Yamaha YZF-R6 Service Manual Download | Manualshive

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8-53

FUEL PUMP SYSTEM

ELEC

WARNING

EB808410

CHECKING THE FUEL PUMP

Gasoline is extremely flammable and under
certain circumstances there can be a dan-
ger of an explosion or fire. Be extremely
careful and note the following points:

Stop the engine before refuelling.

Do not smoke and keep away from open
flames, sparks or any other source of fire.

If you do accidentally spill gasoline, wipe it
up immediately with dry rags.

If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make sure
that the engine is 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 positive lead

blue / black

1

Battery negative lead

black

2

d. If fuel flows out of the fuel hose, the fuel

pump is OK. If fuel does not flow, replace the
fuel pump.

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Summary of Contents for YZF-R6

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Page 3: ...ZF 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 p...

Page 4: ...prove 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 wher...

Page 5: ...e 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 par...

Page 6: ...al 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 Eng...

Page 7: ...ATION 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...

Page 8: ......

Page 9: ...GEN INFO 1...

Page 10: ...RMATION 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...

Page 11: ...GEN INFO...

Page 12: ...CYCLE 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 a...

Page 13: ...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 EB1...

Page 14: ...02040 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 lithiu...

Page 15: ...s 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 a...

Page 16: ...r 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 supp...

Page 17: ...rough 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...

Page 18: ...ince 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 pol...

Page 19: ...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 lev...

Page 20: ...al 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 Micro...

Page 21: ...etor 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 t...

Page 22: ...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 compone...

Page 23: ...GEN INFO...

Page 24: ...SPEC 2...

Page 25: ...ION 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 POI...

Page 26: ...SPEC...

Page 27: ...eight 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 W...

Page 28: ...linder 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...

Page 29: ...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...

Page 30: ...ntake 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...

Page 31: ...alve 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 Exhaus...

Page 32: ...g 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 m...

Page 33: ...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 6...

Page 34: ...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 Fricti...

Page 35: ...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 manufac...

Page 36: ...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 37: ...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...

Page 38: ...on 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 R...

Page 39: ...rtube with the inner tube fullycompressed and without thefork spring Damper adjusting rod locknut distance Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positio...

Page 40: ...eload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum Standard Maximum Compression damping adjusting positions Minimum Standard Maximum from the fully turned i...

Page 41: ...SS SSS SSS Throttle position sensor standard resistance 4 6 k SSS Charging system System type Model manufacturer Nominal output Stator coil resistance AC magneto F4T366 MITSUBISHI 14 V 320W at 5 000 r...

Page 42: ...e 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 FE...

Page 43: ...l manufacturer Resistance 11H NIPPON SEIKI 50 6 64 2 at 80_C 16 1 17 3 at 120_C SSS SSS Fuses amperage quantity Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fu...

Page 44: ...eral 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 thi...

Page 45: ...haft 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 bo...

Page 46: ...hift 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...

Page 47: ...2 21 TIGHTENING TORQUES SPEC Crankcase tightening sequence...

Page 48: ...ket 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 sp...

Page 49: ...er 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 pin...

Page 50: ...ive 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 piv...

Page 51: ...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 52: ...2 26 OIL FLOW DIAGRAMS SPEC 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter 4 Oil cooler...

Page 53: ...2 27 OIL FLOW DIAGRAMS SPEC 1 Cylinder head 2 Crankshaft...

Page 54: ...2 28 OIL FLOW DIAGRAMS SPEC 1 Main axle 2 Oil delivery pipe 3 driveaxle...

Page 55: ...2 29 1 Radiator 2 Radiator fan 3 Oil cooler COOLANT FLOW DIAGRAMS SPEC COOLANT FLOW DIAGRAMS...

Page 56: ...2 30 COOLANT FLOW DIAGRAMS SPEC 1 Thermostat housing 2 Thermostat 3 Radiator 4 Therm...

Page 57: ...2 31 1 Radiator cap 2 Radiator 3 Oil cooler 4 Water jacket joint 5 Water pump COOLANT FLOW DIAGRAMS SPEC...

Page 58: ...2 32 1 Radiator 2 Radiator fan switch 3 Radiator fan COOLANT FLOW DIAGRAMS SPEC...

Page 59: ...oute 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 s...

Page 60: ...e 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 rout...

Page 61: ...rame 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 wit...

Page 62: ...h 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...

Page 63: ...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 cabl...

Page 64: ...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 sta...

