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Yamaha FZS1000N, Service Manual

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Yamaha FZS1000N Service Manual Download Page 277

5-74

CRANKCASE

ENG

NOTE:

NOTE:

EAS00268

INSTALLING THE CONNECTING ROD AND
PISTON
The following procedure applies to all of the
connecting rods and pistons.
1. Install:

top ring 

1

2nd ring 

2

upper oil ring rail 

3

oil ring expander 

4

lower oil ring rail 

5

Be sure to install the piston rings so that the
manufacturer’s marks or numbers 

a

 face up.

2. Install:

piston

1

(onto 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 recommended lubricant)

Recommended lubricant

Engine oil

4. Offset:

piston ring end gaps

a

Top ring

b

Lower oil ring rail

c

Upper oil ring rail

d

2nd ring

e

Oil ring expander

Summary of Contents for FZS1000N

Page 1: ......

Page 2: ......

Page 3: ...y Yamaha Motor Corporation U S A First edition January 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 14 48 ...

Page 4: ...s 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 wh...

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

Page 8: ...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 9: ...GEN INFO ...

Page 10: ...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 11: ...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 12: ... 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 13: ... Connect and disconnect sev eral times 3 Check Sall connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect Slead Scoupler Sconnector Make sure that all connections are tight 5 Check Scontinuity with a pocket tester Pocket tester measurement YU 03112 C SIf there is no continuity clean the terminals SWhen checking the wire harness perform steps 1...

Page 14: ...er This tool is used to hold the generator rotor when removing or installing the generator rotor bolt or pickup coil rotor bolt YU 01304 Piston Pin Puller This tool is used to remove the piston pins YU 01312 A Fuel Level Gauge This tool is used to measure the fuel level in the float chamber Radiator Pressure Tester YU 24460 01 Radiator Pressure Tester Adapter YU 33984 Radiator Pressure Tester Radi...

Page 15: ...A Driver 43 mm Adapters This tool is used to install the front fork s oil seal and dust seal YU 03008 Micrometers 50 X 75 mm This tool is used to measure the piston skirt diameter YU 8030 Carburetor Synchronizer This guide is used to synchronize the carburetors Compression Gauge Set YU 33223 Compression Gauge Set Compression Gauge Adapter These tools are used to measure engine compression YU 03112...

Page 16: ...r pump seal YM 91042 Universal Clutch Holder Grabbit This tool is used to hold the clutch boss when removing or installing the clutch boss nut YM 04111 YM 4116 Valve Guide Remover ø4 Valve Guide Remover ø4 5 This tool is used to remove or install the valve guides YM 04112 YM 4117 Valve Guide Installer ø4 Valve Guide Installer ø4 5 This tool is used to install the valve guides YM 04113 YM 4118 Valv...

Page 17: ......

Page 18: ...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 19: ...SPEC ...

Page 20: ...Wheelbase Minimum ground clearance Minimum turning radius 2 125 mm 83 7 in 765 mm 30 1 in 1 190 mm 46 9 in 820 mm 32 3 in 1 450 mm 57 1 in 140 mm 5 5 in 2 900 mm 114 2 in 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 509 lb 232 kg 512 lb for california 208 kg 459 lb 209 kg 461 lb for california 189 kg 417 lb 188...

Page 21: ...2 206 psi at 400 r min Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Unleaded fuel for USA Regular unleaded gasoline for CDN 21 L 18 5 Imp qt 22 2 US qt 4 0 L 3 52 Imp qt 4 22 US qt 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 p...

Page 22: ...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 2 11 Imp qt 2 53 US qt 95 X 125 kPa 0 95 X 1 25 kg cm2 13 1 X 17 8 psi 340 mm 13 4 in 238 mm 9 4 in 24 mm 0 94 in 0 3 L 0 26 Imp qt 0 32 US qt Single suction centrifugal pump 68 43 X 28 28 1 581 0 15 mm 0 006 in Starting system ...

Page 23: ...ment A Measurement B Measurement C Max camshaft runout Chain drive right 24 500 X 24 521 mm 0 9646 X 0 9654 in 24 459 X 24 472 mm 0 9630 X 0 9635 in 0 028 X 0 062 mm 0 0011 X 0 0024 in 32 5 X 32 6 mm 1 2795 X 1 2835 in 24 95 X 25 05 mm 0 9823 X 0 9862 in 7 45 X 7 65 mm 0 2933 X 0 3012 in 32 95 X 33 05 mm 1 2972 X 1 3012 in 24 95 X 25 05 mm 0 9823 X 0 9862 in 7 75 X 7 95 mm 0 3051 X 0 3126 in 32 4 ...

Page 24: ...aust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaust 22 9 X 23 1 mm 0 9016 X 0 9094 in 24 4 X 24 6 mm 0 9606 X 0 9685 in 1 76 X 2 90 mm 0 0693 X 0 1142 in 1 76 X 2 90 mm 0 0693 X 0 1142 in 0 9 X 1 1 mm 0 035 X 0 043 in 0 9 X 1 1 mm 0 035 X 0 043 in 0 5 X 0 9 mm 0 020 X 0 035 in 0 5 X 0 9 mm 0 020 X 0 035 in 3 975 X 3 ...

Page 25: ...e Exhaust Spring tilt Intake Exhaust Winding direction top view Intake Exhaust SSS 0 9 X 1 1 mm 0 035 X 0 043 in 0 9 X 1 1 mm 0 035 X 0 043 in 38 90 mm 1 53 in 40 67 mm 1 60 in 34 50 mm 1 36 in 35 00 mm 1 38 in 82 X 96 N 8 2 X 9 6 kg 18 4 X 25 4 lb 110 X 126 N 11 0 X 12 6 kg 24 7 X 28 3 lb SSS SSS Clockwise Clockwise 0 01 mm 0 0004 in SSS SSS SSS SSS SSS SSS SSS SSS 2 5_ 1 7 mm 2 5_ 0 067 in 2 5_ ...

Page 26: ...fset Offset direction Piston pins Outside diameter Piston pin to piston pin bore clearance Piston rings Top ring Ring type Dimensions B X T End gap installed Ring side clearance 0 030 X 0 055 mm 0 001 X 0 002 in 73 955 X 73 970 mm 2 9118 X 2 9122 in 5 mm 0 20 in 17 002 X 17 013 mm 0 6694 X 0 6698 in 0 5 mm 0 0197 in Intake side 16 991 X 17 000 mm 0 6689 X 0 6693 in 0 002 X 0 022 mm 0 00008 X 0 000...

Page 27: ...0 0022 in 1 Violet 0 White 1 Blue 2 Black Crankshaft Width A Width B Max runout C Big end side clearance D Crankshaft journal to crankshaft journal bearing clearance Bearing color code 52 40 X 57 25 mm 2 063 X 2 254 in 300 75 X 302 65 mm 11 84 X 11 92 in 0 160 X 0 262 mm 0 006 X 0 010 in 0 029 X 0 053 mm 0 0011 X 0 0021 in 1 Pink violet 0 Pink white 1 Pink blue 2 Pink black 3 Pink brown 0 03 mm 0 ...

Page 28: ...on ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Max 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 0 003 in 0 08 mm 0 003 in Shifting mechanism Shift ...

Page 29: ... 0 20 in 5LV5 40 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 X 4 0 mm 0 118 X 0 157 in Max EXUP ca...

Page 30: ... 04 in 0 5 mm 0 02 in Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17 X MT5 50 Aluminum 135 mm 5 31 in SSS SSS SSS SSS SSS SSS 1 mm 0 04 in 0 5 mm 0 02 in Front tire Tire type Size Model manufacturer Tire pressure cold 0 X 90 kg 90 X 201 kg High speed riding Min tire tread depth Tubeless 120 70 ZR17 58W MEZ4Y FRONT ME...

