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Yamaha YZF-R6 99, Service Manual

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Yamaha YZF-R6 99 Service Manual Download Page 196

4-68

CONNECTING RODS AND PISTONS

ENG

NOTE:

CAUTION:

NOTE:

NOTE:

EAS00393

REMOVING THE CONNECTING RODS AND
PISTONS
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:

connecting rod cap 

1

big end bearings

Identify the position of each big end bearing so
that it can be reinstalled in its original place.

2. Remove:

piston pin clips 

1

piston pin 

2

piston 

3

connecting rod

Do not use a hammer to drive the piston pin
out.

For reference during installation, put identifi-
cation marks on the piston crown.

Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston 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

90890-01304

3. Remove:

top ring

2nd ring

oil ring

To remove a piston ring, open the end gap with
your fingers and lift the other side of the ring
over the piston crown.

Summary of Contents for YZF-R6 99

Page 1: ......

Page 2: ...YZF R6 SERVICE MANUAL 1998 by Yamaha Motor Co Ltd First edition August 1998 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited ...

Page 3: ...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 4: ...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 5: ...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 6: ...MATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETORS CHASSIS ELECTRICAL TROUBLESHOOTING GEN INFO 1 SPEC 2 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 CHK ADJ INDEX ...

Page 7: ...ORMATION 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 FEATURES 1 5 AIR INTAKE SYSTEM 1 5 THERMOSTAT 1 5 IGNITION SYSTEM 1 6 SPECIAL TOOLS 1 8 ...

Page 8: ...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 9: ... all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low 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 replace ments Use oil and grease recommended by Yamaha for all lubrication jobs Other brands may be similar in function and ap pearance b...

Page 10: ...102040 BEARINGS AND OIL SEALS 1 Install bearings and oil seals so that the manufacturer s marks or numbers are vis ible When installing oil seals lubricate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate 1 Oil seal Do not spin the bearing with compressed air because this will damage the bearing sur faces 1 Bearing EB102050 CIRCL...

Page 11: ...ns Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that all connections are tight 5 Check continuity with the pocket tester Pocket tester 90890 03112 If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 3 As a qui...

Page 12: ...ir intake port located under the headlight The system also delivers air pressure from the air filter case to the carburetor side The air pressure is operated to the fuel level in the carburetor to supply the appropriate fuel to increase the power The air chamber 3 is also installed between the air filter case and carburetor for delivery of stabilized air pressure to the carburetor THERMOSTAT Coola...

Page 13: ...hrough the notch depend ing on its area at b section This flow rate is larger than the case of 2 4 When the valve is set as high lift In the same way as the regular thermostat control the coolant flows through clearance c between the valve and flange IGNITION SYSTEM 1 DC CDI 1 Features Battery is used as the power source Stabilized spark performance is provided in the range from a low speed to hig...

Page 14: ...since the plug top ignition coil is equipped in which the plug cap ignition coil are inte grated High tension cord was cut an end to use and ignition energy loss has become lower 3 Spark plug The 2 pole spark plug is applied to improve the ignition quality and combustion efficien cy ...

Page 15: ...o hold the generator rotor when removing or installing the generator ro tor bolt or pickup coil rotor bolt 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 01352 Radiator cap tester Adapter These tools are used to check the cooling sys...

Page 16: ...eal driver 90890 01376 Fork seal driver attachment 90890 01374 Fork seal driver weight Fork seal driver attachment 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 90890 03017 Cylinder bore gauge 50 100mm This gauge is used to measure cylinder bore Vacuum gauge 90890 03094 Valve gauge attachment 90890...

Page 17: ...retor angle driver This tool is used to turn the pilot screw when adjusting the engine idling speed Valve spring compressor 90890 04019 Attachment 90890 04108 Valve spring compressor Attachment These tools are used to remove or install the valve assemblies Middle driven shaft bearing driver 90890 04058 Mechanical seal in staller 90890 04078 Middle driven shaft bearing driver Mechanical seal instal...

Page 18: ...l is used to install the valve guides 90890 04113 Valve guide reamer This tool is used to rebore the new valve guides 90890 06754 Ignition checker This tool is used to check the ignition system components 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating surfaces e g crankcase mating surfaces ...

Page 19: ...SION TABLE 2 18 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: ...height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2025 mm except for NOR SWE FIN AUS NZL 2075 mm for NOR SWE FIN AUS NZL 690 mm 1105 mm 820 mm 1380 mm 135 mm 3400 mm Weight Wet with oil and a full fuel tank Dry without oil and fuel Maximum load total of cargo rider passenger and accessories 188 kg 169 kg 375 kg ...

Page 21: ...ylinder 65 5 44 5 mm 12 4 1 1 250 1 350 r min 24 0 kPa 0 24 kg cm2 1550 kPa 15 5 kgf cm2 at 400 r min Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Regular gasoline 17 L 3 5 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 opening pressur...

Page 22: ... 03 0 09 mm 0 03 0 08 mm 0 15 mm 0 15 mm Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio 2 15 L 110 140 kPa 1 10 1 40 kgf cm2 320 mm 258 mm 24 mm 0 44 L Single suction centrifugal pump 86 44 31 31 1 955 Starting system type Electric starter Spark plugs Model manufacturer quantity S...

Page 23: ...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 23 000 23 021 mm 22 967 22 980 mm 0 020 0 054 mm 33 05 33 15 mm 25 14 25 24 mm 7 81 8 01 mm 32 55 32 65 mm 25 07 25 17 mm 7 38 7 58 mm 0 08 mm 33 0 mm 25 09 mm 32 50 mm 25 02 mm 0 06 mm ...

Page 24: ...Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve 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 24 9 25 1 mm 21 9 22 1 mm 1 14 1 98 mm 1 14 1 98 mm 0 9 1 1 mm 0 9 1 1 mm 0 6 0 8 mm 0 6 0 8 mm 3 975 3 990 mm 3 960 3 975 mm 4 000 4 012 mm 4 000 ...

Page 25: ...ng direction top view Intake Exhaust 37 0 mm 38 4 mm 41 7 mm 30 0 mm 32 5 mm 36 1 mm 69 79 N 7 0 8 0 kgf 114 132 N 11 6 13 4 kgf 160 184 N 16 3 18 7 kgf SSS SSS Clockwise Clockwise 35 mm 36 5 mm 39 5 mm SSS SSS SSS SSS 2 5_ 1 6 mm 2 5_ 1 7 mm 2 5_ 1 8 mm SSS SSS Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max taper Max out of round Forward inclined parallel 4 cylinder 65 5 45...

Page 26: ... Ring type Dimensions B T End gap installed Ring side clearance 2nd ring Ring type Dimensions B T End gap installed Ring side clearance Oil ring Dimensions B T End gap installed 0 025 0 050 mm 65 460 65 475 mm 4 mm 16 002 16 013 mm 0 35 0 65 mm Intake side 0 5 mm 15 991 16 000 mm 0 002 0 022 mm Barrel 0 80 2 45 mm 0 15 0 25 mm 0 030 0 065 mm Taper 0 8 2 5 mm 0 40 0 50 mm 0 020 0 055 mm 1 5 2 3 mm ...

Page 27: ...4 0 058 mm 0 White 1 Blue 2 Black 3 Brown 4 Green 0 03 mm Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play at the end of the clutch lever Friction plates Thickness Plate quantity Clutch plates Thickness Plate quantity Max warpage Clutch plate Thickness Plate quantity Max warpage Clutch springs Free length Spring quantity Wet multiple disc Ra...

Page 28: ...0 02 mm 0 02 mm Shifting mechanism Shift mechanism type Max shift fork guide bar bending installed shift rod length Cam drum 242 mm 0 05 mm Air filter type Dry element Fuel pump Pump type Model manufacturer Output pressure Electrical 5EB MITSUBISHI 15 20 kPa 0 15 0 2 kgf cm2 Carburetors Model manufacturer quantity Throttle cable free play at the flange of the throttle grip ID mark Main jet Main ai...

Page 29: ...2 10 ENGINE SPECIFICATIONS SPEC Item Standard Limit Starter jet 1 Starter jet 2 Butterfly valve size Fuel level below the line on the float chamber 50 0 6 110 17 5 18 5 mm ...

Page 30: ... SSS SSS SSS 1 mm 0 5 mm Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17 MT5 50 Aluminum 120 mm SSS SSS SSS SSS SSS SSS 1 mm 0 5 mm Front tire Tire type Size Model manufacturer Tire pressure cold 0 90 kg 90 197 kg High speed riding Min tire tread depth Tubeless 120 60ZR17 55W BRIDGESTON BT56F E DUNLOP D207F J 250 kPa ...

Page 31: ...ion Brake pad lining thickness Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 298 5 mm 5 5 mm 14 mm 30 2 mm and 27 mm 4 5 mm 0 1 mm 0 5 mm Rear brake Brake type Operation Brake pedal position from the top of the brake pedal to the bottom of the rider footrest bracket bolt center Recommended fluid Brake discs Diameter thickness Min thickn...

Page 32: ...ertube with the inner tube fullycompressed and without thefork 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 from the fully turned in position Telescopic fork Coil spring oil damper 130 mm 251 8 mm 125 mm 247 8 mm 7...

Page 33: ...reload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned in position Swingarm link suspension Coil spring gas oil damper 60 mm 169 5 mm 159 mm 95 1 N mm 9 51 kgf mm 0 60 mm No 1 200 kPa 12 kgf cm2 1 4 9 25 9 1 13 7 1 Swingarm Free play at the end of the swi...

Page 34: ... SSS SSS SSS Throttle position sensor standard resistance 4 6 kΩ SSS Charging system System type Model manufacturer Nominal output Stator coil resistance AC magneto F4T366 MITSUBISHI 14 V 320W at 5 000 r min 0 27 0 33 Ω at 20_C SSS SSS SSS SSS Voltage regulator Regulator type Model manufacturer No load regulated voltage Semiconductor short circuit type SH650A 12 SHINDENGEN 14 1 14 9 V SSS SSS SSS ...

Page 35: ... Model manufacturer quantity Max amperage Plain YF 12 NIKKO 1 3 A Flasher relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage Full transistor FE246BH DENSO No 75 95 cycles min 21 W 2 3 4 W Oil level switch model manufacturer 4XV DENSO Fuel sender Model manufacturer Resistance 1UF NIPPON SEIKI 0 7 1 1 kΩ GW B Sidestand relay Model Coil resistan...

Page 36: ... manufacturer Resistance 11H NIPPON SEIKI 50 6 64 2 Ω at 80_C 16 1 17 3 Ω at 120_C SSS SSS Fuses amperage quantity Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fuse odometer 30 A 1 20 A 1 20 A 1 15 A 1 7 5 A 1 7 5 A 1 SSS SSS SSS SSS SSS SSS ...

Page 37: ...neral tightening torques 10 mm 12 mm 14 mm 18 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 EB201000 CONVERSION TABLE All specification data in this manual are listed in SI and METRIC UNITS Use this table to convert METRIC unit data to IMPERIAL unit data Ex METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in CONVERSION TABLE METRIC TO...

Page 38: ...shaft sprocket Oil pump Oil cooler Engine oil drain bolt Oil pump assembly driven sprocket cover Oil pipe Oil filter bolt Oil filter cartridge Exhaust pipes Muffler clamp Exhaust pipe emission check bolts Exhaust pipe bracket Crankcase Crankcase Crankcase Generator rotor cover Drive sprocket cover Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt M12 M8 ...

Page 39: ...Shift rod locknut Oil level switch Shift arm Stator coil Ignitor unit Neutral switch Pickup coil Thermo unit Thermo switch Bolt Bolt Bolt Bolt Nut Bolt Nut Screw Bolt Bolt Nut Bolt Bolt Bolt Bolt Screw Bolt M6 M6 M6 M6 M8 M20 M6 M18 M6 M6 M8 M6 M8 M6 M6 M6 M6 M6 M5 PT1 8 M18 1 5 10 5 6 3 3 1 6 1 3 2 1 1 1 2 1 3 1 2 2 1 1 12 12 12 12 32 70 8 70 12 10 22 7 10 10 10 10 10 4 0 10 15 28 1 2 1 2 1 2 1 2...

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

Page 41: ...cket Rear master cylinder Rear brake hose union bolts Sidestand Front wheel axle Rear wheel axle nut Front brake caliper and front fork Rear brake caliper and bracket Brake disc and wheel Rear wheel sprocket and rear wheel drive hub Brake caliper and bleed screw Pinch bolt front wheel axle M8 M28 M8 M30 M8 M4 M10 M6 M12 M12 M10 M8 M6 M10 M8 M18 M10 M10 M10 M10 M6 M6 M6 M8 M8 M8 M10 M10 M18 M24 M10...

Page 42: ...ter pump impeller shaft Oil pump rotors inner and outer Oil pump housing Oil strainer Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pinion Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Engine mounting bolts rear Cylinder head cover mating surface Yamaha bond No 1215 Crankcase ...

Page 43: ...rive hub mating surface Rear brake pedal Sidestand pivoting point and metal to metal moving parts Throttle grip inner surface Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and metal to metal moving parts Rear shock absorber assembly oil seal Rear shock absorber assembly bearing Rear shock absorber assembly spacer Pivot shaft Connecting arm bearing left and ...

Page 44: ...2 25 OIL FLOW DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil pipe 5 Oil strainer 6 Oil pump OIL FLOW DIAGRAMS ...

Page 45: ...2 26 OIL FLOW DIAGRAMS SPEC 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter 4 Oil cooler ...

Page 46: ...2 27 OIL FLOW DIAGRAMS SPEC 1 Cylinder head 2 Crankshaft ...

Page 47: ...2 28 OIL FLOW DIAGRAMS SPEC 1 Main axle 2 Oil delivery pipe 3 driveaxle ...

Page 48: ...2 29 1 Radiator 2 Radiator fan 3 Oil cooler COOLANT FLOW DIAGRAMS SPEC COOLANT FLOW DIAGRAMS ...

Page 49: ...2 30 COOLANT FLOW DIAGRAMS SPEC 1 Thermostat housing 2 Thermostat 3 Radiator 4 Therm ...

Page 50: ...2 31 1 Radiator cap 2 Radiator 3 Oil cooler 4 Water jacket joint 5 Water pump COOLANT FLOW DIAGRAMS SPEC ...

