2010

MOTORCYCLE

ASSEMBLY MANUAL

Model : YZ450FZ_

33D28107E000 *33D28107E000*
FOREWORD
This Assembly Manual contains the information required for the correct assembly of this Yamaha vehi-
cle prior to delivery to the customer. Since some external parts of the vehicle have been removed at
the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It
should be noted that the assembled vehicle should be thoroughly cleaned, inspected, and adjusted pri-
or to delivery to the customer.

IMPORTANT
The service specifications given in this assembly manual are based on the model as manufactured. Ya-
maha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and signif-
icant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable. The procedures below are described in
the order that the procedures are carried out correctly and completely. Failure to do so can result in
poor performance and possible harm to the vehicle and/or rider.

IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.

A WARNING indicates a hazardous situation which, if not avoided, could re-

sult in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid dam-

age to the vehicle or other property.

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

YZ450F(Z) 2010
ASSEMBLY MANUAL
©2009 by Yamaha Motor Co., Ltd.
First Edition, September 2009
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
SYMBOLS USED IN THE ASSEMBLY MANUAL
In order to simplify descriptions in this assembly manual, the following symbols are used:
SYMBOL DEFINITION SYMBOL DEFINITION

Filling fluid Coat with lithium-soap-based grease.

Tighten to 10 Nm. (10 Nm = 1.0 m•kgf,

Lubricant
7.2 ft•lbf)

Special tool Towards the front of the vehicle

Tightening torque Clearance required

T.
R
.

Install so that the arrow mark faces

Wear limit, clearance
upward.

Engine speed Apply motor oil.

Electrical data Made of rubber or plastics

A: Ref. No. (indicating the order of operations.)

B: Part name
C: Quantity of parts per vehicle
D: Place where parts are held
V: Stored in plastic bag
C: Stored in carton box
d D d S: Fixed inside the steel frame and/or con-
tained in the Styrofoam tray (upper or
L
lower)
*: Temporarily installed or secured
d D d
E: Size or material of parts
L
d/D: Diameter of part
L: Length of part
e.g., 5 (0.20) = 5 mm (0.20 in)
PREPARATION
To assemble the vehicle correctly, supplies (e.g. oils, greases, and shop rags) and sufficient working
space are required.
Workshop
The workshop where the vehicle is assembled should be clean, spacious, and have a level floor.
Self-protection
Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding
or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing
safety gloves or shoes.

SYMBOLS USED ON CRATE CARTON

Contents of the transport package are

Insertion of the forklift arms from this
fragile, therefore the package must be
side can cause damage.
handled with care.

Indicates correct upright position of Do not step anywhere on the transport

the transport package. package.

Transport package must be kept away Up to 6 of the transport packages can

from rain. be piled up.

Yellow label (1)

Lift arm insertion position
If the forklift arms cannot be inserted under the
transport package in alignment with the two yellow
labels, adjust the arms so that they are positioned
evenly in relation to these marks while taking care
not to damage the package contents.

(1)

(1)
UNPACKING
1. Remove the frame cover (1). 1

To remove the frame cover, cut the plastic

bands around the cover using a cutter or scis-
sors.

1
1

2. Remove the packing frame bolt (1), and

handlebar holder bolts (2).

3. Remove the packing frames (in order of

sideways (1), upward (2), and front/back
(3)).

Hold the frame while removing the frame bolts.

1 2

3 3

4. Remove the bolts (1).

Before starting the assembly, check for dam-

aged or missing parts. Check both the parts
contained in the carton boxes and on the vehi-
cle for damage, scratches, and other defects.

1
PARTS LOCATION

Do not use a cutter, scissors, or other sharp

object to open the carton boxes; otherwise,
the included parts could be damaged.

5 2
1. Carton box 1
2. Carton box 2
3. Front wheel
4. Front fender
5. Sidestand

2
 (2) Carton box 2
(1) Carton box 1

1 2
1

3 4 5 4

6 7 8 9
5
6 7 8 9 10

10 11
12

11 13

1. Handlebar
2. Plastic bag
3. Upper handlebar holder 14
4. Flange bolt (upper handlebar holder) [d = 8
(0.31), L = 35 (1.38)]
5. Front brake master cylinder bracket
6. Flange bolt (front brake master cylinder bracket) 17 18
[d = 6 (0.24), L = 22 (0.87)] 15 16
7. Engine stop switch holder (upper and lower)
8. Screw [d = 3 (0.12), L = 14 (0.55)]
9. Collar (handlebar) [d = 22 (0.87), L = 30 (1.18)]
10.Collar 1 (front wheel) [d = 20 (0.79), L = 20 1. Number plate
(0.79)] 2. Owner's service manual
11.Collar 2 (front wheel) [d = 20 (0.79), L = 13 3. Handlebar protector
(0.51)] 4. Handlebar protector cover
5. Plastic bag
6. Fuel tank holding cable
7. Fuel tank breather hose
8. Spark plug wrench
9. Nipple wrench
10.Boot (clutch cable)
11.Lever cover (clutch lever)
12.Plastic band [L = 110 (4.33)]
13.Plastic band [L = 140 (5.51)]
14.Flange bolt (front fender) [d = 6 (0.24), L = 20
(0.79)]
15.Washer (front fender) [d = 6 (0.24), D = 22 (0.87)]
16.Flange bolt (number plate) [d = 6 (0.24), L = 12
(0.47)]
17.Fuel hose joint cover 1
18.Fuel hose joint cover 2

3
(3) Front wheel

1. Front wheel
(4) Front fender

1. Front fender
(5) Sidestand

1. Sidestand

4
YZ450F(Z) 2010 SETUP AND PREDELIVERY CHECKLIST

Check the following items again after setup and predelivery service have been completed.

