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Yamaha FZS1000(N) 2001, Service Manual

The Yamaha FZS1000(N) 2001 Service Manual is a comprehensive guide that provides detailed instructions and diagrams for maintaining, repairing, and servicing this high-performance motorcycle. You can conveniently download this manual for free from our website, ensuring you have all the necessary information to keep your Yamaha FZS1000(N) running smoothly.

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4-18

FRONT AND REAR BRAKES

CHAS

CAUTION:

NOTE:

EAS00579

Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:

Never disassemble brake components un-
less absolutely necessary.

If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after reas-
sembly.

Never use solvents on internal brake com-
ponents.

Use only clean or new brake fluid for clean-
ing brake components.

Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt fluid immediately.

Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.

First aid for brake fluid entering the eyes:

Flush with water for 15 minutes and get im-
mediate medical attention.

EAS00582

REPLACING THE FRONT BRAKE PADS
The following procedure applies to both brake
calipers.

When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.

1. Remove:

brake hose holder 

1

brake caliper 

2

Summary of Contents for FZS1000(N) 2001

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Page 3: ...S1000 N SERVICE MANUAL 2000 by Yamaha Motor Co Ltd First edition December 2000 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...is policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed eral environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all its models Modifications and signifi cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual w...

Page 5: ...hecks and Adjustments where the sub section title s appears In Chapter 3 Periodic Checks and Adjustments the sub section title appears at the top of each page instead of the section title 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers ...

Page 6: ...al system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Engine speed 17 Electrical data Symbols 18 to 23 in the exploded diagrams indi cate the types of lubricants and lubrication points 18 Engine oil 19 Gear oil 20 Molybdenum disulfide oil 21 Wheel bearing g...

Page 7: ...PECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM CARBURETORS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 3 CHAS 4 ENG 5 COOL 6 CARB 7 ELEC 8 TRBL SHTG 9 CHK ADJ EAS00012 TABLE OF CONTENTS ...

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Page 10: ...ICATION NUMBER 1 1 MODEL CODE 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 2 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 11: ...GEN INFO ...

Page 12: ...OTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head EAS00018 MODEL CODE The model code label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 13: ...ly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all re placements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS00022 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine re...

Page 14: ... Oil bearings liberally when instal ling if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EAS00025 CIRCLIPS 1 Before reassembly check all circlips careful ly and replace damaged or distorted circlips Always replace piston pin clips after one use When installing a circlip 1 make sure that the sharp edged corner 2 is posit...

Page 15: ...stains Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that all connections are tight 5 Check continuity with a pocket tester Pocket tester 90890 03112 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a q...

Page 16: ...ve the generator rotor 90890 01235 Rotor holding tool This tool is used to hold the generator rotor when removing or installing the generator rotor bolt or pickup coil rotor bolt 90890 01304 Piston pin puller set This tool is used to remove the piston pins 90890 01312 Fuel level gauge This tool is used to measure the fuel level in the float chamber Radiator cap tester 90890 01325 Adapter 90890 013...

Page 17: ...ver attachment ø43 90890 01374 Fork seal driver weight Fork seal driver attachment ø43 This tool is used to install the front fork s oil seal and dust seal 90890 03008 Micrometer 50 75 mm This tool is used to measure the piston skirt diameter Vacuum gauge 90890 03094 Vacuum gauge This guide is used to synchronize the car buretors Compression gauge 90890 03081 Compression gauge adapter 90890 04136 ...

Page 18: ... installer 90890 04078 Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal 90890 04086 Universal clutch holder This tool is used to hold the clutch boss when removing or installing the clutch boss nut 90890 04111 90890 04116 Valve guide remover ø4 Valve guide remover ø4 5 This tool is used to remove or install the valve guides 90890 0411...

Page 19: ...1 8 SPECIAL TOOLS GEN INFO Tool No Tool name Function Illustration 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating sur faces e g crankcase mating surfaces ...

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Page 21: ...CAL SPECIFICATIONS 2 15 TIGHTENING TORQUES 2 18 GENERAL TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE 2 23 CHASSIS 2 24 COOLING SYSTEM DIAGRAMS 2 25 ENGINE OIL LUBRICATION CHART 2 29 LUBRICATION DIAGRAMS 2 30 CABLE ROUTING 2 35 ...

Page 22: ...SPEC ...

Page 23: ...F 5LV3 D 5LV4 AUS Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 125 mm 765 mm 1 190 mm 820 mm 1 450 mm 140 mm 2 900 mm Weight Wet with oil and a full fuel tank Dry without oil and fuel Maximum load total of cargo rider passenger and accessories 231 kg 208 kg 189 kg ...

Page 24: ...nder 74 58 mm 11 4 1 1 050 1 150 r min 30 kPa 225 mm Hg 1 450 kPa 14 5 kg cm2 at 400 r min Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Regular unleaded gasoline 21 L 4 0 L Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure hot Relief valve opening pressure ...

Page 25: ... 03 0 08 mm Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max impeller shaft tilt 2 4 L 95 125 kPa 0 95 1 25 kg cm2 340 mm 238 mm 24 mm 0 3 L Single suction centrifugal pump 68 43 28 28 1 581 0 15 mm Starting system type Electric starter Spark plugs Model manufacturer quantity Sp...

Page 26: ...rance Intake camshaft lobe dimensions Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions Measurement A Measurement B Measurement C Max camshaft runout Chain drive right 24 500 24 521 mm 24 459 24 472 mm 0 028 0 062 mm 32 5 32 6 mm 24 95 25 05 mm 7 45 7 65 mm 32 95 33 05 mm 24 95 25 05 mm 7 75 7 95 mm 32 4 mm 24 85 mm 32 85 mm 24 85 mm 0 03 mm ...

Page 27: ...idth B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 22 9 23 1 mm 24 4 24 6 mm 1 76 2 90 mm 1 76 2 90 mm 0 9 1 1 mm 0 9 1 1 mm 0 5 0 9 mm 0 5 0 9 mm 3 975 3 990 mm 4 465 4 480 mm...

Page 28: ...haust Winding direction top view Intake Exhaust 38 9 mm 40 67 mm 34 5 mm 35 mm 82 96 N 8 36 9 79 kg 110 126 N 11 22 12 85 kg SSS SSS Clockwise Clockwise SSS SSS SSS SSS SSS SSS 2 5_ 1 7 mm 2 5_ 1 8 mm SSS SSS Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max taper Max out of round Forward inclined parallel 4 cylinder 74 58 mm 11 4 1 74 00 74 01 mm SSS SSS SSS SSS SSS SSS 0 05 m...

Page 29: ... Piston rings Top ring Ring type Dimensions B T End gap installed Ring side clearance 2nd ring Ring type Dimensions B T End gap installed Ring side clearance Oil ring Dimensions B T End gap installed 0 030 0 055 mm 73 955 73 970 mm 5 mm 17 002 17 013 mm Intake side 16 991 17 000 mm 0 002 0 022 mm Barrel 0 90 2 75 mm 0 32 0 44 mm 0 030 0 065 mm Taper 0 8 2 8 0 43 0 58 mm 0 020 0 055 mm 1 5 2 6 mm 0...

Page 30: ...0 160 0 262 mm 0 029 0 053 mm 1 Pink violet 0 Pink white 1 Pink blue 2 Pink black 3 Pink brown 0 03 mm Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play at the end of the clutch lever Friction plates Thickness Plate quantity Thickness Plate quantity Clutch plates Thickness Plate quantity Max warpage Clutch springs Free length Spring quantity ...

Page 31: ...main axle runout Max drive axle runout Constant mesh 6 speed Spur gear 68 43 1 581 Chain drive 44 16 2 750 Left foot operation 35 14 2 500 35 19 1 842 30 20 1 500 28 21 1 333 30 25 1 200 29 26 1 115 0 08 mm 0 08 mm Shifting mechanism Shift mechanism type Max shift fork guide bar bending Installed shift rod length Guide bar 260 mm 0 1 mm Air filter type Dry element Fuel pump Pump type Model manufac...

Page 32: ...NI 4 3 5 mm 5LV1 00 Carburetors 1 and 4 132 5 Carburetors 2 and 3 130 80 Carburetor 1 and 4 5D129 3 5 Carburetor 2 and 3 5D130 3 5 P OM 85 Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat size Starter jet 1 Starter jet 2 Throttle valve size Fuel level above the line on the float chamber 1 0 15 0 9 0 9 0 9 2 0 1 5 42 5 0 8 115 3 0 4 0 mm Max EXUP cable free play at...

Page 33: ...SS SSS SSS 1 mm 0 5 mm Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17 MT5 50 Aluminum 135 mm SSS SSS SSS SSS SSS SSS 1 mm 0 5 mm Front tire Tire type Size Model manufacturer Tire pressure cold 0 90 kg 90 201 kg High speed riding Min tire tread depth Tubeless 120 70 ZR17 58W MEZ4Y FRONT METZELER BT020F U BRIDGESTONE 2...

Page 34: ...hickness Max deflection Brake pad lining thickness Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 298 5 mm 5 5 mm 14 mm 30 2 mm and 27 mm 4 5 mm 0 1 mm 0 5 mm Rear brake Brake type Operation Brake pedal position from the top of the brake pedal to the top of the rider footrest Recommended fluid Brake discs Diameter thickness Min thickness...

Page 35: ...op of the inner tube with the inner tube fully compressed and without the fork spring Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Telescopic fork Coil spring oil damper 140 mm 344 0 mm 78 5 mm 320 0 mm 8 1 N mm 0 83 kg mm 11...

Page 36: ...ad adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Swingarm link suspension Coil spring gas oil damper 65 mm 182 5 mm 163 mm 73 6 N mm 7 5 kgf mm 0 65 mm No 1 200 kPa 12 kgf cm2 1 6 11 20 10 3 1 7 12 Swingarm Free play at the end of the swinga...

Page 37: ... SSS Spark plug caps Material Resistance Rubber 10 kΩ SSS SSS Throttle position sensor standard resistance 4 6 kΩ SSS Charging system System type Model manufacturer Normal output Stator coil resistance color AC magneto F4T361 MITSUBISHI 14 V 365 W at 5 000 r min 0 27 0 33 Ω at 20_C W W SSS SSS SSS SSS Rectifier regulator Regulator type Model manufacture Semiconductor short circuit SH650C 11 SHINDE...

Page 38: ... 0 7 mm SSS SSS SSS 4 mm SSS SSS 27 mm SSS Starter relay Model manufacturer Amperage Coil resistance MS5F 631 JIDECO 180 A 4 18 4 62 Ω SSS SSS SSS Horn Horn type Model manufacturer quantity Max amperage Plain YF 12 NIKKO 1 3 A SSS SSS SSS Turn signal relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage Full transistor FE246BH DENSO No 75 95 cyc...

Page 39: ...tandard Limit Fuses amperage quantity Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Turn signal relay fuse Backup fuse odometer Reserve fuse 30 A 1 20 A 1 20 A 1 20 A 1 10 A 1 10 A 1 10 A 1 30 A 1 20 A 1 10 A 1 ...

Page 40: ...n dard fasteners with a standard ISO thread pitch Tightening torque specifications for special components or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fastener assemblies in a criss cross pattern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifi cations require clean dry threads ...

Page 41: ... and muffler Emission check bolt EXUP pulley cover EXUP cable bracket EXUP pulley and shaft arm Exhaust joint Exhaust pipe assembly Air induction system pipe Crankcase cylinder head Nut Cap nut Bolt Bolt Bolt Stud bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Screw Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Band Stud bolt M10 M10 M10 M6 M6 M6 M8 M8 M10 M10 M...

Page 42: ...oil Ignitor unit Neutral switch Pick up coil Thermo unit Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Nut Screw Bolt Screw Nut Nut Bolt Bolt Screw Screw Bolt M6 M6 M6 M6 M6 M6 M6 M8 M6 M6 M20 M6 M22 M6 M6 M8 M6 M6 M6 M6 M6 M5 M10 M6 9 4 2 8 8 5 5 1 1 3 1 6 1 3 2 1 1 2 1 1 3 2 1 2 1 12 10 10 12 12 12 10 15 10 12 90 8 85 12 10 22 6 5 6 5 10 10 14 7 20 10 15 1 2 1 0 1 0 1 2 1 2 1 2 1 0 ...

Page 43: ...2 21 TIGHTENING TORQUES SPEC Crankcase tightening sequence ...

Page 44: ...t brake bleed screw Rear brake torque rod Rear wheel sprocket Drive chain adjusting nut Rear brake caliper Rear wheel axle Rear brake hose union bolt Rear brake bleed screw Rear brake disk Rider footrest bracket and frame Rear brake reservoir tank Rear brake master cylinder Rider footrest and bracket Passenger footrest bracket and frame Passenger footrest bracket and muffler M8 M22 M10 M8 M25 M6 M...

Page 45: ... intake and exhaust Water pump impeller shaft Oil pump rotors inner and outer Oil strainer Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Yamaha bond No 1215 Crankcase mating surface Yamaha ...

Page 46: ...il seal lips Swing arm oil seal lips Relay arm bearings Relay arm oil seal lips Rear shock absorber upper bolt Front wheel oil seal lips Rear wheel oil seal lips Clutch hub oil seal lips Throttle cable end Starter cable end and starter lever Rear brake pedal moving point Shift pedal moving point Side stand moving point Passenger footrest ball joint and moving point Engine mounting bracket collar a...

Page 47: ...2 25 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Water pump EAS00033 COOLING SYSTEM DIAGRAMS ...

Page 48: ...2 26 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Oil cooler 5 Water jacket joint ...

Page 49: ...2 27 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator cap 2 Thermostat 3 Thermo unit ...

Page 50: ...2 28 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator ...

Page 51: ...2 29 Oil cooler Exhaust camshaft Intake camshaft Main gallery Oil filter Main axle Drive axle Strainer Relief valve ENGINE OIL LUBRICATION CHART SPEC ENGINE OIL LUBRICATION CHART ...

Page 52: ...2 30 1 Oil cooler 2 Oil filter cartridge 3 Drain bolt 4 Oil level switch 5 Oil strainer 6 Oil pump LUBRICATION DIAGRAMS SPEC EAS00034 LUBRICATION DIAGRAMS ...

