engine YAMAHA WR 450F 2008 Service Manual
Page 79 of 224
3-24
CHASSIS
CHECKING THE TIRE PRESSURE
1. Measure:
• Tire pressure
Out of specification→Adjust.
• Check the tire while it is cold.
• Loose bead stoppers allow the tire 
to slip off its position on the rim 
when the tire pressure is low.
• A tilted tire valve stem indicates that 
the tire slips off its position on the 
rim.
• If the tire valve stem is found tilted, 
the tire is considered to be slipping 
off its position. Correct the tire posi-
tion.
CHECKING AND TIGHTENING THE 
SPOKES
1. Inspect:
• Spokes "1"
Bend/damage→Replace.
Loose spoke→Retighten.
2. Tighten:
• Spokes
Be sure to retighten these spokes be-
fore and after break-in. After a prac-
tice or a race check spokes for 
looseness.
CHECKING THE WHEELS
1. Inspect:
• Wheel runout
Elevate the wheel and turn it.
Abnormal runout→ Replace.
2. Inspect:
• Bearing free play
Exist play→Replace.
CHECKING AND ADJUSTING THE 
STEERING HEAD
1. Elevate the front wheel by placing 
a suitable stand under the engine.
2. Check:
• Steering stem
Grasp the bottom of the forks and 
gently rock the fork assembly 
back and forth.
Free play→Adjust steering head.
3. Check:
• Steering smooth action
Turn the handlebar lock to lock.
Unsmooth action→Adjust steer-
ing ring nut.
4. Adjust:
• Steering ring nut
Steering ring nut adjustment 
steps:
a. Remove the headlight.
b. Remove the handlebar and upper 
bracket.c. Loosen the steering ring nut "1" 
using the steering nut wrench "2".
d. Tighten the steering ring nut "3" 
using steering nut wrench "4".
• Apply the lithium soap base grease 
on the thread of the steering stem.
• Set the torque wrench to the steer-
ing nut wrench so that they form a 
right angle.
e. Loosen the steering ring nut one 
turn.
f. Retighten the steering ring nut us-
ing the steering nut wrench.
Avoid over-tightening.
g. Check the steering stem by turn-
ing it lock to lock. If there is any 
binding, remove the steering stem 
assembly and inspect the steer-
ing bearings.
h. Install the washer "5", upper 
bracket "6", washer "7", steering 
stem nut "8", handlebar "9", han-
dlebar upper holder "10" and 
headlight "11". Standard tire pressure:
100 kPa (1.0 kgf/cm
2, 
15 psi)
Spokes:
3 Nm (0.3 m•kg, 2.2 
ft•lb)
Steering nut wrench:
YU-33975/90890-01403
Steering nut wrench:
YU-33975/90890-01403
Steering ring nut (initial 
tightening):
38 Nm (3.8 m•kg, 27 
ft•lb)
Steering ring nut (final 
tightening):
7 Nm (0.7 m•kg, 5.1 
ft•lb) 
Page 82 of 224
3-27
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode "1"
Wear/damage→Replace.
• Insulator color "2"
Normal condition is a medium to 
light tan color.
Distinctly different color→Check 
the engine condition.
When the engine runs for many hours 
at low speeds, the spark plug insula-
tor will become sooty, even if the en-
gine and carburetor are in good 
operating condition.
3. Measure:
• Plug gap "a"
Use a wire gauge or thickness 
gauge.
Out of specification→Regap.
4. Clean the plug with a spark plug 
cleaner if necessary.
5. Tighten:
• Spark plug
• Before installing a spark plug, clean 
the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug 
before torquing to specification "b".
CHECKING THE IGNITION TIMING
1. Remove:
• Timing mark accessing screw "1"
2. Attach:
• Timing light
• Inductive tachometer
To the ignition coil lead (orange 
lead"1").
3. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
GINE IDLING SPEED" section.
4. Check:
• Ignition timing
Visually check the stationary 
pointer "a" is within the firing 
range "b" on the rotor.
Incorrect firing range→Check ro-
tor and pickup assembly.
5. Install:
• Timing mark accessing screw
CHECKING AND CHARGING THE 
BATTERY
Batteries generate explosive hy-
drogen gas and contain electrolyte 
which is made of poisonous and 
highly caustic sulfuric acid. There-
fore, always follow these preven-
tive measures:
• Wear protective eye gear when 
handling or working near batter-
ies.• Charge batteries in a well-venti-
lated area.
