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Yamaha YZF-R1 1998 Service Manual Download Page 80

3 - 13

CHK

ADJ

ADJUSTING THE VALVE CLEARANCE

VALVE PAD SELECTION TABLE
INTAKE

ı

 MEASURED 

VALVE CLEARANCE

Å

 ORIGINAL VALVE PAD NUMBER

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 ~ 0.02

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225

0.03 ~ 0.07

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

0.08 ~ 0.10

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

0.11 ~ 0.20

Ç

 STANDARD CLEARANCE

0.21 ~ 0.22

125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.23 ~ 0.27

130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.28 ~ 0.32

135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.33 ~ 0.37

140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.38 ~ 0.42

145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.43 ~ 0.47

150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.48 ~ 0.52

155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.53 ~ 0.57

160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.58 ~ 0.62

165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.63 ~ 0.67

170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.68 ~ 0.72

175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.73 ~ 0.77

180 185 190 195 200 205 210 215 220 225 230 235 240

0.78 ~ 0.82

185 190 195 200 205 210 215 220 225 230 235 240

Example:
Valve Clearance (cold)

0.11 ~ 0.20 mm

Rounded value 150

Measured valve clearance is 0.24 mm

Replace pad 150 with pad 160

Pad No. 150 = 1.50 mm
Pad No. 160 = 1.60 mm

Always install the valve pad with the 
number facing down.

0.83 ~ 0.87

190 195 200 205 210 215 220 225 230 235 240

0.88 ~ 0.92

195 200 205 210 215 220 225 230 235 240

0.93 ~ 0.97

200 205 210 215 220 225 230 235 240

0.98 ~ 1.02

205 210 215 220 225 230 235 240

1.03 ~ 1.07

210 215 220 225 230 235 240

1.08 ~ 1.12

215 220 225 230 235 240

1.13 ~ 1.17

220 225 230 235 240

1.18 ~ 1.22

225 230 235 240

1.23 ~ 1.27

230 235 240

1.28 ~ 1.32

235 240

1.33 ~ 1.37

240

EXHAUST

ı

 MEASURED 

VALVE CLEARANCE

Å 

ORIGINAL VALVE PAD NUMBER

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 ~ 0.02

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215

0.03 ~ 0.07

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220

0.08 ~ 0.12

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225

0.13 ~ 0.17

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230

0.18 ~ 0.20

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235

0.21 ~ 0.30

Ç

 STANDARD CLEARANCE

0.31 ~ 0.32

125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.33 ~ 0.37

130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.38 ~ 0.42

135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.43 ~ 0.47

140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.48 ~ 0.52

145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.53 ~ 0.57

150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.58 ~ 0.62

155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.63 ~ 0.67

160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.68 ~ 0.72

165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.73 ~ 0.77

170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.78 ~ 0.82

175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.83 ~ 0.87

180 185 190 195 200 205 210 215 220 225 230 235 240

0.88 ~ 0.92

185 190 195 200 205 210 215 220 225 230 235 240

Example:
Valve Clearance (cold)

0.21 ~ 0.30 mm

Rounded value 175

Measured valve clearance is 0.35 mm

Replace pad 150 with pad 185

Pad No. 175 = 1.75 mm
Pad No. 185 = 1.85 mm

Always install the valve pad with the 
number facing down.

0.93 ~ 0.97

190 195 200 205 210 215 220 225 230 235 240

0.98 ~ 1.02

195 200 205 210 215 220 225 230 235 240

1.03 ~ 1.07

200 205 210 215 220 225 230 235 240

1.08 ~ 1.12

205 210 215 220 225 230 235 240

1.13 ~ 1.17

210 215 220 225 230 235 240

1.18 ~ 1.22

215 220 225 230 235 240

1.23 ~ 1.27

220 225 230 235 240

1.28 ~ 1.32

225 230 235 240

1.33 ~ 1.37

230 235 240

1.38 ~ 1.42

235 240

1.43 ~ 1.47

240

Summary of Contents for YZF-R1 1998

Page 1: ...SERVICEMANUAL YZF R1 4XV1 AE1 98 ...

Page 2: ...YZF R1 SERVICE MANUAL 1997 by Yamaha Motor Co Ltd First edition October 1997 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...els Modifica tions and significant changes in specifications or procedures will be forwarded to all autho rized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice EB002000 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following The Safety Aler...

Page 4: ...of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub sec tion 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 indi cat...

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

Page 6: ...TITLES GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS 3 ENGINE ENG 4 COOLING COOL 5 CARBURETION CARB 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING 9 GEN INFO CHK ADJ TRBL SHTG ...

Page 7: ...GEN INFO 1 ...

Page 8: ...ER 1 1 MODEL CODE 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 USING A DYNAMOMETER 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING THE CONNECTIONS 1 4 SPECIAL TOOLS 1 5 ...

Page 9: ...GEN INFO ...

Page 10: ...RCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EB100020 MODEL CODE The model code label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 11: ... all of the parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB102010 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 but ...

Page 12: ...GS AND OIL SEALS 1 Install bearings and oil seals so that the manufacturer s marks or numbers are visible When installing oil seals lubri cate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate 1 Oil seal ACHTUNG CAUTION Do not spin the bearing with com pressed air because this will damage the bearing surfaces 1 Bearing EB102050 CI...

Page 13: ...isconnect several 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 that all connections are tight 5 Check continuity with the pocket tester NOTE If there is no continuity clean the ter minals When checking the wire harness per form steps 1 to 3 As a quick remedy use a contact re...

Page 14: ...d to hold the generator rotor when removing or installing the gen erator rotor bolt or pickup coil rotor bolt 90890 01286 Drive chain cutter This tool is used to remove the drive chain 90890 01304 Piston pin puller This tool is used to remove the piston pins 90890 01312 Fuel level gauge This tool is used to measure the fuel level in the float chamber Radiator cap tester 90890 01325 Adapter 90890 0...

Page 15: ...sassemble or assem ble the front fork legs 90890 01442 Fork seal driver This tool is used to install the front fork s oil seal and dust seal 90890 03008 Micrometer This tool is used to measure the piston skirt diameter Vacuum gauge 90890 03094 Vacuumgauge attachment 90890 03060 Vacuum gauge Vacuum gauge attachment This gauge is used to synchronize the car buretors Compression gauge 90890 03081 Ada...

Page 16: ...semblies Middledrivenshaft bearing driver 90890 04058 Mechanical seal installer 90890 04078 Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal 90890 04086 Clutch holding tool This tool is used to hold the clutch boss when removing or installing the clutch boss nut 90890 04111 90890 04116 Valve guide remover This tool is used to remove o...

Page 17: ...0 06754 Ignition checker This tool is used to check the ignition sys tem components 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating sur faces e g crankcase mating surfaces Tool No Tool name Function Illustration ...

Page 18: ...SPEC 2 ...

Page 19: ...2 15 TIGHTENING TORQUES 2 18 GENERAL TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2 23 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 2 24 OIL FLOW DIAGRAMS 2 25 COOLANT FLOW DIAGRAMS 2 29 CABLE ROUTING 2 33 ...

Page 20: ...SPEC ...

Page 21: ...cept for N S SF 2 095 mm for N S SF Overall width 695 mm Overall height 1 095 mm Seat height 815 mm Wheelbase 1 395 mm Minimum ground clearance 140 mm Minimum turning radius 3 400 mm Weight Wet with oil and a full fuel tank 198 kg Dry without oil and fuel 177 kg Maximum load total of cargo rider passenger and accessories 197 kg ...

Page 22: ... 3 kPa 220 mm Hg Standard compression pressure at sea level 1 450 kPa 14 5 kgf cm2 at 400 r min Fuel Recommended fuel Regular gasoline Fuel tank capacity Total including reserve 18 L Reserve only 5 5 L Engine oil Lubrication system Wet sump Recommended oil SAE20W40SE or SAE10W30SE Quantity Total amount 3 6 L Without oil filter cartridge replacement 2 7 L With oil filter cartridge replace ment 2 9 ...

Page 23: ...system Radiator capacity 2 55 L Radiator cap opening pressure 95 125 kPa 0 95 1 25 kgf cm2 Radiator core Width 340 mm Height 298 mm Depth 24 mm Coolant reservoir Capacity 0 45 L Water pump Water pump type Single suction centrifugal pump Reduction ratio 68 43 28 28 1 581 Max impeller shaft tilt 0 15 mm Starting system type Electric starter Spark plugs Model manufacturer quantity CR9E U27ESR N NGK D...

Page 24: ...rnal to camshaft cap clearance 0 050 0 084 mm Intake camshaft lobe dimensions Measurement A 32 5 32 6 mm 32 4 mm Measurement B 24 95 25 05 mm 24 85 mm Measurement C 7 45 7 65 mm Exhaust camshaft lobe dimen sions Measurement A 32 95 33 05 mm 32 85 mm Measurement B 24 95 25 05 mm 24 85 mm Measurement C 7 75 7 95 mm Max camshaft runout 0 03 mm Item Standard Limit C A B C A B ...

Page 25: ...ve seat width C Intake 0 9 1 1 mm Exhaust 0 9 1 1 mm Valve margin thickness D Intake 0 5 0 9 mm Exhaust 0 5 0 9 mm Valve stem diameter Intake 3 975 3 900 mm 3 945 mm Exhaust 4 460 4 475 mm 4 43 mm Valve guide inside diameter Intake 4 000 4 012 mm 4 05 mm Exhaust 4 500 4 512 mm 4 55 mm Valve stem to valve guide clear ance Intake 0 010 0 037 mm 0 08 mm Exhaust 0 025 0 052 mm 0 1 mm Valve stem runout...

Page 26: ...alled Intake 82 96 N 8 36 9 79 kgf Exhaust 110 126 N 11 22 12 85 kgf Spring tilt Intake 2 5 1 7 mm Exhaust 2 5 1 8 mm Winding direction top view Intake Clockwise Exhaust Clockwise Cylinders Cylinder arrangement Forward inclined parallel 4 cylinder Bore stroke 74 58 mm Compression ratio 11 8 1 Bore 74 00 74 010 mm Max taper 0 05 mm Max out of round 0 05 mm Item Standard Limit ...

Page 27: ...tside diameter 16 991 17 000 mm Piston pin to piston pin bore clearance 0 002 0 022 mm 0 072 mm Piston rings Top ring Ring type Barrel Dimensions B T 0 90 2 75 mm End gap installed 0 19 0 31 mm Ring side clearance 0 030 0 065 mm 2nd ring Ring type Taper Dimensions B T 0 8 2 8 mm End gap installed 0 30 0 45 mm Ring side clearance 0 020 0 055 mm Oil ring Dimensions B T 1 5 2 6 mm End gap installed 0...

Page 28: ... Bearing color code 1 Pink violet 0 Pink white 1 Pink blue 2 Pink black 3 Pink brown Clutch Clutch type Wet multiple disc Clutch release method Rack and pinion pull rod type Clutch release method operation Cable operation Operation Right foot operation Clutch cable free play at the end of the clutch lever 10 15 mm Friction plates Thickness 2 9 3 1 mm 2 8 mm Plate quantity 8 Clutch plates Thickness...

Page 29: ...mm Shifting mechanism Shift mechanism type Shift drum Max shift fork guide bar bending 0 1 mm Installed shift rod length 305 mm Air filter type Dry element Fuel pump Pump type Electrical Model manufacturer 4SV MITSUBISHI Output pressure 20 kPa 0 2 kgf cm2 Carburetors Model manufacturer quantity BDSR40 MIKUNI 4 Throttle cable free play at the flange of the throttle grip 3 5 mm ID mark 4XV1 00 Main ...

Page 30: ...FICATIONS SPEC 2 10 Starter jet 1 35 Starter jet 2 0 7 Butterfly valve size 100 Fuel level below the line on the float chamber 4 1 5 1 mm Max EXUP cable free play at the EXUP valve pulley 1 5 mm Item Standard Limit ...

Page 31: ...eel runout 0 5 mm Rear wheel Wheel type Cast wheel Rim Size 17 MT6 00 Material Aluminum Wheel travel 130 mm Wheel runout Max radial wheel runout 1 mm Max lateral wheel runout 0 5 mm Front tire Tire type Tubeless Size 120 70 ZR17 58W Model manufacturer MEZ3 FRONT METZELER for GB TX15 MICHELIN for N D NL B E P I GR Tire pressure cold 0 90 kg 250 kPa 2 5 kg cm2 2 5 bar 90 197 kg 250 kPa 2 5 kg cm2 2 ...

Page 32: ...scs Diameter thickness 298 5 mm Min thickness 4 5 mm Max deflection 0 1 mm Brake pad lining thickness 5 5 mm 0 5 mm Master cylinder inside diameter 14 mm Caliper cylinder inside diameter 30 2 mm and 27 mm Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position from the top of the brake pedal to the bottom of the rider footrest bracket 35 40 mm Recommended fluid ...

Page 33: ...o Fork oil Recommended oil Suspension oil 01 or equivalent Quantity each front fork leg 477 cm3 Level from the top of the inner tube with the inner tube fully compressed and without the fork spring 78 mm Damper adjusting rod locknut dis tance 11 mm Spring preload adjusting positions Minimum 8 Standard 6 Maximum 1 Rebound damping adjusting posi tions Minimum 13 Standard 5 Maximum 1 Compression damp...

Page 34: ... 0 65 mm Optional spring available No Standard spring preload gas air pressure 1 200 kPa 12 kgf cm2 Spring preload adjusting positions Minimum 1 Standard 4 Maximum 9 Rebound damping adjusting posi tions Minimum 12 Standard 6 Maximum 1 Compression damping adjusting positions Minimum 12 Standard 8 Maximum 1 from the fully turned in position Swingarm Free play at the end of the swing arm Radial 1 mm ...

Page 35: ...18 kΩ Spark plug caps Material Resin Resistance 10 kΩ Throttle position sensor standard resistance 4 6 kΩ Charging system System type AC magneto Model manufacturer F4T361 MITSUBISHI Nominal output 14 V 26 A at 5 000 r min Stator coil resistance 0 45 0 55 Ω at 20 C Voltage regulator Regulator type Semiconductor field control Model SH650A 12 No load regulated voltage 14 1 14 9 V Rectifier Model SH65...

Page 36: ... Plain Model manufacturer quantity YF 12 NIKKO 1 Max amperage 3 A Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Self cancelling device built in No Turn signal blinking frequency 60 120 cycles min Wattage 21 W 2 Oil level switch model manufac turer 3GM DENSO Fuel sender Model manufacturer 3GM DENSO Resistance 899 7 900 3 kΩ at 25 C Sidestand relay Model 3EN 00 Coil r...

Page 37: ...ufacturer 2YK NIPPON SEIKI Resistance 47 5 56 8 Ω at 80 C 16 5 20 5 Ω at 115 C Fuses amperage quantity Main fuse 30 A 1 Headlight fuse 20 A 1 Signaling system fuse 20 A 1 Ignition fuse 15 A 1 Radiator fan fuse 7 5 A 1 Backup fuse odometer 7 5 A 1 Item Standard Limit ...

Page 38: ...entigrade C 55 997 14 2234 9 5 32 lb in psi lb in2 Fahrenheit F EB202001 TIGHTENING TORQUES GENERAL TIGHTENING TORQUES This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch Tightening torque specifica tions for special components or assemblies are provided for each chapter of this man ual To avoid warpage tighten multi fas tener assemblies in a crisscross ...

