Yamaha YZF-R7 Owner'S Service Manual Download | Manualshive

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YZF-R7 WIRING DIAGRAM

1

Main switch

2

Rectifier/regulator

3

Generator

4

Backup fuse (odometer)

5

Battery

6

Main fuse

7

Starter relay

8

Starter motor

9

Diode

0

Relay unit

A

Diode

B

Sidestand switch

C

Camshaft sensor

D

Throttle position sensor

E

Intake air pressure sensor

F

Atmospheric pressure sensor

G

Intake air temperature sensor

H

Coolant temperature sensor

I

Pickup coil

J

ECU

K

Cylinder #1 - injector 1

L

Cylinder #2 - injector 1

M

Cylinder #3 - injector 1

N

Cylinder #4 - injector 1

O

Cylinder #1 - injector 2

P

Cylinder #2 - injector 2

Q

Cylinder #3 - injector 2

R

Cylinder #4 - injector 2

S

Cylinder #1 - ignition coil

T

Cylinder #2 - ignition coil

U

Cylinder #3 - ignition coil

V

Cylinder #4 - ignition coil

W

CDI unit

X

Fall detection switch

Y

Speed sensor

Z

Neutral switch

[

Meter assembly

\

Fuel level indicator light

]

Warning light (oil level indicator)

^

Neutral indicator light

a

Tachometer

b

Combination meter

c

Warning light (coolant temperature indicator)

d

High beam indicator light

e

Turn signal indicator light

f

Meter light

g

Warning light (engine trouble indicator)

h

Oil level switch

i

Horn

j

Headlight

k

Rear turn signal light (right)

l

Rear turn signal light (left)

m

Front turn signal light (right)

n

Front turn signal light (left)

o

Tail/brake light

p

Rear brake light switch

q

Left handlebar switch

r

Clutch switch

s

Lights switch

t

Pass switch

u

Dimmer switch

v

Turn signal switch

w

Horn switch

x

Turn signal relay

y

Fuel pump

z

Main relay

{

Right handlebar switch

|

Front brake light switch

}

Engine stop switch

~

Start switch

å

Electronic fuel injection system fuse

ç

CYCLELOCK

†

Signaling system fuse

¢

Headlight fuse

£

ECU fuse

§

Radiator fan motor fuse

•

Thermo switch

¶

Radiator fan motor

COLOR CODE

B ............black
Br...........brown
Ch ..........chocolate
Dg..........dark green
G............green
Gy..........gray
L ............blue
Lg ..........light green
O............orange
P ............pink
R ............red
Sb ..........sky blue
W ...........white
Y ............yellow
B/L .........black/blue
B/R.........black/red
B/W .......black/white
B/Y.........black/yellow
Br/G .......brown/green
Br/L........brown/blue
Br/R .......brown/red
Br/W ......brown/white
G/B ........green/black
G/R ........green/red
G/W .......green/white
G/Y ........green/yellow
Gy/B ......gray/black
Gy/G ......gray/green
Gy/R ......gray/red
L/B .........blue/black
L/G.........blue/green
L/R .........blue/red
L/W ........blue/white
L/Y .........blue/yellow
Lg/R .......light green/red
Lg/Y .......light green/yellow
O/B ........orange/black
O/G ........orange/green
P/B .........pink/black
P/L .........pink/blue
P/W........pink/white
R/B.........red/black
R/G ........red/green
R/L .........red/blue
R/W .......red/white
R/Y.........red/yellow
W/B .......white/black
W/G .......white/green
W/L ........white/blue
W/Y .......white/yellow
Y/B.........yellow/black
Y/G ........yellow/green
Y/L .........yellow/blue
Y/R.........yellow/rod

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Summary of Contents for YZF-R7

Page 1: ...5FL 28199 E0 YZF R7 OWNER S SERVICE MANUAL ...

Page 2: ...R S SERVICE MANUAL 1999 by Yamaha Motor Co Ltd 1st Edition December 1998 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 3: ...thoroughly so as to enjoy all your YZF R7 s advantages The owner s service manual does not only instruct you in how to oper ate inspect and basic maintain your motor cycle but also in how to safeguard yourself and others from trouble and injury In addition the many tips given in this man ual will help to keep your motorcycle in the best possible condition If you have any fur ther questions do not ...

Page 4: ...y questions regarding the operation or maintenance of your motorcycle please consult your Yamaha dealer NOTE This manual should be considered a perma nent part of this motorcycle and should remain with it even if the motorcycle is sub sequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any question you have r...

Page 5: ... to the motorcycle NOTE A NOTE provides key information to make procedures easier or clearer WARNING CAUTION EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of eight chapters General Information Specifica tions Periodic checks and adjust ments Engine Cooling system Electronic fuel injection Chassis Electrical 2 The table of contents is at the begin ning of the manual Look over the gen er...

Page 6: ...larify procedure steps there are exploded diagrams at the start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the...

Page 7: ... Filling fluid A Lubricant B Special tool C Tightening torque D Wear limit clearance E Engine speed F Electrical data Symbols G to L in the exploded diagrams indicate the types of lubricants and lubrica tion points G Engine oil H Gear oil I Molybdenum disulfide oil J Wheel bearing grease K Lithium soap base grease L Molybdenum disulfide grease Symbols M to N in the exploded diagrams indicate the f...

Page 8: ......

Page 9: ...ENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS 3 OVERHAULING THE ENGINE ENG 4 COOLING SYSTEM COOL 5 ELECTRONIC FUEL INJECTION EFI 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 GEN INFO CHK ADJ ...

Page 10: ...E CARE AND STORAGE 1 15 CONSUMER INFORMATION 1 17 TROUBLESHOOTING 1 18 IMPORTANT INFORMATION 1 20 CHECKING THE CONNECTIONS 1 22 SPECIAL TOOLS 1 23 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 11 ELECTRICAL SPECIFICATIONS 2 15 TIGHTENING TORQUES 2 17 LUBRICATION POINTS AND LUBRICANT TYPES 2 22 OIL FLOW CHART 2 24 COOLANT FLOW CHART 2 25 CABL...

Page 11: ...S 3 36 ELECTRICAL SYSTEM 3 55 CHAPTER 4 OVERHAULING THE ENGINE ENGINE 4 1 CAMSHAFTS 4 8 CYLINDER HEAD 4 18 VALVES AND VALVE SPRINGS 4 21 GENERATOR 4 32 PICKUP COIL 4 35 CLUTCH 4 39 SHIFT SHAFT 4 48 OIL PAN AND OIL PUMP 4 50 CRANKCASE 4 56 CONNECTING RODS AND PISTONS 4 63 CRANKSHAFT 4 74 TRANSMISSION 4 79 CHAPTER 5 COOLING SYSTEM RADIATOR AND THERMOSTAT 5 1 RADIATOR AND THERMOSTAT 5 3 OIL COOLER 5 ...

Page 12: ...55 HANDLEBARS 7 67 STEERING HEAD 7 72 REAR SHOCK ABSORBER ASSEMBLY 7 76 SWINGARM AND DRIVE CHAIN 7 80 CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS 8 1 SWITCHES 8 2 CHECKING THE SWITCHES 8 3 CHECKING THE BULBS AND BULB SOCKETS 8 4 IGNITION SYSTEM 8 7 ELECTRIC STARTING SYSTEM 8 12 CHARGING SYSTEM 8 16 LIGHTING SYSTEM 8 19 SIGNALING SYSTEM 8 21 COOLING SYSTEM 8 24 ELECTRONIC FUEL INJECTION SYSTEM 8 28 ...

Page 13: ...l and physical best Under the influence of even small amounts of alcohol there is a tendency to take dangerous risks Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers Al ways wear a complete motorcycle suit whether made of leather or tear resistant synthetic materials with protec tors sturdy boots motorcycle gloves and a properly fitting ...

Page 14: ...justing bolt 4 Air filter 5 Starter choke 6 Shift pedal 7 Rear shock absorber spring preload adjusting ring 8 Rear shock absorber compression damping force adjusting screw 9 Rear shock absorber rebound damping force adjusting screw 10 Fuses 11 Rear brake resorvoir 12 Rear brake pedal 13 Radiator cap and coolant reservoir tank cap 14 Engine oil filter 1 4 5 6 7 8 9 2 3 10 1112 13 14 1 ...

Page 15: ...nstruments 1 Clutch lever 2 Left handlebar switches 3 Clutch reservoir 4 Digital speedometer 5 Main switch 6 Tachometer 7 Front brake reservoir 8 Right handlebar switches 9 Throttle grip 10 Front brake lever 1 2 3 45 6 7 8 9 10 ...

Page 16: ...be fore turning the key to OFF or LOCK EAU01574 Parking The steering is locked in this posi tion and the taillights and auxiliary lights come on but all other circuits are off The key can be removed in this position To use the parking position first lock the steering then turn the key to Do not use this position for an extended length of time as the battery may discharge 1 Neutral indicator light ...

Page 17: ...ght circuit can be checked by the procedure on page 1 6 EC000118 CAUTION Do not run the motorcycle until you know it has sufficient en gine oil Do not run the motorcycle if the engine is overheated NOTE Even if the oil is filled to the specified level the indicator light may flicker when riding on a slope or during sud den acceleration or deceleration but this is normal CB 74ECB 74E Coolant temper...

Page 18: ...Warning light goes off No symbol is on Symbol is on OK Go ahead with riding Warning light does not go off If symbol is on inspect the oil level Oil level is OK Oil level is low Have a Yamaha dealer inspect the electrical circuit Supply recommended engine oil If the engine is hot allow it to cool and see Engine overheating in the troubleshooting chart on page 1 19 for instructions If the engine tem...