Page 53: ...2 31 LUBRICATION DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camshaft 3 Oil cooler 4 Oil strainer 5 Oil pump ...

Page 54: ...2 32 LUBRICATION DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camsahft 3 Oil filter cartridge 4 Oil level switch ...

Page 55: ...2 33 LUBRICATION DIAGRAMS SPEC 1 Cylinder head 2 Crankshaft ...

Page 56: ...2 34 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Oil delivery pipe 3 Drive axle ...

Page 57: ... handlebar switch lead right and han dlebar with a plastic band B Route the handlebar switch lead right backward the throttle cable and right side the brake hose guide C Fasten the handlebar switch lead left and handle bar with a plastic band D Fasten the handlebar switch lead left main switch lead clutch cable and starter cable with a plastic band Clamp beneath the horn lead branching posi tion D...

Page 58: ...sten the fuel pump lead pickup coil lead neutral switch lead speed sensor lead rear brake light switch lead and fuel pump with a plastic clamp B Fasten the fuel hose pickup coil lead neutral switch lead and speed sensor lead with a plastic clamp under the fuel hose C Put the EXUP cable into the air box cover D Route the T P S lead inward the EXUP cable E Fasten the water carburetor hose with a pla...

Page 59: ...ank breath er hose forward the neutral switch lead and speed sensor lead I Route the water carburetor hose between the frame cross pipe and fan motor lead J To the carburetor K Fasten the T P S lead with a steel clamp L Fasten the coolant hose with a plastic band M Fasten the pickup coil lead with a steel clamp N Pass the coolant reservoir tank overflow hose fuel tank drain hose and fuel tank brea...

Page 60: ...n the wire harness sidestand switch lead oil level switch and flame with a plastic band Do not fasten the Acgenerator lead white K Route the starter motor lead and battery negative lead inside the plastic band L Route the all hoses outside the fuel hose M Route the fuel hose through the steel guide CABLE ROUTING SPEC 1 Starter cable 2 Clutch cable 3 Handlebar switch lead left 4 Main switch lead 5 ...

Page 61: ... wire harness in the groove N Fasten the sidestand switch lead oil level switch lead ACgenerator lead starter motor lead battery negative lead and air cleaner case drain hose with a plastic clamp O Fasten the sidestand switch lead oil level switch lead ACgenerator lead and air filter case drain hose with a plastic clamp P Fasten the sidestand switch lead and frame with a plastic clamp Q Route the ...

Page 62: ...d 28 Fan motor lead 29 Battery negative lead 30 Starting circuit cutoff relay CABLE ROUTING SPEC 1 Clutch cable 2 Handlebar switch lead 3 Main switch lead 4 Starter cable 5 Thermo unit lead 6 Throttle cable 1 7 Throttle cable 2 8 Handlebar switch lead right 9 Coolant reservoir hose 10 Ignition coil 11 Fuel hose 12 Fan motor lead 13 EXUP servo motor lead 14 Rectifier regulator lead 15 White paint m...

Page 63: ...r cover S Fasten the Rectifier regulator lead with a plastic band in the main harness A Fasten the flasher light lead and headlight lead with a plastic clamp B Route the rectifier regulator lead upper the fan mo tor lead and EXUP servomotor lead C Route the throttle cable right side the fan motor lead EXUP servo motor lead and thermo unit lead D Fasten the flasher light lead with a plastic clamp E...

Page 64: ...handlebar switch lead left right main switch lead EXUP servo motor lead fan motor lead and thermo unit lead with a plastic clamp V Fasten the rectifier regulator stay and rectifier reg ulator lead with a plastic clamp W Route the wire harness under the rectifier regula tor X Fasten the battery negative lead with a battery band Y Insert the ground lead coupler in the battery band Z Fasten the taill...

Page 65: ......

Page 66: ...NG THE CARBURETOR JOINTS AND INTAKE MANIFOLDS 3 24 CHECKING THE FUEL HOSES AND FUEL FILTER 3 24 CHECKING THE CRANKCASE BREATHER HOSE 3 25 CHECKING THE EXHAUST SYSTEM 3 25 ADJUSTING THE EXUP CABLES 3 26 CHECKING THE COOLANT LEVEL 3 27 CHECKING THE COOLING SYSTEM 3 29 CHANGING THE COOLANT 3 30 CHASSIS 3 33 ADJUSTING THE FRONT BRAKE 3 33 ADJUSTING THE REAR BRAKE 3 34 CHECKING THE BRAKE FLUID LEVEL 3 ...

Page 67: ...AND PEDALS 3 50 LUBRICATING THE SIDESTAND 3 50 LUBRICATING THE REAR SUSPENSION 3 50 ELECTRICAL SYSTEMS 3 51 CHECKING AND CHARGING THE BATTERY 3 51 CHECKING THE FUSES 3 56 REPLACING THE HEADLIGHT BULBS 3 58 ADJUSTING THE HEADLIGHT BEAMS 3 59 ADJUSTING THE DIGITAL CLOCK 3 59 ...

Page 68: ...nd regap 3 See page 3 15 Replace 4 Valves See page 3 5 Check valve clearance Adjust Every 40 000 km 5 Air filter element Clean 5 Air filter element See page 3 23 Replace 6 Clutch See page 3 22 Check operation Adjust 7 Front brake See page 3 35 Check operation fluid level and vehicle for fluid leakage See NOTE 7 See page 3 35 See page 3 36 Replace brake pads Whenever worn to the limit 8 Rear brake ...

Page 69: ... oil See page 3 20 Change 24 Engine oil filter cartridge See page 3 20 Replace 25 Cooling system See page 3 29 Check coolant level and vehicle for coolant leakage 25 See page 3 29 See page 3 30 Change Every 3 years 26 Front and rear brake switches See page 3 36 See page 8 38 Chck operation 27 Moving parts and cables See page 2 24 See page 3 50 Lubricate 28 Air induction system See page 7 16 Check ...

Page 70: ...n cowling Inner panel Headlight meter coupler Front cowling assembly Back view mirror Meter unit Headlight unit 2 1 1 1 2 1 1 Remove the4 parts in the order listed Disconnect For installation reverse the removal procedure EAS00038 FRONT COWLING SEAT SIDE COVER FUEL TANK FRONT COWLING ...

Page 71: ...der coupler Fuel tank Fuel tank breather hose Fuel tank drain hose Fuel hose Grab bar Rear cowling 1 2 1 1 1 1 1 1 1 Remove the parts in the order listed Disconnect Befor disconnecting the fuel hose turn the fuel cock off For installation reverse the removal procedure NOTE 10 Nm 1 0 m kg 19 Nm 1 9 m kg 4 Nm 0 4 m kg 10 Nm 1 0 m kg EAS00040 SEAT SIDE COVER AND FUEL TANK ...

Page 72: ...ter 5 2 Measure valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 11 X 0 20 mm Exhaust valve 0 21 X 0 25 mm a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the TDC mark a on the pickup rotor with the crankcase mating sur face b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other ...

Page 73: ...D Combustion cycle 2 Cylinder 180_ 4 Cylinder 360_ 3 Cylilnder 540_ 3 Remove Sintake camshaft Sexhaust camshaft SRefer to DISASSEMBLING THE ENGINE CAMSHAFT AND CYLINDER HEAD in chap ter 5 SWhen removing the timing chain and cam shafts fasten a wire to the timing chain to re trieve it if it falls into the crankcase 4 Adjust Svalve clearance a Remove the valve lifter 1 and the valve pad 2 with a val...

Page 74: ...es the valve lifter Since valve pads of various sizes are originally installed the valve pad number must be rounded in order to reach the closest equiva lent to the original c Round off the original valve pad number ac cording to the following table Last digit Rounded value 0 or 2 0 5 5 8 10 EXAMPLE Original valve pad number 148 thickness 1 48 mm 0 058 in Rounded value 150 d Locate the rounded num...

Page 75: ... 37 240 Measured clearance exa EXAMPLE VALVE CLEARANCE 0 21 X 0 30 mm Installed is 175 Measured clearance is 0 35 mm Replace 175 pad with 185 pad INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 X 0 02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 03 X 0 07 120 125 130 135 140 145 150 1...

Page 76: ...SEMBLING AND ADJUSTING THE ENGINE CYLINDER HEAD AND CAM SHAFT in chapter 4 Lubricate the camshaft bearings camshaft lobes and camshaft journals First install the exhaust camshaft Align the camshaft marks with the camshaft cap marks Rotate the crankshaft clockwise several turns to seat the parts g Measure the valve clearance again h If the valve clearance is still out of specifica tion repeat all o...

Page 77: ...be checked 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand 2 Remove vacuum cap 3 Install vacuum gauge 1 engine tachometer 2 to the spark plug lead of cyl 1 Vacuum gauge 90890 03094 Engine tachometer 90890 03113 4 Start the engine and let it warm up for several minutes 5 Check engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPE...

Page 78: ...2 in ei ther direction until both gauges read the same c Synchronize carburetor 2 to carburetor 3 by turning the synchronizing screw 3 in ei ther direction until both gauges read the same Vacuum pressure at engine idling speed 30 kPa 225 mm Hg The difference in vacuum pressure between two carburetors should not exceed 1 33 kPa 10 mm Hg 7 Measure engine idling speed Out of specification Adjust 8 St...

Page 79: ...mpression 1 Start the engine and let it warm up for several minutes 2 Install engine tachometer to the spark plug lead of cyl 1 Engine tachometer 90890 03113 3 Measure engine idling speed Out of specification Adjust Engine idling speed 1 050 X 1 150 r min 4 Adjust engine idling speed a Turn the pilot screw 1 in or out until it is light ly seated b Turn the pilot screw out the specified number of t...

Page 80: ... 5 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 3 X 5 mm EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting the throttle cable free play the engine idling speed and carburetor synchro nization should be adjusted properly 1 Check throttle cable free play a Out of specification Adjust Throt...

Page 81: ...ained Direction Throttle cable free play is increased Direction Throttle cable free play is decreased e Tighten the locknuts If the specified throttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 1 b Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is o...

Page 82: ...accumulated in the spark plug wells with compressed air to prevent it from fal ling into the cylinders 3 Check spark plug type Incorrect Change Spark plug type manufacturer CR9E NGK U27ESR N DENSO 4 Check electrode 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is a medium to light tan color 5 Clean spark plug with a spark plug cleaner or wire b...

Page 83: ...the ignition timing check the wiring connections of the entire ignition system Make sure that all connections are tight and free of corrosion 1 Remove timing plug 1 2 Install timing light 1 engine tachometer 2 to the spark plug lead of cyl 1 Timing light 90890 03141 Engine tachometer 90890 03113 3 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the s...

Page 84: ...wing procedure applies to all of the cyl inders Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Disconnect spark plug cap 4 Remove spark plug Before removing the spark plugs use com pressed air to blow away an...

Page 85: ...il Piston ring s wear or damage Repair Same as without oil Piston valves cylinder head gasket or piston possibly defective Repair Compression pressure at sea level Compression pressure at sea level Standard 1 450 kPa 14 5 kg cm2 Minimum 1 260 kPa 12 6 kg cm2 Maximum 1 620 kPa 16 2 kg cm2 a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on the compressio...

Page 86: ...d engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temper atures API standard SE or higher grade ACEA standard G4 or G5 Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives or use engine oils with a grade of CD a or higher and do not use oils labeled ENER...

Page 87: ...il drain bolt 2 along with the gasket 4 Drain engine oil completely from the crankcase 5 If the oil filter cartridge is also to be replaced perform the following procedure a Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil filter wrench 90890 01426 b Apply a thin coat of engine oil onto the O ring 1 of the new oil filter cartridge Make sure that the O ring 1 is positioned correctl...

Page 88: ...e engine warm it up for several min utes and then turn it off 11 Check engine for engine oil leaks 12 Check engine oil level Refer to CHECKING THE ENGINE OIL LEVEL 13 Check engine oil pressure a Slightly loosen the oil gallery bolt 1 b Start the engine and keep it idling until en gine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so th...

Page 89: ...olt 2 in direction a or b until the specified clutch cable free play is ob tained Direction Clutch cable free play is increased Direction Clutch cable free play is decreased c Tighten the locknut If the specified clutch cable free play cannot be obtained on the handlebar side of the cable use the adjusting nut on the engine side Engine side a Loosen the locknuts 1 b Turn the adjusting bolt 2 in di...

Page 90: ...to the outer surface of the air filter element 4 Check air filter element Damage Replace 5 Install air filter element air filter case cover Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor en gine...

Page 91: ...NG THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the car buretor joints and intake manifolds 1 Remove seat fuel tank air filter case panel 1 2 Check carburetor joint 1 intake manifold 2 Cracks damage Replace Refer to CARBURETOR in chapter 6 3 Install air chamber cover fuel tank seat EAS00097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure appl...

Page 92: ...e seat fuel tank 2 Check crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly Make sure that the crankcase breather hose is routed correctly 3 Install fuel tank seat EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 2 Che...

Page 93: ...P servomotor connector 1 b Connect the battery to the EXUP servomotor connector and check if the servomotor oper ates properly Battery positive lead black yellow 2 Battery negative lead black red 3 To avoid damaging the servomotor do not leave the battery connected to it for more than a few seconds c Check that the EXUP valve operates properly d Connect the EXUP servomotor connector ...

Page 94: ...lock wise until there is no EXUP cable free play d Turn both adjusting bolts 1 2 of a turn clock wise e Tighten both locknuts and then remove the pin 6 Install EXUP valve pulley cover 7 Install fuel tank seat EAS00102 CHECKING THE COOLANT LEVEL 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Check coolant level The coola...

Page 95: ...r is used instead of coolant check and correct the antifreeze concentration of the coolant Use only distilled water Soft water may be used if distilled water is not available 3 Start the engine warm it up for several min utes and then turn it off 4 Check coolant level Before checking the coolant level wait a few minutes until it settles ...

Page 96: ...CHECKING THE COOLING SYSTEM 1 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 water jacket inlet joint 6 water pump outlet joint 7 Cracks damage Replace Refer to COOLING SYSTEM in chapter 5 ...

