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Yamaha RAPTOR YFM700RF 2015, Service Manual

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Yamaha RAPTOR YFM700RF 2015 Service Manual Download Page 390

EAS28740

WIRING DIAGRAM

YFM700RF/YFM700RSF 2015

1. Crankshaft position sensor
2. AC magneto
3. Main switch
4. Rectifier/regulator
5. Battery
6. Main fuse
7. Starter relay
8. Starter motor
9. Yamaha diagnostic tool coupler
10. Indicator light assembly
11. Fuel level warning light
12. Engine trouble warning light
13. Coolant temperature warning 

light

14. Reverse indicator light
15. Neutral indicator light
16. Diode
17. Clutch switch
18. Fuel pump relay
19. Neutral switch
20. Fuel pump
21. Air induction system solenoid
22. Fuel injector
23. Reverse switch
24. ECU (engine control unit)
25. Ignition coil
26. Spark plug
27. Intake air temperature sensor
28. Coolant temperature sensor
29. Speed sensor
30. Throttle position sensor
31. Intake air pressure sensor
32. Lean angle sensor
33. Joint coupler
34. Resistor
35. Handlebar switch
36. Light switch
37. Engine stop switch
38. Start switch
39. Headlight relay
40. Headlight
41. Fuel injection system fuse
42. Radiator fan motor fuse
43. Ignition fuse
44. Signaling system fuse
45. Headlight fuse
46. Rear brake light switch
47. Front brake light switch
48. Tail/brake light
49. Circuit breaker (fan motor)
50. Radiator fan motor relay
51. Radiator fan motor
A. Wire harness
B. Front brake light switch sub-

wire harness

C. Negative battery sub-wire har-

ness

D. Neutral switch and reverse 

switch sub-wire harness

EAS28750

COLOR CODE

B

Black

Br

Brown

G

Green

Gy

Gray

L

Blue

Lg

Light green

O

Orange

P

Pink

R

Red

Sb

Sky blue

W

White

Y

Yellow

B/L

Black/Blue

B/W

Black/White

B/Y

Black/Yellow

Br/G

Brown/Green

Br/L

Brown/Blue

Br/R

Brown/Red

Br/W

Brown/White

Br/Y

Brown/Yellow

G/L

Green/Blue

G/W

Green/White

G/Y

Green/Yellow

L/B

Blue/Black

L/R

Blue/Red

L/W

Blue/White

L/Y

Blue/Yellow

O/B

Orange/Black

O/G

Orange/Green

O/R

Orange/Red

P/L

Pink/Blue

R/B

Red/Black

R/L

Red/Blue

R/W

Red/White

W/L

White/Blue

Y/G

Yellow/Green

Y/R

Yellow/Red

Summary of Contents for RAPTOR YFM700RF 2015

Page 1: ...2015 SERVICE MANUAL YFM700RF YFM700RSF LIT 11616 28 28 2LS F8197 10 ...

Page 2: ...L 2014 by Yamaha Motor Corporation U S A First edition July 2014 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 LIT 11616 28 28 ...

Page 3: ...th the most satisfaction from his vehicle and to conform to federal environmental quality objectives Yamaha Motor Company Ltd is continually striving to improve all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable TIP This Service Manual contains...

Page 4: ...ub section titles 2 appear in smaller print than the section title To help identify parts and clarify procedure steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a disas sembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction ch...

Page 5: ... 1 2 3 4 5 6 7 8 1 Serviceable with engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening torque 6 Wear limit clearance 7 Engine speed 8 Electrical data 9 Engine oil 10 Gear oil 11 Molybdenum disulfide oil 12 Brake fluid 13 Wheel bearing grease 14 Lithium soap based grease 15 Molybdenum disulfide grease 16 Silicone grease 17 Apply locking agent LOCTITE 18 Replace the part with a n...

Page 6: ......

Page 7: ...EAS20110 TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 ...

Page 8: ......

Page 9: ... 1 3 INSTRUMENT FUNCTIONS 1 4 IMPORTANT INFORMATION 1 5 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 5 REPLACEMENT PARTS 1 5 GASKETS OIL SEALS AND O RINGS 1 5 LOCK WASHERS PLATES AND COTTER PINS 1 5 BEARINGS AND OIL SEALS 1 6 CIRCLIPS 1 6 RUBBER PARTS 1 6 BASIC SERVICE INFORMATION 1 7 QUICK FASTENERS 1 7 ELECTRICAL SYSTEM 1 8 SPECIAL TOOLS 1 12 ...

Page 10: ...0140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame EAS20150 MODEL LABEL The model label 1 is affixed to the air filter case cover This information will be needed to order spare parts 1 1 ...

Page 11: ...ne to deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned manner To accom modate this need this model has adopted an electronically controlled fuel injection FI system in place of the conventional carburetor system This system can achieve an optimum air fuel ratio required by the engine at all times by us...

Page 12: ...e injection duration and the injection timing are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor intake air temperature sensor coolant temperature sensor and speed sensor enable the ECU to determine the injection du ration The injection timing is determined through the signals from the crankshaft position sensor ...

Page 13: ...turned to ON or if the warning light remains on check the electrical cir cuit Coolant temperature warning light This warning light comes on when the engine overheats When this occurs during operation stop the engine as soon as it is safe to do so and allow it to cool down for about 10 minutes The electrical circuit of the warning light can be checked by turning the main switch to ON The warning li...

Page 14: ... correct installation of all parts 5 Keep all parts away from any source of fire EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but inferior in quality EAS20210 GASKETS OIL SEALS AND O RINGS 1 When overhauling the engine replace all gaskets seals ...

Page 15: ... air because this will damage the bearing surfac es EAS20240 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Al ways replace piston pin clips after one use When installing a circlip 1 make sure the sharp edged corner 2 is positioned opposite the thrust 3 that the circlip receives EAS2LS1001 RUBBER PARTS Check rubber parts for deterioration during i...

Page 16: ...tener push its pin so that it protrudes from the fastener head then insert the fastener into the part to be secured and push the pin in with a screwdriver Make sure that the pin is flush with the fastener s head Screw type 1 Remove Quick fastener TIP To remove the quick fastener loosen the screw with a screwdriver then pull the fastener out 2 Install Quick fastener TIP To install the quick fastene...

Page 17: ... a battery lead is difficult to disconnect due to rust on the battery terminal remove the rust us ing hot water NOTICE ECA16760 Be sure to connect the battery leads to the correct battery terminals Reversing the bat tery lead connections could damage the electrical components NOTICE ECA16771 When connecting the battery leads to the battery be sure to connect the positive bat tery lead first then t...

Page 18: ...5 seconds before turning the main switch back to ON Checking the electrical system TIP Before checking the electrical system make sure that the battery voltage is at least 12 V NOTICE ECA14371 Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end a of the coupler tak ing care not to loosen or damage the leads NOTICE ECA16640 For waterproof c...

Page 19: ...sure to check the type of cou pler lock before disconnecting the coupler NOTICE ECA16790 When disconnecting a connector do not pull the leads Hold both sections of the connec tor securely and then disconnect the con nector 2 Check Lead Coupler Connector Moisture Dry with an air blower Rust stains Connect and disconnect sev eral times 3 Check All connections Loose connection Connect properly TIP If...

Page 20: ...cking the wire harness perform steps 1 to 3 As a quick remedy use a contact revitalizer available at most part stores 6 Check Resistance TIP The resistance values shown were obtained at the standard measuring temperature of 20 C 68 F If the measuring temperature is not 20 C 68 F the specified measuring conditions will be shown Pocket tester 90890 03112 Analog pocket tester YU 03112 C Pocket tester...

Page 21: ...e list provided below to avoid any mistakes TIP For U S A and Canada use part number starting with YM YU or ACC For others use part number starting with 90890 Tool name Tool No Illustration Reference pages Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 5 15 5 17 Weight 90890 01084 Weight YU 01083 3 5 15 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 63 Valv...

Page 22: ... 90890 01275 Bolt YU 90060 5 63 Piston pin puller set 90890 01304 Piston pin puller YU 01304 5 27 Spacer 90890 01309 Pot spacer YU 90059 5 63 Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 3 5 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 YU 01304 ø35 ø9 ø8 ø10 ø3 ø4 YM A5970 ...

Page 23: ...30 mm YM 01327 4 47 4 47 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 2 Flywheel puller 90890 01404 Flywheel puller YM 01404 5 33 Steering nut wrench 90890 01443 Spanner wrench YU 33975 3 28 3 30 Ball joint remover 90890 01474 Ball joint remover YM 01474 4 53 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

Page 24: ...Sheave holder 90890 01701 Primary clutch holder YS 01880 A 5 33 5 35 Compression gauge 90890 03081 Engine compression tester YU 33223 3 8 Pocket tester 90890 03112 Analog pocket tester YU 03112 C 1 11 1 11 5 38 8 63 8 64 8 64 8 65 8 69 8 70 8 70 8 71 8 71 8 72 8 72 8 73 8 73 8 74 8 74 8 75 8 76 8 76 8 77 8 77 8 77 Tool name Tool No Illustration Reference pages 90890 03081 YU 33223 ...

Page 25: ... 8 34 Valve spring compressor 90890 04019 Valve spring compressor YM 04019 5 20 5 25 Middle driven shaft bearing driver 90890 04058 Middle drive bearing installer 40 50 mm YM 04058 6 7 Valve guide remover ø6 90890 04064 Valve guide remover 6 0 mm YM 04064 A 5 21 Valve guide installer ø6 90890 04065 Valve guide installer 6 0 mm YM 04065 A 5 21 Valve guide reamer ø6 90890 04066 Valve guide reamer 6 ...

Page 26: ...utch holder 90890 04086 Universal clutch holder YM 91042 5 44 5 48 Adapter M16 90890 04130 Adapter 13 YM 04059 5 63 Mechanical seal installer 90890 04132 Water pump seal installer YM 33221 A 6 7 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 71 Tool name Tool No Illustration Reference pages YM 91044 ...

Page 27: ...SPECIAL TOOLS 1 18 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 35 5 60 Tool name Tool No Illustration Reference pages ...

Page 28: ...SPECIAL TOOLS 1 19 ...

Page 29: ...ENING TORQUES 2 14 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 14 ENGINE TIGHTENING TORQUES 2 15 CHASSIS TIGHTENING TORQUES 2 18 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 ENGINE OIL LUBRICATION CHART 2 23 LUBRICATION DIAGRAMS 2 25 COOLING SYSTEM DIAGRAMS 2 35 CABLE ROUTING 2 41 ...

Page 30: ...1 Dimensions Overall length 1845 mm 72 6 in Overall width 1155 mm 45 5 in Overall height 1115 mm 43 9 in Seat height 830 mm 32 7 in Wheelbase 1280 mm 50 4 in Ground clearance 240 mm 9 4 in Minimum turning radius 3500 mm 138 in Weight Curb weight 192 0 kg 423 lb Maximum loading limit 100 0 kg 220 lb ...

Page 31: ...amount 2 30 L 2 43 US qt 2 02 Imp qt Without oil filter element replacement 1 75 L 1 85 US qt 1 54 Imp qt With oil filter element replacement 1 85 L 1 96 US qt 1 63 Imp qt Oil pressure hot 40 0 kPa 1600 r min 0 40 kgf cm 1600 r min 5 7 psi 1600 r min Oil filter Oil filter type Paper Oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 12 mm 0 0047 in Limit 0 20 mm 0 0079 in O...

Page 32: ...ug gap 0 7 0 8 mm 0 028 0 031 in Cylinder head Combustion chamber volume 57 60 61 20 cm 3 51 3 73 cu in Warpage limit 0 03 mm 0 0012 in Camshaft Drive system Chain drive left Camshaft lobe dimensions Intake A 43 300 43 400 mm 1 7047 1 7087 in Limit 43 200 mm 1 7008 in Intake B 37 026 37 126 mm 1 4577 1 4617 in Limit 36 926 mm 1 4538 in Exhaust A 43 129 43 229 mm 1 6980 1 7019 in Limit 43 029 mm 1 ...

Page 33: ...Valve guide inside diameter intake 6 000 6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve guide inside diameter exhaust 6 000 6 012 mm 0 2362 0 2367 in Limit 6 050 mm 0 2382 in Valve stem to valve guide clearance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Valve stem to valve guide clearance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 100 mm 0 0039 in Valve stem run...

Page 34: ... Taper limit 0 05 mm 0 002 in Out of round limit 0 05 mm 0 002 in Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in Limit 0 13 mm 0 0051 in Diameter D 101 955 101 970 mm 4 0140 4 0146 in Height H 10 0 mm 0 39 in Offset 0 50 mm 0 0197 in Offset direction Intake side Piston pin bore inside diameter 23 004 23 015 mm 0 9057 0 9061 in Limit 23 045 mm 0 9073 in Piston pin outside diame...

Page 35: ...nstalled 0 20 0 70 mm 0 01 0 03 in Crankshaft Width A 74 95 75 00 mm 2 951 2 953 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 350 0 650 mm 0 0138 0 0256 in Limit 1 00 mm 0 040 in Big end radial clearance E 0 010 0 025 mm 0 0004 0 0010 in Small end free play F 0 16 0 40 mm 0 01 0 02 in Balancer Balancer drive method Gear Clutch Clutch type Wet multiple disc Clutch release method ...

Page 36: ...eft foot operation Gear ratio 1st 38 13 2 923 2nd 28 14 2 000 3rd 25 17 1 471 4th 25 22 1 136 5th 22 24 0 917 Reverse gear 24 13 29 12 4 462 Main axle runout limit 0 08 mm 0 0031 in Drive axle runout limit 0 08 mm 0 0031 in Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork thickness 5 76 5 89 mm 0 2268 0 2319 in Reverse knob free play 2 0 4 0 mm 0 08 0 16 in Decompression...

Page 37: ...d 1500 1700 r min CO air induction system ON 1 0 CO air induction system OFF 1 5 8 5 Intake vacuum 33 0 kPa 248 mmHg 9 7 inHg Water temperature 80 C 176 F Oil temperature 55 65 C 131 149 F Throttle lever free play 2 0 4 0 mm 0 08 0 16 in Speed limiter length Less than 12 mm 0 47 in ...

Page 38: ...ateral wheel runout limit 2 0 mm 0 08 in Rear wheel Wheel type Panel wheel Rim size 9 8 0AT Wheel material Aluminum Wheel travel 256 mm 10 1 in Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Front tire Type Tubeless Size AT22 7 10 Manufacturer model MAXXIS MS13 Bias Wear limit front 3 mm 0 12 in Rear tire Type Tubeless Size AT20 10 9 Manufacturer model MAXXIS M9...

Page 39: ...ining thickness inner 5 4 mm 0 21 in Limit 1 0 mm 0 04 in Brake pad lining thickness outer 5 4 mm 0 21 in Limit 1 0 mm 0 04 in Master cylinder inside diameter 12 70 mm 0 50 in Caliper cylinder inside diameter 25 40 mm 2 1 00 in 2 Specified brake fluid DOT 4 Steering Steering bearing type Ball bearing Front suspension Type Double wishbone Spring shock absorber type Coil spring gas oil damper Shock ...

Page 40: ...d length 228 5 mm 9 00 in Spring rate K1 46 00 N mm 4 69 kgf mm 262 66 lbf in Spring stroke K1 0 0 110 0 mm 0 00 4 33 in Optional spring available No Spring preload adjusting positions Minimum 238 5 mm 9 39 in Standard 228 5 mm 9 00 in Maximum 223 5 mm 8 80 in Rebound damping adjusting positions Minimum 30 YFM700RSF Standard 18 YFM700RSF Maximum 1 YFM700RSF Compression damping setting for fast com...

Page 41: ... 68 F 0 310 0 326 kΩ at 80 C 176 F Ignition coil Minimum ignition spark gap 6 0 mm 0 24 in Primary coil resistance 3 40 4 60 Ω Secondary coil resistance 10 40 15 60 kΩ Spark plug cap Material Rubber Resistance 10 0 kΩ AC magneto Standard output 14 0 V 17 2 A 5000 r min Stator coil resistance 0 248 0 372 Ω W W Rectifier regulator Regulator type Semi conductor short circuit Regulated voltage DC 14 1...

Page 42: ...sistance 0 025 0 035 Ω Brush overall length 12 5 mm 0 49 in Limit 5 00 mm 0 20 in Brush spring force 7 65 10 01 N 780 1021 gf 27 54 36 03 oz Commutator diameter 28 0 mm 1 10 in Limit 27 0 mm 1 06 in Mica undercut depth 0 70 mm 0 03 in Starter relay Amperage 180 0 A Coil resistance 4 18 4 62 Ω Fuses Main fuse 30 0 A Headlight fuse 10 0 A Signaling system fuse 10 0 A Ignition fuse 10 0 A Radiator fa...

