Yamaha AVS-700 Service Manual

PRINTED IN JAPAN2010.04—0.4 × 1 !(E)YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED ON RECYCLED PAPERPROTECT YOUR INVESTMENTUse Genuine

MEMO

3-25ENGINEINTAKEEXHAUSTMEASURED CLEARANCEINSTALLED PAD NUMBER120 125 130 135 140 145 150 155 160 165 170175 180 185 190 195 200 205 210 215 220 225 23

3-26ENGINECLEANING THE SPARK ARRESTER (For USA)• Be sure the exhaust pipe and silencer are cool before cleaning the spark arrester.• Do not start the

3-27CHASSISCHASSISBLEEDING THE HYDRAULIC BRAKE SYSTEMBleed the brake system if:• The system has been disassembled.• A brake hose has been loosened or

3-28CHASSIS2. Remove:• Brake lever cover3. Adjust:• Brake lever positionBrake lever position adjustment steps:a. Loosen the locknut "1".b. T

3-29CHASSIS2. Replace:•Brake padBrake pad replacement steps:a. Remove the pad pin plug "1".b. Loosen the pad pin "2".c. Remove the

3-30CHASSISj. Install the pad pin plug "10".3. Inspect:•Brake fluid levelRefer to "CHECKING THE BRAKE FLUID LEVEL" section.4. Chec

3-31CHASSISDo not reuse the drained brake fluid.g. Tighten the bleed screw.h. Install the brake pad "10" and pad pin "11".• Instal

3-32CHASSIS• Use only designated quality brake fluid to avoid poor brake performance.• Refill with same type and brand of brake fluid; mixing fluids c

3-33CHASSIS4. Inspect:• O-ring "1" (drive chain)Damage → Replace the drive chain.• Roller "2"• Side plate "3"Damage/wear

3-34CHASSISBefore checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest

TABLE OF CONTENTSGENERAL INFORMATION1SPECIFICATIONS2REGULAR INSPECTION AND ADJUSTMENTS3TUNING4ENGINE5CHASSIS6ELECTRICAL7

3-35CHASSIS2. Clean:• Dust seal "a"•Oil seal "b"• Clean the dust seal and oil seal after every run.• Apply the lithium soap base g

3-36CHASSIS• STANDARD POSITION:This is the position which is back by the spe-cific number of clicks from the fully turned-in position.Do not force the

3-37CHASSIS• Be sure to remove all dirt and mud from around the locknut and adjuster before adjust-ment.• The length of the spring (installed) changes

3-38CHASSIS• STANDARD POSITION:This is the position which is back by the spe-cific number of clicks from the fully turned-in position. (Which align th

3-39CHASSISCHECKING THE TIRE PRESSURE1. Measure:• Tire pressureOut of specification → Adjust.• Check the tire while it is cold.• Loose bead stoppers a

3-40CHASSISCHECKING AND ADJUSTING THE STEERING HEAD1. Place a stand under the engine to raise the front wheel off the ground. WARNING! Se-curely suppo

3-41CHASSIS• The handlebar upper holder should be in-stalled with the punched mark "a" forward.• Install the handlebar so that the marks &qu

3-42CHASSIS

3-43CHASSISLUBRICATION

3-44CHASSISTo ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every ride.1. All control cabl

CONTENTSCHAPTER 1GENERAL INFORMATIONLOCATION OF IMPORTANT LABELS ... 1-1DESCRIPTION ... 1-2CONSUMER INFORMAT

3-45ELECTRICALELECTRICALCHECKING THE SPARK PLUG1. Remove:• Spark plug2. Inspect:• Electrode "1"Wear/damage → Replace.• Insulator color "

3-46ELECTRICAL5. Install:• Timing mark accessing screwCHECKING AND CHARGING THE BATTERYBatteries generate explosive hydrogen gas and contain electroly

3-47ELECTRICAL• The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal i

3-48ELECTRICALCharging method using a variable voltage charger

3-49ELECTRICALCharging method using a constant voltage charger

3-50ELECTRICAL6. Install:• Battery• Battery band7. Connect:• Battery leads(to the battery terminals)First, connect the positive lead "1", th

3-51ELECTRICALREPLACING THE HEADLIGHT BULBS1. Remove:• HeadlightRefer to "SEAT, FUEL TANK AND SIDE COVERS" section.2. Remove:• Headlight bul

4-1CHASSISTUNINGCHASSISSELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET)<Requirement for selection of secondary gear reduction ratio>• It is

4-2CHASSISFRONT FORK SETTINGThe front fork setting should be made depend-ing on the rider's feeling of an actual run and the circuit conditions.T

4-3CHASSISA. LoadB. Fork stroke1. Without adjustment washer (standard)2. 1 adjustment washer3. 2 adjustment washersSETTING OF SPRING AFTER REPLACEMENT

CHAPTER 3REGULAR INSPECTION AND ADJUSTMENTSPERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ... 3-1GENERAL MAINTENANCE AND LUBRICATION C

4-4CHASSIS2. Setting of damping force• Change the rebound damping.• Change the compression damping.CHOOSING SET LENGTH1. Place a stand or block under

4-5CHASSISREAR SHOCK ABSORBER SETTING PARTS• Rear shock spring "1"• The I.D. mark "a" is marked at the end of the spring.• Spring

4-6CHASSISSUSPENSION SETTING (FRONT FORK)• If any of the following symptoms is experienced with the standard position as the base, make reset-ting by

4-7CHASSISSUSPENSION SETTING (REAR SHOCK ABSORBER)• If any of the following symptoms is experienced with the standard position as the base, make reset

5-1RADIATORENGINEThis section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha de

5-2RADIATOR2 Radiator hose clamp 83 Right radiator 14 Radiator hose 2 15 Radiator hose 3 16 Radiator pipe 4 17 Pipe 2/O-ring 1/18 Catch tank hose 19 L

5-3RADIATORHANDLING NOTEDo not remove the radiator cap when the en-gine and radiator are hot. Scalding hot fluid and steam may be blown out under pres

5-4RADIATOR4. Install:• Radiator guard "1"First fit the inner hook portion "a" and then the outer one "b" onto the radia

5-5CARBURETORCARBURETORREMOVING THE CARBURETOROrder Part name Q'ty RemarksSeat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE COVERS"

5-6CARBURETOR11 Cylinder head breather hose 2 112 Cylinder head breather hose 3 113 Bracket (cylinder head breather pipe) 114 Carburetor joint 1Order