Page 31: ...diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 298 X 5 mm 11 7 X 0 20 in 5 5 mm 0 22 in 14 mm 0 05 in 30 2 mm 1 19 in and 27 mm 1 06 in 4 5 mm 0 18 in 0 1 mm 0 004 in 0 5 mm 0 02 in 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 X thickness Min thickne...

Page 32: ...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 Telescopic fork Coil sprin 140 mm 5 51 in 344 0 mm 13 5 in 66 0 mm 2 60 in 320 0 mm 12 6 in 7 8 N mm 0 78 kg mm 43 7 lb in 11 8 N mm 1 2 kg mm 67 2 lb in 0 X 64 mm 0 X 2 52 in 64 X 140 mm 2 52...

Page 33: ...und 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 2 56 in 182 5 mm 7 19 in 163 mm 6 42 in 73 6 N mm 7 5 kg mm 420 lb in 0 X 65 mm 0 X 2 56 in No 1 200 kPa 12 kg cm2 170 7 psi 1 6 11 20 10 3 1 7 12 Swingarm Free play at the end of the sw...

Page 34: ...Resistance Rubber 10 kΩ SSS SSS Throttle position sensor standard resistance 4 X 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 X 0 33 Ω at 20_C 68_F W W SSS SSS SSS SSS Rectifier regulator Regulator type Model manufacture Semiconductor short circuit SH650C 11 SHINDENGEN SSS SSS No load ...

Page 35: ...0 in 0 7 mm 0 03 in SSS SSS SSS 4 mm 0 16 in SSS SSS 27 mm 1 06 in SSS Starter relay Model manufacturer Amperage Coil resistance MS5F 631 JIDECO 180 A 4 18 X 4 62 Ω SSS SSS SSS Horn Horn type Model manufacturer X quantity Max amperage Plain YF 12 NIKKO X 1 3 A SSS SSS SSS Turn signal relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage Full tra...

Page 36: ...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 37: ...ues for stan 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 d...

Page 38: ...UP 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 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 M6 M7 M6 M6 M6 M6 M20 M14 M6 M6 M6 M20 M20 M6 M6 M6 M6 M6 M8 M8 M8 M...

Page 39: ...it 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 1 5 1 0 1 2 9 0 0 8 8 5 1 2 1 0 2 2 0 65 0 65 1 0 1 0 ...

Page 40: ...2 21 TIGHTENING TORQUES SPEC Crankcase tightening sequence ...

Page 41: ...djusting 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 M10 M10 M8 M10 M8 M6 M18 M10 M10 M10 M12 M12 M6 M6 M6 M5 M6 M6 M16 M8 M10 M6...

Page 42: ... 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 43: ...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 44: ...2 25 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Water pump EAS00033 COOLING SYSTEM DIAGRAMS ...

Page 45: ...2 26 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Oil cooler 5 Water jacket joint ...

Page 46: ...2 27 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator cap 2 Thermostat 3 Thermo unit ...

Page 47: ...2 28 COOLING SYSTEM DIAGRAMS SPEC 1 Radiator ...

Page 48: ...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 49: ...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 50: ...2 31 LUBRICATION DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camshaft 3 Oil cooler 4 Oil strainer 5 Oil pump ...

Page 51: ...2 32 LUBRICATION DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camsahft 3 Oil filter cartridge 4 Oil level switch ...

Page 52: ...2 33 LUBRICATION DIAGRAMS SPEC 1 Cylinder head 2 Crankshaft ...

Page 53: ...2 34 LUBRICATION DIAGRAMS SPEC 1 Main axle 2 Oil delivery pipe 3 Drive axle ...

Page 54: ... 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 55: ...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 56: ...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 breather...

Page 57: ...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 58: ... 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 59: ...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 60: ...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 61: ...r lead fan motor lead and thermo unit lead with a plastic clamp Locate the end of clamp to downward Ensure that the throttle cable and high tension cable do not come into contact with each other V Fasten the rectifier regulator stay and rectifier reg ulator lead with a plastic clamp W Route the wire harness under the rectifier regulator X Fasten the battery negative lead with a battery band Y Inse...

Page 62: ...CLUTCH CABLE FREE PLAY 3 22 CLEANING THE AIR FILTER ELEMENT 3 23 CHECKING 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 CHECKING THE CANISTER 3 26 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...

Page 63: ...ND LUBRICATING THE CABLES 3 50 LUBRICATING THE LEVERS 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 64: ... 20 000 mi 31 000 km or 30 months Replace 6 Exhaust system See page 3 25 S Check for leakage S Retighten if necessary S Replace gasket s if necessary 7 Carburetor synchronization See page 3 10 S Adjust synchronization of carburetors 8 Idle speed See page 3 12 S Check and adjust engine idle speed S Adjust cable free play 9 Evaporative emission control system For California only See page 3 26 S Chec...

Page 65: ...See page 3 39 See page 3 69 S Check chain slack alignment condition S Adjust and lubricate chain thoroughly 1 Every 600 mi 1 000 km or after washing the motorcycle or riding in the rain 16 Wheel bearings See page 4 4 S Check bearings for smooth operation 17 Sidestand and centerstand pivots See page 3 50 S Check operation S Lubricate 2 18 Sidestand switch See page 8 21 S Check and clean or replace ...

Page 66: ...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 the parts in the order listed Disconnect For installation reverse the removal procedure EAS00038 FRONT COWLING SEAT SIDE COVER FUEL TANK FRONT COWLING ...

Page 67: ...nk 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 mDkg 7 2 ftDlb 19 Nm 1 9 mDkg 14 ftDlb 4 Nm 0 4 mDkg 2 9 ftDlb 10 Nm 1 0 mDkg 7 2 ftDlb EAS00040 SEAT SIDE COVER AND FUEL TANK ...

Page 68: ...lve clearance Out of specification Adjust Valve clearance cold Intake valve 0 11 X 0 20 mm 0 0043 X 0 0079 in Exhaust valve 0 21 X 0 25 mm 0 0083 X 0 0098 in 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 a...

Page 69: ...turned clockwise C Cylinder D Combustion cycle 2 Cylinder 180_ 4 Cylinder 360_ 3 Cylilnder 540_ 3 Remove Sintake camshaft Sexhaust camshaft SRefer to REMOVING THE CAMSHAFTS in chapter 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 valve...

Page 70: ...ide that touches 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 t...

Page 71: ...160 pad 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 07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 08 X 0 10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 13...

Page 72: ...efer to INSTALLING THE CAMSHAFTS in chapter 4 Lubricate the camshaft caps 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 of the valve clearance adjust ment...

Page 73: ...torcycle on a level surface Place the motorcycle on a suitable stand 2 Remove vacuum cap 3 Install carburetor synchronizer 1 inductive self powered tachometer 2 to the spark plug lead of cyl 1 Carburetor synchronizer YU 8030 Inductive self powered tachometer YU 8036 B 4 Start the engine and let it warm up for several minutes 5 Check engine idling speed Out of specification Adjust Refer to ADJUSTIN...

Page 74: ...ion 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 8 86 in Hg The difference in vacuum pressure between two carburetors should not exceed 1 33 kPa 10 mm Hg 0 39 in Hg 7 Measure engine idling speed Out of specification Adjust 8...

Page 75: ... the engine and let it warm up for several minutes 2 Install inductive self powered tachometer to the spark plug lead of cyl 1 Inductive self powered tachometer YU 8036 B 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 throttle stop screw 1 in direction a or b until the specified engine idling speed is obtain...