Page 39: ...1 10 1 0 LT Oil water pump assembly driven sprocket Bolt M6 1 15 1 5 LT Oil pump Bolt M6 1 10 1 0 Oil cooler Bolt M20 1 35 3 5 E Engine oil drain bolt M14 1 43 4 3 Oil strainer housing Bolt M6 2 10 1 0 LT Oil water pump assembly driven sprocket cover Bolt M6 1 10 1 0 LT Oil pipe Bolt M6 1 10 1 0 LT Oil filter bolt Bolt M20 1 70 7 0 Oil filter cartridge M20 1 17 1 7 E Exhaust pipes Nut M8 8 20 2 0 ...

Page 40: ... springs Bolt M6 6 8 0 8 Drive sprocket Nut M22 1 85 8 5 Use a lock washer Main axle bearing housing Screw M6 3 12 1 2 LT Shift drum retainer Bolt M6 2 10 1 0 LT Shift shaft spring stopper Bolt M8 1 22 2 2 LT Shift rod locknut Nut M6 2 7 0 7 Shift arm Bolt M6 1 10 1 0 Stator coil Bolt M6 3 10 1 0 LT Ignitor unit Bolt M6 1 10 1 0 Neutral switch M10 1 20 2 0 Pickup coil Bolt M6 2 10 1 0 LT Temperatu...

Page 41: ...2 21 SPEC Crankcase tightening sequence TIGHTENING TORQUES ...

Page 42: ...bolts M10 55 5 5 Pinch bolts M8 24 2 4 Exhaust pipe bracket M8 24 2 4 Pivot shaft nut M18 125 12 5 Connecting arms M10 40 4 0 Relay arm and connecting arms M10 40 4 0 Relay arm M10 40 4 0 Rear shock absorber and relay arm M10 40 4 0 Rear shock absorber assembly M10 40 4 0 Fuel cock M6 7 0 7 Fuel sender and fuel tank M6 7 0 7 Coolant reservoir and radiator M6 5 0 5 Rider footrest bracket M8 28 2 8 ...

Page 43: ... inner and outer E Oil pump housing E Oil strainer E Starter clutch idle gear inner surface E Starter clutch assembly E Primary driven gear E Transmission gears wheel and pinion M Main axle and drive axle M Shift drum E Shift forks and shift fork guide bars E Shift shaft E Shift shaft boss LS Engine mounting bolts rear LS Cylinder head cover mating surface Yamaha bond No 1215 Crankcase mating surf...

Page 44: ...estand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivoting point and metal to metal moving parts LS Clutch lever pivoting point and metal to metal moving parts LS Rear shock absorber assembly oil seal LS Rear shock absorber assembly bearing LS Rear shock absorber assembly spacer LS Pivot shaft LS Connecting arm bearing left and right LS Spacer rela...

Page 45: ...2 25 SPEC EB203000 OIL FLOW DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump OIL FLOW DIAGRAMS ...

Page 46: ...2 26 SPEC 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter OIL FLOW DIAGRAMS ...

Page 47: ...2 27 SPEC 1 Cylinder head 2 Crankshaft OIL FLOW DIAGRAMS ...

Page 48: ...2 28 SPEC 1 Main axle 2 Oil delivery pipe 3 Drive axle OIL FLOW DIAGRAMS ...

Page 49: ...2 29 SPEC EB203000 COOLANT FLOW DIAGRAMS 1 Thermostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint OIL FLOW DIAGRAMS ...

Page 50: ...2 30 SPEC 1 Thermostat housing 2 Water pump 3 Radiator 4 Radiator fan OIL FLOW DIAGRAMS ...

Page 51: ...2 31 SPEC 1 Radiator cap 2 Thermostat 3 Thermostat housing 4 Water pump OIL FLOW DIAGRAMS ...

Page 52: ...2 32 SPEC 1 Radiator 2 Thermo switch 3 Temperature sender OIL FLOW DIAGRAMS ...

Page 53: ... Å Properly insert the meter assembly coupler and rubber boot into the meter assembly ı Route the meter assembly lead through the left side of the headlight housing Ç Install the headlight relays onto the headlight housing bridge Î Connect to the right front turn signal connectors Route the turn signal leads between the headlight housing and headlight housing boss CABLE ROUTING ...

Page 54: ...handlebar switch lead Ô Route the thermo switch temperature sender sub wire harness to the outside of the radiator cap Route the right handlebar switch lead in front of the throttle cables Ò Make sure that the horn leads face out Route the throttle cables and right handle bar switch lead between the frame and plastic frame panel and then between the lower bracket and lower bracket panel Make sure ...

Page 55: ...alifornia only ı Route the coolant reservoir breather hose over the timing chain tensioner Ç Insert the plastic clip through the hole in the plastic frame panel and then fasten the wire har ness and coolant reservoir breather hose with it Î Route the clutch cable between the radiator bracket and frame and in front of the thermo stat assembly breather hose Route the clutch cable to the inside of th...

Page 56: ... case breather hose to the inside of the wire harness ı Route the stator coil lead over all of the hoses and leads and then fasten them with a plastic clip Ç Align the wire harness with the indent in the upper rear fender Î Route the seat lock cable over the wire harness Fasten the wire harness with a plastic clamp Ï Route the rear left turn signal lead through the plastic clamp Ì Route the rear l...

Page 57: ... outlet hose Ò Route the fuel tank overflow hose and fuel tank breather hose over the radiator outlet hose Route the air filter case drain hose and coolant reservoir breather hose to the inside of the radiator outlet hose Make sure that the ends of all of the hoses are below the radiator outlet hose and are not touching the bottom cowling Route the sidestand switch lead and oil level switch lead t...

Page 58: ...Speed sensor lead 2 Charcoal canister California only 3 Neutral switch lead 4 EXUP cables Å Route the EXUP cables on the outside of the engine mount ı Fasten the EXUP cables with a plastic locking tie CABLE ROUTING ...

Page 59: ...e switch coupler 0 Fuel pump coupler A Speed sensor coupler B Neutral switch connector C Fuel tank overflow hose D Fuel tank breather hose except for California E Starter motor lead F Battery positive lead G Battery negative lead H Crankcase breather hose I Fuel sender coupler J Sidestand switch coupler K Engine oil level switch lead L Generator coupler M EXUP servomotor coupler N Ignition coils C...

Page 60: ...the battery negative lead and starter motor lead Ï Fasten the wire harness and ignition coil sub wire harness with a plastic clamp Ì Fasten the EXUP servomotor lead fuel pump lead speed sensor lead neutral switch lead EXUP cables and wire harness with a plastic locking tie Ó Fasten the fuel pump lead speed sensor lead neutral switch lead battery negative lead starter motor lead EXUP cables and wir...

Page 61: ...ver the oil level relay lead Fasten the starter relay lead ground lead and wire harness with a plastic locking tie ˆ Fasten the battery negative lead and wire harness with a plastic locking tie Ø Route the fuel tank overflow hose and fuel tank breather hose in front of the crankcase breather hose and under the fuel hose and EXUP servomotor Fasten the sidestand switch lead engine oil level switch l...

Page 62: ...adiator fan lead over the wire har ness Ë Fasten the wire harness and radiator fan lead to the plastic frame panel with a plastic locking tie The end of the plastic locking tie must face in Route the vacuum chamber air vent hoses through the hole and slit in the rubber baffle Ù Route the ignition coil sub wire harness in front of the foam damper on the ignition coil plate then connect the connecto...

Page 63: ...2 43 SPEC Á Install the rubber baffle over the carburetor air funnels Û The end of the plastic locking tie must face in and down CABLE ROUTING ...

Page 64: ...2 44 SPEC ...

Page 65: ...CHK ADJ 3 ...

Page 66: ...LAY 3 18 CHECKING THE SPARK PLUGS 3 20 CHECKING THE IGNITION TIMING 3 21 MEASURING THE COMPRESSION PRESSURE 3 22 CHECKING THE ENGINE OIL LEVEL 3 24 CHANGING THE ENGINE OIL 3 25 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 28 CLEANING THE AIR FILTER ELEMENT 3 29 CHECKING THE CARBURETOR JOINTS 3 29 CHECKING THE FUEL HOSES AND FUEL FILTER 3 30 CHECKING THE CRANKCASE BREATHER HOSE 3 30 CHECKING THE EXHAUST ...

Page 67: ...TEERING HEAD 3 46 CHECKING THE FRONT FORK 3 49 ADJUSTING THE FRONT FORK LEGS 3 50 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 52 CHECKING THE TIRES 3 54 CHECKING THE WHEELS 3 56 CHECKING AND LUBRICATING THE CABLES 3 57 LUBRICATING THE LEVERS AND PEDALS 3 57 LUBRICATING THE SIDESTAND 3 57 LUBRICATING THE REAR SUSPENSION 3 57 ELECTRICAL SYSTEM 3 58 CHECKING AND CHARGING THE BATTERY 3 58 CHECKING TH...

Page 68: ...000 km or 42 months which ever comes first 5 Air filter element Clean or replace if necessary 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation fluid level and vehicle for fluid leak age See NOTE on page 3 2 Correct accordingly Replace brake pads if necessary 8 Rear brake Check operation fluid level and vehicle for fluid leak age See NOTE on page 3 2 Correct accordingl...

Page 69: ...Check operation Replace if necessary 18 Front fork Check operation and for oil leakage Correct accordingly 19 Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary 20 Rear suspension relay arm and connecting arm pivoting points Check operation Lubricate with lithium soap base grease every 24 000 km or 24 months whichever comes ...

Page 70: ...3 3 CHK ADJ SEATS EB302000 SEATS Order Job Part Q ty Remarks Removing the seats Remove the parts in the order listed 1 Passenger seat 1 2 Rider seat 1 For installation reverse the removal procedure ...

Page 71: ...in the order listed Rider seat Refer to SEATS 1 Bolt 2 Bolt 3 Fuel sender coupler Disconnect 4 Fuel hose 5 Fuel tank overflow hose 1 6 Fuel tank breather hose 1 7 Fuel tank 1 8 Fuel tank side panel 2 For installation reverse the removal procedure NOTE Before disconnecting the fuel hose set the fuel cock to OFF ...

Page 72: ...the order listed Rider and passenger seats Refer to SEATS 1 Rear cowling 1 2 Bottom cowling 1 3 Front cowling inner panel left 1 4 Front cowling inner panel right 1 5 Left side cowling 1 6 Right side cowling 1 7 Windshield 1 8 Rear view mirror 2 9 Front cowling 1 For installation reverse the removal procedure ...

Page 73: ... a screwdriver then pull the fastener out INSTALLATION 1 Install side cowlings rear cowling NOTE To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cowling and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head ...

Page 74: ...Remove the parts in the order listed Rider seat and fuel tank Refer to SEATS and FUEL TANK 1 Crankcase breather hose 1 2 Air filter case breather hose 1 3 Clamp screw 4 Loosen 4 Bolt 1 5 Air filter case 1 6 Quick fastener 2 7 Ignition coil coupler 1 Disconnect 8 Spark plug cap 4 9 Ignition coil plate ignition coil 1 2 10 Rubber baffle 1 For installation reverse the removal procedure ...

Page 75: ...enter in with a screwdriver then pull the fastener out INSTALLATION 1 Install rubber baffle NOTE To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the rubber baffle and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head ...

Page 76: ...ust be at top dead center TDC on the com pression stroke 1 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case rubber baffle Refer to AIR FILTER CASE AND IGNI TION COIL PLATE bottom cowling side cowlings Refer to COWLINGS carburetor assembly Refer to CARBURETORS in chapter 6 radiator assembly thermostat assembly Refer to RADIATOR and THERMO STAT ASSEMBLY in chapter 5 2 Remove ...

Page 77: ... clearance with a thickness gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the fol lowing sequence Å Front d To measure the valve clearances of the other cylinders starting with cyl inder 1 at TDC turn the crankshaft counterclockwise as specified in the following table ı Degrees that the crankshaft is turned counterclockwise Ç Cylinder Î...

Page 78: ...NOTE Cover the timing chain opening with a rag to prevent the valve pad from fall ing into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the following table NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Si...

Page 79: ...measure ment is still incorrect e Install the new valve pad 1 and the valve lifter 2 NOTE Lubricate the valve pad with molybde num disulfide grease Lubricate the valve lifter with molyb denum disulfide oil The valve lifter must turn smoothly when rotated by hand Install the valve lifter and the valve pad in the correct place f Install the exhaust and intake cam shafts timing chain and camshaft cap...

Page 80: ...30 235 240 1 28 1 32 235 240 1 33 1 37 240 EXHAUST ı MEASURED VALVE CLEARANCE Å ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 03 0 07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 08 0 12 ...

Page 81: ...edure Note the following points 8 Install timing chain guide exhaust side timing chain tensioner pickup coil rotor cover cylinder head cover spark plugs Refer to CAMSHAFTS in chapter 4 EB303010 SYNCHRONIZING THE CARBURETORS NOTE Prior to synchronizing the carburetors the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked 1 Stand the mo...

Page 82: ...the engine and let it warm up for several minutes Vacuum gauge 90890 03094 Vacuum gauge attachment 90890 03060 Engine tachometer 90890 03113 6 Measure engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling speed 1 050 1 150 r min 7 Adjust carburetor synchronization a Synchronize carburetor 1 to carbure tor 2 by turning the synchronizing screw 1 in ...

Page 83: ... pressure between two carburetors should not exceed 1 33 kPa 10 mm Hg 8 Measure engine idling speed Out of specification Adjust 9 Stop the engine and remove the mea suring equipment 10 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Vacuum pressure at engine idling speed 29 3 kPa 0 293 kg cm2 220 mm Hg Throttle cable free play at the flange of the throttle grip 3 5 ...

Page 84: ...speed Out of specification Adjust 6 Adjust engine idling speed a Turn the pilot screw 1 in until it is lightly seated b Turn the pilot screw out the specified number of turns c Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained Engine tachometer 90890 03113 Engine idling speed 1 050 1 150 r min Carburetor angle driver 90890 03158 Pilot screw sett...

Page 85: ...BLE FREE PLAY NOTE Prior to adjusting the throttle cable free play the engine idling speed and carbu retor synchronization should be adjusted properly 1 Measure throttle cable free play a Out of specification Adjust Throttle cable free play at the flange of the throttle grip 3 5 mm 2 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case ignition coil plate along with the ignitio...

Page 86: ...ttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Direction a Throttle cable free play is increased Direction b Throttle cable free play is decreased Handlebar side a Slide back the rubber cover 6 b Loosen the locknut 7 c Turn the adjusting nut 8 in direction c or d until the specified throttle cable free play is obtained d Tigh...

Page 87: ...NG CAUTION Before removing the spark plugs blow away any dirt accumulated in the spark plug wells with compressed air to pre vent it from falling into the cylinders 4 Check spark plug type Incorrect Change Spark plugs Model manufacturer CR9E NGK U27ESR N DENSO 5 Check electrodes 1 Damage wear Replace the spark plug insulator 2 Abnormal color Replace the spark plug Normal color is medium to light t...

Page 88: ...ll connections are tight and free of corro sion 1 Remove bottom cowling Refer to COWLINGS rider seat fuel tank Refer to SEATS and FUEL TANK air filter case Refer to AIR FILTER CASE AND IGNI TION COIL PLATE timing mark accessing screw 1 2 Install timing light 1 engine tachometer onto the spark plug lead of cylinder 1 Timing light 90890 03141 Engine tachometer 90890 03113 3 Check ignition timing a S...

Page 89: ... pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE 2 Start the engine warm it up for several minutes and then stop it 3 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case ignition coil plate along with the ignition coils rubber baffle Refer to AIR FILTER CASE AND IGNI TION COIL PLATE 4 Re...

Page 90: ... plug leads before cranking the engine NOTE The difference in compression pressure between cylinders should not exceed 100 kPa 1 kg cm2 1 bar c If the compression pressure is above the maximum specification check the cylinder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification squirt a few drops of oil ...

