Yamaha YZF-R1 2000 Supplementary Service Manual Download Page 1

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Summary of Contents for YZF-R1 2000

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Page 3: ...n procedures it is necessary to use this Supplementary Service Manual together with the following manual YZF R1 SERVICE MANUAL 4XV1 AE1 YZF R1 2000 SUPPLEMENTARY SERVICE MANUAL 1999 by Yamaha Motor Co Ltd First Edition December 1999 Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 4: ...mprove all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable Designs and specifications are subject to change without notice EB002000 IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following ...

Page 5: ...he top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 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 i...

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

Page 7: ...TMENTS INTRODUCTION 33 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 33 COWLINGS 35 AIR FILTER CASE AND IGNITION COIL PLATE 36 OVERHAULING THE ENGINE AIR INDUCTION SYSTEM 37 ENGINE 38 INSTALLING THE ENGINE 39 CYLINDER HEAD 40 CRANKCASE 41 ASSEMBLING THE CRANKCASE 43 COOLING SYSTEM RADIATOR 45 CARBURETORS AIR INDUCTION SYSTEM 47 AIR INJECTION 47 AIR CUTOFF VALVE 47 AIR INDUCTION SYSTEM DIAGRAMS 48...

Page 8: ... COOLANT TEMPERATURE WARNING LIGHT 54 SPEEDOMETER UNIT 55 ELECTRIC STARTING SYSTEM 57 STARTER MOTOR 57 COOLING SYSTEM 62 CIRCUIT DIAGRAM 62 TROUBLESHOOTING 63 SELF DIAGNOSIS 66 TROUBLESHOOTING 67 YZF R1 WIRING DIAGRAM For EUR YZF R1 WIRING DIAGRAM For OCE ...

Page 9: ...verall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2 035 mm 2 095 mm for AUS 695 mm 1 105 mm 815 mm 1 395 mm 140 mm 3 400 mm Weight Wet with oil and a full fuel tank Dry without oil and fuel Maximum load total of cargo rider passenger and accessories 194 kg 175 kg 201 kg ...

Page 10: ...mm 11 8 1 1 000 1 100 r min 29 3 kPa 220 mm Hg 1 450 kPa 14 5 kgf cm2 at 400 r min Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Regular unleaded gasoline Unleaded fuel for AUS 18 L 3 8 L Engine oil Lubrication system Recommended oil Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure hot Relief valve ope...

Page 11: ...ance Intake camshaft lobe dimensions Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions Measurement A Measurement B Measurement C Max camshaft runout Chain drive right 24 500 24 521 mm 24 459 24 472 mm 0 028 0 062 mm 32 5 32 6 mm 24 95 25 05 mm 7 45 7 65 mm 32 95 33 05 mm 24 95 25 05 mm 7 75 7 95 mm 32 4 mm 24 85 mm 32 85 mm 24 85 mm 0 03 mm ...

Page 12: ...e stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaust Valve stem runout Valve seat width Intake Exhaust 22 9 23 1 mm 24 4 24 6 mm 1 76 2 90 mm 1 76 2 90 mm 0 9 1 1 mm 0 9 1 1 mm 0 5 0 9 mm 0 5 0 9 mm 3 975 3 990 mm 4 465 4 480 mm 4 000 4 012 mm 4 500 4 512 mm 0 010 0 037 mm 0 020 0 047 mm 0 9 1 1 mm 0 9 1 1 mm 3 945 mm 4 43 mm ...

Page 13: ...ear 68 43 1 581 Chain drive 43 16 2 688 Left foot operation 35 14 2 500 35 19 1 842 30 20 1 500 28 21 1 333 30 25 1 200 29 26 1 115 0 08 mm 0 08 mm Carburetors Model manufacturer quantity Throttle cable free play at the flange of the throttle grip ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat siz...

Page 14: ...d 0 90 kg 90 197 kg High speed riding Min tire tread depth Tubeless 190 50 ZR17 73W MEZ3Y METZELER D207N DUNLOP 250 kPa 2 5 kg cm2 2 5 bar 290 kPa 2 9 kg cm2 2 9 bar 250 kPa 2 5 kg cm2 2 5 bar 1 6 mm Rear brake Brake type Operation Brake pedal position from the top of the brake pedal to the bottom of the rider footrest bracket Recommended fluid Brake discs Diameter thickness Min thickness Max defl...