Page 51: ...2 32 1 Radiator 2 Radiator fan switch 3 Radiator fan COOLANT FLOW DIAGRAMS SPEC ...

Page 52: ...Route the headlight lead through the plastic guide C Route the right handlebar switch lead in front of the front fork inner tube D Route the throttle cables between the brake hose and right handlebar switch lead E Route the wire harness through under the left handlebar switch lead and starter cable F Fasten the left handlebar switch lead to the front fork with a plastic locking tie and cut the end...

Page 53: ...le with a band Locate the end of band to forward H Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie Cut the end of locking tie And then route the horn lead under the brake hose and clamp it to the under cover ...

Page 54: ...frame D Route the coolant hose under the heat protector plate CABLE ROUTING SPEC E Route the clutch cable through the guide on the ra diator F Fasten the clutch cable to the coolant hose protec tor with a plastic band G Fasten the rear brake switch lead to the footrest bracket with a plastic locking tie and cut the end of locking tie H Fasten the fuel pump lead and rear brake switch lead with a pl...

Page 55: ...ch the wireharness with the throttle cable pully Route the wireharness under the radiator hose D Route the wireharness through the slit of rear fender E Route the rear turn signal light leads left and right through the hole of rear fender F Route the seat lock cable outside of the wirehar ness G Fasten the sidestand switch lead and oil level sen sor lead with a band H Route the fuel tank drain hos...

Page 56: ... position sensor connector 11 Handlebar switch left connec tors 12 Neutral switch lead 13 Fuel pump connector 14 Rear brake switch lead 15 Starter motor lead CABLE ROUTING SPEC 16 Battery negative cable 17 Fuel sender connector 18 Coolant reservoir tank cap 19 Crankcase breather hose 20 Therm unit lead 21 Fan motor lead connector 22 Clutch cable 23 Handlebar switch lead left 24 Stater cable 25 Mai...

Page 57: ... and right main switch lead throttle position sensor lead rear brake switch lead and pickup coil lead with them CABLE ROUTING SPEC H Route the starter motor lead under the wirehar ness I Fasten the starter motor to the rear fender with a band J Fasten the battery positive cable and starter motor cable with a plastic band K Position the rear turn signal light connectors left and right and taillight...

Page 58: ...rter motor lead with a steel band on the engine S Route the fuel tank breather hose and fuel tank drain hose over the wireharness T Route the starter cable with slot of the heat protec tion plate CABLE ROUTING SPEC U Route the starter cable and wireharness through the guide of the heat protection plate V Route the fan motor lead under the throttle cable and then fasten the fan motor lead and throt...

Page 59: ...CKING THE IGNITION TIMING 3 23 MEASURING THE COMPRESSION PRESSURE 3 24 CHECKING THE ENGINE OIL LEVEL 3 26 CHANGING THE ENGINE OIL 3 27 MEASURING THE ENGINE OIL PRESSURE 3 29 ADJUSTING THE CLUTCH CABLE FREE PLAY 3 30 CLEANING THE AIR FILTER ELEMENT 3 31 CHECKING THE CARBURETOR JOINTS 3 32 CHECKING THE FUEL HOSES AND FUEL FILTER 3 32 CHECKING THE CRANKCASE BREATHER HOSE 3 33 CHECKING THE EXHAUST SYS...

Page 60: ...47 CHECKING THE FRONT FORK 3 50 ADJUSTING THE FRONT FORK LEGS 3 51 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 53 CHECKING THE TIRES 3 55 CHECKING THE WHEELS 3 57 CHECKING AND LUBRICATING THE CABLES 3 58 LUBRICATING THE LEVERS AND PEDALS 3 58 LUBRICATING THE SIDESTAND 3 58 LUBRICATING THE REAR SUSPENSION 3 58 ELECTRICAL SYSTEM 3 59 CHECKING AND CHARGING THE BATTERY 3 59 CHECKING THE FUSES 3 64 RE...

Page 61: ...00 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 accordingly...

Page 62: ...00 km or 24 months whichever comes first 21 Carburetors Check engine idling speed synchronization and starter operation Adjust if necessary 22 Engine oil Check oil level and vehicle for oil leakage Correct if necessary Change Warm engine before draining 23 Engine oil filter car tridge Replace 24 Cooling system Check coolant level and vehicle for coolant leakage Correct if necessary Change coolant ...

Page 63: ...2 Removing the rider and passenger seats Passenger seat Rider seat 1 1 Remove the parts in the order listed For installation reverse the removal procedure 7Nm 0 7 m kg RIDER AND PASSENGER SEATS CHK ADJ EB302000 RIDER AND PASSENGER SEATS ...

Page 64: ...l tank overflow hose Fuel tank breather hose Fuel tank 1 2 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS Disconnect Before disconnecting the fuel hose set the fuel cock OFF For installation reverse the removal procedure NOTE 10 Nm 1 0 m kg 10 Nm 1 0 m kg 7 Nm 0 7 m kg 7 Nm 0 7 m kg FUEL TANK CHK ADJ FUEL TANK ...

Page 65: ...ear cowling Bottom cowling left Bottom cowling right Front cowling inner panel left Front cowling inner panel right Side cowling inner panel left Side cowling inner panel right 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS 5 Nm 0 5 m kg 5 Nm 0 5 m kg COWLINGS CHK ADJ COWLINGS ...

Page 66: ...rt Q ty Remarks 8 9 10 11 12 Left side cowling Right side cowling Windshield Rear view mirror Front cowling 1 1 1 2 1 For installation reverse the removal procedure 5 Nm 0 5 m kg 5 Nm 0 5 m kg COWLINGS CHK ADJ COWLINGS ...

Page 67: ...0_ with a screwdriver then pull the fastener out INSTALLATION 1 Install Sside cowlings Srear cowling 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 68: ...anel right Crankcase breather hose Air vent hose Hoses Drain cup Air filter case balance hose Clamp screw Bolt Surge tank joint left Surge tank joint right Air filter case Clamp Quick fastener 1 1 2 1 2 4 1 1 1 1 2 2 Remove the parts in the order listed Refer to SEATS and FUEL TANK Refer to COWLINGS Loosen AIR FILTER CASE AND IGNITION COILS CHK ADJ AIR FILTER CASE AND IGNITION COILS ...

Page 69: ...3 9 AIR FILTER CASE AND IGNITION COILS CHK ADJ Order Job Part Q ty Remarks 13 14 15 Heat protector plate Ignition coil coupler Ignition coil 1 4 4 For installation reverse the removal procedure ...

Page 70: ...its center in with a screwdriver then pull the fastener out INSTALLATION 1 Install heat protector plate 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 71: ...ed the piston must be at top dead center TDC on the compression stroke 1 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case heat protector plate Refer to AIR FILTER CASE AND IGNITION COILS bottom cowling side cowlings Refer to COWLINGS carburetor assembly Refer to CARBURETORS in chapter 6 radiator assembly Refer to RADIATOR in chapter 5 2 Remove ignition coils spark plugs cyl...

Page 72: ...d when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 SIf the valve clearance is incorrect record the measured reading SMeasure the valve clearance in the following sequence Valve clearance measuring sequence Cylinder 1 2 4 3 A Front d To measure the valve clearances of the other cylinders starting with cylinder 1 at TDC turn the cranksha...

Page 73: ...er the timing chain opening with a rag to prevent the valve pad from falling 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 follow ing table Valve pad thick ness range Available valve pads Nos 120 240 1 20 2 40 mm 25 thicknesses in 0 05 mm incre ments The thickness a of ...

Page 74: ...red again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad 1 and the valve lift er 2 Lubricate the valve pad with molybdenum dis ulfide grease Lubricate the valve lifter with molybdenum dis ulfide oil The valve lifter must turn smoothly when ro tated by hand Install the valve lifter and the valve pad in the correct place f Install the exhaust...

Page 75: ...20 225 230 235 240 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 120 125 130 135 140 145 150 155 160 165 170 175 180 1...

Page 76: ...procedure Note the following points 8 Install timing chain guide exhaust side timing chain tensioner pickup coil rotor cover cylinder head cover spark plugs ignition coils Refer to CAMSHAFTS in chapter 4 EB303010 SYNCHRONIZING THE CARBURETORS Prior to synchronizing the carburetors the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked ...

Page 77: ... 03094 Vacuum gauge attachment 90890 03060 Engine tachometer 90793 80009 5 Start the engine and let it warm up for several minutes 6 Measure engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE ID LING SPEED Engine idling speed 1 250 1 350 r min 7 Adjust carburetor synchronization a Synchronize carburetor 1 to carburetor 2 by turning the synchronizing screw 1 in ei ther di...

Page 78: ...re at engine idling speed 24 0 kPa 0 24 kg cm2 The difference in vacuum 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 measuring equipment 10 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Throttle cable free play at the flange of the throttle grip 6 8 m...

Page 79: ...N COILS 5 Measure engine idling speed Out of specification Adjust Engine idling speed 1 250 1 350 r min 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 Carburetor angle driver 90890 03158 Pilot screw setting 2 turns out c Turn the throttle stop screw 2 in direction a or b until the specified engine idling ...

Page 80: ...031 ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting the throttle cable free play the engine idling speed and carburetor synchro nization should be adjusted properly 1 Measure throttle cable free play a Out of specification Adjust Throttle cable free play at the flange of the throttle grip 6 8 mm 2 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case heat protector pla...

Page 81: ... Throttle cable free play in increased Direction Throttle cable free play is decreased e Tighten the locknuts If the specified throttle cable free play cannot be obtained on the carburetor side of the cable use the adjusting nut on the handlebar side Handlebar side a Loosen the locknut 6 b Turn the adjusting nut 7 in direction c or d until the specified throttle cable free play is obtained Directi...

Page 82: ...il counterdockwise 5 to 6 turns would be adequate c Pull out the coil upward Never pry the coupler with a screw driver d Press the coil in the plug hole by hand as fa ras it will go e Turn the coil clockwise and screw it in 5 to 6 turns would be adequate f Reins tall the coupler Do not strike on the coil with a hammer or the like Before removing the spark plugs blow away any dirt accumulated in th...

Page 83: ... gauge Out of specification Regap Spark plug gap 0 6 0 7 mm 8 Install spark plug Before installing the spark plug clean the spark plug and gasket surface EB303050 CHECKING THE IGNITION TIMING Prior to checking the ignition timing check the wiring connections of the entire ignition system Make sure that all connections are tight and free of corrosion 1 Remove bottom cowling Refer to COWLINGS rider ...

Page 84: ...the required firing range b on the pickup coil rotor Incorrect firing range Check the ignition system The ignition timing is not adjustable EB303060 MEASURING THE COMPRESSION PRES SURE The following procedure applies to all of the cyl inders Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEA...

Page 85: ... 6 Measure compression pressure Out of specification Refer to steps c and d Compression pressure at sea level Minimum 1300 kPa 13 0 kg cm2 13 0 bar Standard 1550 kPa 15 5 kg cm2 15 5 bar Maximum 1600 kPa 16 0 kg cm2 16 0 bar a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the compression gauge stabilizes To prevent sparking ground all spark plug lead...

Page 86: ... oil applied into the cylinder Reading Diagnosis Higher than without oil Piston wear or damage Repair Same as without oil Piston ring s valve s cylinder head gasket or piston possibly defective Repair 7 Install spark plug EB303070 CHECKING THE ENGINE OIL LEVEL 1 Stand the motorcycle on a level surface Place the motorcycle on a suitable stand Make sure that the motorcycle is upright 2 Start the eng...

Page 87: ... a grade of CD c or higher and do not use oils labeled ENERGY CONSERV ING II d or higher Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several min utes and then turn it off 5 Check engine oil level Before checking the engine oil level wait a few minutes until the oil has settled EB303081 CHANGING THE ENGINE OIL 1 Remove bottom cowling Refer to COWLINGS 2 S...

Page 88: ...n the groove of the oil filter car tridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench Oil filter cartridge 17 Nm 1 7 m kg 7 Check engine oil drain bolt washer Damage Replace 8 Install engine oil drain bolt 9 Fill crankcase with the specified amount of the recom mended engine oil Quantity Total amount 3 5 L Without oil filter cartridge re placement 2 5 L With ...

Page 89: ...it up for several min utes and then turn it off When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine oil pressure after warming up the engine 3 Remove Soil gallery bolt 1 The engine muffler and engine oil are ex tremely hot 4 Install Soil pressure gauge 1 Sadapter 2 Oil pressure gauge 90890 03153 Ada...

Page 90: ... oil gallery bolt EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Measure clutch cable free play a Out of specification Adjust Clutch cable free play at the end of the clutch lever 10 15 mm 2 Adjust clutch cable free play Handlebar side a Turn the adjusting bolt 1 in direction a or b until the specified clutch cable free play is ob tained Direction Clutch cable free play is in creased Direction Cl...

Page 91: ...move the excess oil The air filter should be wet but not dripping 4 Check air filter element Damage Replace 5 Install air filter element air filter case cover Never operate the engine without the air fil ter element installed Unfiltered air will cause rapid wear of engine parts and may damage the engine Operating the engine without the air filter element will also affect the carburetor tuning lead...

Page 92: ... to CARBURETORS in chapter 6 3 Install carburetor assembly Refer to CARBURETORS in chapter 6 EB303181 CHECKING THE FUEL HOSES 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 Drain and flush the fuel tank if abrasive dam age to any components of the fuel...

Page 93: ...vers front cowling fuel tank 2 Loosen clamps on the inside of the front cowling 3 Remove air intake system air ducts 1 4 Clean air intake system air ducts a Thoroughly flush out the air intake system air ducts with clean water b Hold the air intake system air ducts upside down to allow the water to drain out c Repeat the flushing steps until the excess water is clear and free of debris d Place the...

Page 94: ...EB303200 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust 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 Exhaust pipe nut 4 20 Nm 2 0 m kg Muffler clamp bolt 5 20 Nm 2 0 m kg Exhaust pipe bolt 6 20 Nm 2 0 m kg Muffler b...