Page 97: ... steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap coun terclockwise toward the detent to allow any residual pressure to escape When the his sing sound has stopped press down on the radiator cap while still pressing down turn it counterclockwise and...

Page 98: ...rosion inhibi tors for aluminum engines Mix ratio 50 antifreeze 50 water Quantity Total amount 2 4 L Coolant reservoir capacity 0 3 L From minimum to maximum level mark 0 2 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your clothes qui...

Page 99: ... contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 11 Install radiator cap 12 Fill coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install coolant reservoir cap 14 Start the engine warm it up for several min utes and then turn it off 15 Check coolant level Refer to CHECKING THE COOLANT LEV EL Before checking the ...

Page 100: ...arg est Position 4 Distance is the small est After adjusting the brake lever position make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will co...

Page 101: ...al is raised Direction Brake pedal is lowered After adjusting the brake pedal position check that the end of the adjusting bolt 2 is visible through the hole c c Tighten the locknut 1 to specification Locknut 18 Nm 1 8 m kg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake sy...

Page 102: ...ke 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 perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cant...

Page 103: ...e B Rear brake EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by move ment of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body 1 of the rear brake light ...

Page 104: ... the hydraulic brake system whenev er the system was disassembled a brake hose was loosened or removed the brake fluid level is very low brake operation is faulty 1 Remove reservoir cap 1 diaphragm 2 Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure that there is always enough...

Page 105: ... release the tension and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to specification Bleed screw 6 Nm 0 6 m kg k Fill the reservoir to the proper le...

Page 106: ...ightest point on the chain 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 swin garm or cause an accident Therefore keep the drive chain slack within the specified limits 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over Place the motorcycle on a su...

Page 107: ... 2 d Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is ob tained Direction Drive chain is tightened Direction Drive chain is loosened To maintain the proper wheel alignment adjust both sides evenly e Tighten both locknuts to specification Locknut 16 Nm 1 6 m kg f Tighten the wheel axle nut to specification Wheel axle nut 150 Nm 15 m kg ...

Page 108: ...th engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings Recommended lubricant Engine oil or chain lubricant suitable forO ring chains EAS00146 CHECKING AND ADJUSTING THE STEER ING HEAD 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is...

Page 109: ...orque 18 Nm 1 8 m kg d Check the steering head for looseness or binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and inspect the upper and lower bearings Refer to STEERING HEAD AND HAN DLEBAR in chapter 4 e Install the rubber washer 7 f Install the upper ring nut 8 g Finger tighten the upper ring nut 8 then align the slots of both rin...

Page 110: ...e Replace 3 Hold the motorcycle upright and apply the front brake 4 Check operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Repair Refer to FRONT FORK in chapter 4 EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs Always adjust both front fork legs evenly Uneven adjustment can...

Page 111: ...ositions Standard 2 Minimum 5 Maximum 1 fully turned out position Rebound damping Never go beyond the maximum or minimum adjustment positions 1 Adjust rebound damping a Turn the adjusting screw 1 in direction a or b Rebound damping is Direction p g increased suspension is harder Rebound damping is Direction p g decreased suspension is softer Adjusting positions Standard 7 clicks out Minimum 17 cli...

Page 112: ...n is harder Direction Compression damping is decreased suspension is softer Adjusting positions Standard 6 clicks out Minimum 21 clicks out Maximum 1 clicks out from the fully turned in position EAS00158 ADJUSTING THE REAR SHOCK ABSORB ER ASSEMBLY Securely support the motorcycle so that there is no danger of it falling over Spring preload Never go beyond the maximum or minimum adjustment positions...

Page 113: ...tion creased suspension is softer Adjusting positions Standard 6 Minimum 1 Maximum 11 Rebound damping Never go beyond the maximum or minimum adjustment positions 1 Adjust rebound damping a Turn the adjusting knob 1 in direction a or b Direction Rebound damping is increased s spension is Direction increased suspension is harder Direction Rebound damping is decreased s spension is Direction decrease...

Page 114: ...cks in Minimum 1 clicks in Maximum 12 clicks in from the fully turned out position EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires 1 Measure tire pressure Out of specification Regulate The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature The tire pressure and the suspension must be adjusted according to...

Page 115: ...e immediately 2 Check tire surfaces Damage wear Replace the tire Minimum tire tread depth 1 6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator Do not use a tubeless tire on a wheel de signed only for tube tires to avoid tire fail ure and personal injury from sudden defla tion When using a tube tire be sure to install the correct tube Always replace a new tube tire and a new tube as a set To avoi...

Page 116: ... Yamaha is used on this motorcycle Front tire Manufacturer Type Size BRIDGESTONE Tubeless 120 70 ZR17 58 W METZELER Tubeless 120 70 ZR17 58 W Rear tire Manufacturer Type Size BRIDGESTONE Tubeless 180 55 ZR17 73 W METZELER Tubeless 180 55 ZR17 73 W New tires have a relatively low grip on the road surface until they have been slightly worn Therefore approximately 100 km should be traveled at normal ...

Page 117: ... Lubricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant lithium soap base grease EAS00172 LUBRICATING THE SIDESTAND...

Page 118: ...electrolyte 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 medical attention Internal Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical atten tion This is a sealed battery Never remove the sealing caps...

Page 119: ... Remove Sseat 2 Disconnect Sbattery leads from the battery terminals First disconnect the negative lead 1 then the positive lead 2 3 Remove Sbattery 4 Check Sbattery charge a Connect a pocket tester to the battery termi nals Tester positive lead battery positive Tester positive lead terminal Tester negative lead battery negative Tester negative lead terminal SThe charge state of a MF battery can b...

Page 120: ...done with the battery mounted on the motorcycle disconnect the negative lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger SMake sure that the battery charger lead clips are in ...

Page 121: ...tion checking steps If the current does not exceed the standard charging current after 5 minutes replace the battery If charging requires more than 5 hours it is advisable to check the charging current after a lapse of 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging current Measure the battery open circuit voltage after leaving the battery unused...

Page 122: ...arge the battery until the battery s charging voltage is 15 V Charge the battery until the battery s charging voltage is 15 V This type of battery charger cannot charge the MF battery A variable voltage charger is recommended Measure the battery open circuit voltage after leaving the battery unused for more than 30 minutes 12 8 V or more Charging is complete 12 7 V or less Recharging is required U...

Page 123: ...ck battery terminals Dirt Clean with a wire brush Loose connection Connect properly 10 Lubricate battery terminals Recommended lubricant Dielectric grease 11 Install seat EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short circuit always turn the main switch to OFF when checking or replacing a fuse 1 Remove seat 2 Check fuse a Connect the pocket tester ...

Page 124: ...l circuit Fuses Amperage rating Quantity Main fuse 30A 1 Headlight fuse 20A 1 Signaling system fuse 20A 1 Ignition fuse 20A 1 Turn signal relay fuse 10 A 1 Digital clock fuse 10A 1 Radiator fan fuse 10A 1 Reserve fuse 30A 1 Reserve fuse 20 A 1 Reserve fuse 10 A 1 Never use a fuse with an amperage rating other than that specified Improvising or us ing a fuse with the wrong amperage rating may cause...

Page 125: ...cts and your hands away from the bulb until it has cooled down 4 Install headlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with...

Page 126: ...b Left headlight Direction Headlight beam moves to the right Direction Headlight beam moves to the left Right headlight Direction Headlight beam moves to the left Direction Headlight beam moves to the right EAS00187 ADJUSTING THE DIGITAL CLOCK This digital clock constantly displays the time 1 Adjust digital clock 1 a Hold down the RESET button 2 and SE LECT button 3 b Push the RESET button 2 to se...

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Page 129: ... WHEEL STATIC BALANCE 4 15 FRONT AND REAR BRAKES 4 16 FRONT BRAKE PADS 4 16 REPLACING THE FRONT BRAKE PADS 4 18 REPLACING THE REAR BRAKE PADS 4 20 FRONT BRAKE MASTER CYLINDER 4 23 REAR BRAKE MASTER CYLINDER 4 25 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 27 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 27 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 28 ASSEMBLING AND INSTALLING THE F...

Page 130: ...CKING THE STEERING HEAD 4 59 INSTALLING THE STEERING HEAD 4 60 REAR SHOCK ABSORBER ASSEMBLY 4 61 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4 62 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4 62 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 63 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 64 SWINGARM AND DRIVE CHAIN 4 65 REMOVING THE SWING...

Page 131: ...pinch bolt Front wheel axle Front wheel Collar left and right Oil seal cover left and right brake disc left and right 2 2 1 1 1 2 2 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loosen For installation reverse the removal procedure NOTE 72 Nm 7 2 m kg 40 Nm 4 0 m kg 18 Nm 1 8 m kg EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS ...

Page 132: ...Order Job Part Q ty Remarks Disassembling the front wheel Oil seal left and right Wheel bearing left and right Spacer 2 2 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 EAS00518 FRONT WHEEL ...

Page 133: ...rake caliper right brake caliper Do not squeeze the brake lever when removing the brake calipers 3 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00523 DISASSEMBLING THE FRONT WHEEL 1 Remove oil seals wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel plac...

Page 134: ...ure front wheel radial runout 1 front wheel lateral runout 2 Over the specified limits Replace Front wheel radial runout limit 1 mm Front wheel lateral runout limit 0 5 mm 4 Check wheel bearings Front wheel turns roughly or is loose Re place the wheel bearings oil seals Damage wear Replace 5 Replace wheel bearings New oil seals New a Clean the outside of the front wheel hub b Remove the oil seals ...

Page 135: ...e following procedure applies to all of the brake discs 1 Check brake disc Damage galling Replace 2 Measure brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Brake disc deflection limit maximum 0 1 mm a Place the motorcycle on a suitable stand so that the wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to...

Page 136: ...bolt 18 Nm 1 8 mSkg LOCTITER d Measure the brake disc deflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc EAS00539 ASSEMBLING THE FRONT WHEEL 1 Install Swheel bearings Soil seals New a Install the new wheel bearings and oil seals in the r...

Page 137: ...l axle pinch bolt 2 Before tightening the wheel axle nut push down hard on the handlebar several times and check if the front fork rebounds smoothly 3 Install brake caliper Make sure that the brake hose is routed properly EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE After replacing the tire wheel or both the front wheel static balance should be adjusted Adjust the front wheel static balance w...

Page 138: ...The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Sfront wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X Start with the lightest weight b Turn the front wheel 90_ so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c unti...

Page 139: ...ake torque rod Nut Washer Wheel axle Rear wheel assembly 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated Loosen For installation reverse the removal procedure NOTE 150 Nm 15 m kg 40 Nm 4 0 m kg EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL ...

Page 140: ...ks Disassembling the rear wheel Spacer Bearing Spacer Oil seal Circlip Bearing 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 REAR WHEEL AND BRAKE DISC CHAS EAS00560 ...

Page 141: ...g the brake disc and rear wheel sprocket Brake disc Rear wheel sprocket Collar left and right Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper 1 1 2 1 1 1 6 Remove the parts in the order listed For installation reverse the removal procedure 18 Nm 1 8 m kg 69 Nm 6 9 m kg ...

Page 142: ...ace the motorcycle on a suitable stand so that the rear wheel is elevated 2 Remove brake caliper 1 Do not depress the brake pedal when removing the brake caliper 3 Loosen locknut 1 adjusting nut 2 4 Remove wheel axle nut 3 wheel axle rear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 5 Remove left collar 1 rear wheel drive hub 2 rear wheel drive hub damp...

Page 143: ... HUB 1 Check rear wheel drive hub 1 Cracks damage Replace rear wheel drive hub dampers 2 Damage wear Replace EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check rear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprocket b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace rear wheel sprocket a Remove the self lock...

Page 144: ...lection limit maximum 0 1 mm a Place the motorcycle on a suitable stand so that the wheel is elevated b Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 2 3 mm below the edge of the brake disc...

Page 145: ...ake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc EAS00572 INSTALLING THE REAR WHEEL 1 Lubricate Swheel axle Swheel bearings Soil seal lips Recommended lubricant Lithium soap base grease 2 Tighten Swheel axle nut Sbrake caliper bolts EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE SAfter replacing the tire whee...

Page 146: ...ing the front brake pads Brake pad clip Brake pad pin Brake pad spring brake pad Brake pad shim Bleed scrw 2 1 1 2 2 1 Remove the parts in the order listed For installation reverse the removal procedure 40 Nm 4 0 m kg 6 Nm 0 6 m kg EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 147: ...emarks 1 2 3 4 5 6 Removing the rear brake pads Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw 4 2 1 2 2 2 Remove the parts in the order listed For installation reverse the removal procedure 40 Nm 4 0 m kg 6 Nm 0 6 m kg ...

Page 148: ...ents Use only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid for brake fluid entering the eyes Flush with water for 15 minutes and get im mediate medical attention EAS00582 REPLACING THE...

Page 149: ...e pad wear limit 0 5 mm 5 Install brake pad shims onto the brake pads brake pads brake pad spring Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten...

Page 150: ... the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble ...

Page 151: ...rake pad shims brake pad pins brake pad clips and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install a new brake pad shim 3 onto each new brake pa...

Page 152: ...ake caliper 6 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 153: ...h lead Brake switch Union bolt Brake hose copper washer Master cylinder bracket Master cylinder 1 2 1 1 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to REMOVING ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER section 10 Nm 1 0 m kg 30 Nm 3 0 m kg EAS00584 FRONT BRAKE MASTER CYLINDER ...

Page 154: ... Job Part Q ty Remarks Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 EAS00585 ...

Page 155: ... bolt Union bolt Brake hose copper washer Clip hose Cotter pin Pin Washer Master cylinder 2 1 1 2 2 1 1 1 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure Refer to REMOVING ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER section 30 Nm 3 0 m kg 4 Nm 0 4 m kg 23 Nm 2 3 m kg EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 156: ...r Job Part Q ty Remarks Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 EAS00587 ...

Page 157: ...oupler from the brake switch 2 Remove union bolt 1 copper washers 2 brake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00589 DISASSEMBLING THE REAR BRAKE MAS TER CYLINDER 1 Remove side cover right 2 Remove union bolt 1 copper washers 2 brake hose 3 To collect any remaining brake fluid place a container under the master cyl...