Page 19: ...Push the SELECT button to change between the odometer mode ODO and the trip odometer modes TRIP 1 and TRIP 2 in the following order ODO TRIP 1 TRIP 2 ODO If the fuel level indicator light comes on the odometer display will automatically change to the fuel reserve trip meter mode TRIP F and start counting the distance traveled from that point Push the SELECT button to change be tween the fuel odome...

Page 20: ...e sure to push the SELECT button before turning the main switch to OFF otherwise the clock will not be set 4 6 8 10 12 14 x1000r min 0 1 1 1 Tachometer EAU00101 Tachometer This model is equipped with an electric tachometer so the rider can monitor the engine speed and keep it within the ideal power range EC000003 CAUTION Do not operate at 13 800 r min and above Diagnosis device This model is equip...

Page 21: ...ice for use in an emergency such as when the motorcycle overturns or if trouble occurs in the throttle system Turn the switch to to start the en gine In case of emergency turn the switch to to stop the engine EAU00143 Start switch The starter motor cranks the engine when pushing the start switch EC000005 CAUTION See starting instructions prior to starting the engine a a 1 1 2 2 1 Lever position ad...

Page 22: ...ke pedal is on the right side of the motorcycle Press down on the brake pedal to apply the rear brake 1 Open EAU00172 Fuel tank cap To open Insert the key and turn it 1 4 turn clock wise The lock will be released and the cap can be opened To close Push the tank cap into position with the key inserted To remove the key turn it counterclockwise to the original posi tion 1 1 NOTE This tank cap cannot...

Page 23: ... engine requires a richer air fuel mixture A separate starter cir cuit supplies this mixture Move in direction a to turn on the starter choke Move in direction b to turn off the starter choke EAU00331 Sidestand clutch switch operation check Check the operation of the sidestand switch and clutch switch against the in formation below COPY CD 11ECD 11E TRANSMISSION IS IN GEAR AND SIDESTAND IS UP PULL...

Page 24: ...n you try to turn a corner EAU01382 Starting the engine NOTE This motorcycle is equipped with an ig nition circuit cut off system The engine can be started only under one of the following conditions The transmission is in neutral The sidestand is up the transmis sion is in gear and the clutch is disengaged The motorcycle must not be ridden when the sidestand is down EW000054 WARNING Before going t...

Page 25: ...ld engine 6 After the engine is warm turn off the starter choke completely NOTE The engine is warm when it responds normally to the throttle with the starter choke turned off EAU01258 Starting a warm engine The starter choke is not required when the engine is warm EC000046 CAUTION See the Engine break in section prior to operating the motorcycle for the first time 1 1 6 6 5 5 4 4 3 3 N N 2 2 1 1 1...

Page 26: ...should oc cur during the break in period consult a Yamaha dealer imme diately EAU00460 Parking When parking the motorcycle stop the engine and remove the ignition key EW000058 WARNING The exhaust system is hot Park the motorcycle in a place where pedes trians or children are not likely to touch the motorcycle Do not park the motorcycle on a slope or soft ground the motorcycle may over turn INCLUDE...

Page 27: ...t off with wa ter immediately dry the area and apply a corrosion protec tion spray Improper cleaning can damage windshields cowlings panels and other plastic parts Use only a soft clean cloth or sponge with mild detergent and water to clean plastic Do not use any harsh chemical products on plastic parts Be sure to avoid using cloths or sponges which have been in contact with strong or abrasive cle...

Page 28: ... cleaner or acetone and wash the tires with warm water and mild soap Then carefully test the motorcycle for its braking performance and cornering behavior ECA00013 CAUTION Apply spray oil and wax spar ingly and wipe off any excess Never apply oil or wax on rub ber and plastic parts but treat them with a suitable care prod uct Avoid using abrasive polishing compounds as they wear away the paint NOT...

Page 29: ...n 0 C 30 F or more than 30 C 90 F NOTE Make any necessary repairs before storing the motorcycle CONSUMER INFORMATION EAU01040 Identification numbers record Record the key identification number vehicle identification number and mod el label information in the spaces pro vided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is sto len 1 KEY IDENTIFI...

Page 30: ...tank 1 Fuel Enough fuel No fuel Go to compression check Supply fuel Use electric starter 2 Compression There is compression No compression Go to ignition check Ask a Yamaha dealer to inspect Remove spark plugs and check electrodes 3 Ignition Wet Dry Wipe clean with dry cloth and correct spark gap or replace spark plugs Ask a Yamaha dealer to inspect Engine doesn t start go to battery check Open th...

Page 31: ...allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it NOTE If it is difficult to get the recommended coolant tap water can be temporarily used provided that it is changed to the recom mended coolant as soon as possible Wait until the engine has cooled Check the coolant level in the reservoir tank and or radiator...

Page 32: ... of the parts and place them in trays in the order of disassembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB102010 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in function and appearance but infe...

Page 33: ...AND OIL SEALS 1 Install bearings and oil seals so that the manufacturer s marks or numbers are visible When installing oil seals lubri cate the oil seal lips with a light coat of lithium soap base grease Oil bearings liberally when installing if appropriate 1 Oil seal ACHTUNG CAUTION Do not spin the bearing with compressed air because this will damage the bearing surfaces 1 Bearing EB102050 CIRCLI...

Page 34: ...onnect several times 3 Check all connections Loose connection Connect properly NOTE If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE Make sure that all connections are tight 5 Check continuity with the pocket tester NOTE If there is no continuity clean the termi nals When checking the wire harness perform steps 1 to 3 As a quick remedy use a contact revita...

Page 35: ...ding tool This tool is used to hold the generator rotor when removing or installing the gen erator rotor bolt or pickup coil rotor bolt 90890 01286 Drive chain cutter This tool is used to remove the drive chain 90890 01304 Piston pin puller This tool is used to remove the piston pins Radiator cap tester 90890 01325 Adapter 90890 01352 Radiator cap tester Adapter These tools are used to check the c...

Page 36: ...he engine mounting spacer bolts 90890 01472 Front fork cap bolt wrench This tool is used to remove or install the front fork cap bolt 90890 01473 Damper rod holder This tool is used to hold the damper rod assembly when loosening or tightening the damper rod assembly bolt 90890 03008 Micrometer 50 75 mm This tool is used to measure the piston skirt diameter 90890 03017 Cylinder bore gauge 50 100 mm...

Page 37: ... to check the electrical control system Valve spring com pressor 90890 04019 Attachment 90890 04108 90890 04114 Valve spring compressor Attachment These tools are used to remove or install the valve assemblies Middledrivenshaft bearing driver 90890 04058 Mechanical seal installer 90890 04078 Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump...

Page 38: ...s 90890 06754 Ignition checker This tool is used to check the ignition sys tem components 90890 06756 Mity vac This tool is used to measure the vacuum pressure 90890 06760 Engine tachometer This tool is used to check engine speed 90890 85505 Yamaha bond No 1215 This bond is used to seal two mating sur faces e g crankcase mating surfaces Tool No Tool name Function Illustration ...

Page 39: ...l width 720 mm 28 3 in Overall height 1 125 mm 44 3 in Seat height 840 mm 33 1 in Wheelbase 1 400 mm 55 1 in Minimum ground clearance 120 mm 4 72 in Minimum turning radius 3 800 mm 150 in Weight Wet with oil and a full fuel tank 207 kg 456 lb Dry without oil and fuel 176 kg 388 lb Maximum load total of rider and accessories 317 kg 699 lb 2 ...

Page 40: ... Premium unleaded gasoline Fuel tank capacity Total including reserve 23 L 20 2 Imp qt 24 3 US qt Reserve only 4 8 L 4 22 Imp qt 5 07 US qt Engine oil Lubrication system Wet sump Recommended oil Yamalube 4 20W40 or SAE 20W40 type SE motor oil 40 F 5 C or above Non Friction modified Yamalube 4 10W40 or SAE 10W40 type SE motor oil 60 F 15 C or below Non Friction modified Quantity Total amount 3 6 L ...

Page 41: ...sure 95 125 kPa 0 95 1 25 kgf cm2 13 1 17 8 psi Upper radiator core Width 414 mm 16 3 in Height 248 mm 9 76 in Depth 24 mm 0 94 in Lower radiator core Width 211 mm 8 31 in Height 158 mm 6 22 in Depth 24 mm 0 94 in Coolant reservoir Capacity 0 6 L 0 53 Imp qt 0 63 US qt Water pump Water pump type Single suction centrifugal pump Reduction ratio 88 47 28 25 2 097 Maximum impeller shaft tilt 0 15 mm 0...

Page 42: ...mshaft lobe dimensions Measurement A 33 36 33 46 mm 1 3134 1 3173 in 33 31 mm 1 3114 in Measurement B 24 95 25 05 mm 0 9823 0 9862 in 24 90 mm 0 9803 in Measurement C 8 31 8 51 mm 0 3272 0 3350 in Exhaust camshaft lobe dimen sions Measurement A 33 00 33 10 mm 1 2992 1 3031 in 32 95 mm 1 2972 in Measurement B 24 986 25 086 mm 0 9837 0 9876 in 24 936 mm 0 9817 in Measurement C 7 95 8 15 mm 0 3130 0 ...

Page 43: ...ake 0 7 0 9 mm 0 028 0 035 in Exhaust 0 7 0 9 mm 0 028 0 035 in Valve margin thickness D Intake 0 9 1 2 mm 0 028 0 047 in Exhaust 1 0 1 3 mm 0 039 0 051 in Valve stem diameter Intake 3 983 3 995 mm 0 1568 0 1573 in 3 953 mm 0 1556 in Exhaust 3 978 3 990 mm 0 1566 0 1571 in 3 948 mm 0 1544 in Valve guide inside diameter Intake 4 000 4 012 mm 0 1575 0 1580 in 4 05 mm 0 1594 in Exhaust 4 000 4 012 mm...