Page 43: ...l To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6...

Page 44: ...er bolt M6 2 10 Nm 1 m kg 7 2 ft lb Camshaft sprocket bolt M7 2 20 Nm 2 m kg 14 ft lb Decompressor assembly bolt M7 2 20 Nm 2 m kg 14 ft lb Cylinder bolt M10 4 50 Nm 5 m kg 36 ft lb See TIP Cylinder bolt M6 2 10 Nm 1 m kg 7 2 ft lb Cable guide bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Water jacket joint bolt M6 2 10 Nm 1 m kg 7 2 ft lb AC magneto rotor nut M16 1 60 Nm 6 m kg 43 ft lb AC magneto cover bolt...

Page 45: ... lb Check screw oil filter cover M5 1 5 Nm 0 5 m kg 3 6 ft lb Oil delivery pipe union bolt M10 2 20 Nm 2 m kg 14 ft lb Oil delivery pipe bolt M6 1 10 Nm 1 m kg 7 2 ft lb Oil pipe joint bolt M14 1 50 Nm 5 m kg 36 ft lb Oil tank inlet hose bolt oil tank side M6 1 10 Nm 1 m kg 7 2 ft lb Oil tank inlet hose bolt engine side M6 1 10 Nm 1 m kg 7 2 ft lb Oil tank outlet hose nut M16 1 35 Nm 3 5 m kg 25 f...

Page 46: ...oss nut M20 1 95 Nm 9 5 m kg 68 ft lb Stake Clutch cover bolt M6 14 10 Nm 1 m kg 7 2 ft lb Drive sprocket nut M22 1 85 Nm 8 5 m kg 61 ft lb Use a lock washer Oil seal retainer bolt left crank case M6 2 10 Nm 1 m kg 7 2 ft lb Shift drum segment bolt M8 1 30 Nm 3 m kg 22 ft lb Shift guide bolt M6 2 10 Nm 1 m kg 7 2 ft lb Reverse shift lever bolt M6 1 13 Nm 1 3 m kg 9 4 ft lb Shift pedal bolt M6 1 16...

Page 47: ...1 ft lb Relay arm nut lower M10 1 43 Nm 4 3 m kg 31 ft lb Rear axle pinch bolt M8 4 21 Nm 2 1 m kg 15 ft lb Rear axle guide bolt M12 1 55 Nm 5 5 m kg 40 ft lb Swingarm skid plate bolt M6 4 7 Nm 0 7 m kg 5 1 ft lb Drive chain guide bolt M6 1 7 Nm 0 7 m kg 5 1 ft lb Drive sprocket cover bolt M6 2 10 Nm 1 m kg 7 2 ft lb Upper front arm nut M10 2 40 Nm 4 0 m kg 29 ft lb Lower front arm nut M10 4 55 Nm...

Page 48: ...r bleed screw M8 2 6 Nm 0 6 m kg 4 3 ft lb Front brake master cylinder hold er bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front brake lever pivot bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Front brake master cylinder union bolt M10 1 27 Nm 2 7 m kg 19 ft lb Throttle lever assembly holder bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Clutch lever holder bolt M5 2 4 Nm 0 4 m kg 2 9 ft lb Parking brake lever mounting bolt M6 2 7 ...

Page 49: ... master cylinder ad justing bolt M8 1 17 Nm 1 7 m kg 12 ft lb Parking brake adjusting bolt lock nut M6 1 16 Nm 1 6 m kg 11 ft lb Rear brake disc mounting bolt M8 4 33 Nm 3 3 m kg 24 ft lb Brake hose holder bolt M6 2 7 Nm 0 7 m kg 5 1 ft lb Front guard bolt M8 4 12 Nm 1 2 m kg 8 7 ft lb Front panel bolt M6 2 4 Nm 0 4 m kg 2 9 ft lb Front fender bolt M6 3 7 Nm 0 7 m kg 5 1 ft lb Front fender nut M6 ...

Page 50: ... lobes Decompressor lever pin Decompressor lever spring Water pump impeller shaft Oil pump rotors inner rotor 2 and outer rotor 2 and pump Oil pump rotors inner rotor 1 and outer rotor 1 and pump Torque limiter Starter idle gear and starter wheel gear inner surface Primary driven gear Clutch pull rod Transmission gears wheel and pinion Shift drum Shift forks Shift fork guide bar Shift lever assemb...

Page 51: ...LUBRICATION POINTS AND LUBRICANT TYPES 2 22 ...

Page 52: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 23 EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 10 7 6 5 4 3 1 2 17 3 13 16 15 3 14 11 12 18 8 20 19 21 9 ...

Page 53: ...kcase 5 AC magneto cover 6 Oil tank inlet hose 7 To oil tank 8 Main axle 9 Drive axle 10 Counter axle 11 From oil tank 12 Oil tank outlet hose joint 13 Clutch cover 14 Oil filter element 15 Drain bolt 16 To clutch cover 17 Crankshaft 18 Oil delivery pipe 19 Camshaft 20 Decompression 21 Cylinder head ...

Page 54: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 25 EAS20410 LUBRICATION DIAGRAMS 1 4 3 1 2 3 4 ...

Page 55: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 26 1 Oil tank breather hose 2 Oil tank outlet hose 3 Oil tank inlet hose 4 Oil tank ...

Page 56: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 27 2 3 A A A A 2 1 ...

Page 57: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 28 1 Oil delivery pipe 2 Oil filter 3 Oil pump ...

Page 58: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 29 1 2 3 4 5 6 7 ...

Page 59: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 30 1 Oil filter 2 Oil pump driven gear 3 Oil pump rotor 1 4 Oil pump rotor 2 5 Oil tank outlet hose joint 6 Main axle 7 Counter axle ...

Page 60: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 31 A A A A 4 1 2 3 1 A ...

Page 61: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 32 1 Oil strainer 2 Oil pump rotor 2 3 Oil pump rotor 1 4 Oil pump driven gear A To oil tank ...

Page 62: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 33 2 1 ...

Page 63: ...LUBRICATION SYSTEM CHART AND DIAGRAMS 2 34 1 Balancer 1 2 Crankshaft ...

Page 64: ...COOLING SYSTEM DIAGRAMS 2 35 EAS20420 COOLING SYSTEM DIAGRAMS B B A A A A B B 2 3 4 5 6 7 1 A B C D D E F G H I ...

Page 65: ...ng outward D Position the screw clamp so that its screw can be tightened from the right side of the vehicle E Install the radiator outlet hose with its white paint mark facing outward F Install the radiator outlet hose with its yellow paint mark facing outward G From fast idle plunger H Position the screw clamp so that its screw can be tightened from the right side of the vehicle Make sure that th...

Page 66: ...COOLING SYSTEM DIAGRAMS 2 37 B A C C D D C C A D D B 6 7 1 2 3 4 5 6 1 6 2 6 3 4 A B C D E ...

Page 67: ...r fan motor breather hose through the guide B Install the coolant reservoir hose onto the radiator pipe making sure that it contacts the radiator C Pass the coolant reservoir hose and radiator fan motor breather hose through the guide on the fuel tank shield D 60 mm 2 36 in E Pass the clamp through the hole in the stay on the frame and then fasten the coolant reservoir hose and drain hose with the...

Page 68: ...COOLING SYSTEM DIAGRAMS 2 39 A B B 4 1 1 2 2 3 A B B A A B ...

Page 69: ...er pump 3 Water pump breather hose 4 Water jacket inlet housing A From radiator B Install the water pump outlet hose onto the water jacket inlet housing making sure to align the yellow paint mark on the hose with the projection on the water jacket inlet housing ...

Page 70: ...CABLE ROUTING 2 41 EAS20430 CABLE ROUTING Handlebar top and front view A B 2 1 3 9 4 5 7 7 8 2 4 5 7 9 8 17 18 19 3 12 14 16 C D E F G H I J K L M 6 10 11 13 15 20 21 O N 12 23 22 ...

Page 71: ... hose in front of the handlebar switch lead clutch switch lead front brake light switch lead main switch lead and indicator light assembly lead G Secure the plastic band by inserting the projection on the band into the hole in the frame and then fasten the wire harness with the band making sure to point the end of the band rearward H Route the radiator fan motor breather hose in front of the handl...

Page 72: ... 2 43 Engine left side view A B C 1 2 3 4 6 D E 7 8 9 9 F G H I J K 12 14 15 16 P 17 18 19 7 7 8 8 28 4 26 U 6 27 23 24 25 T V 15 15 16 16 16 17 18 W 17 17 29 30 Y 5 10 11 13 21 20 11 23 X 19 21 20 L M N O Q R S 22 ...

Page 73: ...rear brake light switch lead and speed sensor lead K Secure the plastic band by inserting the projection on the band into the hole in the frame and then fasten the wire harness at the center of its positioning tape with the band making sure that the end of the band points rearward and the leads that branch off from the wire harness do not contact the frame L Route the starter motor lead between th...

Page 74: ...CABLE ROUTING 2 45 Electrical components tray left side view 1 2 4 5 6 7 A 8 10 11 12 13 12 13 C D E F G H B 3 9 ...

Page 75: ... and tail brake light lead with the plastic band making sure to point the end of the band downward Fasten the leads near the tail brake light coupler and after the split in the wire harness making sure to install the plastic band around the protective sleeve of the tail brake light lead not the lead itself E Insert the projection on the wire harness holder into the hole in the frame F Fasten the w...

Page 76: ...CABLE ROUTING 2 47 Electrical components tray top view 8 9 10 11 A 1 2 3 4 5 6 7 12 13 14 15 16 17 18 19 20 B C 21 D 22 E 25 26 27 28 29 30 31 I 31 F 32 K L J M N G O P 24 23 22 22 21 H ...

Page 77: ...temperature sensor lead in the area shown in the illustration D Route the crankcase breather hose between the battery box and the air filter joint and under the wire harness E Route the negative battery lead between the lean angle sensor and the wire harness F Route the negative battery lead connector as shown in the illustration G Connect the AC magneto lead sub wire harness rear brake light swit...

Page 78: ...CABLE ROUTING 2 49 Rear fender top view 1 2 3 4 6 6 7 9 8 A 4 5 5 B 10 11 12 13 14 ...

Page 79: ...c tool lead 8 Starter relay lead 9 Starter motor lead 10 Starter relay 11 Fuse box lead 12 Headlight relay lead 13 Radiator fan motor relay lead 14 Tail brake light lead A Route the starter motor lead under the starter relay lead B Route the Yamaha diagnostic tool lead over the fuel pump relay lead fuse box lead headlight relay lead and radiator fan motor relay lead ...

Page 80: ...CABLE ROUTING 2 51 Engine right side view A B 1 2 3 D C 4 5 6 7 E F 8 9 10 10 12 11 G 14 15 15 15 15 16 16 16 16 17 18 19 H I J K 13 ...

Page 81: ...n system hose air filter case joint to air cut off valve and the fast idle plunger outlet hose C Route the fuel injector lead over the intake air pressure sensor D Route the spark plug lead to the outside of the clutch cable and parking brake cable making sure that the lead does not contact the cylinder head E Route the headlight lead right over the frame connect the headlight coupler and then ins...

Page 82: ...CABLE ROUTING 2 53 Front brake hose front and top view A B 1 2 3 C D E 2 3 2 2 ...

Page 83: ...e pipe upward B Fasten the front brake pipe with the holder C Route the front brake hose over the upper front arm D Fit the grommet on the front brake hose into the slots in the front brake hose holder E Connect the end of the front brake hose that is identified by the green paint mark to the left front brake caliper ...

Page 84: ...CABLE ROUTING 2 55 Rear brake hose right side view A B B C 1 1 1 1 3 2 2 2 2 1 1 2 4 4 ...

Page 85: ...ke light switch lead A Make sure that the ends of the hose clamp are not pointing outward B Face the white paint marks on both ends of the brake fluid reservoir hose rearward Point the ends of the hose clamp to the outward C Route the brake fluid reservoir hose between the battery box and the frame ...

Page 86: ...CABLE ROUTING 2 57 Throttle body left and right side view 1 1 2 9 9 2 2 2 8 4 2 3 4 5 6 7 7 A B C D E G F I D D D J K H 10 11 12 13 ...

Page 87: ...t the ends of the hose clamp downward E When installing the air induction system hose air filter case joint to air cut off valve so that the hose is not pinched between the air filter case joint and the brake fluid reservoir F Point the ends of the hose clamp rearward G Install the fast idle plunger outlet hose with its yellow paint mark facing to the right H Connect the end of the air induction s...

Page 88: ...CABLE ROUTING 2 59 ...

Page 89: ...EED LIMITER 3 7 CHECKING THE SPARK PLUG 3 7 MEASURING THE COMPRESSION PRESSURE 3 8 CHECKING THE ENGINE OIL LEVEL 3 9 CHANGING THE ENGINE OIL 3 10 ADJUSTING THE CLUTCH LEVER FREE PLAY 3 12 CLEANING THE AIR FILTER ELEMENT 3 12 CHECKING THE AIR INDUCTION SYSTEM 3 13 CHECKING THE THROTTLE BODY JOINT 3 13 CHECKING THE FUEL LINE 3 14 CHECKING THE CRANKCASE BREATHER HOSE 3 14 CHECKING THE EXHAUST SYSTEM ...

Page 90: ...TING THE DRIVE CHAIN SLACK 3 24 CHECKING THE STEERING SYSTEM 3 25 ADJUSTING THE TOE IN 3 25 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 26 ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES 3 27 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 3 29 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 30 CHECKING THE TIRES 3 32 CHECKING THE WHEELS 3 33 CHECKING AND LUBRICATING THE CABLES 3 33 LUBRICATING THE CLUTCH...

Page 91: ......

Page 92: ...BRICATION CHART TIP For ATVs not equipped with an odometer or an hour meter follow the month maintenance intervals For ATVs equipped with an odometer or an hour meter follow the km mi or hours maintenance in tervals However keep in mind that if the ATV isn t used for a long period of time the month mainte nance intervals should still be followed Items marked with an asterisk should be performed by...

Page 93: ...ess or damage and replace if nec essary 11 Swingarm pivots Check operation and for excessive play and replace bearings if necessary Lubricate with lithium soap based grease 12 Upper and lower arm pivots Lubricate with lithium soap based grease 13 Drive chain Check chain slack and adjust if necessary Check rear wheel alignment and correct if necessary Clean and lubricate 14 Drive chain roller Check...

Page 94: ...he brake hoses every four years and if cracked or damaged 25 Reverse lock release cable Check operation and adjust or replace if necessary 26 Throttle lever Check operation Check throttle lever free play and adjust if necessary Lubricate cable and lever housing 27 Front and rear brake switches Check operation and correct if necessary 28 Lights and switches Check operation and correct if necessary ...

Page 95: ...r 2 3 Disconnect Spark plug cap 1 4 Remove Spark plug 2 5 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 6 Measure Valve clearance Out of specification Adjust a Turn the crankshaft counterclockwise b When the piston is at TDC on the compres sion stroke align the punch mark a in the camshaft sprocket with the stationary pointer b on the cylinder head c Align the TDC mark c on...

Page 96: ...ained 8 Install Timing mark accessing screw Crankshaft end accessing screw Spark plug 9 Connect Spark plug cap 10 Install O ring Camshaft sprocket cover O ring 1 Intake tappet cover O ring Exhaust tappet cover 11 Install Fuel tank Direction a Valve clearance is increased Direction b Valve clearance is decreased Tappet adjusting tool 90890 01311 Six piece tappet set YM A5970 1 1 2 3 4 a b T R Lockn...

Page 97: ...R FREE PLAY TIP Prior to adjusting the throttle lever free play the engine idling speed should be adjusted 1 Check Throttle lever free play a Out of specification Adjust 2 Adjust Throttle lever free play Throttle body side a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified throttle lever free play is ob tained d Tighten the loc...

Page 98: ...d from increasing 1 Measure Speed limiter length a Out of specification Adjust 2 Adjust Speed limiter length a a Loosen the locknut 1 b Turn the adjuster 2 clockwise or counter clockwise until the specified speed limiter length is obtained c Tighten the locknut WARNING EWA14880 Particularly for a beginner rider the speed limiter should be screwed in completely Screw it out little by little as thei...

Page 99: ...et surface 8 Connect Spark plug cap EAS20710 MEASURING THE COMPRESSION PRESSURE TIP 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 on page 3 4 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 NOTICE ECA1S3L026 B...