A: INSTALLATION OF THE PARTS INCLUDED IN THE CRATE

□ HANDLEBAR □ ENGINE STOP SWITCH
□ THROTTLE GRIP □ HANDLEBAR CLAMP
□ FRONT WHEEL □ NUMBER PLATE
□ FRONT FENDER □ FUEL TANK BREATHER HOSE
□ FRONT BRAKE MASTER CYLINDER □ HANDLEBAR PROTECTOR
□ CLUTCH CABLE
B: TIGHTENING TORQUE OF EACH PART
□ Bolt (upper handlebar holder) 28 Nm (2.8 m•kgf, 20 ft•lbf)
□ Screw (throttle grip) 4 Nm (0.4 m•kgf, 2.9 ft•lbf)
□ Front wheel axle nut 105 Nm (10.5 m•kgf, 75 ft•lbf)
□ Axle pinch bolt 21 Nm (2.1 m•kgf, 15 ft•lbf)
□ Bolt (front fender) 10 Nm (1.0 m•kgf, 7.2 ft•lbf)
□ Bolt (front brake master cylinder) 9 Nm (0.9 m•kgf, 6.5 ft•lbf)
□ Bolt (number plate) 7 Nm (0.7 m•kgf, 5.1 ft•lbf)
C: ROUTING OF WIRE, CABLES, ETC.
□ Throttle cable □ Brake hose
□ Fuel tank breather hose □ Clutch cable
□ Engine stop switch lead
D: ADJUSTMENTS
□ MEASURING THE TIRE PRESSURE □ CHECKING THE BRAKE FLUID LEVEL
□ CHECKING THE ENGINE OIL LEVEL □ BLEEDING THE HYDRAULIC BRAKE SYSTEM
□ CHECKING THE COOLANT LEVEL □ ADJUSTING THE CLUTCH CABLE FREE PLAY
□ ADJUSTING THE THROTTLE CABLE FREE □ ADJUSTING THE CLUTCH LEVER
PLAY
□ ADJUSTING THE ENGINE IDLING SPEED □ ADJUSTING THE FRONT FORK LEGS
□ ADJUSTING THE FRONT BRAKE □ ADJUSTING THE REAR SHOCK ABSORBER
ASSEMBLY
□ ADJUSTING THE REAR BRAKE □ ADJUSTING THE DRIVE CHAIN SLACK
E: FUNCTION AND PERFORMANCE
□ Check the feel of the brakes □ Check for exhaust leak (Yes/ No)
□ Check engine for irregular noise (Yes/ No)
F: ACCESSORIES, ETC. FOR DELIVERY
□ Owner's service manual □ Handlebar protector cover
□ Sidestand □ Fuel tank holding cable
□ Spark plug wrench □ Fuel hose joint cover 1
□ Nipple wrench □ Fuel hose joint cover 2
□ Handlebar protector

5
SETUP PROCEDURES
Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown.

6 1 9 5

7 8 11 2

4 10

6
1. HANDLEBAR 2. THROTTLE GRIP

2 B
4
28
E 4
C C
a F
3 A 2
B
3
A 1
1 Throttle grip 1 *

D 2 Screw 2 * d = 5 (0.20), L = 20 (0.79)

3 Grip cap cover 1 *

1 G A: Slip the throttle grip over the right handlebar

completely and then slide it back about 2
mm (0.08 in).
E b B: Tighten the screws to specification.
Screw
4 Nm (0.4 m•kgf, 2.9 ft•lbf)
C: Check the throttle grip for smooth action.
1 Handlebar 1 C
2 Collar 1 V d = 22 (0.87), L = 30 (1.18)
3 Upper handlebar holder 2 V • The throttle cables should not be twisted,
4 Flange bolt 4 V d = 8 (0.31), L = 35 (1.38) and make sure that the throttle grip rotates
A: Clean the right handlebar end. on the handlebar freely, without binding.
B: Install the collar. • Proper cable routing is essential to assure
C: Apply light coat grease. safe vehicle operation.
D: Insert the throttle grip onto the right handle- Refer to "CABLE ROUTING".
bar end.
E:

• The upper handlebar holder should be in-

stalled with the punched mark (a) forward.
• Install the handlebar so that the marks (b) are
in place on both sides.
F: Tighten the bolts to specification.

First tighten the bolts on the front side of

the handlebar holder, and then tighten the
bolts on the rear side to specification.

Bolt
28 Nm (2.8 m•kgf, 20 ft•lbf)
G:

Proper cable routing is essential to assure

safe vehicle operation.
Refer to "CABLE ROUTING".