Page 95: ...nt If water is used instead of coolant check and correct the antifreeze concentration of the coolant Use only distilled water Soft water may be used if distilled water is not available 3 Start the engine warm it up for several min utes and then turn it off 4 Check coolant level Before checking the coolant level wait a few minutes until it settles EB303230 CHECKING THE COOLING SYSTEM 1 Remove botto...

Page 96: ...lant reservoir 4 Install coolant reservoir bolts reservoir cover 5 Remove radiator cap 1 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the ra...

Page 97: ...thylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 2 15 L Coolant reservoir capacity 0 44 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care If coolant splashes in your eyes thorough ly wash them with water and consult a doc tor If coolant splashes on your clothes qu...

Page 98: ...ant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 11 Install radiator cap 12 Fill coolant reservoir with the recommended coolant to the maxi mum level mark a 13 Install coolant reservoir cap 14 Start the engine warm it up for several min utes and then turn it off 15 Check coolant level Refer to CHECKING THE COOLANT LEV EL Before...

Page 99: ... the arrow mark 2 on the brake lever hold er Position 1 Distance is the largest Position 5 Distance is the smallest After adjusting the brake lever position make sure that the pin on the brake lever holder is firmly inserted in the hole in the ad justing dial EB304010 ADJUSTING THE REAR BRAKE 1 Measure brake pedal position distance a from the top of the brake pedal to the bottom of the rider footr...

Page 100: ...ole d c Tighten the locknut 1 to specification Locknut 16 Nm 1 6 m kg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system Air in the brake system will consid erably reduce braking performance and could result in loss of control and possibly an accident Therefore check an...

Page 101: ...use the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake perfor mance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and cou...

Page 102: ...B Rear brake EB304050 ADJUSTING THE REAR BRAKE LIGHT SWITCH 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 swi...

Page 103: ...IC BRAKE SYS TEM Bleed the hydraulic brake system whenev er the brake system was disassembled a brake hose was loosened disconnected or replaced the brake fluid level is very low brake operation is faulty Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow When bleeding the hydraulic brake system make sure that there is always enough brake fluid before applying t...

Page 104: ...ess the brake pedal and hold it in position g Loosen the bleed screw Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully ex tend 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 Tig...

Page 105: ...rod length increases Direction Installed shift rod length decreases c Tighten both locknuts d Make sure that the installed shift rod length is within specification EB304092 ADJUSTING THE DRIVE CHAIN SLACK The drive chain slack must be checked at the tightest point on the chain A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and dama...

Page 106: ...ain slack a Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is ob tained Direction Drive chain slack is reduced Direction Drive chain slack is increased To maintain the proper wheel alignment adjust both sides evenly d Tighten both locknuts to specification Locknut 16 Nm 1 6 m kg e Tighten the wheel axle n...

Page 107: ...erefore use only kerosine to clean the drive chain Wipe the drive chain dry and thor oughly lubricate it with engine oil or chain lubri cant 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 ...

Page 108: ...rs from the 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 washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 Set the torque wrench at a right angle to the steering nut wrench Steering nut wrench 90890 01403 Lower ring nut initial tightening torque 1...

Page 109: ...nstall the washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 Make sure that the lock washer tabs a sit cor rectly in the ring nut slots b 8 Install steering stem nut upper bracket bolt handlebar pinch bolt u...

Page 110: ...re the steering head tension again as described above h Repeat the above procedure until the steer ing head tension is within specification i Grasp the bottom of the front fork legs and gently rock the front fork Looseness or binding Adjust the steering head EB304141 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface Securely support the motorcycle so that there is no danger of it f...

Page 111: ... and loss of stability Securely support the motorcycle so that there is no danger of it falling over Spring preload Grooves are provided to indicate the ad justment position Never go beyond the maximum or mini mum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt 1 in direction a or b Direction Spring preload is increased suspension is harder Direction Spring preload is decrea...

Page 112: ... softer Adjusting positions Minimum 12 clicks out Standard 6 clicks out Maximum 1 clicks out from the fully turned in position Compression damping Never go beyond the maximum or minimum adjustment positions 1 Adjust compression damping a Turn the adjusting screw 1 in direction a or b Direction Compression damping is increased suspension is harder Direction Compression damping is decreased suspensi...

Page 113: ... or minimum adjustment positions 1 Adjust spring preload Adjust the spring preload with the special wrench and extension bar included in the own er 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 indicator 2 Direction Spring preload is increased suspension is harder Direction Spring preload is decreased suspension is s...

Page 114: ...sion is softer Adjusting positions Minimum 25 clicks out Standard 9 clicks out Maximum 1 click out from the fully turned in position Compression damping Never go beyond the maximum or minimum adjustment positions 1 Adjust compression damping a Turn the adjusting screw 1 in direction a or b Direction Compression damping is increased suspension is harder Direction Compression damping is decreased su...

Page 115: ...d the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and a full fuel tank 188 kg Maximum load 187 kg Cold tire pressure Front Rear Up to 90 kg load 250 kPa 2 5 kgf cm2 2 5 bar 250 kPa 2 5 kgf cm2 2 5 bar 90 kg max imum load 250 kPa 2 5 kgf cm2 2 5 bar 290 kPa 2 9 kgf cm2 2 9 bar Hig...

Page 116: ...the wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement A Tire B Wheel Tube wheel Tube tire only Tubeless wheel Tube or tubeless tire After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires shoul...

Page 117: ... the rim Failure to do so could lead to an accident with possible injury to the rider or damage to the motor cycle For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve installation point EB304180 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Damage out of ro...

Page 118: ...ubricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EB304210 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and pedals Recommended lubricant Lithium soap base grease EB304220 LUBRICATING THE SIDESTAND L...

Page 119: ...electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention This is a sealed battery Never remove the sealing caps ...

Page 120: ...minals 1 Remove Srider seat Refer to SEATS 2 Disconnect Sbattery leads from the battery terminals First disconnect the negative lead 2 then the positive lead 1 3 Remove Sbattery 4 Measure Sbattery charge a Connect a digital voltmeter to the battery ter minals Tester positive probe battery positive terminal Tester negative probe battery nega tive terminal SThe charge state of an MF battery can be c...

Page 121: ...ted on the motorcycle disconnect the negative lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the battery SBefore removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger SMake sure that the battery charger lead clips are in full contact with the batt...

Page 122: ...d charg ing amperage after 5 min utes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the am perage readjust the voltage to obtain the standard charging amper age Leave the battery unused for more than 30 minutes before measur ing its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V...

Page 123: ... Charge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V Charging is complete 12 0 12 7 V Recharging is re quired Under 12 0 V Replace the battery NOTE Set the charging time to a maximum of 20 hours ...

Page 124: ...bricate battery terminals Recommended lubricant Dielectric grease 10 Install rider seat Refer to SEATS EB305040 CHECKING THE FUSES The following procedure applies to all of the fuses 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 Set t...

Page 125: ...l circuit Item Amperage Q ty Main fuse 30 A 1 Headlight fuse 20 A 1 Signaling system fuse 20 A 1 Ignition fuse 15 A 1 Radiator fan motor fuse 7 5 A 1 Backup fuse odometer 7 5 A 1 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 sys tems to malfun...

Page 126: ...ucts and your hands away from the bulb until it has cooled down 4 Install headlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head light bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it wit...

Page 127: ...djusting screw 1 in direction a or b Direction Headlight beams is raised Direction Headlight beams is low ered 2 Adjust headlight beam horizontally a Turn the adjusting knob 1 in direction a or b Left headlight Direction Headlight beam moves to the right Direction Headlight beams moves to the left Right headlight Direction Headlight beam moves to the left Direction Headlight beam moves to the righ...

Page 128: ... OIL PAN 4 58 CRANKCASE 4 59 OIL BAFFLE PLATES AND OIL FILTER BOLT 4 61 DISASSEMBLING THE CRANKCASE 4 62 CHECKING THE CRANKCASE 4 63 CHECKING THE BEARINGS AND OIL SEALS 4 63 CHECKING THE SPROCKETS AND CHAINS 4 63 ASSEMBLING THE CRANKCASE 4 64 CONNECTING RODS AND PISTONS 4 66 REMOVING THE CONNECTING RODS AND PISTONS 4 68 CHECKING THE CYLINDERS AND PISTONS 4 69 CHECKING THE PISTON RINGS 4 70 CHECKIN...

Page 129: ...t Shift rod Shift arm Drive sprocket cover Nut Lock washer Drive sprocket 2 1 1 1 1 1 1 Remove the parts in the order listed Refer to CHANGING THE COOLANT For installation reverse the remove procedure 10 Nm 1 0 m kg 70 Nm 7 0 m kg ENGINE ENG EAS00190 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET ...

Page 130: ...embly Muffler Exhaust pipe assembly Exhaust pipe gasket 1 1 4 Remove the parts in the order listed Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to RADIATOR in chapter 5 For installation reverse the removal procedure 20 Nm 2 0 m kg 20 Nm 2 0 m kg 20 Nm 2 0 m kg 38 Nm 3 8 m kg EXHAUST ASSEMBLY ...

Page 131: ... and joints Engine oil and oil filter cartridge Oil cooler Disconnect the parts in the order listed Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE AND IGNITION COILS in chapter 3 Refer to CARBURETORS in chapter 6 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to OIL COOLER in chapter 5 LEADS AND HOSES ...

Page 132: ...lead Battery positive lead Startor coil assembly coupler Pickup coil coupler Engine earth Clutch wire and holder Crankcase breather hose Separator 1 1 1 1 1 1 1 1 First disconect the negative lead then the positive lead CAUTION For connecting reverse the discomecting procedure ...

Page 133: ...s Rear mounting bolts Engine mounting adjust bolts 4 2 2 2 2 2 2 Remove The Parts In The Order Listed For Installation Reverse The Removal Procedure NOTE Use the point shaft wrench to loosen the engine mounting adjust bolt NOTE Place a suitable stand under the frame and engine Refer to INSTALLING THE ENGINE 24 Nm 2 4 m kg 45 Nm 4 5 m kg 55 Nm 5 5 m kg 7 Nm 0 7 m kg 13 Nm 1 3 m kg ENGINE ...

Page 134: ...h bolts 8 Lubricate the rear mounting bolt threads with lithium soap base grease Do not fully tighten the nuts and bolts 2 Tighten self locking nut front mounting bolts button head bolt pinch bolt M8 M6 engine adjusting bolts Use the pivot shaft wrench 1 to tighten the en gine mounting adjust bolt to finger tightness Pivot shaft wrench 90890 01471 3 Install drive sprocket 4 Install drive sprocket ...

Page 135: ...sembly Spark plugs Cylinder head cover Cylinder head cover gasket Timing chain guide top side 4 1 1 1 Remove the parts in the order listed Refer to CARBURETORS in chapter 6 Refer to RADIATOR in chapter 5 For installation reverse the removal procedure 10 Nm 1 0 m kg 13 Nm 1 3 m kg EAS00194 CAMSHAFTS CYLINDER HEAD COVER ...

Page 136: ...gasket Dowel pin Intake camshaft Exahust camshaft Timing chain guide exhaust side 1 1 1 4 2 1 1 1 Remove the parts in the order listed Refer to PICKUP COIL AND PICK UP COIL COVER During removal the dowel pins may still be connected to the camshaft cap NOTE 12 Nm 1 2 m kg 10 Nm 1 0 m kg 10 Nm 1 0 m kg Refer to REMOVING INSTALLING THE CAMSHAFTS Refer to REMOVING INSTALLING THE CAMSHAFT EAS00196 CAMS...

Page 137: ...s 9 10 11 12 Intake camshaft sproket Exhaust camshaft sproket Pin Timing chain guide intake side 1 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE CAMSHAFTS 10 Nm 1 0 m kg 24 Nm 2 4 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg ...

Page 138: ...face b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 2 Remove timing chain tensioner 3 Remove camshaft cap dowel pins To prevent damage to the cylinder head camshafts or camshaft cap loosen the cam shaft cap bolts in stages and in a crisscross pattern working from the outside in 4 Remove intake camshaft 1 exhaust camshaft 2 To prevent the timing...

Page 139: ...amshaft a 32 50 mm b 25 02 mm 3 Measure camshaft runout Out of specification Replace Max camshaft runout 0 06 mm 4 Measure camshaft journal to camshaft cap clear ance Out of specification Measure the cam shaft journal diameter Camshaft journal to camshaftcap clearance 0 020 0 054 mm Limit 0 08 mm a Install the camshaft into the cylinder head without the dowel pins and camshaft caps b Position a st...

Page 140: ...lt 10 Nm 1 0 m kg d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace the cylinder head and the camshaft caps as a set Camshaft journal diameter 22 967 22 980 mm EAS00208 CHECKING THE CAMSHAFT SPROCKETS AND TIMING CHAIN GUIDES The following procedure applies to all ...

Page 141: ... CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand While pressing the timing chain tensioner 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 that th...

Page 142: ...t cap The brim 1 of intake camshaft is not pro cessed The groove is processed around the brim 1 of exhaust cameshaft as illustration a Turn the crankshaft clockwise b When piston 1 is at TDC on the compres sion stroke align the a mark on the pickup 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...

Page 143: ...crewdriver 1 until if stops C With the screwdriver still inserted into the timing chain tensioner install the timing chain tensioner 2 gasket and float cham ber air vent hose holder 3 onto the cylinder block Then tighten the timing chain tension er bolts 4 to the specified torque Always use a new gasket The UP mark on the timing chain tensioner should face up Timing chain tensioner bolt 12 Nm 1 2 ...

Page 144: ...er to the installation steps above 7 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 8 Install cylinder head cover gasket cylinder head cover 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 Tighte...

Page 145: ...emp senser lead Front mounting bolt Cylinder head Cylinder head gasket Dowel pin 1 1 2 Remove the parts in the order listed Refer to CAMSHAFTS Disconnect Disconnect Refer to ENGINE Refer to REMOVING INSTALLING THE CYLINDER HEAD For installation reverse the removal procedure 10 Nm 1 0 m kg 51 Nm 5 1 m kg EAS00220 CYLINDER HEAD ...

Page 146: ...er carbon deposits with a rounded scraper Do not use a sharp instrument to avoid damag ing 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 cylin der head Max cylinder head warpage 0 05 mm a Place a straightedge 1 and a thickn...