Page 91: ...ING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Start the engine let it idle for several minutes and then stop it 3 Check engine oil level The engine oil level should be between the minimum level mark a and maxi mum level mark b Below the minimum level mark Add the recommended engine oil to ...

Page 92: ...nd then turn it off 5 Check engine oil level NOTE Before checking the engine oil level wait a few minutes until the oil has set tled EB303081 CHANGING THE ENGINE OIL 1 Remove bottom cowling Refer to COWLINGS 2 Start the engine warm it up for several minutes and then turn it off 3 Place a container under the engine oil drain bolt 4 Remove engine oil filler cap 1 engine oil drain bolt 2 along with t...

Page 93: ...e 8 Install engine oil drain bolt 9 Fill crankcase with the specified amount of the rec ommended engine oil 10 Install engine oil filler cap 11 Start the engine warm it up for several minutes and then turn it off 12 Check engine for engine oil leaks 13 Check engine oil level Refer to CHECKING THE ENGINE OIL LEVEL 14 Install bottom cowling Refer to COWLINGS T R Oil filter cartridge 17 Nm 1 7 m kg Q...

Page 94: ... 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 OIL PAN AND OIL PUMP in chapter 4 d Start the engine after solving the problem s and check the engine oil pressure again e Tighten the oil gallery bolt to specifi cation T R Oil gallery bolt 20 Nm 2 0 m kg CHANGING THE ENGINE O...

Page 95: ...cified clutch cable free play is obtained NOTE 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 Direction a Clutch cable free play is increased Direction b Clutch cable free play is decreased Engine side a Loosen the locknut 2 b Turn the adjusting nut 3 in direction c or d until the specified clutch cable free pl...

Page 96: ...he air filter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning leading to poor engine performance and possible overheating NOTE When installing the air filter element into the air filter case cover make sure that their sealing surfaces are aligned to prevent an...

Page 97: ...SES AND FUEL FILTER The following procedure applies to all of the fuel hoses 1 Remove fuel tank Refer to FUEL TANK 2 Check fuel hose 1 Cracks damage Replace fuel filter 2 Contaminants damage Replace NOTE Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident The arrow mark on the fuel filter must point towards the fuel pump 3 as shown 3 Install fuel tank Ref...

Page 98: ...NK EB303200 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets 1 Remove radiator assembly Refer to RADIATOR in chapter 5 2 Check exhaust pipe 1 muffler 2 Cracks damage Replace gasket 3 Exhaust gas leaks Replace 3 Measure tightening torque 4 Install radiator assembly Refer to RADIATOR in chapter 5 T R Exhaust pipe nut 4 20 Nm 2 0 m kg Muffler clamp b...

Page 99: ...ct the battery to the EXUP ser vomotor coupler and check if the ser vomotor operates properly ACHTUNG CAUTION To avoid damaging the servomotor do not leave the battery connected to it for more than a few seconds c Check that the EXUP valve operates properly d Connect the EXUP servomotor cou pler Battery positive lead black yellow 2 Battery negative lead black red 3 4 Measure EXUP cable free play a...

Page 100: ...r to COWLINGS and FUEL TANK EB303220 CHECKING THE COOLANT LEVEL 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Check coolant level The coolant level should be between the minimum level mark a and maxi mum level mark b Below the minimum level mark Add the recommended coolant to the proper level ACHTUNG CAUTION Addin...

Page 101: ...lant has set tled EB303230 CHECKING THE COOLING SYSTEM 1 Remove bottom cowling side cowlings Refer to COWLINGS 2 Check radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler 4 oil cooler inlet hose 5 oil cooler outlet hose 6 water jacket joint inlet hose 7 water pump inlet pipe 8 water pump outlet pipe 9 Cracks damage Replace Refer to COOLING SYSTEM in chap ter 5 3 Install side cowling...

Page 102: ...olant reservoir 5 Install coolant reservoir bolts 6 Engage clutch cable holder 7 Remove radiator cap 1 WARNING WARNING A hot radiator is under pressure There fore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause serious injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiat...

Page 103: ...and should be handled with special care WARNING WARNING If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickly wash it away with water and then with soap and water If coolant is swallowed induce vomit ing and get immediate medical atten tion Recommended antifreeze High quality ethylene glycol antifreeze containing corro si...

Page 104: ...ant comes into contact with painted surfaces immediately wash them with water Do not mix different types of anti freeze 13 Install radiator cap 14 Fill coolant reservoir with the recommended coolant to the maximum level mark a 15 Install coolant reservoir cap 16 Start the engine warm it up for several minutes and then turn it off 17 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE Befo...

Page 105: ...th the arrow mark 2 on the brake lever holder WARNING WARNING After adjusting the brake lever position make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial Position 1 Distance a is the largest Position 5 Distance a is the smallest EB304010 ADJUSTING THE REAR BRAKE 1 Measure brake pedal position distance a from the top of the brake pedal to the botto...

Page 106: ...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 considerably reduce braking performance and could result in loss of control and possibly an accident Therefore check and if necessary bleed the brake system ACHTUNG CAUTION After adjusting the brake pedal position make...

Page 107: ...k age and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ACHTUNG CAUTION Brake flui...

Page 108: ...B304050 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body 1 of the rear brake light switch so th...

Page 109: ...RNING WARNING Bleed the hydraulic brake system when ever the brake system was disassembled a brake hose was loosened discon nected or replaced the brake fluid level is very low brake operation is faulty NOTE Be careful not to spill any brake fluid or allow the brake fluid reservoir to over flow When bleeding the hydraulic brake system make sure that there is always enough brake fluid before applyi...

Page 110: ...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 the bleed screw...

Page 111: ...shift rod length 305 mm Direction b Installed shift rod length increases Direction c Installed shift rod length decreases EB304092 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain ACHTUNG CAUTION A drive chain that is too tight will over load the engine and other vital parts and one that is too loose can skip and damage the swingarm or c...

Page 112: ...osen the wheel axle nut 1 b Loosen both locknuts 2 c Turn both adjusting bolts 3 in direc tion a or b until the specified drive chain slack is obtained NOTE To maintain the proper wheel align ment adjust both sides evenly d Tighten both locknuts to specifica tion e Tighten the wheel axle nut to specifi cation Direction a Drive chain slack is reduced Direction b Drive chain slack is increased T R L...

Page 113: ...y kerosine to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EB304130 CHECKING AND ADJUSTING THE STEERING HEAD...

Page 114: ...e upper bracket 6 Remove steering stem nut 1 washer 2 upper bracket 3 7 Adjust steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 NOTE Set the torque wrench at a right angle to the steering nut wrench Steering nut wrench 90890 01403 T R Lower ring nut initial tighten ing t...

Page 115: ... If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure that the lock washer tabs a sit correctly in the ring nut slots b 8 Install steering stem nut upper bracket bolt handlebar pinch bolt upper bracket pinch bolt T R Lower ring nut final tighten ing torque 9 Nm 0 9 m kg T R 115 Nm 11 5 m kg T R 13 Nm 1 3 m kg T...

Page 116: ...ension is within speci fication i Grasp the bottom of the front fork legs and gently rock the front fork Looseness or binding Adjust the steering head Steering head tension 200 500 g EB304141 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over 2 Check inner tube 1 Damage scratches Replace oi...

Page 117: ... Securely support the motorcycle so that there is no danger of it falling over Spring preload ACHTUNG CAUTION Grooves are provided to indicate the adjustment position Never go beyond the maximum or minimum 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 ...

Page 118: ...Turn the adjusting screw 1 in direc tion a or b Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting positions Minimum 13 clicks out Standard 5 clicks out Maximum 1 clicks out from the fully turned in position Direction a Compression damping is increased suspension is harder Direction b Compression damping is decrease...

Page 119: ... mini mum adjustment positions 1 Adjust spring preload NOTE Adjust the spring preload with the spe cial wrench and extension bar included in the owner s tool kit a Turn the adjusting ring 1 in direction a or b b Align the desired position on the adjusting ring with the position indi cator 2 Direction a Spring preload is increased suspension is harder Direction b Spring preload is decreased suspens...

Page 120: ...ion a or b Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting positions Minimum 12 clicks out Standard 6 clicks out Maximum 1 clicks out from the fully turned in position Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension is softer Adjusting posi...

Page 121: ...anticipated riding speed Operation of an overloaded motorcy cle could cause tire damage an acci dent or an injury NEVER OVERLOAD THE MOTORCYCLE total of cargo rider passenger and accessories WARNING 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 198 kg Maximum load 197 kg Cold t...

Page 122: ...s soon as possible with a good quality replacement Å Tire ı 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 design No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcyc...

Page 123: ...ion of wheel rotation Align the mark 2 with the valve instal lation point Rear tire Manufacturer Size Model BRIDGESTONE 190 50 ZR17 73W BT56R BT57R METZELER 190 50 ZR17 73W MEZ1 RACING METZELER 190 50 ZR17 73W MEZ3 DUNLOP 190 50 ZR17 73W D207L MICHELIN 190 50 ZR17 73W TX25 MICHELIN 190 50 ZR17 73W MACADAM 90X PIRELLI 190 50 ZR17 73W MTR02 PIRELLI 190 50 ZR17 73W MTR02 CORSA EB304180 CHECKING THE W...

Page 124: ...B304210 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and ped als EB304220 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EB304240 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Engine oil ...

Page 125: ...yte as it can cause severe burns or perma nent eye injury FIRST AID IN CASE OF BODILY CON TACT 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 followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention ACHTUNG CAUTION This is a sealed battery Never remove the seal...

Page 126: ...ive lead 1 then the positive lead 2 3 Remove battery 4 Measure battery charge a Connect a digital voltmeter to the bat tery terminals NOTE The charge state of an MF battery can be checked by measuring its open cir cuit voltage i e the voltage when the positive terminal is disconnected No charging is necessary when the open circuit voltage equals or exceeds 12 8 V b Check the charge of the battery ...

Page 127: ...educe the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may ...

Page 128: ...3 61 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger ...

Page 129: ...3 62 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger ...

Page 130: ...ommended lubricant Dielectric grease CHECKING AND CHARGING THE BATTERY CHECKING THE FUSES EB305040 CHECKING THE FUSES The following procedure applies to all of the fuses ACHTUNG CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove rider seat Refer to SEATS 2 Check continuity a Connect the pocket tester to the fuse and check the continuity NO...

Page 131: ...WARNING WARNING Never use a fuse with an amperage other than that specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install rider seat Refer to SEATS Item Amperage Q ty Main fuse 30 A 1 Headlight fuse 20 A 1 Signaling system fuse 20 A 1 Ign...

Page 132: ...d your hands away from the bulb until it has cooled down 4 Install headlight bulb Secure the new headlight bulb with the headlight bulb holder ACHTUNG CAUTION Avoid touching the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it ...

Page 133: ...ew 1 in direc tion 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 knob 1 in direc tion a or b Left headlight Right headlight Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a Headlight beam moves to the left Direction b Headlight beam moves to the right...

Page 134: ...ENG 4 ...

Page 135: ...KING THE VALVES AND VALVE GUIDES 4 24 CHECKING THE VALVE SEATS 4 26 CHECKING THE VALVE SPRINGS 4 28 CHECKING THE VALVE LIFTERS 4 29 INSTALLING THE VALVES 4 29 GENERATOR 4 32 REMOVING THE GENERATOR 4 33 INSTALLING THE GENERATOR 4 33 PICKUP COIL 4 35 REMOVING THE PICKUP COIL ROTOR 4 37 INSTALLING THE PICKUP COIL ROTOR 4 37 CLUTCH 4 39 REMOVING THE CLUTCH 4 43 CHECKING THE FRICTION PLATES 4 43 CHECKI...

Page 136: ...HECKING THE BEARINGS AND OIL SEALS 4 61 CHECKING THE SPROCKETS AND CHAINS 4 61 ASSEMBLING THE CRANKCASE 4 62 CONNECTING RODS AND PISTONS 4 64 REMOVING THE CONNECTING RODS AND PISTONS 4 65 CHECKING THE CYLINDERS AND PISTONS 4 66 CHECKING THE PISTON RINGS 4 67 CHECKING THE PISTON PINS 4 68 CHECKING THE BIG END BEARINGS 4 69 INSTALLING THE PISTONS AND CONNECTING RODS 4 71 CRANKSHAFT 4 74 REMOVING THE...

Page 137: ...ENGINE 4 Order Job Part Q ty Remarks Removing the drive sprocket Remove the parts in the order listed 1 Locknut 2 2 Shift rod 1 3 Drive sprocket cover 1 4 Lock washer 1 5 Drive sprocket 1 6 Shift arm 1 For installation reverse the removal procedure ...

Page 138: ...and FUEL TANK in chapter 3 Bottom cowling and side cowlings Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator assembly Refer to RADIATOR in chapter 5 1 EXUP valve pulley cover 1 2 Spring 1 3 Washer 1 4 EXUP valve pulley 1 5 Locknut 2 Loosen 6 EXUP cable 2 7 Exhaust pipe assembly 1 8 Exhaust pipe gasket 4 ...

Page 139: ...ENG 4 3 ENGINE Order Job Part Q ty Remarks 9 Muffler 1 10 EXUP cable holder 1 11 EXUP valve cover 1 12 Spacer 1 13 EXUP valve 1 14 Spacer 1 For installation reverse the removal procedure ...

Page 140: ...apter 3 Carburetor assembly and carburetor joints Refer to CARBURETORS in chapter 6 Engine oil and oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Oil cooler and thermostat assembly Refer to OIL COOLER and THER MOSTAT ASSEMBLY in chapter 5 1 Battery negative lead 1 2 Battery positive lead 1 ACHTUNG CAUTION First disconnect the negative lead then the positive lead ...

Page 141: ...5 Starter motor lead 1 Disconnect 6 Ground lead 1 Disconnect 7 Starter motor 1 8 Stator coil assembly coupler 1 Disconnect 9 Pickup coil coupler 1 Disconnect 10 Oil level switch connector 1 Disconnect 11 Neutral switch 1 12 Speed sensor 1 For connecting reverse the disconnec tion procedure ...

Page 142: ...he order listed 1 Pinch bolt 2 Loosen 2 Right front mounting bolt 1 3 Washer 1 4 Spacer 1 5 Left front mounting bolt 2 6 Washer 2 7 Self locking nut 2 8 Rear mounting bolt 2 9 Spacer 1 For installation reverse the removal procedure NOTE Place a suitable stand under the frame and engine ...

Page 143: ... lithium soap base grease Do not fully tighten the nuts and bolts 2 Tighten self locking nut left front mounting bolts right front mounting bolt pinch bolts 9 T R 55 Nm 5 5 m kg T R 40 Nm 4 0 m kg T R 55 Nm 5 5 m kg T R 24 Nm 2 4 m kg 3 Install shift arm1 NOTE Align the punch mark a in the shift shaft with the slot in the shift arm T R 10 Nm 1 0 m kg 4 Install drive sprocket cover NOTE Refer to CA...

Page 144: ... the order listed Carburetor assembly Refer to CARBURETORS in chapter 6 Radiator assembly and thermostat assembly Refer to RADIATOR and THERMO STAT ASSEMBLY in chapter 5 1 Spark plug 4 2 Cylinder head cover 1 3 Cylinder head cover gasket 1 4 Timing chain guide top side 1 For installation reverse the removal procedure ...

Page 145: ...o PICKUP COIL 1 Float chamber air vent hose holder 1 2 Timing chain tensioner 1 3 Timing chain tensioner gasket 1 4 Timing chain guide exhaust side 1 5 Intake camshaft cap 3 6 Dowel pin 6 7 Exhaust camshaft cap 3 8 Dowel pin 6 9 Intake camshaft 1 10 Exhaust camshaft 1 NOTE During removal the dowel pins may still be connected to the camshaft caps ...

