2006 YFZ450 Service Manual Supplement

2006 YFZ450 Service Manual Supplement
YFZ450V
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-19-32
5TG-28197-11
FOREWORD
This Supplementary Service Manual has been prepared to introduce new service and data for the
YFZ450V. For complete service information procedures it is necessary to use this Supplementary
Service Manual together with the following manual.
YFZ450S SERVICE MANUAL: LIT-11616-17-11 (5TG-28197-10)
YFZ450V
SUPPLEMENTARY
SERVICE MANUAL
©2005 by Yamaha Motor Corporation, U.S.A.
First edition, May 2005
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-19-32
EBS00002
NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle unsafe
and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
_
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death to
the vehicle operator, a bystander or a person checking or repairing the vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage
to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
EBS00004
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
1
EBS00006
2
GEN
INFO
SYMBOLS
The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.
SPEC
3
4
CHK
ADJ
1 General information
2 Specifications
3 Periodic checks and adjustments
4 Engine
5 Cooling system
6 Carburetor
7 Chassis
8 Electrical
9 Troubleshooting
ENG
5
6
CARB
COOL
7
8
CHAS
ELEC
9
0
–
Symbols 0 to G indicate the following
0 Serviceable with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Tightening torque
E Wear limit, clearance
F Engine speed
G Electrical data (Ω, V, A)
TRBL
SHTG
A
B
C
D
+
T.
R.
E
F
G
H
I
J
G
E
K
M
L
B
M
M
LS
N
Symbols H to N in the exploded diagrams
indicate the types of lubricants and lubrication
points.
O
LT
New
H Apply engine oil
I Apply gear oil
J Apply molybdenum disulfide oil
K Apply wheel bearing grease
L Apply lithium-soap-based grease
M Apply molybdenum disulfide grease
Symbols N to O in the exploded diagrams
indicate where to apply a locking agent N and
when to install a new part O.
N Apply the locking agent (LOCTITE®)
O Replace
CONTENTS
GENERAL INFORMATION ................................................................................ 1
SPECIAL TOOLS ......................................................................................... 1
SPECIFICATIONS .............................................................................................. 2
GENERAL SPECIFICATIONS ..................................................................... 2
ENGINE SPECIFICATIONS......................................................................... 4
CHASSIS SPECIFICATIONS....................................................................... 8
ELECTRICAL SPECIFICATIONS ................................................................ 9
TIGHTENING TORQUES........................................................................... 10
ENGINE TIGHTENING TORQUES .................................................... 10
CHASSIS TIGHTENING TORQUES .................................................. 10
CABLE ROUTING ...................................................................................... 11
PERIODIC CHECKS AND ADJUSTMENTS.................................................... 27
INTRODUCTION ........................................................................................ 27
PERIODIC MAINTENANCE CHART FOR
THE EMISSION CONTROL SYSTEM....................................................... 27
GENERAL MAINTENANCE AND LUBRICATION CHART ........................ 28
CHASSIS.................................................................................................... 29
ADJUSTING THE PARKING BRAKE .................................................. 29
CHECKING THE BRAKE FLUID LEVEL ............................................. 29
ADJUSTING THE DRIVE CHAIN SLACK............................................ 31
ADJUSTING THE FRONT SHOCK ABSORBERS .............................. 32
ADJUSTING THE REAR SHOCK ABSORBER................................... 34
ENGINE ............................................................................................................ 38
ENGINE REMOVAL ................................................................................... 38
MUFFLER AND EXHAUST PIPE ........................................................ 38
INSTALLING THE PISTON.................................................................. 39
COOLING SYSTEM.......................................................................................... 40
RADIATOR ................................................................................................. 40
WATER PUMP ........................................................................................... 42
CHASSIS .......................................................................................................... 44
FRONT AND REAR WHEELS ................................................................... 44
REAR WHEELS ................................................................................... 44
INSTALLING THE REAR WHEEL HUBS ............................................ 45
REAR AXLE AND REAR AXLE HUB ......................................................... 46
REMOVING THE REAR BRAKE CALIPER......................................... 48
REMOVING THE REAR AXLE ............................................................ 48
INSTALLING THE DRIVEN SPROCKET............................................. 49
INSTALLING THE REAR AXLE........................................................... 49
FRONT AND REAR BRAKES .................................................................... 51
FRONT BRAKE PADS......................................................................... 51
REAR BRAKE PADS ........................................................................... 52
REAR BRAKE MASTER CYLINDER................................................... 53
INSTALLING THE REAR BRAKE MASTER CYLINDER..................... 55
FRONT BRAKE CALIPER ................................................................... 57
REAR BRAKE CALIPER...................................................................... 58
REMOVING THE REAR BRAKE CALIPER......................................... 61
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPERS....... 61
CHECKING THE FRONT AND REAR BRAKE CALIPERS ................. 62
ASSEMBLING THE REAR BRAKE CALIPER ..................................... 63
INSTALLING THE REAR BRAKE CALIPER ....................................... 64
STEERING SYSTEM ................................................................................. 66
INSTALLING THE HANDLEBAR ......................................................... 66
REAR SHOCK ABSORBER AND RELAY ARM ........................................ 67
INSTALLING THE RELAY ARM AND CONNECTING ARM ............... 69
SWINGARM AND DRIVE CHAIN............................................................... 70
ELECTRICAL ................................................................................................... 72
ELECTRICAL COMPONENTS................................................................... 72
CHECKING THE SWITCHES .................................................................... 74
LIGHTING SYSTEM................................................................................... 76
CIRCUIT DIAGRAM............................................................................. 76
TROUBLESHOOTING ......................................................................... 77
CHECKING THE LIGHTING SYSTEM ................................................ 80
COOLING SYSTEM ................................................................................... 82
CIRCUIT DIAGRAM............................................................................. 82
TROUBLESHOOTING ......................................................................... 83
YFZ450V WIRING DIAGRAM
SPECIAL TOOLS
GEN
INFO
EBS00021
GENERAL INFORMATION
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACCExcept for US and CDN
P/N. 90890Tool No.
Tool name/Function
Rear axle nut wrench (46 mm)
90890-01498
YM-37134
This tool is used to loosen or tighten the
rear axle nut.
–1–
Illustration
GENERAL SPECIFICATIONS
SPEC
EBS01001
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Engine
Engine type
Cylinder arrangement
Displacement
Bore × stroke
Compression ratio
Starting system
Carburetor
Type/quantity
Manufacturer
Tire
Type
Size
Manufacturer
Type
Tire pressure (cold tire)
Maximum load*
Off-road riding
Standard
5TGC
1,840 mm (72.4 in)
1,170 mm (46.1 in)
1,090 mm (42.9 in)
810 mm (31.9 in)
1,280 mm (50.4 in)
255 mm (10.04 in)
3,500 mm (137.8 in)
Liquid-cooled 4-stroke, DOHC
Forward-inclined single cylinder
449 cm3 (27.40 cu in)
95.0 × 63.4 mm (3.74 × 2.50 in)
11.2:1
Electric starter
FCR39H × 1
KEIHIN
front
rear
front
rear
front
rear
front
rear
*Load is the total weight of cargo, rider and
accessories
Tubeless
AT21 × 7R-10
AT20 × 10-9
DUNLOP
DUNLOP
KT341 Radial
KT355A Radial
100 kg (220 lb)
27.5 kPa (0.28 kg/cm2, 4.0 psi)
30 kPa (0.30 kg/cm2, 4.4 psi)
–2–
GENERAL SPECIFICATIONS
Item
Wheel travel
Front wheel travel
Rear wheel travel
Bulb voltage/wattage × quantity
Headlight
Tail/brake light
Indicator and warning lights
Neutral
Coolant temperature
SPEC
Standard
230 mm (9.06 in)
270 mm (10.63 in)
12 V 30 W/30 W × 2
12 V 0.5 W/3.9 W × 1
12 V 1.7 W × 1
12 V 1.7 W × 1
–3–
ENGINE SPECIFICATIONS
SPEC
EBS01002
ENGINE SPECIFICATIONS
Item
Standard
Camshaft
Drive method
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft-journal-to-camshaft-cap
clearance
Camshaft lobe dimensions
Limit
Chain drive (Left)
22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in)
---21.959 ~ 21.972 mm (0.8645 ~ 0.8650 in)
---0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in)
0.080 mm
(0.0032 in)
A
B
Intake
“A”
31.200 ~ 31.300 mm (1.2283 ~ 1.2323 in) 31.100 mm
(1.2244 in)
22.550 ~ 22.650 mm (0.8878 ~ 0.8917 in) 22.450 mm
(0.8839 in)
30.950 ~ 31.050 mm (1.2185 ~ 1.2224 in) 30.850 mm
(1.2146 in)
22.494 ~ 22.594 mm (0.8856 ~ 0.8895 in) 22.394 mm
(0.8817 in)
---0.03 mm
(0.0012 in)
“B”
Exhaust
“A”
“B”
Camshaft runout limit
