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Yamaha XV1700PCR Road Star Warrior, Service Manual

The Yamaha XV1700PCR Road Star Warrior is a powerful motorcycle designed for speed enthusiasts. To ensure proper maintenance and repairs, download the Service Manual with detailed instructions and diagrams, available for free download at manualshive.com. Maximize your biking experience with this invaluable resource.

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ELEC

CHECKING THE SWITCHES

EAS00731

CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear 

→

 Repair or replace the switch. 

Improperly connected 

→

 Properly connect. 

Incorrect continuity reading 

→

 Replace the switch.

L

/

Y

B

/

Y

Ch

Dg

G

Y

(BLUE)

(BLACK)

R

L

/

B

Br

/

L

L

/

Y

R

/

W

B

L

/

W

R

/

B

G

/

Y

Br

(BLACK)

Br

G

/

Y

(BLUE)

B

B

Sb

(BLUE)

B

B

Y

G

R

/

Y

R

ON

OFF

Br

/

L

L

/

Y L

/

B

P B

R

/

B

R

/

W

B

L

/

W

L

/

Y

B

/

Y

B

Dg

Br

/

W

Y

/

R

(L)

N

(R)

Ch

R

/

Y

Y

/

R

P

Rr

/

W

B

1

2

3

4

5

6

7

8

9

0

A

B

Summary of Contents for XV1700PCR Road Star Warrior

Page 1: ...LIT 11616 16 36 5PX 28197 11 XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL ...

Page 2: ...tary Service Manual together with the following manual XV1700P XV1700PC SERVICE MANUAL LIT 11616 15 37 5PX 28197 10 XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL 2002 by Yamaha Motor Corporation U S A First Edition July 2002 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 1161...

Page 3: ...information changes that apply to this model This policy is intended to provide the customer with 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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and ...

Page 4: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 5: ...id A Lubricant B Special tool C Tightening torque D Wear limit clearance E Engine speed F Electrical data Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap based grease L Molybdenum disulfide grease Symbols M to N in the exploded diagrams indicate the following M A...

Page 6: ... AND ADJUSTMENTS 11 INTRODUCTION 11 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 11 GENERAL MAINTENANCE AND LUBRICATION CHART 12 CHASSIS 14 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 14 CHASSIS 16 FRONT AND REAR BRAKES 16 REAR BRAKE MASTER CYLINDER 16 REAR SHOCK ABSORBER AND SWINGARM 18 ENGINE 22 ROCKER ARMS PUSH RODS AND VALVE LIFTERS 22 GENERATOR AND STARTER CLUTCH 24 STATOR COIL A...

Page 7: ...26 0 0187 in Big end radial clearance E 0 037 0 074 mm 0 0015 0 0029 in 0 09 mm 0 0035 in Crankshaft journal to crankshaft journal bearing clearance 0 032 0 062 mm 0 0012 0 0024 in 0 1 mm 0 0039 in Fuel pump Pump type Electrical Model manufacturer 5PX MITSUBISHI Max consumption amperage 5 A Output pressure 392 588 kPa 3 92 5 88 kg cm2 55 7 83 6 psi Item Standard Limit Front tire Tire type Tubeless...

Page 8: ...36 psi Load is the total weight of the cargo rider passenger and accessories Min tire tread depth 1 0 mm 0 04 in Item Standard Limit Ignition coils Model manufacturer J0447 DENSO Minimum ignition spark gap 6 mm 0 24 in Primary coil resistance 1 32 1 78 Ω Secondary coil resistance 12 18 kΩ Charging system System type AC magneto Model manufacturer F5PX YAMAHA Nominal output 14 V 31 A at 5 000 r min ...

Page 9: ...brake light switch lead with a plastic locking tie to the frame É Fasten the stator coil assem bly lead and rectifier regulator lead with a plastic clamp Ê Fasten the rear brake light switch lead horn lead and stator coil assembly lead with a plastic locking tie to the frame Ë Fasten the stator coil assem bly lead horn lead and rear brake light switch lead with a plastic locking tie to the frame 2...

Page 10: ...plers 3 Main switch coupler 4 Left handlebar switch couplers 5 Left and right turn signal position light connec tors È Secure the wire harness in the holder at the white tape on the harness É Route each lead behind the headlight assembly bracket bolts A A 2 1 5 4 3 É É È CABLE ROUTING ...

Page 11: ...e light switch È Pass throttle cable 1 and throttle cable 2 through the cable guide and then fasten them with a plastic holder É Fasten the engine stop switch lead horn lead and oil temperature sensor lead with a plastic locking tie Ê Fasten the sidestand switch lead starter motor lead crankshaft position sensor lead decom pression solenoid lead cylinder identification sensor lead speed sensor lea...

Page 12: ...uel tank drain hose and fuel tank air filter breather hose with a plastic band to the frame Be sure not to pinch the fuel tank drain hose or the fuel tank air filter breather hose Î Fasten the starter motor lead with a plastic locking tie Ï Clamp the clutch cable between the locknut and washer with a plastic clamp Ð To the engine Ñ Fasten the rear brake light switch with a plastic locking tie Ï Î ...

Page 13: ... light switch coupler 6 Rectifier regulator lead and horn lead 7 Linear control valve lead 8 Ignition coil 1 lead 9 Fuel return hose 0 Fuel inlet hose È To the rectifier regulator horn 1 and rear brake light switch É 30 50 degrees Ê 40 60 degrees A C B 2 1 6 7 9 A B C 8 5 4 0 D D E E D D È 3 É Ê 9 E E CABLE ROUTING ...

Page 14: ...ke hose B Spark plug cap ignition coil 2 R spark plug lead C Engine temperature sensor lead D Stator coil lead E Neutral switch lead F Speed sensor lead G Main wire harness H Ignition coil 1 R spark plug lead I Lean angle cut off switch lead J Crankshaft position sensor lead K Sidestand switch lead L Starter motor lead M Horn 2 lead N Oil temperature sensor lead C C B B A A E 0 A 9 8 7 6 5 4 3 2 1...

Page 15: ...Fasten the main wire harness and spark plug lead 3 with a plastic locking tie Í Fasten the main wire harness intake air pres sure sensor lead 2 ignition coil 1 R spark plug lead and intake air temperature sensor coupler with a plastic locking tie Î Fasten the rear brake light switch lead and igni tion coil lead 2 with a plastic band Ï Fasten the main wire harness and intake vac uum hose with a pla...

Page 16: ...ssion solenoid and cylinder identification sensor Ö To the neutral switch To the speed sensor Ø Fasten the crankshaft position sensor lead side stand switch lead lean angle cut off switch lead starter motor lead and horn lead with a plastic locking tie Ù Fasten the oil temperature sensor lead with the lead holder C C B B A A E 0 A 9 8 7 6 5 4 3 2 1 F E D C B J I M L K G H G H G 2 A A B B C C D D E...

Page 17: ...nths 20 000 mi 31 000km or 30 months 1 Valve clearance Check valve clearance when engine is cold Adjust if necessary Every 16 000 mi 25 000 km 2 Spark plugs Check condition Adjust gap and clean Replace at 8 000 mi 13 000 km or 12 months and thereafter every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventila tion system Check ventilation hose for cracks or damage Replace if necessa...

Page 18: ...nge 8 Throttle grip hous ing and cable Check operation and free play Adjust the throttle cable free play if necessary Lubricate the throttle grip housing and cable 9 Control cables Apply chain lube thor oughly Yamaha Chain and Cable Lube or engine oil API SE 10W 30 10 Rear arm pivot bearing Check bearing assem bly for looseness Moderately repack every 16 000 mi 25 000 km or 24 months Lithium soap ...

Page 19: ...disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 17 Wheel bearings Check bearings for smooth rotation 18 Rear s...

Page 20: ...t positions 1 Adjust spring preload NOTE Adjust the spring preload with the special wrench a Loosen the locknut 1 b Turn the spring preload adjusting nut 2 in direction a or b CAUTION _ Never turn the spring preload adjusting nut beyond the maximum or minimum setting Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Adjusting ...

Page 21: ...nt positions 1 Adjust rebound damping a Turn the adjusting knob 1 in direction a or b Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting positions Minimum 20 clicks out Standard 10 clicks out Maximum 3 clicks out from the fully turned in position ...

Page 22: ...ks Removing the rear brake master cylinder Remove the parts in the order listed 1 Brake master cylinder cover 1 Refer to REMOVING THE REAR BRAKE MASTER CYLINDER and ASSEM BLING AND INSTALLING THE REAR BRAKE MAS TER CYLINDER in chap ter 4 Manual No 5PX 28197 10 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake master cylinder bracket 1 6 Rear brake light switch 1 7 Horn 1 connector...

Page 23: ... m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib New LT Order Job Part Q ty Remarks 9 Cotter pin 1 10 Pin 1 11 Brake rod 1 12 Locknut 1 13 Brake master cylinder 1 For installation reverse the removal procedure FRONT AND REAR BRAKES ...

Page 24: ...wingarm Remove the parts in the order listed Rear brake master cylinder bracket Refer to FRONT AND REAR BRAKES in chapter 4 Manual No 5PX 28197 10 Rear exhaust pipe Refer to ENGINE in chapter 5 Manual No 5PX 28197 10 Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY in chapter 4 Manual No 5PX 28197 10 1 Adjusting bolt 2 2 Locknut 2 3 Lower drive belt cover plate 1 4 Spacer 1 5 Lower ...

Page 25: ...fer to REMOVING THE REAR SHOCK ABSORBER AND SWINGARM in chapter 4 Manual No 5PX 28197 10 and INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM in chap ter 4 Manual No 5PX 28197 10 9 Self locking nut 1 10 Bolt shock absorber connecting arm frame 1 11 Cover left and right 2 12 Pivot shaft nut washer 1 1 13 Pivot shaft 1 14 Rear shock absorber and swingarm assembly 1 For installation reverse the remova...

Page 26: ... and swingarm Remove the parts in the order listed 1 Self locking nut washer bolt 1 1 1 Bolt 100 mm 3 94 in 2 Self locking nut washer bolt 1 1 1 Bolt 124 mm 4 88 in 3 Connecting arm 2 4 O ring 4 5 Rear shock absorber 1 6 Spacer O ring 1 2 7 Self locking nut washer bolt 1 2 1 Bolt 77 mm 3 03 in 8 Relay arm 1 Refer to INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM in chapter 4 Manual No 5PX 28197 1...

Page 27: ...11 10 8 11 10 9 7 14 13 15 LS LS LS LS 1 LS LS LS 9 T R 40 Nm 4 0 m kg 29 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib LS 5 12 Order Job Part Q ty Remarks 12 Swingarm 1 13 Dust cover 2 14 Spacer 1 15 Bearing 2 For installation reverse the removal procedure ...

Page 28: ... order listed Seat fuel tank silencer air filter case Refer to SEAT AND SIDE COVERS FUEL TANK and SILENCER AIR FIL TER CASE in chapter 3 Manual No 5PX 28197 10 Muffler exhaust pipes Refer to ENGINE in chapter 5 Manual No 5PX 28197 10 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Manual No 5PX 28197 10 1 Spark plug cap 2 2 Disconnect Refer to INSTALLING THE CAMSHAFT SPROCKET COVER ...

Page 29: ...left side cover 1 Refer to INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER in chapter 5 Manual No 5PX 28197 10 7 Rubber damper 1 8 Timing mark accessing screw 1 9 Crankshaft end cover 1 10 Decompression solenoid cover 1 11 Camshaft sprocket cover 1 1 12 Dowel pin 2 13 Cylinder identification sensor 1 14 Camshaft sprocket cover 2 1 15 Camshaft sprocket cover gasket 1 For installat...

Page 30: ... ft Ib Order Job Part Q ty Remarks Removing the stator coil assembly Remove the parts in the order listed Muffler exhaust pipes Refer to ENGINE in chapter 5 Manual No 5PX 28197 10 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Manual No 5PX 28197 10 1 Plastic locking tie 3 2 Plastic band 2 3 Rear brake light switch coupler 1 Disconnect 4 Horn 1 connectors 2 5 Rider footrest assembl...

Page 31: ...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 48 Nm 4 8 m kg 35 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 8 Generator cover 1 9 Generator cover gasket 1 10 Dowel pin 2 11 Stator coil assembly lead holder 1 12 Stator coil assembly 1 For installation reverse the removal procedure ...

Page 32: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 33: ...XV1700P XV1700PC SERVICEMANUAL LIT 11616 15 37 5PX 28197 10 ...

Page 34: ...1 by Yamaha Motor Corporation U S A First edition October 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A P N LIT 11616 15 37 ...

Page 35: ...information changes that apply to this model This policy is intended to provide the customer with 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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and ...

Page 36: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 37: ...id A Lubricant B Special tool C Tightening torque D Wear limit clearance E Engine speed F Electrical data Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap based grease L Molybdenum disulfide grease Symbols M to N in the exploded diagrams indicate the following M A...

Page 38: ... OF CONTENTS GENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 FUEL INJECTION SYSTEM FI 6 ELECTRICAL SYSTEM ELEC 7 TROUBLESHOOTING TRBL SHTG 8 ...

Page 39: ... INFORMATION 1 32 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 32 REPLACEMENT PARTS 1 32 GASKETS OIL SEALS AND O RINGS 1 32 LOCK WASHERS PLATES AND COTTER PINS 1 33 BEARINGS AND OIL SEALS 1 33 CIRCLIPS 1 33 CHECKING THE CONNECTIONS 1 34 SPECIAL TOOLS 1 35 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 13 ELECTRICAL SPECIFICATIONS 2 17 CONVERSION...

Page 40: ...9 ENGINE OIL FLOW DIAGRAMS 2 30 TRANSFER GEAR OIL FLOW DIAGRAMS 2 34 CABLE ROUTING 2 36 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION 3 1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3 1 GENERAL MAINTENANCE AND LUBRICATION CHART 3 2 SEAT AND SIDE COVERS 3 4 HEADLIGHT AND METER ASSEMBLIES 3 5 BATTERY 3 6 FUEL TANK 3 7 AIR FILTER CASE 3 8 SILENCER AIR FILTER CASE 3 9 ...

Page 41: ... SYSTEM 3 39 CHASSIS 3 40 ADJUSTING THE FRONT BRAKE 3 40 ADJUSTING THE REAR BRAKE 3 41 CHECKING THE BRAKE FLUID LEVEL 3 42 CHECKING THE FRONT BRAKE PADS 3 43 CHECKING THE REAR BRAKE PADS 3 43 ADJUSTING THE REAR BRAKE LIGHT SWITCH 3 44 CHECKING THE FRONT AND REAR BRAKE HOSES 3 44 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 45 ADJUSTING THE SHIFT PEDAL 3 47 ADJUSTING THE DRIVE BELT SLACK 3 47 CHECKING AND...

Page 42: ...R WHEEL STATIC BALANCE 4 22 FRONT AND REAR BRAKES 4 23 FRONT BRAKE PADS 4 23 REAR BRAKE PADS 4 24 REPLACING THE FRONT BRAKE PADS 4 25 REPLACING THE REAR BRAKE PADS 4 27 FRONT BRAKE MASTER CYLINDER 4 30 REAR BRAKE MASTER CYLINDER 4 33 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 37 REMOVING THE REAR BRAKE MASTER CYLINDER 4 37 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 37 ASSEMBLING AND INST...

Page 43: ...TEERING HEAD 4 77 INSTALLING THE STEERING HEAD 4 78 REAR SHOCK ABSORBER AND SWINGARM 4 80 HANDLING THE REAR SHOCK ABSORBER 4 84 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4 84 REMOVING THE REAR SHOCK ABSORBER AND SWINGARM 4 85 CHECKING THE REAR SHOCK ABSORBER 4 86 CHECKING THE RELAY ARM AND CONNECTING ARM 4 86 CHECKING THE SWINGARM 4 86 INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM 4 87...

Page 44: ...AFT SPROCKET COVER AND ENGINE LEFT SIDE COVER 5 23 CAMSHAFTS 5 25 REMOVING THE CAMSHAFTS 5 27 CHECKING THE CAMSHAFTS 5 28 CHECKING THE DECOMPRESSION SYSTEM 5 30 CHECKING THE OIL DELIVERY PIPE 5 30 INSTALLING THE CAMSHAFTS 5 31 CYLINDER HEADS 5 34 REMOVING THE CYLINDER HEADS 5 36 CHECKING THE CYLINDER HEADS 5 36 CHECKING THE OIL DELIVERY PIPE 5 37 INSTALLING THE CYLINDER HEAD 5 37 VALVES AND VALVE ...

Page 45: ...INSTALLING THE CLUTCH 5 66 SHIFT SHAFT AND STOPPER LEVER 5 70 CHECKING THE SHIFT SHAFT 5 71 CHECKING THE STOPPER LEVER 5 71 INSTALLING THE STOPPER LEVER AND SHIFT SHAFT 5 71 GENERATOR AND STARTER CLUTCH 5 73 STATOR COIL ASSEMBLY 5 73 GENERATOR AND STARTER CLUTCH 5 75 REMOVING THE GENERATOR 5 76 CHECKING THE STARTER CLUTCH 5 76 INSTALLING THE GENERATOR 5 77 TRANSFER GEAR CASE 5 79 FUEL PUMP 5 82 RE...

Page 46: ...MOVING THE CONNECTING RODS 5 110 CHECKING THE CRANKSHAFT AND CONNECTING RODS 5 110 INSTALLING THE CONNECTING RODS 5 116 INSTALLING THE CRANKSHAFT 5 118 TRANSMISSION 5 119 CHECKING THE SHIFT FORKS 5 122 CHECKING THE SHIFT DRUM ASSEMBLY 5 123 CHECKING THE TRANSMISSION 5 123 INSTALLING THE TRANSMISSION 5 124 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 5 124 CHAPTER 6 FUEL INJECTION SYSTEM FUEL...

Page 47: ...ITCH CONTINUITY 7 8 CHECKING THE SWITCHES 7 10 CHECKING THE BULBS AND BULB SOCKETS 7 12 TYPES OF BULBS 7 12 CHECKING THE CONDITION OF THE BULBS 7 12 CHECKING THE CONDITION OF THE BULB SOCKETS 7 14 CHECKING THE LEDs 7 15 IGNITION SYSTEM 7 16 CIRCUIT DIAGRAM 7 16 TROUBLESHOOTING 7 17 ELECTRIC STARTING SYSTEM 7 22 CIRCUIT DIAGRAM 7 22 STARTING CIRCUIT CUT OFF SYSTEM OPERATION 7 23 TROUBLESHOOTING 7 2...

Page 48: ... FUEL PUMP 7 64 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 7 64 CHAPTER 8 TROUBLESHOOTING STARTING FAILURES 8 1 ENGINE 8 1 FUEL SYSTEM 8 1 ELECTRICAL SYSTEMS 8 2 INCORRECT ENGINE IDLING SPEED 8 2 ENGINE 8 2 FUEL SYSTEM 8 2 ELECTRICAL SYSTEMS 8 2 POOR MEDIUM AND HIGH SPEED PERFORMANCE 8 3 ENGINE 8 3 FUEL SYSTEM 8 3 FAULTY GEAR SHIFTING 8 3 SHIFTING IS DIFFICULT 8 3 SHIFT PEDAL DOES NOT MOV...

Page 49: ...LFUNCTION 8 4 UNSTABLE HANDLING 8 5 FAULTY LIGHTING OR SIGNALING SYSTEM 8 6 HEADLIGHT DOES NOT COME ON 8 6 HEADLIGHT BULB BURNT OUT 8 6 TAIL BRAKE LIGHT DOES NOT COME ON 8 6 TAIL BRAKE LIGHT LED BURNT OUT 8 6 TURN SIGNAL DOES NOT COME ON 8 6 TURN SIGNAL BLINKS SLOWLY 8 6 TURN SIGNAL REMAINS LIT 8 6 TURN SIGNAL BLINKS QUICKLY 8 6 HORN DOES NOT SOUND 8 6 ...

Page 50: ...00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts MOTORCYCLE IDENTIFICATION 1 ...

Page 51: ...deliver more performance and cleaner exhaust gases increase it becomes necessary to control the air fuel ratio in a more precise and finely tuned man ner To accommodate 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 using a ...

Page 52: ...iming are controlled by the ECU Signals that are input from the throttle position sensor crankshaft position sensor intake air pressure sensor atmospheric pressure sensor intake temperature sensor engine temperature sensor and oil temperature sen sor enable the ECU to determine the injection duration The injection timing is determined through the signals from the crankshaft position sensor and the...

Page 53: ...Atmospheric pressure detection Engine temperature sensor Engine temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throttle angle detection Oil temperature sensor Engine oil temperature detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine RPM detection Speed senso...

Page 54: ...pective sensor Then the signals are temporarily stored on the RAM in the CPU Based on those stored signals and the basic processing program on the ROM the CPU calculates the fuel injection duration injection timing and ignition timing and then sends con trol commands to the respective output interface circuits D Output interface circuits The output interface circuits convert the control signals ou...

Page 55: ...ignals received from the crank shaft position sensor and the cylinder identification sensor The injection duration control deter mines the duration of injection based on the signals received from the atmospheric pressure sensors temperature sensors and the position sensors to which compensations are made to suit various conditions such as the weather atmospheric pressure starting acceleration and ...

Page 56: ...start switch is being pressed If a malfunction occurs in the system this mode provides an appropriate substitute characteristic operation and alerts the rider of the malfunction by illuminating a warning light After the engine is stopped this mode displays a fault code on the clock LCD Diagnosis mode In this mode a diagnostic code is input into the ECU through the operation of the operating switch...

Page 57: ...lectric motor filter and valves The pump unit is a Wesco type rotary pump that is connected to the motor shaft A relief valve is provided to prevent the fuel pressure from rising abnormally if the fuel hose becomes clogged This valve opens when the fuel pressure at the discharge outlet reaches between 440 and 640 kpa and returns the fuel to the fuel tank 1 Fuel filter 2 Fuel inlet strainer 3 Fuel ...

Page 58: ...uel Thus the valve cannot open unless the fuel pressure overcomes the spring force By the atmospheric pressure applied to the spring chamber and when the fuel pressure exceeds the sum of the atmospheric pressure and spring force the diaphragm opens the valve allowing fuel to return to the fuel tank from the return hose Therefore the fuel pressure applied to the injectors by the pressure regulator ...

Page 59: ... that is integrated with the needle to move to the spacer Since the dis tance of the movement of the needle is thus kept constant the opening area of the fuel passage also becomes constant Because the pressure difference of the fuel to the intake manifold pressure is kept constant by the pressure regulator the fuel volume varies in proportion to the length of time the coil is energized The injecto...

Page 60: ...rdance with the calculated data in order to determine the corresponding injection timing Based on the changes in the time intervals of the signals generated by the crankshaft position sen sor the ECU calculates the ignition timing advance to suit the operating conditions The injection timing is also advanced in accordance with the ignition timing in order to supply fuel to the engine at an optimal...

Page 61: ...nkshaft posi tion sensor to the ECU Once the crank angle is less than 110 degrees the first signal that the ECU receives from the sensor identifies cylinder 1 at 82 BTDC When the ECU receives a signal from the cylinder identification sensor cylinder 1 is at 82 BTDC on the exhaust stroke When the ECU does not receive a signal from the cylinder identification sensor cylinder 1 is at 82 BTDC on the c...

Page 62: ...ween the moving contact that moves in unison with the throttle shaft and the resistor board In actual operation the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve 1 Moving contact 2 Resistor board 3 Spring È Output voltage É Idling output position Ê Full close Ë Full open ...

Page 63: ... intake air pressure into electrical signals Then an integrated circuit IC amplifies and adjusts the signals and makes temperature compensations in order to generate electrical signals that are proportionate to the pressure Atmospheric pressure sensor The atmospheric pressure sensor is used for making compensations to the changes in the air density caused by the changes in the atmospheric pressure...

Page 64: ...air fuel mixture that is associated with the changes in the intake air density which are created by the changes in the intake air temperature that occur due to atmospheric temperatures This sensor uses a semi conductor thermistor that has a large resistance at low temperatures and a small resistance at high temperatures The thermistor converts the temperature dependent changes in resistance into e...

Page 65: ...float the signal from the sensor increases to approximately 4 0 V high level When the ECU receives the high level volt age it determines that the motorcycle has overturned and stops the delivery of fuel to the engine by turning OFF the fuel injection system relay that powers the fuel pump and the injectors Once the cut off switch is tripped the ECU maintains this state therefore even if the motorc...

Page 66: ...rs Furthermore the ECU also controls the length of time the coil is energized by calculating the ignition timing and the coil energizing duration based on the signals from these sensors Determining the basic injection duration The intake air volume determines the basic injection duration In order to operate the engine in an optimal condition it is necessary to supply fuel at an air fuel ratio that...

Page 67: ...ing and when the valve position changes to accommodate the engine temperature and engine oil temperature as the intake air volume increases When the engine oil temperature reaches 80 C 176 F or higher the linear control valve fully closes to stop the air volume from increasing and control returns to basic injection control Composition of basic injection duration during linear control valve operati...

Page 68: ...on of the engine The fuel is cut off under conditions that do not require fuel in order to stop the injection Composition of final injection duration 1 Injection at start 1 2 After start enrichment 2 3 Warm up enrichment 3 4 Acceleration compensation 5 5 Fuel cut off Deceleration compensation 5 6 Basic injection duration 7 Voltage compensation duration È RPM É Injection duration Ê Cranking Ë Warm ...

Page 69: ...e long reactive injection duration LIST OF FUEL INJECTION COMPENSATIONS Compensation item Check item Sensor used Starting injection 1 Engine temperature Engine temperature sensor After start injection After start enrichment 2 Engine temperature Engine temperature sensor Warm up enrichment 3 Engine temperature Engine temperature sensor Intake temperature compensation 4 Intake temperature Intake tem...

Page 70: ...jection duration is based on the basic injection duration obtained through the throttle position intake air pressure and engine speed to which injection duration compensation based on the sig nals from various sensors such as the intake temperature sensor atmospheric pressure sensor is added to determine the final injection duration As a result fuel is supplied to the cylinders Normal synchronous ...

Page 71: ...O FEATURES Fuel injection control during normal driving È 1 cylinder fuel injection timing É Basic injection duration Ê Various types of fuel injection duration compensations Ë Final injection duration É Ê È É Ê Ë ...

Page 72: ... the synchronous injection which is a normal cylinder injection that is effected on a cylinder by cylinder basis After the asynchronous injection is completed and until the ECU receives signals from the cylinder identification sensor with the engine speed at 400 r min or higher the injectors are actuated in pairs in sync with the signals from the crankshaft position sensor cylinder 1 and cylinder ...