CHAPTER 6CHASSISFRONT WHEEL AND REAR WHEEL ... 6-1FRONT BRAKE AND REAR BRAKE... 6-10FRONT FORK ... 6-24H

5-7CARBURETORDISASSEMBLING THE CARBURETOROrder Part name Q'ty Remarks1 Carburetor breather hose 42 Valve lever housing cover 13 Screw (throttle s

5-8CARBURETOR16 Float 117 Needle valve 118 Main jet 119 Needle jet 120 Spacer 121 Pilot jet 122 Starter jet 123 Push rod 1 Pull the push rod.24 Thrott

5-9CARBURETORHANDLING NOTEDo not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to fa

5-10CARBURETORMEASURING AND ADJUSTING THE FLOAT HEIGHT1. Measure:• Float height "a"Out of specification → Adjust.Measurement and adjustment

5-11CARBURETOR2. Inspect:• Throttle shaft "1"• Spring "2"• Lever 1 "3"• Spring 1 "4"• Lever 2 "5"• S

5-12CARBURETOR5. Install:• Push rod link lever assembly "1"Make sure the stopper "a" of the spring 2 fits into the recess "b&

5-13CARBURETOR10.Install:• Starter jet "1"• Pilot jet "2"• Spacer "3"• Needle jet "4"• Main jet "5"1

5-14CARBURETOR• Throttle valve plate "5"To throttle valve "6".16.Install:• Throttle valve assembly "1"• Screw (throttle

5-15CARBURETORINSTALLING THE CARBURETOR1. Install:• Carburetor joint "1"• Bracket (cylinder head breather pipe) "2"• Bolt (carbure

5-16CARBURETOR8. Install:• Throttle position sensor lead coupler "1"•Clamp "2"Refer to "CABLE ROUTING DIAGRAM" section i

1-1LOCATION OF IMPORTANT LABELSGENERAL INFORMATIONLOCATION OF IMPORTANT LABELSPlease read the following important labels carefully before operating th

5-17AIR INDUCTION SYSTEMAIR INDUCTION SYSTEMREMOVING THE AIR INDUCTION SYSTEMOrder Part name Q'ty Remarks1 Bracket 12 Air cut-off valve assembly

5-18AIR INDUCTION SYSTEMCHECKING THE AIR INDUCTION SYSTEM1. Inspect:• Air induction hoseCrack/damage → Replace.• Air induction pipeCrack/damage → Repl

5-19CAMSHAFTSCAMSHAFTSREMOVING THE CYLINDER HEAD COVEROrder Part name Q'ty RemarksSeat and fuel tank Refer to "REMOVING THE SEAT, FUEL TANK

5-20CAMSHAFTSREMOVING THE CAMSHAFTSOrder Part name Q'ty Remarks1 Timing mark accessing screw 1 Refer to removal section.2 Crankshaft end accessin

5-21CAMSHAFTSREMOVING THE CAMSHAFT1. Remove:• Timing mark accessing screw "1"• Crankshaft end accessing screw "2"2. Align:• T.D.C.

5-22CAMSHAFTSCHECKING THE CAMSHAFT1. Inspect:• Cam lobePitting/scratches/blue discoloration → Re-place.2. Measure:• Cam lobe length "a" and

5-23CAMSHAFTS• Tighten the bolts (camshaft cap) in a criss-cross pattern from innermost to outer caps.• Do not turn the camshaft when measuring cleara

5-24CAMSHAFTSINSTALLING THE CAMSHAFT1. Install:• Exhaust camshaft "1"• Intake camshaft "2"Installation steps:a. Turn the crankshaf

5-25CAMSHAFTS2. Install:• Timing chain tensionerInstallation steps:a. While pressing the tensioner rod lightly with fingers, use a thin screwdriver an

5-26CYLINDER HEADCYLINDER HEADREMOVING THE CYLINDER HEADOrder Part name Q'ty RemarksSeat and fuel tank Refer to "REMOVING THE SEAT, FUEL TAN

1-2DESCRIPTIONDESCRIPTION• The machine you have purchased may differ slightly from those shown in the following.• Designs and specifications are subje

5-27CYLINDER HEADTighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, re-move and retighten the cylinder h

5-28CYLINDER HEADCHECKING THE CYLINDER HEAD1. Eliminate:• Carbon deposits (from the combustion chambers)Use a rounded scraper.Do not use a sharp instr

5-29CYLINDER HEADa. Wash the threads and contact surfaces of the bolts, the contact surfaces of the plain washers, the contact surface of the cylinder

5-30VALVES AND VALVE SPRINGSVALVES AND VALVE SPRINGSREMOVING THE VALVES AND VALVE SPRINGSOrder Part name Q'ty RemarksCylinder head Refer to "

5-31VALVES AND VALVE SPRINGSREMOVING THE VALVE LIFTER AND VALVE COTTER1. Remove:• Valve lifter "1"• Pad "2"Identify each lifter &

5-32VALVES AND VALVE SPRINGS2. Replace:• Valve guideReplacement steps:To ease guide removal, installation and to maintain correct fit heat the cylinde

5-33VALVES AND VALVE SPRINGS5. Measure:• Runout (valve stem)Out of specification → Replace.• When installing a new valve always replace the guide.• If

5-34VALVES AND VALVE SPRINGSLapping steps:a. Apply a coarse lapping compound to the valve face.Do not let the compound enter the gap be-tween the valv

5-35VALVES AND VALVE SPRINGSb. Installed length3. Measure:• Spring tilt "a"Out of specification → Replace.CHECKING THE VALVE LIFTERS1. Inspe

5-36VALVES AND VALVE SPRINGS4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.Hitting the valve tip w

1-3CONSUMER INFORMATIONCONSUMER INFORMATIONThere are two significant reasons for knowing the serial number of your machine:1. When ordering parts, you

5-37CYLINDER AND PISTONCYLINDER AND PISTONREMOVING THE CYLINDER AND PISTONOrder Part name Q'ty RemarksCylinder head Refer to "CYLINDER HEAD

5-38CYLINDER AND PISTONREMOVING THE PISTON AND PISTON RING1. Remove:• Piston pin clip "1"• Piston pin "2"•Piston "3"• Pu

5-39CYLINDER AND PISTONa. 8 mm (0.31 in) from the piston bottom edged. If out of specification, replace the piston and piston rings as a set.e. Calcul

5-40CYLINDER AND PISTONCHECKING THE PISTON PIN1. Inspect:• Piston pinBlue discoloration/grooves → Replace, then inspect the lubrication system.2. Meas