Page 158: ...ke master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit 1 Damage scratches wear Replace C Front D Rear 3 Check rear brake fluid reservoir 1 Cracks damage Replace rear brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check front brake master cylinder reservoir 1 Cracks damage Replace front brake master cylinder reservoir dia phragm ...

Page 159: ... Align the end of the brake master cylinder hold er with the punch mark a on the handlebar First tighten the upper bolt then the lower bolt 2 Install copper washers 1 New brake hose 2 union bolt 3 When installing the brake hose onto the brake master cylinder make sure that the brake pipe touches the projection a on the brake master cylinder Proper brake hose routing is essential to in sure safe mo...

Page 160: ...e perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level ...

Page 161: ...o the maximum level mark a Recommended brake fluid DOT 4 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 perfor mance When refilling be careful that wate...

Page 162: ...el mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 5 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 Brake pedal position below the top of the rider footrest 40 mm 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 ...

Page 163: ... Removing the front brake calipers Brake fluid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure 6 Nm 0 6 m kg 30 Nm 3 0 m kg 40 Nm 4 0 m kg EAS00613 FRONT BRAKE CALIPERS ...

Page 164: ...lip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 2 1 1 2 4 8 1 Disassemble the parts in the order listed The following procedure applies to both of the front brake calipers For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 6 Nm 0 6 m kg EAS00615 ...

Page 165: ...s 1 2 3 4 Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure 40 Nm 4 0 m kg 30 Nm 3 0 m kg EAS00616 REAR BRAKE CALIPER ...

Page 166: ...he rear brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 4 2 1 2 2 4 2 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 6 Nm 0 6 m kg EAS00617 ...

Page 167: ...f the brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Rem...

Page 168: ... and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper piston with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis ton from the brake caliper Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Remove the brake caliper piston seals ...

Page 169: ... whenever the brake is disas sembled 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper brake caliper cylinders 2 Scratches wear Replace the brake cali per brake calipers Cracks damage Replace brake fluid delivery passages brake caliper body Obstruction Blow out with compressed Air Whenever a brake caliper Is disassembled replace the brake caliper piston seals A Front B ...

Page 170: ...e the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper temporarily copper washers 1 New brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper make sure that...

Page 171: ...e perfor mance When refilling be careful that water does not enter the reservoir Water will signifi cantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level ...

Page 172: ... the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers New brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper make sure that the brake pipe a touches the projection b on the brake caliper 2 Remove brake caliper 3...

Page 173: ...e brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark a Add the recommended brake f...

Page 174: ... bolt Bolt lower bracket Front fork assembly left right 1 2 2 4 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Loosen Loosen Loosen For installation reverse the removal procedure Refer to REMOVING INSTALLING THE FRONT FORK LEGS section 23 Nm 2 3 m kg 25 Nm 2 5 m kg 30 Nm 3 0 m kg EAS00647 FRONT FORK ...

Page 175: ...djusting rod Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod Inner tube Oil seal Washer Slide metal Oil flow stopper 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 25 Nm 2 5 m kg 35 Nm 3 5 m kg 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 EAS00648 ...

Page 176: ...cycle on a suitable stand so that the front wheel is elevated 2 Loosen upper bracket pinch bolt 1 cap bolt 2 lower bracket pinch bolt 3 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove front fork leg EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt 1 from the damper adjusting rod ...

Page 177: ... inner tube 5 Remove damper rod bolt damper rod 1 While holding the damper rod with the damper rod holder 2 loosen the damper rod bolt Damper rod holder 90890 01447 6 Remove inner tube a Hold the front fork leg horizontally b Securely clamp the brake caliper bracket in a vise with soft jaws c Separate the inner tube from the outer tube by pulling the inner tube forcefully but care fully ...

Page 178: ...e Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length a Over the specified limit Replace Spring free length limit 347 0 mm 3 Check damper rod Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air oil flow stopper Damage Replace The front fork leg has a built in damper ad justing rod and a very sophisticated i...

Page 179: ...outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Install damper rod 1 Allow the damper rod to slide slowly down the inner tube 2 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube Install the oil flow stopper with a flat surface part a downward 2 Lubricate inner tube s outer surface...

Page 180: ...he oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation 5 Install oil seal clip Adjust the oil seal clip so that it fits into the outer tube s groove 6 Fill front fork leg with the specified amount of the recom mended fork oil Quantity each front fork leg 0 44 L 440 cm3 Recommended oil Yamaha suspension oil 01 or equivalent Be sure to use the ...

Page 181: ...p and down to distribute the fork oil once more 1 stroke about 150 mm Be careful not to stroke the inner tube over 150 mm as this will cause air to enter If the inner tube is stroke more than 150 mm repeat steps 10 and 11 10 Before checking the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed Be sure to bleed the front fork leg of any residual air 11 Mea...

Page 182: ...nto the damper rod c Pull up the rod puller and install the rod hold er 1 between the rod puller attachment 2 and the spacer Use the side of the rod holder that is marked B Piston rod holder 90890 01434 d Remove the rod puller and the rod puller at tachment e Install the damper adjusting rod locknut f Tighten the damper adjusting rod locknut Damper adjusting rod locknut 25 Nm 2 5 m kg g Install th...

Page 183: ...ll front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the handlebar holder 2 Tighten lower bracket pinch bolt 1 cap bolt 2 upper bracket pinch bolt 3 Make sure that the brake hoses are routed properly 3 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE FRONT FORK in chapter 3 ...

Page 184: ...tch Throotle cable Grip end right Throttle grip Grip end left Left grip Left handlebar switch Starter cable Clutch cable Clutch lever Handlebar holder Handlebar 1 1 1 1 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed For installation reverse the removal procedure 23 Nm 2 3 m kg 26 Nm 2 6 m kg 10 Nm 1 0 m kg 26 Nm 2 6 m kg EAS00664 HANDLEBAR ...

Page 185: ... 1 throttle grip 2 3 Remove handlebar grip 1 Blow compressed air between the handlebar and the handlebar grip and gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Check handlebar Bends cracks damage Replace Do not attempt to straighten a bent handle bar...

Page 186: ...Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Install handlebar 1 upper handlebar holders 2 First tighten the bolts on the front side of the handlebar holder then on the rear side Turn the handlebar all the way to the left and right If there is any contact with the fuel tank adjust the handlebar position Align the match mark...

Page 187: ... lever holder Align the slit in the clutch lever holder with the punch mark a in the left handlebar 7 Install brake master cylinder Refer to ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYL INDER 8 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm ...

Page 188: ...racket cap nut Upper bracket Lock washer Upper ring nut Rubber washer Lower ring nut Dust cover Steering bearing upper Lower bracket Steering bearing lower 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL Refer to FRONT FORK Refer to HANDLEBAR For installation reverse the removal procedure 1st 2nd 52 Nm 5 2 m kg 18 Nm 1 8 m kg 110 Nm 11 0 m kg EAS00676 STEERING...

Page 189: ... nut 1 with the special tool 2 Ring nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosine 2 Check bearings 1 bearing races 2 Damage pitting Replace 3 Replace bearings bearing races a Remove the bearing races 1 from the steer ing head pipe with a long ...

Page 190: ...place the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install lower ring nut 1 rubber washer 2 upper ring nut 3 lock washer 4 Refer to INSPECTING THE STEERING HEAD in chapter 3 3 Install upper brack...

Page 191: ...sembly Rear wheel Side cover left right Connecting arm Relay arm Rear shock absorber 1 1 1 1 1 Remove the parts in the order listed Refer to REAR WHEEL For installation reverse the removal procedure 40 Nm 4 0 m kg 40 Nm 4 0 m kg 48 Nm 4 8 m kg 48 Nm 4 8 m kg 40 Nm 4 0 m kg EAS00685 REAR SHOCK ABSORBER ASSEMBLY ...

Page 192: ... rear shock absorber or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damping performance will suffer EAS00689 DISPOSING OF A REAR...

Page 193: ...orcycle on a suitable stand so that the rear wheel is elevated 2 Remove connecting arm bolt 1 relay arm bolt 2 rear shock absorber assembly lower bolt 3 While removing the rear shock absorber as sembly lower bolt hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly Raise the swingarm and then remove the rear shock absorber ...

Page 194: ...ings Damage wear Replace dust seals Damage wear Replace bolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORB ER ASSEMBLY 1 Lubricate spacers bearings Recommended lubricant Molybdenum disulfide grease 2 Install rear shock absorber assembly Rear shock absorber assembly upper nut 40 Nm 4 0 m kg Rear shock absorber assembly lower nut 40 Nm 4 0 m kg Relay arm to frame nut 40 Nm 4 0...

Page 195: ...ake hose holder Side protector left right Pivot shaft Swing arm Drive chain case Drive chain guard Dust cover Oil seal 1 2 1 1 1 1 1 1 2 2 Remove the parts in the order listed Refer to REAR WHEEL Refer to REAR SHOCK ABSORBER ASSEMBLY Remove the side protector assembly Do not remove the center cap 125 Nm 12 5 m kg 23 Nm 2 3 m kg NOTE 85 Nm 8 5 m kg EAS00700 SWINGARM AND DRIVE CHAIN ...

Page 196: ...art Q ty Remarks 10 11 12 13 14 15 16 Bearing Spacer Shoft pedal assembly Drive sprocket cover Drive chain guide Drive sprocket Drive chain 2 1 1 1 1 1 1 For installation reverse the removal procedure 125 Nm 12 5 m kg 23 Nm 2 3 m kg 85 Nm 8 5 m kg ...

Page 197: ...r bolt hold the swingarm so that it does not drop down 3 Check swingarm side play A swingarm vertical movement B a Check the tightening torque of the pivot shaft nut Pivot shaft nut 125 Nm 12 5 m kg b Check the swingarm side play A by moving the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at t...

Page 198: ...le on a suitable stand so that the rear wheel is elevated 2 Remove foot rest left drive sprocket cover drive chain guide 1 drive sprocket 2 EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft dust covers spacer washers bearings Recommen...

Page 199: ...ches Replace EAS00709 CHECKING THE DRIVE CHAIN 1 Measure ten link section a of the drive chain Out of specification Replace the drive chain Ten link drive chain section limit maximum 150 1 mm While measuring the ten link section push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and 11 as shown Perform this measurement at two or three dif ferent pl...

Page 200: ...eteriorate the O rings A coarse brush can also damage the O rings Therefore use only kerosine to clean the drive chain 4 Check O rings 1 Damage Replace the drive chain drive chain rollers 2 Damage wear Replace the drive chain drive chain side plates 3 Damage wear Replace the drive chain Cracks Replace the drive chain and make sure that the battery breather hose is proper ly routed away from the dr...

Page 201: ... chains 2 Install drive chain 1 drive sprocket 2 washer 3 New drive sprocket nut 4 drive chain guide 5 While applying the rear brake tighten the drive sprocket nut 3 Bend the lock washer tab a along a flat side of the nut EAS00711 INSTALLING THE SWINGARM 1 Lubricate bearings spacers dust covers pivot shaft Recommended lubricant Molybdenum disulfide grease 2 Install relay arm left connecting arm ri...

Page 202: ...E REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Drive chain slack 40 50 mm 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 ...

Page 203: ......

Page 204: ... TENSIONER 5 11 INSTALLING THE CAMSHAFTS 5 12 CYLINDER HEAD 5 16 REMOVING THE CYLINDER HEADS 5 17 CHECKING THE CYLINDER HEADS 5 17 INSTALLING THE CYLINDER HEAD 5 18 VALVES AND VALVE SPRINGS 5 19 REMOVING THE VALVES 5 21 CHECKING THE VALVES AND VALVE GUIDES 5 22 CHECKING THE VALVE SEATS 5 24 CHECKING THE VALVE SPRINGS 5 26 CHECKING THE VALVE LIFTERS 5 27 INSTALLING THE VALVES 5 27 GENERATOR 5 29 RE...

Page 205: ...5 53 CHECKING THE RELIEF VALVE 5 54 CHECKING THE OIL DELIVERY PIPE 5 54 CHECKING THE OIL STRAINER 5 54 ASSEMBLING THE OIL PUMP 5 54 INSTALLING THE OIL PUMP 5 55 INSTALLING THE OIL STRAINER 5 55 INSTALLING THE OIL PAN 5 56 CRANKCASE 5 57 CRANKCASE 5 57 CONNECTING RODS AND PISTONS 5 59 CRANKSHAFT 5 60 DISASSEMBLING THE CRANKCASE 5 61 REMOVING THE CONNECTING RODS AND PISTONS 5 62 REMOVING THE CRANKSH...

Page 206: ... 78 TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS 5 78 REMOVING THE TRANSMISSION 5 83 CHECKING THE SHIFT FORKS 5 83 CHECKING THE SHIFT DRUM ASSEMBLY 5 84 CHECKING THE TRANSMISSION 5 84 INSTALLING THE TRANSMISSION 5 85 ...

Page 207: ...ENG ...

Page 208: ...it rod Drive sprocket cover Drive sprocket Water outlet hose Exhaust pipe 1 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to CARBURETOR in chapter 6 Refer to AIR INDUCTION SYSTEM in chapter 6 For installation reverse the removal procedure Refer to RADIATOR in chapter 7 10 Nm 1 0 m kg 20 Nm 2 0 m kg 85 Nm 8 5 m kg 20 Nm 2 0 m kg ENGINE ENG EAS00188 OVERHAULING THE ENGINE ENGINE DRIVE SPR...

Page 209: ...ads and hoses Cover Clutch cable Nuetral switch speed sensor pickup coil lead Water head pipe Coolant outlet hose 1 1 1 1 1 1 1 Remove the parts in the order listed Disconnect For installation reverse the removal pro cedure ENGINE ENG EAS00189 LEADS AND HOSES ...

Page 210: ...olt front Engine bracket Engine mounting bolt rear upper Engine mounting bolt rear lower Engine 1 2 1 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 55 Nm 5 5 m kg 24 Nm 2 4 m kg 33 Nm 3 3 m kg 24 Nm 2 4 m kg 55 Nm 5 5 m kg ENGINE ENG EAS00191 ENGINE ...