Piston
Piston to cylinder clearance
0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in)
0.15 mm
(0.0059 in)
94.945 ~ 94.960 mm (3.7380 ~ 3.7386 in)
----
Piston size “D”
H
D
Measuring point “H”
Piston offset
Offset direction
Piston pin bore inside diameter
10 mm (0.39 in)
---1.0 mm (0.0394 in)
---Intake side
---20.004 ~ 20.015 mm (0.7876 ~ 0.7880 in) 20.045 mm
(0.789 in)
–4–
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Piston pin outside diameter
Piston-pin-to-piston-pin-bore clearance
Piston rings
Top ring
Limit
19.991 ~ 20.000 mm (0.7870 ~ 0.7874 in) 19.971 mm
(0.786 in)
0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)
0.074 mm
(0.0029 in)
B
T
Type
Dimensions (B × T)
Barrel
1.2 × 3.5 mm (0.047 × 0.138 in)
End gap (installed)
0.20 ~ 0.30 mm (0.008 ~ 0.012 in)
Side clearance
0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in)
------0.55 mm
(0.022 in)
0.12 mm
(0.0047 in)
2nd ring
B
T
Type
Dimensions (B × T)
End gap (installed)
Taper
1.00 × 3.35 mm (0.039 × 0.132 in)
0.35 ~ 0.50 mm (0.014 ~ 0.020 in)
Side clearance
0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in)
------0.85 mm
(0.034 in)
0.12 mm
(0.0047 in)
Oil ring
B
T
Dimensions (B × T)
End gap (installed)
Side clearance
2.0 × 2.9 mm (0.079 × 0.114 in)
0.20 ~ 0.50 mm (0.008 ~ 0.020 in)
0.040 ~ 0.140 mm (0.0016 ~ 0.0055 in)
–5–
----------
ENGINE SPECIFICATIONS
Item
Carburetor
I. D. mark
Main jet
Main air jet
Jet needle
Cutaway
Pilot air jet
Pilot outlet
Pilot jet
Bypass 1
Valve seat size
Starter jet
Float height
Engine idle speed
Intake vacuum
Standard
(M.J)
(M.A.J)
(J.N)
(C.A)
(P.A.J.1)
(P.O)
(P.J)
(B.P.1)
(V.S)
(G.S.1)
(F.H)
Oil pump
Oil pump type
Inner-rotor-to-outer-rotor-tip clearance
Outer-rotor-to-oil-pump-housing
clearance
Bypass valve setting pressure
5TGC 30
#155
ø1.0
NGNR
1.5
#70
ø0.9
#42
ø1.0
ø3.8
#90
8 mm (0.31 in)
1,750 ~ 1,850 r/min
More than 35.7 kPa
(268 mmHg, 10.5 inHg)
Trochoid
Less than 0.12 mm (0.0047 in)
0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in)
40.0 ~ 80.0 kPa
(300 ~ 602 mmHg, 11.8 ~ 23.7 inHg)
–6–
SPEC
Limit
-------------------------------------------
---0.20 mm
(0.0079 in)
0.24 mm
(0.0094 in)
----
ENGINE SPECIFICATIONS
Cylinder head tightening sequence
–7–
SPEC
CHASSIS SPECIFICATIONS
SPEC
EBS01003
CHASSIS SPECIFICATIONS
Item
Front suspension
Shock absorber travel
Fork spring free length
Spring fitting length
Spring rate (K1)
Spring rate (K2)
Optional spring
Rear suspension
Shock absorber travel
Spring free length
Spring fitting length
Spring rate (K1)
Stroke (K1)
Optional spring
Front disc brake
Type
Disc outside diameter × thickness
Pad thickness inner
Pad thickness outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Rear disc brake
Type
Disc outside diameter × thickness
Pad thickness inner
Pad thickness outer
Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Brake lever and brake pedal
Brake pedal position
Parking brake cable end length
Clutch lever free play (lever end)
Throttle lever free play
Speed limiter length
Shift pedal height
Standard
Limit
110 mm (4.33 in)
265 mm (10.43 in)
255 mm (10.04 in)
15.0 N/mm (1.53 kg/mm, 86 lb/in)
35.0 N/mm (3.57 kg/mm, 200 lb/in)
No
-------------------
126 (4.96 in)
272 mm (10.71 in)
257 mm (10.12 in)
36.0 N/mm (3.67 kg/mm, 206 lb/in)
0 ~ 126 mm (0 ~ 4.96 in)
No
-------------------
Dual
161.0 × 3.5 mm (6.34 × 0.14 in)
4.3 mm (0.17 in)
4.3 mm (0.17 in)
12.7 mm (0.50 in)
25.4 mm (1.00 in)
DOT 4
Single
200.0 × 3.6 mm (7.87 × 0.14 in)
5.4 mm (0.21 in)
5.4 mm (0.21 in)
12.7 mm (0.50 in)
25.4 mm (1.00 in)
DOT 4
11.7 mm (0.46 in)
47 ~ 51 mm (1.85 ~ 2.01 in)
8 ~ 13 mm (0.31 ~ 0.51 in)
2 ~ 4 mm (0.08 ~ 0.16 in)
Less than 12 mm (0.47 in)
25 mm (0.98 in)
–8–
------1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
---------------1.0 mm
(0.04 in)
1.0 mm
(0.04 in)
----------------------------
ELECTRICAL SPECIFICATIONS
SPEC
EBS01004
ELECTRICAL SPECIFICATIONS
Item
Headlight relay
Headlight relay 1
Model/manufacturer
Coil resistance
Headlight relay 2
Model/manufacturer
Coil resistance
Thermo switch
Thermo switch 1
Model/manufacturer
Opening temperature
Closing temperature
Thermo switch 2
Model/manufacturer
Opening temperature
Closing temperature
Standard
Limit
G8HN-1C4T-DJ-Y52/OMRON
94.5 Ω ~ 115.5 Ω
-------
G8HN-1C4T-DJ-Y52/OMRON
94.5 Ω ~ 115.5 Ω
-------
5EB/NIPPON THERMOSTAT
102 ~ 108 °C (215.6 ~ 226.4 °F)
97 ~ 103 °C (206.6 ~ 217.4 °F)
----------
5LP/NIPPON THERMOSTAT
117 ~ 123 °C (242.6 ~ 253.4 °F)
112 ~ 118 °C (233.6 ~ 244.4 °F)
----------
–9–
TIGHTENING TORQUES
SPEC
EBS01005
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Part to be tightened
Cylinder head blind plug screw
Cylinder head (exhaust pipe)
Oil pump housing cover
Oil filter cover
Exhaust pipe
Stator coil
Part name
Screw
Stud bolt
Screw
Bolt
Nut
Screw
Thread
Q’ty
size
M12
M8
M4
M6
M8
M5
1
2
1
3
2
2
Tightening torque
Nm m · kg ft · lb
28
15
3
10
14
7
2.8
1.5
0.3
1.0
1.4
0.7
20
11
2.2
7.2
10
5.1
Remarks
LT
EBS01006
CHASSIS TIGHTENING TORQUES
Part to be tightened
Thread size
Rear axle pinch bolt
Guide pin and swingarm
Front shock absorber and lower front arm
Front shock absorber and frame
Tie-rod end and locknut
Rear axle and rear wheel hub
Rear brake caliper and brake caliper bracket
Driven sprocket and sprocket bracket
Parking brake bracket, spring bracket and rear
brake caliper
Rear axle ring nut
Rear brake disc and brake disc bracket
Rear brake hose holder and swingarm
Footrest and frame
Front brake pad retaining bolt
Rear brake pad retaining bolt
M8
M12
M10
M10
M12
M16
M10
M10
M8
Tightening torque
Nm m · kg ft · lb
21
55
48
48
18
200
43
72
23
2.1
5.5
4.8
4.8
1.8
20.0
4.3
7.2
2.3
Remarks
15
LT
40
35
35
13
145 SEE NOTE.
31
52
17
LT
M36
M8
M6
M10
M10
M10
240
33
7
73
17
17
24.0
3.3
0.7
7.3
1.7
1.7
175
24
5.1
53
12
12
LT
LT
NOTE:
1. Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel
hub surfaces that contact the rear axle washers.
2. Tighten the rear axle nuts 200 Nm (20.0 m · kg, 145 ft · lb).
3. Loosen the rear axle nuts completely.
4. Retighten the rear axle nuts 200 Nm (20.0 m · kg, 145 ft · lb). Do not loosen the axle nuts after
tightening them. If an axle nut slot is not aligned with the cotter pin hole on either side of the axle,
further tighten the axle nut until a slot is aligned with the hole.
– 10 –
CABLE ROUTING
SPEC
È Fasten the clutch switch lead and handlebar
switch lead with the plastic bands at the bends in
the handlebar.
É Fasten the front brake light switch lead and
throttle switch lead with the plastic band at the
bend in the handlebar.
Ê Less than 10 mm (0.39 in)
Ë Make sure that there is no slack in the throttle
switch lead.
Ì Fasten the throttle switch lead to the handlebar
with the plastic band.
EBS00028
CABLE ROUTING
1 Parking brake cable
2 Clutch cable
3 Clutch switch lead
4 Handlebar switch lead
5 Front brake light switch lead
6 Throttle switch lead
7 Front brake hose
8 Throttle cable
1
4
2 3
5 6
7
É
È
A
Ê
Ì
A
– 11 –
6Ë
8
CABLE ROUTING
1 Throttle cable
2 Front brake hose
3 Front brake light switch lead
4 Throttle switch lead
5 Clutch cable
6 Parking brake cable
7 Clutch switch lead
8 Handlebar switch lead
9 Radiator fan breather hose
0 Thermo switch 2 lead
A Headlight coupler (left)
B C.D.I. unit leads
C Rectifier/regulator coupler
D Front brake pipe
E Rectifier/regulator
F Diode 1
G Headlight coupler (right)
H Diode 2
I Thermo switch 1 lead
J Main switch coupler
K C.D.I. unit
– 12 –
SPEC
CABLE ROUTING
È Pass the throttle cable through the cable guide.
É Pass the throttle cable, leads (front brake light
switch, throttle switch, clutch switch, and handlebar switch), parking brake cable, and clutch
cable through the cable guide in the order listed.
Ê Pass the throttle cable through the steering stem
cable guide.
Ë 50 ~ 70 mm (1.97 ~ 2.76 in)
SPEC
Ì Fasten the front brake light switch lead, throttle
switch lead, clutch switch lead, and handlebar
switch lead with the plastic band and then place
the end of the band under the fuel tank cover.
Í Pass the radiator fan breather hose through the
hose guide.
Î Slide the rubber cover over the couplers (front
brake light switch, throttle switch, clutch switch,
and handlebar switch) and fasten the center of
the cover with the plastic band.
– 13 –
CABLE ROUTING
Ï Fasten the radiator fan breather hose, clutch
cable, and parking brake cable with the clamp.
Ð Pass the clutch cable and parking brake cable
through the cable guide in this order.
Ñ Fasten the radiator fan breather hose with the
holder on the radiator grill.
Ò Install the brake hose cover so that the slits in
the cover fit over the brake hose grommet.
Ó Install the brake hose cover, so that the bend in
the cover aligns with the bend in the upper front
arm.
– 14 –
SPEC
CABLE ROUTING
1 Indicator coupler
2 Radiator fan motor coupler
3 Thermo switch 2
4 Fuel tank breather hose
5 Radiator fan motor lead
6 Radiator fan breather hose
7 Wire harness
8 Fuel hose
9 Throttle position sensor lead
0 Carburetor switch lead
A Crankcase breather hose
B Negative battery lead
C Starter motor lead
D Neutral switch lead
E A.C. magneto lead
F Oil tank breather hose
G Resistor lead
H Headlight relay 1
I Headlight relay 2
J A.C. magneto coupler
K Neutral switch coupler
L Front brake hose
M Throttle cable
N Parking brake cable
O Clutch cable
P Indicator leads
Q Cylinder head breather hose
Ü L
7
P
Ý
M
7
B-B
Þ
C-C
4
A
N
ß
A
O
2
3É
1
È
Ï
56
7
Í
Ë
K
J
0
D-D
C
G
G
5
Ì
Ê
B
B
SPEC
C
Î
G
D
89
E
9
Ð 0
Ñ
D
G
Ò
E
H
I
ÛH
G
A
B
C
Ó
F
F
Ú Ù
Ø F
× E
Á
G
D
E
AA
H
Ö Õ DÔ
À
E
D
G-G
Q
F-F
– 15 –
E-E
CABLE ROUTING
É Fasten the wire harness, thermo switch 2 lead,
A.C. magneto lead, resistor lead, neutral switch
lead, and radiator fan motor lead with the plastic
band and then face the end of the band inward
between the frame tubes.
Ê Route the fuel tank breather hose behind the
steering stem.
Ë 7 ~ 21 mm (0.28 ~ 0.83 in)
Ì 50 ~ 70 mm (1.97 ~ 2.76 in)
È Route the neutral switch lead, A.C. magneto
lead, and radiator fan motor lead under the
frame. Connect the neutral switch lead and the
A.C. magneto lead, and then fasten the leads
with the plastic band, making sure that they are
routed under the frame and that they do not contact headlight relay 2.
