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. EAU …

Yamaha WR450F (2012) — page 62

PERIODIC MAINTENANCE AND ADJUSTMENT 6-19 1 2 3 4 5 6 7 8 9 Tire inspection The tires must be checked before each ride. If the center tread dept h reaches the specified limit, if the tire has a nail or glass fragments in it, or if the sidewall is cracked, have a Yamaha dealer re- place the tire immediately. TIP The tire tread depth limits may differ …

Yamaha WR450F (2012) — page 63

PERIODIC MAINTENANCE AND ADJUSTMENT 6-20 2 3 4 5 6 7 8 9 high-quality product.  Ride at moderate speeds after changing a tire since the tire surface must first be “broken in” for it to develop its optimal characteristics. EAU21943 Spoke wheels W ARNING EWA10610 The wheels on this model are not de- signed for use with tubeless tires. Do not a …

Yamaha WR450F (2012) — page 64

PERIODIC MAINTENANCE AND ADJUSTMENT 6-21 1 2 3 4 5 6 7 8 9 could be obtained as described above, skip steps 2–5. 2. Fully turn the adjusting bolt in di- rection (a) to loo sen the clutch ca- ble. 3. Slide the rubber cover back further down the clutch cable, and then loosen the locknut. 4. To increase the clutch lever free play, turn the clutch le …

Yamaha WR450F (2012) — page 65

PERIODIC MAINTENANCE AND ADJUSTMENT 6-22 2 3 4 5 6 7 8 9 sult in loss of control and an acci- dent. EAU44820 Checking the shift pedal The operation of the shift pedal should be checked before each ride. If opera- tion is not smooth, have a Yamaha dealer check the vehicle. EAU22273 Brake light switches The brake light, which is activated by the brak …

Yamaha WR450F (2012) — page 66

PERIODIC MAINTENANCE AND ADJUSTMENT 6-23 1 2 3 4 5 6 7 8 9 EAU22392 Checking the front and rear brake pads The front and rear brake pads must be checked for wear at the intervals spec- ified in the periodic maintenance and lubrication chart. EAU22430 Front brake pads Each front brake pad is provided with wear indicator grooves, which allow you to c …

Yamaha WR450F (2012) — page 67

PERIODIC MAINTENANCE AND ADJUSTMENT 6-24 2 3 4 5 6 7 8 9 Rear brake W ARNING EWA15990 Improper maintenance can result in loss of braking ability. Observe these precautions:  Insufficient brake fluid may al- low air to enter the brake sys- tem, reducing braking perfor mance .  Clean the filler cap before re- moving. Use only DOT 4 brake fluid …

Yamaha WR450F (2012) — page 68

PERIODIC MAINTENANCE AND ADJUSTMENT 6-25 1 2 3 4 5 6 7 8 9 EAU22760 Drive chain slack The drive chain slack should be checked before each ride and adjusted if necessary. EAU52480 To check the drive chain slack 1. Place the motorcycle on the side- stand. TIP When checking and adjusting the drive chain slack, there should be no weight on the motorcyc …

Yamaha WR450F (2012) — page 69

PERIODIC MAINTENANCE AND ADJUSTMENT 6-26 2 3 4 5 6 7 8 9 nuts to their specified torques. 4. Make sure that the drive chain pull- ers are in the same position, the drive chain slack is correct, and the drive chain moves smooth ly. EAU23025 Cleaning and l ubricating the drive chain The drive chain must be cleaned and lubricated at the intervals spec …

Yamaha WR450F (2012) — page 70

PERIODIC MAINTENANCE AND ADJUSTMENT 6-27 1 2 3 4 5 6 7 8 9 EAU23095 Checking and lubricating the cables The operation of all control cables and the condition of the cables should be checked before each ride, and the ca- bles and cable ends should be lubricat- ed if necessary. If a cable is damaged or does not move smoothly, have a Yamaha dealer che …

Yamaha WR450F (2012) — page 71

PERIODIC MAINTENANCE AND ADJUSTMENT 6-28 2 3 4 5 6 7 8 9 Clutch lever EAU23183 Checking and lubr icating the brake pedal The operation of the brake pedal should be checked before each ride, and the pedal pivot should be lubricat- ed if necessary. EAU23202 Checking and lubricating the sidestand The operation of the sidestand should be checked before …

Yamaha WR450F (2012) — page 72

PERIODIC MAINTENANCE AND ADJUSTMENT 6-29 1 2 3 4 5 6 7 8 9 EAUM1652 Lubricating the swingarm pivots The swingarm pivots must be lubricat- ed by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart. EAU23272 Checking the front fork The condition and operation of the f ront fork must be checked as follows at th …

Yamaha WR450F (2012) — page 73

PERIODIC MAINTENANCE AND ADJUSTMENT 6-30 2 3 4 5 6 7 8 9 EAU23283 Checking the steering Worn or loose steering bearings may cause danger. Therefore, the operation of the steering must be checked as fol- lows at the intervals specified in the pe- riodic maintenance and lubrication chart. 1. Place a stand under the en gine to raise the front wheel of …

Yamaha WR450F (2012) — page 74

PERIODIC MAINTENANCE AND ADJUSTMENT 6-31 1 2 3 4 5 6 7 8 9 skin, eyes or clothing and al- ways shield your eyes when working near batteries. In case of contact, administer the fol- lowing FIRST AID. • EXTERNAL: Flush with plenty of water. • INTERNAL: Drink large quan- tities of water or milk and im- mediately call a physician. • EYES: Flush w …

Yamaha WR450F (2012) — page 75

PERIODIC MAINTENANCE AND ADJUSTMENT 6-32 2 3 4 5 6 7 8 9 EAU52422 Replacing the fuse The fuse is located under the seat. (See page 3-13.) If the fuse is blown, replace it as fol- lows. 1. Push the main switch to “OFF” and turn off all electrical circuits. 2. Remove the blown fuse, and then install a new fuse of the specified amperage. WARNING! …

Yamaha WR450F (2012) — page 76

PERIODIC MAINTENANCE AND ADJUSTMENT 6-33 1 2 3 4 5 6 7 8 9 1. Remove the headlight cowling to- gether with the headlight unit by removing the bolts and pulling up- ward as shown. 2. Disconnect the headlight coupler, and then remove the headlight bulb cover. 3. Remove the headlight bulb holder by turning it counterclockwise, and then remove the burn …

Yamaha WR450F (2012) — page 77

PERIODIC MAINTENANCE AND ADJUSTMENT 6-34 2 3 4 5 6 7 8 9 EAU24181 Tail/brake light This model is equipped with an LED-type tail/brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. EAU24204 Replacing a turn signal light bulb 1. Remove the turn signal light lens by removing the screw. 2. Remove the burnt-out bulb by …

Yamaha WR450F (2012) — page 78

PERIODIC MAINTENANCE AND ADJUSTMENT 6-35 1 2 3 4 5 6 7 8 9 EAU24313 Replacing the license plate light bulb 1. Remove the license plate light unit by removing the screws. 2. Remove the license plate light bulb socket (together with the bulb) by pulling it out. 3. Remove the burnt-out bulb by pull- ing it out. 4. Insert a new bulb into the socket. 5. …