Page 147: ...r head using a figure eight sanding pattern To ensure an even surface rotate the cylinder head several times EAS00223 INSTALLING THE CYLINDER HEAD 1 Install cylinder head gasket cylinder head cylinder headbolt M10 M6 Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts and bolts in two stages and in a crisscross pattern ...

Page 148: ...ntake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide 8 8 16 8 8 8 8 8 8 8 Remove the parts in the order listed Refer to CYLINDER HEAD Refer to REMOVING INSTALLING THE VALVES EAS00236 VALVES AND VALVE SPRINGS ...

Page 149: ...valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide 8 8 16 8 8 8 8 8 8 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE VALVES ...

Page 150: ... the valves properly seal 1 Remove valve lifter 1 valve pad 2 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 valv...

Page 151: ... seal 5 lower spring seat 6 Identify the position of each part very carefully so that it can be reinstalled in its original place EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diameter b Out of specification...

Page 152: ...alve guide bore the valve guide with a valve guide reamer 3 to obtain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide remover Intake 4 0 mm Exhaust 4 0 mm 90890 04111 Valve guide installer Intake 4 0 mm Exhaust 4 0 mm 90890 04112 Valve guide reamer Intake and Exhaust 90890 04113 3 Eliminate Scarbon deposits from the valve face and va...

Page 153: ...s replace the valve guide If the valve is removed or replaced always re place the oil seal Valve stem runout 0 04 mm EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specification Replace t...

Page 154: ...lve seat After replacing 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 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 155: ...he valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EAS00241 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 spring Valve spring free l...

Page 156: ...e the valve spring Max Spring tilt Intake valve spring inner 1 6 mm Intake valve spring outer 1 7 mm Exhaust valve spring 1 8 mm EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters 1 Check valve lifter Damage scratches Replace the valve lift ers and cylinder head EAS00247 INSTALLING THE VALVES The following procedure applies to all of the valves and rela...

Page 157: ...to the following em bossed marks Install the valve spring with the larger pitch a facing up b Smaller pitch 4 Install valve cotters 1 Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 Valve spring compressor 90890 04019 Attachment 90890 04114 5 To secure the valve cotters 1 onto the valve stem lightly tap the valve tip with a soft face ha...

Page 158: ... pad with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 7 Install valve pad valve lifter The valve lifter must move smoothly when ro tated with a finger Each valve lifter and valve pad must be rein stalled in its original position ...

Page 159: ... cowling and right side cowling Engine oil Generator cover Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to STARTER CLUTCH AND GENERATOR 12 Nm 1 2 m kg 15 Nm 1 5 m kg 10 Nm 1 0 m kg 35 Nm 3 5 m kg PICKUP COIL AND PICKUP COIL ROTOR ...

Page 160: ...Clutch cable holder Pickup coil coupler Pickup coil cover Pickup coil cover gasket Dowel pin Pickup coil Pickup rotor 1 1 1 1 1 2 1 1 Disconnect For installation reverse the removal procedure Refer to REMOVING INSTALLING THE PICKUP COIL ROTOR 12 Nm 1 2 m kg 35 Nm 3 5 m kg 15 Nm 1 5 m kg 10 Nm 1 0 m kg ...

Page 161: ...ully loosened remove them 2 Remove pickup coil rotor bolt 1 plain washer 2 pickup coil rotor 3 While holding the generator rotor 4 with the ro tor holding tool 5 loosen the pickup coil rotor bolt Sheave holder 90890 01701 INSTALLING THE PICKUP COIL ROTOR 1 Install pickup coil rotor 1 plain washer pickup coil rotor bolt When installing the pickup coil rotor align the pin 2 in the crankshaft sprocke...

Page 162: ... coil rotor bolt Sheave holder 90890 01701 3 Apply sealant onto the pickup coil lead grommet Yamaha bond No 1215 90890 85505 4 Install pickup coil cover clutch cable holder When installing the pickup coil cover align the timing chain guide intake side pin 1 of the with the hole 2 in the pickup coil cover Tighten the pickup coil cover bolts in stages and in a crisscross pattern ...

Page 163: ...Generator rotor cover gasket Dowel pin Stator coil assembly lead holder Stator coil assembly 1 1 1 2 1 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Disconnect Refer to REMOVING INSTALLING THE GENERATOR 12 Nm 1 2 m kg 10 Nm 1 0 m kg ...

Page 164: ...11 12 13 Generator rotor bolt Plain washer Generator rotor Starter one way assy Idler gear shaft Idler hear Starter clutch gear 1 1 1 1 1 1 1 For installation reverse the removal proceduer Refer to REMOVING INSTALLING THE GENERATOR 12 Nm 1 2 m kg 10 Nm 1 0 m kg 65 Nm 6 5 m kg ...

Page 165: ...lts are fully loosened remove them 2 Remove generator rotor bolt 1 Plain washer While holding the generator rotor 2 with the sheave holder 3 loosen the generator rotor bolt Do not allow the sheave holder to touch the pro jection on the generator rotor Sheave holder 90890 01701 3 Remove generator rotor 1 with the flywheel puller 2 and adapter 3 Flywheel puller 90890 01362 Flywheel puller attachment...

Page 166: ...he defective parts 3 Check Starter clutch operation a Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear clockwise A the starter clutch and the start er clutch gear should engage If the starter clutch gear and starter clutch do not engage the starter clutch is faulty and must be replaced c When turning the starter cl...

Page 167: ... the crankshaft and the generator rotor hub with lacquer tinner 2 Tighten generator rotor bolt 3 While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt Do not allow the sheave holder to touch the pro jection on the generator rotor Sheave holder 90890 01701 3 Apply sealant onto the stator coil assembly lead grommet Yamaha bond No 1215 90890 85505 4 Install sta...

Page 168: ...r Drive sprocket cover sift rod and sift arm Shift shaft cover Shift shaft cover gasket Dowel pin Oil seal Sift shaft 1 1 2 1 1 Remove the parts in the order listed Drain Refer to CHNGING THE COOLANT in chapter 3 Refer to ENGINE Refer to INSTALLING THE SHIFT SHAFT 22 Nm 2 2 m kg EAS00327 SHIFT SHAFT ...

Page 169: ...7 8 9 10 11 12 13 14 Shift shaft spring Collar Stopper lever spring Circrip Washer Stopper lever Collar Washer Shift shaft spring stopper 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE SHIFT SHAFT 22 Nm 2 2 m kg ...

Page 170: ...AS00334 INSTALLING THE SHIFT SHAFT 1 Install shift shaft spring stopper 1 stopper lever spring 2 washer stopper lever 3 Apply LOCTITE to the threads of the shift shaft spring stopper Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum seg ment assembly 2 Install shift shaft 1 collor Lubricate the oil seal lips with lith...

Page 171: ...ht side cowling Engine oil Coolant Therm bypass hose Clutch cable 1 1 Remove the parts in the order listed Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 12 Nm 1 2 m kg 12 Nm 1 2 m kg EB405000 CLUTCH CLUTCH COVER ...

Page 172: ...UTCH ENG Order Job Part Q ty Remarks 3 4 5 Clutch cover Clutch cover gasket Dowel pin 1 1 2 Refer to REMOVING INSTALLING THE CLUTCH For installation reverse the removal procedure 12 Nm 1 2 m kg 12 Nm 1 2 m kg ...

Page 173: ...sassembling the clutch cover assembly Circlip Plain washer Pull lever Pull lever spring Oil seal Bearing 2 2 1 1 1 2 Disassemble the parts in the order listed Refer to INSTALLING THE CLUTCH For assembly reverse the disassembly procedure 1 2 3 4 5 6 ...

Page 174: ...ression spling Pressure plate Pull rod Bearing Friction plate Clutch plate Clutch plate Clutch boss nut Look washer Clutch boss 6 1 1 1 8 7 1 1 1 1 Remove the parts in the order listed Refer to REMOVING INSTALLING THE CLUTCH Refer to INSTALLING THE CLUTCH 70 Nm 7 0 m kg 8 Nm 0 8 m kg CLUTCH ...

Page 175: ...4 47 CLUTCH ENG Order Job Part Q ty Remarks 11 Thrust plate 1 For installation reverse the removal procedure 70 Nm 7 0 m kg 8 Nm 0 8 m kg ...

Page 176: ... the clutch boss 2 with the clutch holding tool 3 loosen the clutch boss nut Clutch holding tool 90890 04086 4 Remove clutch boss nut 1 lock washer 2 clutch boss 3 thrust plate 4 EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric tion plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specif...

Page 177: ...SPRINGS The following procedure applies to all of the clutch springs 1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length a Out of specification Replace the clutch springs as a set Clutch spring free length Clutch spring free length 55 mm Limit 54 mm EAS00284 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutc...

Page 178: ... cause er ratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Check pressure plate 1 Cracks damage Replace bearing 2 Damage wear Replace EAS00287 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 ...

Page 179: ...ut 4 Lubricate friction plates clutch plates with the recommended lubricant Recommended lubricant Engine oil 5 Install friction plates clutch plates First install a friction plate and then alternate between a clutch plate and a friction plate 6 Install washer bearing 1 pull rod 2 Install the pull rod so that the teeth a face to wards the rear of the motorcycle Then install the clutch cover Tighten...

Page 180: ...stages and in a criss cross pattern 8 Install clutch cover When installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged Tighten the clutch cover bolts in stages and in a crisscross pattern ...

Page 181: ...st pipe assembly Oil level switch couplar Oil level switch 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to RADIATOR and WATER PUMP in chapter 5 Refer to ENGINE Disconnect 43 Nm 4 3 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg 10 Nm 1 0 m kg EAS00356 OIL PAN AND OIL PUMP ...

Page 182: ...in Oil strainer Oil pipe Oil delivery pipe Gear cover Dowel pin Oil pump assembly Relief valve assembly 1 1 1 2 1 1 1 1 2 1 1 Refer to INSTALLING THE OIL STRAINER Refer to INSTALLING THE OIL PUMP For installation reverse the removal procedure Refer to REMOVEING INSTALLING THE OIL PAN 43 Nm 4 3 m kg 10 Nm 1 0 m kg 12 Nm 1 2 m kg 10 Nm 1 0 m kg ...

Page 183: ...mp assembly Oil pump rotor housing Dowel pin Oil pump inner rotor Oil pump outer rotor Dowel pin Washer Oil pump cover Driver gear 1 2 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 7 8 12 Nm 1 2 m kg EB411010 OIL PUMP ...

Page 184: ...move them EAS00364 CHECKING THE OIL PUMP 1 Check oil pump driven gear 1 rotor housing 2 Cracks damage wear Replace the defec tive part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump cover clearance b Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump cover Inner rotor to outer rotor tip clearance 0 03 0 09 mm Limit 0 15 mm Outer rotor t...

Page 185: ...HE OIL DELIVERY PIPE AND OIL PIPE 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with engine oil EAS00373 CHECKING THE OIL NOZZLES The following procedure applies to all of the oil nozzles 1 Check oil nozzle 1 O ring 2 Damage wear Replace the oil noz...

Page 186: ...LLING THE OIL PUMP 1 Install oil pump 1 Install the oil pump assembly drive chain onto the oil pump assembly driven sprocket EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 The arrow a on the oil strainer housing must point towards the front of the engine EAS00380 INSTALLING THE OIL PAN 1 Install dowel pins oil pan gasket New oil pan 1 oil level switch 2 engine oil drain bolt 3 Tight...

Page 187: ...nd pickup rotor Clutch assembly Water pump assembly Oil pan and oil pump Remove the parts in the order listed Refer to ENGINE Refer to CYLINDER HEAD Refer to STARTER CLUTCH AND GENERATOR Refer to SHIFT SHAFT Refer to PICKUP COIL AND PICKUP ROTOR Refer to CLUTCH Refer to WATER PUMP in chapter 5 Refer to OIL PAN AND OIL PUMP 12 Nm 1 2 m kg CRANKCASE ...

Page 188: ...Part Q ty Remarks 1 2 3 4 5 Timing chain Oil pump drive chain guide Oil pump drive chain Lower crankcase Dowel pin 1 1 1 1 3 Refer to DISASSEMBLY ASSEMBLY THE CRANKCASE For installation reverse the removal procedure 12 Nm 1 2 m kg ...

Page 189: ...smission Oil baffle plate Oil baffle plate Oil delivery pipe Bearing Lower crankcase Oil filter bolt Upper crankcase 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to TRANSMISSION For instalation reverse the removal procedure 80 Nm 8 0 m kg 12 Nm 1 2 m kg 12 Nm 1 2 m kg OIL BAFFLE PLATES AND OIL FILTER BOLT ...

Page 190: ...bers embossed on the crankcase in dicate the crankcase tightening sequence 2 Remove crankcase bolts 3 Remove lower crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinforced por tions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crankcase halves separate evenly M8 85 mm bolts 1 X 7 10 M8 115 mm bolts 8 9 M8 65...

Page 191: ...eck bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace CHECKING THE SPROCKETS AND CHAINS 1 Check crankshaft sprocket 1 oil water pump assembly drive sprocket 2 Cracks damage wear Replace the de fective part s 2 Check timing chain 1 Damage stiffness Replace the timing chain and crankshaft sprocket as a s...

Page 192: ...215 90890 85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 3 mm of the crankshaft journal bearings 3 Install dowel pin 4 Set the shift drum assembly and transmis sion gears in the neutral position 5 Install lower crankcase 1 onto the upper crankcase 2 Before tightening the crankcase bolts make sure that the tr...

Page 193: ...lubricate seal botts 18 12 Tighten the bolts in the tightening sequence cast on the crankcase M8 85 mm bolts 1 X 7 10 M8 115 mm bolts 8 9 M8 65 mm bolts 11 12 M6 65 mm bolts 13 14 17 27 M6 55 mm bolts 15 22 X 26 M6 45 mm bolts 16 19 X 21 M6 75 mm bolt 18 Bolt 15 X 27 12 Nm 1 2 m kg Bolt 13 X 14 14 Nm 1 4 m kg Bolt 1 X 12 24 Nm 2 4 m kg Always use new copper washers ...

Page 194: ...ower crankcase Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod 4 4 4 8 4 4 4 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to REMOVING INSTALLING THE CONNECTING RODS AND PISTONS 15 Nm 1 5 mSkg 90_ EAS00252 CONNECTING RODS AND PISTONS ...