Ü L
7
P
Ý
M
7
B-B
Þ
C-C
4
A
N
ß
A
O
2
3É
1
È
Ï
56
7
Í
Ë
K
J
0
D-D
C
G
G
5
Ì
Ê
B
B
SPEC
C
Î
G
D
89
E
9
Ð 0
Ñ
D
G
Ò
E
H
I
ÛH
G
A
B
C
Ó
F
F
Ú Ù
Ø F
× E
Á
G
D
E
AA
H
Ö Õ DÔ
À
E
D
G-G
Q
F-F
– 16 –
E-E
CABLE ROUTING
Ñ Fasten the negative battery lead and starter
motor lead with the plastic band and then face
the end of the plastic band inward.
Ò Fasten the starter motor lead to the negative
battery lead at the mark on the battery lead with
the plastic band. Then, fasten the starter motor
lead and negative battery lead to the frame with
the plastic band and face the end of the band
inward.
Ó Install the crankcase breather hose with the
paint mark facing to the left.
Í Fasten the wire harness, throttle position sensor
lead, and carburetor switch lead with the plastic
band. Make sure that there is no slack in the
throttle position sensor lead and carburetor
switch lead along the frame as shown.
Î More than 15 mm (0.59 in)
Ï Install the cylinder head breather hose with the
paint mark facing to the left.
Ð Fasten the wire harness with the plastic band on
the positioning tape and then face the end of the
plastic band inward.
Ü L
7
P
Ý
M
7
B-B
Þ
C-C
4
A
N
ß
A
O
2
3É
1
È
Ï
56
7
Í
Ë
K
J
0
D-D
C
G
G
5
Ì
Ê
B
B
SPEC
C
Î
G
D
89
E
9
Ð 0
Ñ
D
G
Ò
E
H
I
ÛH
G
A
B
C
Ó
F
F
Ú Ù
Ø F
× E
Á
G
D
E
AA
H
Ö Õ DÔ
À
E
D
G-G
Q
F-F
– 17 –
E-E
CABLE ROUTING
Ù Pass the neutral switch lead and A.C. magneto
lead through the guide on the fender stay.
Ú Wrap the resistor lead around the frame as
shown in the illustration, and then fasten it with
the plastic band. Face the end of the plastic
band inward.
Û Install headlight relay 1 and headlight relay 2 to
the inside of the frame, making sure to insert the
tab on each relay completely into its rubber
holder and to install the holders all the way onto
the tabs on the stay.
Ô Route the neutral switch lead so that it does not
contact the edges of the joint on the end of the
oil pipe 2.
Õ Fasten the neutral switch lead with the lead
holder.
Ö Fasten the neutral switch lead with the clamp.
× Fasten the A.C. magneto lead with the lead
holder.
Ø Fasten the neutral switch lead and A.C. magneto lead with the plastic band. Face the end of
the plastic band inward on top of the frame.
Ü L
7
P
Ý
M
7
B-B
Þ
C-C
4
A
N
ß
A
O
2
3É
1
È
Ï
56
7
Í
Ë
K
J
0
D-D
C
G
G
5
Ì
Ê
B
B
SPEC
C
Î
G
D
89
E
9
Ð 0
Ñ
D
G
Ò
E
H
I
ÛH
G
A
B
C
Ó
F
F
Ú Ù
Ø F
× E
Á
G
D
E
AA
H
Ö Õ DÔ
À
E
D
G-G
Q
F-F
– 18 –
E-E
CABLE ROUTING
À Fasten the cylinder head breather hose with the
holder, making sure that the catch of the holder
is facing upward.
Á Fasten the A.C. magneto lead and neutral
switch lead with the plastic band, making sure
that the end of the band is on top of the frame,
facing inward.
A A Fasten the resistor lead with the holder.
Ü When installing the fuel tank cover, do not pinch
the front brake hose, throttle cable, front brake
light switch lead, and throttle switch lead.
Ý Route the front brake hose in front of the handlebar cover.
Þ Route the clutch cable and parking brake cable
in front of the handlebar cover.
ß When installing the fuel tank cover, do not pinch
the clutch cable, parking brake cable, clutch
switch lead, and handlebar switch lead.
Ü L
7
P
Ý
M
7
B-B
Þ
C-C
4
A
N
ß
A
O
2
3É
1
È
Ï
56
7
Í
Ë
K
J
0
D-D
C
G
G
5
Ì
Ê
B
B
SPEC
C
Î
G
D
89
E
9
Ð 0
Ñ
D
G
Ò
E
H
I
ÛH
G
A
B
C
Ó
F
F
Ú Ù
Ø F
× E
Á
G
D
E
AA
H
Ö Õ DÔ
À
E
D
G-G
Q
F-F
– 19 –
E-E
CABLE ROUTING
1 Wire harness
2 Air filter case breather hose
3 Cylinder head breather hose
4 Coolant reservoir breather hose
5 Coolant reservoir hose
6 Tail/brake light breather hose
7 Tail/brake light
8 Tail/brake light lead
9 Crankcase breather hose
0 Carburetor drain hose
A Carburetor air vent hose
Ñ
SPEC
B Battery negative lead
C Starter motor lead
È When installing the rear fender, make sure that
the rear fender does not overlap or pinch the cylinder head breather hose, coolant reservoir
hose, or wire harness.
É Install the air filter case breather hose with the
paint mark facing outward.
Ê Install the cylinder head breather hose with the
paint mark facing outward.
A
Ò
0
B
C
0
Ô
9
B
Ó
Ð
C-C
B
Ï
A
È
1
3Ê Ë 4 Ì 5
2 É
G
F
6
E
D
D
C
F
Í
E
A
9
Î
C
7
G 8
B
5
3
Õ
6
×
Ö
5
5
G-G
8
B
C
1
8
F-F
– 20 –
E-E
D-D
CABLE ROUTING
Ï Pass the carburetor drain hose and carburetor
air vent hoses through the hose guide on the
engine from the left side of the vehicle in the
order listed. Do not pinch the hoses.
Ð Route the negative battery lead to the outside of
the carburetor drain hose.
Ñ Make sure that the cover is installed securely on
the negative battery lead terminal.
Ë Install the coolant reservoir breather hose without twisting the hose.
Ì Fasten the coolant reservoir hose and the coolant reservoir breather hose with the holder, making sure that there is no slack in the hose.
Í Install the coolant reservoir breather hose as
shown so that there is no slack.
Î Install the wire harness so that it does not hang
from the rear fender.
Ñ
SPEC
A
Ò
0
B
C
0
Ô
9
B
Ó
Ð
C-C
B
Ï
A
È
1
3Ê Ë 4 Ì 5
2 É
G
F
6
E
D
D
C
F
Í
E
A
9
Î
C
7
G 8
B
5
3
Õ
6
×
Ö
5
5
G-G
8
B
C
1
8
F-F
– 21 –
E-E
D-D
CABLE ROUTING
Õ Fasten the coolant reservoir hose on top of the
cylinder head breather hose with the holder, and
then route the hoses along the frame, making
sure that they are not pinched or crushed.
Ö Fasten the tail/brake light lead, wire harness,
starter motor lead, and negative battery lead
with the holder in the order listed.
× Fasten the coolant reservoir hose, tail/brake light
lead, and tail/brake light breather hose with the
holder, making sure that the catch of the holder
is facing inward.
Ò Route the carburetor drain hose between the
rear shock absorber and swingarm, and then
under the frame.
Ó Route the carburetor drain hose between the
frame and connecting arm and let it hang freely
under the vehicle.
Ô Fasten the crankcase breather hose and starter
motor lead with the holder in the order listed.
Ñ
SPEC
A
Ò
0
B
C
0
Ô
9
B
Ó
Ð
C-C
B
Ï
A
È
1
3Ê Ë 4 Ì 5
2 É
G
F
6
E
D
D
C
F
Í
E
A
9
Î
C
7
G 8
B
5
3
Õ
6
×
Ö
5
5
G-G
8
B
C
1
8
F-F
– 22 –
E-E
D-D
SPEC
CABLE ROUTING
1 Brake fluid reservoir hose
2 Rear brake light switch lead
3 Throttle cable
4 Clutch cable
5 Coolant reservoir hose
6 Oil tank breather hose
7 Thermo switch 1 lead
8 Resistor lead
9 Parking brake cable
È Fasten the coolant reservoir hose with a clamp
so that it is not pinched.
É Route the thermo switch 1 lead under the frame.
Ê Fasten the thermo switch 1 lead with a plastic
band between the diode 1 and the diode 2 and
then face the end of the band inward.
Ë Fasten the resistor lead with a plastic band and
then face the end of the band inward.
Ì Pass the parking brake cable through the cable
guide.
4
9
2
A-A
9
C
D
5
2
B-B
1 2
3 4 È 5 6
7
A
B
É
Ê
B
A
C
D
Ë
9
– 23 –
8
Ì
SPEC
CABLE ROUTING
1 Rear brake hose
2 Parking brake cable
3 Brake fluid reservoir hose
4 Rear brake light switch
5 Rear brake light switch lead
È Pass the brake fluid reservoir hose through the
guide.
É Route the rear brake light switch lead to the
inside of the brake fluid reservoir hose so that it
will not contact the rider’s leg.
Ê Pass the brake fluid reservoir hose and rear
brake light switch lead through the hose holder.
Ë Install the brake hose holder so that the projection on its end aligns with the line on the swingarm as shown the illustration.
1
2
5
A-A
C-C
3
Ë
D
5
2
1
Ê
C
É
C
4
C
C
3
È
B-B
B
1
2
A
B
D
A
– 24 –
CABLE ROUTING
1 Starter relay
2 Positive battery lead
3 Tail/brake light breather hose
4 Tail/brake light lead
5 Starter motor lead
6 Starting circuit cut-off relay
7 Earth lead
8 Negative battery lead
9 Coolant reservoir breather hose
0 Coolant reservoir hose
A Cylinder head breather hose
SPEC
B Wire harness
È Pass the coolant reservoir hose through the
hose guide.
É Route the earth lead and wire harness under the
battery bracket.
Ê Connect the tail/brake light lead between the
coolant reservoir and the rear fender.
Ë Pass the wire harness through the notch in the
rear fender. Be sure that the rear fender and air
filter case do not pinch the wire harness.
È
8
B
B
A
0
0
B
Í
9
Ì
8
Ë
Ê A
8
1
A
É7
2
A-A
6
5
4
– 25 –
3
CABLE ROUTING
SPEC
Ì Route the coolant reservoir breather hose so
that it is not pinched by the rear fender.
Í Fasten the coolant reservoir hose and the cylinder head breather hose to the frame with the
plastic beaded tie at its loosest position so that
the hoses are not pinched.
È
8
B
B
A
0
0
B
Í
9
Ì
8
Ë
Ê A
8
1
A
É7
2
A-A
6
5
4
– 26 –
3
INTRODUCTION/PERIODIC MAINTENANCE CHART
FOR THE EMISSION CONTROL SYSTEM
CHK
ADJ
EBS00029
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All
service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
NOTE:
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month
maintenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
INITIAL
ITEM
ROUTINE
Whichever
comes first
Fuel line*
• Check fuel hose for cracks or damage.
• Replace if necessary.
Spark plug
• Check condition.
• Adjust gap and clean.
• Replace if necessary.