Page 146: ...ENG 4 10 CAMSHAFTS Order Job Part Q ty Remarks 11 Intake camshaft sprocket 1 12 Exhaust camshaft sprocket 1 13 Pin 1 14 Timing chain guide intake side 1 For installation reverse the removal procedure ...

Page 147: ...oke can be found when the camshaft lobes are turned away from each other 2 Remove float chamber air vent hose holder timing chain tensioner 3 Remove timing chain guide exhaust side 4 Remove camshaft caps dowel pins ACHTUNG CAUTION To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a crisscross pattern working from the outside in 5 Remov...

Page 148: ...aust camshaft a 32 85 mm b 24 85 mm 3 Measure camshaft runout Out of specification Replace Max camshaft runout 0 03 mm 4 Measure camshaft journal to camshaft cap clearance Out of specification Measure the camshaft journal diameter a Install the camshaft into the cylinder head without the dowel pins and camshaft caps b Position a strip of Plastigauge 1 onto the camshaft journal as shown c Install t...

Page 149: ...ge 1 T R Camshaft cap bolt 10 Nm 1 0 m kg 5 Measure camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cyl inder head and the camshaft caps as a set Camshaft journal diameter 24 437 24 450 mm EB401421 CHECKING THE TIMING CHAIN CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing ch...

Page 150: ...CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage rough movement Replace a Lightly press the timing chain ten sioner rod into the timing chain ten sioner housing by hand NOTE While pressing the timing chain ten sioner rod wind it clockwise with a thin screwdriver 1 until it stops b Remove the screwdriver and slowly release the timing chain tensioner rod c Make sure t...

Page 151: ...coil rotor with the crankcase mating surface b c Install the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the cam shafts ACHTUNG CAUTION Do not turn the crankshaft when install ing the camshaft to avoid damage or improper valve timing NOTE Make sure that the punch marks c on the camshafts face up d Install the exhaust and intake cam shaft caps NOTE Make su...

Page 152: ... chain tensioner install the timing chain tensioner 2 gasket and float chamber air vent hose holder 3 onto the cylinder block Then tighten the timing chain ten sioner bolts 4 to the specified torque WARNING WARNING Always use a new gasket NOTE The UP mark on the timing chain ten sioner should face up d Remove the screwdriver make sure that the timing chain tensioner rod releases and tighten the ca...

Page 153: ...e installation steps above 8 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 9 Install cylinder head cover gasket cylinder head cover NOTE Apply bond TB1541 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket Apply bond 1215B onto the mating surfaces of the cylinder head cover gasket and cylinder head Tighten th...

Page 154: ... Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Engine Refer to ENGINE Intake and exhaust camshafts Refer to CAMSHAFTS 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal procedure ...

Page 155: ...er carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damaging or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Eliminate 3 Measure cylinder head warpage Out of specification Resurface the cylinder head a Place a straightedge 1 and a thick ness gauge 2 across the cylinde...

Page 156: ...ern NOTE To ensure an even surface rotate the cylinder head several times EB402702 INSTALLING THE CYLINDER HEAD 1 Install cylinder head cylinder head nut cylinder head bolt T R 50 Nm 5 0 m kg T R 12 Nm 1 2 m kg NOTE Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts and bolts in two stages and in a crisscross pattern ...

Page 157: ...lve springs Remove the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake valve spring 12 6 Intake valve oil seal 12 7 Intake valve lower spring seat 12 8 Intake valve 12 9 Intake valve guide 12 ...

Page 158: ...fter 12 11 Exhaust valve pad 12 12 Exhaust valve cotter 24 13 Exhaust valve upper spring seat 12 14 Exhaust valve spring 12 15 Exhaust valve oil seal 12 16 Exhaust valve lower spring seat 12 17 Exhaust valve 12 18 Exhaust valve guide 12 For installation reverse the removal procedure ...

Page 159: ...s properly seal 1 Remove valve lifter 1 valve pad 2 NOTE Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve 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 pr...

Page 160: ... oil seal 4 lower spring seat 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EB403400 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...

Page 161: ...ve guide with a 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 Intake 4 0 mm 90890 04111 Exhaust 4 5 mm 90890 04116 Valve guide installer Intake 4 0 mm 90890 04112 Exhaust 4 5 mm 90890 04117 Valve guide reamer Intake 90890 04113 Exhaust 90890 04118 3 Eliminate carbon deposits from the valv...

Page 162: ...place the valve guide If the valve is removed or replaced always replace the oil seal Valve stem runout 0 01 mm EB403410 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 cylinder head 3 Measure valve seat width a Out of specification Replace the cy...

Page 163: ...placing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face ACHTUNG CAUTION Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve ...

Page 164: ...cylinder head i Press the valve through the valve guide and onto the valve seat to make a clear impression j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EB403420 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure valve spring free length a Out of specification Replace the valve spri...

Page 165: ...valve spring Max spring tilt Intake valve spring 1 7 mm Exhaust valve spring 1 8 mm EB403430 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check valve lifter Damage scratches Replace the valve lifters and cylinder head EB403702 INSTALLING THE VALVES The following procedure applies to all of the valves and related components 1 Deburr valve stem end with an...

Page 166: ...stall the valve spring with the larger pitch a facing up b Smaller pitch New 4 Install valve cotters 1 NOTE Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 5 To secure the valve cotters 1 onto the valve stem lightly tap the valve tip with a soft face hammer ACHTUNG CAUTION Hitting the valve tip with excessive force could damage the valv...

Page 167: ... with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 7 Install valve pad valve lifter NOTE The valve lifter must move smoothly when rotated with a finger Each valve lifter and valve pad must be reinstalled in its original position ...

Page 168: ...in chapter 3 Bottom cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Generator rotor cover 1 2 Generator rotor cover gasket 1 3 Dowel pin 2 4 Generator rotor bolt 1 5 Generator rotor 1 6 Stator coil assembly coupler 1 Disconnect 7 Stator coil assembly lead holder 1 8 Stator coil assembly 1 For installation reverse the removal procedure ...

Page 169: ...r rotor bolt Rotor holding tool 90890 01235 3 Remove generator rotor 1 with the flywheel puller 2 and rotor holding tool 3 Flywheel puller 90890 01080 EB410700 INSTALLING THE GENERATOR 1 Apply sealant onto the stator coil assembly lead grommet 2 Install generator rotor washer generator rotor bolt WARNING WARNING Always use a new generator rotor bolt ACHTUNG CAUTION Clean the tapered portion of the...

Page 170: ...e holding the generator rotor 2 with the rotor holding tool 3 tighten the generator rotor bolt Rotor holding tool 90890 01235 New T R 95 Nm 9 5 m kg 4 Install generator rotor cover NOTE Tighten the generator rotor cover bolts in stages and in a crisscross pattern ...

Page 171: ...tank Refer to SEATS and FUEL TANK in chapter 3 Bottom cowling and right side cowl ing Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Generator rotor cover Refer to GENERATOR 1 Clutch cable 1 2 Clutch cable holder 1 3 Pickup coil lead holder 1 4 Pickup coil rotor cover 1 5 Pickup coil rotor cover gasket 1 6 Dowel pin 2 ...

Page 172: ...ENG 4 36 PICKUP COIL Order Job Part Q ty Remarks 7 Pickup coil coupler 1 Disconnect 8 Pickup coil 1 9 Pickup coil rotor 1 For installation reverse the removal procedure ...

Page 173: ... fully loosened remove them 2 Remove pickup coil rotor bolt 1 washer pickup coil rotor 2 NOTE While holding the generator rotor 3 with the rotor holding tool 4 loosen the pickup coil rotor bolt Rotor holding tool 90890 01235 INSTALLING THE PICKUP COIL ROTOR 1 Install pickup coil rotor 1 washer pickup coil rotor bolt NOTE When installing the pickup coil rotor align the pin 2 in the crankshaft sproc...

Page 174: ...Nm 6 0 m kg 3 Apply sealant onto the pickup coil lead grommet Yamaha bond No 1215 90890 85505 4 Install pickup coil rotor cover pickup coil lead holder clutch cable holder NOTE When installing the pickup coil rotor cover align the timing chain guide intake side pin 1 of the with the hole 2 in the pickup coil rotor cover Tighten the pickup coil rotor cover bolts in stages and in a crisscross pat te...

Page 175: ...Remove the parts in the order listed Bottom cowling and right side cowl ing Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Clutch cable 1 2 Clutch cover 1 3 Clutch cover gasket 1 4 Dowel pin 2 For installation reverse the removal procedure ...

Page 176: ... Job Part Q ty Remarks Removing the pull lever shaft Remove the parts in the order listed 1 Circlip 2 2 Pull lever 1 3 Pull lever spring 1 4 Pull lever shaft 1 5 Oil seal 1 6 Bearing 2 For installation reverse the removal procedure ...

Page 177: ... retainer 1 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Pull rod 1 6 Friction plate 7 Inside diameter 124 mm 7 Clutch plate 6 8 Lock washer 1 9 Wire circlip 1 10 Clutch plate 1 11 Friction plate 1 Inside diameter 135 mm 12 Clutch damper spring 1 13 Clutch damper spring seat 1 14 Clutch boss 1 ...

Page 178: ... Part Q ty Remarks 15 Thrust washer 1 16 Clutch housing 1 17 Bearing 1 18 Starter clutch gear 1 19 Bearing 1 20 Starter clutch assembly 1 21 Circlip 1 22 Starter clutch idle gear 1 For installation reverse the removal procedure ...

Page 179: ...ss nut 1 lock washer 2 clutch boss assembly 3 NOTE There is a built in damper between the clutch boss and the friction plate It is not necessary to remove the wire circlip 4 and disassemble the built in damper unless there is serious clutch chattering EB405400 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the f...

Page 180: ...place the clutch plates as a set Max clutch plate warpage 0 1 mm EB405430 CHECKING THE CLUTCH SPRING PLATE 1 Check clutch spring plate Damage Replace 2 Check clutch spring plate seat Damage Replace EB405440 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 errat...

Page 181: ...1 Check pressure plate 1 Cracks damage Replace bearing 2 Damage wear Replace EB405470 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1 Check pull lever shaft pinion gear teeth a pull rod teeth b Damage wear Replace the pull rod and pull lever shaft as a set 2 Check pull rod bearing Damage wear Replace CHECKING THE STARTER CLUTCH 1 Check starter clutch gear starter clutch idle gear Chips pitting roughn...

Page 182: ...therwise the starter clutch is faulty and must be replaced EB405703 INSTALLING THE CLUTCH 1 Install clutch housing NOTE Make sure that the slots a in the clutch housing align with the tabs b on the oil water pump assembly drive sprocket Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly Make sure that the starter clutch gear teeth and starter clutch idle gear ...

Page 183: ...86 Recommended lubricant Engine oil New T R 70 Nm 7 0 m kg 6 Install friction plates clutch plates NOTE First install a friction plate and then alternate between a clutch plate and a friction plate 7 Install pressure plate 1 clutch spring plate seat 2 clutch spring plate 3 clutch spring plate retainer 4 NOTE Tighten the clutch spring plate retainer bolts in stages and in a crisscross pat tern T R ...

Page 184: ...push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged Tighten the clutch cover bolts in stages and in a crisscross pattern T R 12 Nm 1 2 m kg ...

Page 185: ...rder listed Drive sprocket cover Refer to ENGINE 1 Throttle stop screw holder 1 2 Shift shaft cover 1 3 Shift shaft cover gasket 1 4 Dowel pin 2 5 Shift shaft 1 6 Shift shaft spring 1 7 Spacer 1 8 Stopper lever spring 1 9 Stopper lever 1 10 Circlip 1 11 Collar 1 12 Shift shaft spring stopper 1 For installation reverse the removal procedure ...

Page 186: ...SHIFT SHAFT 1 Install shift shaft spring stopper 1 stopper lever spring 2 stopper lever 3 NOTE Apply LOCTITE to the threads of the shift shaft spring stopper Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum segment assembly T R 22 Nm 2 2 m kg 2 Install shift shaft 1 spacer NOTE Lubricate the oil seal lips with lithiu...

Page 187: ...in Refer to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator assembly and water pump outlet pipe Refer to RADIATOR and OIL COOLER in chapter 5 Exhaust pipe assembly Refer to ENGINE 1 Oil level switch connector 1 Disconnect 2 Oil level switch 1 3 Oil level switch lead holder 1 4 Oil pan 1 5 Oil pan gasket 1 6 Dowel pin 2 ...

Page 188: ...art Q ty Remarks 7 Drain pipe 1 8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Oil water pump assembly drive sprocket cover 1 12 Dowel pin 1 13 Oil water pump assembly 1 14 Relief valve assembly 1 For installation reverse the removal procedure ...

Page 189: ...arks Removing the oil pump Remove the parts in the order listed 1 Oil water pump assembly driven sprocket 1 2 Washer 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For installation reverse the removal procedure ...

Page 190: ...ove them EB411400 CHECKING THE OIL PUMP 1 Check oil water pump assembly driven sprocket 1 oil pump housing 2 Cracks damage wear Replace the defective part s 2 Measure inner rotor to outer rotor tip clear ance a outer rotor to oil pump housing clear ance 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 09 0 15 mm O...

Page 191: ...ar Replace the defective part s EB411421 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EB411430 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with engine oil EB411701 ASSEMBLING THE OIL PUMP 1 Lubricate inner rotor outer rotor impeller shaft with the recommende...

Page 192: ...ER 1 Install oil strainer 1 NOTE The arrow a on the oil strainer housing must point towards the front of the engine T R 10 Nm 1 0 m kg EB411730 INSTALLING THE OIL PAN 1 Install dowel pins oil pan gasket oil pan 1 oil level switch 2 engine oil drain bolt 3 WARNING WARNING Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil level switc...

Page 193: ...r to CYLINDER HEAD Pickup coil and pickup coil rotor Refer to PICKUP COIL Stator coil assembly Refer to GENERATOR Clutch housing and starter clutch idle gear Refer to CLUTCH Oil water pump assembly Refer to OIL PAN AND OIL PUMP 1 Timing chain 1 2 Crankshaft sprocket 1 3 Pin 1 4 Oil water pump assembly drive chain guide 1 5 Oil water pump assembly drive chain 1 ...

Page 194: ...ENG 4 58 CRANKCASE Order Job Part Q ty Remarks 6 Oil water pump assembly drive sprocket 1 7 Washer 1 8 Plate 1 9 Lower crankcase 1 10 Dowel pin 3 For installation reverse the removal procedure ...

Page 195: ...order listed Connecting rod assemblies Refer to CONNECTING RODS AND PISTONS Crankshaft Refer to CRANKSHAFT Transmission Refer to TRANSMISSION 1 Oil baffle plate 1 2 Oil baffle plate 1 3 Oil delivery pipe 1 4 Bearing 1 5 Upper crankcase 1 6 Oil filter bolt 1 7 Lower crankcase 1 For installation reverse the removal procedure ...

Page 196: ...r crankcase ACHTUNG CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on rein forced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crankcase halves separate evenly M9 115 mm bolts 1 M8 60 mm bolt K M8 50 mm bolt L M6 70 mm bolts G I O M6 65 mm bolt Q M6 64 mm bolts F N M6 60 mm bolt M M6 55 mm bolts A E M6 50...

Page 197: ... AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace CHECKING THE SPROCKETS AND CHAINS 1 Check crankshaft sprocket 1 oil water pump assembly drive sprocket 2 Cracks damage wear Replace the defective part s 2 Check timing chain 1 Damage stiffness Replace the tim ing chain and crankshaft sprocket as a set oil water pump a...