Page 73: ...uently changes in accordance with the damping factor The enrichment ratio is the highest immediately after the engine is started and diminishes gradually The enrichment of fuel in this manner ensures a stable engine operation immediately after the engine is started Changes in compensation coefficient and compensation injection duration After start enrichment Basic injection duration Duration Long ...

Page 74: ...e engine tempera ture The coefficient increases with the decrease in the engine temperature and decreases with the increase in the engine temperature The ratio of fuel enrichment also changes with the changes in the coefficient Changes in compensation coefficient and compensation injection duration 1 0 60 C Warm up enrichment Long Short Injection duration Compensation injection duration Duration B...

Page 75: ...ncreases the actual enrich ment volume The enrichment volume is executed in accordance with the acceleration enrichment coefficient when the movement of the throttle position sensor has met the acceleration condition as defined by the ECU Thereafter the enrichment volume is regulated by the coefficient that changes in accordance with the damping rate Acceleration injection duration basic injection...

Page 76: ...Duration Ê Fuel cut off control stopping fuel injection Ë Basic injection duration Ì Basic injection duration Over revolution control The over revolution control of the ECU operates the ignition control and fuel cut off control when the engine speed becomes greater than the specified value The over revolution control first operates the ignition control to reduce the ignition of each cylinder to ke...

Page 77: ...increase the intake air volume When the engine is started and during engine warm up the fuel injection vol ume is increased to compensate the increase in the air volume A signal from the ECU and the temperature of the engine immediately after starting determine the air volume introduced by the linear control valve When the engine is running the engine oil temper ature controls the linear control v...

Page 78: ...he valve moves approximately 0 041 mm The stepper motor is set to make a total of 146 steps thus the total range of the valve from fully closed to fully open is approximately 6 08 mm The linear control valve is operated when the engine is started and adjusts its opening to accommo date the temperature of the engine When the engine is started the control data transfers from the engine temperature t...

Page 79: ...bnormal the clock LCD shows error Er 1 4 The clock LCD reverts to showing the time after the error has been corrected 1 Tachometer 2 Clock 3 Odometer tripmeter fuel reserve tripmeter 4 RESET button 5 SELECT button 6 Speedometer assembly 7 Engine trouble warning light Mode ECU transmission data Meter indication Display description Common to all modes Vehicle speed Tripmeter 4 digits including decim...

Page 80: ...itch The self diagnostic function starts a sys tem check System normal Normal meter display Malfunction detection A fault code number appears on the clock LCD The engine trouble warning light illumi nates The engine cannot be started in this mode Diagnosis mode Enables the verification of the operation of the actuator and various sensors Turn the engine stop switch to OFF Turn it ON when the diagn...

Page 81: ...ean all of the parts and place them in trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance ...

Page 82: ...isible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate 1 Oil seal CAUTION _ Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EAS00025 CIRCLIPS Before reassembly check all circlips carefully and replace damaged or distorted circlips Always re...

Page 83: ...d disconnect sev eral times 3 Check all connections Loose connection Connect properly NOTE _ If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE _ Make sure all connections are tight 5 Check continuity with the pocket tester NOTE _ If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact...

Page 84: ...on Illustration YB 35956 Mity vac This tool used to measure the vacuum pressure YM 01080 A Alternator rotor puller This tool is used to remove the genera tor rotor YM 01423 Damper rod holder This tool is used to hold the damper rod assembly when loosening or tightening the damper rod assembly bolt YM 01434 Rod holder This tool is used to support the damper adjusting rod Rod puller YM 01437 Rod pul...

Page 85: ...ll the valve guides YM 04065 A Valve guide installer ø6 This tool is used to install the valve guides YM 04066 Valve guide reamer ø6 This tool is used to rebore the new valve guides YM 28898 Bearing remover and installer This tool is needed when removing or installing the crankshaft journal bearing YM 33277 A Timing light This tool is used to check the ignition timing YM 03170 Belt tension gauge T...

Page 86: ... sheave holder This tool is used to hold the generator rotor when removing or installing the generator rotor bolt generator shaft bolt or crankshaft position sensor rotor bolt YU 01304 Piston pin puller This tool is used to remove the piston pins YU 03009 Micrometer 75 100 mm This tool is used to measure the piston skirt diameter YU 03017 Cylinder bore gauge 50 100 mm This tool is used to measure ...

Page 87: ...n the steering stem ring nuts YU 38411 Oil filter wrench This tool is needed to loosen or tighten the oil filter cartridge YU 8036 A Inductive tachometer This tool is used for check engine speed ACC 11001 05 01 Quick Gasket This sealant is used to seal two mating surfaces e g crankcase mating sur faces Gauge YU 03153 Oil pressure adaptor E YM 03129 Pressure gauge Oil pressure adaptor E These tools...

Page 88: ...1 39 GEN INFO SPECIAL TOOLS YM 01485 Pivot shaft wrench This tool is needed to loosen or tighten the spacer bolt Tool No Tool name Function Illustration ...

Page 89: ...m 44 1 in Seat height 725 mm 28 5 in Wheelbase 1 665 mm 65 6 in Minimum ground clearance 155 mm 6 10 in Minimum turning radius 3 400 mm 133 9 in Weight Wet with oil and a full fuel tank 295 kg 650 lb Dry without oil and fuel 278 kg 613 lb Gross vehicle weight ratio GVWR 480 kg 1 058 lb Bias weight dry front 133 kg 293 lb Bias weight dry rear 145 kg 320 lb Maximum load total of cargo rider passenge...

Page 90: ...ight 108 kg 238 lb Fuel Recommended fuel Unleaded fuel only USA and California Regular unleaded gasoline only CDN Fuel tank capacity Total including reserve 15 L 13 2 Imp qt 15 86 US qt Reserve only 3 L 2 64 Imp qt 3 17 US qt Engine oil Lubrication system Dry sump Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 40 F 5 C or above Non Friction modified Quantity Total amount 5 0 L 4 4...

Page 91: ...p 0 06 0 11 mm 0 0024 0 0043 in 0 16 mm 0 0063 in Transfer oil pump Oil pump type Trochoid Inner rotor to outer rotor tip clearance 0 07 0 12 mm 0 0028 0 0047 in 0 17 mm 0 0067 in Outer rotor to oil pump housing clear ance 0 03 0 08 mm 0 0012 0 0031 in 0 16 mm 0 0063 in Bypass valve opening pressure 80 120 kPa 0 8 1 2 kg cm2 11 3 17 1 psi Relief valve opening pressure 600 kPa 6 0 kg cm2 85 psi Oil...

Page 92: ...67 27 980 mm 1 1011 1 1016 in Camshaft to crankcase clearance 0 050 0 084 mm 0 0020 0 0033 in Camshaft to camshaft cover clear ance 0 020 0 054 mm 0 0008 0 0021 in Camshaft intake cam dimensions Measurement A 38 231 38 331 mm 1 5052 1 5091 in 38 131 mm 1 5012 in Measurement B 32 013 32 113 mm 1 2604 1 2643 in 31 913 mm 1 2564 in Camshaft exhaust cam dimensions Measurement A 38 232 38 332 mm 1 5052...

Page 93: ... cold Intake 0 0 04 mm 0 0 0016 in Exhaust 0 0 04 mm 0 0 0016 in Valve dimensions Valve head diameter A Intake 33 9 34 1 mm 1 3346 1 3425 in Exhaust 27 9 28 1 mm 1 0984 1 1063 in Valve face width B Intake 1 3 2 3 mm 0 0512 0 0906 in Exhaust 1 2 2 4 mm 0 0472 0 0945 in Valve seat width C Intake 0 9 1 1 mm 0 0354 0 0433 in 2 0 mm 0 079 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in 2 0 mm 0 079 in Valve mar...

Page 94: ...m 0 0004 0 0015 in 0 08 mm 0 0031 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in 0 1 mm 0 0039 in Valve stem runout 0 01 mm 0 0004 in Valve seat material Intake PB 6 Exhaust V557W Valve springs Inner springs Free length Intake 38 26 mm 1 51 in 36 26 mm 1 43 in Exhaust 38 26 mm 1 51 in 36 26 mm 1 43 in Spring rate intake K1 7 3 N mm 41 68 lb in Spring rate intake K2 8 8 N mm 50 25 lb in Spring rate exh...

Page 95: ...r springs Free length Intake 43 25 mm 1 70 in 41 26 mm 1 62 in Exhaust 43 25 mm 1 70 in 41 26 mm 1 62 in Spring rate intake K1 12 2 N mm 69 66 lb in Spring rate intake K2 14 9 N mm 85 08 lb in Spring rate exhaust K1 12 2 N mm 69 66 lb in Spring rate exhaust K2 14 9 N mm 85 08 lb in Installed length valve closed Intake 31 0 mm 1 22 in Exhaust 31 0 mm 1 22 in Compressed spring force installed Intake...

Page 96: ...e inside diameter 23 000 23 021 mm 0 9055 0 9063 in Valve lifter to valve lifter case clear ance 0 0256 0 0530 mm 0 0010 0 0021 in Valve push rods Valve push rod 1 length 288 5 mm 11 358 in Valve push rod 2 length 290 5 mm 11 437 in Valve push rod runout 0 3 mm 0 012 in Cylinders Material Aluminum alloy Sleeve type Ceramic composite plated Bore 97 000 97 010 mm 3 8189 3 8193 in Max taper 0 05 mm 0...

Page 97: ...fset 1 0 mm 0 0394 in Piston pins Outside diameter 21 991 22 000 mm 0 8658 0 8661 in 21 971 mm 0 8650 in Piston pin to piston pin bore clear ance 0 004 0 024 mm 0 00016 0 00094 in 0 074 mm 0 0029 in Piston rings Top ring Ring type Barrel Dimensions B T 1 2 3 8 mm 0 047 0 150 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 65 mm 0 026 in Ring side clearance 0 03 0 08 mm 0 0012 0 0031 in 0 12 mm ...

Page 98: ...ed parkerizing Connecting rods Crankshaft pin to big end bearing clearance 0 037 0 074 mm 0 0015 0 0029 in Bearing color code 1 Blue 2 Black 3 Brown 4 Green 5 Yellow Connecting rod length 191 95 192 05 mm 7 557 7 561 in Crankshaft Width A 132 8 133 2 mm 5 228 5 244 in Max runout C 0 04 mm 0 0016 in Big end side clearance D 0 320 0 474 mm 0 0126 0 0187 in Big end radial clearance E 0 037 0 074 mm 0...

Page 99: ...4 0 122 in 2 8 mm 0 110 in Plate quantity 9 Clutch plates Thickness 2 2 2 4 mm 0 087 0 094 in Plate quantity 8 Max warpage 0 2 mm 0 008 in Clutch springs Free length 7 mm 0 276 in Spring quantity 1 Min length 6 5 mm 0 256 in Clutch housing thrust clearance 0 10 0 37 mm 0 0039 0 0146 in Clutch housing radial clearance 0 017 0 053 mm 0 0007 0 0021 in Primary reduction gear backlash tol erance A A B ...

Page 100: ...08 mm 0 003 in Max drive axle runout 0 08 mm 0 003 in Shifting mechanism Shift mechanism type Guide bar Max shift fork guide bar bending 0 025 mm 0 001 in Shift fork thickness 6 26 6 39 mm 0 2465 0 2516 in Air filter type Wet element Fuel pump Pump type Electrical Model manufacturer 5PX MITSUBISHI Output pressure 392 588 kPa 3 92 5 88 kg cm2 55 7 83 6 psi Throttle bodies Model manufacturer quantit...

Page 101: ...ast wheel Rim Size 17 M C MT 6 00 17 MT 6 00 Material Aluminum Wheel travel 110 mm 4 33 in Wheel runout Max radial wheel runout 1 mm 0 04 in Max lateral wheel runout 0 5 mm 0 02 in Front tire Tire type Tubeless Size 120 70 ZR 18 M C 59 W 120 70 ZR 18 59 W Model manufacturer D220FST DUNLOP BT020FG BRIDGESTONE Tire pressure cold 0 90 kg 0 198 lb 250 kPa 2 5 kgf cm2 36 psi 90 kg 198 lb Maximum load 2...

Page 102: ... weight of the cargo rider passenger and accessories Min tire tread depth 1 0 mm 0 04 in Front brakes Brake type Dual disc brake Operation Right hand operation Brake lever free play lever end 2 5 mm 0 08 0 20 in Recommended fluid DOT 4 Brake discs Diameter thickness 298 5 mm 11 73 0 20 in Min thickness 4 5 mm 0 18 in Max deflection 0 1 mm 0 004 in Brake pad lining thickness 5 5 mm 0 22 in 0 5 mm 0...

Page 103: ...ring type Taper roller bearings Lock to Lock angle left 35 Lock to Lock angle right 35 Front suspension Suspension type Telescopic fork Front fork type Coil spring oil damper Front fork travel 135 mm 5 31 in Spring Free length 296 mm 11 65 in 291 mm 11 46 in Spring rate K1 6 4 N mm 0 64 kg mm 36 54 lb in Spring rate K2 7 8 N mm 0 78 kg mm 44 54 lb in Spring stroke K1 0 85 mm 0 3 35 in Spring strok...

Page 104: ... length 172 mm 6 77 in Spring rate K1 137 N mm 13 7 kg mm 782 27 lb in Spring stroke K1 0 50 mm 0 1 97 in Optional spring available No Standard spring preload gas air pres sure 1 000 kPa 10 kg cm2 142 psi Swingarm Free play at the end of the swin garm Radial 1 mm 0 04 in Axial 1 mm 0 04 in Drive belt Model manufacturer UBD 0568 Drive belt slack on a sidestand 6 8 mm 0 24 0 31 in Drive belt slack o...

Page 105: ...ial Resin Resistance 10 kΩ Charging system System type AC magneto Model manufacturer F5PX YAMAHA Nominal output 14 V 31 A at 5 000 r min Stator coil resistance color 0 12 0 20 Ω W W Rectifier regulator Regulator type Semiconductor short circuit Model manufacturer FH001 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 35 A Withstand voltage 200 V Battery Battery type manufacturer...

Page 106: ... mm 0 2 in Spring force 7 36 11 04 N 736 1 104 g Commutator diameter 28 5 mm 1 12 in 27 5 mm 1 08 in Mica undercut 1 5 mm 0 06 in Starter relay Model manufacturer MS5F 631 JIDECO Amperage 180 A Coil resistance 4 18 4 62 Ω Starting circuit cut off relay Model manufacturer G8R 30Y S OMRON Coil resistance 162 198 Ω Horn Horn type Eddy Model manufacturer quantity YP 12 NIKKO 2 Max amperage 2 A Perform...

Page 107: ...ut voltage at idle 0 605 0 755 V Circuit breaker Circuit breaker type Fuse Fuses amperage quantity Main fuse 30 A 1 Fuel injection system fuse 15 A 1 Headlight fuse 15 A 1 Signaling system fuse 10 A 1 Ignition fuse 10 A 1 ECU fuse 10 A 1 Decompression solenoid fuse 15 A 1 Backup fuse odometer and clock 7 5 A 1 Reserve fuse 30 A 15 A 10 A 7 5 A 1 Engine temperature sensor Model manufacturer 5PX DEN...

Page 108: ...reads Com ponents should be at room temperature A Distance between flats B Outside thread diameter Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Tighten ing torque Metric unit Multiplier Imperial unit m kg m kg cm kg cm kg 7 233 86 794 0 0723 0 8679 ft lb in lb ft lb in lb Weight kg g 2 205 0 03527 lb oz Speed km hr 0 6214 mph Distance km m m cm mm 0 6214 3 28...

Page 109: ... solenoid Bolt M4 2 7 0 7 5 1 Camshaft sprocket cover 1 Bolt M6 2 7 0 7 5 1 Camshaft sprocket cover 1 Bolt M6 1 10 1 0 7 2 Camshaft sprocket cover 2 Bolt M6 5 10 1 0 7 2 Engine left side cover Bolt M6 6 10 1 0 7 2 Rocker arm adjusting screw Nut M7 4 20 2 0 14 Valve lifter case Bolt M6 4 10 1 0 7 2 Engine oil checking bolt Bolt M5 3 4 0 4 2 9 Front cylinder camshaft end cover Bolt M5 2 5 0 5 3 6 En...

Page 110: ...rankcase cylinder head Stud bolt M10 4 See NOTE 2 E Crankcase transfer gear case Stud bolt M8 1 See NOTE 3 E Right crankcase Bolt M8 3 24 2 4 17 Right crankcase Bolt M6 3 10 1 0 7 2 Left crankcase Bolt M6 15 10 1 0 7 2 Crankshaft position sensor Screw M6 2 7 0 7 5 1 LT Crankshaft position sensor lead holder Screw M6 7 7 0 7 5 1 LT Stator coil assembly Screw M6 3 7 0 7 5 1 LT Stator coil assembly B...

Page 111: ... pump cover Bolt M6 2 10 1 0 7 2 Transfer gear oil pump Bolt M6 3 10 1 0 7 2 Drive sprocket case Bolt M10 3 50 5 0 36 Drive sprocket case Bolt M10 5 50 5 0 36 Drive sprocket Nut M22 1 100 10 0 72 Use a lock washer Drive sprocket cover Bolt M6 1 7 0 7 5 1 Shift arm Bolt M6 1 12 1 2 8 7 Shift rod locknut Nut M8 2 12 1 2 8 7 Shift shaft spring stopper Bolt M8 1 22 2 2 16 LT Shift drum assembly Screw ...

Page 112: ...ounting Spacer bolt M18 18 1 8 13 Upper mounting bolt upper engine bracket and engine M10 48 4 8 35 Upper engine bracket and frame M10 48 4 8 35 Lower front mounting nut frame and engine M12 105 10 5 75 Lower rear mounting nut frame and engine M12 88 8 8 64 Rear engine bracket and frame M10 53 5 3 38 Rear engine bracket and engine M12 98 9 8 71 Front engine bracket and frame M10 48 4 8 35 Front en...

Page 113: ... 48 4 8 35 Front brake master cylinder holder M6 10 1 0 7 2 Rear brake master cylinder and rear brake master cylinder bracket M8 23 2 3 17 Rear brake master cylinder cover and frame M8 23 2 3 17 Rear brake fluid reservoir M6 7 0 7 5 1 Union bolt rear brake hose M10 30 3 0 22 Brake rod and rear brake master cylinder M8 16 1 6 11 Front wheel axle M18 72 7 2 52 Front wheel axle pinch bolt M8 23 2 3 1...

Page 114: ...2 Retighten the ring nut to specification Damper rod assembly bolt 40 4 0 29 Reflector bracket front M6 8 0 8 5 8 Footrest bracket and rear brake bracket M8 16 1 6 11 Footrest bracket and shift rod bracket M8 16 1 6 11 Rear brake bracket and brake pedal M8 19 1 9 13 Shift shaft and shift pedal M6 12 1 2 8 7 Item Thread size Tightening torque Remarks Nm m kg ft lb ...

Page 115: ...ke and exhaust E Valve lifters E Rocker arms E Rocker arm shafts E Oil pump rotors inner and outer and oil pump housing E Oil strainer E Starter clutch idle gear inner surface E Starter clutch idle gear shafts E Starter clutch roller and starter clutch gears outer surface E Crankshaft big end bearing upper and lower E Clutch pull rod M Pressure plate bearing E Transmission gears wheel and pinion M...

Page 116: ...ear wheel oil seal LS Rear wheel drive hub mating surface LS Rear brake pedal shaft LS Shift pedal LS Rear footrest pivot LS Sidestand sliding surface LS Tube guide throttle grip inner surface LS Brake lever pivot bolt contact surface LS Clutch lever pivot bolt contact surface LS Swingarm pivot shaft LS Swingarm pivot bearing LS Swingarm pivot oil seal LS Relay arm bearing inner LS Rear shock abso...

Page 117: ... Drive axle gears Connecting rod Crank pin Rocker arm Push rod Valve lifter Rear camshaft Rocker arm Push rod Valve lifter Front camshaft Connecting rod Crank pin Generator shaft journal right Crankshaftjournal left Rear cylinder Front cylinder Crankshaftjournal right Crankshaft journal camshaft cover side Generator shaft journal left Drive axle Main axle Check ball Rotor 2 Rotor 1 Relief valve Oi...

Page 118: ...2 30 SPEC ENGINE OIL FLOW DIAGRAMS ENGINE OIL FLOW DIAGRAMS 1 Oil tank 2 Dipstick 3 Oil delivery pipe 4 Push rod 5 Oil filter cartridge 3 5 5 4 4 3 2 1 ...

Page 119: ...2 31 SPEC ENGINE OIL FLOW DIAGRAMS 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft 3 2 1 4 3 ...

Page 120: ...2 32 SPEC ENGINE OIL FLOW DIAGRAMS 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt engine 3 2 1 1 ...

Page 121: ...2 33 SPEC ENGINE OIL FLOW DIAGRAMS 1 Main axle 2 Drive axle 3 Engine oil pump 4 Oil strainer È To oil filter cartridge 3 4 2 1 È ...

Page 122: ...2 34 SPEC TRANSFER GEAR OIL FLOW DIAGRAMS TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle driven shaft 2 Transfer gear oil pump 2 1 ...

Page 123: ...2 35 SPEC TRANSFER GEAR OIL FLOW DIAGRAMS 1 Transfer gear oil pump 2 Middle driven shaft 1 2 ...

Page 124: ... rear brake light switch lead with a plastic locking tie to the frame É Fasten the stator coil assembly lead rectifier regulator lead and the end of the boot with a plastic band Ê Fasten the rear brake light switch lead horn lead and sta tor coil assembly lead with a plastic locking tie to the frame Ë Fasten the stator coil assembly lead horn lead and rear brake light switch lead with a plastic lo...

Page 125: ...itch lead 3 Right handlebar switch lead 4 Throttle cable 1 5 Throttle cable 2 6 Brake hose È Fasten the left handlebar switch lead with a plas tic holder É Fasten the right handlebar switch lead with a plastic holder Ê 20 30 mm 0 8 1 2 in Ë 50 70 mm 2 0 2 8 in ...

Page 126: ...ug lead È Pass throttle cable 1 and throttle cable 2 through the cable guide and then fasten them with a plastic holder É Fasten the engine stop switch lead horn lead and oil temperature sensor lead with a plastic locking tie Ê Fasten the sidestand switch lead starter motor lead crankshaft position sensor lead decom pression solenoid lead cylinder identification sensor lead speed sensor lead and n...

Page 127: ... tie to the frame Í Fasten the starter motor lead fuel tank drain hose and fuel tank air filter breather hose with a plastic band to the frame Be sure not to pinch the fuel tank drain hose or the fuel tank air filter breather hose Î Fasten the starter motor lead with the plastic clamp Ï Clamp the clutch cable between the locknut and washer with a plastic clamp Ð To the engine Ï Î Ð Í Ì Ë Ê É È 1 2...

Page 128: ... 2 lead 5 Rear brake light switch coupler 6 Rectifier regulator lead and horn lead 7 Linear control valve lead 8 Ignition coil 1 lead 9 Fuel return hose 0 Fuel inlet hose È To the rectifier regulator horn 1 and rear brake light switch É 30 50 degrees Ê 40 60 degrees A C B 2 1 6 7 9 A B C 8 5 4 0 D D D D È 3 É Ê ...

Page 129: ...tarter motor lead È Be sure to position the ECU leads and sensor leads toward the left side of the frame and then fasten the wire harness protector with a plastic locking tie É Route the negative battery lead on top of the other leads Ê To the tail brake light A A B B 2 3 A A 1 4 3 Í Ì Ê É È Ë ...

Page 130: ...haft position sensor lead neutral switch lead and fuel pump lead with a plastic band Ì Position the gray mark on the starter motor lead at the center of the bolt Fit the starter motor lead and sid estand switch lead into the groove in the frame and then fasten them with a plastic locking tie Í 10 30 mm 0 4 1 2 in A A B B 2 3 A A 1 4 3 Í Ì Ê É È Ë ...

Page 131: ...k air filter drain hose 8 Regulator lead 9 Horn lead 0 Rear brake light switch lead A Cut off relay B Turn signal relay C Headlight relay È Clamp the fuel tank air filter breather hose and fuel tank air filter drain hose with a plastic clamp É 45 60 degrees Ê 15 30 degrees C C B B 2 4 5 4 6 7 A A B B C C D 8 9 0 6 7 È A A D 1 É Ê 3 3 B A 1 C ...

Page 132: ...el hose 5 Fuel inlet hose 6 Fuel outlet hose 7 Fuel hose joint 2 8 Fuel hose 9 Fuel pump coupler 0 Sub fuel tank A Fuel tank drain hose B Fuel tank air filter breather hose C Ignition coil 1 È Make sure that the white paint mark is facing for ward A A B A A B C A B 4 1 2 3 4 5 6 7 8 9 0 È B A ...

Page 133: ...ure sensor 2 0 Throttle cables A Brake hose B Spark plug cap ignition coil 2 R spark plug lead C Engine temperature sensor lead D Stator coil lead E Neutral switch lead F Speed sensor lead G Main wire harness H Ignition coil 1 R spark plug lead I Lean angle cut off switch lead J Crankshaft position sensor lead K Sidestand switch lead L Starter motor lead M Horn 2 lead C C B B A A A 0 A 9 8 7 6 5 4...

Page 134: ...fuel delivery pipe Ì Fasten the main wire harness and spark plug lead 3 with a plastic locking tie Í Fasten the main wire harness intake air pres sure sensor lead 2 ignition coil 1 R spark plug lead and intake air temperature sensor coupler with a plastic locking tie Î Fasten the rear brake light switch lead and igni tion coil lead 2 with a plastic band Ï Fasten the main wire harness and intake va...

Page 135: ... locking tie Ô To the stator coil Õ To the decompression solenoid and cylinder identification sensor Ö To the neutral switch To the speed sensor Ø Fasten the crankshaft position sensor lead side stand switch lead lean angle cut off switch lead starter motor lead and horn lead with a plastic locking tie C C B B A A A 0 A 9 8 7 6 5 4 3 2 1 F E D C B J I M L K G H G H G 2 A A B B C C A Ø Ò Ó Ï Í Ì Ë ...

Page 136: ...on coil 1 R spark plug lead 3 Main wire harness 4 Negative battery ground lead 5 Fuse box 6 Main fuse coupler 7 Positive battery lead 8 ECU 9 Fuel hose 0 Ignition coil 1 L spark plug lead A Ignition coil 2 L spark plug lead È 40 60 mm 1 6 2 4 in 1 2 3 4 8 0 A 5 6 7 9 È ...