Page 100: ... until the engine oil has reached a normal temperature of 60 C 140 F let it continue to idle for ten sec onds and then turn the engine off TIP To achieve the proper engine oil temperature for an accurate oil level reading the engine must have first completely cooled down and then warmed up again for several minutes to normal operating temperature 3 Check Engine oil level The engine oil level shoul...

Page 101: ...il level wait a few minutes until the oil has settled EAS20800 CHANGING THE ENGINE OIL 1 Start the engine warm it up for several min utes and then turn it off 2 Place a container under the engine oil drain bolt 3 Remove Engine oil filler bolt 1 Dipstick 2 4 Remove Engine oil drain bolt oil tank 1 along with the gasket 5 Remove Engine oil drain bolt crankcase 1 along with the gasket Recommended bra...

Page 102: ...case with the specified amount of the recom mended engine oil 12 Install Dipstick Engine oil filler bolt 13 Start the engine warm it up for several min utes and then turn it off 14 Check Engine for engine oil leaks 15 Check Engine oil level Refer to CHECKING THE ENGINE OIL LEVEL on page 3 9 16 Check Engine oil pressure a Slightly loosen the oil check bolt 1 T R Oil filter element cover bolt 10 Nm ...

Page 103: ...Loosen the locknut 2 c Turn the adjusting bolt 3 clockwise or coun terclockwise until the specified clutch lever free play is obtained d Tighten the locknut TIP 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 4 b Turn the adjusting bolt 5 until the specified clutch cable free pla...

Page 104: ...he air filter element and squeeze out the excess oil The air filter element should be wet but not dripping 7 Install Air filter element frame Air filter element Wing bolt Air filter case cover NOTICE ECA14401 Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter el...

Page 105: ...e connection Connect properly NOTICE ECA13450 Make sure the crankcase breather hose is routed correctly EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Check Exhaust pipe 1 Muffler 2 Muffler protector 3 Exhaust pipe protector 4 Cracks damage Replace Gaskets 5 Exhaust gas leaks Replace 2 Check Tightening torque 1 1 T R Exhaust pipe nut...

Page 106: ... brush to remove any carbon deposits from the spark arrester portion of the tailpipe and the inner contact surfaces of the muffler g Install the gasket tailpipe and tailpipe cover bracket and align the bolt holes h Insert the bolts and tighten it i Install the tailpipe cover and align the bolt holes j Insert the bolts and tighten it EAS21110 CHECKING THE COOLANT LEVEL 1 Place the vehicle on a leve...

Page 107: ...EAS21120 CHECKING THE COOLING SYSTEM 1 Remove Seat Front fender Refer to GENERAL CHASSIS on page 4 1 2 Check Radiator 1 Radiator outlet hose 2 Radiator inlet hose 3 Water pump assembly 4 Water jacket inlet joint 5 Water jacket outlet hose 6 Cracks damage Replace Refer to RADIATOR on page 6 1 THER MOSTAT on page 6 3 and WATER PUMP on page 6 5 3 Install Front fender Seat Refer to GENERAL CHASSIS on ...

Page 108: ... radiator cap counter clockwise toward the detent to allow any re sidual pressure to escape When the hissing sound has stopped press down on the radi ator cap and turn it counterclockwise to re move The following procedure applies to all of the coolant drain bolts and copper washers 6 Remove Coolant drain bolt 1 along with the copper washer 7 Drain Coolant from the engine and radiator 8 Check Cool...

Page 109: ...e used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 12 Install Air bleed bolt 13 Install Radiator cap 14 Fill Coolant reservoir with the recommended coolant to the maxi mum level mark a 15 Install Coolant reservoir cap 16 Start the engine warm it up for several min utes and then stop it 17 Check Coolant level Refer t...

Page 110: ...ght a Loosen the locknut 1 b Turn the adjusting bolt 2 until the brake ped al height is within the specified limits c Tighten the locknut WARNING EWA14900 After this adjustment is performed lift the front and rear wheels off the ground by plac ing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again EAS21240 C...

Page 111: ...brake fluid level make sure the top of the brake fluid reservoir is horizontal EAS21250 CHECKING THE FRONT BRAKE PADS The following procedure applies to all of the brake pads 1 Remove Front wheel Refer to FRONT WHEELS on page 4 5 2 Check Front brake pad Wear indicator grooves a have almost dis appeared Replace the brake pads as a set Refer to FRONT BRAKES on page 4 17 3 Operate the brake lever 4 I...

Page 112: ...eakage Replace the damaged hose Refer to REAR BRAKE on page 4 28 EAS29210 ADJUSTING THE PARKING BRAKE 1 Check Parking brake cable end length a Out of specification Adjust 2 Adjust Parking brake cable end length a Slide back the rubber cover 1 b Loosen the locknut 2 c Turn the adjusting nut 3 in direction a or b until the specified brake cable end length is obtained d Tighten the locknut e Slide th...

Page 113: ...e brake Ignoring this pre caution could allow air to enter the hydraulic brake system considerably lengthening the bleeding procedure If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed Hydraulic brake system a Fill the brake fluid reservoir to the proper level with the s...

Page 114: ... c Install the shift pedal at the correct height d Tighten the bolt to specification EAS29240 ADJUSTING THE REVERSE CONTROL CABLE 1 Check Reverse knob free play a Out of specification Adjust 2 Adjust Reverse knob free play a Slide back the boots 1 and 2 b Loosen the locknut 3 c Turn the adjusting nut 4 until the reverse control cable 5 is taut or the length a is 33 mm 1 30 in TIP Be sure to hold t...

Page 115: ...ar axle pinch bolts in the proper se quence as shown b Insert an appropriate shaft 2 in the hole 4 of rear axle hub 3 so that the sprocket bracket 5 does not move c Shift the transmission into the neutral posi tion d To loosen the drive chain push the vehicle forward and to tighten the drive chain pull the vehicle backward NOTICE ECA1S3L001 Excessive chain slack will overload the en gine and other...

Page 116: ...hat there is no weight on the front wheels 5 Check Ball joints and wheel bearings Move the wheels laterally back and forth Excessive free play Replace the front arms upper and lower and or wheel bear ings EAS29290 ADJUSTING THE TOE IN 1 Place the vehicle on a level surface 2 Measure Toe in Out of specification Adjust TIP Before measuring the toe in make sure that the tire pressure is correct a Mar...

Page 117: ...umber of turns should be given to both the right and left tie rods 2 until the specified toe in is obtained This is to keep the length of the tie rods the same d Tighten the rod end locknuts of both tie rods TIP Adjust the tie rod ends so that A and B are equal EAS29300 CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES The following procedure applies to both of the front shock absorber assemblies 1 Pla...

Page 118: ...ent can result in poor handling and loss of stability 1 Adjust Spring preload YFM700RF Turn the adjuster 1 in direction a or b 2 Adjust Spring preload YFM700RSF a Elevate the front wheels by placing a suitable stand under the frame b Loosen the locknut 1 c Turn the adjusting ring 2 in direction a or b Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preload is increased suspe...

Page 119: ...1 in direction a or b NOTICE ECA1S3L003 Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged 4 Adjust Compression damping force fast compres sion damping YFM700RSF a Turn the adjusting bolt 1 in direction a or b Steering nut wrench 90890 01443 Spanner wrench YU 33975 T R Locknut 42 Nm 4 2 m kg 30 ft lb c Direction a Rebound damping force is increa...

Page 120: ...LY on page 4 55 Gas cylinder YFM700RSF Damage gas leaks Replace the rear shock absorber assembly Spring Fatigue Replace the rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 3 Check Operation Pump the rear shock absorber assembly up and down several times Unsmooth operation Replace rear shock absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 Compr...

Page 121: ...ring before adjust ment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjusting ring d Tighten the locknut 2 with a steering nut wrench 4 TIP Set the torque wrench at a right angle to the steering nut wrench Always tighten the locknut against the adjust ing ring then torque it to specification Ring nut wrench 90890 01268 Spanner wrench YU 01268 Direction a Spring preloa...

Page 122: ...ection a or b Direction a Rebound damping force is increased suspension is harder Direction b Rebound damping force is decreased suspension is softer Rebound damping adjusting posi tions Minimum 30 click s out Standard 18 click s out Maximum 1 click s out With the adjusting konb fully turned in Direction a Compression damping force is in creased suspension is harder Direction b Compression damping...

Page 123: ... cation could cause the tire to dislodge from the rim under severe riding conditions Use no more than the following pressures when seating the tire beads Front 250 kPa 2 5 kgf cm 36 psi Rear 250 kPa 2 5 kgf cm 36 psi Higher pressures and fast inflation may cause a tire to burst Inflate the tires very slowly and carefully Maximum loading limit WARNING EWA14970 Be extra careful of the vehicle balanc...

Page 124: ...procedure applies to all of the wheels 1 Check Wheel 1 Damage bends Replace WARNING EWA14990 Never attempt even small repairs to the wheel Ride conservatively after installing a tire to allow it to seat itself properly on the rim TIP Always balance the wheel when a tire or wheel has been changed or replaced EAS21690 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the ...

Page 125: ...r EAS27S1002 LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal to metal moving parts of the lever EAS21710 LUBRICATING THE PEDAL Lubricate the pivoting point and metal to metal moving parts of the pedal EAS21740 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Engine oil or a suitable cable lu...

Page 126: ...ight bulb with the head light bulb holder NOTICE ECA13690 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 a cloth moistened with alcohol or lacquer thinner 5 Install Headlight bulb holder Headlight bul...

Page 127: ...ELECTRICAL SYSTEM 3 36 1 a b ...

Page 128: ...ELECTRICAL SYSTEM 3 37 ...

Page 129: ... WHEELS 4 10 REAR AXLE AND REAR AXLE HUB 4 12 REMOVING THE REAR AXLE 4 14 CHECKING THE REAR AXLE 4 14 CHECKING THE REAR WHEEL SPROCKET 4 15 CHECKING THE REAR BRAKE DISC 4 15 INSTALLING THE REAR WHEEL SPROCKET 4 15 INSTALLING THE REAR AXLE 4 15 FRONT BRAKES 4 17 INTRODUCTION 4 22 CHECKING THE FRONT BRAKE DISCS 4 22 REPLACING THE FRONT BRAKE PADS 4 23 DISASSEMBLING THE FRONT BRAKE CALIPERS 4 23 CHEC...

Page 130: ...E HANDLEBAR 4 43 STEERING STEM 4 46 REMOVING THE BEARING RETAINER 4 47 CHECKING THE STEERING STEM 4 47 INSTALLING THE BEARING RETAINER 4 47 INSTALLING THE LOCK WASHER 4 47 INSTALLING THE PITMAN ARM 4 47 TIE RODS AND STEERING KNUCKLES 4 48 REMOVING THE STEERING KNUCKLES 4 49 CHECKING THE TIE RODS 4 49 CHECKING THE STEERING KNUCKLES 4 49 INSTALLING THE TIE RODS 4 49 FRONT ARMS AND FRONT SHOCK ABSORB...

Page 131: ... SHOCK ABSORBER ASSEMBLY 4 57 CHECKING THE RELAY ARM AND CONNECTING ARM 4 57 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 SWINGARM 4 59 REMOVING THE SWINGARM 4 61 CHECKING THE SWINGARM 4 61 INSTALLING THE SWINGARM 4 61 CHAIN DRIVE 4 63 CHECKING THE DRIVE CHAIN 4 64 INSTALLING THE DRIVE CHAIN 4 65 ...

Page 132: ...ck the seat lock lever than pull up on the rear of the seat 2 Front panel 1 3 Left foot protector 1 4 Right foot protector 1 5 Engine skid plate 1 For installation reverse the removal proce dure 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 12 Nm 1 2 m kg 8 7 ft Ib T R 1 4 3 5 2 ...

Page 133: ...Disconnect 2 Left headlight 1 3 Right headlight 1 4 Fuel tank top panel 1 5 Indicator light assembly coupler 1 Disconnect 6 Radiator grill 1 7 Front fender 1 For installation reverse the removal proce dure 4 5 7 6 3 1 1 2 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m...

Page 134: ...holding bracket 1 3 Battery lead 2 Disconnect NOTICE ECA1S3L009 First disconnect the negative lead then disconnect the positive lead 4 Battery 1 5 ECU stay 1 6 ECU electronic control unit 1 7 Intake air temperature sensor coupler 1 Disconnect LT LT LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm ...

Page 135: ...osen 12 Tail brake light lead coupler 1 Disconnect 13 Tail brake light assembly 1 14 Air filter case 1 15 ECU bracket 1 16 Rear fender 1 For installation reverse the removal proce dure LT LT LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 9 Nm 0 ...

Page 136: ...t wheels Place the vehicle on a level surface 1 Front wheel 1 2 Brake disc guard outer 1 3 Cotter pin 1 4 Front wheel axle nut 1 5 Front brake caliper assembly 1 TIP Do not squeeze the brake lever when the brake caliper is off of the brake discs as the brake pads will be forced shut 6 Front wheel hub 1 7 Front brake disc 1 For installation reverse the removal proce dure ...

Page 137: ... and CHECKING THE WHEELS on page 3 33 2 Measure Radial wheel runout 1 Lateral wheel runout 2 Over the specified limit Replace the wheel or check the wheel bearing play 3 3 Check Wheel balance Out of balance Adjust WARNING EWA15000 After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so may cause an accident re sulting in vehicle damage and p...

Page 138: ... strike the center race or balls of the bearing Contact should be made only with the outer race EAS29400 INSTALLING THE FRONT WHEEL HUB BEARINGS 1 Install Bearings 1 TIP Face the oil seal side of the bearing inward EAS1S3L013 INSTALLING THE FRONT BRAKE DISCS 1 Install Brake discs TIP Install the brake disc so that the recessed por tion of the bolt hole faces away from the hub EAS29410 INSTALLING T...

Page 139: ...lowing procedure applies to both of the front wheels 1 Install Brake disc guard outer 1 TIP Install the brake disc guard outer with the punched burrs 2 on the wheel hub side 2 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of rotation A of the wheel 3 Tighten Wheel nut T R Wheel nut 45 Nm 4 5 m kg 32 ft lb ...

Page 140: ...ving the rear wheels Order Job Parts to remove Q ty Remarks The following procedure applies to both of the rear wheels Place the vehicle on a level surface 1 Rear wheel 2 2 Cotter pin 2 3 Rear wheel axle nut 2 4 Rear wheel hub 2 For installation reverse the removal proce dure ...

Page 141: ...amage Replace Splines wheel hub 2 Wear damage Replace EAS29450 INSTALLING THE REAR WHEEL HUBS The following procedure applies to both of the rear wheel hubs 1 Install Rear axle washers 1 Rear axle nuts 2 Cotter pins 3 a Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel hub surfaces that contact the rear axle washers b Tighten the rear axle nuts to spe...

Page 142: ...REAR WHEELS 4 11 1 Install Wheel TIP The arrow mark 1 on the tire must point in the direction of rotation A of the wheel 2 Tighten Wheel nut T R Wheel nut 45 Nm 4 5 m kg 32 ft lb ...

Page 143: ...g washer 1 4 Rear axle pinch bolt 4 5 Rear brake caliper 1 TIP Do not apply the brake pedal and do not use the parking brake when the brake caliper is off of the brake disc as the brake pads will be forced shut 6 Brake disc brake disc bracket 1 1 7 Rear axle 1 1 1 2 3 7 5 6 4 4 4 LS LT LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 33 Nm 3 3 m kg 24 ft Ib T R 240 Nm 24 0 m kg 170 ft lb T R 34 Nm 3 4 m kg 24 ft...

Page 144: ...1 Brake caliper bracket 1 12 Spacer 1 13 Rear axle hub 1 14 Oil seal 2 15 Bearing 2 16 Bearing 2 17 Spacer 1 For installation reverse the removal proce dure 16 16 4 4 11 10 12 17 15 15 14 14 13 8 9 LS LT LT LT 7 Nm 0 7 m kg 5 1 ft Ib T R 33 Nm 3 3 m kg 24 ft Ib T R 240 Nm 24 0 m kg 170 ft lb T R 34 Nm 3 4 m kg 24 ft Ib T R 21 Nm 2 1 m kg 15 ft Ib T R 72 Nm 7 2 m kg 52 ft lb T R ...