5-41CYLINDER AND PISTON• Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the pis-ton pin clip from falling into

5-42CLUTCHCLUTCHREMOVING THE CLUTCHOrder Part name Q'ty RemarksDrain the engine oil. Refer to "CHANGING THE ENGINE OIL" section in the

5-43CLUTCH11 Push rod 2 112 Clutch plate 713 Friction plate 814 Nut (clutch boss) 1 Refer to removal section.15 Lock washer 1 Refer to removal section

5-44CLUTCHREMOVING THE CLUTCH BOSS1. Remove:•Nut "1"• Lock washer "2"• Clutch boss "3"Straighten the lock washer tab and

5-45CLUTCHCHECKING THE CLUTCH PLATES1. Measure:• Clutch plate warpageOut of specification → Replace clutch plate as a set.Use a surface plate "1&

5-46CLUTCHA. For USA and CDNB. Except for USA and CDN3. Bend the lock washer "1" tab.4. Install:• Friction plate "1"• Clutch plate

1-4INCLUDED PARTSINCLUDED PARTSVALVE JOINTThis valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hos

5-47CLUTCH7. Install:• Pressure plate "1"8. Install:• Clutch spring• Bolt (clutch spring)Tighten the bolts in stage, using a crisscross patt

5-48OIL FILTER ELEMENT AND WATER PUMPOIL FILTER ELEMENT AND WATER PUMPREMOVING THE OIL FILTER ELEMENT AND WATER PUMPOrder Part name Q'ty RemarksR

5-49OIL FILTER ELEMENT AND WATER PUMP5Pin 26 Oil tank breather hose 17 Kickstarter crank 18 Right crankcase cover 19Gasket 110 Dowel pin/O-ring 3/111

5-50OIL FILTER ELEMENT AND WATER PUMPREMOVING THE IMPELLER SHAFT1. Remove:• Impeller "1"•Washer "2"• Impeller shaft "3"H

5-51OIL FILTER ELEMENT AND WATER PUMPINSTALLING THE OIL SEAL1. Install:• Oil seal "1" • Apply the lithium soap base grease on the oil seal l

5-52OIL FILTER ELEMENT AND WATER PUMP2. Install:• Right crankcase cover "1"•Bolt "2"•Bolt• Apply the engine oil on the impeller sh

5-53OIL FILTER ELEMENT AND WATER PUMP• Coolant drain bolt "4"3. Install:• O-ring • Coolant pipe "1"• Bolt (coolant pipe) "2&q

5-54BALANCERBALANCERREMOVING THE BALANCEROrder Part name Q'ty RemarksPrimary driven gear Refer to "CLUTCH" section.Right crankcase cov

5-55BALANCERREMOVING THE BALANCER1. Straighten the lock washer tab.2. Loosen:• Nut (balancer) "1"• Nut (primary drive gear) "2"• N

5-56BALANCER3. Install:• Lock washer "1"• Nut (balancer shaft driven gear) "2"• Primary drive gear "3"• Conical washer &

1-5IMPORTANT INFORMATIONIMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DISASSEMBLY1. Remove all dirt, mud, dust, and foreign ma-terial before remova

5-57OIL PUMPOIL PUMPREMOVING THE OIL PUMPOrder Part name Q'ty RemarksPrimary driven gear Refer to "CLUTCH" section.Right crankcase cove

5-58OIL PUMP12 Inner rotor 1 113 Dowel pin 114 Washer 115 Oil pump drive shaft 116 Rotor housing 1Order Part name Q'ty Remarks

5-59OIL PUMPCHECKING THE OIL PUMP1. Inspect:• Oil pump drive gear• Oil pump drive shaft• Rotor housing• Oil pump coverCracks/wear/damage → Replace.2.

5-60OIL PUMP• Dowel pin "3"• Inner rotor 2 "4"• Circlip "5" • Apply the engine oil on the oil pump drive shaft end and i

5-61KICK SHAFT AND SHIFT SHAFTKICK SHAFT AND SHIFT SHAFTREMOVING THE KICK SHAFT AND SHIFT SHAFTOrder Part name Q'ty RemarksOil pump Refer to &qu

5-62KICK SHAFT AND SHIFT SHAFT14 Shift guide 1 Refer to removal section.15 Shift lever assembly 1 Refer to removal section.16 Shift lever 117 Pawl 218

5-63KICK SHAFT AND SHIFT SHAFTREMOVING THE KICK SHAFT ASSEMBLY1. Remove:• Kick shaft assembly "1"Unhook the torsion spring "2" fro

5-64KICK SHAFT AND SHIFT SHAFT• Spring "2"Broken → Replace.CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY1. Inspect:• Shift guide "1

5-65KICK SHAFT AND SHIFT SHAFTApply the engine oil on the spring, pawl pin and pawl.2. Install:• Shift lever assembly "1"To shift guide &quo

5-66KICK SHAFT AND SHIFT SHAFT2. Install:• Torsion spring "1"To kick shaft "2".Make sure the stopper "a" of the torsion

QRead this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.5TJ-9-17_cover-13mm 09.8.17 10:

1-6IMPORTANT INFORMATIONLOCK WASHERS/PLATES AND COTTER PINS1. All lock washers/plates "1" and cotter pins must be replaced when they are rem

5-67AC MAGNETO AND STARTER CLUTCHAC MAGNETO AND STARTER CLUTCHREMOVING THE AC MAGNETO AND STARTER CLUTCHOrder Part name Q'ty RemarksDrain the eng

5-68AC MAGNETO AND STARTER CLUTCHTighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb)

5-69AC MAGNETO AND STARTER CLUTCHREMOVING THE ROTOR1. Remove:• Nut (rotor) "1"•WasherUse the sheave holder "2".2. Remove:•Rotor &q

5-70AC MAGNETO AND STARTER CLUTCHCHECKING THE STARTER CLUTCH1. Check:• Starter clutchDamage/wear → Replace.2. Check:• Idle gear• Idle gear shaft• Star

5-71AC MAGNETO AND STARTER CLUTCH2. Install:• Starter clutch drive gear "1"Apply the engine oil on the starter clutch drive gear inner circu

5-72AC MAGNETO AND STARTER CLUTCHApply the engine oil on the shaft, bearing and idle gear inner circumference.8. Install:• Dowel pin• Gasket [crankcas

5-73ENGINE REMOVALENGINE REMOVALREMOVING THE ENGINEOrder Part name Q'ty RemarksHold the machine by placing the suit-able stand under the frame.Re