Page 137: ...ia only 3 Intake vacuum hose 4 Liner control valve inlet hose 5 Liner control valve outlet hose 6 Throttle position sensor 7 Fuel hose 8 Throttle stop screw 9 Fuel inlet hose 0 Pressure regulator A A I S vacuum hose B Silencer air filter case drain hose 2 1 B A 7 0 7 9 8 7 3 6 5 4 3 ...

Page 138: ...nister purge hose 3 Starter motor lead 4 Canister 5 Fuel tank drain hose 6 Regulator lead 7 Horn lead 8 Rear brake light switch lead È To the fuel tank É To the silencer air filter case Ê To the throttle bodies A A B B C A A B B C 1 2 8 7 6 5 2 1 2 5 1 1 2 3 4 5 C A A B B È É Ê ...

Page 139: ...earance See page 3 11 Check valve clearance when engine is cold Adjust if necessary Every 16 000 mi 25 000 km 2 Spark plugs See page 3 20 Check condition Adjust gap and clean Replace at 8 000 mi 13 000 km or 12 months and thereafter every 8 000 mi 13 000 km or 12 months Replace Replace 3 Crankcase ventila tion system See page 3 38 Check ventilation hose for cracks or damage Replace if necessary 4 ...

Page 140: ...ths SAE 80 API GL 4 hypoid gear oil Change Check Change 8 Control cables See page 3 58 Apply chain lube thor oughly Yamaha chain and cable lube or engine oil 10W 30 9 Rear arm pivot bearing See page 4 86 Check bearing assem bly for looseness Moderately repack every 16 000 mi 25 000 km or 24 months Lithium soap based grease Repack 10 Brake and clutch lever pivot shafts See page 3 59 Lubricate Apply...

Page 141: ...ervice After disassembling the brake master cylinders and calipers always change the fluid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 17 Rear suspension link pivots See page 4 86 Lubr...

Page 142: ... 0 m kg 7 2 ft Ib T R 10 Nm 1 0 m kg 7 2 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 Order Job Part Q ty Remarks Removing the seat and side covers Remove the parts in the order listed 1 Seat 1 2 Cover 1 3 Tool kit 1 4 Left side cover 1 1 5 Left side cover 2 1 6 Right side cover 1 For installation reverse the removal procedure ...

Page 143: ... 2 3 m kg 17 ft Ib Order Job Part Q ty Remarks Removing the headlight and meter assemblies Remove the parts in the order listed 1 Headlight lens unit 1 2 Wire harness in the headlight body 1 Disconnect 3 Headlight body 1 4 Tachometer assembly 1 5 Speedometer assembly 1 For installation reverse the removal procedure HEADLIGHT AND METER ASSEMBLIES ...

Page 144: ...rt Q ty Remarks Removing the battery Remove the parts in the order listed Seat Refer to SEAT AND SIDE COVERS 1 ECU 1 2 Battery cover 1 3 Negative battery lead 1 4 Positive battery lead 1 5 Battery 1 6 Belt 1 For installation reverse the removal procedure ...

Page 145: ... Q ty Remarks Removing the fuel tank Remove the parts in the order listed Seat Refer to SEAT AND SIDE COVERS 1 Air induction system cover 1 2 Air duct 1 3 Fuel hose joint 1 1 Disconnect 4 Fuel hose joint 2 1 Disconnect 5 Fuel tank breather hose 2 Disconnect 6 Fuel tank 1 For installation reverse the removal procedure ...

Page 146: ...T R 3 Nm 0 3 m kg 2 2 ft Ib Order Job Part Q ty Remarks Removing the air filter case Remove the parts in the order listed Fuel tank Refer to FUEL TANK 1 Air filter case 1 2 Air filter case cover 1 3 Air filter element 1 4 Air filter check hose 1 For installation reverse the removal procedure ...

Page 147: ...r air filter case Remove the parts in the order listed Air filter case Refer to AIR FILTER CASE 1 Silencer air filter case cover 1 2 Silencer air filter element 1 3 Silencer air filter case bracket 1 4 Cylinder head breather hose 1 Disconnect 5 Resonator 1 6 Silencer air filter case drain hose 1 7 Atmospheric pressure sensor coupler 1 Disconnect 8 Intake air temperature sensor coupler 1 Disconnect...

Page 148: ...ure sensor 1 coupler 1 Disconnect 10 Liner control valve inlet hose 1 Disconnect 11 Clamp screw 2 Loosen 12 Atmospheric pressure sensor bracket 1 13 Atmospheric pressure sensor 1 14 Intake air pressure sensor 1 1 15 Intake air pressure sensor 1 bracket 1 16 Intake air temperature sensor 1 17 Silencer air filter case 1 For installation reverse the removal procedure SILENCER AIR FILTER CASE ...

Page 149: ...eck if the valve clearance b on the adjusting screw 2 side is within specification É If clearance is on the adjusting screw 2 side tighten the adjusting screw and bring the valve clearance b within specification Valve clearance adjustment should be made on a cold engine at room temperature When the valve clearance is to be measured or adjusted the piston must be at top dead center TDC on the compr...

Page 150: ...5 Remove timing mark accessing screw 1 crankshaft end cover 2 1 2 6 Remove decompression solenoid cover 1 camshaft sprocket cover 2 1 2 7 Measure valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 0 04 mm 0 0 0016 in Exhaust valve 0 0 04 mm 0 0 0016 in ...

Page 151: ...the marks are not aligned turn the crank shaft counterclockwise 360 degrees and recheck step b d Measure the valve clearance with a thick ness gauge d c Piston 2 TDC front cylinder a Turn the crankshaft counterclockwise from the piston 1 TDC by 408 degrees b When piston 2 is at TDC on the compres sion stoke align the TDC mark e on the crankshaft position sensor rotor with the pointer b on the clut...

Page 152: ... Measure the valve clearance again f If the valve clearance is still out of specifica tion repeat all of the valve clearance adjust ment steps until the specified clearance is obtained 9 Install all moved parts NOTE For installation reverse the removal proce dure Note the following points Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS in chapter 5 Valve adjuster YM 08035 Adjusting screw side Sli...

Page 153: ...otorcycle on a suitable stand 2 Remove seat Refer to SEAT AND SIDE COVERS fuel tank Refer to FUEL TANK air filter case Refer to AIR FILTER CASE 3 Remove hose 1 hose 2 4 Install carburetor synchronizer inductive tachometer onto the spark plug lead of cylinder 1 5 Start the engine and let it warm up for sev eral minutes 6 Check engine idling speed Out of specification Adjust Refer to ADJUSTING THE E...

Page 154: ...n NOTE _ The difference in vacuum pressure between the two throttle bodies should not exceed 1 33 kPa 10 mm Hg 0 4 in Hg 8 Check engine idling speed Out of specification Adjust 9 Stop the engine and remove the measuring equipment 10 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY 11 Install air filter case Refer to AIR FILTER CASE fuel tank Refer to FUEL TANK seat R...

Page 155: ...tive tachometer onto the spark plug lead of cylinder 1 3 Check engine idling speed Out of specification Adjust 4 Adjust engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained Inductive tachometer YU 8036 A Engine idling speed 850 950 r min Direction a Engine idling speed is increased Direction b Engine idling speed is decreased ...

Page 156: ...d the accelerator cable 1 is pulled Throttle body side NOTE When not replacing the throttle cable or removing the cable from the throttle body adjust the throttle cable free play by following step a and steps e through h When replacing the throttle cable or remov ing the cable from the throttle body adjust the throttle cable free play by following steps a through h a Remove the seat and fuel tank ...

Page 157: ...lebar side h Install the fuel tank and seat Refer to FUEL TANK and SEAT AND SIDE COVERS Handlebar side a Loosen the locknut 6 b Turn the adjusting nut 7 in direction c or d until the specified throttle cable free play is obtained c Tighten the locknut WARNING _ After adjusting the throttle cable free play start the engine and turn the handlebar to the right or left to ensure that this does not cau...

Page 158: ...r filter case Refer to AIR FILTER CASE silencer air filter case Refer to SILENCER AIR FILTER CASE 2 Disconnect spark plug cap 3 Remove spark plug CAUTION _ Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders 4 Check spark plug type Incorrect Change Spark plug type manufacturer DPR7EA 9 NGK X22EPR U...

Page 159: ...re spark plug gap a with a wire thickness gauge Out of specification Regap Spark plug gap 0 8 0 9 mm 0 0315 0 0354 in 8 Install spark plug NOTE _ Before installing the spark plug clean the spark plug and gasket surface 9 Connect spark plug cap 10 Install silencer air filter case Refer to SILENCER AIR FILTER CASE air filter case Refer to AIR FILTER CASE fuel tank Refer to FUEL TANK seat Refer to SE...

Page 160: ...k accessing screw 1 1 3 Connect timing light 1 inductive tachometer 2 onto the spark plug lead of cylinder 1 Timing light YM 33277 A Inductive tachometer YU 8036 A 4 Check ignition timing a Start the engine warm it up for several min utes and then let it run at the specified engine idling speed b Check that the mark a is within the required firing range b on the timing Incorrect firing range Check...

Page 161: ...tion Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine warm it up for several min utes and then turn it off 3 Remove seat Refer to SEAT AND SIDE COVERS fuel tank Refer to FUEL TANK air filter case Refer to AIR FILTER CASE silencer air filter case Refer to SILENCER AIR FILTER CASE 4 Remove camshaft sprocket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS in chapter 5 decompres...

Page 162: ...e spark plugs use com pressed air to blow away any dirt accumu lated in the spark plug wells to prevent it from falling into the cylinders 8 Install compression gauge set 14 18 mm 1 compression gauge adapter 12 mm 2 Compression gauge set 14 18 mm YU 33223 Compression gauge adapter 12 mm YU 33223 3 ...

Page 163: ...procket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS in chapter 5 13 Install decompression solenoid Refer to CAMSHAFTS in chapter 5 camshaft sprocket cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS in chapter 5 14 Install silencer air filter case Refer to SILENCER AIR FILTER CASE air filter case Refer to AIR FILTER CASE fuel tank Refer to FUEL TANK seat Refer to SEAT AND SIDE COVE...

Page 164: ...m level mark a and maximum level mark b Below the minimum level mark Add the recommended engine oil to the proper level NOTE Do not screw the dipstick in when inspecting the oil level CAUTION _ Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage Therefore do not add any chemical additives Do not allow foreign materials to enter the crankcase NOTE ...

Page 165: ...g the engine oil level wait a few minutes until the oil has settled 9 Install seat Refer to SEAT AND SIDE COVERS EAS00073 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 dipstick 1 engine oil drain bolt oil tank 2 engine oil drain bolt engine 3 4 Drain engine oil completely from the oil tan...

Page 166: ...cartridge with a thin coat of engine oil CAUTION _ Make sure the O ring 3 is positioned cor rectly in the groove of the oil filter car tridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench Oil filter wrench YU 38411 T R Oil filter cartridge 17 Nm 1 7 m kg 12 ft lb 6 Check engine oil drain bolt gasket Damage Replace 7 Install engine oil drain bolts along with the...

Page 167: ... oil tank Quantity Total amount 5 0 L 4 40 Imp qt 5 29 US qt Without oil filter cartridge replacement 3 7 L 3 26 Imp qt 3 91 US qt With oil filter cartridge replacement 4 1 L 3 61 Imp qt 4 33 US qt 9 Fill when engine disassembly crankcase and oil tank NOTE _ After the engine has been disassembled pour the specified amount of engine oil into the crankcase and the oil tank When pouring engine oil in...

Page 168: ...1 b Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for damage or leakage Refer to ENGINE OIL PUMP in chapter 5 d Start the engine after solving the problem s and check the engine oil pressu...

Page 169: ...al min utes and then turn it off CAUTION _ When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove oil gallery bolt 1 WARNING _ The engine muffler and engine oil are extremely hot 4 Install oil pressure gauge 1 oil pressure adaptor E Pressure gauge YU 03...

Page 170: ...mp Clogged oil filter Leaking oil pas sage Broken or dam aged oil seal Above specifica tion Faulty oil filter Oil viscosity too high T R 20 Nm 2 0 m kg 14 ft lb CHECKING THE TRANSFER GEAR OIL LEVEL 1 Stand the motorcycle on a level surface NOTE _ Place the motorcycle on a suitable stand Make sure the motorcycle is upright 2 Remove muffler rear exhaust pipe front exhaust pipe Refer to ENGINE in cha...

Page 171: ...all front exhaust pipe rear exhaust pipe muffler Refer to ENGINE in chapter 5 T R 8 Nm 0 8 m kg 5 8 ft lb CHANGING THE TRANSFER GEAR OIL 1 Remove muffler rear exhaust pipe front exhaust pipe Refer to ENGINE in chapter 5 2 Place a container under the transfer gear oil drain bolt 3 Remove straight plug 1 transfer gear oil drain bolt 2 4 Drain transfer gear oil completely from the transfer gear case ...

Page 172: ...he specified amount of the recom mended transfer gear oil 8 Install straight plug 9 Check transfer gear oil level Refer to CHECKING THE TRANSFER GEAR OIL LEVEL 10 Install front exhaust pipe rear exhaust pipe muffler Refer to ENGINE in chapter 5 Quantity Total amount 0 49 L 0 43 Imp qt 0 52 US qt Periodic oil replacement 0 4 L 0 35 Imp qt 0 42 US qt ...

Page 173: ...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 e Pull the boot 1 in Engine side a Loosen the locknut 4 b Turn the adjusting bolt 5 in direction c or d until the specified clutch cable free play is obtained c Tighten the locknut Clutch cable free play at the end of the clutch lever 10 15 mm 0 39 0 59 in Directio...

Page 174: ...3 Check air filter element Damage Replace 4 Install air filter element air filter case cover Refer to AIR FILTER CASE silencer air filter element silencer air filter case cover Refer to SILENCER AIR FILTER CASE CAUTION _ Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the ...

Page 175: ...r case Refer to AIR FILTER CASE silencer air filter case Refer to SILENCER AIR FILTER CASE 2 Check throttle body joint 1 Cracks damage Replace 3 Install silencer air filter case Refer to SILENCER AIR FILTER CASE air filter case Refer to AIR FILTER CASE fuel tank Refer to FUEL TANK seat Refer to SEAT AND SIDE COVERS 1 EAS00096 CHECKING THE FUEL HOSES The following procedure applies to all of the fu...

Page 176: ...e seat Refer to SEAT AND SIDE COVERS fuel tank Refer to FUEL TANK air filter case Refer to AIR FILTER CASE silencer air filter case Refer to SILENCER AIR FILTER CASE 2 Check oil tank breather hose 1 cylinder head breather hose 2 Cracks damage Replace Loose connection Connect properly CAUTION _ Make sure the breather hoses are routed correctly 3 Install silencer air filter case Refer to SILENCER AI...

Page 177: ... tightening torque T R Front exhaust pipe nut 4 20 Nm 2 0 m kg 14 ft lb Rear exhaust pipe bolt 5 24 Nm 2 4 m kg 17 ft lb Front exhaust pipe and rear exhaust pipe bolt 6 12 Nm 1 2 m kg 8 7 ft lb Exhaust pipe and muffler bolt 7 12 Nm 1 2 m kg 8 7 ft lb Muffler and muffler bracket bolt 8 53 Nm 5 3 m kg 38 ft lb Muffler and muffler bracket bolts 9 20 Nm 2 0 m kg 14 ft lb 3 3 5 6 7 8 2 9 1 4 3 3 CHECKI...

Page 178: ... can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed the brake system CAUTION _ After adjusting the brake lever free play make sure there is no ...

Page 179: ...Tighten the locknut 1 to specification WARNING _ A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if neces sary bleed...

Page 180: ...w the minimum level mark a Add the recommended brake fluid to the proper level È Front brake É Rear brake WARNING _ 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 ...

Page 181: ...BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Check front brake pad Wear indicator groove 1 almost disap peared Replace the brake pads as a set Refer to REPLACING THE FRONT BRAKE PADS in chapter 4 Brake pad wear limit a 0 5 mm 0 02 in EAS00118 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads 1 Operate the brake 2 Chec...

Page 182: ...djust rear brake light operation timing a Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time Direction a Brake light comes on sooner Direction b Brake light comes on later EAS00131 CHECKING THE FRONT AND REAR BRAKE HOSES The following procedure applies to all of the b...

Page 183: ...e brake fluid level is very low brake operation is faulty NOTE _ Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure there is always enough brake fluid before applying the brake Ignoring this precaution could allow air to enter the hydraulic brake system considerably length enin...

Page 184: ...ake pedal and hold it in position g Loosen the bleed screw NOTE _ Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten...

Page 185: ...alled shift rod length is within specification Installed shift rod length 368 372 mm 14 49 14 65 in Direction b Installed shift rod length increases Direction c Installed shift rod length decreases EAS00138 ADJUSTING THE DRIVE BELT SLACK NOTE _ The drive belt slack must be checked at the tightest point on the belt CAUTION _ A drive belt that is too tight will overload the engine and other vital pa...

Page 186: ...htest position of drive belt 3 Check drive belt slack a Out of specification Adjust NOTE _ The level marks of the level window on the lower drive belt cover are in units of 5 mm 0 20 in Use them as a standard for mea suring the drive belt slack Measure the drive belt slack when the drive belt has been pushed with 4 5 kg 10 lbs of pressure using a belt tension gauge 1 Drive belt slack On the sidest...

Page 187: ... direction a or b until the specified drive belt slack is obtained NOTE _ To maintain the proper wheel alignment adjust both sides evenly e Tighten the locknuts to specification f Tighten the wheel axle nut to specification g Tighten the brake caliper bracket bolt to specification Direction a Drive belt is tightened Direction b Drive belt is loosened Locknut 16 Nm 1 6 m kg 11 ft lb T R Wheel axle ...

Page 188: ...of it falling over NOTE _ Place the motorcycle on a suitable stand so that the front wheel is elevated 2 Check steering head Grasp the bottom of the front fork legs and gently rock the front fork Binding looseness Adjust the steering head 3 Remove tachometer speedometer assembly Refer to HEADLIGHT AND METER ASSEMBLIES 4 Loosen upper bracket pinch bolts 1 5 Remove steering stem nut 2 washer upper b...

Page 189: ...ning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 4 e Install the rubber washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If neces sary hold the lower ring nut and tighten the upper ring nut until their slots a...

Page 190: ...m kg 19 ft lb EAS00149 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface WARNING _ Securely support the motorcycle so that there is no danger of it falling over 2 Check inner tube Damage scratches Replace oil seal Oil leakage Replace 3 Hold the motorcycle upright and apply the front brake 4 Check front fork operation Push down hard on the handlebar several times and check if the fr...

Page 191: ...otorcycle so that there is no danger of it falling over CAUTION _ Grooves are provided to indicate the adjustment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt 1 in direction a or b Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Adjusting positions Mi...

Page 192: ...tions 1 Adjust spring preload NOTE Adjust the spring preload with the special wrench a Loosen the locknut 1 b Turn the spring preload adjusting nut 2 in direction a or b CAUTION _ Never turn the spring preload adjusting nut beyond the maximum or minimum setting Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspension is softer Adjusting positi...

Page 193: ...d riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Total weight of rider passenger cargo and accessories WARNING _ It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Basic weight with oil and a full fuel tank 295 kg 650 lb Maximum load 185 kg 408 lb Col...

Page 194: ...tered in the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement È Tire É Wheel After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same d...

Page 195: ...ne NOTE _ For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point Manufacturer Model Size BRIDGESTONE BT020FG 120 70 ZR 18 M C 59 W 120 70 ZR 18 59 W DUNLOP D220FST 120 70 ZR 18 M C 59 W 120 70 ZR 18 59 W Manufacturer Model Size BRIDGESTONE BT020R 200 50 ZR 17 M C 75 W 200 50 ZR 17 7...

Page 196: ...170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the inner and outer cables WARNING _ Damaged outer cable may cause the cable to corrode and interfere with its movement Replace damaged outer cable and inner cables as soon as possible 1 Check outer cable Damage Replace 2 Check cable operation Rough movement Lubricate NOTE _ Hold the cable end upright and pour a few ...

Page 197: ...ING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand Recommended lubricant Lithium soap based grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Lithium soap based grease LUBRICATING THE LEVERS AND PEDALS LUBRICATING THE SIDESTAND LUBRICATING THE REAR SU...

Page 198: ...r permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention CAUTION _ This is a sealed battery Never remove the sealing caps because the balance between cell...

Page 199: ... charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive bat tery terminal is disconnected No charging is necessary when the open cir cuit voltage equals or exceeds 12 8 V b Check the charge of the battery as shown in the charts and the following example Example c Open circuit voltage 12 0 V d Charging time 6 5 hours e Charge of the bat...

Page 200: ...emoving the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip 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 t...

Page 201: ...d NO YES If the amperage does not exceed the standard charging amperage after 5 minutes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circuit ...

Page 202: ... for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is required Under 12 0 V Replace the battery This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage NOTE Set the charging time to a maxi mum of 2...

Page 203: ...negative battery lead 2 2 1 8 Check battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate battery terminals 10 Install seat Refer to SEAT AND SIDE COVERS Recommended lubricant Dielectric grease EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses CAUTION _ To avoid a short circuit always set the main switch to OFF when checking or r...

Page 204: ...emove seat Refer to SEAT AND SIDE COVERS 2 Check fuse a Connect the pocket tester to the fuse and check the continuity NOTE _ Set the pocket tester selector to Ω 1 b If the pocket tester indicates replace the fuse Pocket tester YU 03112 ...

Page 205: ...her than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install seat Refer to SEAT AND SIDE COVERS Fuses Amperage rating Q ty Main 30 A 1 Headlight 15 A 1 Signaling system 10 A 1 Ignition 10 A 1 Fuel injection system 15 A 1 ECU 10 ...

Page 206: ...extremely hot keep flammable products and your hands away from the bulb until it has cooled down 6 Install headlight bulb Secure the new headlight bulb with the headlight bulb holder CAUTION _ 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 bu...

Page 207: ...lens unit screws EAS00184 ADJUSTING THE HEADLIGHT BEAM 1 Adjust headlight beam vertically a Turn the adjusting screw 1 in direction a or b Direction a Headlight beam is raised Direction b Headlight beam is low ered 2 Adjust headlight beam horizontally a Turn the adjusting screw 2 in direction a or b Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left ...

Page 208: ...ter display will automatically change to the fuel reserve tripmeter mode TRIP F and start counting the distance traveled from that point In that case pushing the SELECT but ton switches the display between the various tripmeter and odometer modes in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F To reset a tripmeter select it by pushing the SELECT button and then push the RESET button for at ...

Page 209: ...THE CLOCK NOTE _ This digital clock constantly displays the time 1 Adjust clock a Push the SELECT button and RESET button together for at least two seconds b When the hour digits start flashing push the RESET button to set the hours c Push the SELECT button and the minute digits will start flashing d Push the RESET button to set the min utes e Push the SELECT button and then release it to start th...

Page 210: ...kg 9 4 ft Ib Order Job Part Q ty Remarks Removing the front wheel and brake discs Remove the parts in the order listed NOTE _ Place the motorcycle on a suitable stand so that the front wheel is elevated 1 Reflector bracket left and right 2 2 Brake hose holder 2 3 Reflector left and right 2 4 Brake caliper left and right 2 Refer to INSTALLING THE FRONT WHEEL 5 Front fork guard left and right 2 6 Wh...

Page 211: ...7 ft Ib T R 72 Nm 7 2 m kg 52 ft lb T R 8 Nm 0 8 m kg 5 8 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 40 Nm 4 0 m kg 29 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib Order Job Part Q ty Remarks 8 Collar left and right 2 Refer to INSTALLING THE FRONT WHEEL 9 Front wheel 1 10 Brake disc left and right 2 For installation reverse the removal procedure ...

Page 212: ... 1 2 3 2 1 LS LS New New Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal left and right 2 2 Wheel bearing left and right 2 3 Spacer 1 For assembly reverse the disassembly procedure ...

Page 213: ...move left brake caliper right brake caliper NOTE _ Do not apply the brake lever when removing the brake calipers 3 Elevate front wheel NOTE _ Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent wheel axle 2 Check tire front ...

Page 214: ...ront wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE _ To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel sur face c Remove the wheel bearings 3 with a gen eral bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly CAUTION _ Do not contact the wheel bearing inner race 4 or balls 5 Contact should be made...

Page 215: ...ring the front brake disc deflection turn the handlebar to the left or right to ensure that the front wheel is sta tionary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 006 in below the edge of the brake disc Brake disc deflection limit maximum Front 0 10 mm 0 004 in Rear 0 15 mm 0 006 in 3 Measure brake disc thic...

Page 216: ...djustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc T R Brake disc bolt 18 Nm 1 8 m kg 13 ft lb LOCTITE 648 EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both of the brake discs 1 Install brake discs NOTE Apply locking agent LOCTITE 648 to the threads of the bra...

Page 217: ...check if the front fork rebounds smoothly 5 Install spacer front fork guard left and right front fork guard bolts NOTE _ When installing the front fork guards make sure that there is not dirt between the guard and the front fork 6 Install brake calipers WARNING _ Make sure the brake hose is routed prop erly Recommended lubricant Lithium soap based grease 1 2 T R 72 Nm 7 2 m kg 52 ft lb T R 23 Nm 2...

Page 218: ...e the front wheel on a suitable balancing stand a Spin the front wheel b When the front wheel stops put an X1 mark at the bottom of the wheel c Turn the front wheel 90 so that the X1 mark is positioned as shown d Release the front wheel e When the wheel stops put an X mark at the bottom of the wheel f Repeat steps d through f several times until all the marks come to rest at the same spot g The sp...

Page 219: ... Turn the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check front wheel static balance a Turn the front wheel and make sure it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 220: ...m 4 0 m kg 29 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib 1 Order Job Part Q ty Remarks Removing the rear fender Remove the parts in the order listed Seat Refer to SEAT AND SIDE COVERS in chapter 3 1 Tail sub wire harness coupler 1 Disconnect Refer to INSTALLING THE REAR WHEEL 2 Rear fender assembly 1 3 Rear fender bracket left and right 2 For installation reverse the removal procedure ...

Page 221: ... Ib T R 150 Nm 15 0 m kg 110 ft Ib Order Job Part Q ty Remarks Removing the rear wheel Remove the parts in the order listed NOTE _ Place the motorcycle on a suitable stand so that the rear wheel is elevated 1 Upper drive belt cover 1 Refer to INSTALLING THE REAR WHEEL 2 Upper drive belt cover plate 1 3 Brake caliper 1 4 Brake caliper bracket bolt 1 5 Pin boot 2 6 Brake pad brake pad shim 2 2 7 Bra...