Page 44: ...7 in 30 73 mm 1 21 in Exhaust 28 82 mm 1 13 in 27 37 mm 1 08 in Installed length valve closed Intake 27 96 mm 1 10 in Exhaust 24 6 mm 0 97 in Compressed spring force installed Intake 101 117 N 10 30 11 93 kgf 22 7 26 3 lb Exhaust 106 122 N 10 81 12 44 kgf 23 8 27 4 lb Spring tilt Intake 2 5 1 4 mm 2 5 0 055 in Exhaust 2 5 1 3 mm 2 5 0 051 in Winding direction top view Intake Counter clockwise Exha...

Page 45: ... 23 45 27 12 kgf 51 7 59 8 lb Exhaust 286 329 N 29 16 33 55 kgf 62 3 74 0 lb Spring tilt Intake 2 5 1 6 mm 2 5 0 063 in Exhaust 2 5 1 5 mm 2 5 0 059 in Winding direction top view Intake Clockwise Exhaust Clockwise Cylinders Cylinder arrangement Forward inclined parallel 4 cylinder Bore stroke 72 46 mm 2 83 1 81 in Compression ratio 11 4 1 Bore 72 000 72 008 mm 2 8346 2 8350 in Maximum taper 0 05 m...

Page 46: ...in 16 975 mm 0 6683 in Piston pin to piston pin bore clearance 0 004 0 020 mm 0 00016 0 00079 in 0 070 mm 0 0028 in Piston rings Top ring Ring type Barrel Dimensions B T 0 8 2 7 mm 0 031 0 106 in End gap installed 0 15 0 25 mm 0 006 0 010 in 0 50 mm 0 020 in Ring side clearance 0 03 0 07 mm 0 0012 0 0028 in 0 12 mm 0 0047 in 2nd ring Ring type Taper Dimensions B T 0 8 2 8 mm 0 031 0 110 in End gap...

Page 47: ...m 0 0014 in Big end side clearance D 0 16 0 26 mm 0 006 0 010 in Crankshaft journal to crankshaft journal bearing clearance 0 036 0 056 mm 0 0014 0 0022 in Bearing color code 1 2 Blue 3 4 Black 5 6 Brown 7 8 Green 9 10 Yellow 11 Violet Clutch Clutch type Wet multiple disc Clutch release method Hydraulic inner push Operation Left hand operation Recommended fluid Brake fluid DOT4 Friction plates 1 T...

Page 48: ...19 1 895 3rd gear 35 21 1 667 4th gear 33 23 1 435 5th gear 31 24 1 292 6th gear 27 23 1 174 Maximum main axle runout 0 08 mm 0 003 in Maximum drive axle runout 0 08 mm 0 003 in Shifting mechanism Shift mechanism type Shift drum Maximum shift fork guide bar bending 0 05 mm 0 002 in Installed shift rod length 294 mm 11 57 in Air filter type Dry element Fuel pump Pump type Electrical Model manufactu...

Page 49: ... Rear wheel Wheel type Cast wheel Rim Size 17 MT6 00 Material Aluminum Wheel travel 138 mm 5 43 in Wheel runout Maximum radial wheel runout 1 mm 0 04 in Maximum lateral wheel runout 0 5 mm 0 02 in Front tire Tire type Tubeless Size 120 70 ZR17 58W Model manufacturer MTR01A PIRELLI Tire pressure cold 0 90 kg 0 198 lb 250 kPa 2 5 kg cm2 3 6 psi 90 kg 198 lb Maximum load 250 kPa 2 5 kg cm2 3 6 psi Hi...

Page 50: ...ss 4 5 mm 0 18 in Maximum deflection 0 1 mm 0 004 in Brake pad lining thickness 5 5 mm 0 22 in 0 5 mm 0 02 in Master cylinder inside diameter 14 mm 0 55 in Caliper cylinder inside diameter 30 2 mm 1 19 in and 27 mm 1 06 in Rear brake Brake type Single disc brake Operation Right foot operation Brake pedal position from the top of the brake pedal to the center of the rider footrest bracket bolt 31 3...

Page 51: ...ommended oil Suspension oil 01 or equivalent Quantity each front fork leg 460 cm3 16 2 Imp oz 15 6 US oz Level from the top of the outer tube with the outer tube fully down and without the fork spring 170 mm 6 69 in Damper adjusting rod locknut dis tance 31 mm 1 22 in Spring preload adjusting positions Minimum 0 0 mm 0 in Standard 14 14 mm 0 55 in Maximum 18 1 2 18 5 mm 0 73 in Rebound damping adj...

Page 52: ...available No Standard spring preload gas air pressure 1 200 kPa 12 kgf cm2 171 psi Spring preload adjusting positions Minimum 0 11 mm 0 43 in Standard 6 14 mm 0 55 in Maximum 20 21 mm 0 84 in Rebound damping adjusting posi tions Minimum 50 Standard 10 Maximum 0 Compression damping adjusting positions Minimum 25 Standard 10 Maximum 0 from the fully turned in position Swingarm Free play at the end o...

Page 53: ...Ω Throttle position sensor standard resistance 4 6 kΩ Charging system System type AC magneto Model manufacturer F4T254 MITSUBISHI Nominal output 14 V 22 5 A at 5 000 r min Stator coil resistance 0 38 0 46 Ω at 20 C 68 F Rectifier regulator Regulator type Semiconductor short circuit Model SH650D 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Capacity 18 A Withstand voltage 200 V Battery Batter...

Page 54: ...rage 180 A Coil resistance 4 18 4 62 Ω Horn Horn type Plain Model manufacturer quantity YF 12 NIKKO 1 Max amperage 3 A Turn signal relay Relay type Full transistor Model manufacturer FE246BH DENSO Self cancelling device built in No Turn signal blinking frequency 75 95 cycles min Wattage 21 W 2 3 4 W Oil level switch model manufac turer 071380 0480 DENSO Fuel pump relay model manufac turer G8R 30Y ...

Page 55: ...hten multi fas tener assemblies in a crisscross pattern and progressive stages until the specified tight ening torque is reached Unless otherwise specified tightening torque specifications require clean dry threads Components should be at room temperature A Width across flats B Thread diameter A nut B bolt General tightening torques Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 ...

Page 56: ...6 1 12 1 2 8 7 Oil cooler Bolt M20 1 63 6 3 45 E Engine oil drain bolt M14 1 43 4 3 31 Oil strainer housing Bolt M6 2 10 1 0 7 2 LT Oil water pump assembly driven sprocket cover Bolt M6 1 12 1 2 8 7 LT Oil delivery pipe Bolt M6 1 10 1 0 7 2 LT Oil filter bolt Bolt M20 1 70 7 0 50 Oil filter cartridge M20 1 17 1 7 12 E Exhaust pipe joints Bolt M8 8 20 2 0 14 Exhaust pipe Bolt M8 1 20 2 0 14 Exhaust...

Page 57: ...20 2 0 14 Pickup coil Screw M5 2 4 0 4 2 9 LT Thermo switch M16 1 23 2 3 17 Camshaft sensor Bolt M6 1 10 1 0 7 2 LT Speed sensor Bolt M6 1 10 1 0 7 2 LT Coolant temperature sensor M12 1 18 1 8 13 Intake air temperature sensor M12 1 18 1 8 13 Intake air pressure sensor Screw M5 2 5 0 5 3 6 LT Atmospheric pressure sensor Screw M5 2 5 0 5 3 6 LT Air funnel Bolt M6 8 10 1 0 7 2 LT Throttle body assemb...

Page 58: ...2 20 SPEC Crankcase tightening sequence TIGHTENING TORQUES ...

Page 59: ...5 5 5 40 Pinch bolts M8 17 1 7 12 Exhaust pipe bracket M8 24 2 4 17 Pivot shaft nut M18 125 12 5 90 Connecting arms M10 40 4 0 29 Relay arm and connecting arms M10 40 4 0 29 Relay arm M10 40 4 0 29 Rear shock absorber and relay arm M10 40 4 0 29 Rear shock absorber assembly M10 40 4 0 29 Fuel pump and fuel tank M5 4 0 4 2 9 Coolant reservoir and radiator M6 5 0 5 3 6 Rider footrest bracket M8 28 2...

Page 60: ...outer E Oil pump housing E Oil strainer E Starter clutch idle gear inner surface E Starter clutch assembly E Primary driven gear E Transmission gears wheel and pinion M Main axle and drive axle M Shift drum E Shift forks and shift fork guide bars E Shift shaft E Shift shaft boss LS Cylinder head cover mating surface Yamaha bond No 1215 Cylinder head cover Yamaha bond No 1215 Crankcase mating surfa...

Page 61: ...Rear wheel drive hub mating surface LS Rear brake pedal LS Sidestand pivoting point and metal to metal moving parts LS Throttle grip inner surface LS Brake lever pivoting point and metal to metal moving parts LS Clutch lever pivoting point and metal to metal moving parts LS Pivot shaft M Connecting arm bearing left and right M Spacer relay arm and connecting arm M Oil seal relay arm and connecting...

Page 62: ...rod Big end bearing Nozzle Nozzle Back torque limiter clutch Starter clutch Main axle Main gallery Drive axle Oil filter cartridge Oil cooler Relief valve Oil pump Oil strainer Oil pan Drain bolt Main axle gears Drive axle gears Crankshaft journal 2 4 Crankshaft journal 3 5 Crankshaft journal 1 OIL FLOW CHART ...

Page 63: ...ELECTRICAL SPECIFICATIONS SPEC 2 25 COOLANT FLOW CHART Thermostat assembly Coolant reservoir Upper radiator Lower radiator Water pump Drain bolt Oil cooler Water jacket COOLANT FLOW CHART ...

Page 64: ...ROUTING 1 Front turn signal coupler 2 Auxiliary light lead 3 Headlight lead 4 Throttle cable 5 Left handlebar switch lead 6 Clutch hose 7 Front brake hose 8 Right handlebar switch lead 9 Main switch lead CABLE ROUTING ...