Yamaha WR450F (2012) — page 79

PERIODIC MAINTENANCE AND ADJUSTMENT 6-36 2 3 4 5 6 7 8 9 4. Insert a new bulb into the socket. 5. Install the socket (together with the bulb) by pushing it in. 6. Install the headlight unit. EAU24350 Supporting the motorcycle Since this model is not equipped with a centerstand, follow these precautions when removing the front and rear wheel or perf …

Yamaha WR450F (2012) — page 80

PERIODIC MAINTENANCE AND ADJUSTMENT 6-37 1 2 3 4 5 6 7 8 9 EAU24360 Front wheel EAU49332 To remove the front wheel W ARNING EWA10821 To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Remove the rubber cap, and then loosen the front wheel axle pinch bolts and the axle nut. 2. Lift the front wheel off the grou …

Yamaha WR450F (2012) — page 81

PERIODIC MAINTENANCE AND ADJUSTMENT 6-38 2 3 4 5 6 7 8 9 8. Push down hard on the handlebar several times to check for proper fork operation. EAU25080 Rear wheel EAU45183 To remove the rear wheel W ARNING EWA10821 To avoid injury, securely support the vehicle so there is no danger of it falling over. 1. Loosen the axle nut. 2. Lift the rear wheel o …

Yamaha WR450F (2012) — page 82

PERIODIC MAINTENANCE AND ADJUSTMENT 6-39 1 2 3 4 5 6 7 8 9 TIP The drive chain does not need to be disassembled in order to remove and install the rear wheel. 7. While supporting the brake caliper, pull the wheel axle out. 8. Remove the drive chain puller s, spacers and the wheel. NOTICE: Do not apply the brake after the wheel has been removed to- …

Yamaha WR450F (2012) — page 83

PERIODIC MAINTENANCE AND ADJUSTMENT 6-40 2 3 4 5 6 7 8 9 EAU25871 Troubleshooting Although Yamaha motorcycles receive a thorough inspection before shipment from the factory, trouble may o ccur dur- ing operation. Any problem in the fuel, compression, or ignition systems, for example, can cause poor starting and loss of power. The following troubles …

Yamaha WR450F (2012) — page 84

PERIODIC MAINTENANCE AND ADJUSTMENT 6-41 1 2 3 4 5 6 7 8 9 EAU53122 Troubleshooting charts Starting problems or poo r engine performance Check the fuel level in the fuel tank. 1. Fuel There is enough fuel. There is no fuel. Check the compression. Supply fuel. The engine does not start. Check the battery. Operate the electric starter or the kickstar …

Yamaha WR450F (2012) — page 85

PERIODIC MAINTENANCE AND ADJUSTMENT 6-42 2 3 4 5 6 7 8 9 Engine ov erheatin g W ARNING EWAT1040  Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. Be s ure to wait until the engine has cooled.  Place a thick rag, like a towel, ov …

Yamaha WR450F (2012) — page 86

7-1 1 2 3 4 5 6 7 8 9 MOTORCYCLE CARE AND STORAGE EAU37833 Matte color caution NO TICE ECA15192 Some models are equipped with matte colored finished parts. Be sure to consult a Yamaha dealer for advice on what products to use be- fore cleaning the vehicle. Using a brush, harsh chemical products or cleaning compounds when cleaning these parts will s …

Yamaha WR450F (2012) — page 87

MOTORCYCLE CARE AND STORAGE 7-2 2 3 4 5 6 7 8 9 off any detergent residue using plenty of water, as it is harmful to plastic parts.  Do not use any harsh chemical products on plastic parts. Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cleaning products, solvent or thinner, fuel (gasoline), rust re- …

Yamaha WR450F (2012) — page 88

MOTORCYCLE CARE AND STORAGE 7-3 1 2 3 4 5 6 7 8 9 including chrome- and nickel-plat- ed, surfaces. 5. Use spray oil as a universal clean- er to remove any remaining dirt. 6. Touch up minor paint damage caused by stones, etc. 7. Wax all painted surfaces. 8. Let the motorcycle dry completely before storing or covering it. W ARNING EWA11131 Contaminan …

Yamaha WR450F (2012) — page 89

MOTORCYCLE CARE AND STORAGE 7-4 2 3 4 5 6 7 8 9 stabilizer (if available) to prevent the fuel tank from rusting and the fuel from deteriorating. 3. Perform the following steps to pro- tect the cylinder, piston rings, etc. from corrosion. a. Remove the spark plug cap and spark plug. b. Pour a teaspoonful of engine oil into the spark plug bore. c. In …

Yamaha WR450F (2012) — page 90

8-1 1 2 3 4 5 6 7 8 9 SPECIFICATIONS EAU50975 Dimensions: Overall length: 2315 mm (91.1 in) Overall width: 825 mm (32.5 in) Overall height: 1275 mm (50.2 in) Seat height: 960 mm (37.8 in) Wheelbase: 1475 mm (58.1 in) Ground clearance: 335 mm (13.19 in) Minimum turning radius: 2400 mm (94.5 in) Weight: Curb weight: 129 kg (284 lb) Technical permissi …

Yamaha WR450F (2012) — page 91

SPECIFICATIONS 8-2 2 3 4 5 6 7 8 9 Transmission type: Constant mesh 5-speed Operation: Left foot operation Gear ratio: 1st: 2.417 (29/12) 2nd: 1.733 (26/15) 3rd: 1.313 (21/16) 4th: 1.050 (21/20) 5th: 0.840 (21/25) Chassis: Frame type: Semi double cradle Caster angle: 27.00  Trail: 115 mm (4.5 in) Front tire: Type: With tube Size: 80/100-21M/C 51 …

Yamaha WR450F (2012) — page 92

SPECIFICATIONS 8-3 1 2 3 4 5 6 7 8 9 Tail/brake light: LED Front turn signal light: 12 V, 10.0 W  2 Rear turn signal light: 12 V, 10.0 W  2 Auxiliary light: 12 V, 5.0 W  1 License plate light: 12 V, 5.0 W  1 Meter lighting: EL (Electroluminescent) Neutral indicator light: 12 V, 1.7 W  1 High beam indicator light: 12 V, 1.7 W  1 Tu …

Yamaha WR450F (2012) — page 93

9-1 2 3 4 5 6 7 8 9 CONSUMER INFORMATION EAU48612 Identification numbers Record the vehicle identification num- ber and model label information in the spaces provided bel ow for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is stolen. VEHICLE IDENTIFICATION NUMBER: MODEL LABEL INFORMATION: EAU26400 V …

Yamaha WR450F (2012) — page 94

INDEX A Air filter element and check hose, cleaning ………………………………………. …6-14 Auxiliary light bulb, replacing ………………. 6-35 B Battery………………………… ……………………6-30 Brake and clutch levers, checking and lubricating …………………. ……………………6- 27 Brake fluid, c …

Yamaha WR450F (2012) — page 95

INDEX Turn signal switch ……………………………….. 3-7 V Valve clearance ………………………………… 6-18 Vehicle identification number ………………… 9-1 W Wheel bearings, c hecking ………………….. 6-30 Wheel (front) ………………. ……………………. 6-37 Wheel (rear) ………………………. …

Yamaha WR450F (2012) — page 96

1DX-9-E1.book 4 ページ ２０ １２年７月３ １日　火曜日 　午前９時３ １分 …

Yamaha WR450F (2012) — page 97

U1DXE1_Hyoshi.indd 3 2012/08/08 17:42:01 …

Yamaha WR450F (2012) — page 98

PRINTED ON RECYCLED P APER PRINTED IN JAP AN 2012.08-0.4×1 ! (E) U1DXE1_Hyoshi.indd 4 2012/08/08 17:42:02 …

Page 6: Important Notice

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 regula- tions before riding.