Page 222: ...ft Ib T R 150 Nm 15 0 m kg 110 ft Ib Order Job Part Q ty Remarks 8 Locknut left and right 2 Loosen Refer to REMOVING THE REAR WHEEL and INSTALL ING THE REAR WHEEL 9 Adjusting bolt left and right 2 Loosen 10 Wheel axle nut 1 11 Right adjusting plate 1 12 Left adjusting plate 1 13 Rear wheel axle 1 14 Rear wheel 1 15 Collar left and right 2 16 Brake caliper bracket 1 For installation reverse the rem...

Page 223: ...Order Job Part Q ty Remarks Removing the brake disc and rear wheel pulley Remove the parts in the order listed 1 Brake disc cover 1 Refer to INSTALLING THE REAR WHEEL 2 Brake disc 1 3 Rear wheel pulley 1 4 Oil seal 1 5 Circlip 1 6 Rear wheel drive hub 1 7 Circlip 1 ...

Page 224: ...AR WHEEL BRAKE DISC AND REAR WHEEL PULLEY Order Job Part Q ty Remarks 8 Collar 1 9 Bearing 1 10 Collar 1 11 Bearing 1 12 Rear wheel drive hub damper 6 13 Rear wheel 1 For installation reverse the removal procedure ...

Page 225: ...LEY EAS00560 Order Job Part Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Oil seal 1 Refer to ASSEMBLING THE REAR WHEEL 2 Bearing 1 3 Spacer 1 4 Bearing 2 5 Rear wheel 1 For assembly reverse the disassembly procedure ...

Page 226: ...press the brake pedal when remov ing the brake caliper 3 Loosen locknuts adjusting nuts 4 Remove wheel axle nut wheel axle rear wheel NOTE _ Push the rear wheel forward and remove the drive belt from the rear wheel pulley EAS00565 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals Refer to CHECKING THE FRONT WHEEL 2 Check tire rear wheel Damage wear Replace Refer to CHE...

Page 227: ... wheel pulley Bent teeth Replace the rear wheel pul ley 2 Replace rear wheel pulley a Remove the self locking nuts and the rear wheel pulley b Clean the rear wheel drive hub with a clean cloth especially the surfaces that contact the pulley c Install the new rear wheel pulley NOTE _ Tighten the self locking nuts in stages and in a crisscross pattern T R Rear wheel pulley self locking nut 95 Nm 9 5...

Page 228: ... drive hub assembly 1 4 Install rear wheel pulley 1 NOTE Tighten the self locking nuts in stages and in a crisscross pattern Install the rear wheel pulley with its wider spokes situated on top of the rear wheel spokes 5 Install brake disc brake disc cover NOTE Apply locking agent LOCTITE 648 to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern T...

Page 229: ...djusting plates rear wheel axle washer wheel axle nut NOTE Temporarily tighten the wheel axle nut 8 Adjust drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK in chapter 3 9 Tighten wheel axle nut brake caliper bracket bolts T R 150 Nm 15 0 m kg 110 ft lb T R 30 Nm 3 0 m kg 22 ft lb 10 Install brake pad springs brake pad shims brake pads pin boots 11 Install brake caliper 1 1 T R 27 Nm 2 7 m ...

Page 230: ...r plate 1 upper drive belt cover 2 T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb 13 Install rear fender bracket 1 T R 40 Nm 4 0 m kg 29 ft lb 14 Install rear fender assembly 1 15 Connect tail sub wire harness coupler 2 16 Install seat Refer to SEAT AND SIDE COVERS in chapter 3 ...

Page 231: ...R WHEEL STATIC BALANCE NOTE _ After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel static balance Refer to FRONT WHEEL AND BRAKE DISCS ...

Page 232: ...0 m kg 29 ft Ib Order Job Part Q ty Remarks Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake caliper bolt 2 2 Brake pad clip 2 3 Brake pad pin 1 4 Brake pad spring 1 5 Brake pad 2 6 Brake pad shim 2 For installation reverse the removal procedure ...

Page 233: ... m kg 19 ft Ib T R 6 Nm 0 6 m kg 4 3 ft Ib Order Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Brake caliper retaining bolt 2 2 Brake caliper 1 3 Brake pad 2 4 Brake pad shim 2 5 Brake pad spring 2 For installation reverse the removal procedure ...

Page 234: ...luid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury FIRST AID FOR BRAKE FLUID ENTERING THE EYES Flush with water for 15 minutes and get immediate medical attention EAS00580 REPLACING THE FRONT BRAKE PADS The followin...

Page 235: ... onto the brake pads brake pads brake pad spring NOTE _ Always install new brake pads and a new brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Brake pad wear limit 0 5 mm 0 02 in T...

Page 236: ...uid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 8 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 T R 27 Nm 2 7 m kg 19 ft lb EAS00583 REPLACING THE REAR BRAKE PADS NOTE _ When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1...

Page 237: ... brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper piston into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim 3 onto each new brake pad 4 e Install new brake pads Brake pad wear limit 0 8 mm...

Page 238: ...ake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 a ...

Page 239: ...emoving the front brake master cylinder Remove the parts in the order listed Brake fluid Drain 1 Rear view mirror right 1 2 Brake master cylinder reservoir cap 1 3 Brake master cylinder reservoir diaphragm holder 1 4 Brake master cylinder reservoir diaphragm 1 5 Brake lever 1 6 Brake lever spring 1 ...

Page 240: ...Refer to REMOVING THE FRONT BRAKE MASTER CYLINDER and ASSEM BLING AND INSTALLING THE FRONT BRAKE MAS TER CYLINDER 8 Union bolt 1 9 Brake hose 1 Disconnect 10 Copper washer 2 11 Brake master cylinder holder 1 12 Brake master cylinder 1 13 Front brake light switch 1 For installation reverse the removal procedure ...

Page 241: ...sembling the front brake master cylinder Remove the parts in the order listed 1 Dust boot 1 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE MASTER CYL INDER 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 242: ...s Removing the brake fluid reservoir Remove the parts in the order listed Brake fluid Drain 1 Brake fluid reservoir 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 For installation reverse the removal procedure ...

Page 243: ... Q ty Remarks Removing the rear brake master cylinder Remove the parts in the order listed 1 Brake master cylinder cover 1 Refer to REMOVING THE REAR BRAKE MASTER CYLINDER and ASSEM BLING AND INSTALLING THE REAR BRAKE MAS TER CYLINDER 2 Union bolt 1 3 Copper washer 2 4 Brake hose 1 Disconnect 5 Brake master cylinder bracket 1 6 Rear brake light switch 1 7 Horn 1 connector 2 Disconnect 8 Right foot...

Page 244: ...g 22 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 23 Nm 2 3 m kg 17 ft Ib T R 48 Nm 4 8 m kg 35 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib New Order Job Part Q ty Remarks 9 Cotter pin 1 10 Pin 1 11 Brake rod 1 12 Locknut 1 13 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 245: ...isassembling the rear brake master cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Circlip 1 5 Brake hose joint 1 6 O ring 1 7 Brake master cylinder 1 For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 New ...

Page 246: ...e brake hose EAS00589 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE _ To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders 1 Check brake master cylinder 1 Da...

Page 247: ...front brake master cylinder reservoir 1 Cracks damage Replace front brake master cylinder reservoir dia phragm 2 Damage wear Replace 5 Check brake hoses Cracks damage wear Replace EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING _ Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on interna...

Page 248: ... Install copper washers brake hose union bolt WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 NOTE _ While holding the brake hose tighten the union bolt as shown Turn the handlebar to the left and right to make sure the brake hose does not touch other parts e g wire harness cables leads Correct if necessary New T R 32 Nm 3 2 ...

Page 249: ...ater will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 5 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the pro...

Page 250: ... the maximum level mark WARNING _ 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 bra...

Page 251: ... to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 a 5 Adjust brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3 6 Adjust rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3 Brake pedal position from the top of the rider footrest to the top of the brake pedal 80 mm 3 2 in FRONT AND REAR BRAKES ...

Page 252: ...The following procedure applies to both of the front brake calipers Brake hose holder Refer to FRONT WHEEL AND BRAKE DISCS Brake fluid Drain 1 Union bolt 1 Refer to DISASSEM BLING THE FRONT BRAKE CALIPERS and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper bolt 2 5 Brake caliper 1 For installation reverse the removal procedure FRONT AN...

Page 253: ...arts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake caliper piston 4 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS 7 Brake caliper piston seal 8 8 Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 254: ...iper Remove the parts in the order listed 1 Union bolt 1 Refer to DISASSEM BLING THE REAR BRAKE CALIPER and ASSEM BLING AND INSTALLING THE REAR BRAKE CALI PER 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper retaining bolt 2 5 Brake caliper 1 6 Brake pad 2 7 Brake pad shim 2 8 Brake pad spring 2 For installation reverse the removal procedure FRONT AND REAR BRAKES ...

Page 255: ... Q ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed 1 Brake caliper piston 1 Refer to DISASSEMBLING THE REAR BRAKE CALIPER 2 Brake caliper piston seal 2 3 Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 256: ...r and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pis tons from the brake caliper WARNING _ Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Remove the brake caliper ...

Page 257: ...er and pump out the brake fluid carefully 2 1 3 2 Remove brake caliper piston brake caliper piston seals a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper WARNING _ Cover the brake caliper piston with a rag Be careful not to get injured when the pis tons are expelled from the brake caliper Never try to pry out the brake caliper pis tons b Rem...

Page 258: ...ns 1 Rust scratches wear Replace the brake caliper pistons brake caliper cylinders 2 Scratches wear Replace the brake cali per assembly brake caliper body Cracks damage Replace the brake cali per assembly brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air WARNING _ Whenever a brake caliper is disassembled replace the brake caliper piston seals È Front É Rear ...

Page 259: ...well and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers 2 brake hose 3 union bolt 4 WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the brake hose onto the brake caliper 1 make...

Page 260: ...h 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 master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plast...

Page 261: ...ING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING _ Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components as they will cause the piston seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper p...

Page 262: ... motorcycle operation Refer to CABLE ROUTING in chapter 2 CAUTION _ When installing the brake hose onto the brake caliper 1 make sure the brake pipe a touches the projection b on the brake caliper b 1 4 3 2 New a New T R 30 Nm 3 0 m kg 22 ft lb 2 Remove brake caliper 3 Install brake pad springs brake pad brake caliper brake caliper retaining bolts T R 27 Nm 2 7 m kg 19 ft lb ...

Page 263: ...r does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level Below the minimum level mark ...

Page 264: ...egs Remove the parts in the order listed The following procedure applies to both of the front fork legs Front wheel Refer to FRONT WHEEL AND BRAKE DISCS 1 Front fender 1 2 Upper bracket pinch bolt 2 Loosen Refer to REMOVING THE FRONT FORK LEGS and INSTALLING THE FRONT FORK LEGS 3 Cap bolt 1 Loosen 4 Turn signal light bracket pinch bolt 1 Loosen 5 Lower bracket pinch bolt 2 Loosen 6 Front fork leg ...

Page 265: ... legs Remove the parts in the order listed The following procedure applies to both of the front fork legs 1 Cap bolt 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEMBLING THE FRONT FORK LEGS 2 O ring 1 3 Spacer 1 4 Nut 1 5 Spring seat 1 6 Fork spring 1 7 Outer tube 1 8 Dust seal 1 ...

Page 266: ... Oil seal clip 1 Refer to DISASSEMBLING THE FRONT FORK LEGS and ASSEMBLING THE FRONT FORK LEGS 0 Oil seal 1 A Washer 1 B Damper rod assembly bolt 1 C Copper washer 1 D Damper rod assembly 1 E Inner tube 1 For assembly reverse the disassembly procedure ...

Page 267: ... bolt 2 turn signal light bracket pinch bolt 3 lower bracket pinch bolts 4 WARNING _ Before loosening the upper and lower bracket pinch bolts and turn signal light bracket pinch bolt support the front fork leg 3 Remove front fork leg 2 1 4 3 EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt 1 from the damper rod spacer 2 nut...

Page 268: ...ve the rod holder and fork spring com pressor WARNING _ The fork spring is compressed f Remove the spacer and nut 2 Drain fork oil NOTE _ Stroke the damper rod 1 several times while draining the fork oil 3 Remove dust seal oil seal clip 1 oil seal washer with a flat head screwdriver CAUTION _ Do not scratch the inner tube ...

Page 269: ...der YM 01423 EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Check inner tube 1 outer tube 2 Bends damage scratches Replace WARNING _ Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free length a Out of specification Replace Spring free length 296 mm 11 65 in Limit 291 mm 11 46 in ...

Page 270: ... air CAUTION _ The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particu larly sensitive to foreign material When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork 4 Check cap bolt O ring Damage wear Replace ...

Page 271: ...s inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure all of the components are clean 1 Install damper rod assembly 1 CAUTION _ Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner tube Be careful not to damage the inner tube 2 Tighten damper rod assembly bolt 1 NOTE _ While holding ...

Page 272: ... grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag 5 to pro tect the oil seal during installation 4 Install outer tube onto the inner tube 5 Install washer oil seal 1 with the fork seal driver 2 Fork seal driver YM 01442 6 Install oil seal clip 1 NOTE _ Adjust the oil seal clip so that it fits in...

Page 273: ... fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign material to enter the front fork Quantity each front fork leg 476 cm3 16 8 Imp qt 16 1 US qt Recommended oil Yamaha suspension oil 01 11 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten times to distribute th...

Page 274: ...is stroke more than 150 mm 8 12 in repeat steps 11 and 12 13 Before measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed NOTE _ Be sure to bleed the front fork leg of any resid ual air 14 Measure front fork leg oil level a Out of specification Correct Front fork leg oil level from the top of the outer tube and damper rod with the outer tube ful...

Page 275: ...ith the fork spring compressor 6 f Pull up the rod puller and install the rod holder between the nut 1 and the spacer 4 NOTE _ Use the side of the rod holder that is marked B g Remove the rod puller h Install the nut 1 and position it as specified b i Hold the nut and tighten the cap bolt until it comes into contact with the nut j Hold the cap bolt and tighten the nut to specification Rod puller Y...

Page 276: ...lies to both of the front fork legs 1 Install front fork leg Temporarily tighten the upper and lower bracket pinch bolts NOTE _ Make sure the outer fork tube is flush with the top of the upper bracket 2 Tighten lower bracket pinch bolts 1 turn signal light bracket pinch bolt 2 cap bolt 3 upper bracket pinch bolts 4 WARNING _ Make sure the brake hoses are routed prop erly 1 2 3 4 T R 23 Nm 2 3 m kg...

Page 277: ...4 68 CHAS FRONT FORK 3 Adjust spring preload Refer to ADJUSTING THE FRONT FORK LEGS in chapter 3 ...

Page 278: ...irror left and right 2 2 Plastic clamp 6 Refer to INSTALLING THE HANDLEBAR 3 Front brake light switch connector 2 Disconnect 4 Brake master cylinder holder 1 5 Brake master cylinder 1 6 Right handlebar switch 1 7 Throttle cable holder 1 8 Throttle cable 2 Disconnect 9 Throttle grip 1 10 Clutch switch coupler 1 Disconnect HANDLEBAR ...

Page 279: ...fer to INSTALL ING THE HANDLE BAR 12 Handlebar grip 1 Refer to REMOV ING THE HANDLE BAR 13 Clutch cable 1 Disconnect 14 Clutch lever holder 1 15 Upper handlebar holder 2 16 Handlebar 1 17 Lower handlebar holder 2 For installation reverse the removal procedure HANDLEBAR ...

Page 280: ...nd gradually push the grip off the handlebar EAS00668 CHECKING THE HANDLEBAR 1 Check handlebar Bends cracks damage Replace WARNING _ Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00670 INSTALLING THE HANDLEBAR 1 Stand the motorcycle on a level surface WARNING _ Securely support the motorcycle so that there is no danger of it falling over 2 Install washers lowe...

Page 281: ...t the handlebar position NOTE _ Align the match marks a on the handlebar with the upper surface of the lower handlebar holder a 2 1 T R 28 Nm 2 8 m kg 20 ft lb 4 Tighten lower handlebar holder nuts T R 40 Nm 4 0 m kg 29 ft lb 5 Install clutch lever holder NOTE _ Align the slit of clutch lever holder with the punch mark a on the handlebar 6 Install clutch cable NOTE _ Lubricate the end of the clutc...

Page 282: ...ive onto the left end of the handlebar b Slide the handlebar grip over the left end of the handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING _ Do not touch the handlebar grip until the rubber adhesive has fully dried 10 Install throttle grip 11 Connect throttle cable 12 Install right handlebar switch NOTE _ Align the projection a on the right handlebar switch with the hole b...

Page 283: ...nnect front brake light switch connectors T R 10 Nm 1 0 m kg 7 2 ft lb 15 Install plastic clamps NOTE _ Refer to CABLE ROUTING in chapter 2 16 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 Clutch cable free play at the end of the clutch lever 10 15 mm 0 39 0 59 in 17 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapte...

Page 284: ...Remarks Removing the lower bracket Remove the parts in the order listed Handlebar handlebar holders Refer to HANDLEBAR Meter assemblies Refer to HEADLIGHT AND METER ASSEMBLIES in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK 1 Steering stem nut 1 Refer to INSTALLING THE STEERING HEAD 2 Upper bracket 1 3 Cable guide 1 4 Headlight bracket 1 5 Brake ho...

Page 285: ... ft lb T R 115 Nm 11 5 m kg 85 ft lb Order Job Part Q ty Remarks 8 Lock washer 1 Refer to INSTALL ING THE STEER ING HEAD 9 Upper ring nut 1 10 Rubber washer 1 11 Lower ring nut 1 Refer to REMOV ING THE LOWER BRACKET 12 Lower bracket 1 13 Lower bearing 1 14 Lower bearing cover 1 15 Upper bearing cover 1 16 Upper bearing 1 17 Bearing outer race 1 For installation reverse the removal procedure STEERI...

Page 286: ...anger of it falling over 2 Remove ring nut 1 with the spanner wrench 2 WARNING _ Securely support the lower bracket so that there is no danger of it falling Spanner wrench YU 33975 EAS00681 CHECKING THE STEERING HEAD 1 Wash bearings bearing races Recommended cleaning solvent Kerosene 2 Check bearings bearing races Damage pitting Replace STEERING HEAD ...

Page 287: ... could be damaged NOTE _ Always replace the bearings and bearing races as a set Whenever the steering head is disassem bled replace the rubber seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap based grease 2 Install lower rin...

Page 288: ...ering stem nut NOTE _ Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK NOTE _ Temporarily tighten the lower bracket pinch bolts 5 Tighten steering stem nut T R 115 Nm 11 5 m kg 85 ft lb STEERING HEAD ...

Page 289: ...y Remarks Removing the rear shock absorber and swingarm Remove the parts in the order listed Rear brake master cylinder bracket Refer to FRONT AND REAR BRAKES Rear exhaust pipe Refer to ENGINE in chapter 5 Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 1 Adjusting bolt 2 2 Locknut 2 3 Lower drive belt cover plate 1 4 Spacer 1 5 Lower drive belt cover 1 6 Horn 2 coupler 1 Disconnec...

Page 290: ...Q ty Remarks 8 Brake hose holder 2 Refer to REMOVING THE REAR SHOCK ABSORBER AND SWINGARM and INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM 9 Self locking nut 1 10 Bolt shock absorber connecting arm frame 1 11 Cover left and right 2 12 Pivot shaft nut washer 1 1 13 Pivot shaft 1 14 Rear shock absorber and swingarm assembly 1 For installation reverse the removal procedure REAR SHOCK ABSORBER AND ...

Page 291: ...Remove the parts in the order listed 1 Self locking nut washer bolt 1 1 1 Bolt 100 mm 3 94 in 2 Self locking nut washer bolt 1 1 1 Bolt 124 mm 4 88 in 3 Connecting arm 2 4 O ring 4 5 Rear shock absorber 1 6 Spacer O ring 1 2 7 Self locking nut washer bolt 1 2 1 Bolt 77 mm 3 03 in 8 Relay arm 1 Refer to INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM 9 Spacer oil seal bearing 1 2 1 10 Spacer bearin...

Page 292: ... LS LS 1 LS LS LS 9 T R 40 Nm 4 0 m kg 29 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib T R 59 Nm 5 9 m kg 43 ft Ib LS 5 12 Order Job Part Q ty Remarks 12 Swingarm 1 13 Dust cover 2 14 Spacer 1 15 Bearing 2 For installation reverse the removal procedure REAR SHOCK ABSORBER AND SWINGARM ...

Page 293: ...ct the rear shock absorber to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber in any way Rear shock absorber damage will result in poor damping performance EAS00689 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER Gas pressure must be released before dispos ing of a rear shock absorber ...

Page 294: ...rop down 3 Measure swingarm free play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play È by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers d Check the swingarm vertical movement É by moving the swingarm up and down If swingarm vertical mo...

Page 295: ...ssembly gas cylinder Damage gas leaks Replace bushings Damage wear Replace O ring Damage wear Replace bolts Bends damage wear Replace CHECKING THE RELAY ARM AND CONNECTING ARM 1 Check relay arm 1 connecting arms 2 Damage wear Replace bearings oil seals Damage pitting Replace spacers Damage scratches Replace CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot shaft Roll...

Page 296: ...mage wear Replace bearings Damage pitting Replace EAS00711 INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM 1 Lubricate bearings spacers dust covers O rings pivot shaft 2 Install bearings 1 2 3 to relay arm Recommended lubricant Lithium soap based grease Installed depth a 4 5 mm 0 18 in Installed depth b 1 0 mm 0 04 in Installed depth c 2 0 mm 0 08 in 1 2 2 3 b a b c ...

Page 297: ...nstall bolt shock absorber connecting arm frame 1 NOTE _ When installing the bolt shock absorber con necting arm frame hold the swingarm so that it does not drop down 1 4 Adjust drive belt slack Refer to ADJUSTING THE DRIVE BELT SLACK in chapter 3 ...

Page 298: ...he order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY Rear shock absorber and swingarm assembly Refer to REAR SHOCK ABSORBER AND SWINGARM 1 Drive sprocket cover 1 2 Slider 2 3 Dowel pin 2 4 Transfer gear case bracket 1 5 Drive belt 1 6 Drive sprocket nut 1 7 Lock washer 1 8 Drive sprocket 1 For installation reverse the removal procedure ...

Page 299: ...does not move CHECKING THE DRIVE BELT 1 Clean drive belt a Wipe the drive belt with a clean cloth b Put the drive belt in a mixture of mild deter gent and water Then remove any dirt from the drive belt c Remove the drive belt from the mixture and rinse it off with clean water Then let the drive belt thoroughly dry 2 Check drive belt CAUTION To protect the drive belt from damage handle it with care...

Page 300: ...ll the drive belt facing the same way it was removed Do not twist the drive belt when installing it 3 Install rear shock absorber and swingarm assembly Refer to REAR SHOCK ABSORBER AND SWINGARM rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY 4 Tighten drive sprocket nut NOTE _ When tightening the drive sprocket nut press down on the brake pedal so the drive sprocket does not move 5...

Page 301: ... ft Ib T R 20 Nm 2 0 m kg 14 ft Ib T R 53 Nm 5 3 m kg 38 ft Ib 4 4 4 T R 20 Nm 2 0 m kg 14 ft Ib Order Job Part Q ty Remarks Removing the muffler and exhaust pipes Remove the parts in the order listed 1 Muffler 1 2 Rear exhaust pipe 1 3 Front exhaust pipe 1 4 Gasket 2 5 Gasket 2 For installation reverse the removal procedure ENGINE ...

Page 302: ...ted Seat side covers Refer to SEAT AND SIDE COVERS in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Silencer air filter case Refer to SILENCER AIR FILTER CASE in chapter 3 Throttle bodies intake manifold Refer to FUEL INJECTION SYSTEM in chapter 6 Air induction system parts Refer to AIR INDUCTION SYSTEM in chapter 6 Starter motor Refer to...

Page 303: ...in Refer to CHANGING THE ENGINE OIL in chapter 3 Sub fuel tank Refer to SUB FUEL TANK Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL in chapter 3 Transfer gear case Refer to TRANSFER GEAR CASE Rider footrest left Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Rider footrest right oil delivery pipe Refer to GENERATOR AND STARTER CLUTCH 1 Oil filter bolt 1 2 Oil filter bracket 1 E...

Page 304: ... ft Ib T R 70 Nm 7 0 m kg 50 ft Ib LT Order Job Part Q ty Remarks 3 Rectifier regulator coupler 1 Disconnect 4 Stator coil assembly coupler 1 Disconnect 5 Rectifier regulator 1 6 Rectifier regulator bracket 1 7 Horn 2 1 8 Lean angle cut off switch 1 For installation reverse the removal procedure ENGINE ...

Page 305: ...listed 1 Spark plug caps 4 2 Cylinder head breather hose 1 3 Oil tank breather hose 1 4 Clutch cable 1 5 Plastic clamp 1 6 Decompression solenoid coupler 2 7 Crankshaft position sensor coupler 1 8 Cylinder identification coupler 1 9 Engine temperature sensor coupler 1 10 Neutral switch cover 1 11 Neutral switch 1 12 Speed sensor 1 For connecting reverse the disconnec tion procedure ENGINE ...

Page 306: ...and linear control valve Remove the parts in the order listed 1 Hose bracket 1 2 Wire harness bracket 1 3 Ignition coil connector 4 Disconnect 4 Ignition coil 1 1 5 Ignition coil 2 1 6 Linear control valve coupler 1 Disconnect 7 Linear control valve 1 8 Linear control valve bracket 1 For installation reverse the removal procedure ENGINE ...

Page 307: ...8 Nm 4 8 m kg 35 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE _ Place a suitable stand under the frame and engine 1 Upper mounting bolt 2 2 Upper mounting bracket bolt 2 3 Upper mounting 1 4 Self locking nut 1 5 Front mounting bolt 1 Refer to INSTALLING THE ENGINE 6 Front engine bracket self locking nut 4 7 Front engine bracket 2 8 Front engine br...

Page 308: ...m 4 8 m kg 35 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib 2 1 3 1 R 48 Nm 4 8 m kg 35 ft Ib Order Job Part Q ty Remarks 11 Rear engine bracket nut 2 Refer to INSTALLING THE ENGINE 12 Rear engine bracket bolt 2 13 Rear engine bracket left 1 14 Rear engine bracket right 1 15 Spacer bolt 1 Loosen 16 Lower rear mounting bolt 1 17 Lower front mounting bolt 1 18 Engine 1 For installation reverse the removal proce...

Page 309: ...cket A front mounting bolt B self locking nut C upper engine bracket D upper mounting bolts E NOTE _ Do not fully tighten the bolts and nuts 4 Tighten upper mounting bolts E upper engine bracket bolts F 5 Tighten self locking nut 5 self locking nut 6 nuts G self locking nut 0 self lock nuts H self locking nut C Pivot shaft wrench YM 01485 9 8 6 5 1 H C A 2 G G 3 0 F E E D 7 B A H T R 18 Nm 1 8 m k...