7
3. FRONT WHEEL
Before tightening the pinch bolts, stroke the
4,E
front fork several times to make sure of
B
D proper fork operation.
G: Tighten the axle pinch bolts to specification.
6,G
21 Axle pinch bolt
21 Nm (2.1 m•kgf, 15 ft•lbf)
5,F
105 4. FRONT FENDER
3,C

A,D

1 2,C
2
3, A 10

< < 1 Front fender 1 S

2 Washer 4 V d = 6 (0.24), D = 22 (0.87)
1 Front wheel 1 S 3 Flange bolt 4 V d = 6 (0.24), L = 20 (0.79)
2 Collar 1 1 V d = 20 (0.79), L = 20 (0.79)
3 Collar 2 1 V d = 20 (0.79), L = 13 (0.51)
A: Tighten the bolts to specification.
4 Front wheel axle 1 * Bolt
5 Front wheel axle nut 1 * d = 16 (0.63) 10 Nm (1.0 m•kgf, 7.2 ft•lbf)
6 Axle pinch bolt 4 * d = 8 (0.31), L = 35 (1.38)

A: Clean the brake disc.

B: Clean the front wheel axle. Apply light coat Be careful not to scratch the front fender
grease. with the front fork outer tube.
C: Clean the collars.
D:
Proper hose routing is essential to assure
safe vehicle operation.
Take care not to get grease on the brake Refer to "CABLE ROUTING".
disc or inner surface of the brake pads. If
you do so, clean using a rag dampened with 5. FRONT BRAKE MASTER CYLINDER
a solvent. Foreign material on braking sur-
face may cause impaired braking action. 1 A
E: Lift the front wheel and install the front wheel
axle. C

Do not depress the brake lever when the cali-

per is off the brake disc. 2
F: Tighten the front wheel axle nut to specifica- 3
tion. 9
B
Front wheel axle nut 1
Front brake master cylin-
1 *
der
105 Nm (10.5 m•kgf, 75 ft•lbf)
Front brake master cylin-
2 1 V
der bracket
3 Flange bolt 2 V d = 6 (0.24), L = 22 (0.87)

8
A: Lubricate the pivoting part of the brake lever. c. Install the boot and lever cover to the clutch
Recommended lubricants lever.
Lithium soap base grease
Check the clutch lever for smooth action.
B: Tighten the bolts to specification. Refer to "ADJUSTMENTS AND PREDELIV-
ERY SERVICE".
• Make sure that the "UP" mark on the bracket
is pointed upward.
• First tighten the bolt on the upper side of the Proper cable routing is essential to assure
brake master cylinder bracket, and then tight- safe vehicle operation.
en the bolt on the lower side. Refer to "CABLE ROUTING".

Bolt
9 Nm (0.9 m•kgf, 6.5 ft•lbf) 7. ENGINE STOP SWITCH
C: Check the brake lever for smooth action. 0 mm
2
0 mm (0 in)
Proper hose routing is essential to assure 3 (0 in)
safe vehicle operation.
Refer to "CABLE ROUTING".

6. CLUTCH CABLE
3 A
1
1 Engine stop switch 1 *
2 Screw 1 V d = 3 (0.12), L = 14 (0.55)
C B Engine stop switch holder
1 3 (upper and lower) 2 V
B
A: Pass the engine stop switch lead in the mid-
dle of the clutch lever holder.
3,A
2,A
1 Clutch cable 1 * Proper cable routing is essential to assure
2 Boot (clutch cable) 1 V
safe vehicle operation.
3 Lever cover (clutch lever) 1 V
Refer to "CABLE ROUTING".
A: Install the boot and lever cover to the clutch 8. HANDLEBAR CLAMP
cable.
B: Lubricate the pivoting part of the clutch le-
ver.
Recommended lubricants
Lithium soap base grease
C: To install the clutch cable, be sure to pro- 2
ceed as follows: 1

a. Turn in the adjuster on the lever holder until A

tight. Next, align the slit in the adjuster and 1 Plastic band 1 V L = 110 (4.33)
cable socket with the slit in the lever holder. 2 Plastic band 1 V L = 140 (5.51)
b. Insert the cable end into the lever hole. Next,
while pulling the outer cable in the direction
opposite to the lever, seat the outer cable
into the cable socket.

9
A: Secure the engine stop switch lead with the 11.HANDLEBAR PROTECTOR
plastic band.
a
Refer to "CABLE ROUTING".
2
9. NUMBER PLATE 1,A 1
A
1 2
7

1 Handlebar protector 1 C
2 Handlebar protector cover 1 C

A: Install the handlebar protector so that the

mark (a) face forward.

1 Number plate 1 C
2 Flange bolt 1 V d = 6 (0.24), L = 12 (0.47)

A: Tighten the bolt to specification.

Bolt
7 Nm (0.7 m•kgf, 5.1 ft•lbf)

Proper cable routing is essential to assure

safe vehicle operation.
Refer to "CABLE ROUTING".

10.FUEL TANK BREATHER HOSE

1 Fuel tank breather hose 1 V

A: Connect one end of the breather hose to the

fuel tank filler cap, and insert the other end
into the hole of the steering stem.

Refer to "CABLE ROUTING".

Install the hose joint with its arrow mark fac-

ing the TANK side.

10
CABLE ROUTING

Proper cable and lead routing are essential

to insure safe vehicle operation.

1,A

1. Fuel tank breather hose

2. Clutch cable
3. Brake hose
4. Hose guide
A. Insert the end of the fuel tank breather hose into
the hole in the steering stem.