Page 65: ...itch lead 6 Ground lead 7 Starter motor lead Å Fasten the coolant reservoir breather hose thermo switch lead and thermostat assembly breather hose with a plastic locking tie Do not crush the breather hoses with the plastic locking tie ı Fasten the right handlebar switch lead with a plastic clamp CABLE ROUTING ...

Page 66: ... Main switch lead 9 Headlight and meter sub wire har ness coupler 0 Horn lead A Headlight and meter sub wire harness lead B Throttle cable C Clutch hose D Wire harness to headlight and meter sub wire harness E Wire harness F Fuel tank overflow hose G Water pump breather hose H Coolant reservoir breather hose I Air filter case breather hose CABLE ROUTING ...

Page 67: ... wire harness with a plastic band Ç Fasten the oil level switch lead speed sensor lead sidestand switch lead and stator coil assembly lead with a plastic band Î Fasten the air filter breather hose fuel tank overflow hose clutch hose and fuel tank breather hose with a plastic band 20 mm 0 79 in Ï Route the sidestand switch lead behind the water pump breather hose Ì Route the oil level switch lead t...

Page 68: ... tank overflow hose 7 Fuel pump coupler 8 Rectifier regurator 9 Battery 0 Turn signal relay A ECU B Fuse box C Fall detection switch D Starter relay E Main relay F Throttle stop screw cable G Fuel tank breather hose H Air filter case breather hose I Intake air temperature sensor coupler J Injector 2 sub lead CABLE ROUTING ...

Page 69: ...lead to fuse box T Starter motor lead U Neutral switch lead V Ground lead W Coolant temperature sensor coupler X Throttle cable Å Route the wire harness in front of the ignition coils ı Be sure that there is no slack in the tail brake light lead and rear turn signal leads below the rear fender panel Ç Align the portions of the wire harness ground lead and starter motor lead marked with white tape ...

Page 70: ...nths whichever comes first 5 Air filter element Clean or replace if necessary 6 Clutch Check operation and fluid leakage See NOTE on page 3 2 Correct if necessary 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 ...

Page 71: ...if necessary 17 Sidestand switch Check operation Replace if necessary 18 Front fork Check operation and for oil leakage Correct accordingly 19 Rear shock absorber assembly Check operation and shock absorber for oil leakage Replace shock absorber assembly if necessary 20 Rear suspension relay arm and con necting arm pivot ing points Check operation Lubricate with lithium soap base grease every 24 0...

Page 72: ...3 3 CHK ADJ ...

Page 73: ... filter Remove the parts in the order listed Fuel Drain 1 Fuel tank breather hose 1 2 Bolt 2 3 Bolt 2 4 Fuel pump coupler 1 Disconnect 5 Fuel tank overflow hose 1 6 Fuel return hose 1 Disconnect 7 Fuel hose 1 Disconnect 8 Fuel tank 1 9 Air filter case cover 1 10 Air filter element 1 For installation reverse the removal procedure ...

Page 74: ...el from the fuel tank The fuel tank must be drained to avoid leakage at the fuel pump outlet 2 Disconnect fuel pump coupler fuel hose fuel return hose WARNING WARNING Gasoline is highly flammable Avoid spilling fuel on the hot engine NOTE Wrap the rag over the fuel hose joints to avoid spilling fuel FUEL TANK AND AIR FILTER ...

Page 75: ...s Removing the front cowling Remove the parts in the order listed 1 Bottom cowling 1 2 Rear view mirror 2 3 Front turn signal coupler 2 Disconnect 4 Front cowling 1 5 Windshield 1 6 Front turn signal 2 For installation reverse the removal procedure COWLINGS ...

Page 76: ... the rear cowling Remove the parts in the order listed 1 Rear fender 1 2 Rear fender panel 1 3 Tail brake light connector 2 Disconnect 4 Rear turn signal connector 4 Disconnect 5 Rear cowling 1 For installation reverse the removal procedure COWLINGS ...

Page 77: ... a screwdriver then pull the fastener out INSTALLATION 1 Install rear cowling NOTE To install the quick fastener push its pin so that it protrudes from the fastener head then insert the fastener into the cowling and push the pin a in with a screwdriver Make sure that the pin is flush with the fastener s head ...

Page 78: ...ression stroke 1 Remove bottom cowling front cowling rear cowling Refer to COWLINGS fuel tank air filter case cover Refer to FUEL TANK AND AIR FIL TER air filter case throttle body assembly Refer to ELECTRONIC FUEL INJEC TION IN CHAPTER 6 radiator assembly thermostat assembly Refer to RADIATOR AND THERMO STAT in chapter 5 2 Disconnect camshaft sensor coupler ignition coil couplers 3 Remove ignitio...

Page 79: ...ss gauge 1 NOTE If the valve clearance is incorrect record the measured reading Measure the valve clearance in the fol lowing sequence Å Front d To measure the valve clearances of the other cylinders starting with cyl inder 1 at TDC turn the crankshaft counterclockwise as specified in the following table ı Degrees that the crankshaft is turned counterclockwise Ç Cylinder Î Combustion cycle Valve c...

Page 80: ...NOTE Cover the timing chain opening with a rag to prevent the valve pad from fall ing into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place b Select the proper valve pad from the following table NOTE The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter Si...

Page 81: ...re ment is still incorrect e Install the new valve pad 1 and the valve lifter 2 NOTE Lubricate the valve pad with molybde num disulfide grease Lubricate the valve lifter with molyb denum disulfide oil The valve lifter must turn smoothly when rotated by hand Install the valve lifter and the valve pad in the correct place f Install the exhaust and intake cam shafts timing chain and camshaft caps NOT...

Page 82: ...0 235 240 1 46 1 51 225 230 235 240 1 52 1 57 230 235 240 1 58 1 63 235 240 1 64 1 69 240 EXHAUST ı MEASURED VALVE CLEARANCE Å ORIGINAL VALVE PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 0 01 0 06 120 125 130 135 140 145 150 155 160 165 170 175...

Page 83: ...or installation reverse the removal procedure Note the following points SYNCHRONIZING THE THROTTLE BODIES NOTE Prior to synchronizing the throttle bodies the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked 1 Stand the motorcycle on a level surface NOTE Place the motorcycle on a suitable stand 2 Remove fuel tank Refer to FUEL TANK AN...

Page 84: ... Then install the ignition coil and connect the ignition coil coupler 5 Install fuel tank Refer to FUEL TANK AND AIR FIL TER 6 Start the engine and let it warm up for several minutes Vacuum gauge 90890 03094 Vacuum gauge attachment 90890 03060 Engine tachometer 90890 06760 1 1 2 2 a a 7 Measure engine idling speed Out of specification Adjust Refer to ADJUSTING THE ENGINE IDLING SPEED Engine idling...

Page 85: ...to ADJUSTING THE THROTTLE CABLE FREE PLAY Vacuum pressure at engine idling speed 15 8 18 4 kPa 120 140 mm Hg 4 72 5 51 in Hg Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in ADJUSTING THE ENGINE IDLING SPEED NOTE Prior to adjusting the engine idling speed the throttle body synchronization should be adjusted properly the air filter element should be clean and the engi...

Page 86: ...engine idling speed a Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained 6 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY Direction a Engine idling speed is increased Direction b Engine idling speed is decreased Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in a a b b 1 1 EB303031 AD...

Page 87: ...ttle cable free play NOTE When the throttle is opened the acceler ator cable 1 is pulled Throttle body side a Loosen the locknut 2 on the accelera tor cable b Turn the adjusting bolt 3 in direction a or b until the specified throttle cable free play is obtained c Tighten the locknut NOTE If the specified throttle cable free play cannot be obtained on the throttle body side of the cable use the adj...

Page 88: ... cable free play is increased Direction d Throttle cable free play is decreased C C d d 7 7 5 5 7 7 4 4 EB303040 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs 1 Remove fuel tank air filter case cover Refer to FUEL TANK AND AIR FIL TER air filter case Refer to ELECTRONIC FUEL INJEC TION in chapter 6 2 Disconnect ignition coil couplers 3 Remove ignition coils spa...

Page 89: ...f specification Regap 8 Install spark plug NOTE Before installing the spark plug clean the spark plug and gasket surface Spark plug gap 0 7 0 8 mm 0 028 0 031 in T R 13 Nm 1 3 m kg 9 4 ft lb EB303060 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders NOTE Insufficient compression pressure will result in a loss of performance 1 Measure valve clearance Out of ...

Page 90: ...t accumulated in the spark plug wells to prevent it from falling into the cylinders 5 Install compression gauge 1 adapter 2 Compression gauge 90890 03081 Adapter 90890 04136 1 1 2 2 6 Measure compression pressure Out of specification Refer to steps c and d a Set the main switch to ON b With the throttle wide open crank the engine until the reading on the com pression gauge stabilizes Compression p...

Page 91: ...linder head valve surfaces and piston crown for carbon deposits Carbon deposits Eliminate d If the compression pressure is below the minimum specification squirt a few drops of oil into the cylinder and measure again Refer to the following table 7 Install spark plug Compression pressure with oil applied into the cylinder Reading Diagnosis Higher than with out oil Piston wear or damage Repair Same ...

Page 92: ...mended oil Refer to the chart for the engine oil grade which is best suited for certain atmo spheric temperatures API standard SE or higher grade Non Friction modified ACHTUNG CAUTION Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage There fore do not add any chemical addi tives or use engine oils with a grade of CD c or higher and do not use oi...

Page 93: ... cartridge is also to be replaced perform the following proce dure a Remove the oil filter cartridge 1 with an oil filter wrench 2 Oil filter wrench 90890 01426 b Lubricate the O ring 3 of the new oil filter cartridge with a thin coat of engine oil ACHTUNG CAUTION Make sure that the O ring 3 is posi tioned correctly in the groove of the oil filter cartridge c Tighten the new oil filter cartridge t...