Page 310: ...HE MUFFLER AND EXHAUST PIPES 1 Install gaskets exhaust pipes NOTE Finger tighten the exhaust pipe nuts and bolts 2 Install muffler bolt 1 bolts 2 T R 53 Nm 5 3 m kg 38 ft lb T R 20 Nm 2 0 m kg 14 ft lb 3 Tighten exhaust pipe nuts exhaust pipe bolts clamp bolts 1 T R 20 Nm 2 0 m kg 14 ft lb T R 24 Nm 2 4 m kg 17 ft lb T R 12 Nm 1 2 m kg 8 7 ft lb ENGINE ...

Page 311: ...sprocket cover Remove the parts in the order listed Seat fuel tank silencer air filter case Refer to SEAT AND SIDE COVERS FUEL TANK and SILENCER AIR FIL TER CASE in chapter 3 Muffler exhaust pipes Refer to ENGINE Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Spark plug cap 2 2 Disconnect Refer to INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER 2 Spark plug 4 3 ...

Page 312: ... left side cover 1 Refer to INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER 7 Rubber damper 1 8 Timing mark accessing screw 1 9 Crankshaft end cover 1 10 Decompression solenoid cover 1 11 Camshaft sprocket cover 1 1 12 Dowel pin 2 13 Cylinder identification sensor 1 14 Camshaft sprocket cover 2 1 15 Camshaft sprocket cover gasket 1 For installation reverse the removal procedure R...

Page 313: ...ifier regulator liner control valve Refer to ENGINE 1 Cylinder head breather hose 1 2 Oil tank breather hose 1 3 Bolt 4 60 mm 2 36 in 4 Bolt 12 50 mm 1 97 in 5 Bolt 12 40 mm 1 57 in 6 Rear cylinder head cover 1 Refer to INSTALLING THE CYLINDER HEAD COVERS 7 Front cylinder head cover 1 8 Cylinder head cover gasket 2 9 Dowel pin 4 For installation reverse the removal procedure ROCKER ARMS PUSH RODS ...

Page 314: ... 1 Push rod 1 3 288 5 mm 11 358 in blue painting 2 Push rod 2 1 290 5 mm 11 437 in yellow painting 3 Rear rocker arm base 1 Refer to REMOVING THE ROCKER ARMS PUSH RODS AND VALVE LIFT ERS and INSTALLING THE ROCKER ARMS AND PUSH RODS 4 Front rocker arm base 1 5 Rocker arm base gasket 2 6 Dowel pin 4 7 Rocker arm shaft 4 8 Rocker arm 1 2 9 Rocker arm 2 2 10 Locknut 2 11 Adjusting screw 2 For installa...

Page 315: ...ers Remove the parts in the order listed 1 Push rod cover 2 2 O ring 4 3 Seal 2 4 Air filter bracket 1 5 Rear valve lifter case 1 6 Front valve lifter case 1 7 Valve lifter 4 Refer to REMOVING THE ROCKER ARMS PUSH RODS AND VALVE LIFT ERS and INSTALLING THE VALVE LIFTERS For installation reverse the removal procedure ROCKER ARMS PUSH RODS AND VALVE LIFTERS ...

Page 316: ...camshaft drive gear mark c position and camshaft driven gear mark d position as shown If the marks are not aligned turn the crank shaft counterclockwise 360 degrees and recheck step b 2 Remove rocker arm bases with the rocker arms 3 Remove valve lifters NOTE Make a note of the position of each valve lifter so that they can be installed in the correct place CAUTION Do not lay the removed valve lift...

Page 317: ...rocker arm shaft outside diameter a Out of specification Replace Rocker arm shaft outside diameter 17 976 17 991 mm 0 7077 0 7083 in 5 Calculate rocker arm to rocker arm shaft clearance NOTE Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter Above 0 08 mm 0 003 in Replace the defective part s Rocker arm to rocker arm shaft clearance 0 0...

Page 318: ...unout Out of specification Replace Push rod runout 0 3 mm 0 012 in CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES 1 Check valve lifter Blue discoloration excessive wear pitting scratches Replace and check the lubri cation system 2 Check valve lifter case 1 Damage wear Replace the valve lifter case O ring 2 Damage wear Replace the O ring ROCKER ARMS PUSH RODS AND VALVE LIFTERS ...

Page 319: ...m 0 9055 0 9063 in 5 Calculate valve lifter to valve lifter case clearance NOTE Calculate the clearance by subtracting the valve lifter case outside diameter Above 0 072 mm 0 0028 in Replace the defective part s Valve lifter to valve lifter case clearance 0 0256 0 0530 mm 0 0010 0 0021 in BLEEDING A VALVE LIFTER A valve lifter must be bled in the following cases When installing a new valve lifter ...

Page 320: ...driven gear aligns with the punch mark on the camshaft drive gear as shown This is the condition in which piston 1 is at top dead center TDC NOTE The crankshaft can be rotated smoothly when the spark plugs are removed WARNING Be careful since the engine is hot g With piston 1 at TDC count the indicated number of gear teeth and place marks 2 through 5 on the camshaft driven gear as shown When these...

Page 321: ...ears aligned for five minutes to allow the valve lifter to bleed j If necessary repeat steps h and i to bleed other valve lifters CHECKING THE PUSH ROD COVER 1 Check push rod cover 1 Cranks damage Replace seal 2 O ring 3 Damage wear Replace the oil seal and O ring as a set INSTALLING THE VALVE LIFTERS 1 Install valve lifter cases front and rear valve lifters air filter bracket NOTE Install the val...

Page 322: ...ush rods NOTE Be sure to correctly install the push rods between the rocker arms and valve lifters as shown The illustration is viewed from the right side of the motorcycle È Rear cylinder É Front cylinder 1 Intake side rocker arm 2 Exhaust side rocker arm 3 Intake valve lifter 4 Exhaust valve lifter 5 Push rod 2 288 5 mm 11 358 in blue paint ing 6 Push rod 1 290 5 mm 11 437 in yellow painting The...

Page 323: ...LING THE CYLINDER HEAD COVERS The following procedure applies to both cylin ders 1 Install dowel pins 1 cylinder head cover gasket 2 New 2 Install cylinder head cover 1 Bolts 2 40 mm 1 57 in Bolts 3 50 mm 1 97 in Bolts 4 60 mm 2 36 in T R 10 Nm 1 0 m kg 7 2 ft lb INSTALLING THE CAMSHAFT SPROCKET COVER AND ENGINE LEFT SIDE COVER 1 Install dowel pins 1 camshaft sprocket cover gasket 2 New ROCKER ARM...

Page 324: ...plug caps NOTE Refer to CABLE ROUTING in chapter 2 È Forward 1 Ignition coil 1 L spark plug lead 2 Ignition coil 1 R spark plug lead 3 Ignition coil 2 L spark plug lead 4 Ignition coil 2 R spark plug lead 5 Adjust installed shift rod length Refer to ADJUSTING THE SHIFT PEDAL in chapter 3 ROCKER ARMS PUSH RODS AND VALVE LIFTERS ...

Page 325: ... ty Remarks Removing the camshafts Remove the parts in the order listed Valve lifters Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 1 Decompression solenoid 1 2 Long decompression push rod 1 92 mm 3 6 in 3 Short decompression push rod 1 78 mm 3 1 in 4 Front cylinder camshaft end cover 1 Refer to REMOVING THE CAM SHAFTS and INSTALLING THE CAM SHAFTS 5 Camshaft drive gear 1 6 Straight key 1 CAMSH...

Page 326: ... Nm 5 2 m kg 37 ft Ib New M M Order Job Part Q ty Remarks 7 Camshaft driven gear 1 Refer to REMOVING THE CAM SHAFTS and INSTALLING THE CAM SHAFTS 8 Straight key 1 9 Oil delivery pipe 1 10 Camshaft cover 1 11 Camshaft cover gasket 1 12 Dowel pin 2 13 Front cylinder camshaft 1 14 Rear cylinder camshaft 1 For installation reverse the removal procedure ...

Page 327: ...er 2 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gears 3 Remove front cylinder camshaft end cover camshaft drive gear 1 camshaft driven gear 2 straight keys NOTE _ Cover the crankcase hole with a clean rag 3 to prevent the straight keys from falling into the crankcase 4 Remove oil deli...

Page 328: ...e the cam shaft 4 Measure camshaft journal diameter camshaft cover side b Out of specification Replace the cam shaft Camshaft lobe dimension limit Intake camshaft a 38 231 38 331 mm 1 5052 1 5091 in b 32 013 32 113 mm 1 2604 1 2643 in Exhaust camshaft a 38 232 38 332 mm 1 5052 1 5091 in b 31 995 32 095 mm 1 2596 1 2636 in Camshaft journal diameter crankcase side 24 937 24 950 mm 0 9818 0 9823 in C...

Page 329: ...learance Out of specification Replace the defec tive part s NOTE Calculate the clearance by subtracting the crankcase side camshaft journal diameter crankcase side from the crankcase hole inside diameter 8 Calculate camshaft to camshaft cover clearance Out of specification Replace the defec tive part s NOTE Calculate the clearance by subtracting the camshaft journal diameter camshaft cover side fr...

Page 330: ...e decompression system while the decompression push rod is installed in the camshaft Check that the decompression pin 1 projects from the camshaft Check that the decompression push rod 2 moves smoothly 2 Check decompression push rods Bends damage Replace CHECKING THE OIL DELIVERY PIPE 1 Check oil delivery pipe 1 Damage Replace Obstruction Wash and blow out with compressed air O rings 2 Damage wear...

Page 331: ...lfide oil onto the camshaft journals and lobes Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft 2 Install dowel pins 1 camshaft cover gasket 2 New 3 Install camshaft cover 1 along with the camshafts oil delivery pipe 2 NOTE _ Tighten the camshaft cover bolts in stages and in a crisscross pattern ...

Page 332: ...haft driven gear 2 NOTE _ Cover the crankcase hole with a clean rag 3 to prevent the straight keys from falling into the crankcase Align the punch mark a on the camshaft drive gear 1 with the punch mark b on the camshaft driven gear 2 Insert a cross headed screwdriver into one of the holes in the outer camshaft driven gear and rotate the gear until the teeth of both driven gears are aligned The te...

Page 333: ...e camshaft drive gear and camshaft driven gear T R 52 Nm 5 2 m kg 37 ft lb 7 Tighten camshaft drive gear bolt 1 front cylinder camshaft end cover bolts 2 NOTE _ Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them Do not damage the teeth of the camshaft drive and camshaft driven gear After tightening the camshaft drive gear bolt...

Page 334: ... 5 1 ft Ib Order Job Part Q ty Remarks Removing the cylinder heads Remove the parts in the order listed Throttle bodies intake manifolds Refer to THROTTLE BODIES in chap ter 6 Air cut off valve assembly Refer to AIR CUT OFF VALVE ASSEM BLY AND AIR INDUCTION SYSTEM HOSES in chapter 6 Rocker arms cylinder head covers Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS 1 Engine temperature sensor 1 Refe...

Page 335: ...T R 20 Nm 2 0 m kg 14 ft Ib New T R 20 Nm 2 0 m kg 14 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 5 Rear cylinder head 1 Refer to REMOV ING THE CYLIN DER HEADS Refer to INSTALL ING THE CYLIN DER HEAD 6 Front cylinder head 1 7 Cylinder head gasket 2 8 Dowel pin 4 9 Rear exhaust pipe joint cover 1 10 Rear exhaust pipe joint 1 For installation reverse the removal procedure ...

Page 336: ...use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace 3 Measure cylinder head warpage Out of specification Resurface the cylin der head a Place a straightedge and a thickness gauge across the cylinder head b Measure the warpage c If the limit is exceeded resurface the cylin der head as follows d Place a 400 600 gr...

Page 337: ...ads washers New 3 Tighten cylinder head nuts M12 1 4 cylinder head nuts M10 5 6 NOTE _ Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages T R 60 Nm 6 0 m kg 43 ft lb T R 39 Nm 3 9 m kg 28 ft lb 5 Install copper washers oil delivery pipe 1 oil delivery pipe bolts M10 oil delivery pipe bolts M8 New ...

Page 338: ...5 38 ENG CYLINDER HEADS 6 Install washer engine temperature sensor 1 T R 20 Nm 2 0 m kg 14 ft lb ...

Page 339: ...lve springs Remove the parts in the order listed The following procedure applies to both cylinders Cylinder head Refer to CYLINDER HEADS 1 Valve cotter 8 Refer to REMOVING THE VALVES and INSTALLING THE VALVES 2 Upper spring seat 4 3 Outer valve spring 4 4 Inner valve spring 4 5 Intake valve 2 6 Exhaust valve 2 7 Valve stem seal 4 8 Lower spring seat 4 For installation reverse the removal procedure...

Page 340: ...ly seal 1 Check valve sealing for leakage Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves properly seal NOTE _ There should be no leakage at the valve seat 1 2 Remove valve cotters NOTE _ Remove the valve cotters by compressing the valve springs with t...

Page 341: ...ce EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Valve stem to valve guide clearance Intake 0 010 0 037 mm 0 0004 0 0015 in Limit 0 08 mm 0 0031 in Exh...

Page 342: ...mover 1 c After installing the valve guide bore the valve guide with the valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE _ After replacing the valve guide reface the valve seat Valve guide remover ø6 YM 04064 A Valve guide installer ø6 YM 04065 A Valve guide reamer ø6 YM 04066 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valve face Pitti...

Page 343: ... Replace the valve NOTE _ When installing a new valve always replace the valve guide If the valve is removed or replaced always replace the oil seal Valve stem runout 0 01 mm 0 0004 in EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylin...

Page 344: ...ve 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 NOTE _ Where the valve seat and valve face contacted one another the blueing will have been removed Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in ...

Page 345: ...t are evenly polished then clean off all of the lapping compound NOTE _ For the best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps f After every lapping procedure be sure to clean off all of the lapping compound from the valve face and valve seat g Apply Mechanic s b...

Page 346: ...mit 36 26 mm 1 43 in 2 Measure compressed valve spring force a Out of specification Replace the valve spring b Installed length 3 Measure valve spring tilt a Out of specification Replace the valve spring Compressed valve spring force installed Intake and exhaust inner valve spring 6 3 7 3 kg at 29 0 mm 13 9 16 1 lb at 1 14 in Intake and exhaust outer valve spring 13 9 16 1 kg at 31 0 mm 30 6 35 5 ...

Page 347: ...m end with an oil stone 2 Lubricate valve stem 1 oil seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install lower spring seat 1 valve stem seal 2 valve 3 inner valve spring 4 outer valve spring 5 upper spring seat 6 into the cylinder head NOTE _ Install the valve springs with the larger pitch a facing up b Smaller pitch ...

Page 348: ...valve springs with the valve spring compressor set 1 5 To secure the valve cotters onto the valve stem lightly tap the valve tip with a soft face hammer CAUTION _ Hitting the valve tip with excessive force could damage the valve Valve spring compressor set YM 04019 6 Install cylinder head Refer to CYLINDER HEADS ...

Page 349: ... and pistons Remove the parts in the order listed Cylinder heads Refer to CYLINDER HEADS 1 Front cylinder 1 Refer to INSTALL ING THE PIS TONS AND CYLINDERS 2 Rear cylinder 1 3 Cylinder gasket 2 4 Dowel pin 4 Refer to REMOV ING THE CYLIN DERS AND PISTONS 5 Piston pin clip 4 6 Piston pin 2 7 Piston 2 8 Top ring 2 9 2nd ring 2 10 Oil ring 2 For installation reverse the removal procedure ...

Page 350: ...re vent the piston pin clip from falling into the crankcase For reference during installation put an iden tification mark on each piston crown Before removing the piston pin deburr the piston pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller 4 Piston pin puller YU 01304 2 Remove top ring ...

Page 351: ...ng side to side and front to back measurements of the cylinder Then find the average of the mea surements b If out of specification replace the cylinder and the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer a 5 mm 0 20 in from the bottom edge of the pis ton Cylinder bore gauge 50 100 mm YU 03017 Cylinder bore C 97 000 97 010 mm 3 8189 3 8193 in Taper limit ...

Page 352: ...ce Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 025 0 050 mm 0 001 0 002 in Limit 0 15 mm 0 006 in EAS00263 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a set NOTE _ Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston rings Pisto...

Page 353: ...iston rings Piston ring end gap Top ring 0 30 0 45 mm 0 012 0 018 in Limit 0 65 mm 0 026 in 2nd ring 0 30 0 45 mm 0 012 0 018 in Limit 0 80 mm 0 031 in Oil ring 0 2 0 7 mm 0 008 0 028 in EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication system 2 Measure pist...

Page 354: ...5 mm 0 8663 0 8667 in Limit 22 045 mm 0 8679 in Piston pin to piston clearance Piston pin bore diameter in the piston b Piston pin outside diameter a Piston pin to piston pin bore clearance 0 004 0 024 mm 0 00016 0 00094 in Limit 0 074 mm 0 0029 in EAS00268 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pistons and cylinders 1 Install top ring 2nd ring oil ring ...

Page 355: ... opening with a clean rag to pre vent the clip from falling into the crankcase 3 Install dowel pins 1 cylinder gasket 2 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil New 1 2 1 New New 5 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring È Forward 6 Install cylinder 1 NOTE _ While compressing the p...

Page 356: ...parts in the order listed Left side cover Refer to SEAT AND SIDE COVERS in chapter 3 Sub fuel tank Refer to SUB FUEL TANK Engine left side cover Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Clutch cable 1 Disconnect Refer to INSTALLING THE CLUTCH 2 Pull lever 1 3 Pull lever spring 1 4 Crankshaft position sensor lead 1 Disconnect ...

Page 357: ...t Ib T R 12 Nm 1 2 m kg 8 7 ft Ib New Order Job Part Q ty Remarks 5 Shift arm 1 Refer to INSTALL ING THE CLUTCH 6 Clutch cable holder 1 Refer to REMOV ING THE CLUTCH 7 Clutch cover 1 8 Clutch cover gasket 1 9 Dowel pin 1 For installation reverse the removal procedure ...

Page 358: ...crankshaft position sensor Remove the parts in the order listed Pull lever 1 Pull lever spring 1 1 Circlip 1 2 Pull lever shaft 1 3 Oil seal 2 4 Bearing 3 5 Crankshaft position sensor lead holder 3 Refer to INSTALLING THE CRANK SHAFT POSITION SENSOR AND PULL LEVER SHAFT 6 Crankshaft position sensor 1 For installation reverse the removal procedure ...

Page 359: ...the clutch Remove the parts in the order listed Generator cover Refer to GENERATOR AND STARTER CLUTCH 1 Clutch spring plate retainer 1 Refer to INSTALL ING THE CLUTCH 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Pull rod 1 6 Friction plate 2 6 Green painting 7 Clutch plate 7 8 Cushion spring 2 9 Friction plate 1 3 Black painting 10 Lock washer 1 Refer to REMOV ING THE ...

Page 360: ...arks 13 Clutch damper spring 1 Refer to REMOV ING THE CLUTCH Refer to INSTALL ING THE CLUTCH 14 Clutch damper spring seat 1 15 Clutch boss 1 16 Thrust washer 1 17 Clutch housing 1 18 Circlip 1 19 Oil pump drive gear 1 20 Dowel pin 1 21 Spacer 1 22 Crankshaft position sensor rotor 1 Refer to REMOV ING THE PRIMARY DRIVE GEAR 23 Primary drive gear 1 24 Straight key 1 For installation reverse the remo...

Page 361: ... lock washer tab 3 Loosen clutch boss nut 1 NOTE _ While holding the clutch boss 2 with the uni versal clutch holder 3 loosen the clutch boss nut Universal clutch holder YM 91042 4 Remove clutch boss nut 1 lock washer 2 clutch boss assembly 3 NOTE _ There is a built in damper between the clutch boss and the clutch plate It is not necessary to remove the wire circlip 4 and disassemble the built in ...

Page 362: ...LATES The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the friction plates as a set NOTE _ Measure the friction plate at four places Friction plate thickness 2 9 3 1 mm 0 114 0 122 in EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies...

Page 363: ...ring seat 2 Damage Replace EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE _ Pitting on the clutch housing dogs will cause erratic clutch operation 2 Check bearing Damage wear Replace the bearing and clutch housing EAS00285 CHECKING THE CLUTCH BOSS 1 Check clutch boss splines Damage pitting wear ...

Page 364: ...l lever shaft pinion gear as a set 2 Check pull rod bearing Damage wear Replace EAS00292 CHECKING THE PRIMARY DRIVE 1 Check primary drive gear 1 primary driven gear 2 Damage wear Replace the primary drive gear and clutch housing as a set Excessive noise during operation Replace the primary drive gear and clutch housing as a set INSTALLING THE CRANKSHAFT POSITION SENSOR AND PULL LEVER SHAFT 1 Apply...

Page 365: ...3 INSTALLING THE PRIMARY DRIVE GEAR 1 Install straight key 1 primary drive gear 2 crankshaft position sensor rotor 3 spacer 4 crankshaft position sensor rotor bolt 5 CAUTION The timing marks on the crankshaft posi tion sensor rotor must face outside NOTE _ While holding the generator rotor 6 with the primary sheave holder 7 tighten the crank shaft position sensor rotor bolt 2 Bend the lock washer ...

Page 366: ...ing bearings with engine oil 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 cor rectly 3 Install clutch boss assembly 1 NOTE _ If the wire circlip 2 has been removed care fully install a new one Install the clutch damper spring 3 with the OUTSIDE mark facing out ...

Page 367: ...R 80 Nm 8 0 m kg 58 ft lb 6 Lubricate friction plates clutch plates with the recommended lubricant Recommended lubricant Engine oil 7 Install friction plates clutch plates cushion springs NOTE _ First install a friction plate and then alternate between a clutch plate and a friction plate Apply molybdenum disulfide grease onto the bearing and pull rod teeth Align the two embossed mark a on the clut...

Page 368: ...er 3 NOTE _ Tighten the clutch spring plate retainer bolts in stages and in a crisscross pattern 1 2 3 T R 8 Nm 0 8 m kg 5 8 ft lb 10 Install dowel pins 1 clutch cover gasket 2 New 11 Install clutch cover 1 clutch cable holder 2 NOTE _ Tighten the clutch cover bolts in stages and in a crisscross pattern T R 10 Nm 1 0 m kg 7 2 ft lb 12 Connect crankshaft position sensor coupler NOTE _ Refer to CABL...

Page 369: ...lever spring pull lever NOTE _ If there is no free play in the clutch install the pull lever to the pull lever shaft in order to get the distance a between the pull lever and clutch cable holder to 31 3 mm 1 23 in T R 12 Nm 1 2 m kg 8 7 ft lb 15 Connect clutch cable 1 16 Adjust clutch cable free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY in chapter 3 ...

Page 370: ... ty Remarks Removing the shift shaft and stopper lever Remove the parts in the order listed Engine oil Drain Clutch housing Refer to CLUTCH 1 Shift shaft 1 Refer to INSTALLING THE STOPPER LEVER AND SHIFT SHAFT 2 Circlip 2 3 Shift shaft spring 1 4 Shift shaft spring stopper 1 5 Washer 1 6 Stopper lever 1 7 Stopper lever spring 1 For installation reverse the removal procedure ...

Page 371: ...HE STOPPER LEVER AND SHIFT SHAFT 1 Install stopper lever 1 stopper lever spring 2 NOTE _ Apply locking agent LOCTITE to the threads of stopper lever bolt Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss 3 Mesh the stopper lever with the shift drum segment assembly T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install washer shift shaft spring stopper 1 NOTE _ Apply locking ...

Page 372: ...5 72 ENG SHIFT SHAFT AND STOPPER LEVER 3 Install shift shaft spring circlips shift shaft 1 NOTE _ Install the end of the shift shaft spring onto the shift shaft spring stopper 2 ...

Page 373: ...35 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks Removing the stator coil assembly Remove the parts in the order listed Muffler exhaust pipes Refer to ENGINE Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Plastic locking tie 3 2 Plastic band 2 3 Rear brake light switch coupler 1 Disconnect 4 Horn 1 connectors 2 5 Rider footrest assembly right 1 6 Stator coil assem...

Page 374: ...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 48 Nm 4 8 m kg 35 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 8 Generator cover 1 9 Generator cover gasket 1 10 Dowel pin 2 11 Stator coil assembly lead holder 1 12 Stator coil assembly 1 For installation reverse the removal procedure ...

Page 375: ...moving the generator rotor Remove the parts in the order listed 1 Starter clutch idle gear shaft 2 1 2 Starter clutch idle gear shaft 1 1 3 Starter clutch idle gear 2 1 4 Starter clutch idle gear 1 1 5 Generator rotor 1 6 Woodruff key 1 7 Starter clutch gear 1 For installation reverse the removal procedure ...

Page 376: ...them 2 Remove generator rotor bolt 1 washer NOTE _ While holding the generator rotor 2 with the primary sheave holder 3 loosen the genera tor rotor bolt Primary sheave holder YS 01880 A 3 Remove generator rotor 1 with the alternator rotor puller 2 Alternator rotor puller YM 01080 A EAS00348 CHECKING THE STARTER CLUTCH 1 Check starter clutch idle gears 1 starter clutch gear 2 Burrs chips roughness ...

Page 377: ...d turn freely other wise the starter clutch is faulty and must be replaced EAS00354 INSTALLING THE GENERATOR 1 Install starter clutch gear 1 woodruff key generator rotor 2 washer generator rotor bolt 3 NOTE _ Clean the tapered portion of the crankshaft and the generator rotor hub When installing the generator rotor make sure the woodruff key is properly seated in the keyway of the crankshaft 2 Tig...

Page 378: ...all stator coil assembly 1 stator coil assembly lead holder NOTE _ Apply locking agent LOCTITE to the threads of the stator coil assembly bolts T R 7 Nm 0 7 m kg 5 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Connect stator coil assembly coupler horn 1 connectors rear brake light switch coupler 1 NOTE _ Refer to CABLE ROUTING in chapter 2 ...

Page 379: ... m kg 13 ft Ib T R 100 Nm 10 0 m kg 72 ft lb T R 30 Nm 3 0 m kg 22 ft Ib Order Job Part Q ty Remarks Removing the transfer gear case cover Remove the parts in the order listed Muffler exhaust pipes Refer to ENGINE Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL in chapter 3 Drive sprocket Refer to DRIVE BELT AND DRIVE S...