Page 15: ...ube with the inner tube fully compressed and without the fork spring Damper adjusting rod locknut distance Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum with the adjusting screw fully turned in position Telescopic fork Coil spring oil damper 135 mm 255 mm 85 m...

Page 16: ...g available Standard spring preload gas air pressure Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum with the adjusting screw fully turned in position Swingarm link suspension Coil spring gas oil damper 65 mm 176 mm 162 5 mm 78 4 N mm 7 84 kgf mm 0 65 mm No 1 20...

Page 17: ... wattage quantity Headlight Auxiliary light Tail brake light Turn signal light Meter light 12 V 60 W 55 W 2 12 V 5 W 2 12 V 5 W 21 W 2 12 V 21 W 4 LED SSS SSS SSS SSS SSS Electric starting system System type Starter motor Model manufacturer Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut Constant mesh 5JJ YAMAHA 0 75 kW 9 8 mm 4 88 7 32 N 48...

Page 18: ...hermo unit Model manufacturer 5JJ NIPPON THERMOSTAT Fuses amperage quantity Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fuse odometer Reserve fuse 30 A 1 20 A 1 20 A 1 15 A 1 10 A 1 10 A 1 30 A 1 20 A 1 15 A 1 10 A 1 ...

Page 19: ... Generator rotor Oil water pump assembly driven sprocket cover Air induction system hose Crankcase Crankcase Crankcase Crankcase Ignitor unit Nut Cap nut Bolt Bolt Clamp Bolt Bolt Bolt Bolt Screw M10 M10 M10 M6 M7 M9 M6 M6 M8 M5 8 2 1 1 4 10 2 14 2 2 50 65 65 12 4 14 12 24 7 5 0 6 5 6 5 1 2 0 4 1 4 1 2 2 4 0 7 After tightening to 15 Nm 1 5 mSkg tighten another 45_ 50_ See NOTE ...

Page 20: ...ont mounting bolts Rear upper mounting bolt Rear under mounting bolts Pinch bolts Exhaust pipe bracket Rear master cylinder M30 M10 M10 M10 M8 M8 M8 9 40 55 55 24 24 18 0 9 4 0 5 5 5 5 2 4 2 4 1 8 See NOTE 1 First tighten the ring nut to approximately 18 Nm 1 8 m kg with a torque wrench then loosen the ring nut completely 2 Retighten the ring nut to specification ...

Page 21: ... 13 LUBRICATION POINTS AND LUBRICANT TYPES SPEC E202000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Connecting rod bolts and nuts ...

Page 22: ... 14 OIL FLOW DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump EB203000 OIL FLOW DIAGRAMS ...

Page 23: ... 15 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter OIL FLOW DIAGRAMS SPEC ...

Page 24: ... 16 1 Cylinder head 2 Crankshaft OIL FLOW DIAGRAMS SPEC ...

Page 25: ... 17 COOLANT FLOW DIAGRAMS SPEC 1 Thermostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint EB203000 COOLANT FLOW DIAGRAMS ...

Page 26: ... 18 1 Thermostat housing 2 Water pump 3 Radiator 4 Radiator fan COOLANT FLOW DIAGRAMS SPEC ...

Page 27: ... 19 1 Radiator 2 Thermo unit COOLANT FLOW DIAGRAMS SPEC ...

Page 28: ...f the headlight housing C The speedometer lead with not be tighten D Install the headlight relays onto the headlight housing bridge E Connect to the right front turn signal connectors F Route the turn signal leads upper the headlight housing boss 1 Clutch cable 2 Left handlebar switch lead 3 Starter cable 4 Main switch lead 5 Steering cover EB206000 CABLE ROUTING ...

Page 29: ...rottle cables G Fasten the headlight lead with a plastic clamp at white tape mark H Fasten the wire harness to the headlight housing boss with a plastic locking tie I Route the headlight lead through the plastic guide J Route the throttle cable to the front side of the brake hose K Route the clutch cable behind the front fork leg L Make sure that the horn leads face out M Route the throttle cables...

Page 30: ...ame and in front of the thermostat assem bly breather hose G Route the clutch cable to the inside of the radiator inlet hose H Insert the plastic clamp into the hole in the coolant reservoir s tab 1 Rollover valve California only 2 Charcoal canister California only 3 Rear brake switch lead 4 Timing chain tensioner 5 Thermostat assembly breather hose 6 Radiator inlet hose 7 Coolant reservoir breath...