Page 12: Description

EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING 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.

Page 20: Table Of Contents

EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ………..1-1 MACHINE IDENTIFICATION …..1-2 IMPORTANT INFORMATION ….1-3 CHECKING OF CONNECTION ….1-6 SPECIAL TOOLS ……..1-7 CONTROL FUNCTIONS ……1-10 MULTI-FUNCTION DISPLAY ….1-14 FUEL …………1-21 STARTING AND BREAK-IN ….1-22 TORQUE-CHECK POINTS ……1-26 CLEANING AND STORAGE ….1-27 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ….2-1…

Page 21: Table Of Contents

INHALT TABLES DES ÍNDICE MATIERES KAPITEL 1 CAPÍTULO 1 CHAPITRE 1 ALLGEMEINE INFORMACIÓN ANGABEN RENSEIGNEMENTS GENERAL GENERAUX FAHRZEUGBESCHREIBUNG ..1-1 DESCRIPCIÓN …….1-1 FAHRZEUG-IDENTIFIZIERUNG..1-2 IDENTIFICACIÓN DESCRIPTION ……. 1-1 WICHTIGE INFORMATIONEN..1-3 DE LA MÁQUINA ……1-2 IDENTIFICATION KABELANSCHLÜSSE INFORMACIÓN DE LA MOTO ……… 1-2 KONTROLLIEREN ……

Page 22: Table Of Contents

CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ……..4-1 EXHAUST PIPE AND SILENCER …..4-3 RADIATOR ……….4-5 CARBURETOR ……….4-8 AIR INDUCTION SYSTEM ……4-22 CAMSHAFTS ………..4-24 CYLINDER HEAD ……..4-33 VALVES AND VALVE SPRINGS ….4-37 CYLINDER AND PISTON ……4-46 CLUTCH ………..4-52 OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) ..4-59 BALANCER ……….4-66 OIL PUMP ……….4-70…

Page 23: Table Of Contents

KAPITEL 4 CHAPITRE 4 CAPÍTULO 4 MOTOR MOTEUR MOTOR SELLE, RESERVOIR SITZBANK, KRAFTSTOFFTANK SILLÍN, DEPÓSITO DE CARBURANT UND SEITENABDECKUNGEN… 4-1 DE COMBUSTIBLE ET CACHES LATERAUX….. 4-1 AUSPUFFKRÜMMER Y CUBIERTAS LATERALES ..4-1 TUBE D’ECHAPPEMENT UND SCHALLDÄMPFER…. 4-3 TUBO DE ESCAPE ET SILENCIEUX ……4-3 KÜHLER ……..

Page 24: Table Of Contents

CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ……6-1 IGNITION SYSTEM ……..6-2 ELECTRIC STARTING SYSTEM ….6-6 CHARGING SYSTEM ……6-16 TPS (THROTTLE POSITION SENSOR) SYSTEM ………..6-18 LIGHTING SYSTEM ……..6-23 SIGNALING SYSTEM ……6-26 CHAPTER 7 TUNING ENGINE …………7-1 CHASSIS ………..7-9…

Page 25: Table Of Contents

KAPITEL 6 CHAPITRE 6 CAPÍTULO 6 ELEKTRISCHE PARTIE SISTEMA ELECTRIQUE ANLAGE ELÉCTRICO COMPOSANTS ELECTRIQUES ELEKTRISCHE BAUTEILE COMPONENTES ET SCHEMA DE CABLAGE ..6-1 UND SCHALTPLAN….6-1 Y ESQUEMA ELÉCTRICO ..6-1 SYSTEME D’ALLUMAGE … 6-2 ZÜNDSYSTEM ……6-2 SISTEMA DE ENCENDIDO ..6-2 DEMARRAGE ELECTRIQUE ..

Page 26: General Information

DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever G Rear brake pedal 2 Hot starter lever H Valve joint 3 “ENGINE STOP” button I Fuel cock 4 Multi-function display J Cold starter knob 5 Main switch K Air cleaner 6 Start switch L Catch tank 7 Front brake lever…

Page 27: Allgemeine Angaben

DESCRIPTION FAHRZEUGBESCHREIBUNG DESCRIPCIÓN INFO RENSEIGNEMENTS ALLGEMEINE INFORMACIÓN GENERAUX ANGABEN GENERAL FAHRZEUGBESCHREI- DESCRIPTION DESCRIPCIÓN 1 Levier d’embrayage 1 Maneta de embrague BUNG 2 Levier de démarrage à chaud 2 Mando de arranque en caliente 1 Kupplungshebel 3 Bouton “ENGINE STOP” 3 Botón “ENGINE STOP” (paro del motor) 2 Warmstarthebel 4 Ecran multifonction 4 Visor multifunción…

Page 28: 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.

Page 29: Identification De La Moto

Nummer zur exakten rio Yamaha a fin de facilitar la iden- Identifizierung des Modells. En cas de vol de la moto, la police tificación del modelo que posee.

Page 30: Important Information

IMPORTANT INFORMATION INFO 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. • Silencer exhaust port •…

Page 31: Wichtige Informationen

INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFO INFORMACIÓN IMPORTANTE INFORMATIONS WICHTIGE INFORMACIÓN INFORMATIONEN IMPORTANTES IMPORTANTE VORBEREITUNG FÜR AUSBAU PREPARATION A LA DEPOSE ET PREPARACIÓN PARA LA AU DEMONTAGE UND ZERLEGUNG EXTRACCIÓN Y DESMONTAJE Vor dem Ausbau oder Zerlegen Eliminer soigneusement saletés, Antes de extraer y desmontar, eli- boue, poussière et corps étrangers der Bauteile und -gruppen sämt- mine toda la suciedad, barro, polvo…

Page 33: Informations Importantes

Nur von Yamaha emp- sustituciones. Utilice el aceite o graisses et/ou huiles recommandées fohlene Schmiermittel verwen- grasa recomendados por Yamaha par Yamaha lors des remontages et den. para el montaje y el ajuste. réglages. JOINTS, BAGUES D’ETANCHEITE DICHTUNGEN, DICHTRINGE UND…

Page 36: Checking Of Connection

CHECKING OF CONNECTION INFO 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.

Page 37: Verification Des Connexions

VERIFICATION DES CONNEXIONS KABELANSCHLÜSSE KONTROLLIEREN INFO COMPROBACIÓN DE LAS CONEXIONES VERIFICATION DES KABELANSCHLÜSSE COMPROBACIÓN DE KONTROLLIEREN CONNEXIONS LAS CONEXIONES Sämtliche Steckverbinderkontakte Traitement des taches, de la rouille, de Tratamiento de manchas, óxido, hume- l’humidité, etc., sur le connecteur. und Kabelanschlüsse auf Flecke, dad, etc.