5-74ENGINE REMOVALRear shock absorberRefer to "REAR SHOCK ABSORB-ER" section in the CHAPTER 6.Carburetor Refer to "CARBURETOR" sec

5-75ENGINE REMOVAL7Clip 18 Bolt (brake pedal) 19 Brake pedal 110 Upper engine bracket 211 Lower engine bracket 212 Engine mounting bolt 313 Pivot shaf

5-76ENGINE REMOVALHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE DRIVE SPROCKET1. Remove:• Nut (drive

1-7CHECKING OF CONNECTIONCHECKING OF CONNECTIONDealing with stains, rust, moisture, etc. on the connector.1. Disconnect:• Connector2. Dry each termina

5-77ENGINE REMOVAL• Engine mounting bolt (upper) "10"• Apply the molybdenum disulfide grease on the pivot shaft.• Install the patch with the

5-78ENGINE REMOVAL4. Install:• Drive chain sprocket guide• Drive chain sprocket cover "1"• Bolt (drive chain sprocket cover) "2"IN

5-79CRANKCASE AND CRANKSHAFTCRANKCASE AND CRANKSHAFTREMOVING THE CRANKSHAFTOrder Part name Q'ty RemarksEngineRefer to "ENGINE REMOVAL"

5-80CRANKCASE AND CRANKSHAFT5 Bolt [L = 80 mm (3.15 in)] 3 Refer to removal section.6 Hose guide 1 Refer to removal section.7 Clutch cable holder 1 Re

5-81CRANKCASE AND CRANKSHAFTREMOVING THE CRANKCASE BEARINGOrder Part name Q'ty RemarksTransmissionRefer to "TRANSMISSION, SHIFT CAM AND SHIF

5-82CRANKCASE AND CRANKSHAFTDISASSEMBLING THE CRANKCASE1. Separate:• Right crankcase• Left crankcaseSeparation steps:a. Remove the crankcase bolts, ho

5-83CRANKCASE AND CRANKSHAFTREMOVING THE CRANKCASE BEARING1. Remove:• Bearing "1"• Remove the bearing from the crankcase by pressing its inn

5-84CRANKCASE AND CRANKSHAFTCHECKING THE OIL STRAINER1. Inspect:• Oil strainerDamage → Replace.INSTALLING THE CRANKCASE BEARING1. Install:• Bearing •

5-85CRANKCASE AND CRANKSHAFTA. For USA and CDNB. Except for USA and CDN2. Check:• Shifter operation• Transmission operationUnsmooth operation → Repair

5-86CRANKCASE AND CRANKSHAFT• Bolt (crankcase)Tighten the crankcase tightening bolts in stage, using a crisscross pattern.7. Install:• Timing chain• T

1-8SPECIAL TOOLSSPECIAL TOOLSThe proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool wil

5-87TRANSMISSION, SHIFT CAM AND SHIFT FORKTRANSMISSION, SHIFT CAM AND SHIFT FORKREMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORKOrder Part name Q&a

5-88TRANSMISSION, SHIFT CAM AND SHIFT FORKREMOVING THE TRANSMISSION1. Remove:• Main axle "1"•Drive axle "2"• Shift cam• Shift fork

5-89TRANSMISSION, SHIFT CAM AND SHIFT FORK3. Check:• Shift fork movementUnsmooth operation → Replace shift fork.For a malfunctioning shift fork, repla

5-90TRANSMISSION, SHIFT CAM AND SHIFT FORK3. Install:•Washer "1"• Circlip "2" • Be sure the circlip sharp-edged corner "a&quo

5-91TRANSMISSION, SHIFT CAM AND SHIFT FORK6. Install:• Transmission assembly "1"To left crankcase "2".Apply the engine oil on the

6-1FRONT WHEEL AND REAR WHEELCHASSISThis section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycl

6-2FRONT WHEEL AND REAR WHEEL7Oil seal 18 Bearing 2 Refer to removal section.9 Brake disc 1Order Part name Q'ty Remarks21 Nm (2.1 m kg, 15 ft

6-3FRONT WHEEL AND REAR WHEELREMOVING THE REAR WHEELOrder Part name Q'ty RemarksHold the machine by placing the suit-able stand under the engine.

6-4FRONT WHEEL AND REAR WHEELHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE REAR WHEEL1. Remove:• Whe

6-5FRONT WHEEL AND REAR WHEELCHECKING THE BRAKE DISC1. Measure:• Brake disc deflection (only rear brake disc)Use the dial gauge "1".Out of s

1-9SPECIAL TOOLSSteering nut wrenchYU-33975, 90890-01403 This tool is used when tighten the steering ring nut to speci-fication.Damper rod holderYM-01

6-6FRONT WHEEL AND REAR WHEEL3. Install:• Collar "1"Apply the lithium soap base grease on the oil seal lip.4. Install:• Speed sensor "1

6-7FRONT WHEEL AND REAR WHEELINSTALLING THE REAR WHEEL1. Install:• Bearing (right) "1"• Circlip "2" • Spacer "3"• Bearin

6-8FRONT WHEEL AND REAR WHEEL4. Install:• Collar "1"Apply the lithium soap base grease on the oil seal lip.5. Install:• WheelInstall the bra

6-9FRONT WHEEL AND REAR WHEEL9. Adjust:• Drive chain slack "a"Refer to "ADJUSTING THE DRIVE CHAIN SLACK" section in the CHAPTER 3.

6-10FRONT BRAKE AND REAR BRAKEFRONT BRAKE AND REAR BRAKEREMOVING THE FRONT BRAKEOrder Part name Q'ty RemarksHold the machine by placing the suit-

6-11FRONT BRAKE AND REAR BRAKEREMOVING THE REAR BRAKEOrder Part name Q'ty RemarksHold the machine by placing the suit-able stand under the engine

6-12FRONT BRAKE AND REAR BRAKEDISASSEMBLING THE BRAKE CALIPEROrder Part name Q'ty RemarksA. FrontB. RearAB1Pad pin 112Brake pad 223 Pad support 1

6-13FRONT BRAKE AND REAR BRAKEDISASSEMBLING THE BRAKE MASTER CYLINDEROrder Part name Q'ty RemarksA. FrontB. Rear1 Brake master cylinder cap 12 Di

6-14FRONT BRAKE AND REAR BRAKEHANDLING NOTESupport the machine securely so there is no danger of it falling over.DRAINING THE BRAKE FLUID1. Remove:• B