• Keep batteries away from fire, 
sparks or open flames (e.g., 
welding equipment, lighted ciga-
rettes).
• DO NOT SMOKE when charging 
or handling batteries.
• KEEP BATTERIES AND ELEC-
TROLYTE OUT OF REACH OF 
CHILDREN.
• Avoid bodily contact with elec-
trolyte as it can cause severe 
burns or permanent eye injury.
FIRST AID IN CASE OF BODILY 
CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 
minutes and get immediate med-
ical attention.
INTERNAL
• Drink large quantities of water or 
milk followed with milk of magne-
sia, beaten egg or vegetable oil. 
Get immediate medical attention.
Charging time, charging amperage 
and charging voltage for an MF 
battery are different from those of 
conventional batteries. The MF 
battery should be charged as ex-
plained in the charging method il-
lustrations. If the battery is 
overcharged, the electrolyte level 
will drop considerably. Therefore, 
take special care when charging 
the battery.
Since MF batteries are sealed, it is 
not possible to check the charge state 
of the battery by measuring the spe-
cific gravity of the electrolyte. There-
fore, the charge of the battery has to 
be checked by measuring the voltage 
at the battery terminals.
1. Remove:
• Seat
2. Disconnect:
• Battery leads
(from the battery terminals)
First, disconnect the negative bat-
tery lead "1", and then the positive 
battery lead "2".
Spark plug gap:
0.7–0.8 mm (0.028–
0.031 in)
Spark plug:
13 Nm (1.3 m•kg, 9.4 
ft•lb)
Timing light:
YM-33277-A/90890-
03141 
Page 88 of 224
4-1
ENGINE
TUNING
ENGINE
CARBURETOR SETTING
• The air/fuel mixture will vary de-
pending on atmospheric conditions. 
Therefore, it is necessary to take 
into consideration the air pressure, 
ambient temperature, humidity, 
etc., when adjusting the carburetor.
• Perform a test run to check for prop-
er engine performance (e.g., throt-
tle response) and spark plug(-s) 
discoloration or fouling. Use these 
readings to determine the best pos-
sible carburetor setting.
It is recommended to keep a record of 
all carburetor settings and external 
conditions (e.g., atmospheric condi-
tions, track/surface conditions, lap 
times) to make future carburetor set-
ting easier.
• The carburetor is a part of the 
fuel line. Therefore, be sure to in-
stall it in a wellventilated area, 
away from flammable objects 
and any sources of fire.
• Never look into the carburetor in-
take. Flames may shoot out from 
the pipe if the engine backfires 
while it is being started. Gasoline 
may be discharged from the ac-
celerator pump nozzle when the 
carburetor has been removed.
• The carburetor is extremely sen-
sitive to foreign matter (dirt, 
sand, water, etc.). During instal-
lation, do not allow foreign mat-
ter to get into the carburetor.
• Always handle the carburetor 
and its components carefully. 
Even slight scratches, bends or 
damage to carburetor parts may 
prevent the carburetor from 
functioning correctly. Carefully 
perform all servicing with the ap-
propriate tools and without ap-
plying excessive force.
• When the engine is stopped or 
when riding at no load, do not 
open and close the throttle un-
necessarily. Otherwise, too 
much fuel may be discharged, 
starting may become difficult or 
the engine may not run well.• After installing the carburetor, 
check that the throttle operates 
correctly and opens and closes 
smoothly.
ATMOSPHERIC CONDITIONS AND 
CARBURETOR SETTINGS
The air density (i.e., concentration of 
oxygen in the air) determines the rich-
ness or leanness of the air/fuel mix-
ture.
• Higher temperature expands the air 
with its resultant reduced density.
• Higher humidity reduces the 
amount of oxygen in the air by so 
much of the water vapor in the 
same air.
• Lower atmospheric pressure (at a 
high altitude) reduces the density of 
the air.
EFFECT OF SETTING PARTS IN 
RELATION TO THROTTLE VALVE 
OPENING
A. Closed
B. Fully open
1. Pilot jet
2. Throttle valve cutaway
3. Jet needle
4. Main jetCONSTRUCTION OF 
CARBURETOR AND SETTING 
PARTS
The FLATCR carburetor has a prima-
ry main jet. This type of main jet is 
perfect for racing machines since it 
supplies an even flow of fuel, even at 
full load. Use the main jet and the jet 
needle to set the carburetor.
1. Jet needle
2. Pilot air jet
3. Needle jet
4. Main jet
5. Pilot jet
ADJUSTING THE MAIN JET
The richness of the air-fuel mixture at 
full throttle can be set by changing the 
main jet "1".