Page 38: Special Tools

SPECIAL TOOLS INFO 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.

Page 41: Outils Speciaux

OUTILS SPECIAUX INFO OUTILS SPECIAUX Il est indispensable d’utiliser les outils spéciaux appropriés pour pouvoir effectuer un assemblage et une mise au point complets et précis. L’utilisation des outils spéciaux corrects permettra d’éviter les endommagements dus à l’emploi d’outils impropres ou de techniques improvisées. La forme et le numéro de référence des outils spéciaux pouvant différer selon les pays, il existe parfois deux versions d’un outil.

Page 47: Herramientas Especiales

HERRAMIENTAS ESPECIALES INFO HERRAMIENTAS ESPECIALES Para realizar un reglaje y un montaje completos y precisos es necesario utilizar las herramientas especiales adecuadas. Con el uso de las herramientas especiales correctas evitará los daños provocados por herramientas inadecuadas o técnicas improvisadas. La forma y el número de referencia de las herramientas especiales varía según los países, por lo que se suministran dos tipos.

Page 50: Control Functions

CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indica- tor light 2 to avoid forgetting to turn it off.

Page 51: Engine

FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION INFO FUNCIONES DE LOS MANDOS FONCTIONS DES BEDIENUNGSELEMENTE FUNCIONES DE LOS UND DEREN FUNKTION COMMANDES MANDOS ZÜNDSCHALTER CONTACTEUR A CLE INTERRUPTOR PRINCIPAL Les fonctions correspondant aux diffé- Die einzelnen Zündschalterstellun- Las funciones de las diferentes posicio- gen sind nachfolgend beschrieben: rentes positions du contacteur sont les nes del interruptor son las siguientes:…

Page 53: Fonctions Des Commandes

FONCTIONS DES COMMANDES BEDIENUNGSELEMENTE UND DEREN FUNKTION INFO FUNCIONES DE LOS MANDOS LEVIER D’EMBRAYAGE KUPPLUNGSHEBEL MANETA DE EMBRAGUE Le levier d’embrayage 1 est situé sur la Der Kupplungshebel 1 befindet sich La maneta de embrague 1 se encuentra partie gauche du guidon et permet links am Lenker.

Page 58: Multi-Function Display

MULTI-FUNCTION DISPLAY INFO MULTI-FUNCTION DISPLAY WARNING Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: BASIC MODE: • Speedometer • Clock • Two tripmeters (which shows the distance that has been traveled since it was last set to zero) RACE MODE:…

Page 61: Mode De Base

ECRAN MULTIFONCTION MULTIFUNKTIONSANZEIGE INFO VISOR MULTIFUNCIÓN MODE DE BASE NORMAL-BETRIEBSART FUNCIÓN BÁSICA Modification de l’affichage du comp- Geschwindigkeitsmesseranzeige Cambio de la indicación del velocíme- teur de vitesse (pour le Royaume-Uni) wechseln (für U.K.) tro (Reino Unido) Appuyer sur le bouton “SLCT2” Die Taste “SLCT2”…

Page 72: Fuel

FUEL INFO 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.

Page 74: Starting And Break-In

STARTING AND BREAK-IN INFO 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: •…

Page 75: Puesta En Marcha Y Rodaje

MISE EN MARCHE ET RODAGE STARTEN UND EINFAHREN INFO PUESTA EN MARCHA Y RODAJE MISE EN MARCHE ET STARTEN UND PUESTA EN MARCHA Y EINFAHREN RODAGE RODAJE AVERTISSEMENT WARNUNG ADVERTENCIA Ne jamais démarrer ou faire tourner Den Motor unter keinen Umstän- No arranque ni tenga nunca el motor le moteur dans un endroit clos.

Page 80: Torque-Check Points

STARTING AND BREAK-IN INFO 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”…

Page 83: Points De Verification Des Couples De Serrage

POINTS DE VERIFICATION DES COUPLES DE SERRAGE INFO POINTS DE VERIFICATION DES COUPLES DE SERRAGE Cadre Cadre au cadre arrière Selle et réservoir combinés Réservoir de carburant au cadre Système d’échappement Silencieux au cadre arrière Bâti moteur Cadre au moteur Support de moteur au moteur Support de moteur au cadre Direction…

Page 84: Anzugsdrehmomente Kontrollieren

ANZUGSDREHMOMENTE KONTROLLIEREN INFO ANZUGSDREHMOMENTE KONTROLLIEREN Fahrgestell Rahmen und Rahmenhinterteil Sitzbank-Krafstofftank-Baugruppe Kraftstofftank und Rahmen Auspuffsystem Schalldämpfer und Rahmenhinterteil Motorlager Rahmen und Motor Motorhalterung und Motor Motorhalterung und Rahmen Lenkung Lenkkopf und Lenker Lenkkopf und Rahmen Lenkkopf und obere Gabelbrücke Obere Gabelbrücke und Lenker Radaufhängung Vorn Lenkkopf und Gabelholme…

Page 86: Cleaning And Storage

CLEANING AND STORAGE INFO 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 com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.

Page 87: Limpieza Y Almacenamiento

NETTOYAGE ET REMISAGE PFLEGE UND LAGERUNG INFO LIMPIEZA Y ALMACENAMIENTO NETTOYAGE ET PFLEGE UND LIMPIEZA Y LAGERUNG REMISAGE ALMACENAMIENTO FAHRZEUGWÄSCHE NETTOYAGE LIMPIEZA Un nettoyage fréquent de la moto préser- Regelmäßige Wäsche optimiert das Una limpieza frecuente de la máquina Aussehen, die Leistung und die vera son apparence, maintiendra ses bon- mejora su aspecto, mantiene un buen nes performances et augmentera la durée…

Page 90: General Specifications

SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR450FW (USA, CDN, AUS, NZ) WR450F (EUROPE, ZA) Model code number: 5TJE (USA) 5TJF (EUROPE) 5TJG (CDN, AUS, NZ, ZA) Dimensions: USA, ZA, CDN EUROPE, AUS, NZ Overall length 2,175 mm (85.63 in) 2,190 mm (86.22 in) ←…

Page 91: Chassis

SPEC GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt) Total amount 1.2 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (including all routes): 1.0 L (0.88 Imp qt, 1.06 US qt) Air filter:…

Page 93: Maintenance Specifications

SPEC MAINTENANCE SPECIFICATIONS 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) —-…

Page 109: General Torque Specifications

GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque 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. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.

Page 110: Caracteristiques Generales

SPEC CARACTERISTIQUES GENERALES CARACTERISTIQUES CARACTERISTIQUES GENERALES Nom du modèle: WR450FW (USA, CDN, AUS, NZ) WR450F (EUROPE, ZA) Numéro de code de modèle: 5TJE (USA) 5TJF (EUROPE) 5TJG (CDN, AUS, NZ, ZA) Dimensions: USA, ZA, CDN EUROPE, AUS, NZ Longueur totale 2.175 mm (85,63 in) 2.190 mm (86,22 in) ←…

Page 129: Caracteristiques Generales De Couple

CARACTERISTIQUES GENERALES DE COUPLE/ SPEC DEFINITION DES UNITES CARACTERISTIQUES GENERALES DE COUPLE Ce tableau spécifie les couples de serrage des atta- ches standard avec filet à pas I.S.O. standard. Les spécifications de couple pour les composants ou ensembles spéciaux sont indiquées dans les sec- tions appropriées de ce manuel.