Page 31: ... hose air induction system hose and air induction system vacuum hose outside of the AC mag neto lead Then clamp all of them at just behind of the air induction system protector and air induction system vacuum hose protector moreover at under the three sides pipe 1 Starter cable 2 Air induction system vacuum hose 3 Air induction system hose 4 Sidestand switch lead 5 Oil level switch lead 6 Clamp 7 ...

Page 32: ...ng align the leading ends of the hoses M Route the engine oil level switch lead and side stand switch lead inside the coolant hose C To the connector cover D Route the seat lock cable over the wire harness E Fasten the wire harness with a plastic clamp F Make sure the rear flasher light lead coupler and tail light lead coupler in the rubber cover G Route the rear turn signal lead through the hole ...

Page 33: ...es pipe N Pass the fuel tank breather hose and the air filter drain hose through the inside of the coolant hose No hose must be inserted into the under cowling O Pass the air filter drain hose and the coolant reser voir hose through the inside of the coolant hose and route the leading ends to the bottom of the coolant hose The leading ends must not protrude from the under cowling P Fasten the air ...

Page 34: ...e mount with a plastic locking tie 1 Speed sensor lead 2 Charcoal canister California only 3 EXUP cables 4 EXUP A Route the EXUP cables behind the cross tube B Route the neutral switch lead direct to upper right side C Route the EXUP cables on the outside of the en gine mount CABLE ROUTING SPEC ...

Page 35: ...ght lead 21 Rear flasher light lead 22 Crankcase breather hose 23 Generator coupler 24 Sidestand switch coupler CABLE ROUTING SPEC 1 Headlight sub wire harness 2 Left handlebar switch lead 3 Main switch lead 4 Starter cable 5 Right handlebar switch coupler 6 Throttle cables 7 Engine air vent hose 8 EXUP servomotor coupler 9 Air vent surge tank 10 Starter motor lead 11 Pickup coil coupler 12 Fuel p...

Page 36: ... CABLE ROUTING SPEC 25 Engine oil level switch lead 26 Air filter case drain hose 27 Air induction system hose 28 Ignition coil 29 Cover 30 Rivet 31 Screw 32 Coupler 33 Main harness 34 Frame 35 Rear fender ...

Page 37: ...mp Insert the plastic clamp into the hole on the frame F Route the ignition coil sub wire harness under the throttle position sensor G To the carburetor H Route the coolant reservoir tank breather hose up per the air vent surge tank I Fasten the wire harness and ignition coil subwire harness with a plastic clamp J Route the idle adjust cable upper the ground lead K Fasten the fuel pump lead speed ...

Page 38: ...ad with a plastic clamp Route the rear flasher light lead and taillight lead in the hole on the taillight bracket L Fasten the fuel pump lead speed sensor lead neutral switch lead rear brake light lead fuel send er lead starter motor lead and EXUP cable with a plastic clamp M 125 mm 4 88 in N 50 mm 1 95 in O To the fuel cock P To the fuel sender Q Insert the fuel tank over flow hose into a front s...

Page 39: ...upler and acmagneto coupler in the rubber cover X Fasten the main harness with a plastic band on the rear fender Y Position the ground coupler over the main harness Z Route the ground lead under the starter relay lead A Fasten the starter relay lead ground lead starting circuit cutoff relay lead alam lead and main harness with a plastic clamp Route the clamp end to outside and insert it between wi...

Page 40: ...s T Route the battery positive lead upper the main harness I Fasten the main harness with a plastic clamp In sert the plastic clamp into the hole on the frame J Route the charcoal canister hose under the engine air vent hose coolant reservoir tank breather hose and all of leads California only K Fasten the wire harness with a plastic clamp and then insert the clamp into the frame L To the radiator...

Page 41: ...heck valve clearance Adjust if necessary Every 40 000 km 5 Air filter Clean or replace if necessary 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 8 Rear brake Check operation fluid level and vehicle for fluid leakage Correct accordingly Replace brake pads if necessary 9 Br...

Page 42: ...r cartridge S Replace 25 Cooling system Cooling S Check coolant level and vehicle for coolant leakage S Correct if necessary Cooling system S Change coolant 26 Front and rear brake switches S Check operation S Correct accordingly 27 Moving parts and cables S Lubricate if necessary 28 Air induction system S Check the air cut valve and reed valve for damage S Replace the entire air induction system ...