Page 76: ...e flange of the throttle grip 3 X 5 mm 0 12 X 0 20 in 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 Throttle cable free play at the flange of the throttle grip 3 X 5 mm 0 12 X 0 20 in 2 Remove seat fuel ...

Page 77: ...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 78: ...ed 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 brush 6 Me...

Page 79: ...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 battery powered timing light 1 inductive self powered tachometer 2 to the spark plug lead of cyl 1 Battery powered timing light YM 33277 A Inductive self powered tachometer YU 8036 B 3 Check ignition timing a Start the engine warm it up for several mi...

Page 80: ...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 81: ...ng 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 206 psi Minimum 1 260 kPa 12 6 kg cm2 179 psi Maximum 1 620 kPa 16 2 kg cm2 230 psi a Turn the main switch to ON b With the throttle wide open crank the engine until the reading on th...

Page 82: ...the recommended engine oil to the proper level Recommended engine oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase API Service SE SF and SG type or equiva lent e g SF SE SF SE CC SF SE SD 3 Start ...

Page 83: ... oil 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 YU 38411 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 correctly...

Page 84: ...nstall engine oil filler cap 10 Start the 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 af...

Page 85: ...he adjusting bolt 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 locknut 1 b Turn the adjusting...

Page 86: ...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 87: ...G 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 CARBURETORS in chapter 6 3 Install air chamber cover fuel tank seat EAS00097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure appl...

Page 88: ... 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 Check tightening torq...

Page 89: ...ve Sseat Sfuel tank 2 Remove SEXUP valve pulley cover 1 3 Check SEXUP operation a Disconnect the EXUP 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 ...

Page 90: ... counterclock 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 ...

Page 91: ...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 92: ...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 6 ...

Page 93: ... 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 94: ...um engines Mix ratio 50 antifreeze 50 water Quantity Total amount 2 4 L 2 11 Imp qt 2 53 US qt Coolant reservoir capacity 0 3 L 0 26 Imp qt 0 32 US qt From minimum to maximum level mark 0 2 L 0 18 Imp qt 0 21 US qt 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...

Page 95: ...ontact with painted surfaces immediately wash them with wa ter SDo not mix different types of antifreeze 11 Install Sradiator cap 12 Fill Scoolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install Scoolant reservoir cap 14 Start the engine warm it up for several min utes and then turn it off 15 Check Scoolant level Refer to CHECKING THE COOLANT LEV EL Before checking t...

Page 96: ...arg est Position 5 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 97: ...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 13 ft lb 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...

Page 98: ...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 99: ...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 100: ... 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 101: ...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 4 3 ft lb k Fill the reservoir to the proper l...

Page 102: ...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 suitable s...

Page 103: ...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 12 ft lb f Tighten the wheel axle nut to specification Wheel axle nut 150 Nm 15 m kg 108 ft lb ...

Page 104: ...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 105: ...ue 18 Nm 1 8 m kg 13 ft lb 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 bo...

Page 106: ...eal Oil leakage 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 ...

Page 107: ...ositions Standard 2 Minimum 5 Maximum 1 fully turned out position Rebound damping Never go beyond the maximum or minimum adjustment positions 1 Adjust Srebound 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 cl...

Page 108: ...ion 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 positio...

Page 109: ...n decreased 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 decreased...

Page 110: ...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 111: ... tire tread reaches the wear limit replace the tire immediately 2 Check tire surfaces Damage wear Replace the tire Minimum tire tread depth 1 0 mm 0 04 in 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 Alwa...

Page 112: ...aha is used on this motorcycle Front tire Manufacturer Type Size METZELER Tubeless 120 70 ZR17 58 W BRIDGESTONE Tubeless 120 70 ZR17 58 W Rear tire Manufacturer Type Size METZELER Tubeless 180 55 ZR17 73 W BRIDGESTONE 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 62 mi should be traveled at norma...

Page 113: ... 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 114: ...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 115: ...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 be...

Page 116: ...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 117: ...ition 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 unuse...

Page 118: ... 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 Under 12 0 V Replace the battery Set the charging time at 20 hours maximu...

Page 119: ...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 120: ...ctrical 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...

Page 121: ...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 122: ...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...

Page 123: ......

Page 124: ...C BALANCE 4 16 FRONT AND REAR BRAKES 4 17 FRONT BRAKE PADS 4 17 REPLACING THE FRONT BRAKE PADS 4 19 REPLACING THE REAR BRAKE PADS 4 21 FRONT BRAKE MASTER CYLINDER 4 24 REAR BRAKE MASTER CYLINDER 4 26 REMOVING AND DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 28 REMOVING AND DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 28 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 29 ASSEMBLING AND IN...

Page 125: ...CKING THE STEERING HEAD 4 61 INSTALLING THE STEERING HEAD 4 62 REAR SHOCK ABSORBER ASSEMBLY 4 63 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 4 64 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4 64 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 65 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 66 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 66 SWINGARM AND DRIVE CHAIN 4 67 REMOVING THE SWING...

Page 126: ...ont 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 52 ft lb 40 Nm 4 0 m kg 29 ft lb 18 Nm 1 8 m kg 13 ft lb EAS00514 CHASSIS FRONT WHEEL AND B...

Page 127: ...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 128: ...g over Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Remove brake hose holders left brake caliper right brake caliper Do not squeeze the brake lever when removing the brake calipers 3 Loosen wheel axle pinch bolt front wheel axle 4 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated 5 Remove front wheel axle 6 Remove fro...

Page 129: ...el surface c Remove the wheel bearings with a general bearing puller EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Check tire front wheel Damage wear Replace Refer to CHECKING THE TIRES in chapter 3 3 Measure front wheel radial runout 1 front wheel lateral runout 2 Over the specified limits ...

Page 130: ... wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing center race 1 or balls 2 Contact should be made only with the outer race 3 Use a socket 4 that matches the diameter of the wheel bearing outer race and oil ...

Page 131: ...re the deflection 2 X 3 mm 0 08 X 0 12 in below the edge of the brake disc 3 Measure Sbrake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace Brake disc thickness limit minimum 4 5 mm 0 18 in 4 Adjust Sbrake disc deflection a Remove the brake disc b Rotate the brake disc by one bolt hole c Install the brake disc Tighten the brake disc bolts i...

Page 132: ... Contact should be made only with the outer race 3 Use a shocket 4 that matches the diameter of the wheel bearing outer race and oil seal EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs 1 Lubricate wheel axle oil seal lips Recommended lubricant Lithium soap base grease 2 Tighten wheel axle 1 wheel axle pinch bolt 2 Before tightening the wheel axle nut push d...

Page 133: ...pot a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90_ so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X2 mark at the bottom of the wheel f Repeat steps b through d several times until all the marks come to rest at the same spot g The spot where all the marks come to rest is the...

Page 134: ... heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check Sfront wheel static balance a Turn the front wheel and make sure that it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 135: ...ting nut Wheel axle nut Washer Wheel axle Rear wheel assembly 1 1 2 2 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 Loosen 40 Nm 4 0 m kg 29 ft lb 150 Nm 15 m kg 108 ft lb EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL ...

Page 136: ...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 137: ...ke 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 13 ft lb 69 Nm 6 9 m kg 50 ft lb ...

Page 138: ...cycle 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 brake torque rod 4 Loosen locknut 1 adjusting nut 2 5 Remove wheel axle nut 3 wheel axle rear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket 6 Remove left collar 1 rear wheel drive hub 2 rear wheel d...