6-15FRONT BRAKE AND REAR BRAKERemove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger.Never attempt to

1-10SPECIAL TOOLSTiming lightYM-33277-A, 90890-03141 This tool is necessary for checking ignition timing.Valve spring compressorYM-4019, 90890-04019 T

6-16FRONT BRAKE AND REAR BRAKEA. FrontB. RearCHECKING THE BRAKE CALIPER1. Inspect:• Brake caliper cylinder inner surface "a"Wear/score marks

6-17FRONT BRAKE AND REAR BRAKEA. FrontB. Rear3. Install:• Brake caliper piston "1"Apply the brake fluid on the piston wall.• Install the pis

6-18FRONT BRAKE AND REAR BRAKE2. Install:• Brake disc cover "1"• Bolt (brake disc cover) "2"3. Install:• Brake caliper "1&quo

6-19FRONT BRAKE AND REAR BRAKEA. FrontB. Rear4. Install:• Brake master cylinder kit "1"• Washer (front brake) "2"• Push rod (rear

6-20FRONT BRAKE AND REAR BRAKE• Union bolt "3"Always use new copper washers.Install the brake hose so that its pipe por-tion "a" d

6-21FRONT BRAKE AND REAR BRAKEInstall the brake hose so that its pipe por-tion "a" directs as shown and lightly touch-es the projection &quo

6-22FRONT BRAKE AND REAR BRAKEINSTALLING THE REAR BRAKE HOSE1. Install:• Copper washer "1" • Brake hose "2"• Union bolt "3&qu

6-23FRONT BRAKE AND REAR BRAKEBrake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.A. FrontB. Rear2. Air

6-24FRONT FORKFRONT FORKREMOVING THE FRONT FORKOrder Part name Q'ty RemarksA. For CDNHold the machine by placing the suit-able stand under the en

6-25FRONT FORKDISASSEMBLING THE FRONT FORKOrder Part name Q'ty Remarks1 Front fork cap bolt 1 Refer to removal section.2 Fork spring 1 Drain the

1-11SPECIAL TOOLSCrankcase separating toolYU-A964290890-04152These tool is used to remove the crankshaft from either case.Dynamic spark testerYM-34487

6-26FRONT FORKHANDLING NOTESupport the machine securely so there is no danger of it falling over.The front fork requires careful attention. So it is r

6-27FRONT FORKREMOVING THE DAMPER ROD1. Remove:• Base valve "1"• Damper rod "2"Use a damper rod holder "3" to lock the d

6-28FRONT FORKCHECKING THE OUTER TUBE1. Inspect:• Outer tube "1"Score marks/wear/damage → Replace.CHECKING THE FRONT FORK CAP BOLT1. Inspect

6-29FRONT FORK• Install the spring guide with its smaller dia.end "a" facing downward.• With its thread "b" facing upward, fully f

6-30FRONT FORK10.Install:•Oil seal "1"Press the oil seal into the outer tube with fork seal driver "2".11.Install:• Stopper ring &

6-31FRONT FORK16.After filling, pump the damper rod "1" slowly up and down more than 10 times to distrib-ute the fork oil.17.Fill:• Front fo

6-32FRONT FORK22.Loosen:• Rebound damping adjuster "1"• Loosen the rebound damping adjuster finger tight.• Record the set position of the ad

6-33FRONT FORKInstall the protector guide with its wider side "a" facing downward.INSTALLING THE FRONT FORK1. Install:• Front fork "1&q

6-34FRONT FORK6. Install:• Speed sensor lead "1"• Plate 2 "2"• Screw (plate 2) "3"To right protector "4".Insta

6-35HANDLEBARHANDLEBARREMOVING THE HANDLEBAROrder Part name Q'ty RemarksHeadlight 1 Hot starter cable 1 Disconnect at the lever side.2 Hot starte

1-12CONTROL FUNCTIONSCONTROL FUNCTIONSMAIN SWITCHFunctions of the respective switch positions are as follows:ON:The engine can be started only at this

6-36HANDLEBAR13 Left grip 1 Refer to removal section.14 Handlebar upper holder 215 Handlebar 116 Handlebar lower holder 2Order Part name Q'ty Rem

6-37HANDLEBARREMOVING THE BRAKE MASTER CYLINDER1. Remove:• Brake master cylinder bracket "1"• Brake master cylinder "2"• Do not le

6-38HANDLEBAR• Bolt (handlebar upper holder) "3"• The handlebar upper holder should be in-stalled with the punched mark "a" forwar

6-39HANDLEBAR• Before applying the adhesive, wipe off grease or oil on the tube guide surface "a" with a lac-quer thinner.• Install the grip

6-40HANDLEBAR9. Install:• Grip cap cover "1"• Cover (throttle cable cap) "2"10.Install:• Start switch "1"• Brake master

6-41HANDLEBAR13.Adjust:• Clutch lever free playRefer to "ADJUSTING THE CLUTCH CA-BLE FREE PLAY" section in the CHAPTER 3.• Hot starter lever

6-42STEERINGSTEERINGREMOVING THE STEERINGOrder Part name Q'ty RemarksA. For CDNTIGHTENING STEPS:• Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb)• L

6-43STEERING4 Steering stem nut 15 Front fork 2 Refer to "FRONT FORK" section.6 Upper bracket 17 Steering ring nut 1 Refer to removal sectio

6-44STEERINGHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE STEERING RING NUT1. Remove:• Steering ring

6-45STEERINGApply the lithium soap base grease on the dust seal lip and bearing inner circumference.2. Install:• Bearing race• Upper bearing "1&q

1-13CONTROL FUNCTIONSKICKSTARTER CRANKRotate the kickstarter crank "1" away from the engine. Push the starter down lightly with your foot un

6-46STEERING• Temporarily tighten the pinch bolts (lower bracket).• Do not tighten the pinch bolts (upper bracket) yet.8. Install:• Guide (speed senso

6-47STEERING14.Install:• Holder "1"•Clamp "2"• Install so that the marking "a" on the speed sensor lead aligns with the

6-48SWINGARMSWINGARMREMOVING THE SWINGARMOrder Part name Q'ty RemarksHold the machine by placing the suit-able stand under the engine.Refer to &q

6-49SWINGARMDISASSEMBLING THE SWINGARMOrder Part name Q'ty Remarks1 Cap 2 Refer to removal section.2 Relay arm 13 Connecting rod 14 Collar 25Oil

6-50SWINGARMHANDLING NOTESupport the machine securely so there is no danger of it falling over.REMOVING THE CAP1. Remove:• Left cap "1"Remov