Page 43: ...ar cowling Bottom cowling Front cowling inner panel left Front cowling inner panel right Left side cowling Right side cowling Windshield Rear view mirror Front cowling 1 1 1 1 1 1 1 2 1 Remove the parts in the order listed Refer to SEATS Front installation reverse the removal procedure 5 Nm 0 5 m kg EB302020 COWLINGS ...

Page 44: ...er hose Air filter case breather hose Air induction system hose Clamp screw Bolt Air filter case Quick fastener Ignition coil coupler Spark plug cap Ignition coil plate ignition coil Rubber baffle 1 1 1 4 1 1 2 1 4 1 2 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK Loosen Disconnect For installation reverse the removal procedure EB302040 AIR FILTER CASE AND IGNITION COIL PLATE...

Page 45: ...r induction system Air induction pipe Air cutoff valve Carburetor joint hose Air intake hose 4 1 1 1 Remove the parts in the order listed For installation reverse the removal procedure 4 Nm 0 4 m kg ENGINE CHK ADJ OVERHAULING THE ENGINE AIR INDUCTION SYSTEM ...

Page 46: ...eft front mounting bolt Washer Self locking nut Rear mounting bolt Spacer 2 1 1 1 2 2 2 2 1 Remove the parts in the order listed Place a suitable stand under the frame and engine Loosen For installation reverse the removal procedure NOTE 40 Nm 4 4 m kg 55 Nm 5 5 m kg 24 Nm 2 4 m kg 55 Nm 5 5 m kg 40 Nm 4 0 m kg 24 Nm 2 4 m kg ENGINE ...

Page 47: ...ads with lithium soap base grease d Install the rear mounting bolts 6 7 and self locking nut 8 9 e Tighten the self locking nut 8 and then tight en the self locking nut 9 f Tighten the pinch bolt 10 g Tighten the left mounting bolt 3 h Tighten the right mouthing bolt 2 i Tighten the pinch bolt 11 Self locking nut 8 9 55 Nm 5 5 m kg Right front mounting bolt 2 40 Nm 4 0 m kg Left front mounting bol...

Page 48: ...e and exhaust camshafts Cylinder head Cylinder head gasket Dowel pin 1 1 2 Remove the parts in the order listed Refer to ENGINE Refer to CAMSHAFTS For installation reverse the removal procedure 50 Nm 5 0 m kg 65 Nm 6 5 m kg 12 Nm 1 2 m kg CYLINDER HEAD ENG EB402000 CYLINDER HEAD ...

Page 49: ...h idle gear Oil water pump assembly Timing chain Crankshaft sprocket Pin Oil water pump assembly drive chain guide Oil water pump assembly drive chain 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE Refer to CYLINDER HEAD Refer to PICKUP COIL Refer to GENERATOR Refer to OIL PAN AND OIL PUMP Refer to CLUTCH 10 Nm 1 0 m kg 10 Nm 1 0 m kg CRANKCASE ENG CRANKCASE ...

Page 50: ...Job Part Q ty Remarks 6 7 8 9 10 Oil water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin 1 1 1 1 3 For installation reverse the removal procedure 10 Nm 1 0 m kg 10 Nm 1 0 m kg CRANKCASE ENG ...

Page 51: ... any sealant to come into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings 3 Install dowel pin 4 Install crankshaft journal lower bearings into the lower crankcase Align the projections a on the crankshaft jour nal lower bearings with the notches b in the lower crankcase Install each crankshaft journal lower bea...

Page 52: ...ch bolt at 15 Nm in the tightening se quence cast on the crankcase SLoosen each bolt one time and tighten 15 Nm in the same sequence STighten bolts 1 to 10 45_ X 50_ more STighten bolts 11 to 28 as shown below M9 115 mm bolts 1 X 10 M8 60 mm bolt 21 M8 50 mm bolt 22 M6 70 mm bolts 17 19 25 M6 65 mm bolt 27 M6 64 mm bolts 16 24 M6 60 mm bolt 23 M6 55 mm bolts 11 X 15 M6 50 mm bolt 18 M6 45 mm bolts...

Page 53: ...ose Coolant reservoir Thermo unit coupler 1 1 1 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to AIR FILTER CASE AND IGNI TION COIL PLATE in chapter 3 Refer to COWLINGS in chapter 3 Refer to ENGINE in chapter 4 Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect 20 Nm 2 0 m kg 23 Nm 2 3 m kg 9 Nm 0 9 m kg 10 Nm 1 0 m kg 4 5 Nm 0 45 m kg RADIATOR COO...