Page 139: ...r 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 the drive sprocket and the drive chain as a set Bent teeth Replace the rear wheel sprock et the drive sprocket and the drive chain as a set b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace rear w...

Page 140: ...ection limit maximum 0 1 mm 0 004 in Place the motorcycle on a suitable stand so that the wheel is elevated a Before measuring the front brake disc deflec tion turn the handlebar to the left or right to ensure that the front wheel is stationary b Remove the brake caliper c Hold the dial gauge at a right angle against the brake disc surface d Measure the deflection 2 X 3 mm below the edge of the br...

Page 141: ...s until the brake 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...

Page 142: ...ont 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 29 ft lb 6 Nm 0 6 m kg 4 3 ft lb EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 143: ... 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 6 Nm 0 6 m kg 4 3 ft lb 40 Nm 4 0 m kg 29 ft lb ...

Page 144: ...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 145: ...r limit 0 5 mm 0 02 in 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 146: ...e 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 the...

Page 147: ...ake 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 4 3 ft lb d Install a new brake pad shim 3 onto each new...

Page 148: ... 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 149: ...ke 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 7 2 ft lb 30 Nm 3 0 m kg 22 ft lb EAS00584 FRONT BRAKE MASTER CYLINDER ...

Page 150: ... 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 151: ...r cylinder 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 23 Nm 2 3 mSkg 17 ftSlb 30 Nm 3 0 mSkg 22 ftSlb EAS00586 REAR BRAKE MASTER CYLINDER ...

Page 152: ...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 153: ...hers 2 brake hose 3 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose 3 Remove master cylinder bracket master cylinder 4 Remove master cylinder boot circlip 5 Remove master cylinder kit spring EAS00589 REMOVING AND DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove side cover right 2 Remove union bolt 1 copper washers 2 brake hose 3 T...

Page 154: ...owing procedure applies to the both of the brake master cylinders 1 Check brake master cylinder body Damage scratches wear Replace brake fluid delivery passages brake master cylinder body Obstruction Blow out with compressed air A Front B Rear 2 Check brake master cylinder kit seals 1 Damage scratches wear Replace C Front D Rear 3 Check rear brake fluid reservoir 1 Cracks damage Replace rear brake...

Page 155: ...5 Check brake hoses Cracks damage wear Replace EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents Recommended brake fluid DOT 4 1 Install spring master cylinder kit 2 Install circlip master cylinder boot ...

Page 156: ...ion 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 motorcycle operation Refer to CABLE ROUTING SWhile holding the brake hose tighten the union bolt as shown STurn the handlebar to the left and to the right to make sure that the brake hose ...

Page 157: ...ter 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 6 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 7 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid ...

Page 158: ...ylinder 4 Install washer pin cotter pin hose clip 5 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 as shown Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING 6 Fill brake fluid reservoir to the maximum level mark a Recommended...

Page 159: ...g 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 7 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 8 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 ...

Page 160: ...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 4 3 ft lb 30 Nm 3 0 m kg 22 ft lb 40 Nm 4 0 m kg 29 ft lb EAS00613 FRONT BRAKE CALIPERS ...

Page 161: ...rake 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 4 3 ft lb EAS00615 ...

Page 162: ... 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 30 Nm 3 0 m kg 22 ft lb 40 Nm 4 0 m kg 29 ft lb EAS00616 REAR BRAKE CALIPER ...

Page 163: ...ar 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 4 3 ft lb EAS00617 ...

Page 164: ... the brake hose into a container and pump out the brake fluid carefully 2 Remove Sbrake caliper pistons 1 Sbrake 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 SNever try to pry out the brake caliper pis tons SDo not loosen the bolts 3 c ...

Page 165: ...and pump out the brake fluid carefully 2 Remove Sbrake caliper pistons 1 Sbrake 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 SNever try to pry out the brake caliper pis tons SDo not loosen the bolts 3 c Remove the brake caliper piston sea...

Page 166: ...enever the brake is disas sembled 1 Check Sbrake caliper pistons 1 Rust scratches wear Replace the brake caliper Sbrake caliper cylinders 2 Scratches wear Replace the brake cali per Sbrake calipers Cracks damage Replace Sbrake 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 167: ...will cause the piston seals to swell and distort SWhenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper temporarily Scopper washers 1 New Sbrake hose 2 Sunion 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 ...

Page 168: ...e perfor mance SWhen 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 Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check Sbrake fluid lev...

Page 169: ...eplace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install Sbrake caliper 1 temporarily Scopper washers New Sbrake hose 2 Sunion 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 Sbrak...

Page 170: ...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 Sbrake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check Sbrake fluid level Below the minimum level mark a Add the recommended brake...

Page 171: ...racket pinch bolt 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 mSkg 17 ftSlb 30 Nm 3 0 mSkg 22 ftSlb 25 Nm 2 5 mSkg 18 ftSlb EAS00647 FRONT FORK ...

Page 172: ...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 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 25 Nm 2 5 mSkg 18 ftSlb 35 Nm 3 5 mSkg 25 ftSlb EAS00648 ...

Page 173: ...orcycle on a suitable stand so that the front wheel is elevated 2 Loosen Supper bracket pinch bolt 1 Scap bolt 2 Slower bracket pinch bolt 3 Before loosening the upper and lower bracket pinch bolts support the front fork leg 3 Remove Sfront fork leg EAS00653 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove Scap bolt 1 from the damper adjusti...

Page 174: ...the inner tube 5 Remove Sdamper rod bolt Sdamper rod 1 While holding the damper rod with the damper rod holder 2 loosen the damper rod bolt Damper rod holder YM 01447 6 Remove Sinner 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 175: ...not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure Sspring free length a Over the specified limit Replace Spring free length limit 344 0 mm 13 5 in 3 Check Sdamper rod Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air Soil flow stopper Damage Replace SThe front fork leg has a built in damper ad justing rod and a very sophisti...

Page 176: ...g outer tube bushing oil seal dust seal SBefore assembling the front fork leg make sure that all of the components are clean 1 Install Sdamper 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 Sinner tube s outer su...

Page 177: ...leg with a plastic bag to protect the oil seal during installation 5 Install Soil seal clip Adjust the oil seal clip so that it fits into the outer tube s groove 6 Fill Sfront fork leg with the specified amount of the recom mended fork oil Quantity each front fork leg 0 44 L 435 cm3 15 3 Imp oz 14 7 US oz Recommended oil Yamaha suspension oil 01 or equivalent SBe sure to use the recommended fork o...

Page 178: ...re 1 stroke about 150 mm 5 9 in Be careful not to stroke the inner tube over 150 mm 5 9 in as this will cause air to enter If the inner tube is stroke more than 150 mm 5 9 in 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 Measure Sfront fork leg oil...

Page 179: ... puller onto the damper rod c Pull up the rod puller and install the rod hold er 1 between the rod puller 2 and the spacer Use the side of the rod holder that is marked B Rod holder YM 01434 d Remove the rod puller e Install the damper adjusting rod locknut f Tighten the damper adjusting rod locknut Damper adjusting rod locknut 25 Nm 2 5 mSkg 18 ftSlb g Install the damper adjusting rod and cap bol...

Page 180: ...gs 1 Install Sfront 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 Slower bracket pinch bolt 1 Scap bolt 2 Supper bracket pinch bolt 3 Make sure that the brake hoses are routed properly 3 Adjust Sspring preload Srebound damping Scompression damping Refer to ADJUSTING THE FRONT FORK in c...