6-51SWINGARMINSTALLING THE BEARING AND OIL SEAL1. Install:• Bearing "1"•Oil seal "2"To swingarm.• Apply the molybdenum disulfide g

6-52SWINGARMApply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and con-tact surfaces of the collar and thrust beari

6-53SWINGARM7. Check:• Swingarm side play "a"Free play exists → Replace thrust bearing.• Swingarm up and down movement "b"Unsmooth

6-54SWINGARM13.Install:• Bolt (lower chain tensioner) "1"•Washer "2"• Collar "3"• Lower chain tensioner "4"• N

6-55REAR SHOCK ABSORBERREAR SHOCK ABSORBERREMOVING THE REAR SHOCK ABSORBEROrder Part name Q'ty RemarksHold the machine by placing the suit-able s

1-14CONTROL FUNCTIONSCOLD STARTER KNOBWhen cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is cont

6-56REAR SHOCK ABSORBERBatteryRefer to "CHECKING AND CHARG-ING THE BATTERY" section in the CHAPTER 3.Disconnect the starter relay coupler.St

6-57REAR SHOCK ABSORBER13 Upper spring guide 114 Spring (rear shock absorber) 115 Bearing 2 Refer to removal section.Order Part name Q'ty Remarks

6-58REAR SHOCK ABSORBERHANDLING NOTE• Support the machine securely so there is no danger of it falling over.• This rear shock absorber is provided wit

6-59REAR SHOCK ABSORBERCHECKING THE REAR SHOCK ABSORBER1. Inspect:• Damper rod "1"Bends/damage → Replace rear shock ab-sorber assembly.• Sho

6-60REAR SHOCK ABSORBERINSTALLING THE SPRING (REAR SHOCK ABSORBER)1. Install:• Spring "1"• Upper spring guide "2"• Lower spring gu

6-61REAR SHOCK ABSORBER3. Install:• Rear shock absorber4. Install:• Bolt (rear shock absorber-frame) "1"•Washer "2"• Nut (rear sho

7-1ELECTRICAL COMPONENTS AND WIRING DIAGRAMELECTRICALThis section is intended for those who have basic knowledge and skill concerning the servicing of

7-2ELECTRICAL COMPONENTS AND WIRING DIAGRAMWIRING DIAGRAM1. Headlight2. Multi-function display3. Engine stop switch4. Clutch switch5. Diode6. Starter

7-3IGNITION SYSTEMIGNITION SYSTEMINSPECTION STEPSUse the following steps for checking the possibility of the malfunctioning engine being attributable

7-4IGNITION SYSTEMSPARK GAP TEST1. Disconnect the ignition coil from spark plug.2. Remove the ignition coil cap.3. Connect the dynamic spark tester &q

1-15MULTI-FUNCTION DISPLAYMULTI-FUNCTION DISPLAYBe sure to stop the machine before making any setting changes to the multi-function display.The multi-

7-5IGNITION SYSTEMCHECKING THE MAIN SWITCH1. Inspect:• Main switch conductionNot conductive while the main switch is moved to "ON" → Replace

7-6IGNITION SYSTEM4. Inspect:• Sealed portion of ignition coil "a"• Spark plug terminal pin "b"• Threaded portion of spark plug &q

7-7ELECTRIC STARTING SYSTEMELECTRIC STARTING SYSTEMSTARTING CIRCUIT CUT-OFF SYSTEM OPERATIONIf the main switch is set to "ON", the starter m

7-8ELECTRIC STARTING SYSTEMINSPECTION STEPSIf the starter motor will not operate, use the following inspection steps.*1 marked: Refer to "CHECKIN

7-9ELECTRIC STARTING SYSTEMCHECKING THE COUPLERS AND LEADS CONNECTION1. Check:• Couplers and leads connectionRust/dust/looseness/short-circuit → Repai

7-10ELECTRIC STARTING SYSTEMNot conductive while it is pulled → Replace.Conductive while it is freed → Replace.Set the tester selection position to &q

7-11ELECTRIC STARTING SYSTEMREMOVING THE STARTER MOTOROrder Part name Q'ty RemarksExhaust pipeRefer to "EXHAUST PIPE AND SI-LENCER" sec

7-12ELECTRIC STARTING SYSTEMDISASSEMBLING THE STARTER MOTOROrder Part name Q'ty Remarks1 Starter motor front cover 12 Washer (starter motor front

7-13ELECTRIC STARTING SYSTEMCHECKING AND REPAIRING THE STARTER MOTOR1. Check:• CommutatorDirt → Clean with 600 grit sandpaper.2. Measure:• Commutator

7-14ELECTRIC STARTING SYSTEMASSEMBLING THE STARTER MOTOR1. Install:• Brush spring "1"•Brush "2"2. Install:• Armature assembly &quo

WR450FAOWNER'S SERVICE MANUAL©2010 by Yamaha Motor Corporation, U.S.A.1st Edition, April 2010All rights reserved.Any reprinting or unauthorized u

1-16MULTI-FUNCTION DISPLAY4. To end the setting, push the "RST" button for 2 seconds or more.• In a 30-second absence of button operation, t

7-15CHARGING SYSTEMCHARGING SYSTEMINSPECTION STEPSIf the battery is not charged, use the following inspection steps.*1 marked: Refer to "CHECKING

7-16CHARGING SYSTEMCHECKING THE COUPLERS AND LEADS CONNECTION1. Check:• Couplers and leads connectionRust/dust/looseness/short-circuit → Repair or rep

7-17THROTTLE POSITION SENSOR SYSTEMTHROTTLE POSITION SENSOR SYSTEMINSPECTION STEPSIf the throttle position sensor will not operate, use the following

7-18THROTTLE POSITION SENSOR SYSTEMHANDLING NOTEDo not loosen the screw (throttle position sensor) "1" except when changing the throttle pos

7-19THROTTLE POSITION SENSOR SYSTEMLoosen the screw (throttle position sensor) us-ing the T25 bit.3. Replace:• Throttle position sensor4. Install:• Th

7-20THROTTLE POSITION SENSOR SYSTEM10.Put the aligning marks "a" on the throttle po-sition sensor and carburetor.11.Stop the engine.12.Remov

7-21LIGHTING SYSTEMLIGHTING SYSTEMINSPECTION STEPSRefer to the following flow chart when inspecting the lighting system for possible problems.• Remove

7-22LIGHTING SYSTEMCHECKING THE TAILLIGHT (LEDs)1. Disconnect the taillight coupler.2. Connect two jumper leads "1" from the bat-tery termin