Page 130: Technische Daten

SPEC ALLGEMEINE TECHNISCHE DATEN TECHNISCHE DATEN ALLGEMEINE TECHNISCHE DATEN Modellbezeichnung: WR450FW (USA, CDN, AUS, NZ) WR450F (EUROPE, ZA) Modellcode: 5TJE (USA) 5TJF (EUROPE) 5TJG (CDN, AUS, NZ, ZA) Abmessungen: USA, ZA, CDN EUROPE, AUS, NZ Gesamtlänge 2.175 mm (85,63 in) 2.190 mm (86,22 in) ←…

Page 131: Fahrwerk

SPEC ALLGEMEINE TECHNISCHE DATEN Füllmenge: Motoröl Ölwechsel ohne Filterwechsel 0,95 L (0,84 Imp qt, 1,00 US qt) Ölwechsel mit Filterwechsel 1,0 L (0,88 Imp qt, 1,06 US qt) Gesamtmenge 1,2 L (1,06 Imp qt, 1,27 US qt) Kühlsystem-Fassungsvermögen: 1,0 L (0,88 Imp qt, 1,06 US qt) Luftfilter: Naßfiltereinsatz Kraftstoff:…

Page 132: Allgemeine Technische Daten

SPEC ALLGEMEINE TECHNISCHE DATEN Bremsen: Vorderradbremse Einscheibenbremse Betätigung Handbremshebel (rechts) Hinterradbremse Einscheibenbremse Betätigung Fußbremshebel (rechts) Radaufhängung: Vorn Teleskopgabel Hinten Monocross-Schwinge (mit Umlenkhebelabstüt- zung) Federung/Dämpfung: Vorn Spiralfeder, hydraulisch gedämpft Federbein Federbein mit gasdruckunterstütztem Stoß- dämpfer und Spiralfeder Radfederweg: Vorn 300 mm (11,8 in) Hinten 305 mm (12,0 in) Elektrische Anlage:…

Page 149: Allgemeine Anzugsmomente

ALLGEMEINE ANZUGSMOMENTE/ SPEC MASSEINHEITEN ALLGEMEINE ANZUGSMOMENTE Aus der folgenden Tabelle sind die Anzugsmo- mente für normale Schraubverbindungen mit ISO-Normgewinde ersichtlich. Anzugsmo- mente für spezielle Verschraubungen und Bauteile werden in jedem Abschnitt dieser Anleitung gesondert aufgeführt. Um ein Ver- ziehen der Bauteile zu vermeiden, sollten die Schraubverbindungen über Kreuz angezogen werden, bis die vorgeschriebenen Anzugsmo- mente erreicht sind.

Page 150: Especificaciones Generales

SPEC ESPECIFICACIONES GENERALES ESPECIFICACIONES ESPECIFICACIONES GENERALES Nombre del modelo: WR450FW (USA, CDN, AUS, NZ) WR450F (EUROPE, ZA) Código de modelo: 5TJE (USA) 5TJF (EUROPE) 5TJG (CDN, AUS, NZ, ZA) Dimensiones: USA, ZA, CDN EUROPE, AUS, NZ Longitud total 2.175 mm (85,63 in) 2.190 mm (86,22 in) ←…

Page 153: Especificaciones De Mantenimiento

SPEC ESPECIFICACIONES DE MANTENIMIENTO ESPECIFICACIONES DE MANTENIMIENTO MOTOR Elemento Estándar Límite Culata: Límite de deformación —- 0,05 mm (0,002 in) Cilindro: Diámetro 95,00 ~ 95,01 mm —- (3,7402 ~ 3,7406 in) Límite de deformación circunferencial —- 0,05 mm (0,002 in) Eje de levas: Sistema de accionamiento Transmisión por cadena (izquierda)

Page 169: Especificaciones Generales De Apriete

ESPECIFICACIONES GENERALES DE APRIETE/ SPEC DEFINICIÓN DE UNIDADES ESPECIFICACIONES GENERALES DE APRIETE En este cuadro se especifican los pares de apriete para las fijaciones estándar con pasos de rosca ISO. Los pares de apriete para los componentes o con- juntos especiales se incluyen en las secciones correspondientes de este manual.

Page 170: Lubrication Diagrams

SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Crankshaft 6 Connecting rod È From cylinder É To oil tank 2 — 21…

Page 173: Diagrammes De Lubrification

DIAGRAMMES DE LUBRIFICATION SCHMIERSYSTEM-SCHAUBILDER SPEC DIAGRAMAS DE ENGRASE 1 Arbre à cames d’admission 1 Einlass-Nockenwelle 1 Eje de levas de admisión 2 Arbre à cames d’échappement 2 Auslass-Nockenwelle 2 Eje de levas de escape È Vers l’arbre primaire È Zur Getriebe-Eingangswelle È…

Page 174: Cable Routing Diagram

SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose D Carburetor breather hose 2 Clamp E Carburetor overflow hose 3 Diode F Catch tank breather hose 4 Hot starter cable 5 Throttle position sensor lead 6 Wire harness 7 Hump (frame) 8 Negative battery lead 9 Starter motor lead…

Page 175: De Cheminement Des Cables

DIAGRAMME DE CHEMINEMENT DES CABLES KABELFÜHRUNGS-SCHAUBILD SPEC DIAGRAMA DE CABLEADO DIAGRAMME DE KABELFÜHRUNGS- DIAGRAMA DE SCHAUBILD CHEMINEMENT DES CABLEADO 1 Kraftstofftank-Belüftungsschlauch 1 Tubo respiradero del depósito de combus- CABLES 2 Klemme tible 1 Durit de mise à l’air du réservoir de car- 3 Diode 2 Brida burant…

Page 192: Maintenance Intervals

If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every…

Page 204: Pre-Operation Inspection And Maintenance

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…

Page 206: Routinekontrolle Vor Fahrtbeginn

INSP ROUTINEKONTROLLE VOR FAHRTBEGINN ROUTINEKONTROLLE VOR FAHRTBEGINN Ob zum Einfahren, Training oder Rennen, vor dem Starten stets die “Routinekontrolle vor Fahrtbe- ginn” ausführen. Vor dem ersten Einsatz folgende Punkte kontrollieren. ALLGEMEINE KONTROLL- UND WARTUNGSARBEITEN Bezeichnung Ausführung Seite Sicherstellen, dass die Kühlflüssigkeit bis zum Kühlerdeckel Kühlflüssigkeit reicht.

Page 214: Radiator Cap Inspection

RADIATOR CAP INSPECTION/ INSP RADIATOR CAP OPENING PRESSURE INSPECTION 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. EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1.