11
 1 2
A 3

1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
A. Pass the clutch cable, throttle cables, and engine
stop switch lead through the cable holder. Pass
the clutch cable through the lower guide only.

12
 1 2,A 3,B

3,B
4
2,D
5,C

6 4

1. Throttle cable
2. Clutch cable
3. Clamp
4. Engine stop switch lead
5. Brake hose
6. Hose guide
A. Route the clutch cable to the rear of the number
plate band.
B. Fasten the engine stop switch lead to the handle-
bar.
C. Route the brake hose to the front of the number
plate.
D. Pass the clutch cable through the cable guide on
the number plate.

13
ADJUSTMENTS AND PREDELIVERY SERVICE
Perform the predelivery service in the order indicated by the letters. Always follow the order as shown.

J,K H F

C D

A I L E B G H N I

14
A. MEASURING THE TIRE PRESSURE • Do not leave the check bolt for the oil quantity
1. Measure: upper limit removed. Otherwise, the oil level
• tire pressure drops with time in the engine, allowing the oil
Out of specification → Adjust. to flow out.

• Check the tire while it is cold.

• Loose bead stoppers allow the tire to slip off a
its position on the rim when the tire pressure
is low. b
• A tilted tire valve stem indicates that the tire
slips off its position on the rim.
• If the tire valve stem is found tilted, the tire is
considered to be slipping off its position. Cor-
rect the tire position. 1

Cold tire pressure

Front • Engine oil also luburicates the clutch and
100 kPa (1.0 kgf/cm2, 15 psi) the wrong oil types or additives could
Rear cause clatch slippage. Therefore, do not
100 kPa (1.0 kgf/cm2, 15 psi) oils with a grade of CD or higher and do
B. CHECKING THE ENGINE OIL LEVEL not use oils labeled "ENERGY CONSERV-
1. Stand the vehicle on a level surface. ING II".
• Do not allow foreign material to enter the
crankcase.
• When checking the oil level make sure that
the machine is upright.
• Place the vehicle on a suitable stand. Recommended brand: YAMALUBE
Recommended engine oil type
2. Start the engine, warm it up for 2–3 minutes SAE10W-30, SAE 10W-40,
at engine idling speed, and then stop the en- SAE10W-50, SAE 15W-40, SAE
gine and wait approximately 1 minute. 20W-40 or SAE 20W-50
3. Inspect: Recommended engine oil grade
• oil level API service SG type or higher,
Make sure that the engine oil level is be- JASO standard MA
tween the maximum level line (a) and mini-
mum level line (b) shown for the oil level
check window.
Above the upper limit (a) → Check that no oil
comes out when the check bolt (1) for the oil
quantity upper limit is removed.
If any engine oil comes out, drain it until its
last drop is out.
Below the level mark (b) → Add sufficient oil
and idle run the engine, and after stopping
the engine, recheck through the oil inspec-
tion window that the oil is at the specified C. CHECKING THE COOLANT LEVEL
level. 1. Stand the vehicle on a level surface.

• Check the oil quantity within 5 minutes after • Place the vehicle on a suitable stand.
the engine is shut off. Over 5 minutes, idle the • Make sure that the vehicle is upright.
engine again and recheck the oil quantity.

15
2. Remove:
• radiator cap

Do not remove the radiator cap when the en-

gine is hot.
a
3. Check:
• coolant level (a)
Coolant level should be up to the bottom of
the hole.
Coolant level is too low → Add the recom- 2. Adjust:
mended coolant to the proper level. • throttle cable free play

• Adding water instead of coolant lowers the a. Slide back the rubber cover.
antifreeze content of the coolant. If water b. Loosen the locknut (1).
is used instead of coolant, check and cor- c. Turn the adjusting nut (2) in direction (a) or
rect the antifreeze concentration of the (b) until the specified throttle cable free play
coolant. is obtained.
• Use only distilled water. Soft water may be Throttle cable free play is
Direction (a)
used if distilled water is not available. increased.
Throttle cable free play is
Direction (b)
decreased.
d. Tighten the locknut.
e. Install the rubber cover.

After adjusting the throttle cable free play,

start the engine and turn the handlebar to
the right and to the left to ensure that this
does not cause the engine idling speed to
4. Start the engine, warm it up for several min- change.
utes, and then turn it off.
5. Check: 2 a
1
• coolant level

Before checking the coolant level, wait a few

minutes until it settles. b
6. Install:
• radiator cap
D. ADJUSTING THE THROTTLE CABLE
FREE PLAY

Prior to adjusting throttle cable free play, the E. ADJUSTING THE ENGINE IDLING SPEED
engine idling speed should be adjusted.
• Because the air pressure is lower at high alti-
1. Measure:
tudes, the air-fuel mixture will become richer.
• throttle cable free play (a)
If the engine idling speed is low, turn the start-
Out of specification → Adjust.
er (choke) knob/idling screw a few clicks
Throttle cable free play (at the counterclockwise to increase the idling speed.
flange of the throttle grip)
3–5 mm (0.12–0.20 in)

16
• Before adjusting the engine idling speed,
make sure that the compression pressure is
within specification and that the air filter ele-
ment is not clogged. b a
• Adjust the engine idling speed with the starter
(choke) knob/idling screw pushed in com-
pletely.
1
1. Start the engine and warm it up until the en-
gine oil has reached the specified tempera-
ture.
2. Use a temperature probe tester (1) and con-
2
tact it to the drain bolt thread.
Oil temperature
55.0–65.0 °C (131–149°F)

c
1

F. ADJUSTING THE FRONT BRAKE

1. Measure:
• brake lever position
(distance (a) from the throttle grip to the
3. Adjust: brake lever)
• engine idling speed Out of specification → Adjust.
Brake lever position (distance (a)
a. Turn the starter knob/idle screw (1) until the from the throttle grip to the brake le-
specified engine idling speed is obtained. ver)
Direction (a) Engine idling speed is in- Standard position
creased. 95 mm (3.74 in)
Extent of adjustment
Direction (b) Engine idling speed is de-
86–105 mm (3.39–4.13 in)
creased.