Page 211: ...hten the bolts 2 Tighten the bolts in the following order Engine mount bolt 1 55 Nm 5 5 m kg Engine mount bolt 2 55 Nm 5 5 m kg Engine mount bolt 3 33 Nm 3 3 m kg Engine mount bolt 5 55 Nm 5 5 m kg Down tube 6 24 Nm 2 4 m kg 3 Install shift arm 1 Align the punch mark a in the shift shaft with the slot in the shift arm Align the bottom edge of the shift pedal with the mark on the frame to swingarm ...

Page 212: ...sembly Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide top side 4 1 1 1 Remove the parts in the order listed Refer to CARBURETORS in chapter 6 Refer to RADIATOR and THERMOSTAT ASSEMBLY in chapter 7 For installation reverse the removal procedure 13 Nm 1 3 m kg 12 Nm 1 2 m kg EAS00194 CAMSHAFT CYLINDER HEAD COVERS ...

Page 213: ...Timing chain guide exhaust side Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft 1 1 1 1 3 6 3 6 1 1 Remove the parts in the order listed Refer to PICKUP COIL During removal the dowel pins may still be connected to the camshaft caps NOTE 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 24 Nm 2 4 m kg 10 Nm 1 0 m kg CAMSHAFT ENG EAS00196 CAMSHAFTS ...

Page 214: ...y Remarks 11 12 13 14 Intake camshaft sprocket Exhaust camshaft sprocket Pin Timing chain guide intake side 1 1 1 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 24 Nm 2 4 m kg 10 Nm 1 0 m kg ...

Page 215: ... piston 1 is at TDC on the compres sion stroke align the T mark a with the crankcase mating surface b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 3 Loosen camshaft sprocket bolts 1 4 Loosen cap bolt 1 5 Remove timing chain tensioner 2 gasket 6 Remove camshaft sprocket 1 To prevent the timing chain from falling into the crankcase fasten it with...

Page 216: ...ages and in a criss cross pattern working from the outside in 8 Remove intake camshaft 1 exhaust camshaft 2 EAS00204 CHECKING THE CAMSHAFTS 1 Check camshaft lobes Blue discoloration pitting scratches Re place the camshaft 2 Measure camshaft lobe dimensions a and b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake a 32 4 mm b 24 85 mm Exhaust a 32 85 mm b 24 85 mm ...

Page 217: ...eR 1 onto the camshaft journal as shown c Install the dowel pins and camshaft caps STighten the camshaft cap bolts in stages and in a crisscross pattern working from the inner caps out SDo not turn the camshaft when measuring the camshaft journal to camshaft cap clearance with the PlastigaugeR Camshaft cap bolt 10 Nm 1 0 mSkg d Remove the camshaft caps and then mea sure the width of the Plastigaug...

Page 218: ...nd camshaft sprockets as a set 2 Check camshaft sprocket More than 1 4 tooth a wear Replace the camshaft sprockets and the timing chain as a set a 1 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3 Check timing chain guide exhaust side 1 timing chain guide intake side 2 timing chain guide top side 3 Damage wear Replace the defective part s EAS00210 CHECKING THE TIMING CHAIN TENSIONER ...

Page 219: ...ure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly If there is rough move ment replace the timing chain tensioner 3 Check cap bolt copper washer spring gasket timing chain tensioner rod Damage wear Replace the defective part s EAS00217 INSTALLING THE CAMSHAFTS 1 Install exhaust camshaft 1 intake camshaft 2 Install the camshafts with the punch mark a fa...

Page 220: ...aust camshaft sprocket a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the T mark a on the pick up coil rotor with the crankcase mating sur face b c Place the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts When installing the camshaft sprockets start with the exhaust camshaft and be sure to keep the ti...

Page 221: ... with a thin screwdriver 1 b With the timing chain tensioner rod turned all the way into the timing chain tensioner hous ing with the thin screwdriver still installed install the gasket and the timing chain ten sioner 2 onto the cylinder block Always use a new gasket c Tighten the timing chain tensioner bolts 3 to the specified torque Timing chain tensioner bolt 10 Nm 1 0 m kg d Remove the screwdr...

Page 222: ... camshaft punch marks c Make sure that the marks c on the camshaft are aligned with the arrow marks d in the comshaft caps Out of alignment Adjust Refer to the installation steps above 8 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 9 Install timing mark accessing screw crankshaft end cover ...

Page 223: ... exhaust camshafts Cylinder head Cylinder head gasket Dowel pin 1 1 2 Remove the parts in the order listed Refer to ENGINE Refer to CAMSHAFTS For installation reverse the removal procedure 20 Nm 2 0 m kg 12 Nm 1 2 m kg 1st 50 Nm 5 0 m kg 2nd 20 Nm 2 0 m kg 1st 50 Nm 5 0 m kg 2nd EAS00221 CYLINDER HEAD ...

Page 224: ... use a sharp instrument to avoid damag ing or scratching spark plug threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 1 mm a Place a straightedge 1 and a thickness gauge 2 across the cylinder head b Measure t...

Page 225: ...hten cylinder head nuts 1 X 10 1st 2nd cylinder head bolt 11 12 First tighten the nuts 1 X 10 to approximate ly 20 Nm 2 0 m kg with a torque wrench Retighten the nuts to 50 Nm 5 0 m kg Apply engine oil onto the threads of the cylin der head nuts Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages 4 Install exhaust camshaft intake camshaft Refer t...

Page 226: ...nder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide 12 12 24 12 12 12 12 12 12 Remove the parts in the order listed Refer to CYLINDER HEAD EAS00236 VALVES AND VALVE SPRINGS ...

Page 227: ...ter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide 8 8 16 8 8 8 8 8 8 For installation reverse the removal procedure VALVES AND VALVE SPRINGS ENG ...

Page 228: ...d so that they can be reinstalled in their original place 2 Check valve sealing Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal There should be no leakage at the valve seat 1 3 Remove valve cotters 1 Remove the valve cotters by compressin...

Page 229: ...nal place EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter A Valve stem diameter B Out of specification Replace the valve guide Valve stem to valve guide clearance Intake 0 010 X 0 037 mm Limit 0 08 mm Exhaust 0 020 X 0 047...

Page 230: ...e guide with a valve guide installer 2 and valve guide remover 1 c After installing the valve guide bore the valve guide with a valve guide reamer 3 to obtain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide remover Intake 4 0 mm 90890 04111 Exhaust 4 5 mm 90890 04116 Valve guide installer Intake 4 0 mm 90890 04112 Exhaust 4 5 mm 9089...

Page 231: ...asure valve stem runout Out of specification Replace the valve When installing a new valve always replace the valve guide If the valve is removed or replaced always re place the oil seal Valve stem runout 0 01 mm EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pi...

Page 232: ...nd the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve face and valve seat are evenly polished then clean off all of the lapping compound For the best lapping results lightly tap the valve seat while rotating the valve back and forth be tween your hand e Apply a fine lapping compound to the valve face and ...

Page 233: ...he valve spring Valve spring free length Intake spring 38 9 mm Exhaust spring 40 67 mm 2 Measure compressed spring force a Out of specification Replace the valve spring b Installed length Compressed spring force Intake 8 2 X 9 6 kg at 34 5 mm Exhaust 11 0 X 12 6 kg at 35 0 mm 3 Measure valve spring tilt a Out of specification Replace the valve spring Spring tilt limit Intake 1 7 mm Exhaust 1 8 mm ...

Page 234: ...onents 1 Deburr valve stem end with an oil stone 2 Lubricate valve stem 1 oil seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install valve 1 lower spring seat 2 oil seal 3 valve spring 4 upper spring seat 5 into the cylinder head Install the valve spring with the larger pitch a facing up b Smaller pitch Make sure that each valve is installed in its origi nal...

Page 235: ...90890 04114 Exhaust valve 90890 04108 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer Hitting the valve tip with excessive force could damage the valve 6 Install valve pad 1 valve lifter 2 Apply molybdenum disulfide oil onto the valve lifter and valve pad The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve ...

Page 236: ...Generator rotor Stator coil assembly coupler Stator coil assembly lead holder Stator coil assembly 1 1 2 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Disconnect For installation reverse the removal procedure 14 Nm 1 4 mSkg 12 Nm 1 2 mSkg 65 Nm 6 5 mSlkg 60_ GENERATOR ENG E...

Page 237: ...ool 3 loosen the generator rotor bolt Rotor holding tool 90890 01235 3 Remove generator rotor 1 with the flywheel puller 2 and rotor holding tool 3 Flywheel puller 90890 01080 INSTALLING THE GENERATOR 1 Apply sealant onto the stator coil assembly lead grommet Yamaha bond No 1215 90890 85505 2 Install generator rotor washer generator rotor bolt Always use a new generator rotor bolt Clean the tapere...

Page 238: ...e holding the generator rotor 2 with the rotor holding tool 3 tighten the generator ro tor bolt SAfter tightening to 65 Nm 6 5 mSkg tighten another 60_ Rotor holding tool 90890 01235 4 Install Sgenerator rotor cover Tighten the generator rotor cover bolts in stages and in a crisscross pattern ...

Page 239: ...tor cover Pickup coil lead holder Pickup coil rotor cover Pickup coil rotor cover gasket Dowel pin 1 1 1 2 Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to GENERATOR 12 Nm 1 2 m kg 15 Nm 1 5 m kg 60 Nm 6 0 m kg 10 Nm 1 0 m kg PICKUP COIL ENG PICKUP COIL ...

Page 240: ...OIL ENG Order Job Part Q ty Remarks 5 6 7 Pickup coil coupler Pickup coil Pickup coil rotor 1 1 1 Disconnect For installation reverse the removal procedure 12 Nm 1 2 m kg 15 Nm 1 5 m kg 60 Nm 6 0 m kg 10 Nm 1 0 m kg ...

Page 241: ...fully loosened remove them 2 Remove pickup coil rotor bolt 1 washer pickup coil rotor 2 While holding the generator rotor 3 with the ro tor holding tool 4 loosen the pickup coil rotor bolt Rotor holding tool 90890 01235 INSTALLING THE PICKUP COIL ROTOR 1 Install pickup coil rotor 1 washer pickup coil rotor bolt When installing the pickup coil rotor align the pin 2 in the crankshaft sprocket with t...

Page 242: ...tor holding tool 90890 01235 3 Apply sealant onto the pickup coil lead grommet Yamaha bond No 1215 90890 85505 4 Install pickup coil rotor cover pickup coil lead holder When installing the pickup coil rotor cover align the timing chain guide intake side pin 1 with the hole 2 in the pickup coil rotor cover Tighten the pickup coil rotor cover bolts in stages and in a crisscross pattern ...

Page 243: ...over Engine oil Clutch cable Clutch cover Clutch cover gasket Dowel pin 1 1 1 2 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 For installation reverse the removal procedure 12 Nm 1 2 m kg 12 Nm 1 2 m kg EAS00273 CLUTCH CLUTCH COVER ...

Page 244: ...ks 1 2 3 4 5 6 Removing the pull lever shaft Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing 2 1 1 1 1 2 Remove the parts in the order listed For installation reverse the removal procedure CLUTCH ENG EB405010 ...

Page 245: ...on plate Clutch plate Friction plate Clutch plate Friction plate Friction plate Clutch damper spring Clutch damper spring seat 1 1 1 2 4 6 3 1 1 1 Remove the parts in the order listed Refer to INSTALLING THE CLUTCH Select Color code Black Color code Blue 12 Nm 1 2 m kg 70 Nm 7 0 m kg 8 Nm 0 8 m kg EAS00274 CLUTCH ...

Page 246: ...Q ty Remarks 11 12 13 14 15 16 17 18 19 20 21 Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure ...

Page 247: ...h boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut Universal clutch holder 90890 04086 3 Remove clutch boss nut 1 lock washer 2 clutch boss 3 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check friction plate Damage wear Replace the friction plates as a set ...

Page 248: ...n Adjust Assembly width 43 1 43 9 mm a Assembly width adjusted by clutch plate 1 and 2 b Select the clutch plate from the following table Clutch plate 1 Part No Thickness 168 16325 00 1 6 mm 31A 16325 00 2 0 mm STD 168 16324 00 2 3 mm Clutch plate 2 Part No Thickness 31A 16325 00 2 0 mm STD 168 16324 00 2 3 mm When adjusting the clutch assembly width by replacing the clutch plate s be sure to repl...

Page 249: ...te and thickness gauge 1 Out of specification Replace the clutch plates as a set Clutch plate warpage limit Less than 0 1 mm EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length Out of specification Replace the clutch springs as a set Clutch spring free ...

Page 250: ...ear Replace the clutch hous ing EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pitting wear Replace the clutch boss Pitting on the clutch boss splines will cause er ratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Check pressure plate 1 Cracks damage Replace bearing 2 Damage wear Replace EAS00287 CHECKING THE PULL LEVER AND PULL ROD 1 Check pull lever 1 pull rod ...

Page 251: ...LUTCH 1 Check starter clutch rollers Damage wear Replace 2 Check starter clutch idle gear starter clutch drive gear starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear ...

Page 252: ...ckwise B it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced EAS00299 INSTALLING THE CLUTCH 1 Install clutch housing Make sure that the slots a in the clutch hous ing align with the tabs b on the oil water pump assembly drive sprocket Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Ma...

Page 253: ...en a clutch plate and a friction plate a Install the clutch damper spring seat 1 clutch damper spring 2 and friction plate smaller size 3 b Install the clutch plate and friction plate at fol lowing the illustrated Friction plate 4 Color code Blue Friction plate 5 Color code Black Clutch plate 6 20 mm Clutch plate 7 Select Refer to CHECKING THE FRICTION PLATE 6 Measure assembly width a Out of speci...

Page 254: ...d in a crisscross pattern 9 Install pull lever Align the punch mark a in the pull lever shaft with the mark b on the clutch cover 10 Install dowel pins gasket New clutch cover When installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod groove c and pull lever shaft groove d are engaged...

Page 255: ...hift shaft cover Shift shaft cover gasket Dowel pin Shift shaft Shift shaft spring Spacer Stopper lever spring Stopper lever Collar Shift shaft spring stopper 1 1 2 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE For installation reverse the removal procedure 12 Nm 1 2 m kg EAS00326 SHIFT SHAFT GENERATOR ROTOR COVER ...