Page 228: Engine Oil Level Inspection

INSP ENGINE OIL LEVEL INSPECTION (For USA and CDN) 110 130 ˚F Recommended oil: Yamalube 4, SAE10W30 or YAMALUBE 4(10W-30) or SAE 10W-30 SAE20W40 Yamalube 4-R, SAE10W50 YAMALUBE 4(20W-40) or SAE 20W-40 API service SG type or higher, JASO standard MA YAMALUBE 4-R(10W-50) or SAE 10W-50 50 ˚C CAUTION:…

Page 231: Cambio De Aceite Del Motor

CHANGEMENT DE L’HUILE MOTEUR INSP MOTORÖL WECHSELN CAMBIO DE ACEITE DEL MOTOR Faire tourner le moteur au ralenti Motor mindestens Mantenga el motor al ralentí pendant plus de 10 secondes tout en Sekunden lang betreiben; dabei durante más de 10 segundos mien- gardant la moto verticale.

Page 232: Engine Oil Replacement

INSP ENGINE OIL REPLACEMENT 4. 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.

Page 236: And Side Covers

INSP VALVE CLEARANCE ADJUSTMENT VALVE CLEARANCE ADJUSTMENT NOTE: • 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.

Page 244: Valve Clearance Adjustment

INSP VALVE CLEARANCE ADJUSTMENT INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 0.10 ~ 0.15…

Page 248: Exhaust Pipe And Silencer

INSP SPARK ARRESTER CLEANING (For USA) SPARK ARRESTER CLEANING (For USA) WARNING • Be sure the exhaust pipe and silencer are cool before cleaning the spark arrester. • Do not start the engine when cleaning the exhaust system. 1. Remove: •…

Page 254: Rear Brake Adjustment

REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: • Brake pedal height a Out of specification → Adjust. Brake pedal height a: 10 mm (0.39 in) 2. Adjust: • Brake pedal height Pedal height adjustment steps: •…

Page 258: Front Wheel And Rear Wheel

INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT • Install the pad pin plug 0. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” section. 4.

Page 270: Front Fork Inspection

FRONT FORK INSPECTION/ INSP FRONT FORK OIL SEAL AND DUST SEAL CLEANING • Tighten the axle nut while pushing down the drive chain. Axle nut: 125 Nm (12.5 m • kg, 90 ft • lb) • Tighten the locknuts. Locknut: 19 Nm (1.9 m •…

Page 296: Electrical

INSP 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.

Page 297: Moteur

PARTIE ELECTRIQUE/CONTROLE DE LA BOUGIE INSP ELEKTRISCHE ANLAGE/ZÜNDKERZE KONTROLLIEREN SISTEMA ELÉCTRICO/COMPROBACIÓN DE LA BUJÍA ELEKTRISCHE ANLAGE PARTIE ELECTRIQUE SISTEMA ELÉCTRICO ZÜNDKERZE KONTROLLIEREN CONTROLE DE LA BOUGIE COMPROBACIÓN DE LA BUJÍA Déposer: Demontieren: Extraer: • Zündkerze • Bougie • Bujía Contrôler: Kontrollieren: Comprobar: •…

Page 327: Tubo De Escape Y Silenciador

TUBE D’ECHAPPEMENT ET SILENCIEUX AUSPUFFKRÜMMER UND SCHALLDÄMPFER TUBO DE ESCAPE Y SILENCIADOR TUBE D’ECHAPPEMENT ET SILENCIEUX 1 Dépose du silencieux 2 Dépose du tube d’échappement Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU TUBE D’ECHAPPEMENT ET DU SILENCIEUX Préparation à…

Page 330: Radiator

RADIATOR EC450001 RADIATOR 1 Radiator removal 2 Coolant reservoir removal Extent of 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, fuel tank and side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS”…

Page 336: Carburetor

CARBURETOR CARBURETOR 1 Carburetor removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Rear shock absorber Refer to “REAR SHOCK ABSORBER” section in the CHAPTER 5.

Page 364: Air Induction System

AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 1 Air induction system removal Extent of removal: Extent of removal Order Part name Q’ty Remarks AIR INDUCTION SYSTEM REMOVAL Bracket Air cut-off valve assembly Air induction hose (air cut-off valve — front of cylinder head) Air induction pipe Gasket Air induction hose (air cut-off…

Page 368: Camshafts

CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 1 Cylinder head cover removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM”…

Page 369: Arbres A Cames

ARBRES A CAMES NOCKENWELLEN EJES DE LEVAS ARBRES A CAMES COUVRE-CULASSE 1 Dépose du couvre-culasse Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU COUVRE-CULASSE Préparation à la dépose Selle et réservoir de carburant Se reporter à…

Page 394: Valves And Valve Springs

VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS 1 Valve removal Extent of 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. Valve lifter Use special tool.

Page 395: Soupapes Et Ressorts De Soupapes

SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULAS SOUPAPES ET RESSORTS DE SOUPAPES SOUPAPES ET RESSORTS DE SOUPAPES 1 Dépose de la soupape Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté…

Page 412: Cylinder And Piston

CYLINDER AND PISTON CYLINDER AND PISTON CYLINDER AND PISTON 1 Cylinder removal 2 Piston removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Bolt (cylinder) Cylinder Gasket…

Page 413: Cylindre Et Piston

CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO Y PISTÓN CYLINDRE ET PISTON CYLINDRE ET PISTON 1 Dépose du cylindre 2 Dépose du piston Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DES CYLINDRES ET DES PIS- TONS Préparation à…

Page 424: Clutch

CLUTCH CLUTCH CLUTCH 1 Push rod and push lever removal 2 Push rod 1 disassembly Extent of removal: 3 Friction plate and clutch plate removal 4 Clutch housing removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil.

Page 438: Oil Filter, Water Pump And Crankcase Cover (Right)

OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) 1 Oil filter removal 2 Water pump removal Extent of removal: 3 Crankcase cover (right) removal Extent of removal Order Part name…

Page 446: Balancer

OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) EC4G5220 Impeller shaft 1. Install: • Impeller shaft 1 • Plain washer 2 • Impeller 3 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: • Take care so that the oil seal lip is not dam- aged or the spring does not slip off its posi- tion.

Page 460: Oil Pump

OIL PUMP OIL PUMP OIL PUMP 1 Oil pump removal 2 Oil pump disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Clutch housing Refer to “CLUTCH” section. Crankcase cover (right) Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)”…

Page 461: Pompe A Huile

POMPE A HUILE ÖLPUMPE BOMBA DE ACEITE POMPE A HUILE POMPE A HUILE 1 Dépose de la pompe à huile 2 Démontage de la pompe à huile Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté…

Page 468: Kick Axle And Shift Shaft

KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT 1 Kick axle removal 2 Kick axle disassembly Extent of removal: 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q’ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL…

Page 469: Arbre De Kick Et Axe De Selecteur

ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE EJE DEL PEDAL DE ARRANQUE Y EJE DEL CAMBIO ARBRE DE KICK ET AXE DE SELECTEUR ARBRE DE KICK ET AXE DE SELECTEUR 1 Dépose de l’arbre de kick 2 Démontage de l’arbre de kick Organisation de la dépose: 3 Dépose de l’axe de sélecteur 4 Dépose des segments…

Page 478: Ac Magneto And Starter Clutch

KICK AXLE AND SHIFT SHAFT 3. Install: • Shift lever assembly 1 • Shift guide 2 NOTE: • The shift lever assembly is installed at the same time as the shift guide. • Apply the engine oil on the bolt (segment) shaft.