Page 181: ... 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 mSkg 17 ftSlb 26 Nm 2 6 mSkg 19 ftSlb 10 Nm 1 0 mSkg 7 2 ftSlb 26 Nm 2 6 mSkg 19 ftSlb EAS00664 HANDLEBAR ...

Page 182: ...1 Sthrottle grip 2 3 Remove Shandlebar 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 Shandlebar Bends cracks damage Replace Do not attempt to straighten a bent handle b...

Page 183: ...1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it falling over 2 Install Shandlebar 1 Supper handlebar holders 2 SFirst tighten the bolts on the front side of the handlebar holder then on the rear side STurn 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 matc...

Page 184: ...lder Align the slit in the clutch lever holder with the punch mark a in the left handlebar 7 Install Sbrake master cylinder Refer to ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYL INDER 8 Adjust Sthrottle 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 X 5 mm 0 12 X 0 20 in ...

Page 185: ...t 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 mSkg 38 ftSlb 18 Nm 1 8 mSkg 13 ftSlb 110 Nm 11 0 mSkg 80 ftSlb EAS...

Page 186: ...ut 1 with the special tool 2 Steering nut wrench YU 1268 Securely support the lower bracket so that there is no danger of it falling EAS00681 CHECKING THE STEERING HEAD 1 Wash Sbearings Sbearing races Recommended cleaning solvent Kerosine 2 Check Sbearings 1 Sbearing races 2 Damage pitting Replace 3 Replace Sbearings Sbearing races a Remove the bearing races 1 from the steer ing head pipe with a l...

Page 187: ...ubber seal 4 Check Supper bracket Slower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate Supper bearing Slower bearing Sbearing races Recommended lubricant Lithium soap base grease 2 Install Slower ring nut 1 Srubber washer 2 Supper ring nut 3 Slock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3 3 Install S...

Page 188: ... 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 mSkg 29 ftSlb 48 Nm 4 8 mSkg 35 ftSlb 40 Nm 4 0 mSkg 29 ftSlb 40 Nm 4 0 mSkg 29 ftSlb 48 Nm 4 8 mSkg 35 ftSlb EAS00685 REAR SHOCK ABSORBER ASSEMBLY ...

Page 189: ...er or gas cylinder SDo 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 SDo 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 SHOCK ABSORB ER...

Page 190: ...ycle on a suitable stand so that the rear wheel is elevated 2 Remove Sconnecting arm bolt 1 Srelay arm bolt 2 Srear 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 Srear shock absorber assembly upper bolt 1 Srear shock absorber assembly Raise the swingarm and then remove the rear shock absorbe...

Page 191: ...r Replace Sdust seals Damage wear Replace Sbolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORB ER ASSEMBLY 1 Lubricate Sspacers Sbearings Recommended lubricant Molybdenum disulfide grease 2 Install Srear shock absorber assembly Rear shock absorber assembly upper nut 40 Nm 4 0 mSkg 29 ftSlb Rear shock absorber assembly lower nut 40 Nm 4 0 mSkg 29 ftSlb Relay arm to frame nut 4...

Page 192: ...r 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 NOTE 85 Nm 8 5 mSkg 61 ftSlb 125 Nm 12 5 mSkg 90 ftSlb 23 Nm 2 3 mSkg 17 ftSlb EAS00700 SWINGARM AND DRIVE CHAIN ...

Page 193: ...rks 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 85 Nm 8 5 mSkg 61 ftSlb 125 Nm 12 5 mSkg 90 ftSlb 23 Nm 2 3 mSkg 17 ftSlb ...

Page 194: ...old the swingarm so that it does not drop down 3 Check Sswingarm side play A Sswingarm vertical movement B a Check the tightening torque of the pivot shaft nut Pivot shaft nut 125 Nm 12 5 mSkg 90 ftSlb 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 a...

Page 195: ... a suitable stand so that the rear wheel is elevated 2 Remove Sfoot rest left Sdrive sprocket cover Sdrive chain guide 1 Sdrive sprocket 2 EAS00707 CHECKING THE SWINGARM 1 Check Sswingarm Bends cracks damage Replace 2 Check Spivot shaft Roll the pivot shaft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 3 Wash Spivot shaft Sdust covers Sspacer Swashers Sbearings Re...

Page 196: ... THE DRIVE CHAIN 1 Measure Sten link section a of the drive chain Out of specification Replace the drive chain the drive sprocket and the rear wheel sprocket as a set Ten link drive chain section limit maximum 150 1 mm 5 91 in SWhile measuring the ten link section push down on the drive chain to increase its tension SMeasure the length between drive chain roller 1 and 11 as shown SPerform this mea...

Page 197: ...an also damage the O rings Therefore use only kerosine to clean the drive chain 4 Check SO rings 1 Damage Replace the drive chain Sdrive chain rollers 2 Damage wear Replace the drive chain Sdrive 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 drive chain and be low the swingarm 5 ...

Page 198: ... ring chains 2 Install Sdrive chain 1 Sdrive sprocket 2 Slock washer 3 New Sdrive sprocket nut 4 Sdrive 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 Sbearings Sspacers Sdust covers Spivot shaft Recommended lubricant Molybdenum disulfide grease 2 Install Srelay arm Sl...

Page 199: ...HOCK ABSORBER ASSEMBLY and REAR WHEEL 4 Adjust Sdrive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Drive chain slack 40 X 50 mm 1 57 X 1 97 in 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 200: ... 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 201: ...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 202: ... 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 203: ...ENG ...

Page 204: ...se Air iduction system Side cover left Stator coil coupler oil level switch Shit 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 CARBURETORS in chapter 7 Refer to AIR INDUCTION SYSTEM in chapter 7 For installation reverse the removal procedure Refer to RADIATOR in chapter 6 ENGINE ENG EAS00188 OVERHAULING THE ENGI...

Page 205: ...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 206: ... 40 ft lb Order Job Part Q ty Remarks 1 2 3 4 5 6 Removing the engine Down tube Engine mounting bolt 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 ENGINE ENG EAS00191 ENGINE ...

Page 207: ...Tighten the bolts in the following order Engine mount bolt 1 55 Nm 5 5 m kg 40 ft lb Engine mount bolt 2 55 Nm 5 5 m kg 40 ft lb Engine mount bolt 3 33 Nm 3 3 m kg 24 ft lb Engine mount bolt 5 55 Nm 5 5 m kg 40 ft lb Down tube 6 24 Nm 2 4 m kg 17 ft lb 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 ma...

Page 208: ...embly Radiator assembly and thermostat assembly 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 7 Refer to RADIATOR and THERMOSTAT ASSEMBLY in chapter 6 For installation reverse the removal procedure EAS00194 CAMSHAFT CYLINDER HEAD COVER ...

Page 209: ...shaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft 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 7 2 ft lb 24 Nm 2 4 m kg 17 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb CAMSHAFT ENG EAS00196 CAMSHAFTS ...

Page 210: ...ake 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 7 2 ft lb 24 Nm 2 4 m kg 17 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 211: ... 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 212: ...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 1 2756 in b 24 85 mm 0 9783 in Exhaust a 32 85 mm 1 2933 in b 24 ...

Page 213: ...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 7 2 ftSlb d Remove the camshaft caps and then mea sure the width of the ...

Page 214: ...amshaft sprockets as a set 2 Check R 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 R timing chain guide exhaust side 1 R timing chain guide intake side 2 R timing chain guide top side 3 Damage wear Replace the defective part s EAS00210 CHECKING THE TIMING CHAIN TENSIO...

Page 215: ...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 R cap bolt R copper washer R spring R gasket R timing chain tensioner rod Damage wear Replace the defective part s EAS00217 INSTALLING THE CAMSHAFTS 1 Install R exhaust camshaft 1 R intake camshaft 2 Install the camshafts with the punch mark...