Page 195: ... RODS AND PISTONS ENG Order Job Part Q ty Remarks 8 9 10 Top ring 2nd ring Oil ring 4 4 4 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CONNECTING RODS AND PISTONS 15 Nm 1 5 mSkg 90_ ...

Page 196: ... pin 2 piston 3 connecting rod Do not use a hammer to drive the piston pin out For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the pis ton pin clip groove and the piston 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 197: ...e Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the measure ments Cylinder bore gauge 90890 03017 Cylinder bore C 65 50 65 51 mm Max taper T 0 05 mm Out of round R 0 05 mm b If out of specification replace the crank cases and the piston and piston rings as a set c Measure piston skirt diameter P with the micrometer Micrometer...

Page 198: ...stons and piston rings as a set EAS00263 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a set Before measuring the piston ring side clear ance eliminate any carbon deposits from the piston ring grooves and piston 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 ...

Page 199: ...50 mm Limit 0 85 mm Oil ring 0 10 0 35 mm ABS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis ton pins 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubrication sys tem 2 Measure piston pin outside diameter a Out of specification Replace the piston pin Piston pin outside diameter 15 991 16 000 mm 3 Measure piston pin bore di...

Page 200: ...Crankshaft pin to big end bearing clearance 0 028 0 052 mm The following procedure applies to all of the connecting rods Do not interchange the big end bearings and connecting rods To obtain the correct 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 crankshaft pins and bearing por...

Page 201: ...n both the connecting rod and connecting rod cap are aligned e Tighten the connecting rod nuts SWhen tightening the connecting rod nuts be sure to use an F type torque wrench SAfter tightening the connecting rod nut to the specified torque turn the connecting rod nut another 90_ Refer to INSTALLING THE PISTONS AND CONNECTING RODS Connecting rod nut 15 Nm 1 5 mSkg 90_ f Remove the connecting rod an...

Page 202: ...stration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 1 respectively then the bearing size for P1 is P1 connecting rod P1 crank shaft 5 1 4 BIG END BEARING COLOR CODE 1 blue 2 black 3 brown 4 green EAS00271 INSTALLING THE PISTONS AND CONNECT ING RODS The following procedure applies to all of the pis tons and cylinders 1 Install top ring 2nd ring oil ring Be sure...

Page 203: ... is pointing up Refer to the illustra tion Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring A Intake side 4 Lubricate piston piston rings cylinder with the recommended lubricant Recommended lubricant Engine oil 5 Lubricate bolt threads nut seats with the rec...

Page 204: ...onnecting rod caps SBe sure to reinstall each big end bearing in its original place SWhile compressing the piston rings with one hand install the connecting rod assembly into the cylinder with the other hand SMake sure that the Y marks a on the con necting rods face towards the left side of the crankshaft SMake sure that the characters b on both the connecting rod and connecting rod cap are aligne...

Page 205: ...ghten the nut further to reach the specified angle 90_ When the nut is tightened more than the specified angle do not loosen the nut and then retighten it Replace the bolt with a new one and perform the procedure again SDo not use a torque wrench to tighten the nut to the specified angle STighten the nut until it is at the specified angles When using a hexagonal nut note that the angle from one co...

Page 206: ...s and pistons Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing 1 5 5 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to CONNECTING RODS AND PISTONS For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CRANKSHAFT EAS00381 CRANKSHAFT ...

Page 207: ...3 mm 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1 Measure crankshaft journal to crankshaft journal bearing clearance Out of specification Replace the crank shaft journal bearings Crankshaft journal to crankshaft journal bearing clearance 0 034 0 058 mm Do not interchange the crankshaft ...

Page 208: ...astigauge 2 on each crankshaft journal Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase Align the projections a on the crankshaft jour nal lower bearings with the notches b in the lower crankcase Do not move the crankshaft until the clearance measurement has been completed f Ti...

Page 209: ...d into the lower crankcase are used to determine the replace ment 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 crank shaft web J1 numbers are 6 and 2 respec tively then the bearing size for J1 is Bearing size for J1 J1 crankcase J1 crankshaft web ...

Page 210: ...1 Install crankshaft journal upper bearings into the upper lower crankcase Align the projections a on the crankshaft jour nal upper bearings with the notches b in the upper crankcase Be sure to install each crankshaft journal up per bearing in its original place ...

Page 211: ...sion Crankcase lower Shift shaft and stopper lever Drive axle assembly Circlip Oil seal Bearing Shift bar stopper Shift fork guide bar 1 1 1 1 1 2 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to SHIFT SHAFT 12 Nm 1 2 m kg 10 Nm 1 0 m kg EAS00419 TRANSMISSION ...

Page 212: ...9 10 11 12 Spring Shift fork L Shift fork R Shift drum assembly Shift fork C Main axle assembly 4 1 1 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE TRANSMISSION Refer to REMOVING THE TRANSMISSION 12 Nm 1 2 m kg 10 Nm 1 0 m kg ...

Page 213: ... Disassembling the main axle assembly Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed 1 2 3 4 5 6 7 8 9 10 ...

Page 214: ...4 86 TRANSMISSION ENG Order Job Part Q ty Remarks Washer 5th pinion gear Collar Main axle Bearing housing Bearing 1 1 1 1 1 1 For installation reverse the removal procedure 11 12 13 14 15 16 ...

Page 215: ...mbling the drive axle assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear 1 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed 1 2 3 4 5 6 7 8 9 10 11 ...

Page 216: ... ty Remarks Collar Washer Circrip 6th wheel gear Circrip washer 2nd wheel gear Collar Collar Oil seal Bearing Circrip Drive axle 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure 12 13 14 15 16 17 18 19 20 21 22 23 24 ...

Page 217: ...s until they contact the crank case surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase EAS00421 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 fl...

Page 218: ...t drum bearing 2 Damage pitting Replace the shift drum assembly EAS00425 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 02 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 02 mm 3 Check transmissi...

Page 219: ...mbly shift fork R shift fork L springs shift fork guide bars drive axle assembly 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 Ma...

Page 220: ...ING THE RADIATOR 5 4 OIL COOLER 5 5 CHECKING THE OIL COOLER 5 7 INSTALLING THE OIL COOLER 5 7 THERMOSTAT 5 9 CHECKING THE THERMOSTAT 5 11 INSTALLING THE THERMOSTAT 5 11 WATER PUMP 5 13 DISASSEMBLING THE WATER PUMP 5 15 CHECKING THE WATER PUMP 5 15 ASSEMBLING THE WATER PUMP 5 16 ...

Page 221: ... cowling and side cowlings Coolant Coolant reserver hose Breather hose Radiator outlet hose 1 2 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to AIRFILTER CASE AND IGNI TION COILS in chapter 3 Refer to COWLINGS in chapter 3 Drain Disconnect 9 Nm 0 9 m kg 28 Nm 2 8 m kg 7 Nm 0 7 m kg COOLING SYSTEM RADIATOR ...

Page 222: ...7 8 9 Radiator inlet hose Oil cooler outlet hose Thermo switch coupler Radiator fan motor coupler Radiator Radiator fan 1 1 1 1 1 1 Disconnect Disconnect Disconnect For installation reverse the removal procedure 28 Nm 2 8 m kg 9 Nm 0 9 m kg 7 Nm 0 7 m kg ...

Page 223: ...easure radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 110 140 kPa 1 1 1 4 kg cm2 1 1 1 4 bar a Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 Radiator cap tester 90890 01325 Adapter 90890 01352 b Apply the specified pressure for ten seconds and make sure that there is no drop in pres sure 4 Check radiator f...

Page 224: ...the specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 225: ...bly Exaust pipe assembly Engine oil Oil cooler outlet hose Bolt Washer Oil cooler 1 1 1 1 Remove the parts in the order listed Refer to RADIATOR Refer to ENGINE in chapter 4 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Refer to INSTALLING THE OIL COOLER 63 Nm 6 3 m kg EAS00457 OIL COOLER ...

Page 226: ...t Q ty Remarks 5 6 7 8 9 10 Oil cooler inlet hose Water jacket joint Water jacket joint hose Water pump outlet pipe Water pump outlet hose Water pump inlet hose 1 1 1 1 1 1 For installation reverse the removal procedure 63 Nm 6 3 m kg ...

Page 227: ...e Replace EBS00459 INSTALLING 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 New oil cooler 1 washer 2 New bolt 3 Before installing the oil cooler lubricate the oil cooler bolt and O ring with a thin coat of engine oil Make sure that the O ring is positioned proper ly Align the projection a on the oil cooler wi...

Page 228: ...OOLANT in chapter 3 crankcase with the specified amount of the recom mended 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 229: ...nd fuel tank Coolant Air filter case Carburetor assembly Remove the parts in the order listed Refer to SEAT and FUEL TANK in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to AIRFILTER CASE AND IGNITION COILS in chapter 3 Refer to CARBURETORS in chapter 6 THERMOSTAT ...

Page 230: ...ERMOSTAT COOL Order Job Part Q ty Remarks 1 2 3 4 Radiator inlet hose Carburator outlet hose Thermostat cover Thermostat 1 1 1 1 For installation revers the removal procedure Refer to INSTALLING THE THERMOSTAT ...

Page 231: ...ndicated tempera ture 1 Thermostat 2 Thermometer 3 Water 4 Container A Fully closed B Fully opens If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overheating or overcooling 2 Check Sthermostat housing cover Sthermostat housing Cracks damage Replace EB00467 INSTALLING THE THERMOSTAT 1 Install Install the thermostat with its breather hole a facing up...

Page 232: ...amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 4 Check cooling system Leaks Repair or replace any faulty part 5 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 233: ...p assembly Coolant Water pump inlet hose Water pump outlet hose Water pump hose Clutch wire and holder Water pump 1 1 1 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE COOLANT in chapter 3 For installation reverse the removal procedure 12 Nm 1 2 m kg WATER PUMP ...

Page 234: ...y Water pump cover O ring Impeller shaft along with the impeller Water pump seal Oil seal Bearing Circlip 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEMBLING THE WATER PUMP 1 2 3 4 5 6 7 10 Nm 1 0 m kg ...

Page 235: ...seal from the outside of the water pump housing 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaft EAS00474 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 sea...

Page 236: ...ter pump seal 1 New Never lubricate the water pump seal surface with oil or grease 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 Mechanical seal installer 90890 04078 4 Middle driven shaft bearing driver 5 90890 04058 5 Yamaha bond No 1215 90890 85505 A Push down 3 Install rubber damper 1 New rubber ...

Page 237: ...AUTION 4 Measure impeller shaft tilt Out of specification Repeat steps 3 and 4 Make sure that the rubber damper and rub ber damper holder are flush with the impel ler Max impeller shaft tilt 0 15 mm 1 Straightedge 2 Impeller ...

Page 238: ...ORS 6 7 ASSEMBLING THE CARBURETORS 6 9 INSTALLING THE CARBURETORS 6 11 MEASURING AND ADJUSTING THE FUEL LEVEL 6 12 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 13 CHECKING THE FUEL PUMP 6 16 CHECKING THE FUEL COCK 6 17 CHECKING THE FUEL COCK OPERATION 6 17 ...

Page 239: ...k Air filter case and heat protector plate Starter cable Fuel hose Throttle position sensor coupler Throttle stop screw 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 IGNITION COILS in chapter 3 Disconnect EAS00481 CARBURETORS CARBURETORS ...

Page 240: ...S CARB Order Job Part Q ty Remarks 5 6 7 8 9 10 Therm bypass hose Carburetor joint clamp screw Throttle cable Carburetor assembly Carburetor joint Side cover 2 4 2 1 4 2 For installation reverse the removal procedure ...

Page 241: ...ger link Connecting bolt Connecting bolt Hose joint Spring Fuel feed pipe Fuel feed pipe Pipe Throttle stop screw Throttle position sensor Water pipe 1 1 1 2 2 2 1 2 1 1 2 Remove the parts in the order listed Refer to ASSEMBLING THE CARBURETORS Refer to ASSEMBLING THE CARBURETORS CARBURETORS CARB ...

Page 242: ...6 4 Order Job Part Q ty Remarks 12 13 14 15 Balance pipe Balance pipe bracket Throttle cable bracket Carburetor 2 1 1 4 For installation reverse the removal procedure CARBURETORS CARB ...

Page 243: ...er cover Piston valve spring Jet needle holder Jet needle kit Piston valve Pilot screw Fuel drain bolt Float chamber Float pivot pin 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed The following procedure applies to all of the carburetors NOTE Refer to ASSEMBLING THE CARBURETORS 1 2 3 4 5 6 7 8 9 10 11 ...

Page 244: ...6 6 CARBURETORS CARB Order Job Part Q ty Remarks Float Needle valve Main jet Main jet holder Pilot jet 1 1 1 1 1 For assembly reverse the disassembly procedure 12 13 14 15 16 ...

Page 245: ...Clean a Wash the carburetor in a petroleum based solvent 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 Damage obstruction wear Replace the needle valve needle valve seat and O rin...

Page 246: ...edle kit 1 main jet 2 main jet holder 3 pilot jet 4 pilot screw 5 starter plunger 6 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 10 Check piston valve movement Insert the piston valve into the carburetor body and move it up and down Tightness Replace the piston valve 11 Check fuel feed pipes 1 pipes 2 hose joint 3 Cracks damage Replace Obstruction Clean Blow ou...

Page 247: ...e assembling the carburetors wash all of the parts in a petroleumbased sol vent Always use a new gasket 1 Install pilot screw kit 1 Pilot screw setting 2 turns out 2 Install piston valve 1 jet needle jet needle holder piston valve spring vacuum chamber cover Install the end of the piston valve spring onto the spring guide on the vacuum chamber cov er Align the tab a on the piston valve diaphragm w...

Page 248: ... spring 2 and synchronizing screw 3 4 Install starter plunger link 1 Install the starter plunger link 1 onto each start er plunger 5 Tighten connecting bolts Place the carburetor assembly on a surface plate with the intake manifold side down Then tighten the connecting bolts while push ing down the carburetor assembly with an even force After tightening the connecting bolts check that the throttle...