Using the digital tachometer, measure the en-

gine speed with the detector (c) pinched in the
high tension cord (2) of the ignition coil.

Digital tachometer
YU-39951-B/90890-06760

Engine idling speed

1,900–2,100 r/min

17
2. Remove: G. ADJUSTING THE REAR BRAKE
• brake lever cover 1. Measure:
3. Adjust: • brake pedal position
• brake lever position (distance (a) from the top of the rider footrest
to the top of the brake pedal)
a. Loosen the locknut (1). Out of specification → Adjust.
b. Turn the adjusting bolt (2) in direction (a) or Brake pedal position (above the top
(b) until the specified brake lever position is of the rider footrest)
obtained. Zero mm (Zero in)
Brake lever distance is in-
Direction (a)
creased.
Brake lever distance is de-
Direction (b)
creased.

2. Adjust:
• brake pedal position

a. Loosen the locknut (1).

c. Tighten the locknut to specification. b. Turn the adjusting nut (2) in direction (a) or
(b) until the specified brake pedal position is
Locknut obtained.
5 Nm (0.5 m•kgf, 3.6 ft•lbf)
Direction (a) Brake pedal is raised.
Direction (b) Brake pedal is lowered.
• Be sure to tighten the locknut, as it will
cause poor brake performance.
• A soft or spongy feeling in the brake lever • Adjust the pedal position between the
can indicate the presence of air in the highest position (A) and the lowest posi-
brake system. Before the vehicle is operat- tion (B) as shown. (In this adjustment, the
ed, the air must be removed by bleeding bolt (3) end (c) should protrude out of the
the brake system. Air in the brake system threaded portion (4) but not be less than 2
will considerably reduce braking perfor- mm (0.08 in) (d) away from the brake pedal
mance and could result in loss of control (5)).
and possibly an accident. Therefore, • After the pedal position adjustment, make
check the brake system and bleed if nec- sure that the rear brake does not drag.
essary.

After adjusting the brake lever position,

make sure that there is no brake drag.

4. Install:
• brake lever cover

c. Tighten the locknut.

18
 In order to ensure a correct reading of the brake
A soft or spongy feeling in the brake pedal
fluid level, make sure that the top of the reser-
can indicate the presence of air in the brake
voir is level.
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will consid-
erably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check the brake
system and bleed if necessary.

After adjusting the brake pedal position,

make sure that there is no brake drag.
A. Front brake
B. Rear brake
H. CHECKING THE BRAKE FLUID LEVEL I. BLEEDING THE HYDRAULIC BRAKE
1. Stand the vehicle on a level surface. SYSTEM

• Place the vehicle on a suitable stand.

• Make sure that the vehicle is upright. Bleed the hydraulic brake system whenev-
er:
2. Check: • the system was disassembled,
• brake fluid level • a brake hose was loosened or removed,
Below the minimum level mark (a)→Add the • the brake fluid level is very low,
recommended brake fluid to the proper lev- • brake operation is faulty.
el. A dangerous loss of braking performance
Recommended brake fluid may occur if the brake system is not proper-
DOT 4 ly bled.
1. Remove:
• brake master cylinder cap
• Use only designated brake fluid. Other • diaphragm
brake fluids may cause the rubber seals to • reservoir float (front brake)
deteriorate, causing leakage and poor • protector (rear brake)
brake performance.
• Refill with the same type of brake fluid that • Be careful not to spill any brake fluid or allow
is already in the system. Mixing brake flu- the brake master cylinder reservoir to over-
ids may result in a harmful chemical reac- flow.
tion, leading to poor brake performance. • When bleeding the hydraulic brake system,
• When refilling, be careful that water does make sure that there is always enough brake
not enter the reservoir. Water will signifi- fluid before applying the brake. Ignoring this
cantly lower the boiling point of the brake precaution could allow air to enter the hydrau-
fluid and could cause vapor lock. lic brake system, considerably lengthening
the bleeding procedure.
• If bleeding is difficult, it may be necessary to
Brake fluid may damage painted surfaces let the brake fluid settle for a few hours. Re-
and plastic parts. Therefore, always clean peat the bleeding procedure when the tiny
up any split brake fluid immediately. bubbles in the hose have disappeared.