Page 54: ... hose Oil cooler outlet hose Water pump breather hose Radiator outlet hose Water pump inlet pipe Radiator fan motor coupler Horn bracket Radiator Radiator fan 1 1 1 1 1 1 1 1 1 1 1 Disconnect Disconnect Disconnect For installation reverse the removal procedure 20 Nm 2 0 m kg 23 Nm 2 3 m kg 9 Nm 0 9 m kg 10 Nm 1 0 m kg 4 5 Nm 0 45 m kg ...

Page 55: ...ated by the intake gas pressure through the piston valve diaphragm Normally the air cutoff valve is open to allow fresh air to flow into the exhaust port During sudden deceleration the throttle valve sudden ly closes negative pressure is generated and the air cutoff valve is closed in order to prevent after burning Additionally at high engine speeds and when the pressure decreases the air cutoff v...

Page 56: ... cutoff valve B To cylinder 1 D To cylinder 2 D To cylinder 3 E To cylinder 4 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Carburetor joint cylinder 1 AIR INDUCTION SYSTEM CARB EAS00509 AIR INDUCTION SYSTEM DIAGRAMS ...

Page 57: ... properly Cracks damage Replace pipes Cracks damage Replace 2 Check fibre reed 1 fibre reed stopper reed valve seat Cracks damage Replace 3 Measure fibre reed bending limit a Out of specification Replace the reed valve Fibre reed bending limit 0 4 mm 1 Surface plate 4 Check air cutoff valve Cracks damage Replace ...

Page 58: ...ght Oil seal cover left and right Brake disc left and right 2 2 1 1 1 2 2 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loosen For installation reverse the removal procedure NOTE Refer to INSTALLING THE FRONT WHEEL 72 Nm 7 2 m kg 6 Nm 0 6 m kg 40 Nm 4 0 m kg 18 Nm 1 8 m kg FRONT WHEEL AND BRAKE DISCS CHAS EB700002 CHASSIS FRONT ...

Page 59: ...he brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern 3 Tighten wheel axle 1 wheel axle pinch bolt 1 When front wheel is installed to front fork make sure that wheel axle 1 top end side and front fork end side are align a together Then tight en wheel axle pinch bolt 2 Before tightening the wheel axle nut push down hard on the handlebars several times and check if t...

Page 60: ...uid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Hose joint Union bolt Copper washer Brake hose Brake master cylinder 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain For installation reverse the removal procedure 5 Nm 0 5 m kg 30 Nm 3 0 m kg 23 Nm 2 3 m kg FRONT AND REAR BRAKES CHAS EB702202 FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RES...

Page 61: ... stop switch to and turn the key to ON 2 Shift the transmission into the neutral posi tion or pull the clutch lever 3 Push the start switch If the warning light does not come on while pushing the start switch have a Yamaha dealer check the electrical circuit This model is equipped with a selfdiagnosis de vice for the fuel level warning light circuit Refer to SELF DIAGNOSIS Oil level warning light ...

Page 62: ...e clutch lever 3 Push the start switch If the warning light does not come on while pushing the start switch have a Yamaha dealer check the electrical circuit Do not operate the engine if it is overheated Coolant temperature Display Conditions What to do 0 39_C Message LO is displayed OK Go ahead with riding 40 116_C Temperature is displayed OK Go ahead with riding 117 139_C Temperature flashes War...

Page 63: ... ODO TRIP 1 TRIP 2 ODO If the fuel level warning light comes on see page 3 2 the odometer display will automati cally change to the fuel reserve tripmeter mode TRIP F and start counting the distance trav eled from that point In that case pushing the SELECT button switches the display between the various tripmeter and odometer modes in the following order TRIP F TRIP 1 TRIP 2 ODO TRIP F To reset a ...

Page 64: ...ESET button to set the hours 3 Push the SELECT button and the minute digits will start flashing 4 Push the RESET button to set the minutes 5 Push the SELECT button and then release it to start the clock Tachometer The electric tachometer allows the rider to moni tor the engine speed and keep it within the ideal power range Do not operate the engine in the tachometer red zone Red zone 11 750 r min ...