Page 256: ...r EAS00331 INSTALLING THE SHIFT SHAFT 1 Install shift shaft spring stopper 1 stopper lever spring 2 stopper lever 3 Apply LOCTITE to the threads of the shift shaft spring stopper Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum seg ment assembly 2 Install shift shaft 1 spacer Lubricate the oil seal lips with lithium ...

Page 257: ... switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin 1 1 1 1 1 2 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to RADIATOR and OIL COOLER in chapter 5 Refer to ENGINE Disconnect 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg 43 Nm 4 3 m kg EA...

Page 258: ...3 m kg Order Job Part Q ty Remarks 7 8 9 10 11 12 13 14 Drain pipe Oil strainer Oil pipe Oil delivery pipe Oil water pump assembly drive sprocket cover Dowel pin Oil water pump assembly Relief valve assembly 1 1 1 1 1 1 1 1 For installation reverse the removal pro cedure OIL PAN AND OIL PUMP ENG EB411001 ...

Page 259: ...mp Oil water pump assembly driven sprocket Washer Oil pump housing Bearing Pin Oil pump outer rotor Oil pump inner rotor Pin 1 1 1 1 2 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 10 Nm 1 0 m kg 15 Nm 1 5 m kg EAS00360 ...

Page 260: ...racks damage wear Replace the de fective part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing clearance b oil pump housing to inner rotor and outer rotor clearance c Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 09 0 15 mm Limit 0 23 mm Outer rotor to oil pump housing cleara...

Page 261: ...G THE OIL DELIVERY PIPE 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with engine oil EAS00374 ASSEMBLING THE OIL PUMP 1 Lubricate inner rotor outer rotor oil pump shaft with the recommended lubricant Recommended lubricant Engine oil ...

Page 262: ...in 1 in the oil pump shaft with the groove a on the in ner rotor 2 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump Install the oil water pump drive chain 1 onto the oil water pump driven sprocket 2 EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer housing 1 LOCTITE The arrow a on the oil strainer housing must point towards the...

Page 263: ...NING NOTE EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins gasket New oil pan 1 oil level switch 2 engine oil drain bolt 3 Always use new copper washers Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switch s O ring with en gine oil ...

Page 264: ...lutch idle gear Oil water pump assembly Timing chain Crankshaft sprocket Pin Oil water pump assembly drive chain guide Oil water pump assembly drive chain 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to CYLINDER HEAD Refer to PICKUP COIL Refer to GENERATOR Refer to CLUTCH Refer to OIL PAN AND OIL PUMP 10 Nm 1 0 m kg 10 Nm 1 0 m kg EAS00381 CRANKCASE CRANKCASE ...

Page 265: ... Job Part Q ty Remarks 6 7 8 9 10 Oil water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin 1 1 1 1 3 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg CRANKCASE ENG ...

Page 266: ...pistons Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing Top ring 2nd ring Oil ring 4 4 8 4 4 4 4 4 4 4 Remove the parts in the order listed For installation reverse the removal procedure 36 Nm 3 6 m kg EAS00382 CONNECTING RODS AND PISTONS ...

Page 267: ...ssembly Crankcase Connecting rod caps Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing 1 5 5 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to CONNECTING RODS AND PISTONS For installation reverse the removal procedure CRANKSHAFT ...

Page 268: ...case in dicate the crankcase tightening sequence 3 Remove lower crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crankcase halves separate evenly M9 125 mm bolts 1 X 10 M8 125 mm bolts 21 X 22 M6 100 mm bolts 11 X 20 23 X 28 4 Remove dowel pins O...

Page 269: ...it can be reinstalled in its original place 2 Remove piston pin clips 1 piston pin 2 piston 3 Do not use a hammer to drive the piston pin out For reference during installation put identifica tion marks on the piston crown Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remo...

Page 270: ...your fingers and lift the other side of the ring over the piston crown EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1 Remove crankshaft assembly 1 crankshaft journal upper bearings from the upper crankcase Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place ...

Page 271: ...er clearance a Measure cylinder bore C with the cylinder bore gauge Measure cylinder bore C by taking side to side and front to back measurements of the cyl inder Then find the average of the measure ments Cylinder bore C 74 00 74 01 mm Wear limit 74 06 mm Taper limit T 0 05 mm Out of round R 0 05 mm C maximum of D1 D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum of D1 D3 or D5 minimum of D...

Page 272: ...e Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 030 0 055 mm Limit 0 12 mm f If out of specification replace the cylinder and the piston and piston rings as a set EAS00263 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a set Before measuring the piston ring side clear ance eliminate any carbon depo...

Page 273: ... the oil ring rail s gap is exces sive replace all three piston rings Piston ring end gap Top ring 0 32 0 44 mm 2nd ring 0 43 0 58 mm Oil ring 0 10 0 35 mm EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis ton pins 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure piston pin outside diameter Out o...

Page 274: ...ston pin to piston clearance 0 002 0 022 mm Limit 0 072 mm EAS00395 CHECKING THE CRANKSHAFT AND CON NECTING RODS 1 Measure crankshaft runout Out of specification Replace the crank shaft Crankshaft runout Less than 0 03 mm 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft 3 Measure crankshaft journal to crankshaft journal bearing clea...

Page 275: ...a bench c Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank case Align the projections a of the crankshaft journal upper bearings with the notches b in the crank case d Put a piece of Plastigauge 2 on each crankshaft journal Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings 1 into the lower c...

Page 276: ... each crankshaft journal If the clearance is out of specification select replacement crankshaft journal bearings 4 Select Scrankshaft journal bearings J1 J5 SThe numbers A stamped into the crankshaft web and the numbers 1 stamped into the low er crankcase are used to determine the re placement crankshaft journal bearing sizes S J1 J5 refer to the bearings shown in the crankshaft illustration SIf J...

Page 277: ...cting rods Do not interchange the big end bearings and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their origi nal positions a Clean the big end bearings crankshaft pins and bearing portions of the connecting rods b Install the big end upper bearing into the con necting rod and the big end lo...

Page 278: ... When tightening the connecting rod nuts be sure to use an F type torque wrench Without pausing tighten the connecting rod nuts to the specified torque Apply con tinuous torque between 2 0 and 3 6 m kg Once you reach 2 0 m kg DO NOT STOP TIGHTENING until the specified torque is reached If the tightening is interrupted be tween 2 0 and 3 6 m kg loosen the con necting rod nut to less than 2 0 m kg a...

Page 279: ... is Bearing size for P1 P1 connecting rod P1 crankshaft 2 4 1 2 1 Blue BIG END BEARING COLOR CODE 1 Violet 0 White 1 Blue 2 Black EAS00399 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase mating surfaces 3 Check crankcase Cracks damage Replace oil delivery passages Obstruction Blow out with compressed air EAS00...

Page 280: ... a set oil water pump assembly drive chain 2 Damage stiffness Replace the oil water pump assembly drive chain and oil water pump assembly drive sprocket as a set EAS00407 INSTALLING THE CRANKSHAFT 1 Install crankshaft journal upper bearings 1 into the upper crankcase Align the projections a on the crankshaft jour nal upper bearings with the notches b in the crankcase Be sure to install each cranks...

Page 281: ...to the respective connecting rod 2 piston pin 3 piston pin clip New 4 Apply engine oil onto the piston pin Make sure that the Y mark a on the connect ing rod faces left when the arrow mark b on the piston is pointing up Refer to the illustra tion Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Lubricate piston piston rings cylinder with the recommen...

Page 282: ...install the connecting rod assembly into the cylinder with the other hand Make sure that the Y marks a on the con necting rods face towards the left side of the crankshaft Make sure that the characters b on both the connecting rod and connecting rod cap are aligned 7 Align bolt heads with the connecting rod caps 8 Tighten connecting rod nuts When tightening the connecting rod nuts be sure to use a...

Page 283: ...ome into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 3 mm of the crankshaft journal bearings 3 Install dowel pin 4 Install crankshaft journal lower bearings 1 into the lower crankcase Align the projections a on the crankshaft jour nal lower bearings with the notches b in the crankcase Install each crankshaft journal lower bearing in its original pl...

Page 284: ...ned by hand 7 Install Scrankcase bolts SLubricate the bolt threads with engine oil STighten the bolts in increasing numerical order SInstall washers on bolts 1 X 10 M9 125 mm bolts 1 X 10 M8 125 mm bolts 21 X 22 M6 100 mm bolts 11 X 20 23 X 28 Crankcase bolt Bolt 1 X 10 1st 15 Nm 1 5 mSkg 2nd 15 Nm 1 5 mSkg 45 X 50_ Bolt 11 X 15 17 X 20 23 25 X 28 12 Nm 1 2 mSkg Bolt 16 24 14 Nm 1 4 mSkg Bolt 21 X...

Page 285: ...xle assembly Circlip Oil seal Bearing Shift drum retainer Shift fork guide bar Spring Shift fork L Shift fork R 1 1 1 1 1 2 4 1 1 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to SHIFT SHAFT For installation reverse the removal procedure 12 Nm 1 2 m kg 10 Nm 1 0 m kg EAS00419 TRANSMISSION TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS ...

Page 286: ...mbly 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd 4th pinion gears 5th pinion gear Collar 1 1 1 1 1 2 2 1 1 1 Disassembly the parts in the order listed 1 10 2 3 4 5 6 7 8 9 TRANSMISSION ENG ...

Page 287: ...5 80 Order Job Part Q ty Remarks Main axle 1st pinion gear Bearing Main axle bearing housing 1 1 1 For assembly reverse the disassembly procedure 11 13 12 TRANSMISSION ENG ...

Page 288: ...ive axle assembly Washer 1st wheel gear Spacer 5th wheel gear Circlip Washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 1 1 1 1 3 3 1 2 1 1 Disassembly the parts in the order listed 1 10 2 3 4 5 6 7 8 9 TRANSMISSION ENG ...

Page 289: ... Order Job Part Q ty Remarks 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure 11 13 12 14 15 16 17 TRANSMISSION ENG ...

Page 290: ... axle assembly comes free from the upper crankcase EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components 1 Check shift fork cam follower 1 shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace Do not attempt to straighten a bent shift ...

Page 291: ...mit 0 08 mm 2 Measure drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Drive axle runout limit 0 08 mm 3 Check transmission gears Blue discoloration pitting wear Replace the defective gear s transmission gear dogs Cracks damage rounded edges Replace the defective gear s 4 Check transmission gear engagement each pinion gear to its respective whe...

Page 292: ... installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle Make sure that the drive axle bearing circlip is inserted into the grooves in the upper crank case 2 Check transmission Rough movement...

Page 293: ......

Page 294: ......

Page 295: ...HE RADIATOR 6 2 INSTALLING THE RADIATOR 6 3 THERMOSTAT 6 4 CHECKING THE THERMOSTAT 6 6 ASSEMBLING THE THERMOSTAT 6 6 INSTALLING THE THERMOSTAT 6 7 WATER PUMP 6 8 DISASSEMBLING THE WATER PUMP 6 10 CHECKING THE WATER PUMP 6 10 ASSEMBLING THE WATER PUMP 6 11 ...

Page 296: ...COOL ...

Page 297: ... 5 6 Removing the radiator Coolant Water inlet hose Carburetor hose Oil cooler hose Water outlet hose Radiator Fan motor 1 1 1 1 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure EAS00454 COOLING SYSTEM RADIATOR ...

Page 298: ...ge Replace 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 a Install the radiator cap tester 1 and adapter 2 to the radiator cap 3 Radiator cap tester 90890 01325 Adapter 90890 01352 b Apply the specified pressure for ten seconds and make sure that there is no drop in pres sure 4 Check radiator ...

Page 299: ... the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part a Attach the radiator cap tester 1 to the radia tor Radiator cap tester 90890 01325 b Apply 100 kPa 1 0 kg cm2 of pressure c Measure the indicated pressure with the gauge ...

Page 300: ...moving the thermostat Front cowling Coolant reservoir hose Water inlet hose Water outlet hose Thermostat housing 1 1 1 1 Remove the parts in the order listed Refer to FRONT COWLING in chapter 3 For installation reverse the removal procedure EAS00460 THERMOSTAT ...

Page 301: ...rks Disassembling the thermostat housing Thermostat housing cover Thermostat O ring Thermostat housing Thermo unit 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 15 Nm 1 5 m kg EAS00461 ...

Page 302: ... mometer s indicated temperature 1 Thermometer 2 Water 3 Thermostat 4 Container A Closes B Opens If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Sthermostat housing cover 1 Sthermostat housing 2 Cracks damage Replace EAS00464 ASSEMBLING THE THERMOSTAT 1 Install Sthermostat housing 1 Sthermostat 2 SO ring New Sther...

Page 303: ... the thermo unit Replace any part that was dropped or subjected to a strong impact EAS00466 INSTALLING THE THERMOSTAT 1 Fill cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part ...

Page 304: ...ong with the impeller 1 1 2 1 Disassemble the parts in the order listed The water pump and oil pump are combined into one unit oil water pump assembly It is not necessary to remove the impeller shaft unless the coolant level is extremely low or coolant leaks from the oil pan Refer to OIL PAN AND OIL PUMP in chapter 5 NOTE 1 2 3 4 10 Nm 1 0 m kg EAS00469 WATER PUMP ...

Page 305: ...6 9 WATER PUMP COOL Order Job Part Q ty Remarks Water pump seal Oil seal Bearing 1 1 1 For assembly reverse the disassembly procedure 10 Nm 1 0 m kg 5 6 7 ...

Page 306: ...l seal from the outside of the water pump housing 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaft EAS00473 CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 2 Check water pump seal oil seal water pump inlet pipe C...

Page 307: ...pply tap water or coolant onto its outer surface 2 Install water pump seal New 1 Never apply oil or grease onto the water pump seal surface Install the water pump seal with the water pump seal installers Before installing the water pump seal apply Yamaha bond No 1215 2 to the water pump housing 3 Water pump seal installer 4 90890 04078 Middle driven shaft bearing driver 5 90890 04058 Yamaha bond N...