Page 380: ...m kg 17 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 100 Nm 10 0 m kg 72 ft lb T R 30 Nm 3 0 m kg 22 ft Ib Order Job Part Q ty Remarks 4 Dowel pin 4 5 Transfer gear oil pump 1 6 Transfer gear oil pump gasket 1 7 Transfer gear case cover 1 8 Transfer gear case cover gasket 1 9 Oil strainer 1 10 Lock washer 1 11 Primary chain 1 12 Middle drive gear 1 13 Middle driven shaft 1 For installation reverse the re...

Page 381: ...s Disassembling the transfer gear case oil pump Remove the parts in the order listed 1 Oil pump cover 1 2 Pin 2 3 Pin 1 4 Oil pump shaft 1 5 Oil pump inner rotor 1 6 Oil pump outer rotor 1 7 Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 382: ...cover Refer to SEAT AND SIDE COVERS in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 1 Throttle stop screw bracket 1 2 Fuel hose joint bracket 1 3 Fuel hose joint 1 4 Fuel hose 2 5 Fuel inlet hose 1 6 Hose holder 1 7 Fuel outlet hose 1 8 Fuel pump coupler 1 Disconnect 9 Fuel pump cover 1 10 Fuel pump 1 For installation reverse the removal procedure TRANSFER GEAR CASE ...

Page 383: ...fuel sender INSTALL THE FUEL PUMP 1 Install fuel pump NOTE Do not damage the installation surfaces of the fuel tank when installing the fuel pump Always use a new fuel pump gasket Install the fuel pump as shown in the illustra tion Tighten the fuel pump bolts in the proper tightening sequence as shown T R 5 Nm 0 5 m kg 3 6 ft lb TRANSFER GEAR CASE ...

Page 384: ...the order listed Fuel pump Refer to FUEL PUMP Battery Refer to BATTERY in chapter 3 1 Battery negative lead 1 2 Starter motor lead 1 3 Battery positive lead 1 Disconnect 4 Starter relay coupler 1 Disconnect 5 Relay assembly 1 6 Plastic locking tie 1 7 Battery box 1 8 Sub fuel tank bracket 1 9 Sub fuel tank 1 For installation reverse the removal procedure TRANSFER GEAR CASE ...

Page 385: ...rder Job Part Q ty Remarks Removing the transfer gear case Remove the parts in the order listed Seat right side cover Refer to SEAT AND SIDE COVERS in chapter 3 1 Oil tank breather hose 1 2 Oil temperature sensor coupler 1 Disconnect 3 Oil tank cover 1 4 Dipstick 1 5 Dipstick joint 1 6 Drive sprocket case 1 7 Dowel pin 2 8 Spacer 1 ...

Page 386: ... 4 11 11 2 1 12 9 8 7 6 5 T R 30 Nm 3 0 m kg 22 ft Ib T R 50 Nm 5 0 m kg 36 ft Ib New Order Job Part Q ty Remarks 9 Oil seal 1 10 Transfer gear case 1 11 Dowel pin 2 12 Bearing 2 13 Bearing housing 1 For installation reverse the removal procedure ...

Page 387: ...w Order Job Part Q ty Remarks Disassembling the oil tank Remove the parts in the order listed 1 Oil temperature sensor 1 2 Oil tank left cover 1 3 Oil tank left cover gasket 1 4 Dowel pin 2 5 Oil strainer 1 6 Oil tank right cover 1 7 Oil tank right cover gasket 1 8 Dowel pin 2 9 Oil pipe 1 0 Oil tank 1 For assembly reverse the disassembly procedure ...

Page 388: ...l so the middle drive gear does not move 3 Remove primary chain 1 middle drive gear 2 middle driven shaft 3 NOTE Remove the primary chain middle drive gear and middle driven shaft at the same time CHECKING THE MIDDLE DRIVE 1 Check middle drive gear 1 middle driven gear 2 Damage wear Replace the middle drive gear middle driven shaft and primary chain as a set 2 Check primary chain 1 Damage stiffnes...

Page 389: ... defec tive part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing clearance b Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 07 0 12 mm 0 0028 0 0047 in Outer rotor to oil pump housing clearance 0 03 0 08 mm 0 0012 0 0031 in 3 Check oil pump operation Unsmooth Repair or replac...

Page 390: ...l oil pump housing 1 oil pump outer rotor 2 oil pump inner rotor 3 oil pump shaft 4 pin 5 NOTE _ When installing the oil pump shaft align the pin in the oil pump shaft with the groove in the oil pump inner rotor Align the arrow a on the pump outer rotor with the arrow b on the oil pump inner rotor 3 Install pins 1 oil pump cover 2 NOTE _ Apply locking agent LOCTITE to the threads of the oil pump c...

Page 391: ...ut 4 NOTE _ Install the middle driven shaft middle drive gear and primary chain at the same time Align the splines on the middle gear with the splines on the drive axle Temporarily install the drive sprocket nut onto the middle driven shaft 2 3 1 2 Install oil strainer 1 dowel pins 2 transfer gear case cover gasket 3 2 New 2 3 1 New 3 Install transfer gear case cover 1 nut 2 T R 10 Nm 1 0 m kg 7 2...

Page 392: ...ab along a flat side of the nut New T R 100 Nm 10 0 m kg 72 ft lb 6 Remove drive sprocket nut 7 Install transfer gear oil pump gasket transfer gear oil pump 1 NOTE _ Apply locking agent LOCTITE only to the threads of the transfer gear oil pump bolts M6 25 mm bolts 2 New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 393: ...the order listed Engine Refer to ENGINE Camshafts Refer to CAMSHAFTS Pistons Refer to CYLINDERS AND PISTONS Shift shaft Refer to SHIFT SHAFT AND STOPPER LEVER Generator rotor Refer to GENERATOR AND STARTER CLUTCH 1 Generator shaft end cover 1 2 Oil delivery pipe 1 3 Engine oil pump driven gear stopper 1 ...

Page 394: ...5 94 ENG CRANKCASE Order Job Part Q ty Remarks 4 Engine oil pump driven gear 1 5 Left crankcase 1 6 Dowel 2 7 Joint pipe 1 8 Right crankcase 1 For installation reverse the removal procedure ...

Page 395: ...emoving the baffle plate and bearings Remove the parts in the order listed Crankshaft Refer to CRANKSHAFT AND CON NECTING RODS Transmission Refer to TRANSMISSION 1 Baffle plate 1 2 Oil seal 1 3 Bearing 4 For installation reverse the removal procedure ...

Page 396: ...Remove crankcase bolts holder NOTE _ Loosen each bolt 1 4 of a turn at a time in stages and in a crisscross pattern After all of the bolts are fully loosened remove them Loosen the bolts in decreasing numerical order refer to the numbers in the illustra tion The numbers embossed on the crankcase indicate the crankcase tightening sequence È Right crankcase É Left crankcase M8 100 mm bolts 1 2 M8 80...

Page 397: ...hen remove the right crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinforced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure the crank case halves separate evenly EAS00399 CHECKING THE CRANKCASE 1 Thoroughly wash the crankcase halves in a mild solvent 2 Thoroughly clean all the gasket surfaces and crankcase ma...

Page 398: ...Rough movement Replace 2 Check oil seals Damage wear Replace CHECKING THE OIL DELIVERY PIPE 1 Check oil delivery pipe 1 Damage Replace Obstruction Wash and blow out with compressed air O rings 2 Damage wear Replace CHECKING THE ENGINE OIL PUMP DRIVE 1 Check oil pump drive gear 1 oil pump driven gear 2 Chips pitting roughness wear Replace the defective part s ...

Page 399: ...gallery 2 Install dowel pins 1 joint pipe 2 Quick Gasket ACC 11001 05 01 3 Install left crankcase onto the right crankcase NOTE _ Turn the shift drum segment 1 to the posi tion shown in the illustration In this position the shift drum segment s teeth will not con tact the crankcase during crankcase installa tion Tap lightly on the left crankcase with a soft face hammer ...

Page 400: ...m bolt 3 M6 105 mm bolt K M6 85 mm bolts 9 C M6 75 mm bolts D E M6 60 mm bolts 4 7 M6 40 mm bolts 8 0 B F J 5 Apply engine oil onto the crankshaft pins bearings and oil delivery holes 6 Check crankshaft and transmission operation Rough movement Repair T R Bolt 1 3 24 Nm 2 4 m kg 17 ft lb Bolt 4 K 10 Nm 1 0 m kg 7 2 ft lb È É 7 Install engine oil pump driven gear 1 engine oil pump driven gear stopp...

Page 401: ...ft bolt 1 NOTE _ Apply locking agent LOCTITE to the threads of the generator shaft bolt While holding the generator rotor 2 with the primary sheave holder 3 tighten the gener ator shaft bolt Primary sheave holder YS 01880 A T R 28 Nm 2 8 m kg 20 ft lb ...

Page 402: ...GINE OIL PUMP Order Job Part Q ty Remarks Removing the engine oil pump Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Oil strainer 1 2 Engine oil pump assembly 1 For installation reverse the removal procedure ...

Page 403: ...rks Disassembling the engine oil pump Remove the parts in the order listed 1 Spring retainer 1 2 Spring 1 3 Relief valve 1 4 Oil pump housing cover 1 1 5 Pin 2 6 Spring 1 7 Collar 1 8 Ball 1 9 Oil pump outer rotor 1 1 0 Oil pump inner rotor 1 1 A Pin 1 ...

Page 404: ... Order Job Part Q ty Remarks B Oil pump housing cover 2 1 C Pin 2 D Oil pump shaft 1 E Pin 1 F Oil pump inner rotor 2 1 G Oil pump outer rotor 2 1 H Oil seal 2 I Oil pump housing 1 For assembly reverse the disassembly procedure ...

Page 405: ... Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer rotor tip clearance 0 0 12 mm 0 0 0047 in Outer rotor to oil pump housing clearance feed pump 0 03 0 08 mm 0 0012 0 0031 in Outer rotor to oil pump housing clearance scavenging pump 0 06 0 11 mm 0 0024 0 0043 in 3 Check oil pump operation Rough movement Repeat steps 1 and 2 or replace the defective part s EAS00365 CHECKING THE RELI...

Page 406: ... Replace the defective part s EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with solvent EAS00375 ASSEMBLING THE OIL PUMP 1 Lubricate inner rotor outer rotor oil pump shaft with the recommended lubricant Recommended lubricant Engine oil ...

Page 407: ... housing cover 1 F relief valve G spring H spring retainer I NOTE _ When installing the inner rotor align the pin in the oil pump shaft with the groove in the inner rotor T R 2 Nm 0 2 m kg 1 4 ft lb T R 2 Nm 0 2 m kg 1 4 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb 3 Check oil pump operation Refer to CHECKING THE OIL PUMP EAS00376 INSTALLING THE OIL PUMP 1 Install oil pump 1 CAUTION _ After tightening the b...

Page 408: ...108 ENG ENGINE OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 NOTE _ The arrow mark on the oil strainer cover must point towards the rear of the engine T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 409: ...rks Removing the crankshaft and connecting rods Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Crankshaft 1 2 Generator shaft 1 3 Connecting rod cap 2 4 Big end lower bearing 2 5 Connecting rod 2 6 Big end upper bearing 2 For installation reverse the removal procedure ...

Page 410: ...aring driver YM 04058 EAS00391 REMOVING THE CONNECTING RODS The following procedure applies to all of the connecting rods 1 Remove connecting rod caps 1 connecting rod big end bearings NOTE _ Identify the position of each big end bearing so that it can be reinstalled in its original place EAS00398 CHECKING THE CRANKSHAFT AND CONNECTING RODS 1 Measure crankshaft runout Out of specification Replace ...

Page 411: ...and connecting rods To obtain the correct crankshaft pin to big end bearing clear ance and prevent engine damage the big end bearings must be installed in their orig inal positions a Clean the big end bearings crankshaft pins and the inside of the connecting rod halves b Install the big end upper bearing into the connecting rod and the big end lower bear ing into the connecting rod cap NOTE _ Alig...

Page 412: ...nnecting rod bolts WARNING Replace the connecting rod bolts with new ones Clean the connecting rod bolts NOTE The tightening procedure of the connecting rod bolts is angle controlled therefore tighten the bolts using the following procedure f Tighten the connecting rod bolts to the specified torque g Tighten the connecting rod bolts further to reach the specified angle 90 120 WARNING When the bolt...

Page 413: ...gonal bolt note that the angle from one corner to another is 60 h Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECTING RODS i Measure the compressed Plastigauge width e on each crankshaft pin If the crankshaft pin to big end bearing clearance is out of specification select replacement big end bearings CRANKSHAFT AND CONNECTING RODS ...

Page 414: ... are used to determine the replacement big end bearing sizes P1 P2 refer to the bearings shown in the crankshaft illustration For example if the connecting rod P1 and the crankshaft web P numbers are 5 and 2 respectively then the bearing size for P1 is P1 connecting rod P crankshaft 5 2 3 brown BIG END BEARING COLOR CODE 1 blue 2 black 3 brown 4 green 5 yellow P1 P2 ...

Page 415: ...rankshaft jour nal at two places Crankshaft journal diameter 49 968 49 980 mm 1 9672 1 9677 in 6 Measure crankshaft journal bearing inside diameter a Out of specification Replace the crank case assembly NOTE Measure the inside diameter of each crank shaft journal bearing at two places Crankshaft journal bearing inside diameter 50 010 50 028 mm 1 9689 1 9696 in ...

Page 416: ...kshaft journal diameter from the crank shaft journal bearing inside diameter Crankshaft journal to crankshaft journal bearing clearance 0 030 0 060 mm 0 0012 0 0024 in EAS00403 INSTALLING THE CONNECTING RODS 1 Lubricate bolt threads with the recommended lubricant Recommended lubricant Molybdenum disulfide grease 2 Lubricate crankshaft pins big end bearings connecting rod inner surface with the rec...

Page 417: ... crankshaft Make sure the characters d on both the con necting rod and connecting rod cap are aligned 4 Tighten connecting rod bolts 1 WARNING Replace the connecting rod bolts with new ones Clean the connecting rod bolts NOTE The tightening procedure of the connecting rod bolts is angle controlled therefore tighten the bolts using the following procedure a Tighten the connecting rod bolts to the s...

Page 418: ...nal bolt note that the angle from one corner to another is 60 EAS00408 INSTALLING THE CRANKSHAFT 1 Install generator shaft 1 2 Install crankshaft assembly CAUTION _ To avoid scratching the crankshaft and to ease the installation procedure lubricate the oil seal lips with lithium soap based grease and each bearing with engine oil NOTE _ Make sure that the generator shaft drive gear teeth and genera...

Page 419: ...rum assembly and shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Shift fork guide bar 2 2 Shift fork L 1 3 Shift fork R 1 4 Shift fork C 1 5 Shift drum assembly 1 6 Drive axle assembly 1 7 Main axle assembly 1 8 Spacer 1 For installation reverse the removal procedure ...

Page 420: ...sassembling the main axle assembly Remove the parts in the order listed 1 Circlip 1 2 Washer 1 3 5th pinion gear 1 4 2nd 3rd pinon gear 1 5 Circlip 1 6 Washer 1 7 4th pinon gear 1 8 Main axle 1st pinon gear 1 For assembly reverse the disassembly procedure ...

Page 421: ...axle assembly Remove the parts in the order listed 1 5th wheel gear 1 2 Circlip 1 3 Washer 1 4 2nd wheel gear 1 5 Circlip 1 6 Washer 1 7 1st wheel gear 1 8 4th wheel gear 1 9 Circlip 1 0 Washer 1 A 3rd wheel gear 1 B Drive axle 1 For assembly reverse the disassembly procedure ...

Page 422: ...ft fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WARNING _ Do not attempt to straighten a bent shift fork guide bar 3 Check shift fork movement along the shift fork guide bar Rough movement Replace the shift forks and shift fork guide bar as a set ...

Page 423: ...KING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle 2 Measure drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Main axle runout limit 0 08 mm 0 003 in Drive axle runout limit 0 08 mm 0 003 in 3 Check transmission gears Blue discoloration pitting wear Replace the de...

Page 424: ...s 6 Check circlips Bends damage looseness Replace EAS00428 INSTALLING THE TRANSMISSION 1 Install main axle assembly 1 drive axle assembly 2 O ring spacer EAS00426 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY 1 Install shift fork R shift fork C shift fork L shift drum assembly 1 shift fork guide bars NOTE _ The embossed marks on the shift forks should face towards the right side of the engine...

Page 425: ...5 125 ENG TRANSMISSION 2 Check transmission Rough movement Repair NOTE _ Oil each gear shaft and bearing thoroughly ...

Page 426: ...1 5 Engine temperature sensor 6 Atmospheric pressure sensor 7 Throttle position sensor 8 Spark plug 9 Relay unit 0 ECU A Battery B Fuel pump C Lean angle cut off switch D Oil temperature sensor E Decompression solenoid F Crankshaft position sensor G Cylinder identification sensor H Ignition coil 3 2 1 H G 8 F E D C B A 0 9 8 7 5 4 6 FUEL INJECTION SYSTEM 1 2 3 4 5 6 ...

Page 427: ...GREEN GREEN B B Lg Lg Dg Dg Br Br Y Y Ch Ch RED BLUE P R Br Y O Gy L R B L G R Gy Gy Br G R L R Br Y B L P R Y O G R L R G G G Gy Gy Gy W W W W W R B R B R G P L W G Br L R R G R B B B R R R R R B B R W R B R W R R L B Br W Y R Br W B B ON OFF R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br BLACK R W B L W R B G Y Br BLACK L Y B Y B Y Ch Dg G Y BLUE L Y Ch...

Page 428: ...sure sensor 1 H Intake air pressure sensor 2 I Atmospheric pressure sensor J Cylinder identification sensor K Lean angle cut off switch L Speed sensor M Intake air temperature sensor N Engine temperature sensor O Oil temperature sensor P ECU Q Linear control valve U Cylinder 1 injector V Cylinder 2 injector u Engine stop switch Ignition fuse ECU fuse å Fuel injection system fuse ...

Page 429: ...e fuel injection stop function is active the warning light blinks while the start switch is being pressed to start the engine If a malfunction in the system is detected by the self diagnostic function this mode provides an appropriate substitute characteristic operation and alerts the rider of the detected malfunction by illuminating a warning light After the engine has been stopped digital number...

Page 430: ...The warning light illuminates 1 4 seconds each time the main switch is turned ON The ECU performs a self diagnosis during this time and turns OFF the light thereafter 2 Warning control when unable to start engine This control is effected when any one of the conditions listed below is present and the starter switch is turned ON a Battery voltage below the specified value defective Fuel injection sy...

Page 431: ...determined by observing the self diagnostic fault code number that appears on the tachometer and cross referenc ing it on the fault code number table When used in conjunction with the troubleshooting details and by checking the possible items one by one you will be able to identify the cause of the problem in order to carry out an accurate repair work Warning of the occurrence of a malfunction app...

Page 432: ...sure sensor pipe system 1 a hose is detached causing the constant application of atmospheric pres sure to the sensor or the hose is clogged Able Able 29 Decompression thermostat open or short circuit detected Able Able 15 Throttle position sensor open or short circuit detected Able Able 30 The motorcycle has overturned Unable Unable 16 A stuck throttle position sensor is detected Able Able 37 Line...

Page 433: ...nkshaft position sen sor Stops the engine by stopping the injection and ignition Unable Unable 13 14 25 26 Intake air pressure sensor open or short circuit pipe system Fixes the intake air pressure to 760 mmHg Able Able 15 16 Throttle position sensor open or short circuit stuck Fixes the throttle position sensor to fully open Able Able 19 Sidestand switch open circuit in wire to ECU No start Unabl...

Page 434: ...c fault code number that is displayed on the meter Based on the self diagnostic fault code number select the applicable sensor or actuator from the diagnostic code table If a diagnostic code is available proceed with the operation procedure given below in order to verify the operating conditions of the applicable sensor or actuator Operation procedure make sure to turn OFF the main switch upon com...

Page 435: ...c code number appears on clock LCD 01 70 4 Verifying the operation of the displayed diagnostic code Verifying various sensors The data representing the operating con ditions of the sensors appears on the trip LCD throttle position sensor angle cool ant temperature atmospheric pressure etc Verifying the operation of actuators Start the operation by turning the stop switch ON injectors relay ignitio...

Page 436: ...n reinstating the ECU Verify the reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera tion that is applicable to the malfunctioning item Refer to troubleshooting details Erase the fault code from memory Perform the operation for diagnostic code 62 ...

Page 437: ...ring sub lead Open or short circuit in wiring harness Defective sensor stuck throttle position sensor 01 15 Throttle position sensor open or short circuit detected Open or short circuit in wiring sub lead Open or short circuit in wiring harness Defective throttle position sensor Malfunction in ECU Improperly installed throttle position sensor 01 16 A stuck throttle position sensor is detected Or F...

Page 438: ...in wiring harness Defective engine temperature sensor Malfunction in ECU Improperly installed sensor 11 29 Decompression solenoid thermistor open or short circuit detected Open or short circuit in wiring harness Defective decompression solenoid thermistor Malfunction in ECU Improperly installed sensor 55 30 The motorcycle has overturned Overturned Malfunction in ECU 08 37 A faulty linear control v...

Page 439: ... speed pulse Displays the accumulation of the vehicle pulses that are gen erated when the tire is spun 0 999 resets to 0 after 999 OK if the numbers appear on the meter 08 Lean angle cut off switch Displays the lean angle cut off switch values Upright 0 4 1 4 V Overturned 3 8 4 2 V 09 Fuel system voltage monitor voltage Displays the fuel system voltage battery voltage Engine stop switch is on 0 18...

Page 440: ...des in the past his tory Erases only the history codes when the engine stop switch is turned from OFF to ON If the engine stop switch is ON turn it OFF once and then turn it back ON 00 21 00 Displays when there is no malfunction 70 Control number Displays the program control number 00 255 Diag code Item Description of action Data displayed on meter reference value ...

Page 441: ...rom OFF to ON it actuates the fuel injection system relay five times every second and illuminates the engine trouble warning light the light is OFF when the relay is ON and the light is ON when the relay is OFF If the engine stop switch is ON turn it OFF once and then turn it back ON Check the fuel injection system relay operating sound Same as above 52 Headlight relay After 1 second has elapsed f...

Page 442: ...ction described for diagnostic code 62 in Sensor operation data display verification table to delete the malfunction history The engine trouble warning light does not come on Checking the sensor and actuators Check the action of the following sensor and actuators according to the Description of action column Refer to Sensor operation data display verification table and Actua tor operation verifica...

Page 443: ...it securely Cylinder identification sensor coupler Main wiring harness ECU coupler Sub wire harness coupler 5 Installed state of sensor Check the installed area for looseness or pinching Code No 12 Symptom No normal signals are received from the crankshaft position sensor Used diagnostic code No Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 I...

Page 444: ...cuit Main wiring harness Black Blue Black Blue Pink White Pink White Blue Blue Sub lead Black Blue Black Blue Pink White Pink White Blue Blue Reinstated by turn ing the main switch ON 2 Connected state of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Intake air pressure sens...

Page 445: ...or replace the sensor hose Inspect and repair the connection Replace it if there is a malfunction See page 6 25 Reinstated by starting the engine and operating it at idle 2 2 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Pink White Pink White Blue Blue Sub lead Black Blue Black Blue Pink White Pi...

Page 446: ...Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Throttle position sensor coupler Main wiring harness ECU coupler 3 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black Blue Yellow Yellow Blue Blue 4 ...

Page 447: ...ooseness or pinching Check that it is installed in the specified position Refer to FUEL INJECTION SYSTEM in chapter 7 3 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Yellow Yellow Blue Blue Sub lead Black Blue Black Blue Yellow Yellow Blue Blue 4 Throttle position sensor lead wire open cir cuit o...

Page 448: ...pler illustration Indicate No 43 pin 3 Defective sidestand switch Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 7 Code No 22 Symptom Open or short circuit detected from the intake temperature sensor Used diagnostic code No 05 intake temperature sensor Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed state of sensor Che...

Page 449: ...ess ECU coupler 4 Defective atmospheric pressure sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 7 Code No 25 Symptom Intake air pressure sensor 2 open or short circuit detected Used diagnostic code No 03 intake air pressure sensor 2 Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Open or short circuit in wiring harness or...

Page 450: ...or replace the sensor hose Inspect and repair the connection Replace it if there is a malfunction See page 6 25 Reinstated by starting the engine and operating it at idle 2 2 Open or short circuit in wiring harness or sub lead Repair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue Pink White Pink White Blue Blue Sub lead Black Blue Black Blue Pink White Pi...

Page 451: ...ss ECU coupler 4 Defective oil temperature sensor Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 7 Code No 28 Symptom Open or short circuit is detected from the engine temperature sensor Used diagnostic code No 11 engine temperature sensor Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Installed state of sensor Check the instal...

Page 452: ...coupler 4 Malfunction in decompression solenoid Check the operating sound or that the warn ing light is on 5 times with engine stop switch ON and start switch ON Malfunction in thermistor Replace if defective Refer to ELECTRIC STARTING SYSTEM in chapter 7 Check the resistance value Refer to ELECTRIC STARTING SYSTEM in chapter 7 Code No 30 Symptom The motorcycle has overturned Used diagnostic code ...

Page 453: ...epair or replace if there is an open or short circuit Main wiring harness Black Blue Black Blue White White Reinstated by turn ing the main switch ON 2 2 Connected state of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Main wiring harness oil temperature sensor coupler Main ...

Page 454: ...ed state of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Speed sensor coupler Main wiring harness ECU coupler Reinstated by starting the engine and inputting the vehicle speed sig nals by operating the motorcycle at a low speed of 20 to 30 km h 1 2 Open or short circuit in ...

Page 455: ...on or open circuit in fuel injection system relay Replace if defective Refer to FUEL INJECTION SYSTEM in chapter 7 If there is no malfunction with the fuel injection system relay replace the ECU 4 Connected state of connector Inspect the coupler for any pins that may have pulled out Check the locking condition of the coupler If there is a malfunction repair it and connect it securely Fuel injectio...

Page 456: ...the diagnosis mode Using the results of the diagnosis mode inspection as reference estimate the cause of the mal function and carry out the inspection and repair of the affected area Symptom The engine trouble warning light does not illuminate when the start switch is pressed Probable mal function area Open or short circuit in start switch Open or short circuit in wiring harness Open circuit in wa...

Page 457: ...ION SYSTEM in chapter 7 Open or short circuit in wiring harness Cylinder 1 injector Gray Gray White White Cylinder 2 injector Green Green White White Symptom The ignition system fails to operate no spark or intermittent spark Probable mal function area Open or short circuit in ignition coil Open or short circuit in wiring harness Inspection method 1 Inspection by diagnosis mode Inspection method 2...