Page 249: ...NG THE CARBU RETORS in chapter 3 2 Adjust engine idling speed Engine idling speed 1250 1350 r min Refer to ADJUSTING THE ENGINE ID LING SPEED in chapter 3 3 Adjust throttle cable free play Throttle cable free play at the flange of the throttle grip 6 8 mm Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 ...

Page 250: ...l gauge 90890 01312 d Loosen the fuel drain bolt 3 e Hold the fuel level gauge vertically next to the line 4 on the float chamber f Measure the fuel level a 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 needle valve c If either is worn replace them as a set d If both are fine adjus...

Page 251: ...f specification Replace the throttle position sensor Throttle position sensor maximum resistance 4 0 X 6 0 kΩ at 20_C blue black blue d Connect the pocket tester Ω 1k to the throttle position sensor Tester positive probe yellow 3 Tester negative probe black blue 2 e While slowly opening the throttle check that the throttle position sensor resistance is within the specified range Check mainly that ...

Page 252: ... X 6 0 kΩ at 20_C blue black blue e Connect the pocket tester Ω 1k to the throttle position sensor coupler Tester positive probe yellow 3 Tester negative probe black blue 2 f While slowly opening the throttle check that the throttle position sensor resistance is within the specified range The resistance does not change or it changes abruptly Replace the throttle position sensor The slot is worn or...

Page 253: ...en the throttle position sensor screws 1 e Adjust the throttle position sensor angle ac cording to the following table The angle of the throttle position sensor is indi cated by the r min which are displayed on the tachometer Tachometer Reading Throttle posi tion sensor angle Adjustment direction 5000 rpm Correct 0 rpm Incorrect 10000 rpm Incorrect f After adjusting the throttle position sensor an...

Page 254: ... 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 Fuel flows Fuel pump is OK Fuel does not Replace the fuel flow p pump f Stop the engine and check if the fuel stops flowing from the fuel hose 2 Fuel stops flowing Fuel pump is OK F el flows Replace the f...

Page 255: ...struction Clean Damage Replace 4 Install fuel cock fuel filter fuel tank EAS00506 CHECKING THE FUEL COCK OPERATION After installing the fuel cock check its opera tion 1 Check that the fuel cock lever is turned to ON or OFF 2 Place a container under the end of the fuel hose 3 Check fuel cock operation a Suck on the end of the vacuum hose Fuel flows Fuel cock is OK Fuel does not flow Replace the fue...

Page 256: ...ONT AND REAR BRAKES 7 14 FRONT BRAKE PADS 7 14 REAR BRAKE PADS 7 15 REPLACING THE FRONT BRAKE PADS 7 16 REPLACING THE REAR BRAKE PADS 7 18 FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 7 21 REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 7 24 REMOVING THE FRONT BRAKE MASTER CYLINDER 7 26 REMOVING THE REAR BRAKE MASTER CYLINDER 7 26 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 7 ...

Page 257: ...EAD 7 61 INSTALLING THE STEERING HEAD 7 62 REAR SHOCK ABSORBER ASSEMBLY 7 64 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 7 65 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 7 65 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 7 66 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 7 66 CHECKING THE RELAY ARM AND CONNECTING ARM 7 67 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 7 67 SWIN...

Page 258: ...s left and right 2 2 1 1 1 2 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loosen 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 20 Nm 2 0 m kg Refer to REMOVING INSTALLING THE FRONT WHEEL For installation reverse the removal procedure FRONT WHEEL AND BRAKE DISCS CHAS EAS00514...

Page 259: ...s Disassembling the front wheel Oil seals left and right Wheel bearings left and right Spacer 2 2 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 FRONT WHEEL AND BRAKE DISCS CHAS EAS00518 ...

Page 260: ... Remove Brake hose holders left brake caliper right brake caliper wheel axle Do not squeeze the brake lever when removing the brake calipers 3 Elevate front wheel Place the motorcycle on a suitable stand so that the front wheel is elevated EAS00525 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace Do not attempt to straighten a bent wheel axle 2 Check ...

Page 261: ...arings New oil seals New a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a gener al bearing puller d Install the new wheel bearings and oil seals in the reverse order of disassembly Do not contact the wheel bearing center race...

Page 262: ... front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is station ary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm below the edge of the brake disc 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace ...

Page 263: ...5 INSTALLING THE FRONT WHEEL 1 Lubricate wheel axle oil seal lips Recommended lubricant Lithium soap base grease 2 Tighten wheel axle 1 wheel axle pinch bolt 2 Before tightening the wheel axle nut push down hard on the handlebars several times and check if the front fork rebounds smoothly 3 Install brake calipers brake hose holders Make sure that the brake hose is routed properly EAS00549 ADJUSTIN...

Page 264: ...ll 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 Sfront wheel static balance a Install a balancing weight 1 onto the rim ex actly opposite the heavy spot X Start with the lightest weight b Turn the front wheel 90_ so that the heavy spot is positioned as shown c If the heavy spot does not stay in that posi tion install...

Page 265: ...ket bolt Brake caliper bracket 1 2 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated Loosen Loosen Make sure that the tapered side of the right adjusting block faces the wheel For installation reverse the removal procedure NOTE NOTE 150 Nm 15 m kg 40 Nm 4 0 m kg REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00...

Page 266: ...t Spacers left and right Oil seal Bearing Rear wheel drive hub Rear wheel drive hub dampers Rear wheel 1 1 2 1 1 1 5 1 Remove the parts in the order listed For installation reverse the removal procedure 18 Nm 1 8 m kg 69 Nm 6 9 m kg REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS EAS00556 BRAKE DISC AND REAR WHEEL SPROCKET ...

Page 267: ...sassembling the rear wheel Spacer Bearing Spacer Oil seal Circlip Bearing 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET CHAS ...

Page 268: ... Remove brake caliper Do not depress the brake pedal when removing the brake caliper 3 Remove wheel axle nut washer wheel axle adjusting blocks brake caliper bracket rear wheel Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EAS00565 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals brake disc Refer to BRAKE DISC AND REAR WHEEL SPROK...

Page 269: ...568 CHECKING 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 sprock et 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 ...

Page 270: ...heel axle nut brake caliper 3 Adjust drive chain slack a Drive chain slack 40 50 mm Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 4 Tighten wheel axle nut brake caliper bolts Make sure that the brake hose is routed properly EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static ba...

Page 271: ...Brake pad shims Bleed screw 2 1 1 2 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Refer to REPLACING THE FRONT BRAKE PADS 40 Nm 4 0 m kg 6 Nm 0 6 m kg For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS ...

Page 272: ...aliper bolts Brake pads Brake pad shims Bleed screw 2 2 4 1 Remove the parts in the order listed Refer to REPLACING THE REAR BRAKE PADS 27 Nm 2 7 m kg 6 Nm 0 6 m kg 40 Nm 4 0 m kg For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS EAS00578 REAR BRAKE PADS ...

Page 273: ...se only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt 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 im mediate medical attention EAS00582 REPLACING THE...

Page 274: ...g Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install a new brake pad shim onto each new brake pa...

Page 275: ...id to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EAS00583 REPLACING THE REAR BRAKE PADS When replacing the brake pads it is not neces sary to disconnect the brake hose or disas semble the brake caliper 1 Remove brake caliper 1 2 Remove bra...

Page 276: ... pads Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg d Install a new brake pa shim onto each new brake...

Page 277: ...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 278: ... diaphragm Brake fluid reservoir Brake fluid reservoir hose Circlip Dust cover Hose joint Brake lever Front brake switch connector Union bolt Copper washer 1 1 11 1 1 1 1 1 1 2 1 3 Remove the parts in the order listed Drain Disconnect Refer to INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 3 4 5 6 8 7 9 10 11 12 13 14 13 14 13 15 16 17 30 Nm 3 0 m kg 13 Nm 1 3 m kg New 2 FRONT AND REAR BRAKES CHAS E...

Page 279: ...linder holder Brake master cylinder Front brake switch 2 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE FRONT BRAKE MASTER SYLINDER 1 2 3 4 5 6 8 7 9 10 11 12 13 14 13 14 13 15 16 17 30 Nm 3 0 m kg 13 Nm 1 3 m kg New FRONT AND REAR BRAKES CHAS ...

Page 280: ...embling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 FRONT AND REAR BRAKES CHAS EAS00585 ...

Page 281: ...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 Refer to INSTALLING THE REAR BRAKE MASTER SYLINDER 5 Nm 0 5 m kg 23 Nm 2 3 m kg 30 Nm 3 0m kg For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER AND B...

Page 282: ...Disassembling the rear brake master cylinder Brake master cylinder kit Brake master cylinder 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 16 Nm 1 6 m kg FRONT AND REAR BRAKES CHAS EAS00587 ...

Page 283: ... and the end of the brake hose EAS00589 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 button head bolts 4 To collect any remaining brake fluid place a container under the master cylinder and the end of the brake hose EAS00593 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders 1 Check...

Page 284: ...ks damage Replace brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check brake hoses Cracks damage wear Replace EAS00607 INSTALLING THE FRONT BRAKE MASTER CYLINDER Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents Recommended brake fluid DOT 4 ...

Page 285: ... as shown Turn the handlebars to the left and to the right to make sure that the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill brake fluid reservoir with the specified amount of the recom mended brake fluid Recommended brake fluid DOT 4 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage ...

Page 286: ...id to the proper level Refer 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 EAS00608 INSTALLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers New brake hoses union bolt button head bolts Proper brake hose routing is essential to in sure safe motorcycle ope...

Page 287: ...boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 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 ...

Page 288: ...hose Brake caliper 1 2 1 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Drain Refer to INSTALLING THE FRONT BRAKE CALIPERS 6 Nm 0 6 m kg 30 Nm 3 0 m kg 40 Nm 4 0 m kg For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPERS ...

Page 289: ...ke caliper piston Brake caliper piston seal Bleed screw 2 1 1 2 4 8 1 Disassemble the parts in the order listed The following procedure applies to both of the front brake calipers Refer to REMOVING THE FRONT BRAKE CALIPERS 6 Nm 0 6 m kg 1 2 3 4 5 6 7 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES CHAS EAS00615 ...

Page 290: ...luid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain Refer to INSTALLING THE REAR BRAKE CALIPERS 30 Nm 3 0 m kg 27 Nm 2 7 m kg For installation reverse the removal procedure FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER ...

Page 291: ...er Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 2 2 4 1 Disassemble the parts in the order listed Refer to REMOVING THE REAR BRAKE CALIPERS 1 2 3 4 For assembly reverse the disassembly procedure 6 Nm 0 6 m kg FRONT AND REAR BRAKES CHAS EAS00617 ...

Page 292: ...he end of the brake hose into a container 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 pistons from the brake caliper Never try to pry out the brake caliper pis tons Do not loosen the bolts 3 c Remove...

Page 293: ... brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper Be careful not to get injured when the pistons are expelled from the brake caliper Cover the brake caliper piston with a rag Never try to pry out the brake caliper ...

Page 294: ...henever the brake is disassembled 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper brake caliper cylinders 2 Scratches wear Replace the brake cali per brake calipers 3 Cracks damage Replace brake fluid delivery passages brake caliper body Obstruction Blow out with compressed air Whenever a brake caliper is disassembled replace the brake caliper piston seals A Front B R...

Page 295: ... the piston seals to swell and distort Whenever a brake caliper is disassembled 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 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper 1 make sure that th...

Page 296: ...ance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 6 Check brake fluid level...

Page 297: ...s they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake pads brake caliper 1 copper washers New brake hose 2 union bolt 3 Proper brake hose routing is essential to in sure safe motorcycle operation Refer to CABLE ROUTING When installing the brake hose onto the brake caliper...

Page 298: ...ance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 4 Check brake fluid level...

Page 299: ...per bracket pinch bolts Cap bolts Lower bracket pinch bolts Front fork legs 1 2 2 1 1 2 2 4 2 Remove the parts in the order listed The following procedure applies to both of the front fork legs Refer to FRONT WHEEL AND BRAKE DISCS Refer to COWLINGS in chapter 3 Loosen Loosen Loosen Loosen For installation reverse the removal procedure 23 Nm 2 3 m kg 6 Nm 0 6m kg 6 Nm 0 6m kg 13 Nm 2 3 m kg 23 Nm 2...

Page 300: ...cer Washer Fork spring Copper washer Damper rod assembly bolt Damper rod assembly 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed The following procedure applies to both of the front fork legs Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 23 Nm 2 3 m kg 40 Nm 4 0 m kg 1 2 3 4 5 6 7 8 9 10 EB703002 ...

Page 301: ...Dust seal Oil seal clip Oil seal Washer Outer tube bushing Inner tube Oil lock piece 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 23 Nm 2 3 m kg 40 Nm 4 0 m kg 11 12 13 14 15 16 17 ...

Page 302: ... cap bolt 2 handlebar pinch bolt 1 lower bracket pinch bolt upper bracket bolt 4 handlebar 5 Before loosening the upper and lower bracket pinch bolts and handlebar pinch bolt support the front fork leg 3 Remove front fork leg EAS00655 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs 1 Remove cap bolt 1 from the damper adjusting rod spacer 2 nut 3 a P...

Page 303: ...pressed f Remove the spacer and nut g Remove the fork spring 2 Drain fork oil 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 Slide metal 4 Remove damper rod assembly bolt copper washer While holding the damper rod with the damper rod holder 1 loosen the damper rod assembly bolt Damper rod holder 9089...

Page 304: ...t 2 Measure spring free length a Out of specification Replace Spring free length limit 251 8 mm Limit 246 mm 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with compressed air The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling and asse...

Page 305: ...ront 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 oil lock piece inner tube 2 damper rod assembly 1 Always use new copper washers Allow the damper rod assembly to slide slowly down the inner tube 2 until it pro trudes from the bottom of the inner...

Page 306: ...side of the oil seal faces up 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 6 to protect the oil seal during installation 5 Install washer oil seal 1 with the fork seal driver 2 Fork seal driver weight 90890 01367 Fork s...

Page 307: ...ach front fork leg 476 cm3 Recommended oil Yamaha fork and suspension oil 01 or equivalent Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork 11 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten t...