19
2. Bleed:
• hydraulic brake system
After bleeding the hydraulic brake system,
check the brake operation.
a. Add the recommended brake fluid to the
proper level.
b. Install the brake master cylinder reservoir di- 3. Install:
aphragm. • protector (rear brake)
c. Connect a clear plastic hose (1) tightly to the • reservoir float (front brake)
bleed screw (2). • diaphragm
• brake master cylinder cap
J. ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Measure:
• clutch cable free play (a)
Out of specification → Adjust.
Clutch cable free play
7–12 mm (0.28–0.47 in)

1 2

2. Remove:
A. Front brake
• boot (1)
B. Rear brake
• cap (2)
d. Place the other end of the hose into a con-
3. Adjust:
tainer.
• clutch cable free play
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de-
press the brake pedal and hold it in position. a. Loosen the locknut (3).
g. Loosen the bleed screw. This will release b. Turn the adjusting bolt (4) in direction (a) or
the tension and cause the brake lever to (b) until the specified clutch cable free play
contact the throttle grip or the brake pedal to is obtained.
fully extend. Clutch cable free play is
h. Tighten the bleed screw and then release Direction (a)
increased.
the brake lever or brake pedal. Clutch cable free play is
i. Repeat steps (e) to (h) until all of the air bub- Direction (b)
decreased.
bles have disappeared from the brake fluid
in the plastic hose. c. Tighten the locknut to specification.
j. Tighten the bleed screw to specification. Locknut
Bleed screw 4 Nm (0.4 m•kgf, 2.9 ft•lbf)
6 Nm (0.6 m•kgf, 4.3 ft•lbf)
k. Fill the reservoir to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL".

20
• Make minute adjustment on the lever side us- a 1
ing the adjusting bolt (5).
• After adjustment, check proper operation of 2
clutch lever.
c
b

5 3 4 1 2
a
2. Adjust:
b • clutch cable free play
Refer to "ADJUSTING THE CLUTCH CA-
BLE FREE PLAY".
L. ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
4. Install:
• cap
• boot • Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
Place the tip (a) of the cap in the boot. dling and loss of stability.
• Securely support the vehicle so that there
a is no danger of it falling over.
Rebound damping

Never go beyond the maximum or minimum

adjustment positions.
1. Adjust:
• rebound damping

K. ADJUSTING THE CLUTCH LEVER a. Turn the adjusting screw (1) in direction (a)
1. Adjust: or (b).
• clutch lever position Rebound damping is in-
(distance (a) from the handlebar grip to the Direction (a) creased (suspension is
clutch lever) harder).
Rebound damping is de-
a. Loosen the locknut (1).
Direction (b) creased (suspension is
b. Turn the adjusting bolt (2) in direction (b) or
softer).
(c) until the clutch lever is in the desired po-
sition. Adjusting positions
Clutch lever distance is Standard
Direction (b) 10 clicks out*
increased.
Minimum
Clutch lever distance is
Direction (c) 20 clicks out*
decreased.
Maximum
c. Tighten the locknut to specification. 0 clicks out*
Locknut *: from the fully turned-in position
5 Nm (0.5 m•kgf, 3.6 ft•lbf)

21
 M. ADJUSTING THE REAR SHOCK AB-
1 SORBER ASSEMBLY
Spring preload

Never go beyond the maximum or minimum

adjustment positions.
b
a
1. Stand the vehicle on a level surface.

Securely support the vehicle so that there is

no danger of it falling over.
Compression damping

Both wheels should be on the ground without a

Never go beyond the maximum or minimum rider on the vehicle.
adjustment positions.
2. Measure:
1. Adjust: • spring fitting length
• compression damping
Standard fitting length
One I.D. mark (White)
a. Turn the adjusting screw (1) in direction (a)
252 mm (9.92 in)
or (b).
253 mm (9.96 in)*
Compression damping is
*: except for CDN
Direction (a) increased (suspension is
harder).
Compression damping is The I.D. mark (a) is marked at the end of the
Direction (b) decreased (suspension is spring.
softer).
a
Adjusting positions
Standard
13 clicks out*
12 clicks out*,**
Minimum
20 clicks out*
Maximum
0 clicks out*
*: from the fully turned-in position
**: except for CDN 3. Adjust:
• spring preload

a. Loosen the locknut (1).

b. Loosen the adjusting ring (2) until there is
1
some clearance between the spring and ad-
justing ring.
c. Measure the spring free length (a).
a b d. Turn the adjusting ring in direction (b) or (c).

22
 Rebound damping
Spring preload is in-
Direction (b) creased (suspension is
harder). Never go beyond the maximum or minimum
Spring preload is de- adjustment positions.
Direction (c) creased (suspension is 1. Adjust:
softer). • rebound damping
Preload length
Minimum a. Turn the adjusting screw (1) in direction (a)
Position in which the spring is or (b).
turned in 1.5 mm (0.06 in) from its Rebound damping is in-
free length. Direction (a) creased (suspension is
Maximum harder).
Position in which the spring is Rebound damping is de-
turned in 18 mm (0.71 in) from its Direction (b) creased (suspension is
free length. softer).

