2016 YAMAHA WR 450F lock

ENGINE SPECIFICATIONS
2-4
Valve springFree length (intake) 40.76 mm (1.60 in)
Limit 38.72 mm (1.52 in)
Free length (exhaust) 36.94 mm (1.45 in)
Limit 35.09 mm (1.38 in)
Installed length (intake) 34.78 mm (1.37 in)
Installed length (exhaust) 30.83 mm (1.21 in)
Spring rate K1 (intake) 31.90 N/mm (3.25 kgf/mm, 182.15 lbf/in)
Spring rate K2 (intake) 41.37 N/mm (4.22 kgf/mm, 236.22 lbf/in)
Spring rate K1 (exhaust) 21.76 N/mm (2.22 kgf/mm, 124.25 lbf/in)
Spring rate K2 (exhaust) 28.12 N/mm (2.87 kgf/mm, 160.57 lbf/in)
Installed compression spring force (intake) 178.00–204.00 N (18.15–20.80 kgf,
40.01–45.86 lbf)
Installed compression spring force (exhaust) 124.00–142.00 N (12.64–14.48 kgf,
27.88–31.92 lbf)
Spring tilt (intake) 2.5 °/1.8 mm (2.5 °/0.07 in)
Spring tilt (exhaust) 2.5 °/1.6 mm (2.5 °/0.06 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder Bore 97.000–97.010 mm (3.8189–3.8193 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
PistonPiston-to-cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in)
Limit 0.15 mm (0.006 in)
Diameter 96.955–96.970 mm (3.8171–3.8177 in)
Measuring point (from piston skirt bottom) 9.0 mm (0.35 in)
Offset 0.00 mm (0.0000 in)
Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in)
Limit 18.045 mm (0.7104 in)
Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in)
Limit 17.971 mm (0.7075 in)
Piston ringTop ring Ring type Barrel
Dimensions (B  T) 1.00  3.30 mm (0.04  0.13 in)
End gap (installed) 0.20–0.30 mm (0.0079–0.0118 in)
Limit 0.55 mm (0.0217 in)
Ring side clearance 0.015–0.065 mm (0.0006–0.0026 in)
Limit 0.120 mm (0.0047 in)
2nd ring Ring type Taper
Dimensions (B  T) 1.00  3.10 mm (0.04  0.12 in)
End gap (installed) 0.35–0.50 mm (0.0138–0.0197 in)
Limit 0.85 mm (0.0335 in)
Ring side clearance 0.020–0.060 mm (0.0008–0.0024 in)
Limit 0.120 mm (0.0047 in)
Oil ring
Dimensions (B  T) 1.50  2.25 mm (0.06  0.89 in)
End gap (installed) 0.20–0.50 mm (0.0079–0.0197 in)

CHASSIS SPECIFICATIONS
2-8
Rear brakeType Hydraulic single disc brake
Operation Right foot operation
Brake pedal position 5.0 mm (0.20 in)
Rear disc brake
Disc outside diameter  thickness 245.0  4.0 mm (9.65  0.16 in)
Brake disc thickness limit 3.5 mm (0.14 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness 6.4 mm (0.25 in)
Limit 1.0 mm (0.04 in)
Master cylinder inside diameter 11.0 mm (0.43 in)
Caliper cylinder inside diameter 25.40 mm (1.00 in)
Specified brake fluid DOT 4
Steering Steering bearing type Taper roller bearing
Center to lock angle (left) 43.0 °
Center to lock angle (right) 43.0 °
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/Hydraulic damper
Front fork travel 310.0 mm (12.20 in)
Fork spring free length 470.0 mm (18.50 in)
Limit 465.0 mm (18.31 in)
Fork spring installed length 470.0 mm (18.50 in)
Spring rate K1 4.50 N/mm (0.46 kgf/mm, 25.71 lbf/in)
Spring stroke K1 0.0–310.0 mm (0.00–12.20 in)
Inner tube outer diameter 48 mm (1.9 in)
Inner tube bending limit 0.2 mm (0.01 in)
Optional spring available Yes
Recommended oil Yamaha Suspension Oil S1
Quantity 545.0 cm
3 (18.43 US oz, 19.18 Imp.oz)
Rebound damping adjusting positions
Minimum 20 clicks out*
Standard 11 clicks out*
Maximum Fully turned in * With the adjuster fully turned in
Compression damping adjusting positions Minimum 20 clicks out*
Standard 13 clicks out*
Maximum Fully turned in
* With the adjuster fully turned in

TIGHTENING TORQUES
2-13
EAS2GC1066ENGINE TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEM Thread
size Q’ty TIGHTENING TORQUES Remarks
Camshaft cap bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head blind plug M12 1 28 Nm (2.8 m·kgf, 20 ft·lbf)
Spark plug M10 1 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Cylinder head stud bolt (exhaust
pipe) M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Cylinder head bolt M10 4See TIP.*1
Cylinder head bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head cover bolt M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage plug (cylinder head) M8 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Cylinder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pressure check bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer weight plate screw M6 3 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Balancer driven gear nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf) Use a
lock
washer.