Page 94: ...h oil filter cartridge replacement 2 8 L 2 5 lmp qt 3 0 US qt 14 Check engine oil pressure a Slightly loosen the oil gallery bolt 1 b Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt If no engine oil comes out after one minute turn the engine off so that it will not seize c Check the engine oil passages the oil filter cartridge and the oil pump for dama...

Page 95: ...cause the rubber seals to deteriorate causing leakage and poor clutch performance Refill with the same type of fluid Mix ing fluids may result in a harmful chemical reaction leading to poor clutch performance When refilling be careful that water does not enter the clutch fluid reser voir Water will significantly lower the boiling point of the fluid and could cause vapor lock ACHTUNG CAUTION Clutch...

Page 96: ...o let the clutch fluid settle for a few hours Repeat the bleeding proce dure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic clutch system a Fill the clutch fluid reservoir to the proper level with the recommended clutch fluid b Install the clutch fluid reservoir dia phragm c Connect a clear plastic hose 1 tightly to the bleed screw 2 d Place the other end of the hose into a c...

Page 97: ... air filter case cover air filter element Refer to FUEL TANK AND AIR FIL TER 2 Clean air filter element Apply compressed air to the outer sur face of the air filter element 3 Check air filter element Damage Replace 4 Install air filter element air filter case cover ACHTUNG CAUTION Never operate the engine without the air filter element installed Unfiltered air will cause rapid wear of engine parts...

Page 98: ...lace NOTE Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident 1 1 1 1 1 1 1 1 3 Install air filter case cover fuel tank Refer to FUEL TANK AND AIR FIL TER EB303190 CHECKING THE CRANKCASE BREATHER HOSE 1 Remove fuel tank Refer to FUEL TANK AND AIR FIL TER 2 Check crankcase breather hose 1 Cracks damage Replace Loose connection Connect properly ACHTUNG CAUT...

Page 99: ...embly Refer to RADIATOR AND THERMO STAT in chapter 5 2 Check exhaust pipe joint 1 exhaust pipe 2 muffler 3 Cracks damage Replace gasket 4 Exhaust gas leaks Replace 3 Measure tightening torque 4 Install radiator assembly Refer to RADIATOR AND THERMO STAT in chapter 5 T R Exhaust pipe joint bolt 5 20 Nm 2 0 m kg 14 ft lb Muffler clamp bolt 6 20 Nm 2 0 m kg 14 ft lb Exhaust pipe bolt 7 20 Nm 2 0 m kg...

Page 100: ...rk b Below the minimum level mark Add the recommended coolant to the proper level ACHTUNG CAUTION Adding water instead of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However soft water may be used if distilled water is not available 4 Start the engine war...

Page 101: ...er radiator 2 radiator inlet hose 3 radiator outlet hose 4 radiator outlet pipe 5 radiator joint hose 6 oil cooler 7 oil cooler inlet hose 8 oil cooler outlet hose 9 water jacket joint inlet hose 0 water pump inlet pipe A water pump outlet pipe B Cracks damage Replace Refer to COOLING SYSTEM in chap ter 5 3 Install front cowling bottom cowling Refer to COWLINGS ...

Page 102: ...move radiator cap 1 WARNING WARNING A hot radiator is under pressure There fore do not remove the radiator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause serious injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radia tor cap counterclockwise toward the detent to allo...

Page 103: ...minum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 2 75 L 2 42 lmp qt 2 91 US qt Coolant reservoir capacity 0 25 L 0 22 lmp qt 0 26 US qt Handling notes for coolant Coolant is potentially harmful and should be handled with special care WARNING WARNING If coolant splashes in your eyes thor oughly wash them with water and consult a doctor If coolant splashes on your clothes quickl...

Page 104: ...ant comes into contact with painted surfaces immediately wash them with water Do not mix different types of anti freeze 11 Install radiator cap 12 Fill coolant reservoir with the recommended coolant to the maximum level mark a 13 Install coolant reservoir cap 14 Start the engine warm it up for several minutes and then turn it off a a 15 Check coolant level Refer to CHECKING THE COOLANT LEVEL NOTE ...

Page 105: ...ke pedal position is obtained WARNING WARNING After adjusting the brake pedal position check that the end of the adjusting bolt c is visible through the hole d c Tighten the locknut 1 to specifica tion WARNING WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the air must be removed by bleeding the brake system A...

Page 106: ...the designated brake fluid Other brake fluids may cause the rub ber seals to deteriorate causing leak age and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reser voir Water will significan...

Page 107: ... ı EB304050 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts 1 Check rear brake light operation timing Incorrect Adjust 2 Adjust rear brake light operation timing a Hold the main body 1 of the rear brake light switch s...

Page 108: ...RNING WARNING Bleed the hydraulic brake system when ever the brake system was disassembled a brake hose was loosened discon nected or replaced the brake fluid level is very low brake operation is faulty NOTE Be careful not to spill any brake fluid or allow the brake fluid reservoir to over flow When bleeding the hydraulic brake system make sure that there is always enough brake fluid before applyi...

Page 109: ...it in position g Loosen the bleed screw NOTE Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend h Tighten the bleed screw and then release the brake lever or brake pedal i Repeat steps e to h until all of the air bubbles have disappeared from the brake fluid in the plastic hose j Tighten the bleed screw to s...

Page 110: ...h 294 mm 11 57 in Direction b Installed shift rod length decreases Direction c Installed shift rod length increases 1 1 1 1 a a b b c c EB304092 ADJUSTING THE DRIVE CHAIN SLACK NOTE The drive chain slack must be checked at the tightest point on the chain ACHTUNG CAUTION A drive chain that is too tight will over load the engine and other vital parts and one that is too loose can skip and damage the...

Page 111: ... nut 1 and wheel axle b Loosen both locknuts 2 c Turn both adjusting bolts 3 in direc tion a or b until the specified drive chain slack is obtained NOTE To maintain the proper wheel align ment adjust both sides evenly d Tighten both locknuts e Tighten the wheel axle and wheel axle nut to specification Direction a Drive chain slack is decreased Direction b Drive chain slack is increased T R Wheel a...

Page 112: ...y kerosine to clean the drive chain Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O ring chains Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O rings Recommended lubricant Engine oil or chain lubricant suitable for O ring chains EB304130 CHECKING AND ADJUSTING THE STEERING HEAD...

Page 113: ...3 handlebars from the upper bracket 1 1 3 3 2 2 7 Remove steering stem nut 1 washer 2 upper bracket 3 2 2 1 1 3 3 8 Adjust steering head a Remove the lock washer 1 the upper ring nut 2 and the rubber washer 3 b Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 NOTE Set the torque wrench at a right angle to the steering nut wrench Steering nut wrench 90890 01...

Page 114: ...ower ring nut and tighten the upper ring nut until their slots are aligned h Install the lock washer 1 NOTE Make sure that the lock washer tabs a sit correctly in the ring nut slots b T R Lower ring nut final tightening torque 9 Nm 0 9 m kg 6 5 ft lb 9 Install steering stem nut upper bracket bolt handlebar pinch bolt upper bracket pinch bolt 10 Measure steering head tension with the motorcycle sti...

Page 115: ... Repeat the above procedure until the steering head tension is within speci fication i Grasp the bottom of the front fork legs and gently rock the front fork Looseness or binding Adjust the steering head Steering head tension 200 500 g 7 06 17 65 oz EB304141 CHECKING THE FRONT FORK 1 Stand the motorcycle on a level surface WARNING WARNING Securely support the motorcycle so that there is no danger ...

Page 116: ...ovided to indicate the adjustment position Never go beyond the maximum or minimum adjustment positions 1 Adjust spring preload a Turn the adjusting bolt 1 in direction a or b NOTE With each turn of the adjusting bolt the installed length of the fork spring is changed by 1 mm Direction a turns in Spring preload is increased suspension is harder Direction b turns out Spring preload is decreased susp...

Page 117: ...usting screw 1 in direc tion a or b Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting positions Minimum 17 clicks out Standard 6 clicks out Maximum 1 clicks out from the fully turned in position Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased suspension...

Page 118: ...eload NOTE Adjust the spring preload with the spe cial wrench and extension bar included in the owner s tool kit a Turn the adjusting knob 1 in direc tion a or b Direction a turns in Spring preload is increased suspension is harder Direction b turns out Spring preload is decreased suspension is softer Adjusting positions Minimum 0 turns in Standard 6 turns in Maximum 20 turns in from the fully tur...

Page 119: ...e adjusting screw 1 in direc tion a or b Direction a Rebound damping is increased suspension is harder Direction b Rebound damping is decreased suspension is softer Adjusting positions Minimum 50 clicks out Standard 10 clicks out Maximum 0 clicks out from the fully turned in position Direction a Compression damping is increased suspension is harder Direction b Compression damping is decreased susp...

Page 120: ...ipated riding speed Operation of an overloaded motorcy cle could cause tire damage an acci dent or an injury NEVER OVERLOAD THE MOTORCYCLE total of cargo rider and accessories WARNING WARNING It is dangerous to ride with a worn out tire When the tire tread reaches the wear limit replace the tire immediately Basic weight with oil and a full fuel tank 207 kg 456 lb Maximum load 317 kg 699 lb Cold ti...

Page 121: ...rec ommended If it is absolutely neces sary to do so use great care and replace the tube as soon as possible with a good quality replacement Å Tire ı Wheel After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rear tires should always be by the same manufacturer and of the same design No guarantee concerning handling characteristics can...

Page 122: ...orcycle NOTE For tires with a direction of rotation mark 1 Install the tire with the mark pointing in the direction of wheel rotation Align the mark 2 with the valve instal lation point EB304180 CHECKING THE WHEELS The following procedure applies to both of the wheels 1 Check wheel Damage out of round Replace WARNING WARNING Never attempt to make any repairs to the wheel NOTE After a tire or wheel...