Page 216: ...ket R exhaust 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 ke...

Page 217: ... 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 mR kg 7 2 ftR lb d Remove the screwdr...

Page 218: ...e b R 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 R valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 9 Install R timing mark accessing screw R crankshaft end cover ...

Page 219: ...nd 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 mSkg 14 ftSlb 1st 50 Nm 5 0 mSkg 36 ftSlb 2nd 20 Nm 2 0 mSkg 14 ftSlb 1st 50 Nm 5 0 mSkg 36 ftSlb 2nd EAS00221 CYLINDER HEAD ...

Page 220: ...e a sharp instrument to avoid damag ing or scratching R spark plug threads R valve seats 2 Check R cylinder head Damage scratches Replace R cylinder head water jacket Mineral deposits rust Eliminate 3 Measure R cylinder head warpage Out of specification Resurface the cylin der head Cylinder head warpage Less than 0 1 mm 0 004 in a Place a straightedge 1 and a thickness gauge 2 across the cylinder ...

Page 221: ...ity 3 Tighten R cylinder head nuts 1 X 10 1st 2nd R cylinder head bolt 11 12 R First tighten the nuts 1 X 10 to approximate ly 20 Nm 2 0 mR kg 14 ftR lb with a torque wrench R Retighten the nuts to 50 Nm 5 0 mR kg 36 ftR lb R Apply engine oil onto the threads of the cylin der head nuts R Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages 4 Insta...

Page 222: ...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 223: ...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 224: ...nd valve pad so that they can be reinstalled in their original place 2 Check R 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 R valve cotters 1 Remove the valve cotter...

Page 225: ...NG THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure R 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 0 0004 X 0 0015 in Limit 0 08 mm 0 0031 in Exhaust 0 020 X...

Page 226: ...he new valve 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 YM 04111 Exhaust 4 5 mm YM 4116 Valve guide installer Intake 4 0 mm YM 04112 Exhaust 4 5 mm YM ...

Page 227: ...em runout Out of specification Replace the valve R When installing a new valve always replace the valve guide R If the valve is removed or replaced always re place the oil seal Valve stem runout 0 01 mm 0 0004 in EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate R carbon deposits from the valve face and valve seat 2 Check R valve sea...

Page 228: ... and 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 an...

Page 229: ...ake spring 38 9 mm 1 53 in Exhaust spring 40 67 mm 1 60 in 2 Measure R 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 18 4 X 25 4 lb at 1 36 in Exhaust 11 0 X 12 6 kg at 35 0 mm 24 7 X 28 3 lb at 1 38 in 3 Measure R valve spring tilt a Out of specification Replace the valve spring Spring tilt limit I...

Page 230: ...1 Deburr R valve stem end with an oil stone 2 Lubricate R valve stem 1 R oil seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install R valve 1 R lower spring seat 2 R oil seal 3 R valve spring 4 R 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 ...

Page 231: ...alve YM 4114 Exhaust valve YM 4108 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 R valve pad 1 R valve lifter 2 R Apply molybdenum disulfide oil onto the valve lifter and valve pad R The valve lifter must move smoothly when ro tated with a finger R Each valve lifter and...

Page 232: ...ver Generator rotor cover gasket Dowel pin Generator rotor bolt 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 G...

Page 233: ... the generator rotor bolt Universal magneto rotor holder YU 01235 3 Remove R generator rotor 1 with the alternator roter puller 2 and rotor holding tool 3 Alternator roter puller YM 01080 A INSTALLING THE GENERATOR 1 Apply R sealant onto the stator coil assembly lead grommet Yamaha bond No 1215 ACC 11001 05 01 2 Install R generator rotor R washer R generator rotor bolt Always use a new generator r...

Page 234: ...the generator rotor 2 with the universal magneto rotor holder 3 tighten the generator rotor bolt SAfter tightening to 65 Nm 6 5 mSkg 47 ftSlb tighten another 60_ Universal magneto rotor holder YU 01235 4 Install Sgenerator rotor cover Tighten the generator rotor cover bolts in stages and in a crisscross pattern ...

Page 235: ...er seat and fuel tank Bottom cowling and right side cowling Engine oil Generator rotor 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 PICKUP COIL ENG PICKUP COIL ...

Page 236: ...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 mR kg 8 7 ftR lb 15 Nm 1 5 mR kg 11 ftR lb 60 Nm 6 0 mR kg 43 ftR lb 10 Nm 1 0 mR kg 7 2 ftR lb ...

Page 237: ... remove them 2 Remove R pickup coil rotor bolt 1 R washer R pickup coil rotor 2 While holding the generator rotor 3 with the universal magneto rotor holder 4 loosen the pickup coil rotor bolt Universal magneto rotor holder YU 01235 INSTALLING THE PICKUP COIL ROTOR 1 Install R pickup coil rotor 1 R washer R pickup coil rotor bolt When installing the pickup coil rotor align the pin 2 in the cranksha...

Page 238: ...niversal magneto rotor holder YU 01235 3 Apply R sealant onto the pickup coil lead grommet Yamaha bond No 1215 ACC 11001 05 01 4 Install R pickup coil rotor cover R pickup coil lead holder R 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 R Tighten the pickup coil rotor cover bolts in stages and in a crisscro...

Page 239: ...ty Remarks 1 2 3 4 Removing the clutch cover 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 EAS00273 CLUTCH CLUTCH COVER ...

Page 240: ...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 241: ...rod Friction 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 mSkg 8 7 ftSlb 70 Nm 7 0 mSkg 51 ftSlb EAS00274 CLUTCH ...

Page 242: ...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 8 Nm 0 8 mSkg 5 8 ftSlb 12 Nm 1 2 mSkg 8 7 ftSlb 70 Nm 7 0 mSkg 51 ftSlb ...

Page 243: ...boss 2 with the univer sal clutch holder 3 loosen the clutch boss nut Universal clutch holder YM 91042 3 Remove R clutch boss nut 1 R lock washer 2 R clutch boss 3 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check R friction plate Damage wear Replace the friction plates as a set ...

Page 244: ...n Adjust Assembly width 43 1 X 43 9 mm 1 70 X 1 73 in 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 0 06 in 31A 16325 00 2 0 mm 0 08 in STD 168 16324 00 2 3 mm 0 09 in Clutch plate 2 Part No Thickness 31A 16325 00 2 0 mm 0 08 in STD 168 16324 00 2 3 mm 0 09 in When adjusting the clutch assem...

Page 245: ...ess gauge 1 Out of specification Replace the clutch plates as a set Clutch plate warpage limit Less than 0 1 mm 0 004 in EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs 1 Check R clutch spring Damage Replace the clutch springs as a set 2 Measure R clutch spring free length Out of specification Replace the clutch springs as a set Clutch spring free ...

Page 246: ... Replace the clutch hous ing EAS00285 CHECKING THE CLUTCH BOSS 1 Check R 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 R pressure plate 1 Cracks damage Replace R bearing 2 Damage wear Replace EAS00287 CHECKING THE PULL LEVER AND PULL ROD 1 Check R pull lever 1 R pu...

Page 247: ...H 1 Check R starter clutch rollers Damage wear Replace 2 Check R starter clutch idle gear R starter clutch drive gear R starter clutch gear Burrs chips roughness wear Replace the defective part s 3 Check R starter clutch gear s contacting surfaces Damage pitting wear Replace the starter clutch gear ...

Page 248: ...terclockwise 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 correc...