If the air-fuel mixture is too rich or too 
lean, the engine power will drop, re-
sulting in poor acceleration.
Effects of changing the main jet 
(reference)
A. Idle
B. Fully open
1. #165
2. #160
3. #162 Air 
tem
p.Hu-
midi-
tyAir 
pres-
sure 
(alti-
tude)Mix-
tureSet-
ting
High HighLow 
(high)Rich-
erLean-
er
Low LowHigh 
(low)Lean-
erRich-
er
Standard main jet#162
* #160
* For EUROPE 
Page 89 of 224
4-2
ENGINE
ADJUSTING THE PILOT JET
The richness of the air-fuel mixture 
with the throttle open 1/4 or less can 
be set by adjusting the pilot jet "1".
Effects of adjusting the pilot jet 
(reference)
A. Idle
B. Fully open
1. #48
2. #42
3. #45
ADJUSTING THE JET NEEDLE 
GROOVE POSITION
Adjusting the jet needle "1" position 
affects the acceleration when the 
throttle is 1/8 to 3/4 open.
1. Too rich at intermediate speeds
• Rough engine operation is felt 
and the engine will not pick up 
speed smoothly.
Step up the jet needle clip by one 
groove and move down the nee-
dle to lean out the mixture.
2. Too lean at intermediate speeds
• The engine breathes hard and will 
not pick up speed quickly.
Step down the jet needle clip by 
one groove and move up the nee-
dle to enrich the mixture.Effects of changing the jet needle 
groove position (reference)
A. Idle
B. Fully open
1. No.5 groove
2. No.3 groove
3. No.4 groove
ADJUSTING THE JET NEEDLE
The jet needle is adjusted by chang-
ing it.
The jet needle setting parts, having 
the same taper angle, are available in 
different straight portion diameters.
a. Diameter of the straight por-
tion
Effects of changing the jet needle 
(reference)
(Diameter of the straight portion)
Changing the diameter of the straight 
portion adjusts the air-fuel mixture 
when the throttle is 1/8 to 1/4 open.
A. Idle
B. Fully open
RELATIONSHIP WITH THROTTLE 
OPENING
The flow of the fuel through the car-
buretor main system is controlled by 
the main jet and then, it is further reg-
ulated by the area between the main 
nozzle and the jet needle.
The fuel flow relates to the diameter 
of the straight portion of the jet needle 
with the throttle 1/8 to 1/4 open and 
relates to the clip position with the 
throttle 1/8 to 3/4 open.
Therefore, the fuel flow is balanced at 
each stage of throttle opening by the 
combination of the jet needle straight 
portion diameter and clip position.ADJUSTING THE LEAK JET 
(ADJUSTING THE ACCELERATOR 
PUMP)
The leak jet "1" is a setting part that 
adjusts the flow of fuel discharged by 
the accelerator pump. Since the ac-
celerator pump operates only when 
throttle is open, the leak jet is used to 
adjust a fuel mixture ratio for quick 
throttle opening and is therefore dif-
ferent from other setting parts that ad-
just a fuel mixture for each throttle 
opening (each engine speed).
1. When the engine breathes hard in 
quick throttle opening, select a 
leak jet having lower calibrating 
No. than standard to enrich the 
mixture. <Example> #60→#55
2. When rough engine operation is 
felt in quick throttle opening, se-
lect a leak jet having higher cali-
brating No. than standard to lean 
out the mixture. <Example> #60
→#65 Standard pilot jet#45
* #48
* For EUROPE
Standard clip posi-
tionNo.4 
groove
Supplied jet needleGDDSQ
* GDDUQ
*For EUROPE
Standard leak jet #60
4 
Page 90 of 224
4-3
ENGINE
CARBURETOR SETTING PARTS
Main jet SizePart 
number 
(-14943-)
Rich #185 4MX-44
#182 4MX-94
#180 4MX-43
#178 4MX-93
#175 4MX-42
#172 4MX-92
#170 4MX-41
#168 4MX-91
#165 4MX-40
(STD) #162 4MX-90
*(STD) Lean #160 4MX-39
Pilot jet SizePart 
number 
(-14948-)
Rich #55 4MX-09
#52 4MX-08
#50 4MX-07
*(STD) #48 4MX-06
(STD) Lean #45 4MX-05
Jet needle SizePart 
number 
(-14916-)
Rich GDDUM 5TJ-9M
GDDUN 5TJ-9N
GDDUP 5TJ-9P
GDDUQ 5TJ-91
GDDUR 5TJ-9R
GDDUS 5TJ-9S
Lean GDDUT 5TJ-9T
Rich GDDSM 5TJ-AM
GDDSN 5TJ-AN
GDDSP 5TJ-AP
GDDSQ 5TJ-A1
GDDSR 5TJ-AR
GDDSS 5TJ-AS
Lean GDDST 5TJ-AT
Leak jet SizePart 
number 
(-1494F-)
Rich #35 4JT-01
#40 4JT-03
#45 4JT-05
#50 4JT-07
#55 4JT-09
(STD) #60 4JT-11
Lean #65 4JT-13
* For EUROPE 
Page 91 of 224
4-4
ENGINE
EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM
* This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions 
of the engine.