Page 123: ...304210 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal to metal moving parts of the levers and ped als EB304220 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal to metal moving parts of the sidestand EB304240 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal to metal moving parts of the rear suspension Recommended lubricant Engine oil o...

Page 124: ...r perma nent eye injury FIRST AID IN CASE OF BODILY CON TACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL Drink large quantities of water or milk followed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention ACHTUNG CAUTION This is a sealed battery Never remove the sealing caps because the balance betwe...

Page 125: ...t the negative lead 3 then the positive lead 4 3 Remove battery 4 4 3 3 1 1 2 2 4 Measure battery charge a Connect a digital voltmeter to the bat tery terminals NOTE The charge state of an MF battery can be checked by measuring its open cir cuit voltage i e the voltage when the positive terminal is disconnected No charging is necessary when the open circuit voltage equals or exceeds 12 8 V b Check...

Page 126: ...in the battery charger until the battery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted A corroded battery charger lead clip may generate heat in the con tact area and ...

Page 127: ...3 58 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger ...

Page 128: ...3 59 CHK ADJ CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger ...

Page 129: ...band 3 rear cowling bracket 4 rear cowling Refer to COWLINGS EB305040 CHECKING THE FUSES The following procedure applies to all of the fuses ACHTUNG CAUTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove rear cowling Refer to COWLINGS 2 Check continuity a Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester...

Page 130: ... specified Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the lighting and ignition systems to malfunction and could possibly cause a fire 4 Install rear cowling Refer to COWLINGS Item Amperage Q ty Main fuse 30 A 1 Headlight fuse 20 A 1 Signaling system fuse 20 A 1 Electronic fuelinjection system fuse 20 A 1 ECU fuse 7 5 A 1 Ra...

Page 131: ... and your hands away from the bulb until it has cooled down 1 1 3 Install headlight bulb Secure the new headlight bulb with the headlight bulb holder ACHTUNG CAUTION Avoid touching the glass part of the headlight bulb to keep it free from oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly cl...

Page 132: ...ew 1 in direc tion a or b Direction a Headlight beam is raised Direction b Headlight beam is low ered 2 Adjust headlight beam horizontally a Turn the adjusting screw 1 in direc tion a or b Left headlight Right headlight Direction a Headlight beam moves to the right Direction b Headlight beam moves to the left Direction a Headlight beam moves to the left Direction b Headlight beam moves to the righ...

Page 133: ... ft Ib LT LT 1 3 2 13 14 12 8 5 4 6 7 9 11 10 1 New Order Job Part Q ty Remarks Removing the drive sprocket Remove the parts in the order listed Bottom cowling and front cowling Refer to COWLINGS in chapter 3 1 Locknut 2 Loosen 2 Shift rod 1 3 Shift arm 1 4 Starter cable 1 5 Starter knob 1 6 Clutch release cylinder 1 7 Dowel pin 2 4 ...

Page 134: ...Nm 1 0 m kg 7 2 ft Ib LT LT 1 3 2 13 14 12 8 5 4 6 7 9 11 10 1 New Order Job Part Q ty Remarks 8 Speed sensor 1 9 Drive sprocket cover 1 10 Oil seal support plate 1 11 Dowel pin 2 12 Push rod 2 1 13 Lock washer 1 14 Drive sprocket 1 For installation reverse the removal procedure 4 ...

Page 135: ...rt Q ty Remarks Removing the exhaust assembly Remove the parts in the order listed Rear cowling Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator assembly Refer to RADIATOR AND THERMO STAT in chapter 5 1 Muffler 1 2 Spring 4 3 Exhaust pipe assembly 1 4 Exhaust pipe joint 1 1 5 Exhaust pipe joint 2 2 6 Exhaust pipe joint 4 1 7 Exhaust pipe joint gasket...

Page 136: ...er 3 Air filter case and throttle body assembly Refer to ELECTRONIC FUEL INJEC TION in chapter 6 Engine oil and oil filter cartridge Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Oil cooler and thermostat assembly Refer to OIL COOLER and THER MOSTAT ASSEMBLY in chapter 5 1 Battery negative lead 1 2 Battery positive lead 1 ACHTUNG CAUTION First disconnect the negative lead then the positive l...

Page 137: ...rter motor lead 1 Disconnect 7 Ground lead 1 Disconnect 8 Starter motor 1 9 Pickup coil coupler 1 Disconnect 10 Plastic clip 1 11 Stator coil assembly coupler 1 Disconnect 12 Sidestand switch coupler 1 13 Oil level switch connector 1 Disconnect 14 Neutral switch 1 For connecting reverse the disconnec tion procedure ...

Page 138: ...sted 1 Pinch bolt 2 Loosen 2 Right front mounting bolt 2 3 Left front mounting bolt 2 4 Washer 2 5 Self locking nut 2 6 Spacer bolt 2 Loosen 7 Rear mounting bolt 2 8 Spacer 2 9 Mounting bracket 1 For installation reverse the removal procedure NOTE Place a suitable stand under the frame and engine ...

Page 139: ...t front mounting bolt pinch bolts 9 NOTE Tighten the spacer bolt 7 it to specifi cation with a pivot shaft wrench When tightened the spacer bolt should be flat against the engine sur face Pivot shaft wrench 90890 01471 T R 18 Nm 1 8 m kg 13 ft lb T R 55 Nm 5 5 m kg 40 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T R 17 Nm 1 7 m kg 12 ft lb 3 Install shift arm1 NOTE Align the punch...

Page 140: ...er listed Carburetor assembly Refer to CARBURETORS in chapter 6 Radiator assembly and thermostat assembly Refer to RADIATOR AND THERMO STAT and THERMOSTAT ASSEM BLY in chapter 5 1 Spark plug 4 2 Cylinder head cover 1 3 Cylinder head cover gasket 1 4 Timing chain guide top side 1 For installation reverse the removal procedure ...

Page 141: ... Timing chain tensioner 1 2 Timing chain tensioner gasket 1 3 Timing chain guide exhaust side 1 4 Intake camshaft cap I 1 5 Intake camshaft cap R 1 6 Intake camshaft cap L 1 7 Dowel pin 6 8 Exhaust camshaft cap E 1 9 Exhaust camshaft cap R 1 10 Exhaust camshaft cap L 1 11 Dowel pin 6 NOTE During removal the dowel pins may still be connected to the camshaft caps ...

Page 142: ...rder Job Part Q ty Remarks 12 Intake camshaft 1 13 Exhaust camshaft 1 14 Intake camshaft sprocket 1 15 Exhaust camshaft sprocket 1 16 Pin 1 17 Timing chain guide intake side 1 For installation reverse the removal procedure ...

Page 143: ... away from each other 2 Remove float chamber air vent hose holder timing chain tensioner 3 Remove timing chain guide exhaust side 4 Remove camshaft caps dowel pins ACHTUNG CAUTION To prevent damage to the cylinder head camshafts or camshaft caps loosen the camshaft cap bolts in stages and in a crisscross pattern working from the outside in H H T T a a b b 5 Remove intake camshaft 1 exhaust camshaf...

Page 144: ...t lobe dimensions limit Intake camshaft a 33 31 mm 1 3114 in b 24 90 mm 0 9803 in Exhaust camshaft a 32 95 mm 1 2972 in b 24 936 mm 0 9817 in 3 Measure camshaft runout Out of specification Replace Maximum camshaft runout 0 03 mm 0 0012 in 4 Measure camshaft journal to camshaft cap clearance Out of specification Measure the camshaft journal diameter Camshaft journal to camshaft cap clearance 0 035 ...

Page 145: ... the Plastigauge d Remove the camshaft caps and then measure the width of the Plasti gauge 1 T R Camshaft cap bolt 10 Nm 1 0 m kg 7 2 ft lb 5 Measure camshaft journal diameter a Out of specification Replace the camshaft Within specification Replace the cylin der head and the camshaft caps as a set Camshaft journal diameter 24 452 24 465 mm 0 9627 0 9632 in EB401421 CHECKING THE TIMING CHAIN CAMSHA...

Page 146: ...CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage rough movement Replace a Lightly press the timing chain ten sioner rod into the timing chain ten sioner housing by hand NOTE While pressing the timing chain ten sioner rod wind it clockwise with a thin screwdriver 1 until it stops b Remove the screwdriver and slowly release the timing chain tensioner rod c Make sure t...

Page 147: ...iming chain onto both camshaft sprockets and then install the camshaft sprockets onto the cam shafts ACHTUNG CAUTION Do not turn the crankshaft when install ing the camshaft to avoid damage or improper valve timing NOTE Make sure that the punch marks c on the camshafts face up d Install the exhaust and intake cam shaft caps NOTE Make sure that the punch marks c on the camshafts are aligned with th...

Page 148: ... the timing chain tensioner install the timing chain tensioner and gasket onto the cylinder block Then tighten the timing chain tensioner bolts to the specified torque WARNING WARNING Always use a new gasket NOTE The UP mark on the timing chain ten sioner should face up d Remove the screwdriver make sure that the timing chain tensioner rod releases and tighten the cap bolt to the specified torque ...

Page 149: ...lation steps above H H T T a a b b 8 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3 9 Install cylinder head cover gasket cylinder head cover NOTE Apply bond TB1541 onto the mating surfaces of the cylinder head cover and cylinder head cover gasket Apply bond 1215B onto the mating surfaces of the cylinder head cover gasket and cylinder head Ti...

Page 150: ... Part Q ty Remarks Removing the cylinder head Remove the parts in the order listed Engine Refer to ENGINE Intake and exhaust camshafts Refer to CAMSHAFTS 1 Cylinder head 1 2 Cylinder head gasket 1 3 Dowel pin 2 For installation reverse the removal procedure ...