Page 308: ...er New 2 Before installing the rubber damper apply tap water or coolant onto its outer surface 4 Measure tilt Out of specification Repeat steps 3 and 4 Make sure that the rubber damper and rub ber damper holder are flush with the impel ler Tilt limit 0 15 mm 1 Straightedge 2 Impeller ...

Page 309: ......

Page 310: ...URETORS 7 8 INSTALLING THE CARBURETORS 7 9 MEASURING AND ADJUSTING THE FUEL LEVEL 7 10 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 11 CHECKING THE FUEL PUMP 7 13 AIR INDUCTION SYSTEM 7 14 AIR INJECTION 7 14 AIR CUTOFF VALVE 7 14 AIR INDUCTION SYSTEM DIAGRAMS 7 15 CHECKING THE AIR INDUCTION SYSTEM 7 16 ...

Page 311: ...CARB ...

Page 312: ...t Air filter case panel left right Battery negative lead Battery positive lead Battery Stay 1 1 1 1 1 1 Remove the parts in the order listed Refer to FRONT COWLING SEAT SIDE COVER FUEL TANK section in chapter 3 Refer to CHANGING THE COOLANT section For installation reverse the removal procedure CARBURETORS CARBURETORS AIR FILTER CASE ...

Page 313: ...retors Throttle position sensor lead Air filter joint screw Carburetors joint screw Carburetor inlet outlet hose Carburetors assembly Starter cable Throttle cable 4 4 1 1 1 1 2 Remove the parts in the order listed Disconnect For installation reverse the removal procedure EAS00481 ...

Page 314: ...ter plunger link Connecting bolt Spacer Connecting bolt Spacer Fuel inlet pipe Fuel feed pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Throttle position sensor bracket Carburetor 1 1 1 1 1 1 3 1 2 2 2 2 1 1 4 Remove the parts in the order listed For installation reverse the removal procedure EAS00482 ...

Page 315: ... Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw Fuel drain bolt Float pin 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed The following procedure applies to all of the carburetors NOTE 1 2 3 4 5 6 7 8 9 10 EAS00484 ...

Page 316: ...RBURETORS CARB Order Job Part Q ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure 11 12 13 14 15 16 17 ...

Page 317: ...vent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body 1 Dirt Clean 4 Check float chamber rubber gasket 2 Cracks damage wear Replace 5 Check float 1 Damage Replace 6 Check needle valve 1 needle valve seat 2 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check O ring 3 ...

Page 318: ...ilot jet 5 pilot screw 6 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 11 Check piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 12 Check fuel feed pipes hose joint Cracks damage Replace Obstruction Clean Blow out the pipes with compressed air 13 Check fuel feed hoses fuel hoses Cra...

Page 319: ...t needle kit 2 Install needle jet 1 pilot jet 2 main jet 3 3 Measure float height a Out of specification Adjust Float height 12 5 13 5 mm a Hold the carburetor upside down b Measure the distance from the mating sur face of the float chamber with the gasket re moved to the top of the float The float arm should rest on the needle valve without depressing it c If the float height is not within specif...

Page 320: ...in the carburetor body 5 Install connecting bracket After installing the connecting bracket check that the throttle cable lever and starter plunger link operate smoothly EAS00493 INSTALLING THE CARBURETORS 1 Adjust carburetor synchronization Refer to SYNCHRONIZING THE CARBU RETORS in chapter 3 2 Adjust engine idling speed Engine idling speed 1 050 1 150 r min Refer to ADJUSTING THE ENGINE IDLING S...

Page 321: ...e 90890 01312 d Loosen the fuel drain screw e Hold the fuel level gauge vertically next to the line on the float chamber 3 f Measure the fuel level a on both sides of the carburetor assembly The fuel level readings should be equal on both sides 2 Adjust fuel level a Remove the carburetor assembly b Check the needle valve seat and needle valve c If either is worn replace them as a set d If both are...

Page 322: ...he pocket tester Ω 1k to the throttle position sensor Tester positive lead Black blue 1 Tester negative lead Blue 2 d Check the throttle position sensor maximum resistance Out of specification Replace the throttle position sensor Throttle position sensor maximum resistance 4 X 6 kΩ at 20_C e Install the throttle position sensor onto the carburetor f Connect the pocket tester Ω 1k to the throttle p...

Page 323: ...n the throttle position sensor screws 1 e Adjust the throttle position sensor angle ac cording to the following table The angle of the throttle position sensor is indi cated by the RPM which are displayed on the tachometer Tachometer reading Throttle position Tachometer reading sensor angle 0 r min Too small 5 000 r min Correct 10 000 r min Too large f After adjusting the throttle position sensor ...

Page 324: ... the end of the fuel hose b Start the engine and check if fuel flows from the fuel hose 2 Fuel flows Fuel pump is OK Fuel does not flow Replace the fuel pump c Stop the engine and check if the fuel stops flowing from the fuel hose 2 Fuel stops flowing Fuel pump is OK Fuel flows Replace the fuel pump ...

Page 325: ... air cutoff valve is operated by the intake gas pressure through the piston valve diaphragm Normally the air cutoff valve is open to allow fresh air to flow into the exhaust port During sudden deceleration the throttle valve sudden ly closes negative pressure is generated and the air cutoff valve is closed in order to prevent after burning Additionally at high engine speeds and when the pressure d...

Page 326: ...N SYSTEM CARB EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Carburetor joint cylinder 4 A To the air cutoff valve B To cylinder 1 C To cylinder 2 D To cylinder 3 E To cylinder 4 ...

Page 327: ...ly Cracks damage Replace pipes Cracks damage Replace 2 Check fibre reed 1 fibre reed stopper reed valve seat Cracks damage Replace the reed valve 3 Measure fibre reed bending limit a Out of specification Replace the reed valve Fibre reed bending limit 0 2 mm 1 Surface plate 4 Check air cutoff valve Cracks damage Replace ...

Page 328: ......

Page 329: ...LESHOOTING 8 14 ELECTRIC STARTING SYSTEM 8 17 CIRCUIT DIAGRAM 8 17 STARTING CIRCUIT CUTOFF SYSTEM OPERATION 8 18 TROUBLESHOOTING 8 19 STARTER MOTOR 8 22 CHECKING THE STARTER MOTOR 8 24 ASSEMBLING THE STARTER MOTOR 8 25 CHARGING SYSTEM 8 27 CIRCUIT DIAGRAM 8 27 TROUBLESHOOTING 8 28 LIGHTING SYSTEM 8 30 CIRCUIT DIAGRAM 8 30 TROUBLESHOOTING 8 31 SIGNAL SYSTEM 8 35 CIRCUIT DIAGRAM 8 35 TROUBLESHOOTING...

Page 330: ...ELEC EXUP SYSTEM 8 51 CIRCUT DIAGRAM 8 51 TROUBLESHOOTING 8 52 SELF DIAGNOSIS 8 55 TROUBLESHOOTING 8 57 ...

Page 331: ...nitor unit 6 Starter relay 7 Starting circuit cutoff relay 8 Flasher relay 9 Speed sensor 10 Sidestand switch 11 Neutral switch 12 Oil level gauge 13 Ignition coil 14 Rectifier Regulator 15 Thermo unit 16 Horn 17 Emargency stop switch 18 Fan motor relay EAS00729 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 332: ...8 2 1 Thermo unit 2 T P S 3 Starter motor 4 Pickup rotor 5 Pickup coil ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ELEC ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ...

Page 333: ...T OF THE ELECTRICAL COMPONENTS AND COUPLERS ELEC 1 Ignitor unit 2 Fuse box 3 Battery 4 Fuel pump 5 Fuel pump coupler 6 Brake light switch coupler 7 Newtral switch coupler 8 Pickup coil coupler 9 Speed sensor coupler ...

Page 334: ...8 4 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ELEC 1 Ignition coil 2 3 2 Ignition coil 1 4 3 Rectifier regulator 4 Stator coil ...

Page 335: ...L COMPONENTS AND COUPLERS ELEC 1 Emargency stop switch 2 Flasher relay 3 Starter relay 4 Fan motor relay 5 Starting circuit cutoff relay 6 Stator coil coupler 7 Sidestand switch coupler 8 Fuel sender coupler 9 Oil level switch coupler ...

Page 336: ... is used WARNING LIGHT Oil evel warning light This warning light comes on when the engine oil level is low If this symbol flashes stop the engine immediately and fill it with oil to the specified level Coolant temperature warning light This warning light comes on when the cool ant temperature is too high Fuel level warning light When the fuel level drops below approxi mately 5 5 L this light will ...

Page 337: ...he hour digits start flashing push the RESET button 2 to set the hours 3 Push the SELECT button 1 to change the minutes 4 When the minute digits start flashing push the RESET button 2 to set the minutes 5 Push the SELECT button 1 to start the clock After setting the clock be sure to push the SE LECT button 1 before turning the main switch to OFF otherwise the clock will not be set ...

Page 338: ...r to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates ...

Page 339: ...ake switch 13 Fuse 14 Side stand switch 15 Neutral switch 16 Oil level switch CHECKING THE SWITCHES ELEC EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switc...

Page 340: ... both TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left Bulbs A are used for headlights and usually use a bulb holder which must be detached be fore removing the bulb The majority of these bulbs can be removed from their respective socket by turning them counterclockwise Bulb B is used for turn signal and tail brake lights and can be removed from the socket...

Page 341: ...om oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bult for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 r...

Page 342: ...inuity If any of the readings indicate no continuity replace the bulb socket CHECKING THE LEDs The following procedures applies to all of the LEDs 1 Check LED for proper operation Improper operation Replace a Disconnect the meter assembly coupler me ter assembly side b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minal as shown A wire that is used as a jumpe...

Page 343: ...8 13 1 Main switch 5 Battery 7 Fuse main 15 Ignitor 16 Ignition coil 17 Spark plug 18 Pickup coil 41 Engine stop switch 58 Fuse ignition IGNITION SYSTEM ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 344: ... within specifica tion Re gap or replace the spark plug IGNITION SYSTEM ELEC NOTE YES NO 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in CHAPTER 3 Replace the fuse s SAre the main and ignition fuses OK EAS00737 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 Main and ignition fuses 2 Battery 3 S...

Page 345: ...he spark plug caps SRemove the spark plug cap from the spark plug lead SConnect the pocket tester Ω 1k to the spark plug cap as shown SMeasure the spark plug cap resistance Spark plug cap resistance 10 kΩ at 20_C SIs the spark plug cap OK Replace the spark plug cap 6 Ignition coil resistance The following procedure applies to all of the ignition coils SDisconnect the ignition coil leads from the w...

Page 346: ...ty Refer to CHECKING THE SWITCHES Replace the main switch NO EAS00750 YES Replace the right handlebar switch 8 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES Secondary coil resistance 12 X 18 kΩ at 20_C SIs the ignition coil OK YES NO Replace the ignition coil EAS00748 SIs the main switch OK SIs the engine stop switch OK NO YES 10 Wiring SCheck the e...

Page 347: ...relay 8 Starter motor 9 Starting circuit cutoff relay 10 Side stand switch 19 Neutral switch 41 Engine stop switch 42 Start switch 48 Clutch switch 58 Fuse ignition 59 Alarm ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 348: ...ff relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the en gine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN TH...

Page 349: ... SIs the battery OK NO YES SClean the battery terminals SRecharge or re place the battery ELECTRIC STARTING SYSTEM ELEC NOTE SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in CHAPTER 3 1 Main and ignition fuses SAre the main and ignition fuses OK NO YES Replace the fuse s EAS00757 TROUBLESHOOTING The starter motor fails to turn Check 1 Main and ignition fuses 2 Batt...

Page 350: ... engine stop switch for continuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Disconnect the starting circuit cutoff relay coupler from the wire harness Connect the pocket tester Ω 1 and bat tery 12 V to the starting circuit cutoff relay coupler as shown 4 Starting circuit cutoff relay EAS00759 Positive battery lead red black Negative battery lead black yellow 1 2 Positive tester ...

Page 351: ...witch 10 Clutch switch Check the clutch switch for continuity Refer to CHECKING THE SWITCHES EAS00752 NO YES Replace the side stand switch 9 Sidestand switch Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK EAS00751 NO YES Replace the neutral switch 8 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neut...

Page 352: ...g the starter motor Carburetor Starter motor lead Starter motor O ring 1 1 1 Remove the parts in the order listed Refer to CARBURETOR in chapter 7 For installation reverse the removal procedure ELECTRIC STARTING SYSTEM ELEC EAS00767 STARTER MOTOR ...

Page 353: ...set Brush seat along with the brushes Armature assembly Brush holder along with the brushes O ring Starter motor yoke 1 1 1 1 1 1 1 1 1 1 2 1 Disassemble the parts in the order listed Be sure to remove the installation nut on brush 1 first For assembly reverse the disassembly procedure NOTE 1 2 3 4 5 Refer to ASSEMBLING THE STARTER MOTOR 6 7 8 9 10 11 12 5 Nm 0 5 m kg 10 Nm 1 0 m kg EAS00768 ...

Page 354: ...ca to the proper measurement with a hacksaw blade that has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica must be undercut to ensure proper op eration of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester Pocket tester 90890 08112 Arm...

Page 355: ...he brushes as a set Brush length wear limit 4 mm 6 Measure brush spring force Out of specification Replace the brush springs as a set Brush spring force 7 65 X 10 01 N 7 Check gear teeth Damage wear Replace the gear EAS00772 ASSEMBLING THE STARTER MOTOR 1 Install armature brush seat 1 Align the tab a on the brush seat with the slot b in the starter motor rear cover ...

Page 356: ...ARTING SYSTEM ELEC NOTE 2 Install starter motor front cover 1 starter motor rear cover 2 O ring 3 New Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers ...

Page 357: ...8 27 2 Rectifire reguretor 3 AC magneto 5 Battery 7 Fuse main CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 358: ...tion NO NOTE The charging circuit is OK EAS00775 EAS00738 1 Main fuses SCheck the fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 SAre the fuses OK NO YES Replace the fuse s EAS00739 NO YES SClean the battery terminals SRecharge or re place the battery 2 Battery Minimum open circuit voltage 12 8 V or more at 20_C SIs the battery OK CHARGING SYSTEM ELEC NOTE EAS00774 TROUBLESHOOTING T...