Page 198: ...r crankshaft journal bearings Do not apply sealant to within 2 3 mm of the crankshaft jour nal bearings 3 Install dowel pin Yamaha bond No 1215 90890 85505 4 Install crankshaft journal lower bearings into the lower crankcase NOTE Align the projections a on the crank shaft journal lower bearings with the notches b in the lower crankcase Install each crankshaft journal lower bearing in its original ...

Page 199: ...ankcase bolts NOTE Lubricate the bolt threads with engine oil Install a washer on bolts 1 Tighten the bolts in the tightening sequence cast on the crankcase M9 115 mm bolts 1 M8 60 mm bolt K M8 50 mm bolt L M6 70 mm bolts G I O M6 65 mm bolt Q M6 64 mm bolts F N M6 60 mm bolt M M6 55 mm bolts A E M6 50 mm bolt H M6 45 mm bolts J P R T R Bolt 1 32 Nm 3 2 m kg Bolt A E G J M O R 12 Nm 1 2 m kg Bolt ...

Page 200: ...ting rods and pistons Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal procedure ...

Page 201: ...ting rod 4 ACHTUNG CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put identification marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the pis ton pin bore area in the piston 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 ...

Page 202: ... to back measure ments of the cylinder Then find the average of the measurements b If out of specification replace the crankcases and the pistons and pis ton rings as a set c Measure piston skirt diameter P with the micrometer a 5 mm from the bottom edge of the pis ton d If out of specification replace the pis ton and piston rings as a set Cylinder bore gauge 90890 03017 Cylinder bore C 74 000 74 ...

Page 203: ... 055 mm Limit 0 12 mm EB404410 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the pis ton and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon depos its from the piston ring grooves and pis ton rings Piston ring side clearance Top ring 0 030 0 065 mm Limit 0 115 mm 2nd ring 0 020 0 055 mm Limit 0 115 mm 2 I...

Page 204: ... mm Oil ring 0 10 0 35 mm EB404421 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 lubri cation system 2 Measure piston pin outside diameter a Out of specification Replace the pis ton pin Piston pin outside diameter 16 991 17 000 mm Limit 16 971 mm 3 Measure piston pin bore di...

Page 205: ...cedure applies to all of the connecting rods ACHTUNG CAUTION Do not interchange the big end bearings and connecting rods To obtain the cor rect crankshaft pin to big end bearing clearance and prevent engine damage the big end bearings must be installed in their original positions a Clean the big end bearings crank shaft pins and bearing portions of the connecting rods b Install the big end upper b...

Page 206: ...e connecting rod nuts be sure to use an F type torque wrench Without pausing tighten the connect ing rod nuts to the specified torque Apply continuous torque between 2 0 and 3 6 m kg Once you reach 2 0 m kg DO NOT STOP TIGHTENING until the specified torque is reached If the tightening is interrupted between 2 0 and 3 6 m kg loosen the connecting rod nut to less than 2 0 m kg and start again Refer ...

Page 207: ...n For example if the connecting rod P1 and the crankshaft web P1 num bers are 5 and 1 respectively then the bearing size for P1 is P1 connecting rod P1 crank shaft 2 5 1 2 2 BIG END BEARING COLOR CODE 1 violet 0 white 1 blue 2 black EB404704 INSTALLING THE PISTONS AND CONNECTING RODS The following procedure applies to all of the pistons and cylinders 1 Install top ring 2nd ring oil ring NOTE Be su...

Page 208: ...pointing up Refer to the illustration Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 New 3 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring Å Intake side 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Lubricate bolt threads nut seats with the reco...

Page 209: ...ting rod assembly into the cylinder with the other hand Make sure that the Y marks a on the connecting rods face towards the left side of the crankshaft Make sure that the characters b on both the connecting rod and connect ing rod cap are aligned 8 Align bolt heads with the connecting rod caps 9 Tighten connecting rod nuts ACHTUNG CAUTION When tightening the connecting rod nuts be sure to use an ...

Page 210: ...ankshaft assembly Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 For installation reverse the removal procedure ...

Page 211: ...haft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crank shaft CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1 Measure crankshaft journal to crankshaft jour nal bearing clearance Out of specification Replace the crankshaft journal bearings ACHTUNG CAUTION Do not interchange the crankshaft jour nal bearings To obtain the correct crankshaft journal to crankshaft jou...

Page 212: ... journal NOTE Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase NOTE Align the projections a on the crank shaft journal lower bearings with the notches b in the lower crankcase Do not move the crankshaft until the clearance measurement has been completed f Tighten the bolts to s...

Page 213: ...aft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings For example if the crankcase J1 and crankshaft web J1 numbers are 6 and 2 respectively then the bearing size for J1 is Bearing size for J1 J1 c...

Page 214: ...Install crankshaft journal upper bearings into the upper crankcase NOTE Align the projections a on the crank shaft journal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft jour nal upper bearing in its original place ...

Page 215: ...shift drum assembly and shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Stopper lever Refer to SHIFT SHAFT 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Shift drum retainer 1 6 Shift fork guide bar 2 7 Spring 4 8 Shift fork L 1 9 Shift fork R 1 ...

Page 216: ...ENG 4 80 TRANSMISSION Order Job Part Q ty Remarks 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle assembly 1 For installation reverse the removal procedure ...

Page 217: ...g the main axle assem bly Remove the parts in the order listed 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd 4th pinion gears 1 9 5th pinion gear 1 Collar 1 ...

Page 218: ...ENG 4 82 TRANSMISSION Order Job Part Q ty Remarks A Main axle 1st pinion gear 1 B Bearing 1 C Main axle bearing housing 1 For installation reverse the removal procedure ...

Page 219: ...Disassembling the drive axle assem bly Remove the parts in the order listed 1 Washer 1 2 1st wheel gear 1 3 Spacer 1 4 5th wheel gear 1 5 Circlip 3 6 Washer 3 7 3rd wheel gear 1 8 Toothed spacer 2 9 Toothed lock washer 1 Toothed lock washer retainer 1 ...

Page 220: ...ENG 4 84 TRANSMISSION Order Job Part Q ty Remarks A 4th wheel gear 1 B 6th wheel gear 1 C 2nd wheel gear 1 D Spacer 1 E Drive axle 1 F Bearing 1 G Spacer 1 For installation reverse the removal procedure ...

Page 221: ...rankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase EB413400 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check shift fork cam follower 1 shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WA...

Page 222: ...t drum bearing 2 Damage pitting Replace the shift drum assembly EB413422 CHECKING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Max main axle runout 0 08 mm 2 Measure drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Max drive axle runout 0 08 mm 3 Check transmissi...

Page 223: ...t fork R shift fork L springs shift fork guide bars drive axle assembly NOTE Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle Make s...

Page 224: ...4 88 ENG ...

Page 225: ...COOL 5 ...

Page 226: ...ER 5 5 CHECKING THE OIL COOLER 5 6 INSTALLING THE OIL COOLER 5 6 THERMOSTAT ASSEMBLY 5 8 CHECKING THE THERMOSTAT 5 11 ASSEMBLING THE THERMOSTAT ASSEMBLY 5 11 INSTALLING THE THERMOSTAT ASSEMBLY 5 12 WATER PUMP 5 13 DISASSEMBLING THE WATER PUMP 5 15 CHECKING THE WATER PUMP 5 15 ASSEMBLING THE WATER PUMP 5 16 ...

Page 227: ...COOL ...

Page 228: ... cover Refer to AIR FILTER CASE AND IGNI TION COIL PLATE in chapter 3 Bottom cowling and side cowlings Refer to COWLINGS in chapter 3 Drive sprocket cover Refer to ENGINE in chapter 4 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Coolant reservoir breather hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Thermo switch coupler 1 Disconnect 5 Temperature sender connector 1 Disc...

Page 229: ...reather hose 1 Disconnect 10 Radiator inlet hose 1 11 Oil cooler outlet hose 1 Disconnect 12 Water pump breather hose 1 13 Radiator outlet hose 1 14 Water pump inlet pipe 1 15 Radiator fan motor coupler 1 Disconnect 16 Horn bracket 1 17 Radiator 1 18 Radiator fan 1 For installation reverse the removal procedure ...

Page 230: ...sure radiator cap opening pressure Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 b Apply the specified pressure for ten seconds and make sure that there is no drop in pressure Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 0 95 1 25 bar Radiator cap tester 90890 01325 Adapter 90890 01352 4 Check radiator f...

Page 231: ...the specified amount of the rec ommended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 232: ...er to RADIATOR Exhaust pipe assembly Refer to ENGINE in chapter 4 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Oil cooler outlet hose 1 2 Bolt 1 3 Lock washer 1 4 Oil cooler 1 5 Oil cooler inlet hose 1 6 Water pump outlet pipe 1 7 Water jacket joint inlet hose 1 8 Water jacket joint 1 For installation reverse the removal procedure ...

Page 233: ...LLING THE OIL COOLER 1 Clean mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thinner 2 Install O ring oil cooler 1 lock washer 2 bolt 3 NOTE Before installing the oil cooler lubri cate the oil cooler bolt and O ring with a thin coat of engine oil Make sure that the O ring is positioned properly Align the projection a on the oil cooler with the slot b in the c...

Page 234: ...OOLANT in chapter 3 crankcase with the specified amount of the rec ommended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 5 Check cooling system Leaks Repair or replace any faulty part 6 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 235: ...EATS and FUEL TANK in chapter 3 Air filter case and rubber cover Refer to AIR FILTER CASE AND IGNI TION COIL PLATE in chapter 3 Carburetor assembly Refer to CARBURETORS in chapter 6 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator inlet hose 1 Disconnect 2 Thermostat assembly breather hose 1 3 Thermostat assembly inlet hose left 1 4 Thermostat assembly inlet hose right 1 ...

Page 236: ... COOL THERMOSTAT ASSEMBLY Order Job Part Q ty Remarks 5 Thermostat assembly 1 6 Thermostat assembly inlet pipe left 1 7 Thermostat assembly inlet pipe right 1 For installation reverse the removal procedure ...

Page 237: ...LY EB502010 Order Job Part Q ty Remarks Disassembling the thermostat assembly Remove the parts in the order listed 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 For assembly reverse the disassembly procedure ...

Page 238: ...thermometer s indi cated temperature 1 Thermostat 2 Thermometer 3 Water 4 Container Å Fully closed ı Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling 2 Check thermostat housing cover thermostat housing Cracks damage Replace EB502030 ASSEMBLING THE THERMOSTAT ASSEMBLY 1 Install thermostat housing 1 thermostat...

Page 239: ...system with the specified amount of the rec ommended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 240: ...ly and oil pump rotor Refer to OIL PAN AND OIL PUMP in chapter 4 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impel ler 1 NOTE The water pump and oil pump are combined into one unit oil water pump assembly It is not necessary to remove the impeller shaft unless the coolant level is extremely low or coolant leaks from the oil pan ...

Page 241: ...5 14 COOL WATER PUMP Order Job Part Q ty Remarks 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 For installation reverse the removal procedure ...

Page 242: ...e of the water pump housing 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver NOTE Do not scratch the impeller shaft EB503032 CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 Cracks damage wear Replace 2 Check water pump seal oil seal water pump in...

Page 243: ...AUTION Never lubricate the water pump seal surface with oil or grease NOTE Install the water pump seal with the special tools Before installing the water pump seal apply Yamaha bond No 1215 2 to the water pump housing 3 Å Push down Mechanical seal installer 4 90890 04078 Middle driven shaft bearing driver 5 90890 04058 Yamaha bond No 1215 90890 85505 New 3 Install rubber damper 1 rubber damper hol...

Page 244: ...asure impeller shaft tilt Out of specification Repeat steps 3 and 4 ACHTUNG CAUTION Make sure that the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm ...

Page 245: ...5 18 COOL ...

Page 246: ...CARB 6 ...

Page 247: ...URETORS 6 1 CHECKING THE CARBURETORS 6 6 ASSEMBLING THE CARBURETORS 6 8 INSTALLING THE CARBURETORS 6 10 MEASURING AND ADJUSTING THE FUEL LEVEL 6 11 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 12 CHECKING THE FUEL PUMP 6 15 ...

Page 248: ...CARB ...

Page 249: ...TANK in chapter 3 Air filter case and rubber baffle Refer to AIR FILTER CASE AND IGNI TION COIL PLATE in chapter 3 1 Starter cable 1 2 Fuel hose 1 3 Throttle position sensor coupler 1 Disconnect 4 Float chamber air vent hose 2 5 Throttle stop screw 1 6 Carburetor joint clamp screw 8 7 Throttle cable 2 8 Carburetor assembly 1 9 Carburetor joint 4 For installation reverse the removal procedure ...

Page 250: ... Starter plunger link 1 2 Connecting bolt 1 R 245 mm 3 Copper washer 1 4 Connecting bolt 1 R 270 mm 5 Spacer 1 R 43 mm 6 Spacer 1 R 38 mm 7 Spacer 1 R 36 mm 8 Hose joint 2 9 Float chamber air vent hose 1 R 250 mm 10 Float chamber air vent hose 1 R 355 mm 11 Spring 2 12 Vacuum chamber air vent hose 2 13 Vacuum chamber pipe 1 ...

Page 251: ... 37 mm 15 Fuel feed pipe 1 R 32 mm 16 Fuel feed pipe 1 R 29 mm 17 Pipe 1 R 73 mm 18 Pipe 1 R 68 mm 19 Pipe 1 R 66 mm 20 Throttle stop screw 1 21 Throttle position sensor 1 22 Throttle position sensor bracket 1 23 Carburetor 4 For installation reverse the removal procedure ...

Page 252: ...ts in the order listed 1 Starter plunger 1 2 Air funnel 1 3 Air funnel joint 1 4 Pilot air jet 1 5 Vacuum chamber cover 1 6 Piston valve spring 1 7 Jet needle holder 1 8 Jet needle kit 1 9 Piston valve 1 0 Pilot screw 1 A Fuel drain bolt 1 NOTE The following procedure applies to all of the carburetors ...

Page 253: ...RETORS Order Job Part Q ty Remarks B Float chamber 1 C Float pivot pin 1 D Float 1 E Needle valve 1 F Needle valve seat 1 G Main jet 1 H Main jet holder 1 I Pilot jet 1 For assembly reverse the disassembly procedure ...

Page 254: ...Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chamber rubber gasket 1 Cracks damage wear Replace 5 Check float Damage Replace 6 Check needle valve 1 needle valve seat 2 Damage obstruction wear Replace the needle valve needle valve seat and O ring as a set 7 Check O ring 3 Damage we...

Page 255: ...eedle kit 1 main jet 2 main jet holder 3 pilot jet 4 pilot screw 5 starter plunger 6 pilot air jet 7 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 11 Check piston valve movement Insert the piston valve into the carbu retor body and move it up and down Tightness Replace the piston valve 12 Check fuel feed pipes 1 pipes 2 hose joints 3 Cracks damage Replace Obstru...

Page 256: ...ssembling the carburetors wash all of the parts in a petroleum based solvent Always use a new gasket 1 Install pilot screw kit 1 Pilot screw setting 2 1 2 turns out 2 Install piston valve 1 jet needle jet needle holder piston valve spring vacuum chamber cover NOTE Install the end of the piston valve spring onto the spring guide on the vacuum chamber cover Align the tab a on the piston valve diaphr...

Page 257: ...ew 3 4 Install starter plunger link 1 NOTE Install the starter plunger link 1 onto each starter plunger 5 Tighten connecting bolts NOTE Place the carburetor assembly on a surface plate with the intake manifold side down Then tighten the connect ing bolts while pushing down the car buretor assembly with an even force After tightening the connecting bolts check that the throttle valve lever and star...