Page 145: ... hubs Rear axle ring nut Conical spring washer 7 Remove Rear axle 1 with rear wheel sprocket NOTICE ECA16180 Never directly tap the axle end with a ham mer since this will result in damage to the axle thread and spline Attach a suitable socket on the axle end and tap it with a soft hammer then pull out the rear axle to the left 8 Remove Circlip Rear wheel sprocket bracket EAS29500 CHECKING THE REA...

Page 146: ...29530 INSTALLING THE REAR AXLE 1 Install Conical spring washer 1 Rear axle ring nut TIP Install the conical spring washer with the convex side of the washer facing outward as shown 2 Install Rear wheels Refer to REAR WHEELS on page 4 9 3 Tighten Rear axle ring nut 1 Rear axle ring nut set bolts 2 TIP Apply the brake pedal so that the rear axle does not turn when tightening the nut Use the axle nut...

Page 147: ...REAR AXLE AND REAR AXLE HUB 4 16 4 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 ...

Page 148: ...wing procedure applies to both of the front brake calipers Front wheel Refer to FRONT WHEELS on page 4 5 1 Brake caliper bolt 2 2 Brake pad retaining bolt 2 3 Brake pad pad shim 2 1 4 Brake pad spring 1 For installation reverse the removal proce dure 2 3 T R 17 Nm 1 7 m kg 12 ft Ib 4 1 1 LT 28 Nm 2 8 m kg 20 ft Ib T R ...

Page 149: ...ke fluid reservoir cap 1 2 Brake fluid reservoir diaphragm 1 3 Front brake light switch connector 2 Disconnect 4 Front brake light switch 1 5 Brake lever 1 6 Union bolt 1 7 Copper washer 2 8 Brake hose 1 Disconnect 9 Brake master cylinder bracket 1 10 Brake master cylinder 1 For installation reverse the removal proce dure ...

Page 150: ...isassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder body 1 For assembly reverse the disassembly pro cedure BF ...

Page 151: ... Brake fluid Drain Front wheel Refer to FRONT WHEELS on page 4 5 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake pad retaining bolt 2 Loosen 5 Brake caliper bolt 2 6 Brake caliper assembly 1 For installation reverse the removal proce dure 1 2 6 4 3 5 T R 27 Nm 2 7 m kg 19 ft Ib New T R 28 Nm 2 8 m kg 20 ft Ib LT 17 Nm 1 7 m kg 12 ft Ib T R ...

Page 152: ...calipers 1 Brake caliper retaining bolt 2 2 Brake pad pad shim 2 1 3 Brake pad spring 1 4 Brake caliper bracket 1 5 Brake caliper piston 2 6 Brake caliper piston dust seal 2 7 Brake caliper piston seal 2 8 Bleed screw 1 For assembly reverse the disassembly pro cedure New T R 6 Nm 0 6 m kg 4 3 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib 8 7 6 4 1 2 3 New LT 5 BF S S ...

Page 153: ...tes and get im mediate medical attention EAS22240 CHECKING THE FRONT BRAKE DISCS The following procedure applies to both brake discs 1 Remove Front wheel Refer to FRONT WHEELS on page 4 5 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Hold the dial gauge at a right angle against the brake ...

Page 154: ...ut 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 d Install new brake pads and a new brake pad spring 4 Install Brake pad retaining bolt Brake caliper 5 Check Brake fluid level Below the minimum level mark Add the specified brake fluid to the proper level Refer to CHECKIN...

Page 155: ...e the brake caliper assembly Brake caliper body 3 Cracks damage Replace the brake caliper assembly Brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING EWA1S3L005 Whenever a brake caliper is disassembled replace the brake caliper piston seals and dust seals EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake...

Page 156: ...mount of the specified brake fluid WARNING EWA13090 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 performance When refilling be careful that water does...

Page 157: ...3 Check Brake master cylinder reservoir 1 Cracks damage Replace Brake master cylinder reservoir diaphragm 2 Damage wear Replace 4 Check Brake hoses Cracks damage wear Replace EAS22520 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA1S3L007 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...

Page 158: ...hat is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder reser voir Water will significantly lower the boil ing point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always...

Page 159: ...ear brake pads Order Job Parts to remove Q ty Remarks 1 Brake caliper bolt 2 2 Brake pad retaining bolt 2 3 Brake pad 2 4 Brake pad spring 1 For installation reverse the removal proce dure 4 3 2 1 T R 17 Nm 1 7 m kg 12 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib ...

Page 160: ... fluid reservoir hose cover 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Union bolt 1 LS T R 4 Nm 0 4 m kg 2 9 ft Ib New New T R 20 Nm 2 0 m kg 14 ft Ib 2 3 4 5 6 T R 78 Nm 7 8 m kg 56 ft lb T R 1 7 T R 30 Nm 3 0 m kg 22 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib ...

Page 161: ...isconnect 10 Brake master cylinder 1 11 Rear brake light switch 1 12 Right footrest 1 13 Brake pedal spring 1 1 For installation reverse the removal proce dure LS T R 4 Nm 0 4 m kg 2 9 ft Ib New New T R 20 Nm 2 0 m kg 14 ft Ib T R 78 Nm 7 8 m kg 56 ft lb T R 12 13 11 10 9 8 T R 30 Nm 3 0 m kg 22 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib ...

Page 162: ... 4 31 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Hose joint 1 2 Brake master cylinder kit 1 3 Brake master cylinder 1 For assembly reverse the disassembly pro cedure BF ...

Page 163: ... Brake fluid Drain 1 Parking brake cable 1 Disconnect 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake caliper bolt 2 6 Brake caliper assembly 1 For installation reverse the removal proce dure New New 5 T R 43 Nm 4 3 m kg 31 ft Ib 1 4 6 3 3 2 T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 164: ... 1 5 Parking brake shaft 1 6 Parking brake bracket bolt 2 7 Parking brake case bracket 1 8 Parking brake case 1 9 Gasket 1 10 Brake pad retaining bolt 2 1 2 3 4 6 5 6 7 8 9 10 10 22 Nm 2 2 m kg 16 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R New New New New LT LT LT LT S BF S S S S ...

Page 165: ... caliper piston 2 15 Brake caliper piston dust seal 2 16 Brake caliper piston seal 2 17 Bleed screw 1 For assembly reverse the disassembly pro cedure 11 12 13 14 15 14 16 16 15 17 22 Nm 2 2 m kg 16 ft Ib T R 22 Nm 2 2 m kg 16 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 17 Nm 1 7 m kg 12 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R New New New New LT LT LT LT S BF S S S S ...

Page 166: ... 9 2 Check Brake disc Damage galling Replace 3 Measure Brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 4 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISCS on page 4 22 5 Adjust Brak...

Page 167: ...HYDRAULIC BRAKE SYSTEM on page 3 22 EAS22590 REMOVING THE REAR BRAKE CALIPER 1 Remove Union bolt Copper washers Brake hose TIP Put the end of the brake hose into a container and pump out the brake fluid carefully EAS22630 DISASSEMBLING THE REAR BRAKE CALIPER TIP Before disassembling the brake caliper drain the brake fluid from the entire brake system 1 Remove Brake caliper pistons Brake caliper pi...

Page 168: ...ASSEMBLING THE REAR BRAKE CALIPER WARNING EWA1PE1004 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 as they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals and dust seals 1 Install Brake caliper piston s...

Page 169: ...NING EWA13090 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 performance When refilling be careful that water does not enter the brake fluid reservoir W...

Page 170: ...ase the parking brake lever k Slide the rubber cover to its original position WARNING EWA1S3L010 After this adjustment is performed lift the rear wheels off the ground by placing a block under the engine and spin the rear wheels to ensure there is no brake drag If any brake drag is noticed perform the above steps again EAS22720 CHECKING THE REAR BRAKE MASTER CYLINDER 1 Check Brake master cylinder ...

Page 171: ...ly 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 performance When refilling be careful that water does not enter the brake fluid reservoir Water will significan...

Page 172: ...REAR BRAKE 4 41 6 Adjust Rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH on page 3 22 Brake pedal position from foot rest 15 3 mm 0 60 in ...

Page 173: ...e lever assembly holder 1 1 6 Spacer 1 7 Clutch switch 1 8 Parking brake lever 1 9 Clutch lever bracket 1 1 10 Handlebar switch 1 11 Handlebar grip 2 12 Handlebar holder 2 13 Handlebar 1 For installation reverse the removal proce dure 11 6 13 5 2 4 12 12 2 11 10 7 8 9 9 1 3 4 5 4 Nm 0 4 m kg 2 9 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 23 Nm 2 3...

Page 174: ...attempt to straighten a bent handle bar as this may dangerously weaken it EAS22911 INSTALLING THE HANDLEBAR 1 Place the vehicle on a level surface 2 Install Handlebar Upper handlebar holders NOTICE ECA1S3L014 First tighten the bolts 1 on the front side of the handlebar holders and then tighten the bolts 2 on the rear side Turn the handlebar all the way to the left and right If there is any contact...

Page 175: ...t touch the handlebar grip until the rub ber adhesive has fully dried 4 Install Handlebar switch 1 Clutch lever Clutch lever bracket 2 TIP Install the clutch lever bracket as shown 5 Install Brake master cylinder 1 TIP Install the brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 6 Install Spacer Throttle lever assembly TIP Fit the indentation...

Page 176: ...t of lithium soap based grease 9 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 10 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LE VER FREE PLAY on page 3 6 Clutch lever free play lever end 8 0 13 0 mm 0 31 0 51 in Throttle lever free play 2 0 4 0 mm 0 08 0 16 in a b ...

Page 177: ...o remove Q ty Remarks Front fender fuel tank Refer to GENERAL CHASSIS on page 4 1 1 Pitman arm 1 2 Lock washer 1 3 Steering stem bushing 2 4 Spacer 2 5 Oil seal 2 6 Steering stem 1 7 Oil seal 1 8 Oil seal 1 9 Bearing retainer 1 10 Bearing 1 For installation reverse the removal proce dure ...

Page 178: ...ck washer Steering stem bushing bolts 2 Bend the lock washer tabs along a flat side of the bolts EAS29590 INSTALLING THE PITMAN ARM 1 Install Pitman arm Washer Pitman arm nut Cotter pin TIP Make sure that the threads of the steering stem washers nuts and the installation surfaces of the pitman arm are free of grease and oil Damper rod holder 30 mm 90890 01327 Damper rod holder 30 mm YM 01327 T R B...

Page 179: ...following procedure applies to both of the tie rods and steering knuckles Front wheel brake disc Refer to FRONT WHEELS on page 4 5 Front brake caliper Refer to FRONT BRAKES on page 4 17 1 Brake disc guard inner 1 2 Tie rod 2 3 Pitman arm 1 4 Front guard 1 5 Lower front arm 1 6 Upper front arm 1 7 Steering knuckle 1 For installation reverse the removal proce dure ...

Page 180: ...d movement Rough movement Replace the tie rod end 2 Check Tie rod Bends damage Replace Rubber boot damage Replace the tie rod end EAS29690 CHECKING THE STEERING KNUCKLES The following procedure applies to both of the steering knuckles 1 Check Steering knuckle Damage pitting Replace EAS29700 INSTALLING THE TIE RODS The following procedure applies to both of the tie rods 1 Install Tie rod TIP Instal...

Page 181: ...d front shock absorber assemblies Front wheel brake disc Refer to FRONT WHEELS on page 4 5 Front brake caliper Refer to FRONT BRAKES on page 4 17 Steering knuckle Refer to TIE RODS AND STEERING KNUCKLES on page 4 48 1 Lower front arm 1 2 Brake hose guide 1 3 Upper front arm 1 4 Front shock absorber 1 5 Dust cover 6 5 5 5 1 5 4 2 3 New New New New LS 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft...

Page 182: ... to remove Q ty Remarks 6 Spacer 1 7 Spacer 2 8 Bushing 6 9 Circlip 2 10 Ball joint assembly 2 For installation reverse the removal proce dure 8 8 6 8 8 8 7 9 9 10 8 7 10 New New New New LS 7 Nm 0 7 m kg 5 1 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R ...

Page 183: ...g performance EAS1PE1003 DISPOSING OF A FRONT SHOCK ABSORBER ASSEMBLY YFM700RSF 1 Gas pressure must be released before dis posing of a front shock absorber assembly To release the gas pressure press on the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chip...

Page 184: ... 1 Damage pitting Replace the ball joint as sembly Rubber boot damage Replace the ball joint assembly Rough movement Replace the ball joint assembly a Clean the surface of the front arm b Remove the circlip 1 c Remove the ball joint assembly with the spe cial tools d Install the body 2 long bolt 3 base 4 and remover attachment 5 onto ball joint assem bly e Hold the body 2 in place while turning in...

Page 185: ...1 Install Front upper arm Front lower arm Front shock absorber assembly a Install the front upper arm 1 and front lower arm 2 TIP Be sure to position the front upper and lower arm bolts so that the bolt heads face forward Temporarily tighten the front upper and lower arm nuts Apply lithium soap based grease to the grease nipple b Install the front shock absorber assembly c Install the steering knu...

Page 186: ...t bolt spacer 1 1 1 3 Self locking nut bolt 1 1 4 Self locking nut bolt 1 1 5 Rear shock absorber assembly 1 6 Spacer oil seal bearing 1 2 1 7 Spacer oil seal bearing 1 2 1 8 Self locking nut bolt 1 1 9 Relay arm 1 10 Spacer oil seal bushing 1 2 2 LS LS LS LS New LS LS LS New LS LS 2 2 2 1 1 1 6 3 6 LS 7 5 3 8 9 7 4 4 10 10 8 New New New New T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib ...

Page 187: ...1 Connecting arm 1 12 Dust cover 4 13 Spacer 1 14 Spacer 1 15 Bushing 4 For installation reverse the removal proce dure LS LS LS LS New LS LS LS New LS LS LS 12 12 12 12 11 13 15 15 15 14 15 New New New New T R 55 Nm 5 5 m kg 40 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib T R 43 Nm 4 3 m kg 31 ft Ib ...

Page 188: ...orber assembly To release the gas pressure press on the gas valve needle with a suitable tool as shown until all of the gas is released the hissing has stopped WARNING EWA13760 Wear eye protection to prevent eye damage from released gas or metal chips EAS23230 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Place the vehicle on a level surface TIP Place the vehicle on a suitable stand so that the rear...

Page 189: ...rm TIP Apply lithium soap based grease on the bush ings when installing 2 Install Bushing 1 Oil seal 2 to relay arm TIP Apply lithium soap based grease on the bush ings when installing 3 Install Connecting arm Relay arm Rear shock absorber TIP When installing the rear shock absorber lift up the swingarm Installed depth of bushing a 1 0 mm 0 04 in Installed depth of bushing a 6 5 mm 0 26 in New ...

Page 190: ...ck absorber assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 1 Rear axle pinch bolt 4 2 Dust seal 1 3 Swingarm skid plate 1 4 Drive chain guide 1 1 5 Pivot shaft nut 1 6 Pivot shaft 1 7 Swingarm 1 7 3 2 4 1 6 4 5 100 Nm 10 0 m kg 72 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R ...

Page 191: ...over washer 2 2 9 Spacer 2 10 Oil seal 2 11 Bushing 2 12 Bearing 2 For installation reverse the removal proce dure 4 8 9 12 11 11 10 10 12 9 8 100 Nm 10 0 m kg 72 ft lb T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 55 Nm 5 5 m kg 40 ft Ib T R ...

Page 192: ...frame pivot 3 Remove Pivot shaft nut Washer Pivot shaft Swingarm EAS23360 CHECKING THE SWINGARM 1 Check Swingarm Bends cracks damage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Clean Pivot shaft Spacers Bearings Bushings 4 Check Dust covers Spacers Oil seals Damage wear Replace Bearings Bushings...

Page 193: ...assembly Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 4 Install Rear wheels Refer to and REAR WHEELS on page 4 9 5 Adjust Drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK on page 3 24 Drive chain slack 25 0 35 0 mm 0 98 1 38 in 1 2 2 1 b a ...

Page 194: ...garm Refer to SWINGARM on page 4 59 1 Drive sprocket cover 1 2 Drive chain guide 2 1 3 Drive sprocket nut 1 4 Lock washer 1 5 Drive sprocket 1 6 Drive chain 1 For installation reverse the removal proce dure 1 2 5 3 4 6 85 Nm 8 5 m kg 61 ft Ib T R 32 Nm 3 2 m kg 23 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R New ...

Page 195: ...n with a clean cloth b Put the drive chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it NOTICE ECA14290 This motorcycle has a drive chain with small rubber O rings 1 between the drive chain side plates Never use high pressure water or air steam gasoline certain sol vents e g benzine or a coarse brush to clean the drive chain High pressu...