Page 249: ...tch 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 2 0 mm Clutch plate 7 Select Refer to CHECKING THE FRICTION PLATE 6 Measure Sassembly width a Out of specificati...

Page 250: ... stages and 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 a...

Page 251: ...ive sprocket cover Shift 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 EAS00326 SHIFT SHAFT GENERATOR ROTOR COVER ...

Page 252: ... lever 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 lit...

Page 253: ...ad 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 in chapter 6 Refer to ENGINE Disconnect 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb...

Page 254: ...ocket 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 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 43 Nm 4 3 m kg 31 ft lb OIL PAN AND OIL PUMP ENG EB411001 ...

Page 255: ...t Q ty Remarks Disassembling the oil pump 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 EAS00360 ...

Page 256: ...art 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 X 0 15 mm 0 004 X 0 006 in Limit 0 23 mm 0 009 in Outer rotor to oil pump housing clearance 0 03 X 0 0...

Page 257: ...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 258: ...tor align the pin 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 po...

Page 259: ...kg 31 ft lb WARNING 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 260: ... 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 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb EAS00381 CRANKCASE CRANKCASE ...

Page 261: ...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 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb CRANKCASE ENG ...

Page 262: ...ons 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 25 ft lb EAS00382 CONNECTING RODS AND PISTONS ...

Page 263: ...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 264: ...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 265: ... 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 rem...

Page 266: ...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 267: ...nder 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 X 74 01 mm 2 9134 X 2 9138 in Wear limit 74 06 mm 2 9157 in Taper limit T 0 05 mm 0 0016 in Out of round R 0 05 mm 0 0016 in C maximum of D1 X D6 T maximum of D1 or D2 maximum of D5 or D6 R maximum o...

Page 268: ...on skirt diameter P Piston to cylinder clearance 0 030 X 0 055 mm 0 001 X 0 002 in Limit 0 12 mm 0 005 in 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 carbo...

Page 269: ...ive replace all three piston rings Piston ring end gap Top ring 0 32 X 0 44 mm 0 010 X 0 020 in 2nd ring 0 43 X 0 58 mm 0 017 X 0 023 in Oil ring 0 10 X 0 35 mm 0 004 X 0 014 in 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 ...

Page 270: ...arance 0 002 X 0 022 mm 0 00008 X 0 00087 in Limit 0 072 mm 0 0028 in 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 0 0012 in 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft 3 Measure crankshaft journal to crankshaft...

Page 271: ...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 272: ...sed Plastigauge width c on each crankshaft journal If the clearance is out of specification select replacement crankshaft journal bearings 4 Select Scrankshaft journal bearings J1 X 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 X J5 refer to the bearings shown in the...

Page 273: ...f the connecting 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...

Page 274: ... 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 and st...

Page 275: ...P1 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 EAS...

Page 276: ... 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 277: ...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 278: ...hand 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 ...

Page 279: ...come into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 X 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...

Page 280: ...crankcase 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 11 ftSlb 2nd 15 Nm 1 5 mSkg 11 ftSlb 45 X 50_ Bolt 11 X 15 17 X 20 23 25 X 28 12 Nm 1 2 mSkg 8 7 ftSlb Bolt 16 24 14 Nm 1 4 mSkg 10 f...

Page 281: ...ly 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 8 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb EAS00419 TRANSMISSION TRANSMISSION SHIFT DRUM ASSEMBLY AND SHIFT FORKS ...

Page 282: ...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 283: ...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 284: ...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 285: ... 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 286: ... 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 287: ...mm 0 003 in 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 0 003 in 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 respe...

Page 288: ... 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 289: ......

Page 290: ...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 291: ...COOL ...

Page 292: ... 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 293: ...opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 95 X 125 kPa 0 95 X 1 25 kg cm2 13 1 X 17 8 psi a Install the radiator pressure tester 1 and ra diator pressure adapter 2 to the radiator cap 3 Radiator pressure tester YU 24460 01 Radiator pressure tester adapter YU 33984 b Apply the specified pressure for ten seconds and make sure that there is n...

Page 294: ...m mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check Scooling system Leaks Repair or replace any faulty part a Attach the radiator pressure tester 1 to the radiator Radiator pressure tester YU 24460 01 b Apply 100 kPa 1 0 kg cm2 14 2 psi of pres sure c Measure the indicated pressure with the gauge ...

Page 295: ...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 296: ...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 mSkg 11 ftSlb EAS00461 ...

Page 297: ...he ther 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 Ne...

Page 298: ...ling 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 299: ...ith 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 7 2 ft lb EAS00469 WATER PUMP ...

Page 300: ...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 5 6 7 10 Nm 1 0 m kg 7 2 ft lb ...

Page 301: ...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 302: ...eal apply 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 YM 33221 40 and 50 mm Bearing driver 5 YM 4058 Yamaha bond No 1215 AC...

Page 303: ...w 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 0 006 in 1 Straightedge 2 Impeller ...

Page 304: ...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 305: ...CARB ...

Page 306: ...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 307: ...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 308: ...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 309: ...r plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Fuel drain bolt Float pin 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 EAS00484 ...

Page 310: ...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 10 11 12 13 14 15 16 ...

Page 311: ...ent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check Sfloat chamber body 1 Dirt Clean 4 Check Sfloat chamber rubber gasket 2 Cracks damage wear Replace 5 Check Sfloat 1 Damage Replace 6 Check Sneedle valve 1 Sneedle valve seat 2 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check SO ri...

Page 312: ...lder 4 Spilot jet 5 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 11 Check Spiston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 12 Check Sfuel feed pipes Shose joint Cracks damage Replace Obstruction Clean Blow out the pipes with compressed air 13 Check Sfuel feed hoses Sfuel hoses Cra...

Page 313: ...kit 2 Install Sneedle jet 1 Spilot jet 2 Smain jet 3 3 Measure Sfloat height a Out of specification Adjust Float height 12 5 X 13 5 mm 0 49 X 0 53 in 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 w...

Page 314: ...buretor body 5 Install Sconnecting bracket After installing the connecting bracket check that the throttle cable lever and starter plunger link operate smoothly EAS00493 INSTALLING THE CARBURETORS 1 Adjust Scarburetor synchronization Refer to SYNCHRONIZING THE CARBU RETORS in chapter 3 2 Adjust Sengine idling speed Engine idling speed 1 050 X 1 150 r min Refer to ADJUSTING THE ENGINE IDLING SPEED ...

Page 315: ...level gauge YU 01312 A 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 Sfuel 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 I...

Page 316: ...cket 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 68_F e Install the throttle position sensor onto the carburetor f Connect the pocket tester Ω 1k to the throttle p...

Page 317: ...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 318: ... 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 319: ...ALVE The 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 pr...

Page 320: ...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 321: ...ks 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 0 008 in 1 Surface plate 4 Check _air cutoff valve Cracks damage Replace ...

Page 322: ...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 323: ...ELEC EXUP SYSTEM 8 51 CIRCUT DIAGRAM 8 51 TROUBLESHOOTING 8 52 SELF DIAGNOSIS 8 55 TROUBLESHOOTING 8 57 ...

Page 324: ...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 325: ...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 326: ...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 327: ...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 328: ...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 329: ...NG 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 come on When t...

Page 330: ...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 331: ...ester to 0 and to the Ω X 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 indi...

Page 332: ...se 12 Side stand switch 13 Neutral switch 14 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 switch ...

Page 333: ... 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 334: ...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 measurement YU 03112 C Before checking for continuity set the pocket tester to 0 and to the Ω...

Page 335: ...r continuity 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...