Valves*
• Check valve clearance.
• Adjust if necessary.
Carburetor*
• Check starter (choke) operation.
• Adjust engine idle speed.
Crankcase breather
system*
• Check breather hose for cracks or damage.
• Replace if necessary.
Exhaust system*
• Check for leakage.
• Tighten if necessary.
• Replace gasket if necessary.
Spark arrester
• Clean.
– 27 –
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
GENERAL MAINTENANCE AND LUBRICATION CHART
CHK
ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL
ITEM
ROUTINE
Whichever
comes first
EVERY
month
1
3
6
6
12
km
(mi)
320
(200)
1300
(800)
2500
(1600)
2500
(1600)
5000
(3200)
hours
20
80
160
160
320
Air filter element
• Clean.
• Replace if necessary.
Clutch*
• Check operation.
• Adjust if necessary.
Front brake*
• Check free play/operation/fluid leakage/ See NOTE.
• Correct if necessary.
Rear brake*
• Check operation/fluid leakage/ See NOTE.
• Correct if necessary.
Wheels*
• Check balance/damage/runout.
• Replace if necessary.
Wheel bearings*
• Check bearing assemblies for looseness/damage.
• Replace if damaged.
Rear arm pivots*
• Lubricate every 6 months with lithium-soap-based
grease.
Every 20–40 hours
(more often in wet or dusty areas)
Upper and lower arm
• Lubricate every 6 months with lithium-soap-based
pivot and steering
grease.
shaft*
Drive chain
• Check and adjust slack/alignment/clean/lube.
Fittings and fasteners*
• Check all chassis fittings and fasteners.
• Correct if necessary.
Front and rear suspension*
• Check operation.
• Correct if necessary.
Steering system*
•
•
•
•
Engine oil
• Replace (Warm engine before draining).
Engine oil filter element
• Replace.
Cooling system
• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.
Lights and switches*
• Check operation.
• Adjust headlight beams.
Check operation.
Repair if damaged.
Check toe-in.
Adjust if necessary.
NOTE:
• Recommended brake fluid: DOT 4
• Brake fluid replacement:
• When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally
check the brake fluid level and add the fluid as required.
• On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two
years.
• Replace the brake hoses every four years, or if cracked or damaged.
WARNING
Indicates a potential hazard that could result in serious injury or death.
– 28 –
ADJUSTING THE PARKING BRAKE/
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
CHASSIS
ADJUSTING THE PARKING BRAKE
1. Check:
• parking brake cable end length a
Out of specification → Adjust.
a
Parking brake cable end length
47 ~ 51 mm (1.85 ~ 2.01 in)
1
2. Adjust:
• parking brake cable end length
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b
2
3
a. Slide back the rubber cover 1.
b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or
b until the specified brake cable end length
is obtained.
d. Tighten the locknut 2.
e. Slide the rubber cover to its original position.
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00087
CHECKING THE BRAKE FLUID LEVEL
1. Place the vehicle on a level surface.
NOTE:
When checking the brake fluid level, make
sure that the top of the brake master cylinder
and brake fluid reservoir is horizontal.
_
– 29 –
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
2. Remove:
• Right side cover
Refer to “SEAT, FENDERS AND FUEL
TANK”. (Manual No.: 5TG-28197-10)
È
1
3. Check:
• brake fluid level
Below the minimum level mark 1 → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT 4
È Front brake
É Rear brake
É
WARNING
_
1
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
_
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure that the top of the
brake master cylinder and brake fluid reservoir
is horizontal.
_
– 30 –
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
Measure the drive chain slack halfway
between the drive axle and the rear axle.
CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the specified limits.
a
1. Measure:
• drive chain slack a
Out of specification → Adjust.
Drive chain slack
25 ~ 35 mm (0.98 ~ 1.38 in)
4
2. Adjust:
• drive chain slack
3
NOTE:
The drive chain slack is adjusted by the rotation of the rear axle hub.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3
24
2
1
31
1
a. Loosen the rear axle pinch bolts 1.
NOTE:
Loosen the rear axle pinch bolts in the proper
sequence as shown.
b. Insert an appropriate shaft 2 in the hole 3
of rear axle hub 4.
c. Shift the transmission into the neutral position.
d. To loosen the drive chain, push the vehicle
forward and to tighten the drive chain, pull
the vehicle backward.
CAUTION:
Excessive chain slack will overload the
engine and other vital parts; keep the slack
within the specified limits.
– 31 –
ADJUSTING THE DRIVE CHAIN SLACK/
ADJUSTING THE FRONT SHOCK ABSORBERS
CHK
ADJ
e. If the chain slack cannot be adjusted,
replace the sprockets and drive chain as a
set.
f. Tighten the rear axle pinch bolts 1.
31
24
T.
Rear axle pinch bolt
21 Nm (2.1 m · kg, 15 ft · lb)
R.
1
1
NOTE:
• Tighten the rear axle pinch bolts 1 in the
proper sequence as shown.
• The chain should be cleaned and lubricated
after every use of the vehicle.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00111
ADJUSTING THE FRONT SHOCK
ABSORBERS
WARNING
_
Always adjust the spring preload, rebound
damping force and compression damping
force of both front shock absorbers to the
same setting. Uneven adjustment can
result in poor handling and loss of stability.
1
2
a
b
1. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Elevate the front wheels by placing a suitable stand under the frame.
b. Loosen the locknut 1.
c. Turn the adjusting ring 2 in direction a or
b.
c
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting length c
Standard: 255 mm (10.04 in)
Minimum: 246.5 mm (9.70 in)
Maximum: 261.5 mm (10.30 in)
– 32 –
ADJUSTING THE FRONT SHOCK ABSORBERS
CHK
ADJ
NOTE:
• Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
adjustment.
• The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
_
CAUTION:
_
Never attempt to turn the adjusting ring
beyond the maximum or minimum setting.
d. Tighten the locknut 1 with a steering nut
wrench 3.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
Steering nut wrench
P/N. YU-33975, 90890-01443
T.
Locknut
30 Nm (3.0 m · kg, 22 ft · lb)
R.
NOTE:
Always tighten the locknut against the adjusting ring, then torque it to specification.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• rebound damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
b
1
a
Direction a
Rebound damping force
is increased.
Direction b
Rebound damping force
is decreased.
From the fully turned-in position
Standard: 11 clicks out
Minimum: 22 clicks out
Maximum: 1 click out
– 33 –
ADJUSTING THE FRONT SHOCK ABSORBERS/
ADJUSTING THE REAR SHOCK ABSORBER
CHK
ADJ
CAUTION:
_
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• compression damping force
a
b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
1
Direction a
Compression damping
force is increased.
Direction b
Compression damping
force is decreased.
From the fully turned-in position
Standard: 11 clicks out
Minimum: 20 clicks out
Maximum: 1 click out
CAUTION:
_
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS00111
ADJUSTING THE REAR SHOCK
ABSORBER
1. Remove:
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”. (Manual No.: 5TG-28197-10)
2. Loosen the clamp screw 1, and then disconnect the air intake duct.
1
– 34 –
ADJUSTING THE REAR SHOCK ABSORBER
CHK
ADJ
3. Disconnect the air filter case breather hose
1, and then remove the air filter case 2
with the air intake duct.
2
1
1
2
a
b
4. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Elevate the rear wheels by placing a suitable stand under the frame.
b. Loosen the locknut 1.
c. Turn the adjusting ring 2 in direction a or
b.
Direction a
Spring preload is
increased (suspension
is harder).
Direction b
Spring preload is
decreased (suspension
is softer).
Adjusting length c
Standard: 257mm (10.12 in)
Minimum: 250 mm (9.84 in)
Maximum: 264 mm (10.39 in)
c
NOTE:
• Be sure to remove all dirt and mud from
around the locknut and adjusting ring before
adjustment.
• The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
_
CAUTION:
_
Never attempt to turn the adjusting ring
beyond the maximum or minimum setting.
d. Tighten the locknut 1 with a steering nut
wrench 3.
NOTE:
Set the torque wrench at a right angle to the
steering nut wrench.
– 35 –
ADJUSTING THE REAR SHOCK ABSORBER
CHK
ADJ
Steering nut wrench
P/N. YU-33975, 90890-01443
T.
Locknut
44 Nm (4.4 m · kg, 32 ft · lb)
R.
NOTE:
Always tighten the locknut against the adjusting ring, then torque it to specification.
_
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b
a
5. Install:
• air filter case with air intake duct
NOTE:
Align the projection a on the carburetor with
the slot b in the air intake duct.
_
6. Adjust:
• rebound damping force
1
c
b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a
1
a. Turn the adjusting screw 1 in direction a
or b.
Direction a
Rebound damping force
is increased.
Direction b
Rebound damping force
is decreased.
Minimum (soft): Adjusting screw fully
turned out
Standard: Adjusting screw 1 1/4 turns
out from the fully turned in position
Maximum (hard): Adjusting screw fully
turned in
NOTE:
Make sure that the position indicator marks c
are aligned when the shock absorber is set to
the standard setting.
CAUTION:
_
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 36 –
ADJUSTING THE REAR SHOCK ABSORBER
CHK
ADJ
7. Adjust:
• compression damping force
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direction a
or b.
a
1
b
1
c
Direction a
Compression damping
force is increased.
Direction b
Compression damping
force is decreased.
Minimum (soft): Adjusting screw fully
turned out
Standard: Adjusting screw 1 3/4 turns
out from the fully turned in position
Maximum (hard): Adjusting screw fully
turned in
NOTE:
Make sure that the position indicator marks c
are aligned when the shock absorber is set to
the standard setting.
CAUTION:
_
Do not force the adjuster past the minimum
or maximum extent of adjustment. The
adjuster may be damaged.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• seat
Refer to “SEAT, FENDERS AND FUEL
TANK”. (Manual No.: 5TG-28197-10)
– 37 –
ENGINE REMOVAL
ENG
EBS00198
ENGINE
ENGINE REMOVAL
MUFFLER AND EXHAUST PIPE
T.
R.
34 Nm (3.4 m • kg, 24 ft • Ib)
2
1
7
New 4
New
LT
3
T.
20 Nm (2.0 m • kg, 14 ft • Ib)
R.
6
5
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
LT
T.
R.
T.
R.
Order
1
2
3
4
5
6
7
14 Nm (1.4 m • kg, 10 ft • Ib)
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Job/Part
Removing the muffler and exhaust
pipe
Seat/fuel tank cover/side covers (left
and right)
Fuel tank
Right foot protector/engine skid plate
Clamp
Muffler
Muffler protector
Gasket
Exhaust pipe
Exhaust pipe protector
Gasket
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
(Manual No.: 5TG-28197-10)
1
1
1
1
1
1
1
Loosen.
Refer to “INSTALLING
THE EXHAUST PIPE
AND MUFFLER”. (Manual No.: 5TG-28197-10)
For installation, reverse the removal procedure.
– 38 –
ENGINE REMOVAL
ENG
EBS00252
INSTALLING THE PISTON
1. Install:
• piston rings
(onto the piston)
NOTE:
• Be sure to install the piston rings so that the
manufacturer’s marks or numbers are
located on the upper side of the rings.