Page 196: ...Drive chain Drive sprocket 1 Lock washer 2 Drive sprocket nut 3 Drive chain guide TIP While applying the rear brake tighten the drive sprocket nut 3 Bend the lock washer tab along a flat side of the nut Recommended lubricant Engine oil or chain lubricant suitable for O ring chains b Correct 1 Drive chain roller 2 Drive chain sprocket Recommended lubricant Engine oil or chain lubricant suitable for...

Page 197: ...TALLING THE CAMSHAFT AND ROCKER ARMS 5 16 VALVES AND VALVE SPRINGS 5 19 REMOVING THE VALVES 5 20 CHECKING THE VALVES AND VALVE GUIDES 5 20 CHECKING THE VALVE SEATS 5 22 CHECKING THE VALVE SPRINGS 5 23 INSTALLING THE VALVES 5 24 CYLINDER AND PISTON 5 26 REMOVING THE PISTON 5 27 CHECKING THE CYLINDER AND PISTON 5 27 CHECKING THE PISTON RINGS 5 28 CHECKING THE PISTON PIN 5 29 INSTALLING THE PISTON AN...

Page 198: ...ING THE OIL PUMP 5 52 SHIFT SHAFT 5 53 CHECKING THE SHIFT SHAFT 5 54 CHECKING THE STOPPER LEVER 5 54 CHECKING THE SHIFT GUIDE 5 54 CHECKING THE SHIFT DRUM SEGMENT 5 54 INSTALLING THE SHIFT LEVER 5 54 INSTALLING THE SHIFT SHAFT 5 55 CRANKCASE 5 56 SEPARATING THE CRANKCASE 5 59 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 5 59 CHECKING THE OIL STRAINER 5 59 CHECKING THE BEARINGS AND OIL SEALS 5 ...

Page 199: ......

Page 200: ...ks 1 Muffler 1 2 Muffler protector 1 3 Gasket 1 4 Exhaust pipe 1 5 Exhaust pipe protector 1 6 Gasket 1 For installation reverse the removal proce dure New New 1 2 3 5 4 6 LT LT LT T R 38 Nm 3 8 m kg 27 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib 20 Nm 2 0 m kg 14 ft Ib T R ...

Page 201: ... the gasket and the chamfer b located on an outer rim of the gasket as shown 2 Tighten Muffler bolts 1 Exhaust pipe nuts 2 Muffler and exhaust pipe bolt 3 Installed depth of gasket c 1 0 1 5 mm 0 04 0 06 in T R Muffler bolt 38 Nm 3 8 m kgf 27 ft lbf Exhaust pipe nut 20 Nm 2 0 m kgf 14 ft lbf Muffler and exhaust pipe bolt 18 Nm 1 8 m kgf 13 ft lbf New a c 1 b New 1 2 3 ...

Page 202: ...nlet hose 1 3 Oil tank outlet hose 1 4 Oil tank breather hose 1 5 Oil tank 1 For installation reverse the removal proce dure T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib LS New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 19 Nm 1 9 m kg 13 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib 2 1 3 4 5 New New LS LS T R 7 Nm 0 7 m kg 5 1 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib ...

Page 203: ... footrest Refer to REAR BRAKE on page 4 28 Radiator inlet hose Refer to THERMOSTAT on page 6 3 Radiator outlet hose Refer to WATER PUMP on page 6 5 Throttle body Refer to THROTTLE BODY on page 7 4 Air cut off valve Refer to AIR INDUCTION SYSTEM on page 7 9 Drive sprocket Refer to CHAIN DRIVE on page 4 63 1 Spark plug cap 1 Disconnect 2 Starter motor lead 1 Disconnect 3 Coolant temperature sensor c...

Page 204: ...connect 7 AC magneto coupler 1 Disconnect 8 Crankshaft position sensor coupler 1 Disconnect 9 Rear brake light switch coupler 1 10 Rear brake light switch lead 1 11 Neutral switch and reverse switch sub wire har ness 1 12 Ground lead 1 13 Clutch cable 1 Disconnect 14 Parking brake cable 1 Disconnect 15 Reverse control cable 1 Disconnect For installation reverse the removal proce dure ...

Page 205: ...ine mounting bolt lower nut 1 1 8 Pivot shaft pivot shaft nut 1 1 Refer to REMOVING THE SWINGARM on page 4 61 9 Engine assembly 1 TIP Remove the engine assembly from the right side of the vehicle For installation reverse the removal proce dure T R 66 Nm 6 6 m kg 48 ft Ib T R 66 Nm 6 6 m kg 48 ft Ib T R 41 Nm 4 1 m kg 30 ft Ib T R 41 Nm 4 1 m kg 30 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib 6 5 4 6 4 5 7 8 ...

Page 206: ...TIP Do not fully tighten the bolts and nuts 3 Tighten Engine upper bracket bolt 1 Engine upper bracket bolt 2 Engine mounting bolt upper nut 3 Pivot shaft nut 4 Engine mounting bolt lower nut 5 Engine mounting bolt middle nut 6 Engine lower bracket bolts nuts 7 TIP Tighten the bolts and nuts in the proper tighten ing sequence as shown T R Engine upper bracket bolt 1 33 Nm 3 3 m kg 24 ft lb Engine ...

Page 207: ...r O ring 1 1 4 Tappet cover O ring 2 2 5 Oil delivery pipe 1 6 Timing chain tensioner cap bolt 1 Loosen 7 Timing chain tensioner gasket 1 1 LS M LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 20 Nm 2 0 m kg 14 f...

Page 208: ...moval proce dure LS M LS T R 13 Nm 1 3 m kg 9 4 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 38 Nm 3 8 m kg 27 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 20 Nm 2 0 m kg 14 ft Ib New New New New New New New 8 11 12 4 LS LS E E 9 10 4 New T R 40 Nm 4 0 m kg 29 ft Ib T R...

Page 209: ...Timing chain tensioner along with the gasket Camshaft sprocket Timing chain TIP To prevent the timing chain from falling into the crankcase fasten it with a wire 5 Remove Cylinder head TIP Loosen the nuts in the proper sequence as shown Loosen each nut 1 2 of a turn at a time After all of the nuts are fully loosened remove them EAS24160 CHECKING THE CYLINDER HEAD 1 Eliminate Combustion chamber car...

Page 210: ...oth wear a Replace the camshaft sprockets and the timing chain as a set EAS23940 CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET COVER The following procedure applies to both of the tappet covers and O rings 1 Check Tappet covers 1 Camshaft sprocket cover 2 O ring Damage wear Replace the defective part s EAS23960 CHECKING THE TIMING CHAIN TENSIONER 1 Check Timing chain tensioner Cracks damage Rep...

Page 211: ...ft sprock et with the stationary pointer d on the cylin der head d Install the timing chain 1 onto the camshaft sprocket 2 and then install the camshaft sprocket onto the camshaft TIP When installing the camshaft sprocket be sure to keep the timing chain as tight as possible on the exhaust side Align the pin on the camshaft with the slot in the camshaft sprocket NOTICE ECA1S3L016 Do not turn the c...

Page 212: ...y pointer b on the AC mag neto cover I mark c Align the I mark on the camshaft sprocket with the stationary pointer d on the cylinder head Out of alignment Correct Refer to the installation steps above 7 Tighten Camshaft sprocket bolts NOTICE ECA13750 Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine 8 ...

Page 213: ... 1 2 Rocker arm shaft 2 3 Rocker arm 2 4 Locknut valve adjuster 4 4 5 Camshaft 1 NOTICE ECA1S3L017 Do not disassemble the camshaft assem bly 6 Decompressor lever 1 7 Decompressor lever pin 1 8 Bearing 1 For installation reverse the removal proce dure E E T R 14 Nm 1 4 m kg 10 ft Ib T R 14 Nm 1 4 m kg 10 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E LT 1 5 7 6 2 E 8 3 2 3 4 4 4 4 E M ...

Page 214: ...tion pitting scratches Re place the camshaft 2 Measure Camshaft lobe dimensions a and b Out of specification Replace the camshaft 3 Measure Camshaft runout Out of specification Replace Slide hammer bolt 90890 01083 Slide hammer bolt 6 mm YU 01083 1 Weight 90890 01084 Weight YU 01083 3 1 1 2 Camshaft lobe dimension limit Intake A 43 300 43 400 mm 1 7047 1 7087 in Limit 43 200 mm 1 7008 in Intake B ...

Page 215: ...ssive wear pit ting scratches Replace or check the lubri cation system 3 Measure Rocker arm inside diameter Out of specification Replace 4 Measure Rocker arm shaft outside diameter Out of specification Replace 5 Calculate Rocker arm to rocker arm shaft clearance Out of specification Replace the defective part s TIP Calculate the clearance by subtracting the rock er arm shaft outside diameter from ...

Page 216: ... holes b 5 Lubricate Rocker arms Rocker arm shafts 6 Install Exhaust rocker arm 1 Exhaust rocker arm shaft 2 Intake rocker arm Intake rocker arm shaft TIP Use a slide hammer bolt 3 to install the rocker arm shaft Make sure the exhaust rocker arm shaft is completely pushed into the cylinder head 7 Install Camshaft retainer Camshaft retainer bolts Installed depth b 0 mm 0 in Recommended lubricant Ca...

Page 217: ...CAMSHAFT 5 18 T R Camshaft retainer bolt 10 Nm 1 0 m kg 7 2 ft lb ...

Page 218: ... Refer to CYLINDER HEAD on page 5 8 Rocker arms rocker arm shafts camshaft Refer to CAMSHAFT on page 5 14 1 Valve cotter 8 2 Valve spring retainer 4 3 Valve spring 4 4 Exhaust valve 2 5 Intake valve 2 6 Valve stem seal 4 7 Valve spring seat 4 For installation reverse the removal proce dure New M M New New M M M 7 6 5 5 4 4 3 2 1 6 7 7 6 3 2 3 2 1 2 3 6 7 ...

Page 219: ...ove the valve cotters by compressing the valve spring with the valve spring compressor 1 and the valve spring compressor attachment 2 3 Remove Valve spring retainer 1 Valve spring 2 Valve 3 Valve stem seal 4 Valve spring seat 5 TIP Identify the position of each part very carefully so that it can be reinstalled in its original place EAS24290 CHECKING THE VALVES AND VALVE GUIDES The following proced...

Page 220: ...er valve stem to valve guide clearance TIP After replacing the valve guide reface the valve seat 3 Eliminate Carbon deposits from the valve face and valve seat 4 Check Valve face Pitting wear Grind the valve face Valve stem to valve guide clear ance intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 080 mm 0 0031 in Valve stem to valve guide clear ance exhaust 0 025 0 052 mm 0 0010 0 0020 in Limit 0 1...

Page 221: ... blue layout fluid b onto the valve face b Install the valve into the cylinder head c Press the valve through the valve guide and onto the valve seat to make a clear impres sion d Measure the valve seat width TIP Where the valve seat and valve face contacted one another the blue layout fluid will have been removed 4 Lap Valve face Valve seat TIP After replacing the cylinder head or replacing the v...

Page 222: ...re to clean off all of the lapping compound from the valve face and valve seat g Apply blue layout fluid b onto the valve face h Install the valve into the cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EAS24310 CHECKING T...

Page 223: ...m seal 2 with the recommended lubricant 3 Install Valve spring seat 1 Valve stem seal 2 Valve 3 Valve spring 4 Valve spring retainer 5 into the cylinder head b Installed length Installed compression spring force intake 169 00 199 00 N 17 23 20 29 kgf 37 99 44 73 lbf Installed compression spring force exhaust 169 00 199 00 N 17 23 20 29 kgf 37 99 44 73 lbf Installed length intake 35 00 mm 1 38 in I...

Page 224: ...h the valve spring compressor 1 and the valve spring compressor attachment 2 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer NOTICE ECA13800 Hitting the valve tip with excessive force could damage the valve b Smaller pitch Valve spring compressor 90890 04019 Valve spring compressor YM 04019 Valve spring compressor attach ment 90890 01243 Valve sp...

Page 225: ...ater jacket joint 1 3 O ring 1 4 Cylinder 1 5 Cylinder gasket 1 6 Dowel pin 2 7 Piston pin clip 2 8 Piston pin 1 9 Piston 1 10 Top ring 1 11 2nd ring 1 12 Oil ring 1 For installation reverse the removal proce dure T R 1st 15Nm 1 5 m kg 11 ft lb 2nd 50Nm 5 0m kg 5 1 ft lb T R 10 Nm 1 0 m kg 7 2 ft Ib New 7 6 6 5 9 New New 7 New 3 10 1 2 8 11 12 4 T R 10 Nm 1 0 m kg 7 2 ft Ib LS E E E E T R 7 Nm 0 7...

Page 226: ...2 Remove Top ring 2nd ring Oil ring TIP When removing a piston ring open the end gap with your fingers and lift the other side of the ring over the piston crown EAS24400 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure cylinder bore C with the ...

Page 227: ...rance eliminate any carbon deposits from the piston ring grooves and piston rings 2 Install Piston ring into the cylinder TIP Use the piston crown to level the piston ring near bottom of cylinder a where cylinder wear is lowest Bore 102 000 102 010 mm 4 0157 4 0161 in Wear limit 102 080 mm 4 0189 in Taper limit 0 05 mm 0 002 in Out of round limit 0 05 mm 0 002 in b 10 mm 0 39 in from the bottom ed...

Page 228: ...nd piston as a set EAS24450 INSTALLING THE PISTON AND CYLINDER 1 Install Lower oil ring rail 1 Oil ring expander 2 Upper oil ring rail 3 2nd ring 4 Top ring 5 TIP Be sure to install the piston rings so that the manufacturer s marks or numbers face up Top ring End gap installed 0 20 0 35 mm 0 008 0 014 in Limit 0 60 mm 0 024 in 2nd ring End gap installed 0 75 0 90 mm 0 03 0 04 in Limit 1 25 mm 0 04...

Page 229: ...ming chain guide exhaust side TIP While compressing the piston rings with one hand install the cylinder with the other hand Pass the timing chain and timing chain guide exhaust side through the timing chain cavity 7 Install Cylinder bolts 1 TIP Lubricate the cylinder bolt 1 threads and mat ing surface with engine oil 8 Tighten Cylinder bolts 1 Cylinder bolts timing chain side 2 Recommended lubrica...

Page 230: ... ENGINE REMOVAL on page 5 1 Drive sprocket cover Refer to CHAIN DRIVE on page 4 63 1 AC magneto coupler 1 Disconnect 2 Crankshaft position sensor coupler 1 Disconnect 3 AC magneto cover 1 4 AC magneto cover gasket 1 5 Dowel pin 2 6 Lead holder 1 7 Crankshaft position sensor 1 LT LT E LS New LT E E E New LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R ...

Page 231: ...e gear shaft 1 12 AC magneto rotor 1 13 Starter clutch 1 14 Woodruff key 1 15 Starter wheel gear 1 16 Washer 1 For installation reverse the removal proce dure LT LT E LS New LT E E E New LT LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib 8 14 3 15 16 11 9 14 10 13 12 T R 60 Nm 6 0 m kg 43 ft Ib T R 30 Nm 3 0 m kg 22 ft Ib ...

Page 232: ...CA13880 To protect the end of the crankshaft place an appropriate sized socket between the fly wheel puller set center bolt and the crank shaft TIP Use the flywheel puller 2 Install the flywheel puller bolts to the threaded holes of the starter clutch Make sure the flywheel puller is centered over the AC magneto rotor EAS1S3L027 CHECKING THE STATOR COIL AND CRANKSHAFT POSITION SENSOR 1 Check Stato...

Page 233: ...nter clockwise A the starter clutch and the start er wheel gear should engage otherwise the starter clutch is faulty and must be replaced c When turning the starter wheel gear clock wise B it should turn freely otherwise the starter clutch is faulty and must be replaced EAS1S3L028 CHECKING THE TORQUE LIMITER 1 Check Torque limiter Damage wear Replace TIP Do not disassemble the torque limiter EAS1S...

Page 234: ...aft 4 Tighten AC magneto rotor nut 1 TIP While holding the AC magneto rotor 2 with the sheave holder 3 tighten the AC magneto rotor nut Do not allow the sheave holder to touch the projection on the AC magneto rotor 5 Install Gasket AC magneto cover AC magneto cover bolts TIP Tighten the AC magneto cover bolts in stages using a crisscross pattern Yamaha bond No 1215 90890 85505 Three bond No 1215 T...