Page 458: ...e replace Inspect the wiring harness and the couplers for continuity Defective repair or replace Replace The relay operates but the headlight does not illuminate Inspect the headlight bulb Blown bulb replace Check the headlight relay contact point for continuity Refer to LIGHTING SYSTEM in chapter 7 Defective replace Check the handlebar switch Defective repair or replace Inspect the wiring harness...

Page 459: ...hod 1 Inspection by diagnosis mode Inspection method 2 Inspection of a malfunction that cannot be identified in the diagnosis mode and in case the area of the malfunction has been narrowed down in the inspection method 1 given on the left Inspect ECU coupler Inspect the wiring harness and couplers for continuity Defective repair or replace Inspect meter coupler Inspect the wiring harness and coupl...

Page 460: ... meter to display the ON OFF status of the sidestand switch in gear and sidestand is up ON is displayed in gear and sidestand is down OFF is displayed To distinguish whether the problem is in the switch or in other areas Execute diagnostic code 20 Enable the meter to display the ON OFF status of the neutral switch in neutral ON is dis played in gear OFF is displayed To distinguish whether the prob...

Page 461: ...e malfunction has been narrowed down in the inspection method 1 Execute diagnostic code 50 To trip the relay unit Execute diagnostic code 09 To check the monitor voltage To distinguish whether the problem is in the relay or in other areas Relay unit does not trip Inspect the coil side of the relay unit Refer to FUEL INJECTION SYSTEM in chapter 7 Defective replace Inspect the wiring harness and cou...

Page 462: ...at Refer to SEAT AND SIDE COVERS in chapter 3 Fuel tank Air induction system cover air duct Refer to FUEL TANK in chapter 3 Air filter case Refer to AIR FILTER CASE in chapter 3 Silencer air filter case Refer to SILENCER AIR FILTER CASE in chapter 3 1 Throttle position sensor coupler 1 Disconnect 2 A I S vacuum hose 1 Disconnect 3 Intake vacuum hose 4 Disconnect 4 Intake vacuum hose bracket 1 ...

Page 463: ... m kg 7 2 ft Ib Order Job Part Q ty Remarks 5 Throttle stop screw 1 6 Throttle body joint screw 2 7 Throttle bodies 1 8 Throttle cable 2 Disconnect 9 Throttle position sensor 1 Refer to FUEL INJECTION SYSTEM in chapter 7 For installation reverse the removal procedure ...

Page 464: ...Removing the intake manifolds Remove the parts in the order listed 1 Engine temperature sensor coupler 1 Disconnect 2 Injection sub wire harness coupler 1 Disconnect 3 Fuel hose 2 Disconnect 4 Linear control valve outlet hose 2 Disconnect 5 Intake manifolds 1 6 Gasket 2 For installation reverse the removal procedure ...

Page 465: ... Q ty Remarks Removing the injectors Remove the parts in the order listed 1 Cylinder 1 injector coupler 1 Disconnect 2 Cylinder 2 injector coupler 1 Disconnect 3 Injector sub wire harness 1 4 Fuel pipe 1 5 Injector joint 1 1 6 Injector joint 2 1 7 Injector 2 For installation reverse the removal procedure ...

Page 466: ...TOR 1 Check injector Damage Replace CHECKING THE THROTTLE BODY 1 Check throttle body Cracks damage Replace the throttle bodies 2 Check fuel passages Obstruction Clean a Wash the throttle body in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of passages with compressed air ...

Page 467: ...e gauge 7 f Connect the fuel pressure adapter between the fuel hose 2 and fuel injection pipe 3 g Start the engine h Measure the fuel pressure i Use the vacuum pressure pump gauge set to adjust the fuel pressure in relation to the vacuum pressure as described below NOTE The vacuum pressure should not exceed 100 kPa 1 mmHg Faulty Replace the pressure regulator Mity vac YB 35956 Pressure gauge YU 03...

Page 468: ...ssure through the piston valve dia phragm Normally the air cut off valve is open to allow fresh air to flow into the exhaust port During sudden deceleration the throttle valve suddenly closes negative pressure is gener ated and the air cut off valve is closed in order to prevent after burning Additionally at high engine speeds and when the pressure decreases the air cut off valve automatically clo...

Page 469: ...g the air cut off valve assembly and hoses Remove the parts in the order listed Fuel hose joint 1 air duct Refer to FUEL TANK in chapter 3 1 Fuel hose joint 1 Disconnect 2 Fuel hose 2 3 A I S vacuum hose 1 4 Resonator hose 1 5 Reed valve case to front cylinder head hose 1 6 Reed valve case to rear cylinder head hose 1 7 Air cut off valve assembly 1 For installation reverse the removal procedure ...

Page 470: ...ob Part Q ty Remarks Removing the reed valves Remove the parts in the order listed Air cut off valve assembly hoses 1 A I S vacuum hose 1 2 Reed valve cover 1 3 Reed valve assembly 1 4 Reed valve case 1 5 Pressure regulator 1 6 A I S bracket 1 For installation reverse the removal procedure ...

Page 471: ...mage Replace EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1 Check hoses Loose connection Connect properly Cracks damage Replace pipes Cracks damage Replace 2 Check fiber reed fiber reed stopper reed valve seat Cracks damage Replace the reed valve 3 Check air cut off valve Cracks damage Replace ...

Page 472: ...ake light switch 5 Main switch 6 Intake air pressure sensor 1 7 Clutch switch 8 Atmospheric pressure sensor 9 ECU 0 Battery A Fuel pump B Horn 2 C Decompression solenoid D Sidestand switch E Crankshaft position sensor F Starter motor G Horn 1 H Rectifier regulator 1 2 3 4 5 6 7 8 0 A B C D E F G H 9 ELECTRICAL COMPONENTS 1 2 3 4 5 6 7 ...

Page 473: ...mperature sensor 5 Spark plugs 6 Fuse box 7 Main fuse 8 Starter relay 9 Turn signal relay 0 Headlight relay A Relay unit B Speed sensor C Lean angle cut off switch D Oil temperature sensor E Neutral switch F Stator coil assembly G Rear brake light switch H Cylinder identification sensor 1 5 2 3 4 5 6 7 0 A B C D E F G H 9 8 ...

Page 474: ...hometer couplers right handlebar switch coupler and front turn signal position connectors 2 Speedometer coupler main switch coupler and left handlebar switch couplers 3 Headlight coupler 1 Rear turn signal light left connectors and license plate light connectors 2 Rear turn signal light right connectors 3 Tail brake light coupler 2 1 3 2 3 1 ...

Page 475: ...nsor coupler 5 Spark plug cap ignition coil 2 L spark plug lead 6 Spark plug cap ignition coil 1 L spark plug lead 7 Crankshaft position sensor 8 Sidestand switch 9 Starter motor 0 Starter motor lead A Rectifier regulator coupler B Stator coil assembly coupler C Horn 1 connectors D Horn 1 E Rectifier regulator F Linear control valve coupler 7 8 0 9 B D E F 1 2 4 5 C 6 A 3 ...

Page 476: ... coupler decompression solenoid couplers cylinder identification coupler crankshaft position sensor coupler speed sensor coupler neutral switch connector and sidestand switch coupler 4 Fuel pump coupler 5 Horn 2 6 Horn 2 coupler 7 Lean angle cut off switch coupler 8 Lean angle cut off switch 1 2 3 4 6 7 8 5 ...

Page 477: ...OUPLERS 1 ECU fuse 2 Fuse box 3 Starter relay coupler 4 Main fuse 5 Starter relay 6 Turn signal relay 7 Battery 8 Battery positive lead 9 Headlight relay 0 Battery negative lead A Horn 2 B Startr motor lead C Relay unit 2 C 6 3 2 1 0 8 7 4 4 5 5 9 A 6 A A B ...

Page 478: ...ler 5 Intake air temperature sensor coupler 6 Intake air pressure sensor 2 coupler 7 Main switch 8 Ignition coil 2 front cylinder 9 Spark plug cap ignition coil 2 R spark plug lead 0 Rear brake light switch A Stator coil B Cylinder identification sensor C Decompression solenoid D Neutral switch E Oil temperature sensor coupler F Speed sensor G Ignition sub wire harness coupler 1 2 3 4 5 6 7 8 9 0 ...

Page 479: ...n checking for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration NOTE _ indicates a continuity of electric...

Page 480: ...o CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch L Y B Y Ch Dg G Y BLUE BLACK R L B Br L L Y R W B L W R B G Y Br BLACK Br G Y BLUE B B Sb BLUE B B Y G R Y R ON OFF Br L L Y L B P B R B R W B L W L Y B Y B Dg Br W Y R L N R Ch R Y Y R P Rr W B 1 2 3 4 5 6 7 8 9 0 A B ...

Page 481: ...E SWITCHES 1 Dimmer switch 2 Horn switch 3 Turn signal switch 4 Clutch switch 5 Engine stop switch 6 Start switch 7 Front brake light switch 8 Main switch 9 Fuse 0 Rear brake light switch A Neutral switch B Sidestand switch ...

Page 482: ...e illustration on the left Bulbs A and B are used for the headlights and usually use a bulb holder that must be detached before removing the bulb The majority of these types of bulbs can be removed from their respective socket by turning them counterclockwise Bulbs C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise Bu...

Page 483: ...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 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE _ Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the positive tester probe to termi nal 1 and the negative tes...

Page 484: ...ster No continuity Replace NOTE _ Check each bulb socket for continuity in the same manner as described in the bulb section however note the following a Install a good bulb into the bulb socket b Connect the pocket tester probes to the respective leads of the bulb socket c Check the bulb socket for continuity If any of the readings indicate no continuity replace the bulb socket Pocket tester YU 03...

Page 485: ...e bat tery terminals to the respective coupler ter minal as shown WARNING _ A wire that is used as a jumper lead must have at least the same capacity of the bat tery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure no flammable gas or fluid is in the vicinity c When the jumper leads are connected to the terminals the respective LED should illu mina...

Page 486: ...Br Y B L P R Y O G R L R G G G Gy Gy Gy W W W W W R B R B R G P L W G Br L R R G R B B B R R R R R B B R W R B R W R R L B Br W Y R Br W B B ON OFF R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br BLACK R W B L W R B G Y Br BLACK L Y B Y B Y Ch Dg G Y BLUE L Y Ch Dg G Y BLUE A A L L L L Y A B B Y Y Y A Ch Ch A B B A B B B B Dg Dg Dg Y Ch B B B B G G B Y R Y...

Page 487: ...YES NO EAS00741 The ignition system fails to operate no spark or intermittent spark Dynamic spark tester YM 34487 Pocket tester YU 03112 1 Main and ignition fuses Check the main and ignition fuses for con tinuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in c...

Page 488: ... ON Measure the ignition spark gap a Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs Minimum ignition spark gap 6 mm 0 24 in Is there a spark and is the spark gap within specification The ignition system is OK 5 Spark plug cap resistance The following procedure applies to all of the spark plug caps Remove the spark plug cap from the spark ...

Page 489: ...wn Negative tester probe spark plug lead 1 Positive tester probe spark plug lead 2 Measure the secondary coil resistance Secondary coil resistance 12 18 kΩ at 20 C 68 F Is the ignition coil OK Replace the ignition coil 7 Crankshaft position sensor resistance Disconnect the crankshaft position sensor coupler from the wire harness Connect the pocket tester Ω 100 to the crankshaft position sensor cou...

Page 490: ...uity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch 11 Sidestand switch Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK Replace the side stand switch 12 Lean angle cut off switch voltage Remove the lean angle cut off switch Connect the pocket tester Ω 1 to the lean angle cut off switch terminals as shown Positi...

Page 491: ...ster probe blue yellow 2 Negative tester probe sky blue 1 No continuity Positive tester probe blue yellow 2 Negative tester probe blue green 3 NOTE _ When you switch the tester s positive and negative probes the readings in the above chart will be reversed Are the testing readings correct Replace the starting circuit cut off relay L G L Y Sb B Y Lg B R L W L R R L Br B L 3 2 1 14 Wiring Check the ...

Page 492: ...B B R R R R R B B R W R B R W R R L B Br W Y R Br W B B ON OFF R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br BLACK L Y B Y B Y Ch Dg G Y BLUE L Y Ch Dg G Y BLUE A A L L L L Y A B B Y Y Y A Ch Ch A B B A B B B B Dg Dg Dg Y Ch B B B B G G B Y R Y G L Y B R Y Br W B W P B B G B R R Y R W B G L W1 B R R W B Y L Y B Y B L P B Y G B Ch Dg B Y G L Y B Y R Y R R...

Page 493: ... conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the starter switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HAN DLEBAR 1...

Page 494: ...ression solenoid fuses Check the main ignition and decompres sion solenoid fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main ignition and decompression solenoid fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the ...

Page 495: ...the relay unit terminals as shown Measure the diode for continuity as fol lows L G L Y Sb B Y Lg B R L W L R R L Br B L 3 1 2 4 Positive tester probe sky blue 1 Negative tester probe black yellow 2 Continuity Positive tester probe sky blue 1 Negative tester probe blue yellow 3 Positive tester probe blue green 4 Negative tester probe blue yellow 3 Positive tester probe black yellow 2 Negative teste...

Page 496: ... the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch 8 Engine stop switch Check the engine stop switch for continu ity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutr...

Page 497: ...ce thermistor 70 Ω at 25 C 77 F NOTE _ The resistance value for the thermistor changes when the temperature changes therefore measure the decompression sole noid resistance at the specified temperature Connect the pocket tester Ω 1 to the decompression solenoid coupler as shown Positive tester prove black 3 Negative tester probe black 4 Decompression solenoid resistance 1 2 Ω at 20 C 68 F Check th...

Page 498: ...STARTER MOTOR 2 1 T R 5 Nm 0 5 m kg 3 6 ft Ib Order Job Part Q ty Remarks Removing the starter motor Remove the parts in the order listed 1 Starter motor lead 1 2 Starter motor assembly 1 For installation reverse the removal procedure ...

Page 499: ... ty Remarks Disassembling the starter motor Remove the parts in the order listed 1 Circlip 1 Refer to ASSEMBLING THE STARTER MOTOR 2 Starter motor gear 1 3 Starter motor rear cover 1 4 Lock washer 1 5 Washer set 1 6 Oil seal 1 7 Bearing 1 8 Circlip 1 9 Starter motor front cover 1 0 Brush 2 ...

Page 500: ...New New Order Job Part Q ty Remarks A Brush holder along with the brushes 1 Refer to ASSEMBLING THE STARTER MOTOR B Brush seat along with the brushes 1 C Bearing 1 D Gasket 2 E Armature assembly 1 F Starter motor yoke 1 For assembly reverse the disassembly procedure ...

Page 501: ...pecification Replace the starter motor Commutator wear limit 27 5 mm 1 08 in 3 Measure mica undercut a Out of specification Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator NOTE _ The mica of the commutator must be undercut to ensure proper operation of the commutator Mica undercut 1 5 mm 0 06 in ...

Page 502: ...re brush length a Out of specification Replace the brushes as a set Pocket tester YU 03112 Armature coil Commutator resistance 1 0 0081 0 0099 Ω at 20 C 68 F Insulation resistance 2 Above 1 MΩ at 20 C 68 F Brush length wear limit 5 mm 0 2 in 6 Measure brush spring force Out of specification Replace the brush springs as a set 7 Check gear teeth Damage wear Replace the gear 8 Check bearing oil seal ...

Page 503: ...at with the tab b in the starter motor front cover 1 a b 2 Install brush holder along with the brushes 1 1 3 Install armature assembly 1 1 4 Install gasket starter motor yoke 1 circlip NOTE _ Align the tab a on the brush holder with the slot b in the starter motor yoke 1 b a New 5 Install bearing oil seal washer set lock washer 1 1 ...

Page 504: ...tall gasket 1 starter motor cover 2 bolts NOTE _ Align the match marks a on the starter motor yoke with the match marks b on the starter motor rear cover a b 2 1 New New 7 Install O rings 1 starter motor gear 2 circlip 3 3 2 1 New ...

Page 505: ...B B R R R R R B B R W R B R W R R L B B ON OFF R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br BLACK R W B L W R B G Y Br BLACK A A L L L L Y Y Y Y Y G G R Y G L Y B R Y Br P R Y R W B G L W1 B R R W B Y L Y B L Y G B Y G L Y B R Y R Y L Y L W1 L B L B L L B R Br Br L 9 0 A Y Ch L B Dg Ch Y L B Dg 1 2 3 4 5 6 7 F E B C G H I J K M N O f g h i j k l s t u v...

Page 506: ...USES in chapter 3 Are the main fuse OK Replace the fuse 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Charging voltage Connect the inductive tachometer to the spark plug lead of cylinder 1 Connect the pocket ...

Page 507: ... shown Positive tester probe white 1 Negative tester probe white 2 Positive tester probe white 1 Negative tester probe white 3 Measure the stator coil resistances Stator coil resistance 0 12 0 20 Ω at 20 C 68 F Is the stator coil OK Replace the stator coil assembly W W W Ω 1 1 2 3 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s ...

Page 508: ... L W G Br L R R G R B B B R R R R R B B R W R B R W R R L B Br W Y R Br W B B ON OFF R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br BLACK R W B L W R B G Y Br BLACK L Y B Y B Y Ch Dg G Y BLUE L Y Ch Dg G Y BLUE A A L L L L Y A B B Y Y Y A Ch Ch A B B A B B B B Dg Dg Dg Y Ch B B B B G G B Y R Y G L Y B R Y Br W B W P B B G B R R Y R W B G L W1 B R R W B Y ...

Page 509: ... 1 Main headlight and signaling system fuses Check the main headlight and signaling system fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main headlight and signaling sys tem fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery O...

Page 510: ...efer to CIRCUIT DIAGRAM Is the lighting system s wiring properly connected and without defects Check the condition of each of the lighting system s circuits Refer to CHECK ING THE LIGHTING SYSTEM Properly connect or repair the lighting system s wiring R Y G L R Y Y B 3 4 2 1 1 Headlight bulb and socket Check the headlight bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS ...

Page 511: ...ation This circuit is OK The wiring circuit from the main switch to the headlight cou pler is faulty and must be repaired Ch Y Br Dg Lg B Ch Y Br Dg Lg B 4 5 1 Tachometer and speedometer light LED Check the LED of the tachometer and speedometer light Refer to CHECKING THE BULBS AND BULB SOCKETS Are the tachometer and speedometer light LED OK Replace the tachom eter assembly or speedometer assem bl...

Page 512: ...he tail brake light assembly Ch Y Dg Lg B Dg Lg B Br Ch Y Br 4 3 2 Voltage Connect the pocket tester DC 20 V to the tail brake light assembly coupler tail sub wire harness side as shown Positive tester probe blue 1 Negative tester probe black 2 Set the main switch to ON Measure the voltage DC 12 V of blue 1 on the tail brake light assembly coupler tail sub wire harness side Is the voltage within s...

Page 513: ...ght bulb and socket L B L B 1 2 Check the front turn signal position light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the front turn signal position light bulb and socket OK Replace the front turn signal position light bulb socket or both 2 Voltage Connect the pocket tester DC 20 V to the front turn signal position light connectors wire harness side as shown Po...

Page 514: ...L G R Gy G R GREEN GREEN B B Lg Lg Dg Dg Br Br Y Y Ch Ch RED BLUE P R Br Y O Gy L R B L G R Gy Gy Br G R L R Br Y B L P R Y O G R L R G G G Gy Gy Gy W W W W W R B R B R G P L W G Br L R R G R B B B R R R R R B B R W R B R W R R L B Br W Y R Br W B B ON OFF R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br BLACK R W B L W R B G Y Br BLACK L Y B Y B Y Ch Dg G ...

Page 515: ...edometer _ Fuel level warning light a Left turn signal indicator light b Right turn signal indicator light e Turn signal relay f Horn 1 g Horn 2 l Horn switch m Turn signal switch n Front turn signal position light left o Front turn signal position light right p Rear turn signal light right q Rear turn signal light left t Front brake light switch w Tail brake light y Rear brake light switch Signal...

Page 516: ...up fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Minimum open circuit voltage 12 8 V or more at 20 C 68 F Is the battery OK Clean the battery terminals Recharge or replace the battery 3 Main switch Check the main switch for conti...

Page 517: ...tive tester probe black white 1 Negative tester probe ground Set the main switch to ON Push the horn switch Measure the voltage DC 12 V of black white at the horn 1 terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired B W B 1 3 Horn 1 Disconnect the black connector at the horn 1 terminal Connect a jumper lead 1 to...

Page 518: ... voltage DC 12 V of brown 1 at the horn 2 coupler Is the voltage within specification The wiring circuit from the main switch to the horn coupler is faulty and must be repaired 3 Horn 2 Disconnect the horn 2 coupler at the horn 2 Connect a jumper lead 1 to the brown ter minal in the horn coupler and the horn ter minal Connect a jumper lead 2 to the horn ter minal and ground the jumper lead Set the...

Page 519: ...il brake light assembly coupler tail sub wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the tail brake light assembly coupler is faulty and must be repaired Y L B L Y B 1 2 1 Turn signal light bulb and socket Check the turn signal light bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Is the turn signal...

Page 520: ...within specification The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired 5 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as shown Positive tester probe brown white 1 Negative tester probe ground Set the main switch to ON Set the turn signal switch to or Measure the voltage DC 12 V on brown white 1 at...

Page 521: ...tch to ON Set the turn signal switch to or Measure the voltage DC 12 V of the chocolate 1 or dark green 2 at the turn signal light connectors or the speedometer assembly coupler wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the turn signal switch to the turn sig nal light connector or the speedometer coupler are faulty and must be repaired 1 Neutr...

Page 522: ...speedometer assembly coupler is faulty and must be repaired B Lg Dg Ch Y Br B Lg Dg Ch Y Br 2 1 1 Fuel level indicator light LED Check the LED of the fuel level indicator light Refer to CHECKING THE BULBS AND BULB SOCKETS Are the fuel level indicator light LED OK Replace the speed ometer assembly 2 Fuel pump fuel sender Drain the fuel from the fuel tank and remove the fuel pump from the sub fuel t...

Page 523: ...epaired 1 Engine trouble warning light LED Check the LED of the engine trouble warn ing light Refer to CHECKING THE BULBS AND BULB SOCKETS Are the engine trouble warning light LED OK Replace the speed ometer assembly B Lg Dg Ch Y Br B Lg Dg Ch Y Br 2 1 2 Voltage Connect the pocket tester DC 20 V to the speedometer assembly coupler wire har ness side as shown Positive tester probe brown 1 Negative ...

Page 524: ...L G R Gy G R GREEN GREEN B B Lg Lg Dg Dg Br Br Y Y Ch Ch RED BLUE P R Br Y O Gy L R B L G R Gy Gy Br G R L R Br Y B L P R Y O G R L R G G G Gy Gy Gy W W W W W R B R B R G P L W G Br L R R G R B B B R R R R R B B R W R B R W R R L B Br W Y R Br W B B ON OFF R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br BLACK R W B L W R B G Y Br BLACK L Y B Y B Y Ch Dg G ...

Page 525: ...essure sensor 1 H Intake air pressure sensor 2 I Atmospheric pressure sensor J Cylinder identification sensor K Lean angle cut off switch L Speed sensor M Intake air temperature sensor N Engine temperature sensor O Oil temperature sensor P ECU Q Linear control valve U Cylinder 1 injector V Cylinder 2 injector u Engine stop switch Ignition fuse ECU fuse å Fuel injection system fuse ...

Page 526: ...emove the following part s 1 seat 2 headlight lens unit 3 fuel tank 4 air induction system cover 5 air filter case 6 silencer air filter case 7 muffler and exhaust pipes 8 intake manifold Troubleshoot with the following special tool s EAS00738 YES NO EAS00739 YES NO EAS00749 YES NO If the fuel injection system fails to oper ate Pocket tester YU 03112 1 Main ignition ECU and fuel injection sys tem ...

Page 527: ... terminal blue red 2 Positive tester probe brown black 3 Negative tester probe red blue 4 Does the fuel injection system relay have continuity between brown and red blue Replace the relay unit L G L Y Sb B Y Lg B R L W L R R L Br B L 3 1 2 4 6 Cylinder 1 injector resistance Disconnect the injection sub wire harness coupler from the cylinder 1 injector Connect the pocket tester Ω 1 to the cylinder ...

Page 528: ...easure the cylinder 2 injector resis tance Cylinder 2 injector resistance 14 2 14 8 Ω at 20 C 68 F Is the cylinder 2 injector OK Replace the cylinder 2 injector W G 1 2 8 Fuel pump resistance Disconnect the fuel pump coupler from the fuel pump Connect the pocket tester Ω 1 to the fuel pump terminal as shown Positive tester probe red blue 1 Negative tester probe black 2 Measure the fuel pump resist...

Page 529: ...0 C 68 F between gray and black Is the crankshaft position sensor OK Replace the crank shaft position sensor 10 Cylinder identification sensor output volt age Connect the pocket tester DC 20 V to the cylinder identification sensor coupler as shown Positive tester probe white 1 Negative tester probe black 2 Set the main switch to ON Measure the cylinder identification sensor output voltage Cylinder...

Page 530: ...intake air temperature sensor coupler as shown Immerse the intake air temperature sensor 1 in a container filled with water 2 NOTE _ Make sure that the intake air temperature sensor terminals do not get wet Place a thermometer 3 in the water Slowly heat the water then let it cool down to the specified temperature W L W Y B L L B 1 2 Measure the intake air temperature sensor resistance Intake air t...

Page 531: ...OK Replace the intake air pressure sensor 1 L B L P W 2 1 14 Intake air pressure sensor 2 output volt age Connect the pocket tester DC 20 V to the intake air intake air pressure sensor 2 cou pler as shown Positive tester probe blue 1 Negative tester probe black blue 2 Set the main switch to ON Measure the intake air pressure sensor 2 output voltage Intake air pressure sensor output voltage 4 75 5 ...

Page 532: ... as shown Immerse the engine temperature sensor 1 in a container filled with water 2 NOTE _ Make sure that the engine temperature sen sor terminals do not get wet Place a thermometer 3 in the water Slowly heat the water then let it cool down to the specified temperature P B L L 1 2 Measure the engine temperature sensor resistance Engine temperature sensor resistance 898 1 098 Ω at 100 C 212 F WARN...

Page 533: ...ed temperature Measure the oil temperature sensor resis tance Oil temperature sensor resistance 308 339 Ω at 150 C 302 F 209 231 Ω at 170 C 338 F WARNING Handle the oil temperature sensor with special care Never subject the oil temperature sensor to strong shocks If the oil temperature sensor is dropped replace it T R Oil temperature sensor 18 Nm 1 8 m kg 13 ft lb Is the oil temperature sensor OK ...