Page 65: ...ter 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...

Page 66: ...SPEC...

Page 67: ...CHK ADJ 3...

Page 68: ...KING 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...

Page 69: ...7 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...

Page 70: ...0 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 f...

Page 71: ...0 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 Cor...

Page 72: ...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...

Page 73: ...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 installa...

Page 74: ...ar 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...

Page 75: ...t 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...

Page 76: ..._ 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 t...

Page 77: ...nel 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...

Page 78: ...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 79: ...ts 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 inser...

Page 80: ...d 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 IGNIT...

Page 81: ...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 cle...

Page 82: ...r 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 c...

Page 83: ...ed 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 Lu...

Page 84: ...0 225 230 235 240 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...

Page 85: ...rocedure 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...

Page 86: ...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 ADJ...

Page 87: ...e 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...

Page 88: ...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 pi...

Page 89: ...31 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 f...

Page 90: ...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...

Page 91: ...l 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 clo...

Page 92: ...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...

Page 93: ...he 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 pr...

Page 94: ...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 k...

Page 95: ...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...

Page 96: ...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 the...

Page 97: ...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 Dam...

Page 98: ...t 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 o...

Page 99: ...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 cl...

Page 100: ...ove 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 f...

Page 101: ...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...

Page 102: ...ers 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 a...

Page 103: ...B303200 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...

Page 104: ...t 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 engi...

Page 105: ...ant 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 f...

Page 106: ...hylene 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 coolan...

Page 107: ...nt 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...

Page 108: ...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 ho...

Page 109: ...le 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...

Page 110: ...se 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 chemica...

Page 111: ...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...

Page 112: ...C 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 fau...

Page 113: ...ss 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 ful...

Page 114: ...od 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 SL...

Page 115: ...in 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 redu...

Page 116: ...refore 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 lubr...

Page 117: ...s 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...

Page 118: ...stall 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...

Page 119: ...e 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...

Page 120: ...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...

Page 121: ...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 posi...

Page 122: ...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...

Page 123: ...ion 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 adjustmen...

Page 124: ...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 Max...

Page 125: ...he 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 Wh...

Page 126: ...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...

Page 127: ...bricate 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 LUBR...

Page 128: ...lectrolyte 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 attenti...

Page 129: ...inals 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 char...

Page 130: ...ed 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 batt...

Page 131: ...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 per...

Page 132: ...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...

Page 133: ...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...

Page 134: ...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...

Page 135: ...cts 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 ligh...

Page 136: ...justing 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...

Page 137: ...CHK ADJ...

Page 138: ...ENG 4...

Page 139: ...YLINDER HEAD 4 19 VALVES AND VALVE SPRINGS 4 20 REMOVING THE VALVES 4 22 CHECKING THE VALVES AND VALVE GUIDES 4 23 CHECKING THE VALVE SEATS 4 25 CHECKING THE VALVE SPRINGS 4 27 CHECKING THE VALVE LIFT...

Page 140: ...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...

Page 141: ...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...

Page 142: ...mbly 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 c...

Page 143: ...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 CAR...

Page 144: ...ead 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...

Page 145: ...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...

Page 146: ...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 M...

Page 147: ...embly 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...

Page 148: ...asket 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 dow...

Page 149: ...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...

Page 150: ...ace 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 cylin...

Page 151: ...mshaft 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 c...

Page 152: ...t 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 Repla...

Page 153: ...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...

Page 154: ...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 com...

Page 155: ...rewdriver 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...

Page 156: ...r 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 Ap...

Page 157: ...mp 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 IN...

Page 158: ...r 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...

Page 159: ...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...

Page 160: ...take 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 gui...

Page 161: ...alve 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...

Page 162: ...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 le...

Page 163: ...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 a...

Page 164: ...lve 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...

Page 165: ...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 valv...

Page 166: ...ve 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 lap...

Page 167: ...e 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...

Page 168: ...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 a...

Page 169: ...o 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...

Page 170: ...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...

Page 171: ...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 ENGI...

Page 172: ...lutch 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...

Page 173: ...lly 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 Sheav...

Page 174: ...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 c...

Page 175: ...enerator 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...

Page 176: ...1 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 REM...

Page 177: ...ts 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 hold...

Page 178: ...e 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 th...

Page 179: ...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 all...

Page 180: ...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 i...

Page 181: ...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 procedur...

Page 182: ...S00334 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 t...

Page 183: ...t 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...