Page 235: ... Order Job Parts to remove Q ty Remarks Exhaust pipe Refer to ENGINE REMOVAL on page 5 1 1 Starter motor lead 1 Disconnect 2 Parking brake cable 1 3 Starter motor 1 For installation reverse the removal proce dure T R 5 Nm 0 5 m kg 3 6 ft Ib 3 2 1 T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 236: ...emove Q ty Remarks 1 O ring 1 2 Starter motor front cover 1 3 Square ring 1 4 Lock washer 1 5 Shim 1 6 Armature assembly 1 7 Starter motor yoke 1 8 Brush holder assembly 1 9 Square ring 1 10 Shim 1 11 Starter motor rear cover 1 For assembly reverse the disassembly pro cedure ...

Page 237: ...ces commutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specification re place the starter motor 5 Measure Brush length a Out of specification Replace the brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set Commutator diameter 28 0 ...

Page 238: ...R MOTOR 1 Install Brush seat 1 TIP Align the tab a on the brush seat with the slot b in the starter motor yoke 2 Install Starter motor yoke Starter motor front cover Starter motor rear cover TIP Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers Brush spring force 7 65 10 01 N 780 1021 gf 27 54 36 03 oz b b a ...

Page 239: ...er to REAR BRAKE on page 4 28 Oil delivery pipe Refer to CYLINDER HEAD on page 5 8 1 Oil filter cover O ring 1 1 2 Oil filter 1 3 O ring 1 4 Clutch cover 1 5 Clutch cover gasket 1 6 Dowel pin 2 7 Oil seal retainer 1 For installation reverse the removal proce dure LS LS LS LS 1 6 5 7 6 4 2 New 3 14 New New T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 12...

Page 240: ...ft Order Job Parts to remove Q ty Remarks 1 Circlip 1 2 Pull lever 1 3 Pull lever spring 1 4 Circlip 1 5 Pull lever shaft 1 6 Oil seal 1 7 Bearing 1 8 Bearing 1 For installation reverse the removal proce dure E 5 8 7 6 4 3 2 1 New New New LS ...

Page 241: ...r 1 8 Wire circlip 1 9 Friction plate 2 1 10 Clutch damper spring 1 11 Clutch damper spring seat 1 12 Clutch boss 1 13 Thrust washer 1 14 Clutch housing 1 LS New New New 14 New T R 8 Nm 0 8 m kg 5 8 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 110 Nm 11 0 m kg 80 ft lb T R 95 Nm 9 5 m kg 68 ft Ib 1 5 6 6 2 4 3 E E 7 8 6 9 10 11 12 13 E E E E M ...

Page 242: ... drive gear 1 22 Balancer drive gear 1 23 Straight key 1 24 Lock washer 1 25 Balancer driven gear 2 1 26 Straight key 1 For installation reverse the removal proce dure 25 24 22 LS New 19 New New 16 17 New T R 8 Nm 0 8 m kg 5 8 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 60 Nm 6 0 m kg 43 ft Ib T R 110 Nm 11 0 m kg 80 ft lb T R 95 Nm 9 5 m kg 68 ft Ib 6 18 23 26 E E 21 20 15 ...

Page 243: ... AND BALANCER DRIVEN GEAR 1 Straighten the lock washer tabs 2 Remove Balancer driven gear 1 nut 1 Primary drive gear nut 2 Balancer driven gear 2 nut 3 TIP Place an aluminum plate 4 between the teeth of the balancer driven gear 1 5 and balancer drive gear 6 then loosen the nut 1 Place an aluminum plate 4 between the teeth of the balancer driven gear 2 7 and balancer drive gear 6 then loosen the nu...

Page 244: ...ee length a Out of specification Replace the clutch springs as a set EAS25150 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er ratic clutch operation EAS25160 CHECKING THE CLUTCH BOSS 1 Check Clutch boss splines Damage pitting wear Replace the clutch boss TIP...

Page 245: ...ancer drive gear and balancer driven gear as a set Replace the water pump drive gear and water pump driven gear as a set Excessive noise during operation Replace the balancer drive gear and balancer driven gear as a set Replace the water pump drive gear and water pump driven gear as a set EAS25220 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check Pull lever shaft pinion gear teeth a Pull rod teet...

Page 246: ...eth of the balancer drive gear 6 and balancer driven gear 1 7 then tighten the nut 3 3 Bend the lock washer tabs along a flat side of the nut EAS25240 INSTALLING THE CLUTCH 1 Install Clutch housing 1 TIP Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Make sure that the oil pump drive gear teeth and oil pump driven gear teeth mesh correctly 2 Install Clutch...

Page 247: ...tall Pull lever spring 1 Pull lever 2 Washer Circlip TIP Install the pull lever with the UP mark facing up Align the mark a on the pull lever with the sta tionary pointer b on the clutch cover Install the pull lever spring 1 as shown 7 Install Clutch cable 1 8 Check Clutch cable length a Out of specification Adjust TIP Push the pull lever in direction b and check the cable length a Bend the tab c ...

Page 248: ...49 9 Adjust Clutch cable length TIP Move the pull lever a notch until the cable length is within specification 10 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY on page 3 12 b a 1 c ...

Page 249: ...rder Job Parts to remove Q ty Remarks Clutch housing Refer to CLUTCH on page 5 40 1 Oil baffle plate 1 1 2 Circlip 1 3 Oil pump driven gear 1 4 Oil baffle plate 2 1 5 Oil pump 1 6 Oil pump gasket 1 7 O ring 2 For installation reverse the removal proce dure ...

Page 250: ...ng 1 oil seal 1 1 2 Oil pump outer rotor 1 1 3 Dowel pin 1 4 Oil pump inner rotor 1 1 5 Oil pump housing cover oil seal 1 1 6 Dowel pin 2 7 Oil pump shaft 1 8 Dowel pin 1 9 Oil pump inner rotor 2 1 10 Oil pump outer rotor 2 1 11 Oil pump housing 2 1 For assembly reverse the disassembly pro cedure ...

Page 251: ... 1 Lubricate Inner rotor Outer rotor Oil pump shaft with the recommended lubricant 2 Install Oil pump outer rotor 2 1 Oil pump inner rotor 2 2 to the oil pump housing 2 Oil pump housing TIP Align the match mark a on the inner rotor 2 with the match mark b on the outer rotor 2 3 Check Oil pump operation Refer to CHECKING THE OIL PUMP on page 5 52 Inner rotor to outer rotor tip clearance 0 12 mm 0 0...

Page 252: ...utch housing Refer to CLUTCH on page 5 40 1 Shift pedal 1 2 Shift shaft 1 3 Shift shaft spring 1 4 Stopper lever washer 1 1 5 Stopper lever spring 1 6 Roller 1 7 Shift guide 1 8 Shift lever assembly 1 9 Pawl holder 1 10 Pawl 2 11 Pawl pin 2 12 Spring 2 13 Shift drum segment 1 For installation reverse the removal proce dure ...

Page 253: ...NG THE SHIFT GUIDE 1 Check Shift guide 1 Pawl holder 2 Pawls 3 Pawl pins 4 Springs 5 Wear cracks damage Replace EAS1S3L034 CHECKING THE SHIFT DRUM SEGMENT 1 Check Shift drum segment Damage wear Replace EAS1S3L035 INSTALLING THE SHIFT LEVER 1 Install Shift drum segment 1 Shift drum segment bolt TIP Align the notch a on the shift drum segment with the pin b on the shift drum 2 Install Springs 1 Pawl...

Page 254: ... Shift shaft spring TIP Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 5 Install the end of the shift shaft spring onto the shift shaft spring stopper 6 Install the end of the shift shaft lever onto the roller 4 2 Install Shift pedal Refer to ADJUSTING THE SHIFT PEDAL on page 3 23 T R Shift guide bolt 10 Nm 1 0 m kg 7 2 ft lb LOCTITE 4 3 3 2 2 1 1 1 2 T R S...

Page 255: ...R AND PISTON on page 5 26 AC magneto Refer to AC MAGNETO AND STARTER CLUTCH on page 5 31 Balancer driven gears Refer to CLUTCH on page 5 40 Oil pump Refer to OIL PUMP on page 5 50 Shift drum segment Refer to SHIFT SHAFT on page 5 53 Starter motor Refer to ELECTRIC STARTER on page 5 36 1 Timing chain guide intake side 1 2 Timing chain 1 3 Neutral switch 1 4 Reverse switch 1 ...

Page 256: ...s to remove Q ty Remarks 5 Oil pipe joint 1 6 Reverse shift lever 1 7 Reverse shift lever spring 1 8 Circlip 1 9 Right crankcase 1 10 Left crankcase 1 11 Dowel pin 2 12 Dowel pin O ring 1 1 13 Oil strainer 1 For installation reverse the removal proce dure ...

Page 257: ...ansmission Refer to TRANSMISSION on page 5 65 1 Oil seal retainer 1 2 Bearing retainer 1 3 Bearing retainer 2 4 Oil seal 4 5 Bearing 10 For installation reverse the removal proce dure LS LS LT T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib E E 5 5 3 3 5 5 LT 5 4 4 1 5 5 5 2 5 5 E E E E New New T R 10 Nm 1 0 m kg 7 2 ft Ib ...

Page 258: ...wly and carefully and make sure the crankcase halves sepa rate evenly EAS1S3L023 CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Check Timing chain Damage stiffness Replace the timing chain and camshaft sprockets as a set 2 Check Timing chain guide intake side Damage wear Replace the defective part s EAS24990 CHECKING THE OIL STRAINER 1 Check Oil strainer Damage Replace Contaminants Clean with ...

Page 259: ...nt the bearing retainer screws 2 from becoming loose flatten the edge a of each screw into the depression b using a punch etc Be careful not to damage the hole for the screwdriver in the screw heads 2 Thoroughly clean all the gasket mating sur faces and crankcase mating surfaces 3 Apply Sealant 1 onto the crankcase mating surfaces TIP Do not allow any sealant to come into contact with the oil gall...

Page 260: ...smission is functioning properly by manually rotating the shift drum in both di rections 6 Install Crankcase bolts 7 Tighten Crankcase bolts TIP Tighten the bolts in stages using a crisscross pattern 8 Apply Engine oil to the crankshaft pin bearing and oil delivery hole 9 Check Crankshaft and transmission operation Rough operation Repair A Left crankcase B Right crankcase T R Crankcase bolt 10 Nm ...

Page 261: ... CRANKSHAFT Removing the crankshaft Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 56 1 Balancer 1 1 2 Balancer 2 1 3 Crankshaft 1 For installation reverse the removal proce dure M 2 1 3 ...

Page 262: ...k shaft EAS1S3L040 INSTALLING THE CRANKSHAFT 1 Install Crankshaft 1 TIP Install the crankshaft with the crankshaft installer pot 2 crankshaft installer bolt 3 adapter M16 4 and spacer crankshaft installer 5 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B Width A 74 95 75 00 mm 2 951 2 953 in Runout limit C 0 030 mm 0 0012 in Big end side clearance D 0 350 0 650 mm 0 0138 0 025...

Page 263: ...ft against scratches and to make installation easier TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft as sembly bottoms against the bearing 1 5 4 3 2 ...

Page 264: ...forks Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 56 1 Spacer 1 2 Circlip 1 3 Washer 1 4 Reverse wheel gear 2 1 5 Spacer 1 6 Counter axle assembly 1 7 Shift drum 1 8 Shift fork R 1 9 Shift fork C 1 10 Shift fork L 1 M New 8 7 9 10 2 3 4 5 6 1 New LS M M M ...

Page 265: ...ansmission shift drum assembly and shift forks Order Job Parts to remove Q ty Remarks 11 Drive axle assembly 1 12 Main axle assembly 1 13 Reverse shift shaft 1 For installation reverse the removal proce dure M 12 13 New 11 New LS M M M ...

Page 266: ...d pinion gear 1 3 Toothed lock washer 1 4 Toothed washer retainer 1 5 4th pinion gear 1 6 Toothed spacer 1 7 Toothed washer 2 8 Circlip 2 9 3rd pinion gear 1 10 5th pinion gear 1 11 Main axle 1st pinion gear 1 For assembly reverse the disassembly pro cedure 11 10 7 8 9 8 1 2 3 4 5 6 7 New New New M M M ...

Page 267: ...asher 1 3 Reverse wheel gear 2 1 4 Spacer 1 5 Dog clutch 1 6 Circlip 1 7 Toothed washer 1 8 1st wheel gear 1 9 Toothed spacer 1 10 5th wheel gear 1 11 Toothed lock washer 1 12 Toothed washer retainer 1 13 3rd wheel gear 1 14 Toothed spacer 1 M M M 11 2 3 4 5 6 7 8 9 10 1 12 13 14 New New New New M M M ...

Page 268: ...rts to remove Q ty Remarks 15 Toothed washer 1 16 Circlip 1 17 4th wheel gear 1 18 Circlip 1 19 Toothed washer 1 20 2nd wheel gear 1 21 Spacer 1 22 Drive axle 1 For assembly reverse the disassembly pro cedure M M M 22 21 15 16 17 19 20 18 New New New New M M M ...

Page 269: ... Disassembling the counter axle Order Job Parts to remove Q ty Remarks 1 Circlip 2 2 Washer 2 3 Spacer 1 4 Reverse wheel gear 1 1 5 Counter axle 1 For assembly reverse the disassembly pro cedure 5 4 3 2 1 2 1 New New M ...

Page 270: ...ork guide bar 3 Check Shift fork movement Rough movement Replace the shift forks EAS26270 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum grooves Damage scratches wear Replace the shift drum assembly EAS26300 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Check Transmission gears Blue discoloration pitt...

Page 271: ...ll Drive axle assembly 1 Main axle assembly 2 Shift fork L 3 to drive axle Shift fork C 4 to main axle Shift fork R 5 to drive axle Shift drum 6 TIP The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence R C L Be sure that the shift fork cam follower is properly seated in the shift drum groove 2 Install Counter axle assembly TIP Enga...

Page 272: ...TRANSMISSION 5 73 ...

Page 273: ...CHECKING THE RADIATOR 6 2 INSTALLING THE RADIATOR 6 2 THERMOSTAT 6 3 CHECKING THE THERMOSTAT 6 4 INSTALLING THE THERMOSTAT 6 4 WATER PUMP 6 5 DISASSEMBLING THE WATER PUMP 6 7 CHECKING THE WATER PUMP 6 7 ASSEMBLING THE WATER PUMP 6 7 ...

Page 274: ...r hose 1 3 Radiator fan motor breather hose 1 Disconnect 4 Radiator outlet hose 1 Disconnect 5 Radiator inlet hose 1 Disconnect 6 Fast idle plunger outlet hose 1 Disconnect 7 Radiator 1 8 Radiator fan 1 9 Coolant reservoir breather hose 1 10 Coolant reservoir 1 11 Coolant reservoir cap 1 For installation reverse the removal proce dure 1 4 8 2 2 10 11 9 5 6 3 7 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm ...

Page 275: ...and make sure there is no drop in pressure 4 Check Radiator fan Damage Replace Malfunction Check and repair Refer to COOLING SYSTEM on page 8 25 EAS26400 INSTALLING THE RADIATOR 1 Fill Cooling system with the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT on page 3 16 2 Check Cooling system Leaks Repair or replace any faulty part 3 Measure Radiator cap opening pressure ...

Page 276: ...nder Refer to GENERAL CHASSIS on page 4 1 Coolant Drain 1 Radiator inlet hose 1 2 Thermostat cover 1 3 O ring 1 4 Thermostat 1 5 Coolant temperature sensor 1 6 Copper washer 1 For installation reverse the removal proce dure LS 5 6 2 3 4 1 T R 10 Nm 1 0 m kg 7 2 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib New New New ...

Page 277: ...he thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Thermostat cover Thermostat housing cylinder head Cracks damage Replace EAS1S3L009 INSTALLING THE THERMOSTAT 1 Install Thermostat 1 O ring 2 Thermostat cover 3 TIP Install the thermostat with its breather hole a facing up 2 Fill Cooling system with the specified amount of the recom mend...

Page 278: ...ely low or the coolant contains engine oil Coolant Drain 1 Radiator outlet hose 1 Disconnect 2 Water pump outlet hose 1 3 Water pump 1 4 O ring 1 5 Water pump breather hose 1 6 Water jacket inlet housing 1 7 O ring 1 For installation reverse the removal proce dure LS T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 ft Ib New 1 2 5 7 6 New 4 3 LS ...