• Lubricate the piston and piston rings liberally
with engine oil.
_
ad
2.
•
•
•
90˚
45˚ 45˚
c
be
a Top ring end
b 2nd ring end
c Oil ring end (upper)
d Oil ring
e Oil ring end (lower)
3.
•
•
•
Install:
piston 1
piston pin 2
piston pin clips 3 New
NOTE:
• Apply engine oil onto the piston pin, piston
rings and piston.
• Be sure that the punch mark a on the piston
points to the exhaust side of the engine.
• Before installing the piston pin clips, cover
the crankcase with a clean rag to prevent the
piston pin clips from falling into the crankcase.
• When installing a piston pin clip, make sure
that the clip ends are 3 mm (0.12 in) a or
more from the cutout in the piston.
_
a
Position:
top ring
2nd ring
oil ring
Offset the piston ring end gaps as shown.
3 New
– 39 –
COOL
RADIATOR
EBS00125
COOLING SYSTEM
RADIATOR
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
T.
R.
28 Nm (2.8 m • kg, 20 ft • Ib)
9 Nm (0.9 m • kg, 6.5 ft • Ib)
15
7
9
(2)
13
16 8
2
14
3 4
New
(2)
11
1
5 6
10
12
New
T.
R.
28 Nm (2.8 m • kg, 20 ft • Ib)
T.
.
RR.
Order
1
2
3
4
5
6
7
8
9
10
Job/Part
Removing the radiator
Seat/fuel tank cover/side covers (left
and right)/front fender
Coolant
Plastic band
Radiator fan coupler
Thermo switch 1 coupler
Thermo switch 1
Thermo switch 2 coupler
Thermo switch 2
Radiator fan breather hose
Coolant reservoir hose
Radiator outlet hose
Radiator inlet hose
Q’ty
1
1
1
1
1
1
1
1
1
1
– 40 –
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
(Manual No.: 5TG-28197-10)
Drain.
Disconnect.
Disconnect.
Disconnect.
COOL
RADIATOR
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
T.
R.
28 Nm (2.8 m • kg, 20 ft • Ib)
9 Nm (0.9 m • kg, 6.5 ft • Ib)
15
7
9
(2)
13
16 8
2
14
3 4
New
(2)
11
1
5 6
10
12
New
T.
R.
28 Nm (2.8 m • kg, 20 ft • Ib)
T.
.
RR.
Order
11
12
13
14
15
16
Job/Part
Radiator
Radiator grill
Radiator fan
Coolant reservoir breather hose
Coolant reservoir cap
Coolant reservoir
Q’ty
1
1
1
1
1
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
Remarks
For installation, reverse the removal procedure.
– 41 –
WATER PUMP
COOL
EBS00134
WATER PUMP
Order
Job/Part
Removing the water pump
Engine oil
Coolant
Exhaust pipe
Q’ty
Rear brake light switch/footrest (right)
Clutch cover
1
2
3
4
5
Radiator outlet hose
Water pump inlet pipe
Water pump housing
Oil filter element cover
Oil filter element
1
1
1
1
1
– 42 –
Remarks
Remove the parts in the order listed.
Drain.
Drain.
Refer to “ENGINE REMOVAL” in
chapter 4. (Manual No.: 5TG-28197-10)
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
(Manual No.: 5TG-28197-10)
Refer to “CLUTCH” in chapter 4.
(Manual No.: 5TG-28197-10)
WATER PUMP
Order
6
7
8
9
10
11
12
13
14
15
16
17
Job/Part
Parking brake holder
Oil delivery pipe 1
Oil pipe 1
Water pump breather hose
Right crankcase cover
Gasket
Impeller
Washer
Impeller shaft
Oil seal
Bearing
Oil seal
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
COOL
Remarks
For installation, reverse the removal procedure.
– 43 –
FRONT AND REAR WHEELS
CHAS
CHASSIS
FRONT AND REAR WHEELS
REAR WHEELS
Order
Job/Part
Removing the rear wheels
Q’ty
Remarks
Remove the parts in the order listed.
Place the vehicle on a level surface.
WARNING
_
Securely support the vehicle so there
is no danger of it falling over.
1
2
3
4
Rear wheel
Cotter pin
Axle nut
Wheel hub
2
2
2
2
Refer to “INSTALLING THE REAR
WHEEL HUBS”.
For installation, reverse the removal procedure.
– 44 –
FRONT AND REAR WHEELS
CHAS
INSTALLING THE REAR WHEEL HUBS
1. Install:
• rear axle washers 1 New
• rear axle nuts 2 New
• cotter pins 3 New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a rust preventive lubricant to the
threads on both sides of the rear axle and to
the wheel hub surfaces that contact the rear
axle washers.
b. Tighten the rear axle nuts to specification.
T.
Rear axle nut
200 Nm (20.0 m · kg, 145 ft · lb)
R.
c. Loosen the rear axle nuts completely.
d. Retighten the rear axle nuts to specification.
T.
Rear axle nut
200 Nm (20.0 m · kg, 145 ft · lb)
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE:
Do not loosen the axle nuts after torquing
them. If an axle nut slot is not aligned with the
cotter pin hole on either side of the axle, further tighten the axle nut until a slot is aligned
with the hole.
– 45 –
REAR AXLE AND REAR AXLE HUB
CHAS
EBS00382
REAR AXLE AND REAR AXLE HUB
Order
1
2
3
4
5
Job/Part
Removing the rear axle and rear axle
hub
Rear wheels/rear wheel hubs
Rear axle ring nut set bolt
Rear axle ring nut
Conical spring washer
Rear axle pinch bolt
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “FRONT AND REAR WHEELS”.
(Manual No.: 5TG-28197-10)
2
1
1
4
1
Refer to “REMOVING THE REAR
AXLE” and “INSTALLING THE REAR
AXLE”.
NOTE:
Do not apply the brake pedal and do not
use the parking brake when the brake
caliper is off of the brake disc as the
brake pads will be force shut.
_
– 46 –
REAR AXLE AND REAR AXLE HUB
Order
6
7
8
9
10
11
12
13
14
15
16
17
Job/Part
Brake disc/brake disc bracket
Rear axle
Circlip
Driven sprocket/sprocket bracket
Circlip
Brake caliper bracket
Spacer
Rear axle hub
Oil seal
Bearing
Bearing
Spacer
CHAS
Q’ty
Remarks
1/1
Refer to “REMOVING THE REAR
1
AXLE”.
1
1/1 Refer to “INSTALLING THE DRIVEN
SPROCKET”.
1
1
1
1
2
2
2
1
For installation, reverse the removal procedure.
– 47 –
REAR AXLE AND REAR AXLE HUB
CHAS
REMOVING THE REAR BRAKE CALIPER
1. Remove:
• rear brake caliper mounting bolts
NOTE:
If the rear brake caliper can not be removed
easily, first remove the brake pads and then
remove the rear brake caliper.
EBS00393
2
REMOVING THE REAR AXLE
1. Place the vehicle on a level surface.
2. Remove:
• rear axle ring nut set bolts 1
3. Loosen:
• rear axle ring nut 2
NOTE:
• Apply the brake pedal so that the rear axle
does not turn, when loosening the rear axle
ring nut.
• Use the rear axle nut wrench (46 mm) 3.
_
1
3
Rear axle nut wrench (46 mm)
P/N. YM-37134, 90890-01498
2
4. Loosen:
• driven chain
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK”.
5. Elevate the rear wheels by placing the suitable stand under the frame.
6. Remove:
• rear wheels
• wheel hubs
• nuts
• washers
– 48 –
REAR AXLE AND REAR AXLE HUB
CHAS
7. Remove:
• rear axle 1
(with driven sprocket)
CAUTION:
_
1
• Never directly tap the axle end with a
hammer, since this will result in damage
to the axle thread and spline.
• Attach a suitable socket 2 on the axle
end and tap it with a soft hammer, then
pull out the rear axle to the left.
8. Remove:
• circlip
• driven sprocket bracket
a
INSTALLING THE DRIVEN SPROCKET
1. Install:
• driven sprocket
NOTE:
Make sure that the blunt-edged corner a of
the driven sprocket is facing outward.
EBS00397
1
INSTALLING THE REAR AXLE
1. Install:
• conical spring washer 1
NOTE:
Install the conical spring washer with the convex side of the washer facing outward as
shown.
– 49 –
REAR AXLE AND REAR AXLE HUB
CHAS
2. Tighten:
• rear axle ring nut 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the rear axle ring nut with rear axle
nut wrench (46 mm) 2 to specification
while holding the rear axle.
1
Rear axle nut wrench (46 mm)
P/N. YM-37134, 90890-01498
2
3
T.
1
R.
Rear axle ring nut
240 Nm (24.0 m · kg, 175 ft · lb)
LOCTITE®
b. Tighten rear axle ring nut set bolts 3.
T.
R.
3
Rear axle ring nut set bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
LOCTITE®
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 50 –
FRONT AND REAR BRAKES
CHAS
EBS00400
FRONT AND REAR BRAKES
FRONT BRAKE PADS
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
LT
4
3
2
3
1
1
T.
R.
28 Nm (2.8 m • kg, 20 ft • Ib)
Order
Job/Part
Removing the front brake pads
Q’ty
Front wheel
1
2
3
4
Brake caliper mounting bolt
Brake pad retaining bolt
Brake pad/pad shim
Brake pad spring
2
2
2/1
1
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
Refer to “FRONT AND REAR WHEELS”.
(Manual No.: 5TG-28197-10)
Refer to “REPLACING THE FRONT
BRAKE PADS”.
(Manual No.: 5TG-28197-10)
For installation, reverse the removal procedure.
– 51 –
FRONT AND REAR BRAKES
CHAS
EBS00401
REAR BRAKE PADS
4
LT
LT
3
2
LT
LT
T.
R.
17 Nm (1.7 m • kg, 12 ft • Ib)
1
T.
R.
Order
1
2
3
4
43 Nm (4.3 m • kg, 31 ft • Ib)
Job/Part
Removing the rear brake pads
Brake caliper mounting bolt
Brake pad retaining bolt
Brake pad
Brake pad spring
Q’ty
2
2
2
2
Remarks
Remove the parts in the order listed.
Refer to “REPLACING THE REAR
BRAKE PADS”.
(Manual No.: 5TG-28197-10)
For installation, reverse the removal procedure.
– 52 –
FRONT AND REAR BRAKES
CHAS
EBS00410
REAR BRAKE MASTER CYLINDER
Order
1
2
3
4
5
6
Job/Part
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order listed.
inder
Right side cover/right foot protector
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
(Manual No.: 5TG-28197-10)
Brake fluid
Drain.
Brake fluid reservoir hose cover
1
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm holder
1
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
– 53 –
FRONT AND REAR BRAKES
Order
7
8
9
10
11
12
13
Job/Part
Union bolt
Copper washer
Brake hose
Brake master cylinder
Rear brake light switch
Right footrest
Brake pedal/spring
CHAS
Q’ty
Remarks
1
Refer to “INSTALLING
2
THE REAR BRAKE MAS1
Disconnect.
TER CYLINDER”.
1
1
1
1/1
For installation, reverse the removal procedure.