Balancer nut M10 1 45 Nm (4.5 m·kgf, 33 ft·lbf) Use a
lock
washer.
Timing chain guide stopper plate
(exhaust side) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Coolant drain bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator hose clamp screw M6 8 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Radiator bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator pipe joint bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Radiator fan bolt M6 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Water pump housing cover bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump bolt M5 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil pump cover screw M4 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Oil strainer bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil passage cover bolt (left crank-
case cover) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Throttle cable cover bolt M5 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Throttle body joint bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
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TIGHTENING TORQUES
2-14
Throttle body joint clamp boltM5 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Air filter joint clamp bolt M4 1 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Air filter case bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Air filter bolt M6 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Air filter guide holder screw M5 8 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Air filter case cap screw M5 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Starter knob/Idle screw M12 1 2.1 Nm (0.21 m·kgf, 1.5 ft·lbf)
Throttle cable nut (pull) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle cable nut (return) M10 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Clutch cable adjuster and locknut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Clutch cable locknut (engine side) M8 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Exhaust pipe nut M6 3See TIP.*2
Exhaust pipe protector screw M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Exhaust pipe bracket bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Frame and silencer bolt (front) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Frame and silencer bolt (rear) M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Exhaust pipe clamp bolt M8 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Spark arrester bolt M5 4 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Muffler cap bolt M5 6 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Oil nozzle bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil drain bolt M10 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Crankcase bolt M6 12 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Clutch cable holder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankshaft end accessing screw M36 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing mark accessing screw M14 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Drive chain sprocket cover bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankcase bearing cover plate
screw M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Crankcase bearing cover plate
screw (crankshaft) M8 4 18 Nm (1.8 m·kgf, 13 ft·lbf) Crimp.
Clutch cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Left crankcase cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Right crankcase cover bolt M6 11 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil filter element cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil level check window bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Kick shaft ratchet wheel guide bolt M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Kickstarter lever bolt M8 1 33 Nm (3.3 m·kgf, 24 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES Remarks
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TIGHTENING TORQUES
2-15
TIP
*1:Cylinder head bolt
First, tighten the cylinder head bolts to 30 Nm (3.0 m·kgf, 22 ft·lbf) in the proper tightening sequence
and remove them. Retighten the cylinder head bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf) in the proper tight-
ening sequence, and then tighten the cylinder head bolts further to reach the specified angle 150° in
the proper tightening sequence.Kickstarter lever boss screw
M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Primary drive gear nut M20 1 100 Nm (10 m·kgf, 72 ft·lbf)
Clutch spring bolt M6 6 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Clutch boss nut M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf)
Drive sprocket nut M20 1 75 Nm (7.5 m·kgf, 54 ft·lbf) Use a
lock
washer.
Drive axle oil seal stopper bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Segment M8 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Shift guide bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Stopper lever bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift pedal bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rotor nut M12 1 65 Nm (6.5 m·kgf, 47 ft·lbf)
Stator screw M5 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
AC magneto lead holder bolt M5 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Damper assembly cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter clutch bolt M6 6 16 Nm (1.6 m·kgf, 12 ft·lbf)
Starter motor bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Starter motor cover bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Coolant temperature sensor M10 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
Neutral switch bolt M5 2 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Intake air temperature sensor screw M5 1 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
ECU bolt M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Ignition coil bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle position sensor screw M5 2 3.4 Nm (0.34 m·kgf, 2.5 ft·lbf)
Intake air pressure sensor screw M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES Remarks
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TIGHTENING TORQUES
2-17
EAS2GC1067CHASSIS TIGHTENING TORQUES
TIP
- marked portion shall be checked for torque tightening after break-in or before each race.