Symptom Setting Checking
At full throttle
Hard breathing
Shearing noise
Whitish spark plug
↓
Lean mixtureIncrease main jet calibration no. (Gradual-
ly)Discoloration of spark plug→If tan color, it 
is in good condition.
If cannot be corrected:
Clogged float valve seat
Clogged fuel hose
Clogged fuel cock
Check that the accelerator pump operates 
smoothly.
At full throttle
Speed pick-up stops
Slow speed pick-up
Slow response
Sooty spark plug
↓
Rich mixtureDecrease main jet calibration no. (Gradual-
ly)Discoloration of spark plug→If tan color, it 
is in good condition.
If cannot be corrected:
Clogged air filter
Fuel overflow from carburetor
Lean mixture Lower jet needle clip position. (1 groove 
down)
The clip position is the jet needle groove on 
which the clip is installed.
The positions are numbered from the top.
Check that the accelerator pump operates 
smoothly. (except for rich mixture symp-
tom). Rich mixture Raise jet needle clip position. (1 groove up)
1/4–3/4 throttle
Hard breathing
Lack of speedLower jet needle clip position. (1 groove 
down)
1/4–1/2 throttle
Slow speed pick-up
Poor accelerationRaise jet needle clip position. (1 groove up)
Closed to 1/4 throttle
Hard breathing
Speed downUse jet needle with a smaller diameter. Slow-speed-circuit passage
Clogged→Clean.
Overflow from carburetor
Closed to 1/4 throttle
Poor accelerationUse jet needle with a larger diameter.
Raise jet needle clip position. (1 groove up)
Poor response in the low to in-
termediate speedsRaise jet needle clip position.
If this has no effect, lower the jet needle clip 
position.
Poor response when throttle is 
opened quicklyCheck overall settings.
Use main jet with a lower calibration no.
Raise jet needle clip position. (1 groove up)
If these have no effect, use a main jet with 
a higher calibration no. and lower the jet 
needle clip position.Check air filter for fouling.
Check that the accelerator pump operates 
smoothly.
Jet needleClip
Groove 7 Groove 6
Groove 5
Groove 4
Groove 3
Groove 2
Groove 1 
Leaner
(Standard)
Richer 
Page 92 of 224
4-5
CHASSIS
CHASSIS
SELECTION OF THE SECONDARY 
REDUCTION RATIO (SPROCKET)
<Requirement for selection of sec-
ondary gear reduction ratio>
• It is generally said that the second-
ary gear ratio should be reduced for 
a longer straight portion of a speed 
course and should be increased for 
a course with many corners. Actual-
ly, however, as the speed depends 
on the ground condition of the day 
of the race, be sure to run through 
the circuit to set the machine suit-
able for the entire course.
• In actuality, it is very difficult to 
achieve settings suitable for the en-
tire course and some settings may 
be sacrificed. Thus, the settings 
should be matched to the portion of 
the course that has the greatest ef-
fect on the race result. In such a 
case, run through the entire course 
while making notes of lap times to 
find the best balance; then, deter-
mine the secondary reduction ratio.
• If a course has a long straight por-
tion where a machine can run at 
maximum speed, the machine is 
generally set such that it can devel-
op its maximum revolutions toward 
the end of the straight line, with care 
taken to avoid the engine over-rev-
ving.
Riding technique varies from rider to 
rider and the performance of a ma-
chine also vary from machine to ma-
chine. Therefore, do not imitate other 
rider's settings from the beginning but 
choose your own setting according to 
the level of your riding technique.
DRIVE AND REAR WHEEL 
SPROCKETS SETTING PARTS
TIRE PRESSURE
Tire pressure should be adjust to suit 
the road surface condition of the cir-
cuit.• Under a rainy, muddy, sandy, or 
slippery condition, the tire pressure 
should be lower for a larger area of 
contact with the road surface.