– 54 –
FRONT AND REAR BRAKES
CHAS
EBS00419
2
1
b
T.
R.
a
INSTALLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• copper washers New
• brake hose 1
30 Nm (3.0 m · kg, 2.2 ft · lb)
• union bolt 2
CAUTION:
_
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe a touches the projection b as shown.
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
2. Install:
• brake fluid reservoir hose 1
1
NOTE:
Install the brake fluid reservoir hose with the
white paint mark a facing up as shown.
10˚
a
3. Fill:
• brake fluid reservoir
Recommended brake fluid
DOT 4
CAUTION:
_
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
– 55 –
FRONT AND REAR BRAKES
CHAS
• Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
(Manual No.: 5TG-28197-10)
5. Check:
• brake fluid level
Brake fluid level is under the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
– 56 –
CHAS
FRONT AND REAR BRAKES
EBS00423
FRONT BRAKE CALIPER
3
T.
R.
T.
R.
6 Nm (0.6 m • kg, 4.3 ft • Ib)
8
New
7
17 Nm (1.7 m • kg, 12 ft • Ib)
2
2
6
1
LS
LT
5
4
New
LS
LS
Order
Job/Part
Disassembling the front brake calipers
Q’ty
Remarks
Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
1
2
3
4
5
6
7
Brake pad retaining bolt
Brake pad/pad shim
Brake pad spring
Caliper bracket
Caliper piston
Dust seal
Caliper piston seal
8
Bleed screw
2
2/1
1
1
2
2
2
Refer to “DISASSEMBLING THE
FRONT AND REAR BRAKE CALIPERS” and “ASSEMBLING THE
FRONT BRAKE CALIPERS”.
(Manual No.: 5TG-28197-10)
1
For assembly, reverse the disassembly
procedure.
– 57 –
FRONT AND REAR BRAKES
CHAS
EBS00424
REAR BRAKE CALIPER
6
1
4
New 3
New 3
2
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib)
5
T.
R.
Order
43 Nm (4.3 m • kg, 31 ft • Ib)
1
Job/Part
Removing the rear brake caliper
Brake fluid
Parking brake cable
2
3
4
5
6
Union bolt
Copper washer
Brake hose
Brake caliper mounting bolt
Brake caliper assembly
Q’ty
1
Remarks
Remove the parts in the order listed.
Drain.
Disconnect.
Refer to “REMOVING THE PARKING
BRAKE CABLE”.
(Manual No.: 5TG-28197-10)
1
2
1
2
1
Disconnect.
Refer to “INSTALLING
THE REAR BRAKE CALIPER”.
For installation, reverse the removal procedure.
– 58 –
CHAS
FRONT AND REAR BRAKES
EBS00425
LT
LS
0
B
C
LS
New
D
E
F
T.
23 Nm (2.3 m • kg, 17 ft • Ib)
R.
A
New
8
9
LT
LT
D
F New
T.
R.
2
4
3
17 Nm (1.7 m • kg, 12 ft • Ib)
G
5
1
T.
6
R.
7
T.
R.
T.
R.
Order
0
E New
6
LS
LT
6 Nm (0.6 m • kg, 4.3 ft • Ib)
LT
23 Nm (2.3 m • kg, 17 ft • Ib)
16 Nm (1.6 m • kg, 11 ft • Ib)
1
2
3
4
5
Job/Part
Disassembling the rear brake caliper
Adjusting bolt
Locknut
Parking brake arm
Rubber boot
Parking brake shaft
6
7
8
9
0
Parking brake bracket bolt
Parking brake case bracket
Parking brake case
Gasket
Brake pad retaining bolt
Q’ty
1
1
1
1
1
2
1
1
1
2
– 59 –
Remarks
Remove the parts in the order listed.
Refer to “DISASSEMBLING THE
FRONT AND REAR BRAKE CALIPERS” and “ASSEMBLING THE REAR
BRAKE CALIPER”.
CHAS
FRONT AND REAR BRAKES
LT
LS
0
B
C
LS
New
D
E
F
T.
23 Nm (2.3 m • kg, 17 ft • Ib)
R.
A
New
8
9
LT
LT
D
F New
T.
R.
2
4
3
G
T.
6
R.
7
T.
R.
T.
R.
G
17 Nm (1.7 m • kg, 12 ft • Ib)
5
1
Order
A
B
C
D
E
F
0
E New
6
LS
LT
6 Nm (0.6 m • kg, 4.3 ft • Ib)
LT
23 Nm (2.3 m • kg, 17 ft • Ib)
16 Nm (1.6 m • kg, 11 ft • Ib)
Job/Part
Brake pad
Brake pad spring
Caliper bracket
Brake caliper piston
Dust seal
Caliper piston seal
Bleed screw
Q’ty
2
2
1
2
2
2
Remarks
Refer to “DISASSEMBLING THE
FRONT AND REAR BRAKE CALIPERS” and “ASSEMBLING THE REAR
BRAKE CALIPER”.
1
For assembly, reverse the disassembly
procedure.
– 60 –
FRONT AND REAR BRAKES
CHAS
REMOVING THE REAR BRAKE CALIPER
1. Remove:
• rear brake caliper mounting bolts
NOTE:
If the rear brake caliper can not be removed
easily, first remove the rear brake pads and
then remove the rear brake caliper.
EBS00427
È
1
2
DISASSEMBLING THE FRONT AND REAR
BRAKE CALIPERS
1. Remove:
• brake caliper pistons
• dust seals 1
• caliper piston seals 2
È Front
É Rear
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.
É
1
2
WARNING
_
• Never try to pry out the caliper piston.
• Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the caliper cylinder.
b. Remove the caliper piston seals.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 61 –
FRONT AND REAR BRAKES
CHAS
EBS00429
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
Brake pads
As required
Piston seals, dust
seals
Every two years
Brake hoses
Every four years
Brake fluid
Replace when
brakes are
disassembled.
WARNING
_
All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.
È
2
1
2
3
1
É
3
2
1. Check:
• brake caliper pistons 1
Scratches/rust/wear → Replace the brake
caliper assembly.
• brake caliper cylinders 2
Wear/scratches → Replace the brake caliper assembly.
• brake caliper body 3
Cracks/damage → Replace.
• brake fluid delivery passage
(brake caliper body)
Blockage → Blow out with compressed air.
WARNING
_
Replace the caliper piston seals and dust
seals whenever the brake caliper is disassembled.
1
2
1
È Front
É Rear
– 62 –
FRONT AND REAR BRAKES
CHAS
EBS00432
ASSEMBLING THE REAR BRAKE CALIPER
WARNING
_
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid
DOT 4
• Replace the caliper piston seals and dust
seals whenever the brake caliper is disassembled.
New
1
1. Install:
• caliper piston seals 1 New
• dust seals 2 New
2
New
2. Install:
• brake caliper piston 1
1
3. Install:
• parking brake shaft 1
1
NOTE:
Screw the parking brake shaft all the way into
the parking brake case, making sure that the
punch mark a in the shaft is between the
embossed marks b on the case.
b
a
4. Install:
• parking brake arm 1
1
a
NOTE:
Align the center a of the parking brake arm
with the punch mark b in the parking brake
shaft as shown.
b
– 63 –
FRONT AND REAR BRAKES
CHAS
EBS00436
a
b
INSTALLING THE REAR BRAKE CALIPER
1. Install:
• brake caliper assembly
• brake caliper mounting bolts 1
T.
R.
2
1
1
T.
R.
3
43 Nm (4.3 m · kg, 31 ft · lb)
• brake hose 2
• copper washers New
30 Nm (3.0 m · kg, 22 ft · lb)
• union bolt 3
CAUTION:
_
When installing the brake hose on the
brake caliper, make sure that the brake
pipe a touches the projection b on the
brake caliper.
WARNING
_
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
2. Fill:
• brake reservoir
Recommended brake fluid
DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
_
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
– 64 –
FRONT AND REAR BRAKES
CHAS
3. Air bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
(Manual No.: 5TG-28197-10)
4. Check:
• brake fluid level
Brake fluid level is below the “LOWER”
level line → Add the recommended brake
fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Adjust:
• parking brake cable end length a
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a.
b.
c.
d.
1
2
3
Loosen the locknut 1 and adjusting bolt 2.
Slide back the rubber cover 3.
Loosen the locknut 4.
Turn the adjusting nut 5 in direction b or
c until the specified brake cable end length
a is obtained.
b
Parking brake cable end length
47 ~ 51 mm (1.85 ~ 2.01 in)
c
4
5
e. Tighten the locknut.
f. Slowly turn the adjusting bolt 2 clockwise
until resistance is felt.
g. Turn it 1/8 counterclockwise.
h. Tighten the locknut 1.
T.
Locknut
16 Nm (1.6 m · kg, 11 ft · lb)
R.
i. Set the parking brake lever and wait more
than 5 minutes.
j. Release the parking brake lever.
k. Slide the rubber cover to its original position.
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 65 –
STEERING SYSTEM
CHAS
STEERING SYSTEM
EBS00449
INSTALLING THE HANDLEBAR
1. Install:
• handlebar
• handlebar holders
T.
R.
23 Nm (2.3 m · kg, 17 ft · lb)
NOTE:
• Install the handlebar at a 6° angle to the horizontal line shown in the illustration.
• The upper handlebar holders should be
installed with the punched mark 1 forward
2.
_
CAUTION:
_
First tighten the bolt 3 on the front side of
the handlebar holders, and then tighten the
bolt 4 on the rear side.
– 66 –
REAR SHOCK ABSORBER AND RELAY ARM
CHAS
EBS00484
REAR SHOCK ABSORBER AND RELAY ARM
.
7
T
R.
80 Nm (8.0 m • kg, 58 ft • Ib)
T.
7
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
New
LS
9
1
8
9
LS
New
10
1
6
10
New 5
4
4
LS
3
LS
New
New
13
2
New
LS
LS
New
12
13
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
New
15
14
Q’ty
5
Cotter pin
43 Nm (4.3 m • kg, 31 ft • Ib)
Remarks
Remove the parts in the order listed.
Refer to “SEAT, FENDERS AND FUEL
TANK” in chapter 3.
(Manual No.: 5TG-28197-10)
Refer to “REAR AXLE AND REAR AXLE
HUB”.
Rear axle hub
Self-locking nut/bolt
Self-locking nut/bolt
Connecting arm
Bearing/oil seal/spacer
C
5TG
L
R.
15 11
T.
12
Job/Part
Removing the rear shock absorber
and relay arm
Seat
1
2
3
4
LS
LS
LS
Order
New
14
2
1/1
1/1
1
2/2/1 Refer to “INSTALLING THE RELAY ARM
AND CONNECTING ARM”.
1
– 67 –
REAR SHOCK ABSORBER AND RELAY ARM
.
7
CHAS
T
R.
80 Nm (8.0 m • kg, 58 ft • Ib)
T.
7
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
New
LS
9
1
8
9
LS
New
10
1
6
10
New 5
4
4
LS
3
LS
New
New
13
2
New
LS
LS
New
12
13
T.
R.