7-23SIGNALING SYSTEMSIGNALING SYSTEMINSPECTION STEPSIf the speedometer will not operate, use the following inspection steps.*1 marked: Refer to "

7-24SIGNALING SYSTEMCHECKING THE COUPLERS AND LEADS CONNECTION1. Check:• Couplers and leads connectionRust/dust/looseness/short-circuit → Repair or re

1-17MULTI-FUNCTION DISPLAY4. Push the "SLCT1" button and "RST" button for 2 seconds or more at the same time will finish the setti

7-25SIGNALING SYSTEMMeasurement steps:a. Elevate the front wheel and slowly rotate it.b. Measure the voltage (DCV) of white lead and black lead. With

QRead this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.5TJ-9-17_cover-13mm 09.8.17 10:

PRINTED IN JAPAN2010.04—0.4 × 1 !(E)YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPANPRINTED ON RECYCLED PAPERPROTECT YOUR INVESTMENTUse Genuine

1-18MULTI-FUNCTION DISPLAYRACE MODEPutting measurement on standbyStarting measurement consists of the following two starts, either of which can be sel

1-19MULTI-FUNCTION DISPLAYResetting measurement dataResetting can be made in the following three manners. Resetting is possible while timer measuremen

1-20MULTI-FUNCTION DISPLAYCorrecting tire diameter• Correction can be made any time while timer measurement is or is not being made.• Change in the tr

1-21MULTI-FUNCTION DISPLAYFUNCTION DIAGRAMThe following diagram illustrates the multi-function display regarding the direction and operation con-ditio

1-22STARTING AND BREAK-INSTARTING AND BREAK-INFUELAlways use the recommended fuel as stated below. Also, be sure to use new gasoline.Use only unleaded

1-23STARTING AND BREAK-IN• If the starter motor will not turn when pushing the start switch, stop pushing it immediately and kick start the engine in

1-24STARTING AND BREAK-IN6. Restart the engine and check the operation of the machine throughout its entire operat-ing range. Restart the machine and

1-25TORQUE-CHECK POINTSTORQUE-CHECK POINTSConcerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.Frame con

INTRODUCTIONCongratulations on your purchase of a Yamaha WR series. This model is the culmination of Ya-maha's vast experience in the production

1-26CLEANING AND STORAGECLEANING AND STORAGECLEANINGFrequent cleaning of your machine will en-hance its appearance, maintain good overall performance,

2-1GENERAL SPECIFICATIONSSPECIFICATIONSGENERAL SPECIFICATIONSModel name: WR450FA (USA, CDN, AUS, NZ)WR450F (EUROPE, ZA)Model code number: 1HB1 (USA)1H

2-2GENERAL SPECIFICATIONSOil capacity:Engine oilPeriodic 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.

2-3GENERAL SPECIFICATIONSTire:Type With tubeSize (front) 80/100-21 51M (USA, CDN, ZA)90/90-21 M/C 54M M+S (EUROPE, AUS, NZ)Size (rear) 110/100-18 64M

2-4MAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONSENGINEItem Standard LimitCylinder head:Warp limit---- 0.05 mm (0.002 in)Cylinder:Bore size 95.0

2-5MAINTENANCE SPECIFICATIONSTiming chain:Timing chain type/No. of links 98XRH2010-118M/118 ----Timing chain adjustment method Automatic ----Valve, va

2-6MAINTENANCE SPECIFICATIONSGuide inside diameter (IN) 4.500–4.512 mm (0.1772–0.1776 in)4.550 mm (0.1791 in)Guide inside diameter (EX) 5.000–5.012 mm

2-7MAINTENANCE SPECIFICATIONSPiston:Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in)0.1 mm (0.004 in)Piston size "D" 94.965–94

2-8MAINTENANCE SPECIFICATIONSCrankshaft:Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ----Runout limit "C" 0.03 mm (0.0012 in) 0

2-9MAINTENANCE SPECIFICATIONSCarburetor: USA, CDN, AUS, NZ, ZAEUROPEI. D. mark 5TJE E0 5TJL L0 ----Main jet (M.J) #162 #160 ----Main air jet (M.A.J) ø

SAFETY INFORMATIONTHIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any

2-10MAINTENANCE SPECIFICATIONSCHASSISWater pumpType Single-suction centrifugal pump ----Item Standard LimitItem Standard LimitSteering system:Steering

2-11MAINTENANCE SPECIFICATIONSWheel:Front wheel type Spoke wheel ----Rear wheel type Spoke wheel ----Front rim size/material 21 × 1.60/Aluminum ----Re

2-12MAINTENANCE SPECIFICATIONSELECTRICALItem Standard LimitIgnition system:Advancer type Electrical ----CDI:USA, CDN EUROPE AUS, NZ, ZAPickup coil res

2-13MAINTENANCE SPECIFICATIONSSpring force 3.92–5.88 N (400–600 g, 14.1–21.2 oz) ----Commutator diameter 17.6 mm (0.69 in) 16.6 mm (0.65 in)Mica under

2-14TIGHTENING TORQUESTIGHTENING TORQUESENGINE△ - marked portion shall be checked for torque tightening after break-in.*1: Tighten the cylinder head b

2-15TIGHTENING TORQUESHot starter plunger M12 × 1.0 1 2 0.2 1.4Hot starter cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9Air filter element M6 ×

2-16TIGHTENING TORQUESCHASSIS△ - marked portion shall be checked for torque tightening after break-in.Clutch boss M20 × 1.0 1 75 7.5 54Clutch cable ad

2-17TIGHTENING TORQUESBrake lever position locknut M6 × 1.0 1 5 0.5 3.6△ Hose guide (front brake hose) and hose guide bracketM5 × 0.8 1 4 0.4 2.9△ Hos

2-18TIGHTENING TORQUES1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen t

2-19TIGHTENING TORQUESELECTRICALTighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m •kg, 47 ft•lb)

YAMAHA MOTOR CORPORATION, U.S.A. WR MOTORCYCLE LIMITED WARRANTY

2-20TIGHTENING TORQUESGENERAL TORQUE SPECIFICATIONSThis chart specifies torque for standard fasten-ers with standard I.S.O. pitch threads. Torque spec

2-21TIGHTENING TORQUESDEFINITION OF UNITSUnit Read Definition Measuremmmillimeter 10-3 meter Lengthcmcentimeter 10-2 meter Lengthkgkilogram 103 gram W