Page 359: ...stance SRemove the generator cover SConnect the pocket tester Ω 1 to the sta tor coils as shown Positive tester probe white Negative tester probe white NO YES Replace the rectifi er regulator Properly connect or repair the charging system s wiring EAS00779 5 Wiring SCheck the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM SIs the charging system s wiring properly connect...

Page 360: ...0 Fuse Alarm 61 Fuse headlight 66 Headlight relay on off 67 Headlight relay dimmer 1 Main switch 5 Battery 7 Fuse main 31 Hi beam indicator light 34 Meter light 40 Headlight switch 45 Pass switch LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 361: ...and alarm fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 EAS00738 YES NO EAS00739 1 Main headlight and alarm fuses SAre the main headlight and alarm fuses OK Replace the fuse s 2 Battery SCheck the condition of the battery Refer to CHECKING THE BATTERY in CHAPTER 3 Minimum open circuit voltage 12 8 V or more at 20_C SIs the battery OK EAS00781 TROUBLESHOOTING Any of the following fa...

Page 362: ...ck Does the headlight rrelay dimmer have continuity NO YES Replace the head light relay dimmer 1 2 Hi beam Positive battery lead yellow Negative battery lead black Positive tester probe black blue Negative tester probe black yellow 3 4 8 Headlight relay dimmer Disconnect the headlight relay dimmer from the coupler Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay dimmer couple...

Page 363: ...CHECKING THE LIGHTING SYSTEM 1 The headlight and the high beam indicator light fail to come on 1 Headlight buld and scocket Check the headlight bulb and socket for continuity 1 2 3 4 5 2 Voltage Connect the pocket tester DC 20 V to the headlight and high beam indicator light cou plers as shown A B When the dimmer switch is set to When the dimmer switch is seto to Set the main switch to ON Set the ...

Page 364: ...of blue red on the tail brake light coupler tail brake light side The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired 1 This circuit is OK Set the main switch to ON Set the light switch to PO or ON Measure the voltage 12 V of blue on the meter light coupler wire harness side YES NO This circuit is OK The wiring circuit from the main switch to the ...

Page 365: ...8 35 SIGNAL SYSTEM ELEC EAS00793 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 366: ... signal indicator light left 33 Turn signal indicator light right 35 Oil level gauge 36 Fuel sender 37 Turn signal relay 39 Front brake light switch 43 Horn 47 Horn switch 49 Hazard switch 50 Turn signal switch 51 Front turn signal light left 52 Front turn signal light right 53 Rear turn signal light left 54 Rear turn signal light right 56 Tail brake light 57 Fuse turn signal 58 Fuse ignition 60 F...

Page 367: ...out defects SIs the horn switch OK SIGNAL SYSTEM ELEC NOTE EAS00738 1 Main signal alarm and ignition fuses SCheck the main signal alarm and ignition fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 SAre the main signal alarm and ignition fuses OK YES NO Replace the fuse s EAS00739 2 Battery SCheck the condition of the battery Refer to CHECKING THE BATTERY in CHAPTER 3 Minimum open cir...

Page 368: ...gative tester probe black 1 Is the voltage within specification Does the horn sound YES NO Set the main switch to ON Measure the voltage 12 V of black at the horn terminal Replace the horn Repair or replace the horn 1 1 Positive tester probe black Negative tester probe ground Is the voltage within specification NO EAS00797 2 The tail brake light fails to come on YES 1 Tail brake light bulb and soc...

Page 369: ...ignal switch for continuity Refer to CHECKING THE SWITCHES NO YES Replace the left han dlebar switch 1 Positive tester probe brown Negative tester probe ground YES NO Set the main switch to ON Measure the voltage 12 V on brown at the turn signal relay coupler wire harness side The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be re paired 3 Voltage Connect...

Page 370: ... side as shown NO YES The wiring circuit from the turn signal switch to the turn sig nal light connector is faulty and must be repaired This circuit is OK Set the main switch to ON Set the turn signal switch to or Measure the voltage 12 V of the chocolate or dark green at the turn signal light connector wire harness side Rear turn signal light Turn signal indicator light 1 2 1 2 A B 1 4 Voltage Co...

Page 371: ...gative tester probe ground YES NO Set the main switch to ON Measure the voltage 12 V The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired 3 Voltage Connect the pocket tester DC 20 V to the meter light bulb coupler wire harness side as shown Is the voltage within specification This circuit is OK Are the oil level warning light bulb and sock et OK Is...

Page 372: ...he main switch to ON SMeasure the voltage 12 V of brown on the meter light coupler wire harness side SIs the voltage within specification 1 Positive tester probe brown Negative tester probe black 1 2 Voltage SConnect the pocket tester DC 20 V to the meter light coupler wire harness side as shown 2 Before reading the fuel level gauge leave the float in one position either up or down for at least th...

Page 373: ...3 COOLING SYSTEM ELEC 1 Main switch 5 Battery 7 Fuse main 21 Thermo unit 27 Combination meter 28 Water temp warning light 62 Fues fan 63 Fan motor relay 64 Fan motor EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 374: ... the battery Refer to CHECKING THE BATTERY in CHAPTER 3 SCheck the main and radiator fan motor fuses for continuity Refert to CHECKING THE FUSES in CHAPTER 3 1 Main and radiator fan motor fuses SAre the main and radiator fan motor fuses OK YES NO Replace the fuse s EAS00739 2 Battery Minimum open circuit voltage 12 8 V or more at 20_C EAS00808 TROUBLESHOOTING SThe radiator fan motor fails to turn ...

Page 375: ...wn SImmerse the termo unit in a container filled with coolant 1 EAS00812 2 3 Make sure the termo unit terminals do not get wet NOTE SPlace a thermometer in the coolant SSlowly heat the coolant and then let it cool to the specified temperature indicated in the table SCheck the thermo unit for continuity at the temperatures indicated in the table SIs the cooling system s wiring properly con nected a...

Page 376: ...8 46 1 Main switch 5 Battery 7 Fuse main 9 Starting circuit cutoff relay 11 Fuel pump 15 Ignitor 41 Engine stop switch 51 Fuse ignition FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 377: ...M ELEC EAS00815 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump ...

Page 378: ...k Negative tester probe black blue 1 2 3 4 Replace the starting circuit cutoff relay FUEL PUMP SYSTEM ELEC If the fuel pump fails to operate NOTE EAS00738 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in CHAPTER 3 Minimum open circuit voltage 12 8 V or more at 20_C SIs the battery OK SAre the main and ignition fuses OK EAS00739 2 Battery S...

Page 379: ...ack blue Negative tester probe black Replace the fuel pump SMeasure the fuel pump resistance 1 2 SIs the fuel pump OK Fuel pump resistance 4 30 Ω at 20_C EAS00817 7 Wiring SCheck the entire fuel pump system s wiring Refer to CIRCUIT DIAGRAM SIs the fuel system s wiring properly con nected and without defects YES NO Properly connect or repair the fuel sys tem s wiring Replace the ignitor unit EAS00...

Page 380: ...en flames sparks or any other source of fire If you do accidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is not a fire may occur Therefore make sure that the engine is completely cool before performing the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open con tainer c Turn the fuel cock ...

Page 381: ...8 51 1 Main switch 5 Battery 7 Fuse main 12 EXUP servomotor 15 Ignitor 58 Fuse ignition EXUP SYSTEM ELEC EAS00827 EXUP SYSTEM CIRCUIT DIAGRAM ...

Page 382: ... with the EXUP servomotor coupler connected to the wire harness Does the EXUP servomotor pulley turn Procedure 1 EAS00829 NOTE EAS00828 TROUBLESHOOTING When the engine speed changes the EXUP servomotor does not operate Procedure 1 Check 1 EXUP servomotor operation with the EXUP servomotor coupler con nected to the wire harness 2 Voltage 3 EXUP servomotor operation with the EXUP servomotor coupler ...

Page 383: ...sconnect the EXUP servomotor coupler from the wire harness Connect the battery leads to the EXUP ser vomotor coupler as shown 3 EXUP servomotor operation with the servomotor coupler disconnected to the wire harness Positive battery lead black yellow Negative battery lead black red 1 2 Check that the EXUP servomotor pulley ro tates several times CAUTION To prevent damaging the EXUP servomo tor perf...

Page 384: ... sys tem s wiring Replace the ignitor unit EAS00750 SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES 4 Engine stop switch SIs the engine stop switch OK YES NO Replace the right handlebar switch Minimum open circuit voltage 12 8 V or more at 20_C EAS00739 SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 2 Battery SIs the battery ...

Page 385: ...throttle ignition timing The motorcycle can be ridden The tachometer displays the condition code 3 000 r min EXUP Improper connection Short circuit The EXUP valve stays in the open position for three seconds and then the servomotor shuts off The motorcycle can be ridden The tachometer displays the condition code 7 000 r min Servomotor is locked The servomotor s power supply is constantly inteerupt...

Page 386: ...3 seconds Condition code 2 5 seconds Engine speed 3 seconds 1 2 3 Tachometer display sequence When more than one item is being monitored the tachometer needle displays the condition codes in ascending order cycling through the sequence repeatedly If the engine is stopped the engine speed 3 is 0 r min ...

Page 387: ...er 6 Is the throttle position sensor OK YES Replace the throttle position sensor Replace the ignitor unit NOTE 13 Throttle position sensor 15 Ignitor unit TROUBLESHOOTING The tachometer starts to display the self diagnosis sequence Check 1 Throttle position sensor 2 EXUP 3 Speed sensor 4 Emargency stop switch Before troubleshooting remove the following part s 1 Rider seat 2 Fuel tank 3 Air filter ...

Page 388: ...otor for continuity Refer to EXUP SYSTEM Is the EXUP servomotor OK YES Repair or replace the wire harness NO 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK YES Replace the ignitor unit 12 EXUP servomotor 15 Ignitor unit 2 EXUP CIRCUIT DIAGRAM ...

Page 389: ...y Refer to CIRCUIT DIAGRAM 1 Wire harness Is the wire harness OK YES NO Replace the speed sensor BAD Repair or replace the wire harness Replace the ignitor unit SELF DIAGNOSIS ELEC 15 lgnitor unit 20 Speed sensor 3 Speed sensor CIRCUIT DIAGRAM ...

Page 390: ...CUIT DIAGRAM 1 Wire harness Is the wire harness OK YES NO Replace the emar gency stop switch BAD Repair or replace the wire harness Replace the ignitor unit SELF DIAGNOSIS ELEC 14 Emargency stop switch 15 lgnitor unit 4 Emargency stop switch CIRCUIT DIAGRAM ...

Page 391: ......

Page 392: ...ERFORMANCE ENGINE 9 3 FUEL SYSTEM 9 3 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT 9 3 SHIFT PEDAL DOES NOT MOVE 9 3 JUMPS OUT OF GEAR 9 3 FAULTY CLUTCH CLUTCH SLIPS 9 4 CLUTCH DRAGS 9 4 OVERHEATING ENGINE 9 4 COOLING SYSTEM 9 4 FUEL SYSTEM 9 4 CHASSIS 9 4 ELECTRICAL SYSTEMS 9 4 OVERCOOLING COOLING SYSTEM 9 5 POOR BRAKING PERFORMANCE 9 5 FAULTY FRONT FORK LEGS LEAKING OIL 9 5 MALFUNCTION 9 5 UNSTABL...

Page 393: ...S NOT LIGHT 9 7 HEADLIGHT BULB BURNT OUT 9 7 TAIL BRAKE LIGHT DOES NOT LIGHT 9 7 TAIL BRAKE LIGHT BULB BURNT OUT 9 7 TURN SIGNAL DOES NOT LIGHT 9 7 TURN SIGNAL BLINKS SLOWLY 9 7 TURN SIGNAL REMAINS LIT 9 7 TURN SIGNAL BLINKS QUICKLY 9 7 HORN DOES NOT SOUND 9 7 ...

Page 394: ...following guide for troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure in this manual for checks adjustments and replacement of parts STARTING PROBLEMS ENGINE Cylinder s and cylinder head s Loose spark plug Loose cylinder head or cylinder Damaged cylinder head gasket Damaged cylinder gas...

Page 395: ...ion coil Ignition system Faulty ignitor unit Faulty pickup coil Broken generator rotor woodruff key ELECTRICAL SYSTEMS Battery Discharged battery Faulty battery Fuse s Blown damaged or incorrect fuse Improperly installed fuse Spark plug s Incorrect spark plug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap Ignition coi...

Page 396: ...ransmission Worn gear dog EAS00848 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING PROBLEMS ENGINE Air filter Clogged air filter element EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift f...

Page 397: ...n system Faulty ignitor unit EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil EAS00855 OVERHEATING ENGINE Clogged coolant passages Cylinder head s and piston s Heavy carbon buildup Engine oil Incorre...

Page 398: ...ORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged oil seal lip ...

Page 399: ... steering head pipe Improperly installed bearing race EAS00862 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracket improperly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork leg s Uneven oil levels both front fork legs Unevenly tensioned fork spring bo...

Page 400: ...n Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Improperly grounded circuit Poor contacts main or light switch Burnt out headlight bulb HEADLIGHT BULB BURNT OUT Wrong headlight bulb F...

Page 401: ......

Page 402: ...45 Pass switch 46 Dimmer switch 47 Horn switch 48 Clutch switch 49 Hazard switch 50 Turn signal switch 51 Front turn signal light left 52 Front turn signal light right 53 Rear turn signal light left 54 Rear turn signal light right 55 Headlight 56 Tail brake light 57 Fuse turn signal 58 Fuse ignition 59 Alarm 60 Fuse alarm 61 Fuse headlight 62 Fuse fan 63 Fan motor relay 64 Fan motor 65 Rear brake ...

Page 403: ...Handlebar switch left 44 Pass switch 45 Dimmer switch 46 Horn switch 47 Clutch switch 48 Turn signal switch 49 Front turn signal light left 50 Front turn signal light right 51 Rear turn signal light left 52 Rear turn signal light right 53 Headlight 54 Tail brake light 55 Fuse ignition 56 Fuse turn signal 57 Fuse headlight 58 Fuse fan 59 Fan motor relay 60 Fan motor 61 Rear brake light switch 62 He...

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