Page 184: ...TCH 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...

Page 185: ...assembling 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 assembl...

Page 186: ...ession 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 REMOVIN...

Page 187: ...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 188: ...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...

Page 189: ...PRINGS 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...

Page 190: ...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...

Page 191: ...t 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 be...

Page 192: ...tages 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 co...

Page 193: ...t 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...

Page 194: ...n 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 i...

Page 195: ...p 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...

Page 196: ...ove 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...

Page 197: ...E 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 Dama...

Page 198: ...LING 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...

Page 199: ...d 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...

Page 200: ...art 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 rem...

Page 201: ...mission 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 instala...

Page 202: ...ers 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 reinfor...

Page 203: ...ck 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 cranksha...

Page 204: ...15 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 dow...

Page 205: ...ubricate 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...

Page 206: ...wer 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 CRANK...

Page 207: ...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...

Page 208: ...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...

Page 209: ...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...

Page 210: ...tons 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 rin...

Page 211: ...0 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 p...

Page 212: ...rankshaft 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 correc...

Page 213: ...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 conn...

Page 214: ...tration 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 COD...

Page 215: ...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...

Page 216: ...nnecting 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 othe...

Page 217: ...hten 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 th...

Page 218: ...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 Fo...

Page 219: ...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 cranksha...

Page 220: ...stigauge 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 c...

Page 221: ...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 si...

Page 222: ...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...

Page 223: ...ion 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...

Page 224: ...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...

Page 225: ...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 t...

Page 226: ...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 227: ...bling 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 Rem...

Page 228: ...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...

Page 229: ...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 ap...

Page 230: ...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 m...

Page 231: ...bly 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...

Page 232: ...ENG...

Page 233: ...COOL 5...

Page 234: ...NG 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 TH...

Page 235: ...COOL...

Page 236: ...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...

Page 237: ...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...

Page 238: ...asure 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 a...

Page 239: ...he 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...

Page 240: ...ly 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...

Page 241: ...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...

Page 242: ...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...

Page 243: ...OLANT 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 Mea...

Page 244: ...d 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 AIRFILTE...

Page 245: ...RMOSTAT 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 TH...

Page 246: ...dicated 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 overh...

Page 247: ...mount 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...

Page 248: ...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 c...

Page 249: ...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 pr...

Page 250: ...eal 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 shaf...

Page 251: ...er 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 t...

Page 252: ...UTION 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...

Page 253: ...COOL...

Page 254: ...CARB 6...

Page 255: ...RS 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 C...

Page 256: ...CARB...

Page 257: ...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 chap...

Page 258: ...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 re...

Page 259: ...er 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...

Page 260: ...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 261: ...r 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...

Page 262: ...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 263: ...lean 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...

Page 264: ...dle 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 Inse...

Page 265: ...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 j...

Page 266: ...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...

Page 267: ...G 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 cab...

Page 268: ...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...

Page 269: ...f specification Replace the throttle position sensor Throttle position sensor maximum resistance 4 0 X 6 0 k at 20_C blue black blue d Connect the pocket tester 1k to the throttle position sensor Test...

Page 270: ...X 6 0 k at 20_C blue black blue e Connect the pocket tester 1k to the throttle position sensor coupler Tester positive probe yellow 3 Tester negative probe black blue 2 f While slowly opening the thr...

Page 271: ...n 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 dis...

Page 272: ...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...

Page 273: ...truction 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 i...

Page 274: ...CARB...

Page 275: ...CHAS 7...

Page 276: ...NT 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 REA...

Page 277: ...AD 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...

Page 278: ...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...

Page 279: ...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...

Page 280: ...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 sta...

Page 281: ...rings 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 whe...

Page 282: ...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 d...

Page 283: ...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...

Page 284: ...l 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...

Page 285: ...et 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 ta...

Page 286: ...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 procedur...

Page 287: ...assembling 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 BRA...

Page 288: ...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 forw...

Page 289: ...68 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 c...

Page 290: ...eel 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...

Page 291: ...rake 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...

Page 292: ...liper 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 reve...

Page 293: ...e 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 c...

Page 294: ...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 Loos...

Page 295: ...d 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 c...

Page 296: ...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...

Page 297: ...rake 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 fe...

Page 298: ...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...

Page 299: ...inder 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...

Page 300: ...mbling 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...

Page 301: ...iaphragm 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 I...

Page 302: ...isassembling 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 F...

Page 303: ...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 cont...