55 Nm (5.5 m • kg, 40 ft • Ib)
New
LS
LS
LS
12
15 11
Bolt/washer
Self-locking nut/bolt/washer
Rear shock absorber
Q’ty
1/1
1/1/2
1
Dust seal/bearing/spacer
Self-locking nut/bolt
Relay arm
Dust cover
Spacer/bearing/oil seal
Spacer/bearing/oil seal
Spacer/bearing/oil seal
2/1/1
1/1
1
2
1/1/2
1/1/2
1/2/2
C
5TG
L
R.
9
10
11
12
13
14
15
Job/Part
15
14
T.
Order
6
7
8
New
14
2
43 Nm (4.3 m • kg, 31 ft • Ib)
Remarks
Refer to “REMOVING THE REAR
SHOCK ABSORBER” and “INSTALLING THE REAR SHOCK ABSORBER”.
(Manual No.: 5TG-28197-10)
Refer to “INSTALLING THE RELAY
ARM AND CONNECTING ARM”.
For installation, reverse the removal procedure.
– 68 –
REAR SHOCK ABSORBER AND RELAY ARM
CHAS
EBS00490
1
1
INSTALLING THE RELAY ARM AND
CONNECTING ARM
1. Install:
• bearings 1
(to connecting arm)
Installed depth of bearing a
4 mm (0.16 in)
a
a
2. Install:
• bearings 1 to 3
(to relay arm)
a
1
Installed depth of bearing a
5.0 mm (0.20 in)
Installed depth of bearing b
5.0 mm (0.20 in)
Installed depth of bearing c
4.6 mm (0.18 in)
2
2
b
b
3
c
– 69 –
SWINGARM AND DRIVE CHAIN
CHAS
EBS00492
SWINGARM AND DRIVE CHAIN
Order
Job/Part
Removing the swingarm and drive
chain
Rear axle hub
Q’ty
Refer to “REAR AXLE AND REAR AXLE
HUB”.
Refer to “REAR SHOCK ABSORBER
AND RELAY ARM”.
Rear shock absorber
1
2
3
4
5
6
Swingarm skid plate
Pivot shaft nut/washer
Pivot shaft
Swingarm
Drive chain guide 1
Drive sprocket cover
Remarks
Remove the parts in the order listed.
1
1/1
1
1
1
1
– 70 –
SWINGARM AND DRIVE CHAIN
Order
7
8
9
10
11
12
13
14
15
Job/Part
Drive chain guide 2
Nut
Lock washer
Drive sprocket
Drive chain
Dust cover/washer/bearing
Spacer
Oil seal
Bushing
Q’ty
1
1
1
1
1
2/2/2
2
2
2
CHAS
Remarks
Refer to “INSTALLING THE DRIVEN
SPROCKET”.
Refer to “INSTALLING THE SWINGARM”. (Manual No.: 5TG-28197-10)
For installation, reverse the removal procedure.
– 71 –
ELECTRICAL COMPONENTS
ELEC
EBS00500
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch
2 Throttle switch
3 Front brake light switch
4 Indicator lights
5 Clutch switch
6 Handlebar switch
7 Fuse
8 Starter relay
9 Starting circuit cut-off relay
0 Tail/brake light
A Battery
B Ignition coil
C Spark plug
D Throttle position sensor
– 72 –
–
+
ELECTRICAL COMPONENTS
E Carburetor switch
F Thermo switch 2
G Pickup coil/stator assembly
H Neutral switch
I Rear brake light switch
J Headlight relay 1
K Headlight relay 2
L Radiator fan
M Circuit breaker
(fan motor)
N Rectifier/regulator
O C.D.I. unit
P Resistor
Q Headlight
R Diode 2
S Diode 1
T Thermo switch 1
– 73 –
ELEC
–
+
CHECKING THE SWITCHES
ELEC
–
+
EBS01029
CHECKING THE SWITCHES
Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. (Manual No.: 5TG-28197-10)
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
– 74 –
CHECKING THE SWITCHES
1 Light switch
2 Engine stop switch
3 Start switch
4 Front brake light switch
5 Throttle switch
6 Main switch
7 Clutch switch
8 Carburetor switch
9 Fuse
0 Rear brake light switch
A Neutral switch
– 75 –
ELEC
–
+
– 76 –
Y
Y L
B
L
B
W
Y
(BLACK)
(BLACK)
B
L
Y Br
(BLACK)
(BLACK)
Y Br
B B
B B
X
W Y
Y/R W/B
Y
(BLACK)
(BLACK)
Br
W R
R W
Y
Y
Br
1
B
(BLACK)
B
Br/L
B
Y/L
L Y/W
R
V
Y/L
L
Br
Br
B
R
B
R
(BLACK)
T
OFF
PUSH
R
G/R
R/B
R Br
R Br/L
B
B
4B
G/R
Y
Y/W G B
Y
B
OFF
RUN
Q
Br R/W
Br/L R
R
G
Y/W
L/B
7
B
R
15A
B
B
Y G
6
5
R
(BLACK)
G Y
B
(BLACK)
B
B
(BLACK)
G Y
B
(BLACK)
B
S
Y G
S
Y G
N
M
Y G
L/B
Y/B
R
Y/B L/B
B
W/L
W/L
L/B
(BROWN)
R/B
R/B
Br
W/L
Sb
Sb
Sb
Sb
Br Sb
R/B W/L
Sb Br
W/L Br
L
Sb
9
JK
(BLACK)
L/B
Y/B
8
(BLACK)
W/L B
W/L
L/B
L/B
Y/B
B/Y Y/B
Sb R/B
Y/B B/Y
B
0
B/Y
B
L
L
B
L
L
B
(GRAY)
B/L Y/B
(GRAY)
B/L
B/L
(GRAY)
B/L Y/B
(GRAY)
E
B/Y B
Y/B
B
O
L
Y
B/L
B/Y B
Y/B
L
Y
B/L
Y/B
O
F
(BLACK)
R/W L
B
A
(BLACK)
O W
B W/B
O B
D
B
Y
(GRAY)
B/L
Y L
(GRAY)
L
C
B
(BLACK)
1 A.C. magneto
2 Rectifier/regulator
3 Main switch
4 Battery
5 Fuse
P Light switch
S Headlight
T Headlight relay 1
U Headlight relay 2
V Resistor
W Tail/brake light
I
H
R/W
R/W
G
Br/L
Sb
R/B
W/B
W
R
(BLACK)
Y/B Y L R
B/L R/B
Sb
ELEC
B Y/L
B
U
OFF
LO
HI
P
Y/R
Y/R
G/R
L Y/L B
G Y
B
Br R/W
Y/W
R/B L
L R/B
G/R
B
O
OFF
ON
3
R
R
B W
Y
R Y/R
2
W/B B
W/B
Y/R
L/B Br
W/B
Y/R
W
R
LIGHTING SYSTEM
–
+
EBS00518
LIGHTING SYSTEM
CIRCUIT DIAGRAM
LIGHTING SYSTEM
EBS01067
–
ELEC
+
2. Battery
TROUBLESHOOTING
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
(Manual No.: 5TG-28197-10)
Any of the following fail to light: headlight, tail/brake light.
Check:
1. fuse
2. battery
3. main switch
4. light switch
5. lighting coil resistance
6. headlight relay 1
7. headlight relay 2
8. resistor resistance
9. wiring connections
(of the entire lighting system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank cover
3. side covers (left and right)
4. front fender
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EAS00783
3. Main switch
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
Replace
switch.
Pocket tester
P/N. YU-03112-C, 90890-03112
1. Fuse
NO
YES
the
main
4. Light switch
• Check the fuse for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the fuse OK?
YES
• Check the light switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the light switch OK?
NO
YES
Replace the fuse.
NO
Replace the handlebar switch.
– 77 –
ELEC
LIGHTING SYSTEM
EAS00776
–
+
6. Headlight relay 1
5. Lighting coil resistance
• Disconnect the A.C. magneto coupler from
the wire harness.
• Connect the pocket tester (Ω × 1) to the
lighting coil terminals as shown.
Positive tester probe → yellow 1
Negative tester probe → ground 2
• Remove the headlight relay 1.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay 1 terminal
as shown.
• Check the headlight relay 1 for continuity.
Positive tester probe → green/red 1
Negative tester probe → green 2
1
1
2
1
W
2
Y
B
G Y/W
Y
G/R
• Measure the lighting coil resistance.
Lighting coil resistance
0.224 ~ 0.336 Ω at 20 °C (68 °F)
• Is the lighting coil OK?
YES
Positive battery terminal → yellow/white 3
Negative battery terminal → black 4
Positive tester probe → green/red 5
Negative tester probe → yellow 6
5
NO
6
Replace the pickup
coil/stator assembly.
+
4
3
B
G Y/W
Y
G/R
• Does the headlight relay 1 have continuity
between green/red and green or yellow?
YES
NO
Replace the headlight relay 1.
– 78 –
ELEC
LIGHTING SYSTEM
–
+
8. Resistor resistance
7. Headlight relay 2
• Remove the headlight relay 2.
• Connect the pocket tester (Ω × 1) and battery (12 V) to the headlight relay 2 terminal
as shown.
• Check the headlight relay 2 for continuity.
Positive tester probe → yellow/red 1
Negative tester probe → yellow/blue 2
• Disconnect the resistor coupler from the
wire harness.
• Connect the pocket tester (Ω × 1) to the
resistor coupler as shown.
Positive tester probe → black 1
Negative tester probe → black 2
1
1
2
B
B
2
B Y/L L
G/R
Y/R
• Measure the resistor resistance.
Positive battery terminal → blue 3
Negative battery terminal → black 4
Resistor resistance
2.755 ~ 3.045 Ω at 25 °C (77 °F)
Positive tester probe → yellow/red 5
Negative tester probe → green/red 6
• Is the resistor OK?
YES
5
6
NO
+
Replace the resistor.
4
3
B Y/L L
G/R
Y/R
• Does the headlight relay 2 have continuity
between yellow/red and yellow/blue or
green/red?
YES
NO
Replace the headlight relay 2.
– 79 –
ELEC
LIGHTING SYSTEM
EBS01069
–
+
2. Voltage
9. Wiring
• Check the entire lighting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the lighting system’s wiring properly
connected and without defects?
NO
YES
Check the condition
of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING
SYSTEM”.
Properly connect or
repair the lighting
system’s wiring.
• Connect the pocket tester (AC 20 V) to the
headlight couplers as shown.
È When the light switch is set to “LO”
É When the light switch is set to “HI”
Headlight coupler (wire harness side)
Headlight
Positive tester probe →
yellow 1 or green 2
Negative tester probe → black 3
É
2
1
AC20V
G
Y
B
EBS01070
CHECKING THE LIGHTING SYSTEM
1. The headlights fail to come on.
È
3
1. Headlight bulbs and sockets
•
•
•
•
Set the main switch to “ON”.
Start the engine.
Set the light switch to “LO” or “HI”.
Measure the voltage (AC 12 V) of yellow
1 or green 2 on the headlight coupler
(wire harness side).
• Is the voltage within specification?
• Check the headlight bulbs and sockets for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
(Manual No.: 5TG-28197-10)
• Are the headlight bulbs and sockets OK?
YES
NO
YES
Replace the headlight bulb, socket or
both.