Adjusting positions
The length of the spring (installed) changes 1.5 Standard
mm (0.06 in) per turn of the adjusting ring. 14 clicks out*
16 clicks out*,**
Minimum
30 clicks out*
Maximum
0 clicks out*
*: from the fully turned-in position
**: except for CDN

This is the position which is back by the specific

e. Tighten the locknut to specification. number of clicks from the fully turned-in posi-
tion. (Which align the punch mark (c) on the ad-
Locknut juster with the punch mark (d) on the bracket.)
30 Nm (3.0 m•kgf, 22 ft•lbf)
c d

b
1

23
Compression damping • high compression damping

Never go beyond the maximum or minimum a. Turn the adjusting nut (2) in direction (a) or
adjustment positions. (b).
High compression damp-
1. Adjust:
Direction (a) ing is increased (suspen-
• low compression damping
sion is harder).
High compression damp-
a. Turn the adjusting screw (1) in direction (a)
Direction (b) ing is decreased (suspen-
or (b).
sion is softer).
Low compression damp-
Direction (a) ing is increased (suspen- Adjusting positions
sion is harder). Standard
1-1/4 turns out*
Low compression damp-
1-1/2 turns out*,**
Direction (b) ing is decreased (suspen-
Minimum
sion is softer).
2 turns out*
Adjusting positions Maximum
Standard 0 turns out*
8 clicks out* *: from the fully turned-in position
12 clicks out*,** **: except for CDN
Minimum
20 clicks out*
Maximum This is the position which is back by the specific
0 clicks out* number of turns from the fully turned-in posi-
*: from the fully turned-in position tion. (Which align the punch mark (c) on the ad-
juster with the punch mark (d) on the adjuster
**: except for CDN
body.)

This is the position which is back by the specific

number of clicks from the fully turned-in posi-
tion. (Which align the punch mark (c) on the ad-
b
juster with the punch mark (d) on the high
compression damping adjuster.) 2 a

d
b
1
a
c N. ADJUSTING THE DRIVE CHAIN SLACK

d The drive chain slack must be checked above

the drive chain guide bolt.

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 speci-
fied limits.

24
1. Stand the vehicle on a level surface.
2

Securely support the vehicle so that there is

no danger of it falling over. a

Both wheels should be on the ground without a

rider on the vehicle. b
2. Rotate the rear wheel several times and 1 3
check the drive chain to locate its tightest
point. 3
3. Measure:
• drive chain slack (a) b
Out of specification → Adjust.
Drive chain slack
50–60 mm (2.0–2.4 in) a

2
A. Right
B. Left

4. Loosen:
• wheel axle nut (1)
5. Adjust:
• drive chain slack

a. Loosen both locknuts (2).

b. Turn both adjusting bolts (3) in direction (a)
or (b) until the specified drive chain slack is
obtained.
Direction (a) Drive chain is tightened.
Direction (b) Drive chain is loosened.

To maintain the proper wheel alignment, adjust

both sides evenly.
c. Tighten the wheel axle nut to specification.
Wheel axle nut
135 Nm (13.5 m•kgf, 98 ft•lbf)
d. Tighten the locknuts to specification.
Locknut
21 Nm (2.1 m•kgf, 15 ft•lbf)

25
APPENDICES
SERVICE DATA
Engine idling speed 1,900–2,100 r/min
Spark plug
Type/Manufacturer CR8E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Fuel
Recommended fuel Premium unleaded gasoline only
Fuel tank capacity 6.0 L (1.30 US gal, 1.59 Imp. gal)
Valve clearance (cold)
IN 0.10–0.15 mm (0.0039–0.0059 in)
EX 0.20–0.25 mm (0.0079–0.0098 in)
Tire pressure (measured on cold tires)
Front 100 kPa (1.0 kgf/cm2, 15 psi)
Rear 100 kPa (1.0 kgf/cm2, 15 psi)
STANDARD EQUIPMENT
1. Owner's service manual 1 pc.
2. Sidestand 1 pc.
3. Handlebar protector 1 pc.
4. Handlebar protector cover 1 pc.
OWNER'S TOOL KIT
1. Nipple wrench 1 pc.
2. Spark plug wrench 1 pc.
3. Fuel tank holding cable 1 pc.
4. Fuel hose joint cover 1 1 pc.
5. Fuel hose joint cover 2 1 pc.
TIGHTENING TORQUE
Tightening torque
Item Thread size
Nm m•kgf ft•lbf
Engine:
Engine oil drain bolt M8 × 1.25 20 2.0 14
Spark plug M10S × 1.0 13 1.3 9.4
Chassis:
Upper bracket and outer tube M8 × 1.25 21 2.1 15
Lower bracket and outer tube M8 × 1.25 21 2.1 15
Upper bracket and steering stem M24 × 1.0 145 14.5 105
Handlebar holder (upper) M8 × 1.25 28 2.8 20
Handlebar holder (lower) M10 × 1.25 34 3.4 24
Steering ring nut M28 × 1.0 Refer to TIP.
Front fork and damper assembly M51 × 1.5 30 3.0 22