Page 485: Lichtmaschine Und Starterkupplung

ALTERNATEUR AVEC ROTOR A ALIMENTATION PERMANENTE ET EMBRAYAGE DU DEMARREUR LICHTMASCHINE UND STARTERKUPPLUNG MAGNETO CA Y EMBRAGUE DEL MOTOR DE ARRANQUE ALTERNATEUR AVEC ROTOR A ALIMENTATION PERMANENTE ET EMBRAYAGE DU DEMARREUR 1 Dépose de l’embrayage/du pignon du démarreur 2 Dépose du rotor Organisation de la dépose: 3 Dépose de la bobine d’excitation/du stator Organisation de la dépose…

Page 498: Engine Removal

ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the WARNING suitable stand under the frame. Support the machine securely so there is no danger of it falling over. Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”…

Page 499: Depose Du Moteur

DEPOSE DU MOTEUR MOTOR DEMONTIEREN DESMONTAJE DEL MOTOR DEPOSE DU MOTEUR Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU MOTEUR AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de basculer. sous le cadre.

Page 501: Desmontaje Del Motor

DEPOSE DU MOTEUR MOTOR DEMONTIEREN DESMONTAJE DEL MOTOR 1 Dépose du moteur Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques Durits de mise à l’air de la culass Se reporter à la section “ARBRES A CAMES”. Bobine d’allumage Déconnecter le fil de l’alternateur avec rotor à…

Page 510: Crankcase And Crankshaft

CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 1 Crankcase separation 2 Crankshaft removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CRANKCASE SEPARATION Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” sec- tion.

Page 511: Carter Moteur Et Vilebrequin

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL CARTER MOTEUR ET VILEBREQUIN CARTER MOTEUR ET VILEBREQUIN 1 Séparation du carter moteur 2 Dépose du vilebrequin Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté…

Page 514: Transmission, Shift Cam And Shift Fork

CRANKCASE AND CRANKSHAFT CRANKCASE BEARING 1 Crankcase bearing removal Extent of 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. Shift cam and shift fork Oil seal Bearing Refer to “REMOVAL POINTS”.

Page 541: Roue Avant Et Roue Arriere

ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD CHAS RUEDA DELANTERA Y RUEDA TRASERA CHASSIS ROUE AVANT ET ROUE ARRIERE ROUE AVANT 1 Dépose de la roue avant 2 Dépose du roulement de roue Organisation de la dépose: 3 Dépose du disque de frein Organisation de la dépose Ordre Nom de la pièce…

Page 558: Front Brake And Rear Brake

CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 1 Brake hose removal 2 Caliper removal Extent of removal: 3 Master cylinder removal Extent of removal Order Part name Q’ty Remarks FRONT BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the…

Page 559: Frein Avant Et Frein Arriere

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN CHAS FRENO DELANTERO Y FRENO TRASERO FREIN AVANT ET FREIN ARRIERE FREIN AVANT 1 Dépose de la durit de frein 2 Dépose de l’étrier de frein Organisation de la dépose: 3 Dépose du maître-cylindre Organisation de la dépose Ordre Nom de la pièce…

Page 590: Front Fork

CHAS FRONT FORK EC550000 FRONT FORK 1 Front fork removal Extent of removal: Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.

Page 591: Horquilla Delantera

FOURCHE TELESKOPGABEL CHAS HORQUILLA DELANTERA FOURCHE 1 Dépose de la fourche Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DE LA FOURCHE AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de bascu- sous le moteur.

Page 630: Steering

CHAS STEERING EC560000 STEERING 1 Under bracket removal 2 Bearing removal Extent of removal: Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.

Page 642: Swingarm

CHAS SWINGARM EC570000 SWINGARM 1 Swingarm Extent of removal: removal Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine. danger of it falling over.

Page 643: Frein Avant Et Frein Arriere

BRAS OSCILLANT SCHWINGE CHAS BASCULANTE BRAS OSCILLANT 1 Dépose du bras oscillant Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DU BRAS OSCILLANT AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de bascu- sous le moteur.

Page 645: Bras Oscillant

BRAS OSCILLANT SCHWINGE CHAS BASCULANTE DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 2 Dépose et démontage de la bielle Organisation de la dépose: 3 Dépose et démontage du bras relais Organisation de la dépose Ordre Nom de la pièce Qté…

Page 659: Et Caches Lateraux

AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO AMORTISSEUR ARRIERE 1 Dépose de l’amortisseur arrière 2 Démontage de l’amortisseur arrière Organisation de la dépose: Organisation de la dépose Ordre Nom de la pièce Qté Remarques DEPOSE DE L’AMORTISSEUR ARRIERE AVERTISSEMENT Préparation à la dépose Caler la moto en plaçant un support adéquat Bien caler la moto afin qu’elle ne risque pas de bascu- sous le moteur.

Page 661: Amortisseur Arriere

AMORTISSEUR ARRIERE FEDERBEIN CHAS AMORTIGUADOR TRASERO Organisation de la dépose Ordre Nom de la pièce Qté Remarques Durit de mise à l’air de la culasse La débrancher sur le côté du boîtier du filtre à air. Batterie Se reporter à la section “CONTROLE ET CHARGE DE LA BATTERIE”…

Page 676: And Wiring Diagram

– ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight A CDI unit COLOR CODE 2 Multi-function display B Taillight W ….. White B …… Black Y …… Yellow 3 “ENGINE STOP” but- C Neutral switch Br …..

Page 677: Ecran Multifonction

COMPOSANTS ELECTRIQUES ET SCHEMA DE CABLAGE ELEKTRISCHE BAUTEILE UND SCHALTPLAN – ELEC COMPONENTES Y ESQUEMA ELÉCTRICO PARTIE ELEKTRISCHE SISTEMA ELECTRIQUE ANLAGE ELÉCTRICO ELEKTRISCHE BAU- COMPOSANTS ELECTRI- COMPONENTES Y TEILE UND SCHALTPLAN QUES ET SCHEMA DE ESQUEMA ELÉCTRICO CABLAGE ELEKTRISCHE BAUTEILE COMPONENTES ELÉCTRICOS 1 Scheinwerfer 1 Faro…

Page 678: Ignition System

– ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. No good Replace fuse and *1 Check fuse.

Page 679: Carburant

– ELEC SYSTEME D’ALLUMAGE SYSTEME D’ALLUMAGE ETAPES DU CONTROLE Suivre la procédure ci-dessous pour déterminer si le mauvais fonctionnement du moteur est dû à une panne dans le circuit d’allumage et pour vérifier une bougie qui ne produit pas d’étincelle. Problème Remplacer le fusible et *1 Contrôler le fusible.

Page 681: Sistema De Encendido

– ELEC SISTEMA DE ENCENDIDO SISTEMA DE ENCENDIDO PROCEDIMIENTO DE REVISIÓN Utilice el procedimiento siguiente para verificar la posibilidad de que se esté produciendo un fallo del motor atribuible a un fallo del sistema de encendido, así como para comprobar la bujía. Incorrecto Cambiar el fusible y com- *1 Comprobar fusible.