• Under a stony or hard road condi-
tion, the tire pressure should be 
higher to prevent a flat tire.
FRONT FORK SETTING
The front fork setting should be made 
depending on the rider's feeling of an 
actual run and the circuit conditions.
The front fork setting includes the fol-
lowing three factors:
1. Setting of air spring characteris-
tics
• Change the fork oil level.
2. Setting of spring preload
• Change the spring.
• Install the adjustment washer.
3. Setting of damping force
• Change the compression damp-
ing.
• Change the rebound damping.
The spring acts on the load and 
the damping force acts on the 
cushion travel speed.
CHANGE IN LEVEL AND 
CHARACTERISTICS OF FORK OIL
Damping characteristic near the final 
stroke can be changed by changing 
the fork oil amount.
Adjust the oil level in 5 mm (0.2 in) 
increments or decrements. Too 
low oil level causes the front fork 
to produce a noise at full rebound 
or the rider to feel some pressure 
on his hands or body. Alternative-
ly, too high oil level will develop 
unexpectedly early oil lock with 
the consequent shorter front fork 
travel and deteriorated perfor-
mance and characteristics. There-
fore, adjust the front fork within 
the specified range.
Secondary reduction ratio = 
Number of rear wheel sprocket 
teeth/Number of drive sprocket 
teeth
Standard secondary 
reduction ratio50/13 
(3.846)
* 47/14 
(3.357)
* For EUROPE
Part 
nameSize Part number
Drive 
sprocket 
"1"
(STD) 13T 9383E-13233
* 14T 9383E-14215
** (STD) ** 14T 5NG-17460-00
* For AUS and NZ
** For EUROPE
Part 
nameSize Part number
Rear 
wheel 
sprocket 
"2"
** (STD) ** 47T 1C3-25447-00
48T 5GS-25448-50
* 48T 1C3-25448-00
* 49T 1C3-25449-00
(STD) 50T 5TJ-25450-80
* (STD) * 50T 1C3-25450-00
* 51T 1C3-25451-00
52T 5TJ-25452-80
* 52T 1C3-25452-00
* For AUS and NZ
** For EUROPE
Standard tire pressure:
100 kPa (1.0 kgf/cm
2, 
15 psi)
Extent of adjustment:
60–80 kPa (0.6–0.8 kgf/
cm
2, 9.0–12 psi)
Extent of adjustment:
100–120 kPa (1.0–1.2 
kgf/cm
2, 15–18 psi) 
Page 94 of 224
4-7
CHASSIS
2. Setting of damping force
• Change the rebound damping.
• Change the compression damp-
ing.
CHOOSING SET LENGTH
1. Place a stand or block under the 
engine to put the rear wheel 
above the floor, and measure the 
length "a" between the rear wheel 
axle center and the rear fender 
holding bolt.
2. Remove the stand or block from 
the engine and with a rider astride 
the seat, measure the sunken 
length "b" between the rear wheel 
axle center and the rear fender 
holding bolt.
3. Loosen the locknut "1" and make 
adjustment by turning the spring 
adjuster "2" to achieve the stan-
dard figure from the subtraction of 
the length "b" from the length "a".
• If the machine is new and after it is 
broken in, the same set length of 
the spring may change because of 
the initial fatigue, etc. of the spring. 
Therefore, be sure to make reeval-
uation.
• If the standard figure cannot be 
achieved by adjusting the spring 
adjuster and changing the spring 
set length, replace the spring with 
an optional one and make re-ad-
justment.
SETTING OF SPRING AFTER 
REPLACEMENT
After replacement, be sure to adjust 
the spring to the set length [sunken 
length 90–100 mm (3.5–3.9 in)] and 
set it.
1. Use of soft spring
• Set the soft spring for less re-
bound damping to compensate 
for its less spring load. Run with 
the rebound damping adjuster 
one or two clicks on the softer 
side and readjust it to suit your 
preference.
2. Use of stiff spring
• Set the soft spring for more re-
bound damping to compensate 
for its greater spring load. Run 
with the rebound damping adjust-
er one or two clicks on the stiffer 
side and readjust it to suit your 
preference.
Adjusting the rebound damping will 
be followed more or less by a change 
in the compression damping. For cor-
rection, turn the low compression 
damping adjuster on the softer side.
When using a rear shock absorber 
other than currently installed, use 
the one whose overall length "a" 
does not exceed the standard as it 
may result in faulty performance. 