ITEM Thread
size Q’ty TIGHTENING TORQUES Remarks
Outer tube and upper bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Outer tube and lower bracket bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
Upper bracket and steering stem nut M24 1 145 Nm (14.5 m·kgf, 105 ft·lbf)
Upper handlebar holder bolt M8 4 28 Nm (2.8 m·kgf, 20 ft·lbf)
Lower handlebar holder nut M10 2 40 Nm (4.0 m·kgf, 29 ft·lbf)
Engine stop switch screw M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Start switch screw M4 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Lower ring nut M28 1See TIP.
Outer tube and damper assembly M51 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Inner tube and adjuster M22 2 55 Nm (5.5 m·kgf, 40 ft·lbf)
Damper assembly and base valve M42 2 28 Nm (2.8 m·kgf, 20 ft·lbf)
Damper assembly adjuster M12 2 29 Nm (2.9 m·kgf, 21 ft·lbf)
Bleed screw (front fork) and base
valve M5 2 1.3 Nm (0.13 m·kgf, 0.94 ft·lbf)
Front fork protector bolt M6 6 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Front fork protector and brake hose
holder nut M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Throttle grip cap screw M5 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever holder bolt M6 2 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf)
Clutch lever nut M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Front brake master cylinder holder
bolt M6 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake master cylinder reser-
voir cap screw M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Front brake lever pivot bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever pivot nut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front brake lever position locknut M6 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front brake hose holder and lower
bracket bolt M6 1 9 Nm (0.9 m·kgf, 6.5 ft·lbf)
Front brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Front brake caliper bolt M8 2 23 Nm (2.3 m·kgf, 17 ft·lbf)
Front brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Front brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Front brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Front wheel axle nut M16 1 90 Nm (9.0 m·kgf, 65 ft·lbf)
Front wheel axle pinch bolt M8 4 21 Nm (2.1 m·kgf, 15 ft·lbf)
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TIGHTENING TORQUES
2-18
Front brake disc boltM6 6 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Rear brake disc bolt M6 6 14 Nm (1.4 m·kgf, 10 ft·lbf)
Footrest bracket bolt M10 4 55 Nm (5.5 m·kgf, 40 ft·lbf)
Sidestand bolt M10 1 25 Nm (2.5 m·kgf, 18 ft·lbf)
Rear brake pedal bolt M8 1 26 Nm (2.6 m·kgf, 19 ft·lbf)
Rear brake pedal position locknut M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake master cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake master cylinder reservoir
cap bolt M4 2 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf)
Rear brake hose union bolt M10 2 30 Nm (3.0 m·kgf, 22 ft·lbf)
Rear brake caliper bleed screw M8 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Rear brake pad pin M10 1 17 Nm (1.7 m·kgf, 12 ft·lbf)
Rear brake pad pin plug M10 1 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear wheel axle nut M22 1 125 Nm (12.5 m·kgf, 90 ft·lbf)
Drive chain puller adjust bolt and
locknut M8 2 21 Nm (2.1 m·kgf, 15 ft·lbf)
Rear wheel sprocket nut M8 6 50 Nm (5.0 m·kgf, 36 ft·lbf)
Nipple (spoke) — 72 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear brake disc cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear brake caliper protector bolt M6 2 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Engine mounting bolt (upper side) M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting bolt (front side) M10 1 55 Nm (5.5 m·kgf, 40 ft·lbf)
Engine mounting bolt (lower side) M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Engine bracket bolt (upper side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Engine bracket bolt (front side) M8 4 34 Nm (3.4 m·kgf, 25 ft·lbf)
Rear frame and frame bolt M8 4 38 Nm (3.8 m·kgf, 27 ft·lbf)
Engine guard bolt M6 3 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Pivot shaft and nut M16 1 85 Nm (8.5 m·kgf, 61 ft·lbf)
Rear shock absorber assembly up-
per bolt M10 1 56 Nm (5.6 m·kgf, 41 ft·lbf)
Rear shock absorber assembly low-
er bolt M10 1 53 Nm (5.3 m·kgf, 38 ft·lbf)
Rear shock absorber locknut M60 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Relay arm bolt (swingarm side) M14 1 70 Nm (7.0 m·kgf, 51 ft·lbf)