Page 279: ...ing cover 1 2 Gasket 1 3 Circlip 1 4 Impeller shaft gear 1 5 Pin 1 6 Washer 1 7 Impeller shaft assembly 1 8 Water pump seal 1 9 Oil seal 1 10 Bearing 1 11 Water pump housing 1 For assembly reverse the disassembly pro cedure E 7 5 10 6 4 8 11 New 2 1 New New 3 New 9 New LS T R 11 Nm 1 1 m kg 8 0 ft Ib ...

Page 280: ...place EAS26560 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 into the water pump housing 2 TIP Before installing the oil seal apply tap water or coolant onto its outer surface Install the oil seal with a socket 3 that match es its outside diameter 2 Install Water pump seal 1 into the water pump housing 2 NOTICE ECA14080 Never lubricate the water pump seal surface with oil or grease TIP Install th...

Page 281: ...ATER PUMP 6 8 3 Measure Impeller shaft tilt 3 Mechanical seal installer 4 Middle driven shaft bearing driver A Push down Impeller shaft tilt limit 0 15 mm 0 006 in 1 Straightedge 2 Impeller 4 A 1 2 3 New ...

Page 282: ...WATER PUMP 6 9 ...

Page 283: ...MP 7 2 INSTALLING THE FUEL HOSE 7 3 THROTTLE BODY 7 4 CHECKING THE INJECTOR 7 7 CHECKING THE THROTTLE BODY 7 7 CHECKING THE PRESSURE REGULATOR OPERATION 7 7 ADJUSTING THE THROTTLE POSITION SENSOR 7 7 INSTALLING THE THROTTLE BODY 7 8 AIR INDUCTION SYSTEM 7 9 CHECKING THE AIR INDUCTION SYSTEM 7 13 INSTALLING THE AIR INDUCTION SYSTEM 7 13 ...

Page 284: ...l hose connector holder 1 3 Fuel hose 1 4 Fuel tank 1 TIP When installing the fuel tank pass the fuel tank breather hose through the hole in the handlebar cover and then insert the end of the hose into the steering stem 5 Drain hose 1 6 Fuel tank shield 1 7 Fuel pump 1 For installation reverse the removal proce dure 4 2 1 7 3 6 T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib T R 7 Nm 0 7 m...

Page 285: ...he hose Before removing the hoses place a few rags in the area under where it will be removed 3 Remove Fuel tank TIP Do not set the fuel tank down on the installation surface of the fuel pump Be sure to lean the fuel tank against a wall or like EAS26640 REMOVING THE FUEL PUMP 1 Remove Fuel pump bracket Fuel pump Fuel pump gasket NOTICE ECA14720 Do not drop the fuel pump or give it a strong shock D...

Page 286: ... the fuel hose make sure that it is securely connected and that the fuel hose holder is in the correct position other wise the fuel hose will not be properly in stalled TIP Install the fuel hose connector cover 1 securely onto the fuel tank until a distinct click is heard and then make sure that it does not come loose 1 3 5 2 4 6 a a 1 1 ...

Page 287: ...OOLANT on page 3 16 1 Fuel hose 1 Disconnect 2 Fuel injector coupler 1 Disconnect 3 Intake air pressure sensor coupler 1 Disconnect 4 Throttle position sensor coupler 1 Disconnect 5 Throttle cable housing cover 1 6 Throttle cable 1 7 Hose air filter joint to throttle body left side 1 Disconnect 8 Fast idle plunger inlet hose 1 4 Nm 0 4 m kg 2 9 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib T R 1 2 3 4 5 6 7 8...

Page 288: ... 1 Disconnect 10 Intake air pressure sensor hose 1 11 Intake air pressure sensor 1 12 Intake manifold clamp screw 1 Loosen 13 Air filter case joint clamp screw 1 Loosen 14 Throttle body assembly 1 For installation reverse the removal proce dure 4 Nm 0 4 m kg 2 9 ft Ib T R 3 Nm 0 3 m kg 2 2 ft Ib T R 12 13 9 10 11 14 ...

Page 289: ...Order Job Parts to remove Q ty Remarks 1 Throttle position sensor 1 2 Fuel injection pipe 1 3 Fuel injector 1 4 Throttle body 1 NOTICE ECA1S3L008 The throttle body should not be disas sembled For assembly reverse the disassembly pro cedure 3 2 4 1 New ...

Page 290: ...he fuel hose connec tor cover 2 then slide it in the direction of the arrow and remove the fuel hose Before removing the hose place a few rags in the area under where it will be removed d Connect the pressure gauge 3 and adapter 4 to the fuel pump and fuel hose e Start the engine f Measure the fuel pressure Out of specification Replace the fuel pump EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR ...

Page 291: ...n the projection a on the throttle body with the slot b in the throttle body joint 2 Install Throttle cable 3 Adjust Throttle lever free play Refer to ADJUSTING THE THROTTLE LE VER FREE PLAY on page 3 6 4 Adjust Engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED on page 3 6 5 Check Throttle position sensor Refer to ADJUSTING THE THROTTLE PO SITION SENSOR on page 7 7 Digital circuit tes...

Page 292: ...AIR INDUCTION SYSTEM 7 9 EAS27040 AIR INDUCTION SYSTEM 3 2 1 4 A ...

Page 293: ...ION SYSTEM 7 10 1 Air induction system hose air filter case joint to air cut off valve 2 Air cut off valve 3 Air induction system hose air cut off valve to reed valve 4 Reed valve A from the air filter case joint ...

Page 294: ...r Refer to GENERAL CHASSIS on page 4 1 Fuel tank shield Refer to FUEL TANK on page 7 1 1 Air cut off valve coupler 1 Disconnect 2 Air induction system hose air cut off valve joint to reed valve 1 3 Air induction system hose air filter case joint to air cut off valve 1 4 Air cut off valve 1 For installation reverse the removal proce dure 1 2 4 3 ...

Page 295: ...e Q ty Remarks Air induction system hose air cut off valve to reed valve Disconnect Refer to Removing the air cut off valve 1 Reed valve cover 1 2 Reed valve assembly 1 3 Reed valve plate 1 For installation reverse the removal proce dure 10 Nm 1 0 m kg 7 2 ft Ib T R LT 1 3 2 ...

Page 296: ...w during idle and closes to cut off the flow when the vehicle is be ing driven However if the coolant temperature is below the specified value the air cut off valve remains open and allows the air to flow into the exhaust pipe until the temperature becomes higher than the specified value 1 Check Hoses Loose connections Connect properly Cracks damage Replace 2 Check Reed valve Reed valve stopper Re...

Page 297: ...ROUBLESHOOTING 8 13 LIGHTING SYSTEM 8 15 CIRCUIT DIAGRAM 8 15 TROUBLESHOOTING 8 17 SIGNALING SYSTEM 8 19 CIRCUIT DIAGRAM 8 19 TROUBLESHOOTING 8 21 COOLING SYSTEM 8 25 CIRCUIT DIAGRAM 8 25 TROUBLESHOOTING 8 27 FUEL INJECTION SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 ECU SELF DIAGNOSTIC FUNCTION 8 31 TROUBLESHOOTING METHOD 8 33 YAMAHA DIAGNOSTIC TOOL 8 34 TROUBLESHOOTING DETAILS 8 37 FUEL PUMP SYSTEM 8 55 CI...

Page 298: ...ON SENSOR 8 72 CHECKING THE LEAN ANGLE SENSOR 8 72 CHECKING THE STARTER MOTOR OPERATION 8 72 CHECKING THE STATOR COIL 8 73 CHECKING THE RECTIFIER REGULATOR 8 73 CHECKING THE FUEL SENDER 8 74 CHECKING THE SPEED SENSOR 8 74 CHECKING THE RADIATOR FAN MOTOR 8 75 CHECKING THE RADIATOR FAN MOTOR CIRCUIT BREAKER 8 75 CHECKING THE COOLANT TEMPERATURE SENSOR 8 75 CHECKING THE THROTTLE POSITION SENSOR 8 76 ...

Page 299: ......

Page 300: ... O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L B L B ...

Page 301: ...tch 5 Battery 6 Main fuse 24 ECU engine control unit 25 Ignition coil 26 Spark plug 32 Lean angle sensor 33 Joint coupler 35 Handlebar switch 37 Engine stop switch 41 Fuel injection system fuse 43 Ignition fuse A Wire harness C Negative battery sub wire harness ...

Page 302: ...tery terminals Recharge or replace the battery 3 Check the spark plug Refer to CHECKING THE SPARK PLUG on page 3 7 Re gap clean or replace the spark plug 4 Check the ignition spark gap Refer to CHECKING THE IGNI TION SPARK GAP on page 8 71 Ignition system is OK 5 Check the spark plug cap Refer to CHECKING THE SPARK PLUG CAP on page 8 70 Replace the spark plug cap 6 Check the ignition coil Refer to...

Page 303: ...ch Refer to CHECKING THE SWITCHES on page 8 61 The engine stop switch is faulty Replace the handlebar switch 10 Check the lean angle sensor Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 72 Replace the lean angle sensor 11 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM on page 8 1 Properly connect or replace the wire har ness Replace the ECU ...

Page 304: ...G B O G B O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B...

Page 305: ... 16 Diode 17 Clutch switch 19 Neutral switch 24 ECU engine control unit 33 Joint coupler 35 Handlebar switch 37 Engine stop switch 38 Start switch 41 Fuel injection system fuse 43 Ignition fuse A Wire harness C Negative battery sub wire harness D Neutral switch and reverse switch sub wire harness ...

Page 306: ...least one of the following conditions is met The transmission is in neutral the neutral switch is closed The clutch lever is pulled to the handlebar the clutch switch is closed 1 12 9 2 3 6 5 4 7 8 10 11 M 1 Battery 2 Main fuse 3 Fuel injection system fuse 4 ECU engine control unit 5 Main switch 6 Ignition fuse 7 Engine stop switch 8 Start switch 9 Starter relay 10 Clutch switch 11 Neutral switch ...

Page 307: ...harge or replace the battery 3 Check the starter motor Refer to CHECKING THE START ER MOTOR on page 5 38 Repair or replace the starter motor 4 Check the diode Refer to CHECKING THE DIODE on page 8 70 Replace the diode 5 Check the starter relay Refer to CHECKING THE RE LAYS on page 8 69 Replace the starter relay 6 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main sw...

Page 308: ...n page 8 61 Replace the clutch switch 10 Check the start switch Refer to CHECKING THE SWITCHES on page 8 61 The start switch is faulty Replace the han dlebar switch 11 Check the entire starting system wiring Refer to CIRCUIT DIAGRAM on page 8 5 Properly connect or replace the wire har ness Replace the ECU ...

Page 309: ...ELECTRIC STARTING SYSTEM 8 10 ...

Page 310: ...B O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L B L B...

Page 311: ...CHARGING SYSTEM 8 12 2 AC magneto 4 Rectifier regulator 5 Battery 6 Main fuse A Wire harness C Negative battery sub wire harness ...

Page 312: ...CKING AND CHARGING THE BATTERY on page 8 66 Clean the battery terminals Recharge or replace the battery 3 Check the stator coil Refer to CHECKING THE STATOR COIL on page 8 73 The stator coil is faulty Replace the crank shaft position sensor stator assembly 4 Check the rectifier regulator Refer to CHECKING THE RECTI FIER REGULATOR on page 8 73 Replace the rectifier regulator 5 Check the entire char...

Page 313: ...CHARGING SYSTEM 8 14 ...

Page 314: ...B O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L B L B...

Page 315: ...NG SYSTEM 8 16 3 Main switch 5 Battery 6 Main fuse 35 Handlebar switch 36 Light switch 39 Headlight relay 40 Headlight 45 Headlight fuse 48 Tail brake light A Wire harness C Negative battery sub wire harness ...

Page 316: ... THE FUS ES on page 8 65 Replace the fuse s 3 Check the battery Refer to CHECKING AND CHARGING THE BATTERY on page 8 66 Clean the battery terminals Recharge or replace the battery 4 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 5 Check the light switch Refer to CHECKING THE SWITCHES on page 8 61 The light switch is faulty Replace the han dlebar switch 6 ...

Page 317: ...LIGHTING SYSTEM 8 18 ...

Page 318: ... B O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L B L ...

Page 319: ...switch 20 Fuel pump 23 Reverse switch 24 ECU engine control unit 28 Coolant temperature sensor 33 Joint coupler 34 Resistor 41 Fuel injection system fuse 43 Ignition fuse 44 Signaling system fuse 46 Rear brake light switch 47 Front brake light switch 48 Tail brake light A Wire harness B Front brake light switch sub wire harness C Negative battery sub wire harness D Neutral switch and reverse switc...

Page 320: ...tery Refer to CHECKING AND CHARGING THE BATTERY on page 8 66 Clean the battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Check the condition of each of the sig naling system circuit...

Page 321: ...ral switch 2 Check the diode Refer to CHECKING THE DIODE on page 8 70 Replace the diode 3 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the indicator light assembly 1 Check the reverse switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the reverse switch 2 Check the entire signaling system wiring Refer t...

Page 322: ...ge 8 19 Properly connect or replace the wire har ness Replace the indicator light assembly or ECU 1 Check the fuel sender Refer to CHECKING THE FUEL SENDER on page 8 74 Replace the fuel pump 2 Check the entire signaling system wiring Refer to CIRCUIT DIAGRAM on page 8 19 Properly connect or replace the wire har ness Replace the indicator light assembly or ECU ...

Page 323: ...SIGNALING SYSTEM 8 24 ...

Page 324: ... O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L B L B ...

Page 325: ...ine control unit 28 Coolant temperature sensor 33 Joint coupler 41 Fuel injection system fuse 42 Radiator fan motor fuse 43 Ignition fuse 49 Circuit breaker fan motor 50 Radiator fan motor relay 51 Radiator fan motor A Wire harness C Negative battery sub wire harness ...

Page 326: ...the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the radiator fan motor Refer to CHECKING THE RADIA TOR FAN MOTOR on page 8 75 The radiator fan motor is faulty and must be replaced 5 Check the radiator fan motor relay Refer to CHECKING THE RE LAYS on page 8 69 Replace the radiator fan motor relay 6 Check the circuit breaker fan mo tor ...

Page 327: ...COOLING SYSTEM 8 28 NG OK 8 Check the entire cooling system wiring Refer to CIRCUIT DIAGRAM on page 8 25 Properly connect or replace the wire har ness Replace the ECU ...

Page 328: ...B O G B O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L...

Page 329: ...tem solenoid 22 Fuel injector 24 ECU engine control unit 25 Ignition coil 26 Spark plug 27 Intake air temperature sensor 28 Coolant temperature sensor 29 Speed sensor 30 Throttle position sensor 31 Intake air pressure sensor 32 Lean angle sensor 33 Joint coupler 35 Handlebar switch 37 Engine stop switch 41 Fuel injection system fuse 43 Ignition fuse 50 Radiator fan motor relay A Wire harness C Neg...

Page 330: ...rouble warning light flashes when the start switch is being pushed to start the engine If a malfunction is detected in the system by the self diagnostic function the ECU provides an appro priate substitute characteristic operation and alerts the rider of the detected malfunction by illuminat ing the engine trouble warning light After the engine has been stopped the lowest fault code number is indi...

Page 331: ...provides the engine with alternate operating instructions that are appropriate for the type of malfunction When an abnormal signal is received from a sensor the ECU processes the specified values that are programmed for each sensor in order to provide the engine with alternate operating instructions that enable the engine to continue operating or stop operating depending on the conditions Warning ...

Page 332: ...ayed repeat steps 1 to 4 until no fault code number is dis played 5 Erase the malfunction history in the diagnos tic mode code No 62 Refer to SELF DI AGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE on page 9 5 TIP Turning the main switch to OFF will not erase the malfunction history The engine operation is not normal but the engine trouble warning light does not come on 1 Check the operation of follow...

Page 333: ...stic Tool cannot be used to freely change the basic vehicle functions such as adjusting the ignition timing Connecting the Yamaha diagnostic tool Remove the protective cap 1 and then connect the Yamaha diagnostic tool to the coupler Yamaha diagnostic tool US 90890 03234 Fault diagnosis mode Fault codes recorded on the ECU are read and the contents are displayed Function diagnostic mode Check the o...

Page 334: ...st of the malfunction detected in the past already recovered are displayed 2 Detected The item list of the malfunction currently occurred are displayed 3 Code The following icons and the fault code numbers for the detected malfunctions are displayed 4 ECU The types of the control units are displayed 2 3 1 4 5 6 7 8 9 10 11 12 A B A Detected malfunction B Recovered malfunction ...