Page 534: ...hes the engine when it is hot a fire may occur Therefore make sure the engine is completely cool before performing the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open container c Connect the battery 12 V to the fuel pump coupler as shown d If fuel flows out of the fuel hose the fuel pump is OK If fuel does not flow replace the fuel pump P...

Page 535: ...pening the throttle check that the throttle position sensor resistance is within the specified range NOTE Check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ slightly from those specified Out of specification or the resistance changes abruptly Go to step 2 below Positive tester probe blue 1 Negative tester pro...

Page 536: ...ng the throttle check that the throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace the throttle position sensor The slot is worn or broken Replace the throttle position sensor NOTE Check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ sl...

Page 537: ...ximum resistance 0 13 0 15 L Y B 2 1 3 Example If the maximum resistance 5 kΩ then the throttle position sensor s maximum resistance when the throttle is fully closed should be 5 kΩ 0 13 0 15 650 750 Ω Lift the throttle body assembly slightly out of the intake manifolds Loosen the throttle posi tion sensor screws 4 Connect the pocket tester Ω 100 to the throttle position sensor e Adjust the thrott...

Page 538: ...rrect valve to valve seat contact Incorrect valve timing Faulty valve spring Seized valve Piston s and piston ring s Improperly installed piston ring Damaged worn or fatigued piston ring Seized piston ring Seized or damaged piston Air filter Improperly installed air filter Clogged air filter element Crankcase and crankshaft Improperly assembled crankcase Seized crankshaft FUEL SYSTEM Fuel tank Emp...

Page 539: ...Starting system Faulty starter motor Faulty starter relay Faulty starting circuit cut off relay Faulty starter clutch EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Cylinder s and cylinder head s Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Throttle body ies Damaged or loose throttle body joint Improperly synchronized throttle bodies Imp...

Page 540: ...n gears Improperly assembled transmission JUMPS OUT OF GEAR Shift shaft Incorrect shift pedal position Improperly returned stopper lever Shift forks Worn shift fork Shift drum Incorrect axial play Worn shift drum groove Transmission Worn gear dog EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch Improperly assembled clutch Improperly adjusted clutch cable Loose or fatigued clutch spring Worn friction pla...

Page 541: ...n 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 EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL Bent damaged or rusty inner tube Cracked or damaged outer tube Improperly installed oil seal Damaged...

Page 542: ...venly tensioned fork spring both front fork legs Broken fork spring Bent or damaged inner tube Bent or damaged outer tube Swingarm Worn bearing or bushing Bent or damaged swingarm Rear shock absorber assembly ies Faulty rear shock absorber spring Leaking oil or gas Tire s Uneven tire pressures front and rear Incorrect tire pressure Uneven tire wear Wheel s Incorrect wheel balance Deformed cast whe...

Page 543: ...T LED BURNT OUT Wrong tail brake light LED Faulty battery Incorrectly adjusted rear brake light switch Tail brake light LED life expired TURN SIGNAL DOES NOT COME ON Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Improperly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY Fau...

Page 544: ...1 injector V Cylinder 2 injector W Tachometer assembly X Tachometer Y Tachometer light Z Speedometer assembly Engine trouble warning light Neutral indicator light Speedometer _ Fuel level warning light a Left turn signal indicator light b Right turn signal indicator light c High beam indicator light d Speedometer light e Turn signal relay f Horn 1 g Horn 2 h Headlight relay i Left handlebar switch...

Page 545: ...ate Dark green Green Gray Light green Orange Pink Red Sky blue White Yellow Black Green Black Blue Blue Yellow Brown Black Brown Blue Brown White Black Orange Black Red Black White Black Yellow Brown Yellow Green Blue Green Red Green Yellow Blue Black Blue Green Blue Red Blue White Gray Red Pink Blue Pink White Pink Yellow Red Yellow White Black White Green White Yellow COLOR CODE Red Black Red Gr...

Page 546: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 547: ...LIT 11616 19 46 5PX 28197 12 XV17PCV C XV17PCMV C SUPPLEMENTARY SERVICE MANUAL ...

Page 548: ...llowing manual XV1700P XV1700PC SERVICE MANUAL LIT 11616 15 37 5PX 28197 10 XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL LIT 11616 16 36 5PX 28197 11 XV17PCV C XV17PCMV C SUPPLEMENTARY SERVICE MANUAL 2005 by Yamaha Motor Corporation U S A First edition June 2005 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is express...

Page 549: ...information changes that apply to this model This policy is intended to provide the customer with 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 significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and ...

Page 550: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears 3 Sub section titles appear in smaller print than the section title 4 To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal and disassembly section 5 Numbers are given in the order of the jobs in the exploded diagram A circled number indicates...

Page 551: ...id A Lubricant B Special tool C Tightening torque D Wear limit clearance E Engine speed F Electrical data Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap based grease L Molybdenum disulfide grease Symbols M to N in the exploded diagrams indicate the following M A...

Page 552: ...TROL SYSTEM 18 GENERAL MAINTENANCE AND LUBRICATION CHART 19 SEAT AND SIDE COVERS 21 FUEL TANK 22 INSTALLING THE FUEL HOSE JOINT 2 23 CHASSIS 24 FRONT WHEEL AND BRAKE DISCS 24 FRONT AND REAR BRAKES 26 FRONT BRAKE PADS 26 FRONT BRAKE CALIPERS 27 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 29 FRONT FORK 32 DRIVE BELT AND DRIVE PULLEY 33 INSTALLING THE DRIVE BELT AND DRIVE PULLEY 35 ENGINE 36 E...

Page 553: ...hout oil filter cartridge replace ment 3 7 L 3 26 Imp qt 3 91 US qt With oil filter cartridge replacement 4 1 L 3 61 Imp qt 4 33 US qt Oil pressure hot 60 kPa 0 6 kg cm2 8 5 psi at 900 r min Relief valve opening pressure 600 kPa 6 0 kg cm2 85 psi Oil temperature 70 90 C 158 194 F Valve lifters Valve lifter outside diameter 22 9620 22 9744 mm 0 9040 0 9045 in Valve lifter case inside diameter 23 00...

Page 554: ... 8 mm 0 047 0 150 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 65 mm 0 026 in Ring side clearance 0 03 0 08 mm 0 0012 0 0031 in 0 12 mm 0 0047 in Plating coating Chrome plated parkerizing 2nd ring Ring type Taper Dimensions B T 1 2 3 8 mm 0 047 0 150 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 8 mm 0 031 in Ring side clearance 0 03 0 07 mm 0 0012 0 0028 in 0 12 mm 0 0047 in Plating co...

Page 555: ...operation Operation Left hand operation Clutch cable free play at the end of the clutch lever 10 15 mm 0 39 0 59 in Friction plates Thickness 2 9 3 1 mm 0 114 0 122 in 2 8 mm 0 110 in Plate quantity 9 Clutch plates Thickness 2 2 2 4 mm 0 087 0 094 in Plate quantity 8 Max warpage 0 2 mm 0 008 in Clutch springs Free length 7 mm 0 276 in Spring quantity 1 Min length 6 5 mm 0 256 in Clutch housing thr...

Page 556: ...pad lining thickness 5 8 mm 0 23 in 0 8 mm 0 03 in Master cylinder inside diameter 12 7 mm 0 5 in Caliper cylinder inside diameter 41 3 mm 1 63 in Item Standard Limit Bulbs voltage wattage quantity Headlight 12 V 60 W 55 W 1 Licence plate light 12 V 3 8 W 2 Tail brake light LED Front turn signal position light 12 V 23 W 8 W 2 Rear turn signal light 12 V 21 W 2 Speedometer light LED 1 Tachometer li...

Page 557: ...6 4 10 1 0 7 2 LT A I S bracket Bolt M5 4 6 0 6 4 3 LT Crankshaft position sensor Bolt M6 2 7 0 7 5 1 LT Stator coil assembly Screw M6 1 10 1 0 7 2 LT Generator rotor Bolt M12 1 80 8 0 58 E Clutch boss Nut M20 1 105 10 5 75 Use a lock washer Middle drive gear Nut M22 1 100 10 0 72 Stake Drive pulley Nut M22 1 120 12 0 85 Stake Shift drum assembly Screw M6 1 12 1 2 8 7 LT Shift drum assembly plate ...

Page 558: ...nd seat bracket M6 7 0 7 5 1 Throttle stop screw bracket and frame M8 23 2 3 17 Left side cover 1 and left side cover 2 M6 7 0 7 5 1 LT Lean angle sensor bracket and frame M6 7 0 7 5 1 Sidestand bracket and frame M10 63 6 3 45 LT Front brake caliper M10 35 3 5 25 Lubrication point Lubricant Clutch boss nut and washer E Transmission gears wheel and pinion and spacers M Middle drive gear nut and was...

Page 559: ...ndlebar switch lead 3 Right handlebar switch lead 4 Throttle cable 1 5 Throttle cable 2 6 Brake hose È Fasten the left handlebar switch lead with the plastic holders É Fasten the right handlebar switch lead with the plastic holders Ê 50 70 mm 2 0 2 8 in Ë 35 55 ...

Page 560: ...witch lead 7 Starter motor lead È Be sure to position the ECU leads and sensor leads toward the left side of the vehicle and then fasten the wire harness protector with a plastic locking tie Face the end of the plastic locking tie upward É Route the negative battery lead on top of the other leads B Í4 A A 2 1 7 6 Ð Ï É Ë È Î A A B 3 Ì Ê 5 ...

Page 561: ...o pinch the tail brake light lead and the fuel pump lead in the shaded areas shown in the illustration Í Route the fuel pump lead under the seat lock cable Î Fasten the decompression solenoid lead speed sensor lead cylinder identification sensor lead sidestand switch lead crankshaft position sen sor lead neutral switch lead and fuel pump lead with a plastic band Position the buckle of the plastic ...

Page 562: ...e bolt Fit the starter motor lead and sidestand switch lead into the groove in the frame and then fasten them with a plastic lock ing tie Face the end of the plastic locking tie out ward and then cut off the excess end of the tie Ð 10 30 mm 0 4 1 2 in B Í4 A A 2 1 7 6 Ð Ï É Ë È Î A A B 3 Ì Ê 5 ...

Page 563: ... wire harness C Spark plug cap ignition coil 2 R spark plug lead D Engine temperature sensor lead E Cylinder identification sensor lead F Stator coil lead G Neutral switch lead H Speed sensor lead I Ignition coil 1 R spark plug lead J Oil temperature sensor lead K Crankshaft position sensor lead L Horn 2 lead M Lean angle sensor lead N Starter motor lead O Sidestand switch lead C C B B A A E 0Ñ A ...

Page 564: ...ic locking tie under the fuel hose with the end facing outward and then cut off the excess end of the tie Ë Route the throttle position sensor lead engine temperature sensor lead injector lead and igni tion coil 1 R spark plug lead in the order listed from left to right C C B B A A E 0Ñ A B 9 8 Ð 7 6 5 4 3 É H G F Ù D C K M L N O B I B I B 2 A A B B C C D D E Ó Ï Î Í Ì Ë Ê È Ý Ü Ú Õ Ô Ò D D J 2 1 ...

Page 565: ...er the spark plug lead with the end facing outward and then cut off the excess end of the tie so that it does not contact the air filter case joint Í Fasten the throttle position sensor lead engine temperature sensor lead and injector lead with a plastic locking tie to the fuel delivery pipe Face the end of the plastic locking tie outward and then cut off the excess end of the tie C C B B A A E 0Ñ...

Page 566: ...o that it does not contact the air filter case joint Ï Fasten the main wire harness intake air pres sure sensor 2 lead ignition coil 1 R spark plug lead and intake air temperature sensor coupler with a plastic locking tie Position the buckle of the plastic locking tie under the main wire har ness with the end facing outward and then cut off the excess end of the tie Ð Pass the intake air pressure ...

Page 567: ... rear brake light switch coupler and to face the end of the plastic band downward Ó Fasten the main wire harness and intake vac uum hose with a plastic locking tie Ô To the engine temperature sensor Õ To the injector sub lead Ö Pass the cylinder identification sensor lead between the decompression solenoid and the decompression solenoid cover To the stator coil Ø 10 30 mm 0 4 1 2 in C C B B A A E ...

Page 568: ...al switch Þ Route the oil temperature sensor lead under the rear engine bracket right ß Position the buckle of the plastic locking tie so that it is not to the outside of the fuel hose À Position the buckle of the plastic locking tie so that it is not to the outside of the ignition coil 1 R spark plug lead Á Pass the oil temperature sensor lead through the guide and then bend the guide as shown in...

Page 569: ...en cut off the excess end of the tie Install the plastic locking ties 0 20 mm 0 0 79 in below the bends in the frame Fasten the corrugated tube with the plastic locking tie Face the end of the plastic locking tie outward and then cut off the excess end of the tie A A A B A C C C B B A A E 0Ñ A B 9 8 Ð 7 6 5 4 3 É H G F Ù D C K M L N O B I B I B 2 A A B B C C D D E Ó Ï Î Í Ì Ë Ê È Ý Ü Ú Õ Ô Ò D D J...

Page 570: ...INGS 600 mi 1000 km or 1 month 4000 mi 7000 km or 6 months 8000 mi 13000 km or 12 months 12000 mi 19000 km or 18 months 16000 mi 25000 km or 24 months 20000 mi 31000 km or 30 months 1 Fuel line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plugs Check condition Adjust gap and clean Replace every 8000 mi 13000 km or 12 months Replace Replace 3 Valve clearance Check and adjust v...

Page 571: ...eness Moderately repack with lithium soap based grease Repack 10 Drive belt Check belt tension Adjust if necessary Every 2500 mi 4000 km 11 Steering bearings Check bearing assemblies for looseness Moderately repack with lithium soap based grease every 16000 mi 25000 km or 24 months Repack 12 Chassis fasteners Check all chassis fitting and fasteners Correct if necessary 13 Brake and clutch lever pi...

Page 572: ...luid Regularly check the brake fluid levels and fill the reservoirs as required Every two years replace the internal components of the brake master cylinders and calipers and change the brake fluid Replace the brake hoses every four years and if cracked or damaged 23 Front and rear brake switches Check operation 24 Control cables Apply Yamaha chain and cable lube or engine oil SAE 10W 30 thoroughl...

Page 573: ...t 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 LT LT T R 16 Nm 1 6 m kg 11 ft Ib Order Job Part Q ty Remarks Removing the seat and side covers Remove the parts in the order listed 1 Rider seat 1 2 Passenger seat 1 3 Cover 1 4 Tool kit 1 5 Left side cover 1 1 6 Left side cover 2 1 7 Right side cover 1 For installation reverse the removal procedure ...

Page 574: ...arks Removing the fuel tank Remove the parts in the order listed Seat Refer to SEAT AND SIDE COVERS 1 Air induction system cover 1 2 Air duct 1 3 Fuel hose joint 1 1 Disconnect 4 Hose joint cover 1 5 Fuel hose joint 2 1 Disconnect 6 Fuel tank breather hose 2 Disconnect 7 Fuel tank 1 For installation reverse the removal procedure ...

Page 575: ... 23 CHK ADJ FUEL TANK INSTALLING THE FUEL HOSE JOINT 2 1 Install fuel hose joint 2 1 hose joint cover 2 NOTE Install the hose joint cover completely onto fuel hose joint 2 1 2 ...

Page 576: ... kg 25 ft Ib Order Job Part Q ty Remarks Removing the front wheel and brake discs Remove the parts in the order listed NOTE _ Place the motorcycle on a suitable stand so that the front wheel is elevated 1 Reflector bracket left and right 2 2 Brake hose holder 2 3 Reflector left and right 2 4 Brake caliper left and right 2 Refer to INSTALLING THE FRONT WHEEL in chapter 4 Manual No 5PX 28197 10 5 Fr...

Page 577: ... Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 13 Nm 1 3 m kg 9 4 ft Ib T R 16 Nm 1 6 m kg 11 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib T R 35 Nm 3 5 m kg 25 ft Ib Order Job Part Q ty Remarks 8 Collar left and right 2 Refer to INSTALLING THE FRONT WHEEL in chapter 4 Manual No 5PX 28197 10 9 Front wheel 1 10 Brake disc left and right 2 For installation reverse the removal procedure ...

Page 578: ... ty Remarks Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake caliper bolt 2 2 Brake pad clip 2 3 Brake pad pin 1 4 Brake pad spring 1 Refer to ASSEMBLING AND INSTALL ING THE FRONT BRAKE CALIPERS 5 Brake pad 2 6 Brake pad shim 2 For installation reverse the removal procedure ...

Page 579: ...ed The following procedure applies to both of the front brake calipers Brake hose holders Refer to FRONT WHEEL AND BRAKE DISCS Brake fluid Drain 1 Union bolt 1 Refer to DISASSEM BLING THE FRONT BRAKE CALIPERS in chapter 4 Manual No 5PX 28197 10 and ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS 2 Copper washer 2 3 Brake hose 1 Disconnect 4 Brake caliper bolt 2 5 Brake caliper 1 For installatio...

Page 580: ... in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Brake caliper piston 4 Refer to DISASSEMBLING THE FRONT BRAKE CALIPERS in chapter 4 Manual No 5PX 28197 10 7 Dust seal 4 8 Brake caliper piston seal 4 9 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 581: ...on seals to swell and distort Whenever a brake caliper is disassem bled replace the brake caliper piston seals and dust seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers 2 brake hose 3 union bolt 4 WARNING _ Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING CAUTION _ When installing the brake hose onto the brake...

Page 582: ... 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 master cylinder reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock CAUTION _ Brake fluid may damage painted surfaces and plastic pa...

Page 583: ... a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 Manual No 5PX 28197 10 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Manual No 5PX 28197 10 ...

Page 584: ...s in the order listed The following procedure applies to both of the front fork legs Front wheel Refer to FRONT WHEEL AND BRAKE DISCS 1 Front fender 1 2 Upper bracket pinch bolt 2 Loosen Refer to REMOVING THE FRONT FORK LEGS and INSTALLING THE FRONT FORK LEGS in chapter 4 Manual No 5PX 28197 10 3 Cap bolt 1 Loosen 4 Turn signal light bracket pinch bolt 1 Loosen 5 Lower bracket pinch bolt 2 Loosen ...

Page 585: ...order listed Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY in chapter 4 Manual No 5PX 28197 10 Rear shock absorber and swingarm assembly Refer to REAR SHOCK ABSORBER AND SWINGARM Manual No 5PX 28197 11 1 Drive pulley cover 1 2 Slider 2 3 Dowel pin 2 4 Transfer gear case bracket 1 5 Drive belt 1 6 Drive pulley nut 1 7 Conical spring washer 1 ...

Page 586: ... 34 CHAS DRIVE BELT AND DRIVE PULLEY Order Job Part Q ty Remarks 8 Drive pulley 1 For installation reverse the removal procedure ...

Page 587: ...e drive belt facing the same way it was removed Do not twist the drive belt when installing it 3 Install rear shock absorber and swingarm assembly Refer to REAR SHOCK ABSORBER AND SWINGARM Manual No 5PX 28197 11 rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL PULLEY in chapter 4 Manual No 5PX 28197 10 4 Tighten drive pulley nut 1 NOTE _ When tightening the drive pulley nut press down on t...

Page 588: ... AND SIDE COVERS Fuel tank Refer to FUEL TANK Air filter case Refer to AIR FILTER CASE in chapter 3 Manual No 5PX 28197 10 Silencer air filter case Refer to SILENCER AIR FILTER CASE in chapter 3 Manual No 5PX 28197 10 Throttle bodies intake manifold Refer to FUEL INJECTION SYSTEM in chapter 6 Manual No 5PX 28197 10 Air induction system parts Refer to AIR INDUCTION SYSTEM in chapter 6 Manual No 5PX...

Page 589: ...ter 3 Manual No 5PX 28197 10 Sub fuel tank Refer to SUB FUEL TANK in chapter 5 Manual No 5PX 28197 10 Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL in chapter 3 Manual No 5PX 28197 10 Transfer gear case Refer to TRANSFER GEAR CASE Rider footrest left Refer to ROCKER ARMS PUSH RODS AND VALVE LIFTERS Manual No 5PX 28197 11 Rider footrest right oil delivery pipe Refer to GENERATOR A...

Page 590: ... 1 ft Ib T R 7 Nm 0 7 m kg 5 1 ft Ib Order Job Part Q ty Remarks 1 Oil filter bracket 1 2 Rectifier regulator coupler 1 Disconnect 3 Stator coil assembly coupler 1 Disconnect 4 Rectifier regulator 1 5 Rectifier regulator bracket 1 6 Horn 2 1 7 Lean angle sensor 1 For installation reverse the removal procedure ...

Page 591: ...48 Nm 4 8 m kg 35 ft Ib Order Job Part Q ty Remarks Removing the engine Remove the parts in the order listed NOTE _ Place a suitable stand under the frame and engine 1 Upper mounting bolt 2 2 Upper mounting bracket bolt 2 3 Upper mounting 1 4 Self locking nut 1 5 Front mounting bolt 1 Refer to INSTALLING THE ENGINE in chapter 5 Manual No 5PX 28197 10 6 Nut cap 4 7 Front engine bracket self locking...

Page 592: ...R 18 Nm 1 8 m kg 13 ft Ib 2 1 3 1 R 48 Nm 4 8 m kg 35 ft Ib Order Job Part Q ty Remarks 11 Upper rear mounting bolt 1 Refer to INSTALLING THE ENGINE in chapter 5 Manual No 5PX 28197 10 12 Rear engine bracket nut 2 13 Rear engine bracket bolt 2 14 Rear engine bracket left 1 15 Rear engine bracket right 1 16 Spacer bolt 1 Loosen 17 Lower rear mounting bolt 1 18 Lower front mounting bolt 1 19 Engine ...

Page 593: ...Nm 1 8 m kg 13 ft Ib T R 100 Nm 10 0 m kg 72 ft lb Order Job Part Q ty Remarks Removing the transfer gear case cover Remove the parts in the order listed Muffler exhaust pipes Refer to ENGINE in chapter 5 Manual No 5PX 28197 10 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Manual No 5PX 28197 10 Transfer gear oil Drain Refer to CHANGING THE TRANSFER GEAR OIL in chapter 3 Manual No...

Page 594: ...t Ib T R 24 Nm 2 4 m kg 17 ft Ib T R 18 Nm 1 8 m kg 13 ft Ib T R 100 Nm 10 0 m kg 72 ft lb Order Job Part Q ty Remarks 4 Dowel pin 4 5 Transfer gear oil pump 1 6 Transfer gear oil pump gasket 1 7 Transfer gear case cover 1 8 Transfer gear case cover gasket 1 1 9 Oil strainer 1 10 Middle drive gear nut 1 11 Conical spring washer 1 12 Primary chain 1 13 Middle drive gear 1 14 Middle driven shaft 1 F...

Page 595: ...r with the splines on the drive axle Temporarily install the drive pulley nut onto the middle driven shaft 2 Install oil strainer 1 dowel pins 2 transfer gear case cover gasket 3 New 3 Install transfer gear case cover 1 nut 2 T R 10 Nm 1 0 m kg 7 2 ft lb T R 30 Nm 3 0 m kg 22 ft lb 4 Install conical spring washer 1 middle drive gear nut 2 NOTE Lubricate the middle driven gear nut threads and conic...

Page 596: ... 1 at a cutout a in the drive axle 6 Remove drive pulley nut New T R 100 Nm 10 0 m kg 72 ft lb 7 Install transfer gear oil pump gasket transfer gear oil pump 1 NOTE _ Apply locking agent LOCTITE only to the threads of the transfer gear oil pump bolts M6 25 mm bolts 2 New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 597: ...gs Remove the parts in the order listed Crankshaft Refer to CRANKSHAFT AND CON NECTING RODS in chapter 5 Manual No 5PX 28197 10 Transmission Refer to TRANSMISSION 1 Baffle plate 1 2 Bearing retainer 1 3 Bearing retainer 1 4 Oil seal 1 5 Bearing 4 For installation reverse the removal procedure ...

Page 598: ...SE INSTALLING THE BEARING RETAINER 1 Install Bearing retainer 1 NOTE Install the bearing retainer 1 with its OUT mark a facing outward Apply locking agent LOCTITE to the threads of the bearing retainer bolt O U T a 1 ...

Page 599: ...orks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE in chapter 5 Manual No 5PX 28197 10 1 Shift fork guide bar 2 2 Shift drum assembly 1 3 Shift fork L 1 4 Shift fork R 1 5 Shift fork C 1 6 Drive axle assembly 1 7 Main axle assembly 1 8 Spacer O ring 1 1 For installation reverse the removal procedure ...

Page 600: ...n axle assembly Remove the parts in the order listed 1 Circlip 1 2 Washer 1 3 5th pinion gear 1 4 Spacer 1 5 Washer 1 6 2nd 3rd pinion gear 1 7 Circlip 1 8 Washer 1 9 4th pinion gear 1 0 Spacer 1 A Main axle 1st pinion gear 1 For assembly reverse the disassembly procedure ...

Page 601: ...arks Disassembling the drive axle assembly Remove the parts in the order listed 1 5th wheel gear 1 2 Circlip 1 3 Washer 1 4 2nd wheel gear 1 5 Spacer 1 6 Circlip 1 7 Washer 1 8 1st wheel gear 1 9 Spacer 1 0 Washer 1 A 4th wheel gear 1 B Circlip 1 ...

Page 602: ... 50 ENG TRANSMISSION Order Job Part Q ty Remarks C Washer 1 D 3rd wheel gear 1 E Spacer 1 F Drive axle 1 For assembly reverse the disassembly procedure ...

Page 603: ... R GREEN GREEN B B Lg Lg Dg Dg Br Br Y Y Ch Ch RED BLUE P R Br Y O Gy L R B L G R Gy Gy Br G R L R Br Y B L P R Y O G R L R G G G Gy Gy Gy W W W W W R B R B R G P L W G Br L R R G R B B B R R R R R B B R W R W R B R W R R L B Br W Y R Br W B B ON OFF R L B Br L L Y R L B Br L L Y R B R Br L L B L Y R R B R B Gy R R Br B BLACK Y Br BLACK B B BLACK B G L W1 B R R W Y Br RED R W B L W R B G Y Br RED ...

Page 604: ...orn 2 h Headlight relay i Left handlebar switch j Clutch switch k Dimmer switch l Horn switch m Turn signal switch n Front turn signal position light left o Front turn signal position light right p Rear turn signal light right q Rear turn signal light left r Headlight s Right handlebar switch t Front brake light switch u Engine stop switch v Start switch w Tail brake light x License plate light y ...

Page 605: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

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