Page 151: ...lly loosened remove them Loosen the bolts and nuts in decreas ing numerical order refer to the num bers in the illustration EB402402 CHECKING THE CYLINDER HEAD 1 Eliminate combustion chamber carbon deposits with a rounded scraper NOTE Do not use a sharp instrument to avoid damaging or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head water ...

Page 152: ...igure eight sanding pattern NOTE To ensure an even surface rotate the cylinder head several times Maximum cylinder head warpage 0 06 mm 0 0024 in EB402702 INSTALLING THE CYLINDER HEAD 1 Install cylinder head cylinder head nut 1 10 cylinder head bolt 11 12 NOTE Lubricate the cylinder head nuts with engine oil Tighten the cylinder head nuts and bolts in two stages and in a crisscross pattern Tighten...

Page 153: ...the parts in the order listed Cylinder head Refer to CYLINDER HEAD 1 Intake valve lifter 12 2 Intake valve pad 12 3 Intake valve cotter 24 4 Intake valve upper spring seat 12 5 Intake outer valve spring 12 6 Intake inner valve spring 12 7 Intake valve oil seal 12 8 Intake valve lower spring seat 12 9 Intake valve 12 10 Intake valve guide 12 ...

Page 154: ...st valve pad 8 13 Exhaust valve cotter 16 14 Exhaust valve upper spring seat 8 15 Exhaust outer valve spring 8 16 Exhaust inner valve spring 8 17 Exhaust valve oil seal 8 18 Exhaust valve lower spring seat 8 19 Exhaust valve 8 20 Exhaust valve guide 8 For installation reverse the removal procedure ...

Page 155: ...s properly seal 1 Remove valve lifter 1 valve pad 2 NOTE Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve for leakage Leakage at the valve seat Check the valve face valve seat and valve seat width Refer to CHECKING THE VALVE SEATS a Pour a clean solvent a into the intake and exhaust ports b Check that the valves pr...

Page 156: ...al 5 NOTE Identify the position of each part very carefully so that it can be reinstalled in its original place EB403400 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides 1 Measure valve stem to valve guide clearance Out of specification Replace the valve guide Valve stem to valve guide clearance Valve guide inside diameter a Valve stem diam...

Page 157: ... installing the valve guide bore the valve guide with a valve guide reamer 3 to obtain the proper valve stem to valve guide clearance NOTE After replacing the valve guide reface the valve seat Valve guide remover Intake 4 0 mm 90890 04111 Valve guide installer Intake 4 0 mm 90890 04112 Valve guide reamer Intake 90890 04113 3 Eliminate carbon deposits from the valve face and valve seat 4 Check valv...

Page 158: ...l seal Valve margin thickness Intake 0 9 1 2 mm 0 028 0 047 in Exhaust 1 0 1 3 mm 0 039 0 051 in Valve stem runout 0 01 mm 0 0004 in EB403410 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats 1 Eliminate carbon deposits from the valve face and valve seat 2 Check valve seat Pitting wear Replace the cylinder head 3 Measure valve seat width a Out of specifi...

Page 159: ...placing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face ACHTUNG CAUTION Do not let the lapping compound enter the gap between the valve stem and the valve guide b Apply molybdenum disulfide oil onto the valve stem c Install the valve into the cylinder head d Turn the valve until the valve ...

Page 160: ... clear impression j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat EB403420 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs 1 Measure valve spring free length a Out of specification Replace the valve spring Valve spring free length Inner spring Intake valve spring 32 35 mm 1 27 in Limit 30 73...

Page 161: ...kg at 24 6 mm 23 8 27 4 lb at 0 97 in Outer spring Intake valve spring 23 45 27 12 kg at 32 03 mm 51 7 59 8 lb at 1 26 in Exhaust valve spring 29 16 33 55 kg at 30 25 mm 62 3 74 0 lb at 1 19 in Maximum spring tilt Inner spring Intake valve spring 1 4 mm 0 055 in Exhaust valve spring 1 3 mm 0 051 in Outer spring Intake valve spring 1 6 mm 0 063 in Exhaust valve spring 1 5 mm 0 059 in EB403430 CHECK...

Page 162: ...one 2 Lubricate valve stem 1 oil seal 2 with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 3 Install oil seal 1 valve 2 lower spring seat 3 valve springs 4 upper spring seat 5 into the cylinder head NOTE Make sure that each valve is installed in its original place Install the valve spring with the larger pitch a facing up b Smaller pitch New a a b b a ...

Page 163: ...UNG CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor 90890 04019 Attachment for the intake valve spring 9080 04114 for the exhaust valve spring 90890 04108 6 Lubricate valve pad with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 7 Install valve pad valve lifter NOTE The valve lifter must move smoothly when rotated with a f...

Page 164: ...LINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Throttle stop screw holder 1 2 Generator rotor cover 1 3 Generator rotor cover gasket 1 4 Dowel pin 2 5 Generator rotor bolt 1 6 Generator rotor 1 7 Stator coil assembly coupler 1 Disconnect 8 Stator coil assembly lead holder 1 9 Stator coil assembly 1 For installation reverse the removal procedure ...

Page 165: ...tor rotor bolt Rotor holding tool 90890 01235 3 Remove generator rotor 1 with the flywheel puller 2 and rotor holding tool 3 Flywheel puller 90890 01080 EB410700 INSTALLING THE GENERATOR 1 Apply sealant onto the stator coil assembly lead grommet 2 Install generator rotor washer generator rotor bolt WARNING WARNING Always use a new generator rotor bolt ACHTUNG CAUTION Clean the tapered portion of t...

Page 166: ...ding the generator rotor 2 with the rotor holding tool 3 tighten the generator rotor bolt 4 Install generator rotor cover NOTE Tighten the generator rotor cover bolts in stages and in a crisscross pattern Rotor holding tool 90890 01235 New T R 65 Nm 6 5 m kg 47 ft lb ...

Page 167: ...emoving the pickup coil and pickup coil rotor Remove the parts in the order listed Fuel tank Refer to FUEL TANK AND AIR FIL TER in chapter 3 Bottom cowling and front cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Generator rotor cover Refer to GENERATOR 1 Pickup coil lead holder 1 2 Pickup coil rotor cover 1 3 Pickup coil rotor cover gasket 1 ...

Page 168: ... 1 2 m kg 8 7 ft Ib T R 4 Nm 0 4 m kg 2 9 ft Ib T R 15 Nm 1 5 m kg 11 ft Ib E LT LT L T LT 1 6 2 3 4 5 6 4 7 New Order Job Part Q ty Remarks 5 Pickup coil coupler 1 Disconnect 6 Pickup coil 1 7 Pickup coil rotor 1 For installation reverse the removal procedure ...

Page 169: ... 1 washer pickup coil rotor 2 NOTE While holding the generator rotor 3 with the rotor holding tool 4 loosen the pickup coil rotor bolt Rotor holding tool 90890 01235 2 2 1 1 INSTALLING THE PICKUP COIL ROTOR 1 Install pickup coil rotor 1 washer pickup coil rotor bolt NOTE When installing the pickup coil rotor align the groove 2 in the crankshaft sprocket with the projection a in the pickup coil rot...

Page 170: ...m kg 32 ft lb 3 Apply sealant onto the pickup coil lead grommet Yamaha bond No 1215 90890 85505 4 Install pickup coil rotor cover pickup coil lead holder clutch cable holder NOTE When installing the pickup coil rotor cover align the timing chain guide intake side pin 1 of the with the hole 2 in the pickup coil rotor cover Tighten the pickup coil rotor cover bolts in stages and in a crisscross pat ...

Page 171: ...utch cover Remove the parts in the order listed Bottom cowling and front cowling Refer to COWLINGS in chapter 3 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 For installation reverse the removal procedure ...

Page 172: ...listed 1 Clutch spring plate retainer 1 2 Clutch spring plate 1 3 Clutch spring plate seat 1 4 Pressure plate 1 5 Push rod 1 1 6 Ball 1 7 Push rod 2 1 8 Friction plate 1 8 3 00 mm 0 12 in 9 Clutch plate 8 10 Friction plate 2 1 3 85 mm 0 15 in 11 Lock washer 1 12 Clutch boss 1 13 Thrust washer 1 ...

Page 173: ... torque limiter bearing 1 16 Back torque limiter inner boss 1 17 Thrust plate 1 18 Thrust washer 1 19 Clutch housing 1 20 Bearing 1 21 Starter clutch gear 1 22 Bearing 1 23 Starter clutch assembly 1 24 Circlip 1 25 Starter clutch idle gear 1 For installation reverse the removal procedure ...

Page 174: ...ng tool 3 loosen the clutch boss nut Clutch holding tool 90890 04086 EB405400 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates 1 Check friction plate Damage wear Replace the friction plates as a set 2 Measure friction plate thickness Out of specification Replace the fric tion plates as a set NOTE Measure the friction plate at four places Friction plate 1 t...

Page 175: ...he clutch plates as a set Maximum clutch plate warpage 0 1 mm 0 004 in EB405430 CHECKING THE CLUTCH SPRING PLATE 1 Check clutch spring plate Damage Replace 2 Check clutch spring plate seat Damage Replace EB405440 CHECKING THE CLUTCH HOUSING 1 Check clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE Pitting on the clutch housing dogs will cause...

Page 176: ...ING THE PRESSURE PLATE 1 Check pressure plate 1 Cracks damage Replace bearing 2 Damage wear Replace CHECKING THE PUSH RODS AND BALL 1 Check push rod 1 1 push rod 2 2 ball 3 Damage wear Replace the pull rods and ball as a set 2 Check push rod bearing 4 Damage wear Replace CHECKING THE BACK TORQUE LIMITER 1 Check back torque limiter outer boss splines Damage pitting wear Replace the back torque limi...

Page 177: ...unterclockwise ı it should turn freely otherwise the back torque limiter is faulty and must be replaced CHECKING THE STARTER CLUTCH 1 Check starter clutch gear starter clutch idle gear Chips pitting roughness wear Replace the defective part s 2 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 ...