Page 335: ...display freeze frame data The mark is displayed when the freeze frame data is available 10 ECU conduction time hour minute second The total ECU conduction time total hours the vehicle s main switch was ON when the malfunction was detected is displayed 11 Number of main switch operation after detection The number of times the main switch was turned on between the malfunction detection and code read...

Page 336: ...enance job Confirmation of service completion 1 Connection of crankshaft po sition sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Crank the engine Fault code number is not dis played Service is finished Faul...

Page 337: ...and check that the intake air pressure chang es Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of intake air pressure sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or repla...

Page 338: ...yed Go to item 5 5 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx 101 kPa 757 6 mmHg 29 8 inHg 1000 m 3300 ft above sea level Approx 90 kPa 675 1 mmHg 26 6 inHg 2000 m 6700 ft above sea level Approx 80 kPa 600 0 mmHg 23 6 inHg 3000 m 9800 ft above...

Page 339: ...e Repair or replace the sen sor hose Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 2 2 Defective intake air pressure sensor Execute the diagnostic mode Code No 03 When engine is stopped Atmospheric pressure at the current altitude and weather conditions is indicated At sea level Approx...

Page 340: ... of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open ...

Page 341: ...not dis played Service is finished Fault code number is dis played Go to item 7 7 Malfunction in ECU Replace the ECU Fault code No 16 Item Throttle position sensor stuck throttle position sensor is de tected Fail safe system Able to start engine Able to drive vehicle Diagnostic code No 01 Indicated Throttle position sensor signal 14 20 fully closed position Procedure Check with throttle valve full...

Page 342: ...Procedure Check the coolant temperature Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of coolant tem perature sensor coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the ...

Page 343: ...tempera ture sensor Execute the diagnostic mode Code No 06 When engine is cold Displayed temperature is close to the ambient temper ature The displayed temperature is not close to the ambient tem perature Check the cool ant temperature sensor Replace if defective Refer to CHECKING THE COOLANT TEMPERATURE SENSOR on page 8 75 Turn the main switch to on Fault code number is not dis played Service is ...

Page 344: ...e black blue Between intake air tempera ture sensor coupler and ECU coupler brown white brown white Between joint coupler and ECU coupler black blue black blue Turn the main switch to on Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of intake air temperature sensor Check for looseness or pinching Improperly installed sens...

Page 345: ...on Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Defective lean angle sensor Execute the diagnostic mode Code No 08 An indicated value is out of the specified range Check the lean angle sensor Replace if defective Refer to CHECKING THE LEAN ANGLE SENSOR on page 8 72 Turn the main switch to on then to off and then back to on Fault code number...

Page 346: ...t Re place the wire harness Between ignition coil connec tor and ECU coupler orange orange Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 4 4 Installed condition of ignition coil Check for looseness or pinching Improperly installed ignition coil Reinstall or replace the ignition coil St...

Page 347: ... mode Code No 36 Operating sound Go to item 6 No operating sound Go to item 3 3 Connection of ECU coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Execute the diagnostic mode Code No 36 Operating sound Go to item 6 N...

Page 348: ...place the wire har ness Turn the main switch to on then to off and then back to on Fault code number is not dis played Service is finished Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harness Between lean angle sensor coupler and ECU coupler yellow green yellow green Between lean angle sensor coupler and joint coupler blue blue blac...

Page 349: ...e coupler and check the pins bent or bro ken terminals and locking condition of the pins Improperly connected Connect the coupler secure ly or replace the wire har ness Turn the main switch to on and then rotate the rear wheel by hand Fault code number is not dis played Go to item 6 Fault code number is dis played Go to item 3 3 Wire harness continuity Open or short circuit Re place the wire harne...

Page 350: ... indicator and on the Yamaha diagnostic tool screen come on Procedure Check that the fuel pump relay is actuated five times by listening for the operating sound Item Probable cause of mal function and check Maintenance job Confirmation of service completion 1 Connection of fuel pump re lay coupler Check the locking condition of the coupler Disconnect the coupler and check the pins bent or bro ken ...

Page 351: ...stem voltage is be low 3 V Replace the fuel pump relay Start the engine and let it idle for approximately 5 seconds Fault code number is not dis played Service is finished Fault code number is dis played Go to item 6 6 Malfunction in ECU Replace the ECU Fault code No 44 Item EEPROM fault code number an error is detected while reading or writing on EEPROM Fail safe system Able to start engine Able ...

Page 352: ...onds Fault code number is not dis played Service is finished Fault code number is dis played Repeat the mainte nance job Fault code No 50 Item Faulty ECU engine control unit memory When this malfunc tion is detected in the ECU the fault code number might not appear Fail safe system Unable to start engine Unable to drive vehicle Diagnostic code No Indicated Procedure Item Probable cause of mal func...

Page 353: ...FUEL INJECTION SYSTEM 8 54 ...

Page 354: ... B O G B B Gy Gy R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L B L ...

Page 355: ...5 Battery 6 Main fuse 18 Fuel pump relay 20 Fuel pump 24 ECU engine control unit 33 Joint coupler 35 Handlebar switch 37 Engine stop switch 41 Fuel injection system fuse 43 Ignition fuse A Wire harness C Negative battery sub wire harness ...

Page 356: ...battery terminals Recharge or replace the battery 3 Check the main switch Refer to CHECKING THE SWITCHES on page 8 61 Replace the main switch 4 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 61 The engine stop switch is faulty Replace the handlebar switch 5 Check the fuel pump relay Refer to CHECKING THE RE LAYS on page 8 69 Replace the fuel pump relay 6 Check the fuel pump ...

Page 357: ...FUEL PUMP SYSTEM 8 58 ...

Page 358: ...ELECTRICAL COMPONENTS 8 59 EAS27972 ELECTRICAL COMPONENTS 2 3 16 26 ...

Page 359: ...lay 9 Main fuse 10 Circuit breaker fan 11 Fuse box 12 Radiator fan motor relay 13 Headlight relay 14 Fuel pump relay 15 Tail brake light 16 ECU engine control unit 17 Speed sensor 18 Rear brake light switch 19 Neutral switch 20 Reverse switch 21 Coolant temperature sensor 22 Ignition coil 23 Rectifier regulator 24 Radiator fan 25 Headlight 26 Air induction system solenoid ...

Page 360: ...ELECTRICAL COMPONENTS 8 61 EAS27980 CHECKING THE SWITCHES Y R L Y L Y Y R Br B L B R B R L L B B Br R B OFF ON R Br R B Br B B B B B 1 2 3 4 5 6 10 7 8 9 ...

Page 361: ...ELECTRICAL COMPONENTS 8 62 1 Light switch 2 Engine stop switch 3 Start switch 4 Main switch 5 Front brake light switch 6 Clutch switch 7 Fuse 8 Reverse switch 9 Neutral switch 10 Rear brake light switch ...

Page 362: ... continuity set the pocket tester to 0 and to the Ω 1 range When checking for continuity switch back and forth between the switch positions a few times The switches and their terminal connections are illustrated as in the following example of the main switch The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row The continuity i e a closed cir...

Page 363: ...old the socket firmly when re moving the bulb Never pull the lead other wise it may be pulled out of the terminal in the coupler Avoid touching the glass part of a headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adverse ly affected If a headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcoh...

Page 364: ...tester selector to Ω 1 b If the pocket tester indicates replace the fuse 3 Replace Blown fuse a Set the main switch to OFF b Install a new fuse of the correct amperage rating c Set the switches to on to verify if the corre sponding electrical circuits are operational d If the fuse immediately blows again check the electrical circuit WARNING EWA13310 Never use a fuse with an amperage rating other t...

Page 365: ... battery are different from those of conventional batteries The VRLA Valve Regulated Lead Acid battery should be charged as explained in the charging method section If the battery is over charged the electrolyte level will drop con siderably Therefore take special care when charging the battery TIP Since VRLA Valve Regulated Lead Acid bat teries are sealed it is not possible to check the charge st...

Page 366: ...may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process dis connect the battery charger and let the bat tery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of a VRLA Valve Reg ulated Lead Acid battery stabilizes about 30 minute...

Page 367: ... charger and ammeter to the bat tery and start charging c Make sure that the current is higher than the standard charging current written on the bat tery TIP If the current is lower than the standard charging current written on the battery this type of battery charger cannot charge the VRLA Valve Regu lated Lead Acid battery A variable voltage charger is recommended d Charge the battery until the ...

Page 368: ...03112 C 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe R R L W L B R B 1 2 4 3 Result Continuity between 3 and 4 1 Positive tester probe 2 Negative tester probe 3 Negative tester probe Result Continuity be...

Page 369: ... from the spark plug lead b Connect the pocket tester Ω 1k to the spark plug cap as shown c Measure the spark plug cap resistance EAS28090 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace 1 Positive battery terminal 2 Negative battery terminal 3 Positive tester probe 4 Negative tester probe Result Continuity between 3 and 4 Pocket tester 90890 03112 Analog po...

Page 370: ...efer to TROUBLESHOOTING on page 8 3 TIP If the ignition spark gap is within specification the ignition system circuit is operating normally a Disconnect the spark plug cap from the spark plug b Connect the ignition checker 1 as shown c Turn the main switch to ON and engine stop switch to d Measure the ignition spark gap a Primary coil resistance 3 40 4 60 Ω Pocket tester 90890 03112 Analog pocket ...

Page 371: ... coupler as shown c Set the main switch to ON d Tilt the lean angle sensor to 65 e Measure the lean angle sensor output volt age EAS28940 CHECKING THE STARTER MOTOR OPERATION 1 Check Starter motor operation Does not operate Perform the electric starting system troubleshooting starting with step 4 Refer to TROUBLESHOOTING on page 8 8 a Connect the positive battery terminal 1 and starter motor lead ...

Page 372: ...age Out of specification Replace the rectifi er regulator a Connect the engine tachometer to the spark plug lead b Connect the pocket tester DC 20 V to the rectifier regulator coupler as shown c Start the engine and let it run at approximate ly 5000 r min d Measure the charging voltage Stator coil resistance 0 248 0 372 Ω W W Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive teste...

Page 373: ...d sensor output voltage Out of specification Replace a Connect the pocket tester DC 20 V to the speed sensor coupler as shown Fuel sender current Level is less than a Less than 60 mA Level is more than a More than 135 mA Pocket tester 90890 03112 Analog pocket tester YU 03112 C Positive tester probe Positive battery terminal Negative tester probe orange green 1 Negative battery terminal black whit...

Page 374: ...otor circuit breaker from the wire harness TIP The radiator fan motor circuit breaker 1 is at tached to the wire harness with white tape near the headlight relay 2 2 Check Radiator fan motor circuit breaker resistance Out of specification Replace the radiator fan motor circuit breaker a Connect the pocket tester Ω 1 to the radi ator fan motor circuit breaker as shown b Measure the radiator fan mot...

Page 375: ...ce EAS28300 CHECKING THE THROTTLE POSITION SENSOR 1 Remove Throttle position sensor from the throttle body 2 Check Throttle position sensor maximum resistance Out of specification Replace the throttle position sensor a Connect the pocket tester Ω 1k to the throttle position sensor terminal as shown b Measure the throttle position sensor resis tance 3 Install Throttle position sensor TIP When insta...

Page 376: ...nect the pocket tester Ω 100 to the in take air temperature sensor terminal as shown b Measure the intake air temperature sensor resistance EAS30587 CHECKING THE AIR INDUCTION SYSTEM SOLENOID 1 Check Air induction system solenoid resistance Out of specification Replace a Disconnect the air induction system solenoid coupler from the air induction system sole noid b Connect the pocket tester Ω 1 to ...

Page 377: ... COMPONENTS 8 78 c Measure the air induction system solenoid re sistance Positive tester probe Air induction system solenoid terminal 1 Negative tester probe Air induction system solenoid terminal 2 Br R R B 2 1 ...

Page 378: ...ELECTRICAL COMPONENTS 8 79 ...

Page 379: ... HIGH SPEED PERFORMANCE 9 2 FAULTY GEAR SHIFTING 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 2 OVERHEATING 9 3 OVERCOOLING 9 3 POOR BRAKING PERFORMANCE 9 3 FAULTY SHOCK ABSORBER ASSEMBLY 9 3 UNSTABLE HANDLING 9 3 FAULTY LIGHTING OR SIGNALING SYSTEM 9 4 SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 5 ...

Page 380: ...lve Clogged rollover valve hose Deteriorated or contaminated fuel 2 Fuel pump Faulty fuel pump Faulty fuel injection system relay Clogged or damaged fuel hose 3 Throttle body Deteriorated or contaminated fuel Vacuum leak Electrical system 1 Battery Discharged battery Faulty battery 2 Fuse s Blown damaged or incorrect fuse Improperly installed fuse 3 Spark plug Incorrect spark plug gap Incorrect sp...

Page 381: ...aft Improperly adjusted shift rod Bent shift shaft Shift drum and shift forks Foreign object in a shift drum groove Seized shift fork Bent shift fork guide bar Transmission Seized transmission gear Foreign object between transmission gears Improperly assembled transmission EAS28550 JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift...

Page 382: ...POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper kit Faulty brake caliper seal Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EAS1S3L012 FAULTY SHOCK ABSORBER ASSEMBLY Leaking oil Bent damaged or rusty damper rod Cracked or damaged shock abso...

Page 383: ...ulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired Tail brake light does not come on Wrong tail brake light Faulty battery Too many electrical accessories Incorrectly adjusted rear brake light switch Incorrect connection Broken tail brake light LED Tail brake ligh...

Page 384: ... 42 21 Coolant temperature sensor open or short circuit detected 8 43 22 Intake air temperature sensor open or short circuit detected 8 44 30 Latch up detected 8 46 33 Ignition coil malfunction detected in the primary lead of the ignition coil 8 46 39 Injector open or short circuit detected 8 47 41 Lean angle sensor open or short circuit detected 8 48 42 Speed sensor no normal signals are received...

Page 385: ...ambient temperature When engine is hot Dis plays current coolant tem perature Check the coolant temper ature 07 Vehicle speed pulse 0 999 Check that the number in creases when the rear wheels are rotated The number is cumulative and does not reset each time the wheel is stopped 08 Lean angle sensor Lean angle sensor output voltage Remove the lean angle sensor and incline it more than 65 degrees Up...

Page 386: ... cess 62 Malfunction history code erasure No history 00 History exists Displays the total num ber of malfunctions in cluding the current malfunction that have occurred since the histo ry was last erased For example if there have been three malfunc tions 03 is displayed Save the malfunction his tory to the computer and then delete the fault codes 70 Control number 0 254 Diagnostic code No Item Actu...

Page 387: ...a diagnostic tool screen come on each time the air induction system solenoid is actuated Check that the air induc tion system solenoid is ac tuated five times by listening for the operating sound 50 Main relay fuel pump re lay Actuates the main relay fuel pump relay five times at one second inter vals The CHECK indicator and on the Yamaha diagnostic tool screen come on each time the re lay is actu...

Page 388: ...nd on the Yamaha diagnostic tool screen come on each time the re lay is actuated When the relay is on the CHECK indicator and on the Yamaha diag nostic tool screen go off When the relay is off the CHECK indicator and on the Yamaha diag nostic tool screen come on Check that the radiator fan motor relay is actuated five times by listening for the operating sound Diagnostic code No Item Actuation Pro...

Page 389: ...SELF DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 9 10 ...

Page 390: ...switch 37 Engine stop switch 38 Start switch 39 Headlight relay 40 Headlight 41 Fuel injection system fuse 42 Radiator fan motor fuse 43 Ignition fuse 44 Signaling system fuse 45 Headlight fuse 46 Rear brake light switch 47 Front brake light switch 48 Tail brake light 49 Circuit breaker fan motor 50 Radiator fan motor relay 51 Radiator fan motor A Wire harness B Front brake light switch sub wire h...

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Page 393: ...R L R B G Y B B G Y B B B L L B L B R B R B R B L B R L Br L Y Y Y B B G Y G R B L B R L Br R Br R Y R L W L B Br L Br B W O B B Y R L L R R B Br G Br R R B R B Br G L W O B W L G Y G L R B L B Y G P L B L B Y Br W O O Br W R B B Y B L B L L W B L L W B W O R P B L P L B L B L Y G L L L Y Y L R R L Sb O G O G R L R L R L R L B O G B W B L L L L L B B B B W B W B W B W B L B L B L B L B L B L B L B...

Page 394: ...N OFF A A B C C A B C B B L Gy B B B B B B B B B B Gy Gy B B B B B B Gy Gy Gy Gy B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 41 42 43 44 45 46 47 48 49 51 50 A A A B C D ...

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