Never use one whose overall 
length is greater than standard.
REAR SHOCK ABSORBER 
SETTING PARTS
• Rear shock spring "1"
The I.D. color "a" is marked at the end 
of the spring.
• Extent of adjustment (spring length) Standard figure:
90–100 mm (3.5–3.9 in)
Length "a" of standard 
shock:
488.5 mm (19.23 in)
TY
PESPR
ING 
RAT
ESPRIN
G 
PART 
NUM-
BER (-
22212-)I.D. 
COLOR/
POINTSPRI
NG 
FRE
E 
LEN
GTH
SO
FT4.3 5UN-00 Brown/1 260
4.5 5UN-10 Green/1 260
4.7 5UN-20 Red/1 260
4.9 5UN-30 Black/1 260
5.1 5UN-40 Blue/1 260
5.3 5UN-50Yellow/
1260
ST
D5.5 5UN-60 Pink/1 260
STI
FF5.7 5UN-70 White/1 260
SPRING FREE 
LENGTHEXTENT OF AD-
JUSTMENT "b"
260 mm (10.24 
in)238.5–258.5 
mm (9.39–10.18 
in) 
Page 97 of 224
5-1
RADIATOR
ENGINE
RADIATOR
REMOVING THE RADIATOR
Order Part name Q'ty Remarks
Drain the coolant.Refer to "CHANGING THE COOLANT" sec-
tion in the CHAPTER 3.
Seat, fuel tank and left side coverRefer to "REMOVING THE SEAT, FUEL 
TANK AND SIDE COVERS" section in the 
CHAPTER 3.
Exhaust pipeRefer to "REMOVING THE EXHAUST PIPE 
AND SILENCER" section in the CHAPTER 3.
1 Radiator guard 2
2 Radiator hose clamp 8
3 Right radiator 1
4 Radiator hose 2 1
5 Radiator hose 3 1
6 Radiator hose 4 1
7 Pipe 2/O-ring 1/1
8 Catch tank hose 1
9 Left radiator 1
10 Radiator hose 1 1
5 
Page 99 of 224
5-3
RADIATOR
HANDLING NOTE
Do not remove the radiator cap 
when the engine and radiator are 
hot. Scalding hot fluid and steam 
may be blown out under pressure, 
which could cause serious injury. 
When the engine has cooled, open 
the radiator cap by the following 
procedure:
Place a thick rag, like a towel, over 
the radiator cap, slowly rotate the 
cap counterclockwise to the de-
tent. This procedure allows any re-
sidual pressure to escape. When 
the hissing sound has stopped, 
press down on the cap while turn-
ing counterclockwise and remove 
it.
CHECKING THE RADIATOR
1. Inspect:
• Radiator core "1"
Obstruction→Blow out with com-
pressed air through rear of the ra-
diator.
Bent fin→Repair/replace.
INSTALLING THE RADIATOR
1. Install:
• Pipe 1 "1"
• Radiator hose 1 "2"
• Pipe 2 "3"
• Radiator hose 3 "4"
• Radiator hose 4 "5"2. Install:
• Radiator hose 2 "1"
• Left radiator "2"
3. Install:
• Catch tank hose "1"
• Right radiator "2"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER 
2.
4. Install:
• Radiator guard "1"
First fit the inner hook portion "a" and 
then the outer one "b" onto the radia-
tor.
5. Install:
• Catch tank "1"
• Bolt (catch tank) "2"
• Bolt (catch tank) "3"
• Catch tank hose "4"
• Catch tank breather hose "5"
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER 
2.
Pipe 1:
10 Nm (1.0 m•kg, 7.2 
ft•lb)
Radiator hose 1:
2 Nm (0.2 m•kg, 1.4 
ft•lb)
Pipe 2:
10 Nm (1.0 m•kg, 7.2 
ft•lb)
Radiator hose 3:
2 Nm (0.2 m•kg, 1.4 
ft•lb)
Radiator hose 4:
2 Nm (0.2 m•kg, 1.4 
ft•lb)
Radiator hose 2:
2 Nm (0.2 m•kg, 1.4 
ft•lb)
Left radiator:
10 Nm (1.0 m•kg, 7.2 
ft•lb)
Right radiator:
10 Nm (1.0 m•kg, 7.2 
ft•lb)
Bolt (catch tank):
7 Nm (0.7 m•kg, 5.1 
ft•lb)
Bolt (catch tank):
16 Nm (1.6 m•kg, 11 
ft•lb)