26
 Tightening torque
Item Thread size
Nm m•kgf ft•lbf
Front fork and adjuster M22 × 1.25 55 5.5 40
Damper assembly and base valve M42 × 1.5 29 2.9 21
Adjuster and damper assembly M12 × 1.25 29 2.9 21
Bleed screw (front fork) and base valve M5 × 0.8 1 0.1 0.7
Front fork and protector M6 × 1.0 5 0.5 3.6
Front fork protector and brake hose holder M6 × 1.0 8 0.8 5.8
Throttle grip cap M5 × 0.8 4 0.4 2.9
Clutch lever holder mounting M6 × 1.0 5 0.5 3.6
Clutch lever mounting M6 × 1.0 4 0.4 2.9
Clutch lever position locknut M5 × 0.8 5 0.5 3.6
Front brake master cylinder and bracket M6 × 1.0 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 0.2 1.4
Brake lever mounting (bolt) M6 × 1.0 6 0.6 4.3
Brake lever mounting (nut) M6 × 1.0 6 0.6 4.3
Brake lever position locknut M6 × 1.0 5 0.5 3.6
Front brake hose guide and lower bracket M6 × 1.0 9 0.9 6.5
Front brake hose union bolt (master cylinder) M10 × 1.25 30 3.0 22
Front brake hose union bolt (caliper) M10 × 1.25 30 3.0 22
Front brake caliper and front fork M8 × 1.25 28 2.8 20
Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 0.2 1.4
Brake caliper (front and rear) and pad pin M10 × 1.0 18 1.8 13
Brake caliper (front and rear) and bleed screw M8 × 1.25 6 0.6 4.3
Front wheel axle and nut M16 × 1.5 105 10.5 75
Front wheel axle holder M8 × 1.25 21 2.1 15
Front brake disc and wheel hub M6 × 1.0 12 1.2 8.7
Rear brake disc and wheel hub M6 × 1.0 14 1.4 10
Footrest bracket and frame M10 × 1.25 55 5.5 40
Brake pedal mounting M8 × 1.25 26 2.6 19
Brake pedal position locknut M6 × 1.0 6 0.6 4.3
Rear brake master cylinder and frame M6 × 1.0 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 0.2 1.4
Rear brake hose union bolt (caliper) M10 × 1.25 30 3.0 22
Rear brake hose union bolt (master cylinder) M10 × 1.25 30 3.0 22
Rear wheel axle and nut M22 × 1.5 135 13.5 98
Rear wheel sprocket M8 × 1.25 42 4.2 30
Nipple (spoke) — 3 0.3 2.2
Disc cover and rear brake caliper M6 × 1.0 10 1.0 7.2
Protector and rear brake caliper M6 × 1.0 7 0.7 5.1
Chain puller adjust bolt and locknut M8 × 1.25 21 2.1 15

27
 Tightening torque
Item Thread size
Nm m•kgf ft•lbf
Upper engine bracket and frame M8 × 1.25 45 4.5 32
Front engine bracket and frame M8 × 1.25 34 3.4 24
Engine and engine bracket (front) M10 × 1.25 53 5.3 38
Engine and engine bracket (upper) M10 × 1.25 45 4.5 32
Engine and frame (lower) M10 × 1.25 53 5.3 38
Engine guard M6 × 1.0 10 1.0 7.2
Lower engine guard M6 × 1.0 10 1.0 7.2
Pivot shaft and nut M16 × 1.5 85 8.5 61
Relay arm and swingarm M14 × 1.5 70 7.0 50
Relay arm and connecting rod M14 × 1.5 80 8.0 58
Connecting rod and frame M14 × 1.5 80 8.0 58
Rear shock absorber and frame M10 × 1.25 56 5.6 40
Rear shock absorber and relay arm M10 × 1.25 53 5.3 38
Rear shock absorber locknut M60 × 1.5 30 3.0 22
Rear frame and frame (upper) M8 × 1.25 32 3.2 23
Rear frame and frame (lower) M8 × 1.25 32 3.2 23
Swingarm and brake hose holder M5 × 0.8 3 0.3 2.2
Drive chain tensioner mounting (upper) M8 × 1.25 16 1.6 11
Drive chain tensioner mounting (lower) M8 × 1.25 16 1.6 11
Chain support and swingarm M6 × 1.0 7 0.7 5.1
Seal guard and swingarm M5 × 0.8 4 0.4 2.9
Fuel tank mounting boss and frame M10 × 1.25 20 2.0 14
Fuel tank (front) M6 × 1.0 9 0.9 6.5
Fuel tank bracket (front) M6 × 1.0 7 0.7 5.1
Fuel tank (rear) M6 × 1.0 9 0.9 6.5
Fuel tank bracket (rear) M6 × 1.0 7 0.7 5.1
Fuel pump M5 × 0.8 4 0.4 2.9
Fuel tank side cover M6 × 1.0 7 0.7 5.1
Fuel tank and seat set bracket M6 × 1.0 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 7 0.7 5.1
Seat mounting M8 × 1.25 22 2.2 16
Side cover mounting M6 × 1.0 7 0.7 5.1
Heat protector M5 × 0.8 4 0.4 2.9
Air scoop and fuel tank M6 × 1.0 9 0.9 6.5
Air scoop and radiator guard M6 × 1.0 7 0.7 5.1
Air scoop and air duct M6 × 1.0 7 0.7 5.1
Radiator and radiator guard M6 × 1.0 10 1.0 7.2
Front fender mounting M6 × 1.0 10 1.0 7.2
Rear fender mounting (front) M6 × 1.0 7 0.7 5.1

28
 Tightening torque
Item Thread size
Nm m•kgf ft•lbf
Rear fender mounting (rear) M6 × 1.0 18 1.8 13
Mud flap — 1 0.1 0.7
Number plate M6 × 1.0 7 0.7 5.1

1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kgf, 27 ft•lbf) by using the steering
nut wrench, then loosen the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kgf, 5.1 ft•lbf).

29
Yamaha Motor Canada Ltd.
480 Gordon Baker Road
Toronto, ON M2H 3B4