Page 65: ...ling EXUP servomotor Throttle stop screw Starter motor lead Starter motor assembly 1 1 1 1 Remove the parts in the order listed Refer to SEATS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 For installation reverse the removal procedure 5 Nm 0 5 m kg 7 Nm 0 7 m kg ELECTRIC STARTING SYSTEM STARTER MOTOR ...

Page 66: ...rter motor rear cover Bearing Starter motor yoke O ring Armature assembly Brush Brush holder Starter motor front cover Bearing 1 1 1 2 1 2 1 1 1 Disassembly the parts in the order listed For assembly reverse the disassembly procedure 5 Nm 0 5 m kg ELECTRIC STARTING SYSTEM ELEC EB803501 ...

Page 67: ...saw blade which has been grounded to fit the commuta tor Mica undercut 1 5 mm The mica must be undercut to ensure proper op eration of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resistances with the pocket tester Pocket tester 90890 03112 Armature assembly Commutator resistance 1 ...

Page 68: ... Out of specification Replace the brush springs as a set Brush spring force 5 28 X 7 92 N 7 Check gear teeth Damage 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 Align the tab a on the brush seat with the slot b in the starter motor front cover 2 Install armature 1 ...

Page 69: ...ARTING SYSTEM ELEC 5 Nm 0 5 m kg NOTE 3 Install starter motor yoke 2 O rings 1 New starter motor rear cover 3 bolts Align the match marks a on the starter motor yoke with the match marks b on the front and rear covers ...

Page 70: ...OOLING SYSTEM ELEC 1 Main switch 5 Battery 6 Main fuse 22 Thermo unit 28 Combination meter 48 Radiator fan motor 49 Radiator fan motor relay 50 Radiator fan motor fuse EB807000 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 71: ...aced Battery positive lead blue Battery negative lead black 1 2 SDoes the radiator fan motor turn COOLING SYSTEM ELEC CAUTION NOTE EB807010 EB802401 TROUBLESHOOTING SThe radiator fan motor fails to turn SThe coolant temperature meter needle fails to move when the engine is warm SIf the engine is kept running at over 1 500 rpm for at least one minute with the switch remaining placed in neutral posi...

Page 72: ...ure display HI and warning light comes on 1 3 2 SRemove the thermo unit from the radiator SConnect the pocket tester Ω 1 to the ther mo unit as shown SImmerse the thermo unit in a container filled with coolant Make sure that the thermo unit terminals do not get wet SPlace a thermometer in the coolant SSlowly heat the coolant then let it cool to the specified temperature as indicated in the table S...

Page 73: ...as de scribed above Properly connect or repair the cooling system s wiring NO EB807403 8 Wiring Check the entire cooling system s wiring Refer to CIRCUIT DIAGRAM Is the cooling system s wiring properly con nected and without defects YES This circuit is OK COOLING SYSTEM ELEC ...

Page 74: ...lays 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 ridden 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 out The motorcycle can be ridden The tachome...

Page 75: ...nuity Refer to CIRCUIT DIAGRAM Is the wire harness OK YES 16 Ignitor unit 21 Speed sensor Tester lead White terminal Tester lead Body earth 1 Set the main switch to ON Turn the rear wheel slowly Check the tester voltage 0V 5V 0V Is the speed sensor OK 2 Fuel level warning light Refer to signal system SELF DIAGNOSIS ELEC NOTE EB812010 TROUBLESHOOTING The tachometer starts to display the self diagno...

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Page 77: ... 16 Ignition unit 17 Ignition coil 18 Spark plug 19 Pickup coil 20 Neutral switch 21 Speed sensor 22 Thermo unit 23 Meter assembly 24 Fuel level indicator light 25 Oil level warning light 26 Neutral indicator light 27 Tachometer 28 Combination meter 29 Coolant temperature meter 30 High beam indicator light 31 Turn signal indicator light 32 Meter light 33 Fuel sender 34 Left handlebar switch 35 Pas...

Page 78: ... 15 Throttle position sensor 16 Ignition unit 17 Ignition coil 18 Spark plug 19 Pickup coil 20 Neutral switch 21 Speed sensor 22 Thermo unit 23 Meter assembly 24 Fuel level indicator light 25 Oil level warning light 26 Neutral indicator light 27 Tachometer 28 Combination meter 29 Coolant temperature meter 30 High beam indicator light 31 Turn signal indicator light 32 Meter light 33 Left handlebar ...

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