Page 258: ...G THE CAR BURETORS in chapter 3 2 Adjust engine idling speed Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3 Engine idling speed 1 050 1 150 r min 3 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm ...

Page 259: ... next to the line 4 on the float cham ber f Measure the fuel level a NOTE Fuel level readings should be equal on both sides of the carburetor assembly 2 Adjust fuel level a Remove the carburetor assembly b Check the needle valve seat and nee dle valve c If either is worn replace them as a set d If both are fine adjust the float level by slightly bending the float tang 1 e Install the carburetor as...

Page 260: ...ocket tester Ω 1k to the throttle position sensor e While slowly opening 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 G...

Page 261: ...ottle 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 slightly from those specified Tester...

Page 262: ... throttle position sensor screws 1 e Adjust the throttle position sensor angle according to the following table NOTE The angle of the throttle position sensor is indicated by the r min which are dis played on the tachometer f After adjusting the throttle position sensor angle tighten the throttle position sensor screws NOTE To exit the throttle position sensor adjustment mode start the engine or s...

Page 263: ...the fuel tank to fuel pump fuel hose to the fuel tank and then set the fuel cock to ON d Place a container under the end of the fuel hose 2 e Start the engine and check if fuel flows from the fuel hose 2 f Stop the engine and check if the fuel stops flowing from the fuel hose 2 Fuel flows Fuel pump is OK Fuel does not flow Replace the fuel pump Fuel stops flow ing Fuel pump is OK Fuel flows Replac...

Page 264: ...6 16 CARB ...

Page 265: ...CHAS 7 ...

Page 266: ... 7 16 REPLACING THE FRONT BRAKE PADS 7 18 REPLACING THE REAR BRAKE PADS 7 20 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 7 28 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 7 28 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 7 28 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER 7 29 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 7 31 DISASSEMBLING THE FRONT BRAKE CALIPERS 7 37 DISASSEMBLIN...

Page 267: ...EAR SHOCK ABSORBER AND GAS CYLINDER 7 67 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 7 67 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 7 68 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 7 68 CHECKING THE RELAY ARM AND CONNECTING ARM 7 69 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 7 69 SWINGARM AND DRIVE CHAIN 7 70 REMOVING THE SWINGARM 7 72 REMOVING THE DRIVE CHAIN 7 73 CHECKING...

Page 268: ...he order listed 1 Brake hose holder left and right 2 2 Brake caliper left and right 2 3 Wheel axle pinch bolt 1 Loosen 4 Front wheel axle 1 5 Front wheel 1 6 Collar left and right 2 7 Oil seal cover left and right 2 8 Brake disc left and right 2 For installation reverse the removal procedure NOTE Place the motorcycle on a suitable stand so that the front wheel is ele vated ...

Page 269: ...E DISCS EB700010 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 270: ...r right brake caliper NOTE Do not squeeze 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 EB700110 DISASSEMBLING THE FRONT WHEEL 1 Remove oil seals wheel bearings a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel ...

Page 271: ...ter 3 3 Measure radial wheel runout 1 lateral wheel runout 2 Over the specified limits Replace 4 Check wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings oil seals Damage wear Replace Max radial wheel runout 1 0 mm Max lateral wheel runout 0 5 mm 5 Replace wheel bearings oil seals a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head scre...

Page 272: ...e following procedure applies to both of the brake discs 1 Check brake disc Damage galling Replace 2 Measure brake disc deflection Out of specification Correct the brake disc deflection or replace the brake disc a Place the motorcycle on a suitable stand so that the wheel is elevated b Before measuring the front brake disc deflection turn the handlebars to the left or right to ensure that the fron...

Page 273: ...eflection e If out of specification repeat the adjustment steps until the brake disc deflection is within specification f If the brake disc deflection cannot be brought within specification replace the brake disc EB700711 ASSEMBLING THE FRONT WHEEL 1 Install wheel bearings oil seals a Install the new wheel bearings and oil seals in the reverse order of disas sembly ACHTUNG CAUTION Do not contact t...

Page 274: ...eel axle 1 wheel axle pinch bolt 2 ACHTUNG CAUTION Before tightening the wheel axle nut push down hard on the handlebars sev eral times and check if the front fork rebounds smoothly T R 72 Nm 7 2 m kg T R 23 Nm 2 3 m kg 4 Install brake calipers WARNING WARNING Make sure that the brake hose is routed properly T R 40 Nm 4 0 m kg EB700901 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE After replacing ...

Page 275: ...ps put an X2 mark at the bottom of the wheel g Repeat steps a through d several times until all the marks come to rest at the same spot h The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust front wheel static balance a Install a balancing weight 1 onto the rim exactly opposite the heavy spot X NOTE Start with the lightest weight b Turn the front wheel 90 so that th...

Page 276: ... WHEEL AND BRAKE DISCS 4 Check front wheel static balance a Turn the front wheel and make sure that it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 277: ...cknut left and right 2 Loosen 3 Adjusting bolt left and right 2 Loosen 4 Wheel axle nut 2 5 Washer 1 6 Rear wheel axle 1 7 Left adjusting block 1 8 Right adjusting block 1 9 Rear wheel 1 10 Brake caliper bracket 1 For installation reverse the removal procedure NOTE Place the motorcycle on a suitable stand so that the rear wheel is ele vated NOTE Make sure that the tapered side of the right adjusti...

Page 278: ...ke disc and rear wheel sprocket Remove the parts in the order listed 1 Brake disc 1 2 Rear wheel sprocket 1 3 Oil seal cover left and right 2 4 Spacer left and right 2 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Rear wheel 1 For installation reverse the removal procedure ...

Page 279: ...ND REAR WHEEL SPROCKET Order Job Part Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Spacer 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly procedure ...

Page 280: ...el is elevated 2 Remove brake caliper NOTE Do not depress the brake pedal when removing the brake caliper 3 Remove wheel axle nut washer wheel axle adjusting blocks rear wheel NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EB701400 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals brake disc Refer to FRONT WHEEL 2 Check tire re...

Page 281: ...KING AND REPLACING THE REAR WHEEL SPROCKET 1 Check rear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprocket b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace rear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that cont...

Page 282: ...r 3 Drive chain slack 40 50 mm 3 Tighten wheel axle nut brake caliper bolts WARNING WARNING Make sure that the brake hose is routed properly T R 150 Nm 15 0 m kg T R 40 Nm 4 0 m kg EB701900 ADJUSTING THE REAR 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...

Page 283: ...s 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 pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Bleed screw 1 For installation reverse the removal procedure ...

Page 284: ...der Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Bleed screw 2 For installation reverse the removal procedure ...

Page 285: ...se only clean or new brake fluid for cleaning brake components Brake fluid may damage painted sur faces 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 EB702112 REPLACING THE ...

Page 286: ...install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open con tainer b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim onto each new brake pads e Install new brake pads and a ...

Page 287: ...VEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EB702113 REPLACING THE REAR BRAKE PADS NOTE When replacing the brake pads it is not necessary to disconnect the brake hose or disassemble the brake caliper 1 Remove brake caliper 1 brake pad cover 2 Remove brake pad clips 1 brake pad pins 2 brake pa...

Page 288: ...pring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open con tainer b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim onto each new brake pad T R Bleed scre...

Page 289: ...0 Nm 4 0 m kg 6 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 290: ...e order listed Brake fluid Drain 1 Brake fluid reservoir cap stopper 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Circlip 1 8 Hose joint 1 9 Brake lever 1 10 Front brake switch connector 2 Disconnect 11 Union bolt 1 12 Copper washer 3 ...

Page 291: ...4 CHAS FRONT AND REAR BRAKES Order Job Part Q ty Remarks 13 Brake hose 2 14 Brake master cylinder holder 1 15 Brake master cylinder 1 16 Front brake switch 1 For installation reverse the removal procedure ...

Page 292: ... Order Job Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 293: ... listed Brake fluid Drain 1 Brake fluid reservoir cap stopper 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Hose joint 1 8 Union bolt 1 9 Copper washer 2 10 Brake hose 1 11 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 294: ...RAKES EB702203 Order Job Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Brake master cylinder kit 1 2 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 295: ... of the brake hose EB702220 DISASSEMBLING 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 cylin der and the end of the brake hose EB702243 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders 1 Check brake master cylinde...

Page 296: ... fluid reservoir diaphragm 2 Cracks damage Replace 4 Check brake hoses Cracks damage wear Replace Å ı EB702283 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING WARNING Before installation all internal brake components should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components Recommended brake fluid DOT 4 ...

Page 297: ...nd to the right to make sure that the brake hose does not touch other parts e g wire harness cables leads Correct if necessary New T R 30 Nm 3 0 m kg 3 Fill brake fluid reservoir with the specified amount of the rec ommended brake fluid WARNING WARNING Use only the designated brake fluid Other brake fluids may cause the rub ber seals to deteriorate causing leak age and poor brake performance Refil...

Page 298: ...r to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EB702290 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers brake hoses union bolt WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHT...

Page 299: ...d and could cause vapor lock ACHTUNG CAUTION Brake fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Recommended brake fluid DOT 4 4 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING ...

Page 300: ... Removing the front brake calipers Remove the parts in the order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal procedure ...

Page 301: ...li pers Remove the parts 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 caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly procedure ...

Page 302: ...B702304 Order Job Part Q ty Remarks Removing the rear brake caliper Remove the parts in the order listed Brake fluid Drain 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal procedure ...

Page 303: ...rks Disassembling the rear brake caliper Remove the parts in the order listed 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 2 6 Brake caliper piston seal 4 7 Bleed screw 2 For assembly reverse the disassembly procedure ...

Page 304: ...ose into a con tainer 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 pistons from the brake cali per WARNING WARNING Never try to pry out the brake caliper pistons Do not loosen the bolts 3 c ...

Page 305: ...ut the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper piston with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side piston from the brake caliper WARNING WARNING Never try to pry out the brake caliper pistons Do not loosen the bolt 3 c Remove the brake caliper piston seal...

Page 306: ...e brake fluid delivery passages brake caliper body Obstruction Blow out with com pressed air WARNING WARNING Whenever a brake caliper is disassem bled replace the brake caliper piston seals Å Front ı Rear Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassem bl...

Page 307: ...disassem bled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHTUNG CAUTION When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touches the projecti...

Page 308: ...er does not enter the brake fluid reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ACHTUNG CAUTION Brake fluid may damage painted sur faces 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 Recommended brake fluid DOT 4 6 Check brake fl...

Page 309: ...caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHTUNG CAUTION When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touches the projection b on the brake caliper 2 Remo...

Page 310: ...er does not enter the brake fluid reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ACHTUNG CAUTION Brake fluid may damage painted sur faces 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 Recommended brake fluid DOT 4 6 Check brake fl...

Page 311: ...llowing procedure applies to both of the front fork legs Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front cowling inner panels Refer to COWLINGS in chapter 3 1 Front fender 1 2 Upper bracket pinch bolt 1 3 Cap bolt 1 4 Handlebar pinch bolt 1 5 Lower bracket pinch bolt 2 6 Front fork leg 1 For installation reverse the removal procedure ...

Page 312: ...t fork legs Remove the parts in the order listed The following procedure applies to both of the front fork legs 1 Cap bolt 1 2 O ring 1 3 Spacer 1 4 Nut 1 5 Spring seat 1 6 Fork spring 1 7 Damper adjusting rod 1 8 Outer tube 1 9 Dust seal 1 0 Oil seal clip 1 A Oil seal 1 B Washer 1 ...

Page 313: ...7 46 CHAS FRONT FORK Order Job Part Q ty Remarks C Damper rod assembly bolt 1 D Copper washer 1 E Damper rod assembly 1 F Inner tube 1 For assembly reverse the disassembly procedure ...

Page 314: ...olt 1 cap bolt 2 handlebar boss pinch bolt 3 lower bracket pinch bolts WARNING WARNING Before loosening the upper and lower bracket pinch bolts and handlebar pinch bolt support the front fork leg 3 Remove front fork leg EB703113 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt 1 from the damper adjusting rod spacer 2 nut 3 a Press d...

Page 315: ...pring 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 4 Remove damper rod assembly bolt copper washer NOTE While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt Damper rod holder 90890 01423 ...

Page 316: ...t 2 Measure spring free length a Out of specification Replace Spring free length limit 255 mm 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil passages with compressed air ACHTUNG CAUTION The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particularly sensitive to for eign material When disassembling and assem...

Page 317: ...t fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Install damper rod assembly 1 WARNING WARNING Always use new copper washers ACHTUNG CAUTION Allow the damper rod assembly to slide slowly down the inner tube 2 until it protrudes from the bottom of the inner...

Page 318: ... oil seal faces up NOTE Before installing the oil seal lubricate its lips with lithium soap base 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 protect the oil seal during installation 5 Install outer tube onto the inner tube 6 Install washer oil seal 1 with the fork seal driver 2 Fork se...

Page 319: ... may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any for eign material to enter the front fork Rod puller 90890 01437 Adapter 90890 01436 Quantity each front fork leg 477 cm3 Recommended oil Yamaha fork and shock oil 01 or equivalent 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten tim...

Page 320: ...asuring 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 residual air 15 Measure front fork leg oil level a Out of specification Correct Front fork leg oil level from the top of the inner tube with the inner tube fully com pressed and without the spring 78 mm 16 Install nut 1 fork spring 2 spring seat 3...

Page 321: ...se the side of the rod holder that is marked B g Remove the rod puller and adapter h Install the nut 1 and position it as specified b i Install the damper adjusting rod and cap bolt and then finger tighten the cap bolt j Hold the cap bolt and tighten the nut to specification k Remove the rod holder and fork spring compressor WARNING WARNING The fork spring is compressed Always use a new cap bolt O...

Page 322: ... lower bracket pinch bolts NOTE Make sure that the inner fork tube is flush with the top of the handlebar holder 2 Tighten lower bracket pinch bolt handlebar pinch bolt 1 cap bolt 2 upper bracket pinch bolt 3 WARNING WARNING Make sure that the brake hoses are routed properly 3 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE FRONT FORK LEGS in chapter 3 T R 23 Nm 2 ...

Page 323: ...parts in the order listed 1 Left grip end 1 2 Handlebar grip 1 3 Clutch switch connector 2 Disconnect 4 Left handlebar switch 1 5 Starter cable 1 Disconnect 6 Starter lever 1 7 Clutch cable 1 Disconnect 8 Clutch lever 1 9 Right grip end 1 10 Throttle cable housing 1 11 Throttle cable 2 12 Throttle grip 1 ...

Page 324: ...4 Right handlebar switch 1 15 Brake master cylinder holder 1 16 Brake master cylinder 1 17 Handlebar pinch bolt 2 18 Upper bracket bolt 2 19 Upper bracket pinch bolt 2 20 Steering stem nut 1 21 Upper bracket 1 22 Left handlebar 1 23 Right handlebar 1 For installation reverse the removal procedure ...

Page 325: ...ressed air between the left handlebar and the handlebar grip and gradually push the grip off the handle bar 3 Remove throttle cable housing 1 throttle grip 2 NOTE Pull back the rubber cover 3 when removing the throttle cable housing EB704401 CHECKING THE HANDLEBARS 1 Check left handlebar right handlebar Bends cracks damage Replace WARNING WARNING Do not attempt to straighten bent han dlebars as th...

Page 326: ...pper bolt then the lower bolt NOTE Align the mating surfaces of the brake master cylinder holder with the punch mark a in the right handlebar There should be 2 mm of clearance between the right handlebar switch and the brake master cylinder holder 3 Install throttle grip 1 throttle cable housing 2 throttle cables NOTE Align the projection a on the throttle cable housing with the hole b in the righ...