Connecting arm bolt (relay arm side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Connecting arm bolt (frame side) M14 1 80 Nm (8.0 m·kgf, 58 ft·lbf)
Swingarm and brake hose holder
screw M5 4 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf)
Drive chain tensioner bolt (upper
side) M8 1 16 Nm (1.6 m·kgf, 12 ft·lbf)
ITEM
Thread
size Q’ty TIGHTENING TORQUES RemarksLT
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CABLE ROUTING DIAGRAM
2-34
1. Clutch cable
2. Throttle cable (return)
3. Throttle cable (pull)
4. Engine stop switch lead
5. Coupler for connecting optional part
6. Engine stop switch coupler
7. Rectifier/regulator coupler
8. AC magneto lead
9. Starter knob/idle screw
10. Engine ground sub-lead
11. Starter motor lead
12. Radiator fan fuse
13. Taillight lead
14. Headlight relay (yellow tape)
15. Starting circuit cut-off relay (no identification tape)
16. Diode
17. Holder plate
18. Left of the vehicle:radiator fan motor relay (blue tape)
Right of the vehicle:main relay (red tape)
19. Neutral switch lead
20. Front engine bracket
21. Plastic locking tie
22. Radiator hose
23. Neutral switch coupler
24. Crankshaft position sensor coupler
25. Tension arm
26. Wire harness
27. Tank rail
28. Rectifier/regulator
29. Rectifier/regulator bracket
30. Rear frame
31. Side cover 5
32. Crankcase cover
33. Crankcase
34. Lead holder
35. Frame
36. Engine ground sub-lead coupler
A. Pass the engine stop switch lead between the frame and the cable holder.
B. Insert the coupler for connecting optional part into the connector, and fix it to the bracket.
C. Insert and fix the engine stop switch coupler to the bracket.
D. Insert and fix the rectifie r/regulator coupler to the
bracket.
E. Pass the AC magneto lead to the front of the ve- hicle beyond the starter knob/idle screw and to
the rear of the vehicle beyond the radiator. No
pinch is allowed between the radiator and the
tension arm.
F. Make sure that there is no slack so that the starter motor lead cannot touch the end of the bolt.
G. Place the rear grommet of the starter motor lead matching the rear end of the side cover.
H. Insert the radiator fan motor fuse into the protru- sion of the holder plate.
I. Place the diode on top of the rear fender on the inner side of the rear frame.
J. Bring the neutral switch lead into line with the crankcase cover with no sag allowed.
K. Route the AC magneto lead inside the starter clutch cover.
L. Pass the neutral switch l ead to the inside of the
front engine bracket (the side of the vehicle).
M. Insert the plastic locking tie into the bracket hole and clamp the clutch cable. Clamp it so that the
lock of the plastic locking tie faces downward,
and then cut off the end of the plastic locking tie. N. Pass the clutch cable
with no downward sag al-
lowed.
O. Place the grommet of the clutch cable so that it contacts the radiator hose. Route the clutch cable
outside the neutral switch lead, AC magneto lead
and starter motor lead.
P. Route each lead so that the leads are not pinched
between the radiator hose and the frame.
Q. 40 mm (1.57 in)
R. Clamp the clutch cable, AC magneto lead, neu- tral switch lead and starter motor lead by the plas-
tic locking tie. Make sure that they are clamped at
the positioning tapes in the clutch cable and the
starter motor lead. Make the lock on the plastic
locking tie face the front of the vehicle, and cut
the end.
S. Clamp the starter motor lead to the inside of the tension arm with a plastic locking tie. Clamp it so
that the lock of the plastic locking tie faces up-
ward and outward, and do not cut off the end of
the plastic locking tie. R oute the lead so that there
is no slack at the bottom from the clamp position
onwards.
T. After connecting the neutral switch coupler, at- tach the coupler cover.
U. After connecting the crankshaft position sensor coupler, attach the coupler cover.
V. Pass the rectifier/regulator lead to the inside of the tension arm (the side of the vehicle).
W. Pass the main harness to the front of the radiator
hose (the front of the vehicle), and to the inside of
the clutch cable (the side of the vehicle).
X. Pass the engine stop switch lead between the coupler for connecting optional part and the tank
rail, with the lead on the main harness side facing
the top of the vehicle.
Y. Insert the starter motor lead completely into the end of the side cover 5.
Z. Clamp the clutch cable at the front of the lead (the
front of the vehicle).
AA.Insert the clip of the pl astic locking tie into the
frame. Face the lock of the plastic locking tie for-
ward, and then cut off the end.