This circuit is OK.
– 80 –
NO
Replace the rectifier/
regulator.
LIGHTING SYSTEM
2. The taillight fails to come on.
ELEC
• Disconnect the tail/brake light coupler.
• Connect the battery (12 V) to the tail/brake
light coupler terminals as shown.
• When the jumper leads are connected to
the terminals, the tail/brake light should
illuminate.
• Connect the pocket tester (DC 20 V) to the
tail/brake light coupler as shown.
Tail/brake light coupler (wire harness side)
Tail/brake light
Positive tester probe → blue 1
Negative tester probe → black 2
Positive battery terminal → blue 1
Negative battery terminal → black 2
1
L
Y
B
1
Y
B
Y
+
2. Voltage
1. Tail/brake light
L
–
L
Y
L
B
2
B
2
•
•
•
•
Set the main switch to “ON”.
Start the engine.
Set the light switch to “LO” or “HI”.
Measure the voltage (DC 12 V) of blue 1
on the tail/brake light coupler (wire harness side).
• Is the voltage within specification?
• Is the tail/brake light OK?
YES
NO
Replace the
brake light.
tail/
YES
This circuit is OK.
– 81 –
NO
The wiring circuit
from the main switch
to the tail/brake light
coupler is faulty and
must be replaced.
– 82 –
Y
Y L
B
L
B
W
Y
(BLACK)
(BLACK)
B
L
Y Br
(BLACK)
(BLACK)
Y Br
B B
B B
X
W Y
Y/R W/B
Y
(BLACK)
(BLACK)
Br
W R
Y
Y
Br
1
3 Main switch
4 Battery
5 Fuse
G Circuit breaker (fan motor)
H Thermo switch 1
I Fan motor
R W
B
(BLACK)
B
Br/L
B
Y/L
L Y/W
R
V
Y/L
L
Br
Br
B
R
B
R
(BLACK)
T
OFF
PUSH
R
G/R
R/B
R Br
R Br/L
B
B
4B
G/R
Y
Y/W G B
Y
B
OFF
RUN
Q
Br R/W
Br/L R
R
G
Y/W
L/B
7
B
R
15A
B
B
Y G
6
5
R
(BLACK)
G Y
B
(BLACK)
B
B
(BLACK)
G Y
B
(BLACK)
B
S
Y G
S
Y G
N
M
Y G
L/B
Y/B
R
Y/B L/B
B
W/L
W/L
L/B
(BROWN)
R/B
R/B
Br
W/L
Sb
Sb
Sb
Sb
Br Sb
R/B W/L
Sb Br
W/L Br
L
Sb
9
JK
(BLACK)
L/B
Y/B
8
(BLACK)
W/L B
W/L
L/B
L/B
Y/B
B/Y Y/B
Sb R/B
Y/B B/Y
B
0
B/Y
B
L
L
B
L
L
B
I
H
R/W
R/W
G
Br/L
Sb
R/B
W/B
W
R
O
(GRAY)
B/L Y/B
(GRAY)
B/L
B/L
(GRAY)
B/L Y/B
(GRAY)
E
B/Y B
Y/B
B
O
L
Y
B/L
B/Y B
Y/B
L
Y
B/L
Y/B
(BLACK)
O W
B W/B
F
(BLACK)
R/W L
B
A
(BLACK)
Y/B Y L R
B/L R/B
Sb
O B
D
B
Y
(GRAY)
B/L
Y L
(GRAY)
L
C
B
(BLACK)
ELEC
B Y/L
B
U
OFF
LO
HI
P
Y/R
Y/R
G/R
L Y/L B
G Y
B
Br R/W
Y/W
R/B L
L R/B
G/R
B
O
OFF
ON
3
R
R
B W
Y
R Y/R
2
W/B B
W/B
Y/R
L/B Br
W/B
Y/R
W
R
COOLING SYSTEM
–
+
EBS00532
COOLING SYSTEM
CIRCUIT DIAGRAM
COOLING SYSTEM
EBS01085
–
ELEC
+
EBS01044
TROUBLESHOOTING
2. Battery
The radiator fan motor fails to turn.
• Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
(Manual No.: 5TG-28197-10)
Check:
1. fuse
2. battery
3. main switch
4. radiator fan motor
5. circuit breaker (fan motor)
6. thermo switch 1
7. wiring connections
(the entire cooling system)
Minimum open-circuit voltage
12.8 V or more at 20 °C (68 °F)
• Is the battery OK?
NO
YES
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. fuel tank cover
3. side covers (left and right)
4. front fender
• Troubleshoot with the following special
tool(s).
• Clean the battery
terminals.
• Recharge or
replace the battery.
_
EBS01041
3. Main switch
Pocket tester
P/N. YU-03112-C, 90890-03112
• Check the main switch for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
NO
YES
EBS01043
Replace
switch.
1. Fuse
• Check the fuse for continuity.
Refer to “CHECKING THE SWITCHES”.
• Is the fuse OK?
YES
NO
Replace the fuse.
– 83 –
the
main
COOLING SYSTEM
EBS01086
ELEC
–
+
5. Circuit breaker (fan motor)
4. Radiator fan motor
• Disconnect the radiator fan motor coupler
from the wire harness.
• Connect the battery (DC 12 V) as shown.
Positive battery lead → blue 1
Negative battery lead → black 2
• Remove the circuit breaker from the wire
harness.
NOTE:
The circuit breaker and its leads are attached
to the wire harness with black tape at two
locations.
• Connect the pocket tester (Ω × 1) to the
circuit breaker.
• Does the radiator fan motor turn?
YES
NO
The
radiator
fan
motor is faulty and
must be replaced.
Circuit breaker resistance
Zero Ω at 20 °C (68 °F)
YES
NO
Replace the circuit
breaker.
– 84 –
COOLING SYSTEM
ELEC
–
+
EBS01088
WARNING
6. Thermo switch 1
_
È The thermo switch circuit is open and the radiator fan is off.
É The thermo switch circuit is closed and the
radiator fan is on.
Coolant temperature Continuity
Thermo switch
1
Less than 105 ± 3°C
(221.0 ± 5.4 °F)
2
More than 105 ± 3 °C
(221.0 ± 5.4 °F)
YES
3*
More than 100 ± 3 °C
(212.0 ± 5.4 °F)
YES
4*
Less than 100 ± 3 °C
(212.0 ± 5.4 °F)
NO
Thermo switch 1
28 Nm (2.8 m · kg, 20 ft · lb)
R.
Test step
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
T.
• Remove the thermo switch 1 from the radiator.
• Connect the pocket tester (Ω × 1) to the
thermo switch 1 1 as shown.
• Immerse the thermo switch 1 in a container filled with coolant 2.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool
down to the specified temperature.
• Check the thermo switch 1 for continuity at
the temperatures indicated below.
É
ON
NO
È
OFF
100 ± 3 ˚C
(212 ± 5.4 ˚F)
105 ± 3 ˚C
(221 ± 5.4 ˚F)
• Does the thermo switch 1 operate properly
as described above?
YES
Steps 1 & 2: Heating phase
Steps 3* & 4*: Cooling phase
NO
Replace the thermo
switch 1.
EBS01090
7. Wiring
• Check the entire cooling system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the cooling system’s wiring properly
connected and without defects?
YES
This circuit is OK.
– 85 –
NO
Properly connect or
repair the cooling
system’s wiring.
YFZ450V WIRING DIAGRAM
1 A.C. magneto
2 Rectifier/regulator
3 Main switch
4 Battery
5 Fuse
6 Starter relay
7 Starter motor
8 Diode 1
9 Starting circuit cut-off relay
0 Clutch switch
A C.D.I. unit
B Ignition coil
C Spark plug
D Throttle position sensor
E Throttle switch
F Carburetor switch
G Circuit breaker (fan motor)
H Thermo switch 1
I Fan motor
J Coolant temperature warning light
K Neutral indicator light
L Neutral switch
M Diode 2
N Thermo switch 2
O Handlebar switch
P Light switch
Q Engine stop switch
R Start switch
S Headlight
T Headlight relay 1
U Headlight relay 2
V Resistor
W Tail/brake light
X Rear brake light switch
Y Front brake light switch
COLOR CODE
B ............ Black
Br........... Brown
G ........... Green
L ............ Blue
O ........... Orange
R............ Red
Sb .......... Sky blue
W ........... White
Y ............ Yellow
B/L ......... Black/Blue
B/Y ........ Black/Yellow
Br/L........ Brown/Blue
G/R ........ Green/Red
L/B ......... Blue/Black
R/B ........ Red/Black
R/W ....... Red/White
W/B ....... White/Black
W/L ........ White/Blue
Y/B ........ Yellow/Black
Y/L ......... Yellow/Blue
Y/R ........ Yellow/Red
Y/W ....... Yellow/White
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.
YFZ450V WIRING DIAGRAM
W
R
R W
W R
(BLACK)
(BLACK)
Y/R W/B
W Y
1
W/B
Y/R
W/B
Y/R
R
2
R
Y/B Y L R
B/L R/B
Sb
O W
B W/B
(BLACK)
(BLACK)
R
B W
W/B B
Y
R Y/R
R
R
O B
R
4
15A
(BLACK)
B
B
5
R
Y/B L/B
W/B
W
R
O
C
6
L/B
A
R/B
B/Y
Y/B B/Y
B
B
B
B/Y Y/B
Sb R/B
7
0
(BLACK)
Y/B
L
Y
B/L
Y/B
Sb
9
R/B
R
L
Y
B/L
3
Sb
(GRAY)
Y/B
L/B
Br
Br/L
(BLACK)
Br/L
Y/B
Br
O
Br
Y
Br
R/B
L/B
L/B
X
R/B
M
R/B L
L R/B
B B
B B
(BLACK)
(BLACK)
Y
Y
Y Br
Y Br
(BLACK)
(BLACK)
L/B Br
Br R/W
Y/W
G Y
P
Q
OFF
LO
HI
OFF
RUN
L Y/W
Sb
Br Sb
R/B W/L
B
H
Y L
B
Y/R
Y
Y
B
Y/L
L
Y
B
L
Y G
Y/R
G/R
L Y/L B
G/R
Y
Y/W G B
Y/L
(BLACK)
(BLACK)
V
B
B
B Y/L
Y G
S
S
Y G
Y G
B
B
(BLACK)
(BLACK)
B
B
L
Sb
G
Y/W
B
B
(GRAY)
(BLACK)
(BROWN)
T
U
G/R
B
L
B/L Y/B
(GRAY)
R/W L
G/R
Sb
I
L
B
G Y
B
G Y
B
(BLACK)
(BLACK)
L
B
B
L
Sb
B
B/L
B/L Y/B
R/W
W/L B
W
B/Y B
(GRAY)
W/L
N
L
B/Y B
B/L
R/W
W/L
W/L
E
(GRAY)
Sb Br
W/L Br
W/L
B
B
G
L/B
OFF
PUSH
Y/B
F
Br
J K
R
(GRAY)
B/L
B
R Br
R Br/L
L/B
Y
B
Y L
8
Br R/W
Br/L R
L
D
B
OFF
ON
B
B
Y/B
B
R
O
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