Page 327: ... end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 7 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 8 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FR...

Page 328: ...ont wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK 1 Main switch coupler 2 Disconnect 2 Upper bracket bolt 2 3 Left handlebar assembly 1 4 Right handlebar assembly 1 5 Steering stem nut 1 6 Upper bracket 1 7 Lower bracket panel 1 8 Brake hose holder bolt 2 9 Lock washer 1 10 Upper ring nut 1 11 Rubber washer 1 ...

Page 329: ...r Job Part Q ty Remarks 12 Lower ring nut 1 13 Lower bracket 1 14 Bearing cover 1 15 Bearing inner race 2 16 Upper bearing 1 17 Lower bearing 1 18 Dust seal 1 19 Bearing outer race 2 For installation reverse the removal procedure ...

Page 330: ...e special tool 2 WARNING WARNING Securely support the lower bracket so that there is no danger of it falling Ring nut wrench 90890 01403 EB705401 CHECKING THE STEERING HEAD 1 Wash bearing balls bearing races Recommended cleaning solvent Kerosine 2 Check bearing balls 1 bearing races 2 Damage pitting Replace 3 Replace bearing balls bearing races a Remove the bearing races from the steering head pip...

Page 331: ...the bearing balls and bearing races as a set Whenever the steering head is disas sembled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EB705700 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install lower ring nut 1 rubber washer 2 upper ring nut...

Page 332: ...rk legs Refer to FRONT FORK NOTE Temporarily tighten the upper and lower bracket pinch bolts and handlebar pinch bolts 5 Tighten steering stem nut lower bracket pinch bolt upper bracket pinch bolt upper bracket bolt handlebar pinch bolt T R 115 Nm 11 5 m kg T R 23 Nm 2 3 m kg T R 23 Nm 2 3 m kg T R 13 Nm 1 3 m kg T R 17 Nm 1 7 m kg ...

Page 333: ...1 1 Bolt R 54 mm 2 Self locking nut bolt 1 1 Bolt R 80 mm 3 Self locking nut bolt spacer 1 1 1 Bolt R 65 mm 4 Rear shock absorber assembly 1 5 Spacer oil seal bearing 1 2 1 6 Self locking nut bolt 1 1 Bolt R 54 mm 7 Relay arm 1 8 Spacer oil seal bearing 1 2 2 9 Self locking nut bolt spacer 1 1 1 Bolt R 65 mm 10 Connecting arm 1 11 Spacer oil seal bearing 2 4 2 For installation reverse the removal ...

Page 334: ...or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damp ing performance will suffer EB706111 DISPOSING OF A REAR SHOCK ABSORBER AND ...

Page 335: ... hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly NOTE Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm EB706401 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1 Check rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorbe...

Page 336: ...earings oil seals spacers 2 Install connecting arm relay arm rear shock absorber assembly NOTE When installing the rear shock absorber assembly lift up the swingarm 3 Tighten connecting arm to frame nut relay arm to connecting arm nut relay arm to swingarm nut rear shock absorber assembly upper nut rear shock absorber assembly lower nut Recommended lubricant Lithium soap base grease T R 40 Nm 4 0 ...

Page 337: ...arts in the order listed Drive sprocket Refer to ENGINE in chapter 4 Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY 1 Adjusting bolt locknut 2 2 2 Drive chain guard 1 3 Rear fender 1 4 Brake hose holder 2 5 Pivot shaft nut washer 1 1 6 Pivot shaft 1 7 Swingarm 1 ...

Page 338: ...CHAS SWINGARM AND DRIVE CHAIN Order Job Part Q ty Remarks 8 Drive chain 1 9 Dust cover 2 10 Drive chain guide 1 11 Spacer 1 12 Left bearing 1 13 Right bearing 1 For installation reverse the removal procedure ...

Page 339: ... so that the rear wheel is elevated 2 Measure swingarm side play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play Å by moving the swingarm from side to side c If the swingarm side play is out of specification check the spacers bear ings washers and dust covers d Check the swingarm vertical move ment ı by moving the swingarm up and d...

Page 340: ...ter 90890 01286 EB707400 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace NOTE If the swingarm must be replaced the drive chain must be cut with a drive chain cutter 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING WARNING Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft dust covers spacer bearings Recommended cleaning solvent Ker...

Page 341: ...ain NOTE While measuring the ten link section push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and A as shown Perform this measurement at two or three different places Max ten link drive chain sec tion 150 1 mm 2 Check drive chain Stiffness Clean and lubricate or replace 3 Clean drive chain a Wipe the drive chain with a clean cloth b Put the driv...

Page 342: ...ents will deteriorate the O rings A coarse brush can also damage the O rings Therefore use only kero sine to clean the drive chain 4 Check O rings 1 Damage Replace the drive chain drive chain rollers 2 Damage wear Replace the drive chain drive chain side plates 3 Cracks damage wear Replace the drive chain 5 Lubricate drive chain Recommended lubricant Engine oil or chain lubricant suitable for O ri...

Page 343: ...tall swingarm pivot shaft washer pivot shaft nut 3 Install rear shock absorber assembly rear wheel Refer to REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Recommended lubricant Lithium soap base grease Drive chain slack 40 50 mm T R 125 Nm 12 5 m kg ...

Page 344: ...ELEC 8 ...

Page 345: ...TION OF THE BULBS 8 8 CHECKING THE CONDITION OF THE BULB SOCKETS 8 10 CHECKING THE LEDs 8 10 IGNITION SYSTEM 8 11 CIRCUIT DIAGRAM 8 11 TROUBLESHOOTING 8 12 ELECTRIC STARTING SYSTEM 8 16 CIRCUIT DIAGRAM 8 16 STARTING CIRCUIT CUTOFF SYSTEM OPERATION 8 17 TROUBLESHOOTING 8 18 STARTER MOTOR 8 22 CHECKING THE STARTER MOTOR 8 24 ASSEMBLING THE STARTER MOTOR 8 25 CHARGING SYSTEM 8 26 CIRCUIT DIAGRAM 8 26...

Page 346: ...STEM 8 38 COOLING SYSTEM 8 44 CIRCUIT DIAGRAM 8 44 TROUBLESHOOTING 8 45 FUEL PUMP SYSTEM 8 48 CIRCUIT DIAGRAM 8 48 FUEL PUMP CIRCUIT OPERATION 8 49 TROUBLESHOOTING 8 50 CHECKING THE FUEL PUMP 8 52 EXUP SYSTEM 8 53 CIRCUIT DIAGRAM 8 53 TROUBLESHOOTING 8 54 SELF DIAGNOSIS 8 57 TROUBLESHOOTING 8 58 ...

Page 347: ...6 EXUP servomotor 7 Relay unit 8 Fuse box 9 Turn signal relay 0 Ignitor unit A Starter relay B Main fuse C Oil level relay D Battery E Rectifier regulator F Rear brake light switch G Neutral switch H Speed sensor I Sidestand switch J Stator coil assembly K Oil level switch L Pickup coil M Radiator fan N Horn O Temperature sender P Thermo switch Q Headlight relay ...

Page 348: ...ght has two functions The light will come on and symbol will flash if the engine oil level is low If this symbol flashes stop the engine immediately and fill it with oil to the specified level The light will come on and symbol will flash if the coolant tempera ture is too high The following chart shows the conditions of the indicator light symbol and temperature display in accordance with the cool...

Page 349: ...ow it to cool Refer to OVERHEATING in chapter 9 This combination meter is equipped with the following A speedometer An odometer Two trip odometers A fuel reserve tripmeter A clock For GB and USA models only To change the speedometer display from kilometers to miles press the SELECT button for at least two seconds Odometer and trip meters Use the trip meters to estimate how far you can ride on a ta...

Page 350: ...isplay will return to TRIP 1 If you do not reset the fuel reserve trip meter manu ally it will automatically reset and return to TRIP 1 after refueling and the motorcycle has traveled both 5 km and for approxi mately 3 minutes Clock To change the display to the clock mode push both the SELECT and RESET but tons To set the clock 1 Push both the SELECT and RESET buttons for at least two seconds 2 Wh...

Page 351: ...ack 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 col ors b are shown in the top row in the switch illustration NOTE indicates a continuity of elec tricity between switch terminals i e a...

Page 352: ...Check each switch for damage or wear proper connections and also for continuity between the terminals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 353: ...2 Pass switch 3 Dimmer switch 4 Turn signal switch 5 Horn switch 6 Clutch switch 7 Light switch 8 Engine stop switch 9 Start switch 0 Front brake light switch A Fuse B Sidestand switch C Rear brake light switch D Neutral switch E Oil level switch ...

Page 354: ...e shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them counterclock wise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise B...

Page 355: ...life of the bulb and the lumi nous flux will be adversely affected If the headlight bulb gets soiled thor oughly 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 tester positive probe to terminal 1 and the tester n...

Page 356: ...ings indicate no con tinuity replace the bulb socket CHECKING THE LEDs The following procedure applies to all of the LEDs 1 Check LED for proper operation a Disconnect the meter assembly cou pler meter assembly side b Connect two jumper leads 1 from the battery terminals to the respective coupler terminals as shown WARNING WARNING A wire that is used as a jumper lead must have at least the same ca...

Page 357: ... Y W Y W G R Y R Y B R Y B PASS BLUE BLACK BROWN BLACK Option BLACK BROWN BROWN BROWN BROWN BROWN BLUE OFF GREEN GREEN L B B B L B BLACK BLACK B B BLUE BLUE L Y R W Br L R G R G L W R B B Y L R L Y L B L B B L G W L Y Sb L W R W R L Br L Br L Br L R Y B R R R R B B B B B B B B R B R W R B R B R B L R B L R B R W O L L L Y Y B W P B Y Ch Ch Dg Ch Br Br W Br Br Br B Y G Dg L Br Y B Sb Sb Sb Sb Sb B ...

Page 358: ...t tester 90890 03112 EB802400 YES NO 1 Main and ignition fuses Check the main and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Min open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the ...

Page 359: ... Disconnect the spark plug cap from the spark plug Connect the pocket tester Ω 1k to the spark plug cap as shown Measure the spark plug cap resistance YES NO Spark plug cap resistance 10 kΩ at 20 C Is the spark plug cap OK Replace the spark plug cap EB802409 6 Ignition coil resistance The following procedure applies to all of the ignition coils Disconnect the ignition coil connectors from the igni...

Page 360: ...eplace the pickup coil EB802411 YES NO 8 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EB802412 YES NO 9 Engine stop switch Check the engine stop switch for conti nuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch EB802413 YES NO 10 Neutral switch Check the neutral swit...

Page 361: ...ity Tester positive probe blue yellow 2 Tester negative probe sky blue 1 No conti nuity Are the tester readings correct Replace the relay unit NOTE When you switch the tester s positive and negative probes the readings in the above chart will be reversed EB802416 NO YES 13 Wiring Check the entire ignition system s wir ing Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly connected ...

Page 362: ...W G R Y R Y B R Y B PASS BLUE BLACK BROWN BLACK Option BLACK BROWN BROWN BROWN BROWN BROWN BLUE OFF GREEN GREEN L B B B L B BLACK BLACK B B BLUE BLUE L Y R W Br L R G R G L W R B B Y L R L Y L B L B B L G W L Y Sb L W R W R L Br L Br L Br L R Y B R R R R B B B B B B B B R B R W R B R B R B L R B L R B R W O L L L Y Y B W P B Y Ch Ch Dg Ch Br Br W Br Br Br B Y G Dg L Br Y B Sb Sb Sb Sb Sb B O B B R...

Page 363: ...off relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When at least one of the above con ditions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN ...

Page 364: ...Check the main and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the battery terminals Recharge or replace the battery EB803400 YES NO 3...

Page 365: ... YES NO 5 Relay unit Disconnect the relay unit from the cou pler Connect the pocket tester Ω 1 to the relay unit terminals as shown Measure the starting circuit cutoff relay for continuity as follows Tester positive probe sky blue 1 Tester negative probe black yellow 2 Continu ity Tester positive probe sky blue 1 Tester negative probe blue yellow 3 Tester positive probe black yellow 2 Tester negat...

Page 366: ...E SWITCHES Is the main switch OK Replace the main switch EB802412 YES NO 8 Engine stop switch Check the engine stop switch for conti nuity Refer to CHECKING THE SWITCHES Is the engine stop switch OK Replace the right handlebar switch EB802413 YES NO 9 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch EB802414 Y...

Page 367: ...HE SWITCHES Is the start switch OK Replace the right handlebar switch EB803408 NO YES 13 Wiring Check the entire starting system s wir ing Refer to CIRCUIT DIAGRAM Is the starting system s wiring properly connected and without defects Properly connect or repair the start ing system s wir ing The starting system circuit is OK ...

Page 368: ...move the parts in the order listed Rider seat Refer to SEATS in chapter 3 Fuel tank Refer to FUEL TANK in chapter 3 Left side cowling Refer to COWLINGS in chapter 3 1 EXUP servomotor 1 2 Throttle stop screw 1 3 Starter motor lead 1 4 Starter motor assembly 1 For installation reverse the removal procedure ...

Page 369: ...der listed 1 Starter motor front cover 1 2 Lock washer 1 3 Oil seal 1 4 Bearing 1 5 Washer set 1 6 Starter motor rear cover 1 7 Washer set 1 8 Armature assembly 1 9 Brush seat along with the brushes 1 0 Brush holder along with the brushes 1 A O ring 2 B Starter motor yoke 1 For assembly reverse the disassembly procedure ...

Page 370: ... fit the commutator NOTE The mica must be undercut to ensure proper operation of the commutator Min commutator diameter 27 mm Mica undercut 0 7 mm 4 Measure armature assembly resistances com mutator and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester b If any resistance is out of specifica tion replace the starter motor P...

Page 371: ...amage wear Replace the gear 8 Check bearing oil seal Damage wear Replace the defective part s EB803701 ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 NOTE Align the tab a on the brush seat with the slot b in the starter motor rear cover 2 Install starter motor yoke 1 O rings 2 starter motor front cover 3 starter motor rear cover 4 bolts NOTE Align the match marks a on the starter motor yoke w...

Page 372: ...G B Y L Y W Y Dg W G O L Y B Y B B B B Br B Br R L L B R Y L L B B B B R Br L R Br L OFF ON Br L PAS BLACK Option BLACK BROWN BROWN BROWN BROWN L Y R W Br L R G R G L W R W R L Br L Br L Br L R Y R B R R R R B B B Br W Br Br B R R R W W W W W W B Br L Br B L W W Br Br L L R L B B B B B B B B B B Br R G Y G Y n 2 l k j 5 6 7 8 4 3 1 m o p i s q r t X Y P 3 Rectifier regulator 4 Generator 5 Battery ...

Page 373: ...HE FUSES in chapter 3 Is the main fuse OK Replace the fuse EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the battery terminals Recharge or replace the battery EB804400 3 Charging voltage Connect the engine tachometer to the spark plug lead of cylinder 1 Connect...

Page 374: ...robe white 1 Tester negative probe white 2 Tester positive probe white 1 Tester negative probe white 3 Measure the stator coil assembly resis tances Stator coil resistance 0 45 0 55 Ω at 20 C Is the stator coil assembly OK Replace the stator coil assembly EB804404 NO YES 5 Wiring Check the wiring connections of the entire charging system Refer to CIRCUIT DIAGRAM Is the charging system s wiring pro...