Page 336: ...8 13 1 Main switch 5 Battery 7 Fuse main 15 Ignitor 16 Ignition coil 17 Spark plug 18 Pickup coil 40 Engine stop switch 54 Fuse ignition IGNITION SYSTEM ELEC EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 337: ... type and is its gap 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...

Page 338: ...k 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 68_F 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 wir...

Page 339: ...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 68_F 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 ...

Page 340: ...Fuse main 8 Starter motor 9 Starting circuit cutoff relay 10 Side stand switch 19 Neutral switch 40 Engine stop switch 41 Start switch 46 Clutch switch 54 Fuse ignition ELECTRIC STARTING SYSTEM ELEC EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 341: ...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 342: ...s 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 Battery...

Page 343: ... 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 X 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 teste...

Page 344: ...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 345: ...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 346: ...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 10 Nm 1 0 m kg 7 2 ft lb 5 Nm 0 5 m kg 3 6 ft lb EAS0...

Page 347: ...proper measurement with a hacksaw blade that has been grounded to fit the commuta tor Mica undercut 0 7 mm 0 03 in 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 measurement YU 03...

Page 348: ... Brush length wear limit 4 mm 0 16 in 6 Measure brush spring force Out of specification Replace the brush springs as a set Brush spring force 7 65 X 10 01 N 780 X 1 021 gf 27 5 X 36 0 oz 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 349: ...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 350: ...8 27 2 Rectifire reguretor 3 AC magneto 5 Battery 7 Fuse main CHARGING SYSTEM ELEC EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 351: ... 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 68_F SIs the battery OK CHARGING SYSTEM ELEC NOTE EAS00774 TROUBLESHOOTING The...

Page 352: ...sistance 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 conne...

Page 353: ...brake light 54 Fuse ignition 56 Fuse headlight 61 Headlight relay dimmer 1 Main switch 5 Battery 7 Fuse main 31 Hi beam indicator light 34 Meter light 44 Dimmer switch 48 Front turn signal light left LIGHTING SYSTEM ELEC EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 354: ... YES NO EAS00739 1 Main ignition and headlight fuses SAre the main ignition and headlight 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 68_F SIs the battery OK EAS00781 TROUBLESHOOTING Any of the following fail to light headlight high beam indicator light taillight auxilia ry ...

Page 355: ...er Connect the pocket tester Ω X 1 and bat tery 12 V to the headlight relay dimmer coupler as shown 1 2 Low beam Positive tester probe red yellow Negative tester probe black green YES NO EAS00787 6 Wiring Check entire lighting system s wiring Refer to CIRCUIT DIAGRAM Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Properly connect or repair the ...

Page 356: ...oth EAS00788 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 t...

Page 357: ...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 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 meter light coupler is faulty and...

Page 358: ...8 35 SIGNAL SYSTEM ELEC EAS00793 SIGNAL SYSTEM CIRCUIT DIAGRAM ...

Page 359: ...l gauge 32 Turn 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 42 Horn 45 Horn switch 47 Turn signal switch 48 Front turn signal light left 49 Front turn signal light right 50 Rear turn signal light left 51 Rear turn signal light right 53 Tail brake light 54 Fuse ignition 55 Fuse turn signal 60 Rea...

Page 360: ...ithout defects SIs the horn switch OK SIGNAL SYSTEM ELEC NOTE EAS00738 1 Main signal and ignition fuses SCheck the main signal and ignition fuses for continuity Refer to CHECKING THE FUSES in CHAPTER 3 SAre the main signal 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 circuit voltage 12...

Page 361: ...egative 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 so...

Page 362: ...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 363: ... 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 364: ...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 365: ... SSet the 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 l...

Page 366: ...3 COOLING SYSTEM ELEC 1 Main switch 5 Battery 7 Fuse main 21 Thermo unit 27 Combination meter 28 Water temp warning light 57 Fues fan 58 Fan motor relay 59 Fan motor EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 367: ...attery 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 SThe w...

Page 368: ... unit as shown 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 ...

Page 369: ...8 46 1 Main switch 5 Battery 7 Fuse main 9 Starting circuit cutoff relay 11 Fuel pump 15 Ignitor 40 Engine stop switch 54 Fuse ignition FUEL PUMP SYSTEM ELEC EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 370: ...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 371: ...ve 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 68_F SIs the battery OK SAre the main and ignition fuses OK EAS00739 2 Battery SChe...

Page 372: ... 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 X 30 Ω at 20_C 68_F 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 E...

Page 373: ...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 374: ...8 51 1 Main switch 5 Battery 7 Fuse main 12 EXUP servomotor 15 Ignitor 54 Fuse ignition EXUP SYSTEM ELEC EAS00827 EXUP SYSTEM CIRCUIT DIAGRAM ...

Page 375: ...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 discon...

Page 376: ...isconnect 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 per...

Page 377: ...ys 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 68_F EAS00739 SCheck the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 2 Battery SIs the batte...

Page 378: ...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 379: ...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 380: ...s 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 case T...

Page 381: ...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 382: ...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 383: ...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 384: ...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 385: ...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 386: ...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 SLoose spark plug SLoose cylinder head or cylinder SDamaged cylinder head gasket SDamaged cylinder...

Page 387: ...ion coil Ignition system SFaulty ignitor unit SFaulty pickup coil SBroken generator rotor woodruff key ELECTRICAL SYSTEMS Battery SDischarged battery SFaulty battery Fuse s SBlown damaged or incorrect fuse SImproperly installed fuse Spark plug s SIncorrect spark plug gap SIncorrect spark plug heat range SFouled spark plug SWorn or damaged electrode SWorn or damaged insulator SFaulty spark plug cap...

Page 388: ...ansmission SWorn gear dog EAS00848 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING PROBLEMS ENGINE Air filter SClogged air filter element EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS SHIFT PEDAL DOES NOT MOVE Shift shaft SImproperly adjusted shift rod SBent shift shaft Shift drum and shift forks SForeign object in a shift drum groove SSeized shift fork SBent s...

Page 389: ...tem SFaulty ignitor unit EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch SImproperly assembled clutch SImproperly adjusted clutch cable SLoose or fatigued clutch spring SWorn friction plate SWorn clutch plate Engine oil SIncorrect oil level SIncorrect oil viscosity low SDeteriorated oil EAS00855 OVERHEATING ENGINE Clogged coolant passages SCylinder head s and piston s SHeavy carbon buildup Engine oil S...

Page 390: ...CE SWorn brake pad SWorn brake disc SAir in hydraulic brake system SLeaking brake fluid SFaulty brake caliper seal SLoose union bolt SDamaged brake hose SOil or grease on the brake disc SOil or grease on the brake pad SIncorrect brake fluid level EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL SBent damaged or rusty inner tube SCracked or damaged outer tube SImproperly installed oil seal SDamaged oil ...

Page 391: ...steering head pipe SImproperly installed bearing race EAS00862 UNSTABLE HANDLING Handlebar SBent or improperly installed handlebar Steering head components SImproperly installed upper bracket SImproperly installed lower bracket improperly tightened ring nut SBent steering stem SDamaged ball bearing or bearing race Front fork leg s SUneven oil levels both front fork legs SUnevenly tensioned fork sp...

Page 392: ...ty horn SFaulty main switch SFaulty horn switch SFaulty battery SBlown damaged or incorrect fuse SFaulty wire harness EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT SWrong headlight bulb SToo many electrical accessories SHard charging SIncorrect connection SImproperly grounded circuit SPoor contacts main or light switch SBurnt out headlight bulb HEADLIGHT BULB BURNT OUT SWro...

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Page 394: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

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