Page 304: ...s 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 inte...

Page 305: ...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 wi...

Page 306: ...d 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 c...

Page 307: ...oiling 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 Re...

Page 308: ...ose 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 N...

Page 309: ...e 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...

Page 310: ...uid 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 reve...

Page 311: ...r 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 disa...

Page 312: ...e 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...

Page 313: ...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...

Page 314: ...enever 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 Crac...

Page 315: ...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...

Page 316: ...nce 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...

Page 317: ...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...

Page 318: ...nce 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...

Page 319: ...er 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 t...

Page 320: ...er 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...

Page 321: ...ust 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 2...

Page 322: ...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...

Page 323: ...ressed 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...

Page 324: ...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...

Page 325: ...ont 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 Insta...

Page 326: ...ide 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...

Page 327: ...ch 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 d...

Page 328: ...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...

Page 329: ...ut 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...

Page 330: ...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 lo...

Page 331: ...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 Discon...

Page 332: ...r 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 INSTAL...

Page 333: ...ebar 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 gr...

Page 334: ...es 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...

Page 335: ...r 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 pl...

Page 336: ...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 FOR...

Page 337: ...er 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 procedur...

Page 338: ...r 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...

Page 339: ...s 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 INST...

Page 340: ...pper 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 b...

Page 341: ...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...

Page 342: ...orber 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 de...

Page 343: ...r 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 assembl...

Page 344: ...e 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...

Page 345: ...sembly 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 t...

Page 346: ...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 instal...

Page 347: ...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...

Page 348: ...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...

Page 349: ...ft 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...

Page 350: ...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 d...

Page 351: ...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...

Page 352: ...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 A...

Page 353: ...CHAS...

Page 354: ...ELEC 8...

Page 355: ...ON 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...

Page 356: ...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 CHE...

Page 357: ...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...

Page 358: ...n 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...

Page 359: ...shes 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...

Page 360: ...r 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...

Page 361: ...ng 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 on...

Page 362: ...eck 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 P...

Page 363: ...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 swit...

Page 364: ...hown 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 fro...

Page 365: ...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 continui...

Page 366: ...et 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 Disconne...

Page 367: ...y 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...

Page 368: ...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 TROUBLESHO...

Page 369: ...increase 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 resista...

Page 370: ...r 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...

Page 371: ...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 r...

Page 372: ...lay 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 EL...

Page 373: ...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...

Page 374: ...e 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 CHEC...

Page 375: ...r Connect the pocket tester 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...

Page 376: ...ES 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...

Page 377: ...t 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 S...

Page 378: ...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 COOLA...

Page 379: ...or 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 part...

Page 380: ...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...

Page 381: ...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...

Page 382: ...8 26 CHARGING SYSTEM ELEC 3 Rectifier regulator 4 AC magneto 5 Battery 6 Main fuse EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM...

Page 383: ...ry 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 fu...

Page 384: ...place 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 1...

Page 385: ...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 Ligh...

Page 386: ...tch 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...

Page 387: ...f 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 socke...

Page 388: ...from the cou pler Connect the pocket tester 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 he...

Page 389: ...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...

Page 390: ...h 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 lig...

Page 391: ...8 35 SIGNALING SYSTEM ELEC EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM...

Page 392: ...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...

Page 393: ...m 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 o...

Page 394: ...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...

Page 395: ...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 ligh...

Page 396: ...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 th...

Page 397: ...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 s...

Page 398: ...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 neg...

Page 399: ...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 coup...

Page 400: ...ive 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 Meas...

Page 401: ...use 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 EB...

Page 402: ...oupler 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...

Page 403: ...oolant 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 swit...

Page 404: ...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 s...

Page 405: ...witch 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 CIR...

Page 406: ...EC 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 contro...

Page 407: ...he 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 t...

Page 408: ...wire harness SConnect the pocket tester 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 pr...

Page 409: ...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 performin...

Page 410: ...N 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 wid...

Page 411: ...ce 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 diagno...

Page 412: ...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 C...

Page 413: ...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 414: ...ELEC...

Page 415: ...TRBL SHTG 9...

Page 416: ...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 O...

Page 417: ...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 SIGN...

Page 418: ...ng 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 check...

Page 419: ...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 Fau...

Page 420: ...it 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...

Page 421: ...teering 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...

Page 422: ...rn 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...

Page 423: ...TRBL SHTG...

Page 424: ...l 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...

Page 425: ...ht 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 s...

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