Page 308: ... measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed Be sure to bleed the front fork leg of any residual air 14 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 compressed and without the spring 107 mm 15 Install nut 1 fork spring 2 washer 3 spacer...

Page 309: ...nut 1 and the spacer 4 Use the side of the rod holder that is marked B Fork spring compressor 90890 01441 Rod holder 90890 01434 g Remove the rod puller and adapter h Install the nut 1 and position it as specified b Distance b 11 mm 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 speci fication Nut 15 Nm 1 5 m kg k Rem...

Page 310: ...o both of the front fork legs 1 Install front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the handlebar 2 Tighten lower bracket pinch bolt handlebar pinch bolt 1 cap bolt 2 upper bracket pinch bolt 3 Make sure that the brake hoses are routed properly 3 Adjust spring preload rebound damping compression damping Refe...

Page 311: ...r Clutch cable Clutch lever holder Right grip end Throttle cable Throttle grip 1 1 2 1 1 1 1 1 1 2 1 Remove the parts in the order listed Disconnect Refer to INSTALLING THE HANDLEBARS Disconnect Disconnect Refer to INSTALLING THE HANDLEBARS Refer to REMOVING INSTALLING THE HANDLEBARS 13 Nm 1 3 m kg 115 Nm 11 5 m kg 13 Nm 1 3 m kg 13 Nm 1 3 m kg 13 Nm 1 3 m kg 23 Nm 2 3 m kg 18 EAS00665 HANDLEBARS ...

Page 312: ...er Brake master cylinder Handlebar pinch bolt Upper bracket bolt Upper bracket pinch bolt Steering stem nut Left handlebar Right handlebar Upper bracket 2 1 1 1 2 2 2 1 1 1 1 Disconnect Refer tp INSTALLING THE HANDLEBARS For installation reverse the removal procedure 13 Nm 1 3 m kg 115 Nm 11 5 m kg 13 Nm 1 3 m kg 13 Nm 1 3 m kg 13 Nm 1 3 m kg 23 Nm 2 3 m kg 18 ...

Page 313: ...lebar switch clutch lever holder Blow compressed air between the left handle bar and the handlebar grip and gradually push the grip off the handlebar 3 Remove grip end right handle switch 1 throttle grip 2 right handlebar switch brake master cylinder holder EAS00669 CHECKING THE HANDLEBARS 1 Check left handlebar right handlebar Bends cracks damage Replace Do not attempt to straighten bent handle b...

Page 314: ...ces 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 mas ter cylinder holder 2 Install right handlebar switch 1 throttle cables grip end Align the projection a on the throttle cable housing with the hole b in the right handlebar 3 Install clutch lever holder 1 Align the slit in the cl...

Page 315: ...ar grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag Do not touch the handlebar grip until the rubber adhesive has fully dried 6 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 7 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FR...

Page 316: ... Lower bracket panel Brake hose holder bolt Lock washer Upper ring nut Rubber washer 2 2 1 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT FORK Disconnect Refer to CHECK AND ADJUSTING THE STEERING HEAD in chapter 3 23 Nm 2 3 m kg 13 Nm 1 3 m kg 115 Nm 11 5 m kg 13 Nm 1 3 m kg 23 Nm 2 3 m kg 17 Nm 1 7 m kg 9 Nm 0 9 m kg 1st 2nd STEERING HEA...

Page 317: ...ver Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race 1 1 1 2 1 1 1 2 Refer to CHECK AND ADJUSTING THE STEERING HEAD in chapter 3 For installation reverse the removal procedure 23 Nm 2 3 m kg 13 Nm 1 3 m kg 115 Nm 11 5 m kg 13 Nm 1 3 m kg 23 Nm 2 3 m kg 17 Nm 1 7 m kg 9 Nm 0 9 m kg 1st 2nd ...

Page 318: ...er bracket ring nuts 1 with the special tool 2 Ring nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling EAS00682 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 ste...

Page 319: ...ls and bearing races as a set Whenever the steering head is disassembled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INSTALLING THE STEERING HEAD 1 Lubricate upper bearing lower bearing bearing races Recommended lubricant Lithium soap base grease 2 Install bearing bearing cover lower ring nut 1 rubber washer 2 upper ri...

Page 320: ...upper bracket steering stem nut Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK 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 ...

Page 321: ...r assembly Coller oil seal bearing Relay arm Coller oil seal bearing Connecting arm Coller oil seal bearing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 2 1 Remove the parts in the order listed Refer to REMOVING THE REAR WHEEL Refer to REMOVING THE REAR SHOCK ABSORBER ASSEMBLY For installation reverse the removal procedure 40 Nm 4 0 m kg 40 Nm 4 0 m kg 40 Nm 4 0 m kg REAR SHOCK ABSORBER ASSEMBLY CH...

Page 322: ...sorber 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 pres sure 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 damping performance will suffer EAS00689 DISPOSING OF A REAR SHOCK ABSORB...

Page 323: ...er bolt hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bin 1 rear shock absorber assembly Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm EAS00696 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 absorb...

Page 324: ...ce spacers Damage scratches Replace EAS00698 INSTALLING THE REAR SHOCK ABSORB ER ASSEMBLY 1 Lubricate bearings oil seals spacers Recommended lubricant Lithium soap base grease 2 Install connecting arm relay arm rear shock absorber assembly When installing the rear shock absorber assem bly lift up the swingarm 3 Tighten connecting arm to frame nut relay arm to connecting arm nut relay arm to swinga...

Page 325: ...ssembly Adjusting bolt locknut Drive chain guard Rear fender Flap Pivot shaft nut washer Pivot shaft Swingarm 2 2 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE in chapter 4 Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Refer to REAR SHOCK ABSORBER ASSEMBLY 95 Nm 9 5 m kg 6 Nm 0 6 m kg 6 Nm 0 6 m kg EAS00700 SWINGARM AND DRIVE CHAIN ...

Page 326: ... 14 15 16 17 Pivot shaft adjust bolt Drive chain Dust cover Oil seal Bush Shim Drive chain guide Bush Left bearing Right bearing 2 1 1 1 1 1 1 1 1 1 Refer to REMOVING INSTALLING THE SWINGARM For installation reverse the removal procedure 95 Nm 9 5 m kg 6 Nm 0 6 m kg 6 Nm 0 6 m kg ...

Page 327: ...n EC573000 REMOVING THE SWINGARM 1 Remove Bolt connecting rod 1 Connecting rod 2 Remove the bolt while holding the swingarm 2 Loosen Pivot shaft adjust bolt 1 Loosen the pivot shaft adjust bolt using a pivot shaft wrench 2 Pivot shaft wrench 90890 01471 3 Remove Pivot shaft 1 Swingarm EAS00704 REMOVING THE DRIVE CHAIN 1 Remove drive chain Only cut the drive chain if or the swingarm is to be replac...

Page 328: ...t Pivot shaft nut 95 Nm 9 5m kg b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and dust covers Swingarm side play at the end of the swingarm 1 0mm d Check the swingarm vertical movement B by moving the swingarm up and down If swingarm vertical movement is not smooth or if there is ...

Page 329: ...aft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 5 Wash pivot shaft pivot shaft adjust bolt dust covers spacer bearings Recommended cleaning solvent Kerosine 6 Check dust covers spacer oil seals Damage wear Replace bearings Damage pitting Replace ...

Page 330: ...9 mm 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 11 as shown Perform this measurement at two or three dif ferent places 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 drive chain in kerosine and remove any remaining ...

Page 331: ... can also damage the O rings Therefore use only kerosine to clean the drive chain Don t soak drive drain in kerosine more them ten minutes O ring is damage by kero sine 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 oi...

Page 332: ... pivot shaft nut Use the pivot shaft wrench 2 to tighten the piv ot adjust bolt to finger tightness Pivot shaft wrench 90890 1471 3 Install rear shock absorber assembly rear wheel Refer to REAR SHOCK ABSORBER AS SEMBLY and REAR WHEEL 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Drive chain slack 40 50 mm EAS00713 INSTALLING THE DRIVE CHAIN 1 Lubricate drive chai...

Page 333: ...ION 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 334: ... 37 CHECKING THE SIGNALING SYSTEM 8 38 COOLING SYSTEM 8 45 CIRCUIT DIAGRAM 8 45 TROUBLESHOOTING 8 46 FUEL PUMP SYSTEM 8 49 CIRCUIT DIAGRAM 8 49 FUEL PUMP CIRCUIT OPERATION 8 50 TROUBLESHOOTING 8 51 CHECKING THE FUEL PUMP 8 53 SELF DIAGNOSIS 8 54 TROUBLESHOOTING 8 55 ...

Page 335: ... 8 Flasher relay 9 CDI unit 10 Starter relay 11 Main fuse 12 Oil level relay 13 Battery 14 Rectifier regulator 15 Rear brake light switch 16 Neutral switch 17 Speed sensor 18 Sidestand switch 19 Stator coil assembly 20 Oil level switch 21 Pickup coil 22 Radiator fan 23 Horn 24 Thermo unit 25 Thermo switch 26 Headlight relay HI LO EB800000 ELECTRICAL ELECTRICAL COMPONENTS ...

Page 336: ...on When this light comes on fill the fuel tank at the first opportunity OIL LEVEL COOLANT TEMPERATURE WARNING LIGHT This warning light has two functions The light will come on and symbol will flash if the engine oil level is low If this sym bol 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 temperature is ...

Page 337: ...ashes and the indicator light comes on Stop the engine and allow it to cool Refer to OVERHEATING in chapter 9 COMBINATION METER This combination meter is equipped with the fol lowing SA speedometer SAn odometer STwo trip odometers SA fuel reserve tripmeter SA clock For GB and USA models only To change the speedometer display from kilo meters to miles press the SELECT button for at least two second...

Page 338: ...or at least one second The display will return to TRIP 1 If you do not reset the fuel reserve trip meter manually it will automatically reset and return to TRIP 1 after refueling and the motorcycle has traveled both 5 km and for approximately 3 minutes Clock To change the display to the clock mode push both the SELECT and RESET buttons To set the clock 1 Push both the SELECT and RESET but tons for...

Page 339: ...king for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the one on the left The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration indicates a continuity of electricity between s...

Page 340: ...heck each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected Properly connect Incorrect continuity reading Replace the switch ...

Page 341: ...h 3 Dimmer switch 4 Turn signal switch 5 Horn switch 6 Clutch switch 7 Light switch for Europe 8 Engine stop switch 9 Start switch 10 Front brake light switch 11 Rear brake light switch 12 Neutral switch 13 Fuse 14 Sidestand switch 15 Oil level switch for AUS ...

Page 342: ...shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed from their re spective 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 counterclock wise ...

Page 343: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace Pocket tester 90890 03112 Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to terminal...

Page 344: ...ket for continuity If any of the readings indicate no continuity 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 coupler meter assembly side b Connect two jumper leads 1 from the bat tery terminals to the respective coupler ter minals as shown A wire that is used as a jumper lead must have...

Page 345: ...ay 11 Sidestand switch 14 CDI unit 15 Ignition coil 1 16 Ignition coil 2 17 Ignition coil 3 18 Ignition coil 4 19 Spark plugs 20 Pick up coil 21 Neutral switch 56 Ignition fuse 63 Engine stop switch 66 Diode 2 IGNITION SYSTEM ELEC EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM ...

Page 346: ... YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK EB802011 TROUBLESHOOTING The ignition system fails to operate no spark or intermittent spark Check 1 main and ignition fuses 2 battery 3 spark plugs 4 ignition spark gap 5 spark plug cap resistance 6 ignition coil resi...

Page 347: ...ncrease the spark gap until a misfire occurs Min ignition spark gap 6 mm SIs there a spark and is the spark gap within specification NO The ignition system is OK YES EB802409 6 Ignition coil resistance The following procedure applies to all of the ignition coils SDisconnect the ignition coil connectors from the ignition coil terminals SConnect the pocket tester Ω 1 to the igni tion coil as shown P...

Page 348: ...efer to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 8 Main switch EB802412 SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES Replace the right handlebar switch NO 9 Engine stop switch EB802413 SCheck the neutral switch for continuity Refer to CHECKING THE SWITCHES SIs the neutral switch OK YES Replace the n...

Page 349: ... 2 Tester positive probe blue yellow Tester negative probe sky blue 2 1 Continuity No continuity NOTE When you switch the and leads of the digital pocket tester the readings in the above chart will be reversed Are the tester readings correct EB802416 Check the entire ignition system s wiring Refer to CIRCUIT DIAGRAM Is the ignition system s wiring properly con nected and without defects NO Replace...

Page 350: ...elay 8 Starter motor 9 Starting circuit cutoff relay 11 Sidestand switch 21 Neutral switch 38 Clutch switch 56 Ignition fuse 63 Engine stop switch 64 Start switch 65 Diode 1 ELECTRIC STARTING SYSTEM ELEC EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM ...

Page 351: ...f relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the en gine can be started by pressing the start switch WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE...

Page 352: ...he vicinity SDoes the starter motor turn EB802401 ELECTRIC STARTING SYSTEM ELEC NOTE YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK EB803020 TROUBLESHOOTING The starter motor fails to turn Check 1 main and ignition fuses 2 battery 3 starter motor 4 starting circuit ...

Page 353: ...er Connect the pocket tester Ω 1 to the relay terminals as shown Measure the starting circuit cutoff relay for continuity as follows YES Replace the starting circuit cutoff relay NO Tester positive probe sky blue Tester negative probe black yellow 1 2 Tester positive probe sky blue Tester negative probe blue yellow 1 3 Continuity NOTE When you switch the and leads of the digital pocket tester the ...

Page 354: ...TCHES Is the engine stop switch OK YES Replace the right handlebar switch NO 8 Engine stop switch EB802413 Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES Replace the diode NO 9 Neutral switch 10 Diode 1 Tester positive probe red Tester negative probe black 3 4 Does the starter relay have continuity be tween red and black EB802411 Check the main ...

Page 355: ...rt switch OK YES Replace the right handlebar switch NO 13 Start switch Properly connect or repair the starting system s wiring EB803406 Check the sidestand switch for continuity Refer to CHECKING THE SWITCHES Is the sidestand switch OK YES Replace the sidestand switch NO 11 Sidestand switch EB803405 Check the clutch switch for continuity Refer to CHECKING THE SWITCHES Is the clutch switch OK YES R...