2-22LUBRICATION DIAGRAMSLUBRICATION DIAGRAMS

2-23LUBRICATION DIAGRAMS1. Oil filter element2. Oil pump3. Drive axle4. Main axle5. Crankshaft6. Connecting rodA. From cylinderB. To oil tank

2-24LUBRICATION DIAGRAMS

2-25LUBRICATION DIAGRAMS1. Intake camshaft2. Exhaust camshaftA. To main axleB. From oil pump

2-26CABLE ROUTING DIAGRAMCABLE ROUTING DIAGRAM

2-27CABLE ROUTING DIAGRAM1. Fuel tank breather hose2. Clamp3. Diode4. Hot starter cable5. Throttle position sensor lead6. Wire harness7. Hump (frame)8

2-28CABLE ROUTING DIAGRAM

2-29CABLE ROUTING DIAGRAM1. Throttle cable (pull)2. Throttle cable (return)3. Catch tank hose4. Ignition coil5. Clamp6. Air induction hose (air cut-of

HOW TO USE THIS MANUALFINDING THE REQUIRED PAGE1. This manual consists of seven chapters; "General Information", "Specifications",

2-30CABLE ROUTING DIAGRAM

2-31CABLE ROUTING DIAGRAM1. Brake master cylinder2. Brake hose holder3. Brake hoseA. Install the brake hose so that its pipe por-tion directs as shown

2-32CABLE ROUTING DIAGRAM

2-33CABLE ROUTING DIAGRAM1. Clamp2. Positive battery lead3. Battery4. Negative battery lead5. Taillight coupler6. CDI unit coupler (6-pin)7. CDI unit

2-34CABLE ROUTING DIAGRAM

2-35CABLE ROUTING DIAGRAM1. Throttle cable2. Clamp3. Brake hose4. Clutch cable5. Hose guide6. Main switch coupler7. Wire harness8. Headlight coupler9.

3-1PERIODIC MAINTENANCE CHART FOR THE EMISSIONCONTROL SYSTEMREGULAR INSPECTION AND ADJUSTMENTSPERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYST

3-2GENERAL MAINTENANCE AND LUBRICATION CHARTGENERAL MAINTENANCE AND LUBRICATION CHARTNo. ITEMCHECKS AND MAINTENANCE JOBSINI-TIALODOMETER READINGS600 m

3-3GENERAL MAINTENANCE AND LUBRICATION CHART• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.• Hydraulic

3-4MAINTENANCE INTERVALS FOR COMPETITION USEMAINTENANCE INTERVALS FOR COMPETITION USE• The following schedule is intended as a general guide to mainte

HOW TO READ DESCRIPTIONSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly s

3-5MAINTENANCE INTERVALS FOR COMPETITION USEPISTON RINGInspect ● Check ring end gap.Replace ●●PISTON PINInspect ●Replace ●CYLINDER HEAD Inspect carbon

3-6MAINTENANCE INTERVALS FOR COMPETITION USEDRIVE CHAIN Use chain lube.Lubricate, slack, align-ment●● Chain slack: 48–58 mm (1.9–2.3 in)Replace ●COOLI

3-7MAINTENANCE INTERVALS FOR COMPETITION USEFRONT FORKSInspect and adjust ●●Replace oil ●●Suspension oil "S1"Replace oil seal ●FRONT FORK OI

3-8MAINTENANCE INTERVALS FOR COMPETITION USETHROTTLE, CONTROL CABLECheck routing and con-nection●●Lubricate ●● Yamaha cable lube or SAE 10W-40 motor o

3-9PRE-OPERATION INSPECTION AND MAINTENANCEPRE-OPERATION INSPECTION AND MAINTENANCEBefore riding for break-in operation or practice, make sure the mac

3-10ENGINEENGINEREMOVING THE SEAT, FUEL TANK AND SIDE COVERSOrder Part name Q'ty RemarksTurn the fuel cock to "OFF".Disconnect the fuel

3-11ENGINEREMOVING THE SIDE COVER1. Remove:• Bolt (side cover)• Right side cover "1"Draw the side cover backward to remove it be-cause its c

3-12ENGINEREMOVING THE EXHAUST PIPE AND SILENCEROrder Part name Q'ty RemarksRight side coverRefer to "REMOVING THE SEAT, FUEL TANK AND SIDE

3-13ENGINECHECKING THE SILENCER AND EXHAUST PIPE1. Inspect:•Gasket "1"Damage → Replace.INSTALLING THE SILENCER AND EXHAUST PIPE1. Install:•G

3-14ENGINE1. RadiatorCHANGING THE COOLANTDo not remove the radiator cap when the en-gine is hot.Take care so that coolant does not splash on painted s

ILLUSTRATED SYMBOLS (Refer to the illustration)Illustrated symbols "1" to "7" are used to identi-fy the specifications appearing i

3-15ENGINE10.Check:• Coolant levelCoolant level low → Add coolant.CHECKING THE RADIATOR CAP1. Inspect:• Seal (radiator cap) "1"• Valve and v

3-16ENGINE2. Adjust:• Clutch lever free playClutch lever free play adjustment steps:a. Loosen the locknuts "1".b. Turn the adjuster "2&

3-17ENGINE2. Apply:• Lithium soap base greaseOn the throttle cable end "a".3. Install:• Throttle grip cap• Screw (throttle grip cap)• Cover

3-18ENGINE3. Remove:• Air filter element "1"• Filter guide "2"4. Clean:• Air filter elementClean them with solvent.After cleaning,

3-19ENGINECHECKING THE ENGINE OIL LEVEL1. Stand the machine on a level surface.• When checking the oil level make sure that the machine is upright.• P

3-20ENGINECHANGING THE ENGINE OIL1. Start the engine and let it warm up for sever-al minutes.2. Stop the engine and place an oil pan under the drain b

3-21ENGINE8. Inspect:• Engine (for oil leaks)•Oil levelRefer to "CHECKING THE ENGINE OIL LEVEL".CHECKING THE OIL PRESSURE1. Check:• Oil pres

3-22ENGINE2. Remove:• Air cut-off valve assemblyRefer to "AIR INDUCTION SYSTEM" sec-tion in the CHAPTER 5.• Spark plug• Engine upper bracket

3-23ENGINE• Place a rag in the timing chain space to pre-vent pads from falling into the crankcase.• Identity each valve lifter and pad position very

3-24ENGINEh. Install the timing chain tensioner.Refer to "CAMSHAFTS" section in the CHAPTER 5.Turn the crankshaft counterclockwise several t