Page 688: Electric Starting System

– ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the fol- lowing conditions is met: • The transmission is in neutral (the neutral switch is closed).

Page 689: Demarrage Electrique

DEMARRAGE ELECTRIQUE E-STARTER – ELEC SISTEMA DE ARRANQUE ELÉCTRICO DEMARRAGE E-STARTER SISTEMA DE ARRANQUE ELECTRIQUE FUNKTION DES ELÉCTRICO ANLASSSPERRSYSTEMS FONCTIONNEMENT DU FUNCIONAMIENTO DEL Wenn der Zündschalter auf “ON” DISPOSITIF DE COUPURE DU SISTEMA DE CORTE DEL gestellt ist, arbeitet der Starter nur, CIRCUIT DE DEMARRAGE CIRCUITO DE ARRANQUE wenn eine der folgenden Bedingun-…

Page 710: Charging System

– ELEC CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wire harness. No good *2 Check battery. Recharge or replace. No good Check each coupler and Repair or replace.

Page 711: Systeme De Charge

– ELEC SYSTEME DE CHARGE SYSTEME DE CHARGE ETAPES DU CONTROLE Si la batterie n’est pas chargée, effectuer les contrôles suivants. Remplacer le fusible et Problème *1 Contrôler le fusible. contrôler le faisceau de fils. Problème *2 Contrôler la batterie. Recharger ou remplacer.

Page 713: Sistema De Carga

– ELEC SISTEMA DE CARGA SISTEMA DE CARGA PROCEDIMIENTO DE REVISIÓN Si la batería no está cargada utilice el procedimiento de comprobación siguiente. Cambiar el fusible y Incorrecto *1 Comprobar fusible. comprobar el mazo de cables. Correcto Incorrecto *2 Comprobar batería. Recargar o cambiar.

Page 723: Carburateur

SYSTEME TPS (CAPTEUR DE POSITION DE PAPILLON DES GAZ) DROSSELKLAPPENSENSOR – ELEC SISTEMA TPS (SENSOR DE POSICIÓN DEL ACELERADOR) Contrôler: Kontrollieren: Comprobar: • Résistance variable de la bobine • Drosselklappensensor-Wider- • Resistencia variable de la bobina du TPS stand del TPS Vérifier que la résistance aug- Darauf achten,…

Page 728: Lighting System

– ELEC LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. No good Check the bulb and bulb Replace the bulb socket. and/or bulb socket. No good Replace the taillight Check the taillight (LEDs).

Page 736: Signaling System

– ELEC SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. No good *1 Check battery. Recharge or replace. No good Check each coupler and Repair or replace. wire connection. No good Check multi-function dis- Input voltage Replace wire harness.

Page 737: Systeme De Signalisation

– ELEC SYSTEME DE SIGNALISATION SYSTEME DE SIGNALISATION PROCEDURE DE CONTROLE Si le compteur de vitesse ne fonctionne pas, effectuer les contrôles suivants. Problème *1 Contrôler la batterie. Recharger ou remplacer. Problème Contrôler chaque fiche rapide Réparer ou remplacer. et connexion de fils. Problème Contrôler l’écran multifonc- Tension…

Page 738: Signalanlage

– ELEC SIGNALANLAGE SIGNALANLAGE KONTROLLE Folgende Prüfschritte dienen zur Diagnose des Geschwindigkeitssensors, wenn dieser nicht funkti- oniert. Nicht in Ordnung *1 Batterie kontrollieren. Laden, ggf. erneuern. In Ordnung Sämtliche Steckverbinder- Nicht in Ordnung Instand setzen, ggf. und Kabelanschlüsse kon- erneuern. trollieren.

Page 739: Sistema De Señalización

– ELEC SISTEMA DE SEÑALIZACIÓN SISTEMA DE SEÑALIZACIÓN PROCEDIMIENTO DE REVISIÓN Si el velocímetro no funciona utilice el procedimiento de comprobación siguiente. Incorrecto *1 Comprobar batería. Recargar o cambiar. Correcto Incorrecto Comprobar todos los acopla- Reparar o cambiar. dores y conexiones de cables. Correcto Incorrecto Comprobar el visor multifun-…

Page 741: Kabelanschlüsse Kontrollieren

SYSTEME DE SIGNALISATION SIGNALANLAGE – ELEC SISTEMA DE SEÑALIZACIÓN CONTROLE DES CONNEXIONS STECKVERBINDER- UND COMPROBACIÓN DE LA DES FICHES RAPIDES ET DES KABELANSCHLÜSSE CONEXIÓN DE ACOPLADORES Y FILS KONTROLLIEREN CABLES Contrôler: Kontrollieren: Comprobar: • Connexion des fiches rapides et • Steckverbinder- und Kabelan- •…

Page 762: Kraftstoff

T U N EINSTELLUNG Beispiele von Symptomen mit entsprechenden Vergasereinstellungen Symptom Einstellung Kontrolle Verfärbung der Zündkerze → Bei völlig geöffneter Dros- Hauptdüsen-Nr. erhöhen. selklappe (schrittweise) Falls rehbraun, in Ordnung. Schweres Saugen Falls nicht korrigierbar: Schergeräusch Schwimmer-Ventilsitz verstopft Weißliches Zündkerzen- Kraftstoffschlauch verstopft gesicht Kraftstoffhahn verstopft Sicherstellen, dass die Beschleuni-…

Page 763: Combustible

T U N PUESTA A PUNTO Ejemplos de ajuste del carburador dependiendo del síntoma Síntoma Ajuste Comprobación Decoloración de la bujía → A pleno gas Aumente el nº de calibrado del surtidor Al motor le cuesta respirar principal. Un color canela significa que está en Ruido cortante (gradualmente) buen estado.

Page 769: Fourche

REGLAGE EINSTELLUNG T U N PUESTA A PUNTO Réglage de la fourche Teleskopgabel einstellen Ajuste de la horquilla delantera Régler la fourche en fonction de l’expé- Teleskopgabel-Einstellung La horquilla delantera se debe ajustar rience de conduite du pilote sur le terrain eine Sache persönlichen…

Page 773: Lenker

REGLAGE EINSTELLUNG T U N PUESTA A PUNTO Réglage du ressort après remplace- Feder nach Austausch einstellen Ajuste del muelle después de cam- ment Da die Einstellung der Hinterradfede- biarlo La suspension arrière pouvant influencer rung sich auch auf die Vorderradfe- Dado que el ajuste de la horquilla delan- le réglage de la fourche, il convient donc derung…

Page 781: Federbein

REGLAGE EINSTELLUNG T U N PUESTA A PUNTO ATTENTION: ACHTUNG: ATENCION: Beim Austauschen des Feder- Lors du remplacement de l’amortis- Cuando vaya a utilizar un amortigua- seur arrière, veiller à monter un beins darauf achten, dass dessen dor que no sea el instalado actual- amortisseur dont la longueur totale a Gesamtlänge a das Standardmaß…

Page 784: Suspension Setting

T U N SETTING EC72H002 Suspension setting • Front fork NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. •…