Page 356: ...r assembly Throttle stop screw 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 CARBURETORS in chapter 6 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to THERMOSTAT in chapter 5 For installation reverse the removal procedure 5Nm 0 5m kg STARTER MOTOR ELEC EAS00767 STARTER MOTOR ...

Page 357: ...tor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set O ring Brush holder set O ring Armature assembly Starter motor yoke 1 1 1 1 1 1 1 1 2 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 5Nm 0 5m kg 10 Nm 1 0m kg STARTER MOTOR ELEC ...

Page 358: ...aw blade which has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commuta tor and insulation Out of specification Replace the starter motor a Measure the armature assembly resis tances with the pocket tester Pocket tester 90890 03112 Armature assembly Commutator resistance 1 0...

Page 359: ...6 9 52 gf 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 starter motor rear cover with the slot b in the yoke 2 Install starter motor yoke 1 O rings 2 New starter motor front cover 3 starter motor rear cover 4 bolts Align the match marks a on the st...

Page 360: ...8 26 CHARGING SYSTEM ELEC 3 Rectifier regulator 4 AC magneto 5 Battery 6 Main fuse EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM ...

Page 361: ...ery positive terminal Tester negative probe battery negative terminal SStart the engine and let it run at approximate ly 5 000 r min SMeasure the charging voltage NOTE YES NO Replace the fuse 1 Main fuse SCheck the main fuse for continuity Refer to CHECKING THE FUSES in chap ter 3 SIs the main fuse OK EB804010 EB802401 TROUBLESHOOTING The battery is not being charged Check 1 main fuse 2 battery 3 ...

Page 362: ...lace the rectifier regulator YES 5 Wiring Properly connect or repair the charging system s wiring EB804401 4 Stator coil assembly resistances SRemove the generator cover SConnect the pocket tester Ω 1 to the sta tor coil assembly coupler as shown Stator coil resistance 0 27X 0 33 Ω at 20_C SIs the stator coil assembly OK YES Replace the stator coil assembly NO Tester positive probe white Tester ne...

Page 363: ... 32 Illumination light 34 Pass switch 35 Dimmer switch 45 Headlight 46 Auxiliary light 47 Headlight relay Hi 48 Headlight relay LO 49 Tail brake light 53 Headlight fuse 54 Signaling system fuse 62 Light switch LIGHTING SYSTEM ELEC EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM ...

Page 364: ...itch for Europe NOTE YES NO Replace the fuse s 1 Main signaling system and headlight fuses SCheck the main signaling system and headlight fuses for continuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main signaling system and head light fuses OK EB805010 EB802401 TROUBLESHOOTING Any of the following fail to light head light high beam indicator light taillight auxiliary light or meter lig...

Page 365: ...of the lighting system s circuits Refer to CHECKING THE LIGHTING SYSTEM Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socket OK YES Replace the head light bulb socket or both NO 1 Headlight bulb and socket Check the LED of the high beam indicator light Refer to CHECKING THE LEDs Is the high beam indicator light LED OK YE...

Page 366: ...from the cou pler Connect the pocket tester Ω 1 and bat tery 12 V to the headlight relay terminals as shown Tester positive probe yellow green Tester negative probe red yellow 1 2 4 3 YES Replace the head light relay NO Does the headlight relay have continuity be tween yellow green and red yellow This circuit is OK EB805411 2 Illumination fails to come on 1 Meter light bulb and socket Check the me...

Page 367: ... on the meter assembly coupler wire harness side Is the voltage within specification 1 YES The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired NO This circuit is OK Set the main switch to ON Set the light switch to or Measure the voltage 12 V of blue red on the tail brake light coupler wire harness side Is the voltage within specification 1 Replac...

Page 368: ...ch to the auxiliary light connectors is faulty and must be re paired NO This circuit is OK Set the main switch to ON Set the light switch to or Measure the voltage 12 V of blue red on the auxiliary light couplers wire harness side Is the voltage within specification 1 ...

Page 369: ...8 35 SIGNALING SYSTEM ELEC EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM ...

Page 370: ...g light 27 Neutral indicator light 28 Tachometer 29 Combination meter 31 Turn signal indicator light 36 Horn switch 37 Horn 39 Turn signal switch 40 Flasher relay 41 Front turn signal light L 42 Front turn signal light R 43 Rear turn signal light L 44 Rear turn signal light R 49 Tail brake light 54 Signaling system fuse 57 Oil level relay 58 Oil level switch 59 Rear brake light switch 61 Front bra...

Page 371: ...em s wiring Refer to CIRCUIT DIAGRAM SIs the signaling system s wiring properly con nected and without defects YES Properly connect or repair the signaling system s wiring Check the condition of each of the signal ing system s circuits Refer to CHECKING THE SIGNALING SYSTEM SIGNALING SYSTEM ELEC NOTE EB806010 EB802401 TROUBLESHOOTING SAny of the following fail to light turn sig nal light brake lig...

Page 372: ...e horn switch Does the horn sound NO 4 Voltage Connect the pocket tester DC 20 V to the horn connector at the black terminal as shown Tester positive probe black Tester negative probe ground 1 Set the main switch to ON Push the horn switch Measure the voltage 12 V of Pink at the horn terminal Is the voltage within specification The wiring circuit from the main switch to the horn connector is fault...

Page 373: ... coupler is faulty and must be repaired NO This circuit is OK 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 Replace the turn sig nal light bulb socket or both NO EB806413 3 A turn signal light turn signal indicator light or both fail to blink ...

Page 374: ... 1 5 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as shown The turn signal relay is faulty and must be replaced NO YES 1 Set the main switch to ON Set the turn signal switch to or Measure the voltage 12 V or brown white at the turn signal relay coupler wire harness side Is the voltage within specification Tester positive probe brown white Tester nega...

Page 375: ...e Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe brown Tester negative probe sky blue 1 2 1 2 Replace the neutral switch NO 2 Neutral switch Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK YES Set the main switch to ON Measure the voltage 12 V of brown and sky blue at the meter assembl...

Page 376: ...er positive probe red blue Tester negative probe black 1 2 3 4 4 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe brown Tester negative probe red blue 1 2 Set the main switch to ON Measure the voltage 12 V of brown and red blue at the meter assembly coupler Is the voltage within specification YES The wiring circuit from the ma...

Page 377: ... circuit OK Set the main switch to ON Measure the voltage 12 V Is the voltage within specification NO EAS00805 7 The clock fails to come on 1 Voltage Connect the pocket tester 20 V DC to the clock coupler clock side as shown YES Tester positive probe green yellow Tester negative probe ground 1 Set the main switch to ON Measure the voltage 12 V Is the voltage within specification The wiring circuit...

Page 378: ...tive probe blue Tester negative probe blue black 1 2 3 Voltage Connect the pocket tester 20 V DC to the speedometer bulb socket coupler wire har ness side as shown NO YES Set the main switch to ON Measure the voltage 12 V of blue on the speedometer bulb socket coupler wire har ness side Is the voltage within specification The wiring circuit from the main switch to the speedometer bulb socket coupl...

Page 379: ...fuse 23 Thermo unit 26 Oil level coolant temperature warning light 29 Combination meter 50 Radiator fan motor 51 Thermo switch 52 Radiator fan motor fuse 54 Signaling system fuse COOLING SYSTEM ELEC EB807000 COOLING SYSTEM CIRCUIT DIAGRAM ...

Page 380: ...coupler from the wire harness SConnect the battery 12 V as shown YES The radiator fan mo tor is faulty and must be replaced Battery positive lead blue Battery negative lead black 1 2 SDoes the radiator fan motor turn Open circuit voltage 12 8 V or more at 20_C COOLING SYSTEM ELEC NOTE EB807010 TROUBLESHOOTING SThe radiator fan motor fails to turn SThe coolant temperature display and or warning lig...

Page 381: ... coolant SSlowly heat the coolant then let it cool to the specified temperature as indicated in the table SCheck the thermo switch for continuity at the temperatures indicated in the table 6 Thermo switch NOTE Test step Coolant temperature Thermo switch Continuity 1 2 3 4 0 X 105 3_C More than 105 3_C 105 3_C to 100 3_C Less than 100 3_C NO YES YES NO Test steps 1 2 Heating phase Test steps 3 4 Co...

Page 382: ...dicated below 7 Thermo unit Handle the temperature sender with spe cial care Never subject the temperature sender to strong shocks If the temperature sender is dropped replace it WARNING Temperature sender 15 Nm 1 5 mSkg Three bond sealock 10 Thermo unit resistance 50 6 X 64 2 Ω at 80_C 17 3 X 16 1 Ω at 120_C Replace the tempera ture sender NO YES Properly connect or repair the cooling system s wi...

Page 383: ...switch 5 Battery 6 Main fuse 9 Starting circuit cutoff relay 10 Fuel pump 14 CDI unit 54 Signaling system fuse 56 Ignition fuse 63 Engine stop switch FUEL PUMP SYSTEM ELEC EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM ...

Page 384: ...LEC 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 CDI unit 7 Starting circuit cutoff relay 8 Fuel pump EB808010 FUEL PUMP CIRCUIT OPERATION The CDI unit includes the control unit for the fuel pump ...

Page 385: ...the battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 SIs the battery OK NO EB802412 4 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop switch OK YES Replace the right handlebar switch NOTE EB808020 EB802401 TROUBLESHOOTING The fuel pump fails to operate Check 1 main and ignition fuses 2 battery 3 main switch 4 engine ...

Page 386: ...wire harness SConnect the pocket tester Ω 1 to the fuel pump coupler fuel pump side as shown Tester positive probe blue black Tester negative probe black 1 2 Tester positive probe red Tester negative probe blue black 1 3 EB808400 Fuel pump resistance 4 X 30 Ω at 20_C YES Replace the fuel pump NO Replace the CDI unit NO EB808401 7 Wiring SCheck the entire fuel pump system s wiring Refer to CIRCUIT ...

Page 387: ...o 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 completely cool before performing the following test 1 Check fuel pump operation a Fill the fuel tank b Put the end of the fuel hose into an open con tainer c Connect the battery 12 V to the fuel pump coupler as shown Battery posit...

Page 388: ...ON irrespective of whether the engine is running or not Circuit Defect s System response Condition code Throttle posi tion sensor Disconnected Short circuit Locked The ignitor unit stays set to the wide open throttle ignition timing The motorcycle can be ridden The tachometer displays the condition code 3 000 r min Fuel level indi cator light Improper connec tion The tachometer displays the condit...

Page 389: ...ace the throttle position sensor Replace the CDI unit EB812401 SELF DIAGNOSIS ELEC NOTE 13 Throttle position sensor 14 CDI unit EB812010 TROUBLESHOOTING The tachometer starts to display the self diagnosis sequence Check 1 throttle position sensor 2 fuel level indicator light Before troubleshooting remove the following part s 1 rider seat 2 fuel tank 3 air filter case 4 right side cowling inner pan...

Page 390: ... 2 Fuel sender Disconnect the fuel sender coupler from the wire harness Connect the pocket tester W 1 to the fuel sender coupler as shown YES Tester positive probe green Tester negative probe black 1 Check the fuel sender for continuity Is the fuel sender OK 2 EB812404 SELF DIAGNOSIS ELEC 12 Fuel sender 14 CDI unit 25 Fuel level indicator light 29 Combination meter EB812040 EB812403 2 Fuel level i...

Page 391: ...8 57 Replace or replace the wire harness NO 3 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK YES Replace the CDI unit SELF DIAGNOSIS ELEC EB812405 ...

Page 392: ...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 393: ... 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 394: ...ing guide for troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure is this manual for checks adjustments and replacement of parts STARTING PROBLEMS ENGINE Cylinders and cylinder head s Loose spark plug Loose cylinder head Damaged cylinder head gasket Worn or damaged cylinder Incorrect valv...

Page 395: ... dog EB901000 INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Carburetors Faulty starter plunger Loose or clogged pilot jet Loose or clogged pilot air jet Damaged or loose carburetor joint Incorrectly synchronized carburetors Incorrectly adjusted engine idling speed throttle ...

Page 396: ...nit EB904000 FAULTY CLUTCH CLUTCH SLIPS Clutch Incorrectly assembled clutch Incorrectly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate Engine oil Incorrect oil level Incorrect oil viscosity low Deteriorated oil EB905001 OVERHEATING ENGINE Clogged coolant passages Cylinder head s and piston s Heavy carbon buildup Engine oil Incorrect oil level Incorrect ...

Page 397: ...steering head pipe Incorrectly installed bearing race EB907000 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper piston seal EB908001 FAULTY FRONT FORK LEGS LEAKING OIL Bent damaged or rusty inner tube Damaged outer tube Incorrectly installed oil seal Damaged oil seal lip Incorrect oil level high Loose damper rod assembly...

Page 398: ...orn Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness EB910000 FAULTY LIGHTING AND SIGNALING SYSTEMS HEADLIGHT DOES NOT LIGHT Wrong headlight bulb Too many electrical accessories Hard charging Incorrect connection Incorrectly grounded circuit Poor contacts main or light switch Burnt out headlight bulb HEADLIGHT BULB BURNT OUT Wrong headlight b...

Page 399: ...al light R 43 Rear turn signal light L 44 Rear turn signal light R 45 Headlight 46 Auxiliary light 47 Headlight relay Hi 48 Headlight relay Lo 49 Tail brake light 50 Radiator fan motor 51 Thermo switch 52 Fuse radiator fan motor 53 Fuse headlight 54 Fuse signaling system 55 Alarm 56 Fuse ignition 57 Oil level relay 58 Oil level switch 59 Rear brake light switch 60 Handlebar switch right 61 Front b...

Page 400: ...ght L 42 Front turn signal light R 43 Rear turn signal light L 44 Rear turn signal light R 45 Headlight 47 Headlight relay Hi 48 Headlight relay Lo 49 Tail brake light 50 Radiator fan motor 51 Thermo switch 52 Fuse radiator fan motor 53 Fuse headlight 54 Fuse signaling system 56 Fuse ignition 57 Oil level relay 58 Oil level switch 59 Rear brake light switch 60 Handlebar switch right 61 Front brake...

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