Page 375: ... BLUE BLACK BROWN BLACK Option BLACK BROWN BROWN BROWN BROWN BROWN BLUE OFF GREEN GREEN L B B B L B BLACK BLACK B B BLUE BLUE L Y R W Br L R G R G L W R B B Y L R L Y L B L B B L G W L Y Sb L W R W R L Br L Br L Br L R Y B R R R R B B B B B B B B R B R W R B R B R B L R B L R B R W O L L L Y Y B W P B Y Ch Ch Dg Ch Br Br W Br Br Br B Y G Dg L Br Y B Sb Sb Sb Sb Sb B O B B R R R W W W W W W B Br L ...

Page 376: ...ing system and headlight fuses Check the main signaling system and headlight fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signaling system and headlight fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the ...

Page 377: ...r cuits Refer to CHECK ING THE LIGHTING SYSTEM Properly connect or repair the light ing system s wir ing EB805410 CHECKING THE LIGHTING SYSTEM 1 The headlight and the high beam indi cator light fail to come on YES NO 1 Headlight bulb and socket Check the headlight bulb and socket for continuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK Replace the head light...

Page 378: ...oupler Connect the pocket tester Ω 1 and battery 12 V to the headlight relay ter minals as shown Battery positive terminal red yellow 1 Battery negative terminal black yellow black blue 2 Tester positive probe white yellow white green 3 Tester negative probe black 4 YES NO Does the headlight relay have continuity between white yellow white green and black This circuit is OK Replace the head light ...

Page 379: ... brake light coupler wire harness side as shown Tester positive probe blue red 1 Tester negative probe black 2 YES NO Set the main switch to ON Set the light switch to or Measure the voltage 12 V of blue red 1 on the tail brake light coupler wire har ness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty an...

Page 380: ...r Measure the voltage 12 V of blue red 1 on the auxiliary light couplers wire har ness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the auxil iary light connec tors is faulty and must be repaired LIGHTING SYSTEM ...

Page 381: ...W Y B Dg Ch R G Sb L L R G R Br L R L G Y G R Br L Ch Sb L R G W R G L Dg G Y Br B W L Y W Y W G R Y R Y B R Y B PASS BLUE BLACK BROWN BLACK Option BLACK BROWN BROWN BROWN BROWN BROWN BLUE OFF GREEN GREEN L B B B L B BLACK BLACK B B BLUE BLUE L Y R W Br L R G R G L W R B B Y L R L Y L B L B B L G W L Y Sb L W R W R L Br L Br L Br L R Y B R R R R B B B B B B B B R B R W R B R B R B L R B L R B R W ...

Page 382: ...ht Q Neutral indicator light R Tachometer S Combination meter V Turn signal indicator light Horn switch Horn _ Turn signal switch a Turn signal relay b Rear turn signal light c Front turn signal light g Tail brake light l Signaling system fuse o Oil level relay p Oil level switch q Rear brake light switch s Front brake light switch SIGNALING SYSTEM ...

Page 383: ...continuity Refer to CHECKING AND CHARGING THE FUSES in chapter 3 Are the main and signaling system fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the battery terminals Recharge or replace the battery EB802411 YES NO 3 Main switch Check the main sw...

Page 384: ...t the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is faulty and must be repaired NO YES 3 Horn Disconnect the black connector at the horn terminal Connect a jumper lead 1 to the horn ter minal and ground the jumper lead Set the main switch to ON Push the horn switch Does the horn sound The horn is OK YES NO 4 Voltage Connect the p...

Page 385: ...2 YES NO Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage 12 V of yellow at the tail brake light coupler wire harness side Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired EB806413 3 A turn signal light turn signal indicator light or both...

Page 386: ... faulty and must be repaired 5 Voltage Connect the pocket tester DC 20V to the turn signal relay coupler wire har ness side as shown YES NO Tester positive probe brown white 1 Tester negative probe ground Set the main switch to ON Set the turn signal switch to or Measure the voltage 12V of brown white at the turn signal relay coupler wire harness side Is the voltage within specification The turn s...

Page 387: ...ES NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK Replace the neutral switch YES NO 3 Voltage Connect the pocket tester DC 20V to the meter assembly coupler wire har ness side as shown Tester positive probe brown 1 Tester negative probe sky blue 2 Set the main switch to ON Measure the voltage 12 V of brown 1 and sky blue 2 at the...

Page 388: ... level relay have continuity between red blue and black Replace the oil level relay YES NO 4 Voltage Connect the pocket tester DC 20V to the meter assembly coupler wire har ness side as shown Tester positive probe brown 1 Tester negative probe black red 2 Set the main switch to ON Measure the voltage 12 V of brown 1 and black red at the meter assembly coupler Is the voltage within specification Th...

Page 389: ...Tester negative probe black 2 Is the fuel sender OK Replace the fuel sender 3 Voltage Connect the pocket tester DC 20V to the meter assembly coupler wire har ness side as shown Tester positive probe brown 1 Tester negative probe green red 2 YES NO Set the main switch to ON Measure the voltage 12V Is the voltage within specification This circuit is OK The wiring circuit from the main switch to the ...

Page 390: ... Y R Y B R Y B PASS BLUE BLACK BROWN BLACK Option BLACK BROWN BROWN BROWN BROWN BROWN BLUE OFF GREEN GREEN L B B B L B BLACK BLACK B B BLUE BLUE L Y R W Br L R G R G L W R B B Y L R L Y L B L B B L G W L Y Sb L W R W R L Br L Br L Br L R Y B R R R R B B B B B B B B R B R W R B R B R B L R B L R B R W O L L L Y Y B W P B Y Ch Ch Dg Ch Br Br W Br Br Br B Y G Dg L Br Y B Sb Sb Sb Sb Sb B O B B R R R ...

Page 391: ...l system and radi ator fan motor fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main signal system and radia tor fan motor fuses OK Replace the fuse s EB802401 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C YES NO Is the battery OK Clean the battery terminals Recharge or replace...

Page 392: ...oolant Slowly heat the coolant then let it cool to the specified temperature as indicated in the table Check the thermo switch for continuity at the temperatures indicated in the table NOTE Make sure that the thermo switch termi nals do not get wet Test step Coolant temperature Continuity Thermo switch 1 0 98 C NO 2 More than 105 3 C YES 3 105 to 98 C YES 4 Less than 98 C NO Test steps 1 2 Heating...

Page 393: ...mperature sender for conti nuity at the temperatures indicated below Temperature sender resistance 47 5 56 8 Ω at 80 C 16 5 20 5 Ω at 115 C YES NO T R Temperature sender 15 Nm 1 5 m kg Three bond sealock 10 Replace the temper ature sender WARNING WARNING Handle the temperature sender with spe cial care Never subject the temperature sender to strong shocks If the temperature sender is dropped repla...

Page 394: ...R G W R G L Dg G Y Br B W L Y W Y W G R Y R Y B R Y B PASS BLUE BLACK BROWN BLACK Option BLACK BROWN BROWN BROWN BROWN BROWN BLUE OFF GREEN GREEN L B B B L B BLACK BLACK B B BLUE BLUE L Y R W Br L R G R G L W R B B Y L R L Y L B L B B L G W L Y Sb L W R W R L Br L Br L Br L R Y B R R R R B B B B B B B B R B R W R B R B R B L R B L R B R W O L L L Y Y B W P B Y Ch Ch Dg Ch Br Br W Br Br Br B Y G Dg...

Page 395: ...SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump ...

Page 396: ...n and ignition fuses for continuity Refer to CHECKING THE FUSES in chapter 3 Are the main and ignition fuses OK Replace the fuse s EB802401 YES NO 2 Battery Check the condition of the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the battery terminals Recharge or replace the battery EB802411 YES NO 3 Main switch ...

Page 397: ...e relay unit EB808400 6 Fuel pump resistance Disconnect the fuel pump coupler from the wire harness Connect the pocket tester Ω 1 to the fuel pump coupler fuel pump side as shown Tester positive probe black blue 1 Tester negative probe black 2 YES NO Measure the fuel pump resistance Fuel pump resistance 4 30 Ω at 20 C Is the fuel pump OK Replace the fuel pump EB808401 YES NO 7 Wiring Check the ent...

Page 398: ...ou do accidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure that the engine is com pletely cool before performing the fol lowing 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 12V to the fuel pump coupler as shown d If fuel...

Page 399: ... L Ch Sb L R G W R G L Dg G Y Br B W L Y W Y W G R Y R Y B R Y B PASS BLUE BLACK BROWN BLACK Option BLACK BROWN BROWN BROWN BROWN BROWN BLUE OFF GREEN GREEN L B B B L B BLACK BLACK B B BLUE BLUE L Y R W Br L R G R G L W R B B Y L R L Y L B L B B L G W L Y Sb L W R W R L Br L Br L Br L R Y B R R R R B B B B B B B B R B R W R B R B R B L R B L R B R W O L L L Y Y B W P B Y Ch Ch Dg Ch Br Br W Br Br ...

Page 400: ...ine speed changes the EXUP servomotor does not operate Pocket tester 90890 03112 EB811400 Procedure 1 1 EXUP servomotor operation with the EXUP servomotor coupler connected to the wire harness Disconnect the EXUP cables from the EXUP servomotor pulley Start the engine and rev it to 2 000 r min NO YES Does the EXUP servomotor pulley turn Check that the EXUP cables are properly installed If OK check...

Page 401: ... sec onds of connecting the battery EB811403 4 EXUP servomotor resistance Disconnect the EXUP servomotor cou pler from the wire harness Connect the pocket tester Ω 1k to the EXUP servomotor coupler Tester positive probe white black 1 Tester negative probe yellow blue 2 YES NO Measure the EXUP servomotor resis tance EXUP servomotor resistance 5 3 9 8 kΩ between white black and yel low blue Connect ...

Page 402: ...Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 Open circuit voltage 12 8 V or more at 20 C Is the battery OK Clean the battery terminals Recharge or replace the battery EB802411 YES NO 3 Main switch Check the main switch for continuity Refer to CHECKING THE SWITCHES Is the main switch OK Replace the main switch EB802412 YES NO 4 Engine stop switch Check the engine stop switch for conti nu...

Page 403: ...torcycle can be rid den The tachometer displays the condition code 3 000 r min EXUP Improper connec tion Short circuit The EXUP valve stays in the open position for three seconds and then the servomotor shuts off The motorcycle can be rid den The tachometer displays the condition code 7 000 r min Servomotor is locked The servomotor s power supply is constantly interrupted so that it will not burn ...

Page 404: ...R W B B Y B L G Y R W B Y Sb O B R Y B Gy L R B Y L W R W Gy B Y L B L R B R B R B L R B L R B R W O L L L Y Y B W Y B Sb B O B B Gy B Y G Y B R B L B L B L W R Gy Gy Gy B E F G F Throttle position sensor G Ignitor unit YES NO 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire harness EB812401 YES NO 2 Throttle position s...

Page 405: ...B Y G Y B R B L B L B L W R G Gy G B E F G E EXUP servomotor G Ignitor unit EB812400 YES NO 1 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Repair or replace the wire harness EB812402 YES NO 2 EXUP servomotor Check the EXUP servomotor for continu ity Refer to EXUP SYSTEM Is the EXUP servomotor OK Replace the ignitor unit Replace the EXUP servomo...

Page 406: ... Y B Sb Sb Sb B B B Gy B Y G Y B R B L O Y B L Y Y B L Y B W L Y B L B L B L W R Gy A W W A A Dg A Br A L O O A A A G R G Y B R Br W R G B L G W G R A B R R L A G W A G Y A R G A B L A A D C F E G a W c b b N O P Q T U V R S M D Fuel sender G Ignitor unit O Fuel level indicator light S Combination meter EB812403 YES NO 1 Fuel level indicator light LED Check the LED of the fuel level indicator ligh...

Page 407: ...8 61 ELEC SELF DIAGNOSIS EB812405 YES NO 3 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK Replace the ignitor unit Replace or replace the wire harness ...

Page 408: ...8 62 ELEC ...

Page 409: ...TRBL SHTG 9 ...

Page 410: ...D PERFORMANCE 9 2 ENGINE 9 2 FUEL SYSTEM 9 2 FAULTY GEAR SHIFTING 9 2 SHIFTING IS DIFFICULT 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 3 CLUTCH SLIPS 9 3 CLUTCH DRAGS 9 3 OVERHEATING 9 3 ENGINE 9 3 COOLING SYSTEM 9 3 FUEL SYSTEM 9 3 CHASSIS 9 3 ELECTRICAL SYSTEMS 9 3 OVERCOOLING 9 3 COOLING SYSTEM 9 3 POOR BRAKING PERFORMANCE 9 4 FAULTY FRONT FORK LEGS 9 4 LEAKING OIL ...

Page 411: ... HEADLIGHT DOES NOT LIGHT 9 5 HEADLIGHT BULB BURNT OUT 9 5 TAIL BRAKE LIGHT DOES NOT LIGHT 9 5 TAIL BRAKE LIGHT BULB BURNT OUT 9 5 TURN SIGNAL DOES NOT LIGHT 9 5 TURN SIGNAL BLINKS SLOWLY 9 5 TURN SIGNAL REMAINS LIT 9 5 TURN SIGNAL BLINKS QUICKLY 9 5 HORN DOES NOT SOUND 9 5 ...

Page 412: ...ug gap Incorrect spark plug heat range Fouled spark plug Worn or damaged electrode Worn or damaged insulator Faulty spark plug cap Ignition coils Damaged ignition coil Broken or shorted primary or second ary coils Faulty spark plug lead FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel filter Clogged fuel tank breather hose Clogged rollover valve California only Clogged rollover valve to fuel tan...

Page 413: ... Ignition coils Broken or shorted primary or second ary coils Faulty spark plug lead Damaged ignition coil Ignition system Faulty ignitor unit Faulty pickup coil EB902000 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING PROBLEMS ENGINE Air filter Clogged air filter element FUEL SYSTEM Carburetors Faulty diaphragm Incorrect fuel level Loose or clogged main jet Fuel pump Faulty fuel pump EB9...

Page 414: ...ant passages Cylinder head s and piston s Heavy carbon buildup Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality COOLING SYSTEM Coolant Low coolant level Radiator Damaged or leaking radiator Faulty radiator cap Bent or damaged radiator fin Water pump Damaged or faulty water pump Thermostat Thermostat stays closed Oil cooler Clogged or damaged oil cooler Hoses and pipes Da...

Page 415: ...mper rod Incorrect oil viscosity Incorrect oil level EB909001 UNSTABLE HANDLING Handlebars Bent or incorrectly installed right han dlebar Bent or incorrectly installed left han dlebar Steering head components Incorrectly installed upper bracket Incorrectly installed lower bracket incorrectly tightened ring nut Bent steering stem Damaged ball bearing or bearing race Front fork legs Unevenoil levels...

Page 416: ...T BULB BURNT OUT Wrong tail brake light bulb Faulty battery Incorrectly adjusted rear brake light switch Tail brake light bulb life expired TURN SIGNAL DOES NOT LIGHT Faulty turn signal switch Faulty turn signal relay Burnt out turn signal bulb Incorrect connection Damaged or faulty wire harness Incorrectly grounded circuit Faulty battery Blown damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY F...

Page 417: ...9 6 TRBL SHTG ...

Page 418: ...te yellow Y B yellow black Y L yellow blue W W W W W W L R Y B Y L B B R W W B W R L B W Br R R W R L W B L R Y B W G L Y L B L L R B L Y L R L B B B B B B B B B B B Br R W B R B B G Y R W Br R B B G Y L W Dg Y Ch G B Y L Y W Y Dg W G O L Y B Y L B Br W R Y Br B Br W L B Br R B Br B R L B Y B L Y L B R W B B Y B B B B Br Y B B Br R L L B R Y L L B Br W Br Br G L R B Br G L Y B L R B G B G W B Gy B...

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