Page 178: ...the starter clutch gear teeth and starter clutch idle gear teeth mesh correctly 2 Install back torque limiter inner boss 1 back torque limiter bearing 2 back torque limiter outer boss 3 ACHTUNG CAUTION Be sure that the back torque limiter bearing is installed facing in the correct direction as shown 3 Install lock washer clutch boss nut 1 NOTE While holding the clutch boss 2 with the clutch holdin...

Page 179: ...ction plates clutch plates with the recommended lubricant Recommended lubricant Engine oil 6 Install friction plates 1 3 00 mm 0 12 in clutch plates 2 friction plate 3 3 85 mm 0 15 in NOTE First install a friction plate and then alternate between a clutch plate and a friction plate 1 3 2 ...

Page 180: ...e parts in the order listed Drive sprocket cover Refer to ENGINE 1 Shift shaft cover 1 2 Shift shaft cover gasket 1 3 Dowel pin 2 4 Shift shaft 1 5 Shift shaft spring 1 6 Spacer 1 7 Stopper lever spring 1 8 Stopper lever 1 9 Circlip 1 10 Collar 1 11 Shift shaft spring stopper 1 For installation reverse the removal procedure ...

Page 181: ...1 Install shift shaft spring stopper 1 stopper lever spring 2 stopper lever 3 NOTE Apply locking agent LOCTITE to the threads of the shift shaft spring stop per Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss Mesh the stopper lever with the shift drum segment assembly T R 22 Nm 2 2 m kg 16 ft lb 2 Install shift shaft 1 spacer NOTE Lubricate the oil seal lips...

Page 182: ... to CHANGING THE ENGINE OIL in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Radiator assembly and water pump outlet pipe Refer to RADIATOR AND THERMO STAT and OIL COOLER in chapter 5 Exhaust pipe assembly Refer to ENGINE 1 Oil level switch connector 1 Disconnect 2 Oil level switch 1 3 Oil level switch lead holder 1 4 Oil pan 1 5 Oil pan gasket 1 6 Dowel pin 2 ...

Page 183: ...PUMP EB411001 Order Job Part Q ty Remarks 7 Drain pipe 1 8 Oil strainer 1 9 Oil pipe 1 10 Oil delivery pipe 1 11 Dowel pin 1 12 Oil water pump assembly 1 13 Relief valve assembly 1 For installation reverse the removal procedure ...

Page 184: ...arks Removing the oil pump Remove the parts in the order listed 1 Oil water pump assembly driven sprocket 1 2 Washer 1 3 Oil pump housing 1 4 Bearing 1 5 Pin 2 6 Oil pump outer rotor 1 7 Oil pump inner rotor 1 8 Pin 1 For installation reverse the removal procedure ...

Page 185: ...driven sprocket Flywheel puller 90890 01080 EB411400 CHECKING THE OIL PUMP 1 Check oil water pump assembly driven sprocket 1 oil pump housing 2 Cracks damage wear Replace the defective part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor to oil pump housing clear ance b Out of specification Replace the oil pump 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner rotor to outer ...

Page 186: ...ar Replace the defective part s EB411421 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with compressed air EB411430 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Damage Replace Contaminants Clean with engine oil EB411701 ASSEMBLING THE OIL PUMP 1 Lubricate inner rotor outer rotor impeller shaft with the recommende...

Page 187: ...ER 1 Install oil strainer 1 NOTE The arrow a on the oil strainer housing must point towards the front of the engine T R 10 Nm 1 0 m kg 7 2 ft lb EB411730 INSTALLING THE OIL PAN 1 Install dowel pins oil pan gasket oil pan 1 oil level switch 2 engine oil drain bolt 3 WARNING WARNING Always use new copper washers NOTE Tighten the oil pan bolts in stages and in a crisscross pattern Lubricate the oil l...

Page 188: ...linder head Refer to CYLINDER HEAD Pickup coil and pickup coil rotor Refer to PICKUP COIL Stator coil assembly Refer to GENERATOR Clutch housing and starter clutch idle gear Refer to CLUTCH Oil water pump assembly Refer to OIL PAN AND OIL PUMP 1 Timing chain 1 2 Oil water pump assembly drive chain guide 1 3 Oil water pump assembly drive chain 1 ...

Page 189: ...ENG 4 57 CRANKCASE Order Job Part Q ty Remarks 4 Oil water pump assembly drive sprocket 1 5 Washer 1 6 Lower crankcase 1 7 Dowel pin 3 For installation reverse the removal procedure ...

Page 190: ...order listed Connecting rod assemblies Refer to CONNECTING RODS AND PISTONS Crankshaft Refer to CRANKSHAFT Transmission Refer to TRANSMISSION 1 Oil baffle plate 1 2 Oil baffle plate 1 3 Oil delivery pipe 1 4 Bearing 1 5 Upper crankcase 1 6 Oil filter bolt 1 7 Lower crankcase 1 For installation reverse the removal procedure ...

Page 191: ... 3 Remove lower crankcase ACHTUNG CAUTION Tap on one side of the crankcase with a soft face hammer Tap only on rein forced portions of the crankcase not on the crankcase mating surfaces Work slowly and carefully and make sure that the crankcase halves separate evenly M9 105 mm bolts 1 M8 60 mm bolt K L M6 70 mm bolts G I O Q M6 64 mm bolts F N M6 60 mm bolt M M6 55 mm bolts A E M6 50 mm bolt H M6 ...

Page 192: ... BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace CHECKING THE SPROCKETS AND CHAINS 1 Check crankshaft sprocket oil water pump assembly drive sprocket Cracks damage wear Replace the defective part s 2 Check timing chain Damage stiffness Replace the tim ing chain and crankshaft as a set oil water pump assembl...

Page 193: ...haft journal bearings Do not apply sealant to within 2 3 mm 0 08 0 12 in of the crankshaft journal bearings 3 Install dowel pins 1 Yamaha bond No 1215 90890 85505 4 Install crankshaft journal lower bearings into the lower crankcase NOTE Align the projections a on the crank shaft journal lower bearings with the notches b in the lower crankcase Install each crankshaft journal lower bearing in its or...

Page 194: ...ase bolts NOTE Lubricate the bolt threads with engine oil Install a washer on bolts 1 Tighten the bolts in the tightening sequence cast on the crankcase M9 105 mm bolts 1 M8 60 mm bolt K L M6 70 mm bolts G I O Q M6 64 mm bolts F N M6 60 mm bolt M M6 55 mm bolts A E M6 50 mm bolt H M6 45 mm bolts J P R T R Bolt 1 32 Nm 3 2 m kg 23 ft lb Bolt A E G J M O R 12 Nm 1 2 m kg 8 7 ft lb Bolt F N 14 Nm 1 4...

Page 195: ...ting rods and pistons Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE 1 Connecting rod cap 4 2 Big end lower bearing 4 3 Piston pin clip 8 4 Piston pin 4 5 Piston 4 6 Connecting rod 4 7 Big end upper bearing 4 8 Top ring 4 9 2nd ring 4 10 Oil ring 4 For installation reverse the removal procedure ...

Page 196: ...ing rod 4 ACHTUNG CAUTION Do not use a hammer to drive the piston pin out NOTE For reference during installation put identification marks on the piston crown Before removing the piston pin deburr the piston pin clip groove and the pis ton pin bore area in the piston If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller 4 Piston pin puller 9...

Page 197: ...inder Then find the average of the measurements b If out of specification replace the crankcases and the pistons and pis ton rings as a set c Measure piston skirt diameter P with the micrometer a 10 mm 0 39 in from the bottom edge of the piston d If out of specification replace the pis ton and piston rings as a set Cylinder bore gauge 90890 03017 Cylinder bore C 72 000 72 008 mm 2 8346 2 8350 in M...

Page 198: ...004 in EB404410 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the pis ton and piston rings as a set NOTE Before measuring the piston ring side clearance eliminate any carbon depos its from the piston ring grooves and pis ton rings Piston ring side clearance Top ring 0 03 0 07 mm 0 0012 0 0028 in Limit 0 12 mm 0 0047 in 2nd ring 0 02 0 06 mm 0 0008 0 00...

Page 199: ...ng 0 1 0 3 mm 0 004 0 012 in EB404421 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins 1 Check piston pin Blue discoloration grooves Replace the piston pin and then check the lubri cation system 2 Measure piston pin outside diameter a Out of specification Replace the pis ton pin Piston pin outside diameter 16 995 17 000 mm 0 6691 0 6693 in Limit 16 975 mm 0 6683 i...

Page 200: ...g procedure applies to all of the connecting rods ACHTUNG CAUTION Do not interchange the big end bearings and connecting rods To obtain the cor rect crankshaft pin to big end bearing clearance and prevent engine damage the big end bearings must be installed in their original positions a Clean the big end bearings crank shaft pins and bearing portions of the connecting rods b Install the big end up...

Page 201: ... the connecting rod faces towards the left side of the crankshaft Make sure that the characters d on both the connecting rod and connect ing rod cap are aligned e Tighten the connecting rod nuts Refer to INSTALLING THE PISTONS AND CONNECTING RODS f Remove the connecting rod and big end bearings Refer to REMOVING THE CONNECT ING RODS AND PISTONS g Measure the compressed Plasti gauge width e on the ...

Page 202: ... example if the connecting rod P1 and the crankshaft web P1 num bers are 9 and 3 respectively then the bearing size for P1 is P1 connecting rod P1 crank shaft 9 3 6 BIG END BEARING COLOR CODE 2 blue 3 black 4 5 brown 6 7 green 8 9 yellow EB404704 INSTALLING THE PISTONS AND CONNECTING RODS The following procedure applies to all of the pistons and cylinders 1 Install top ring 2nd ring oil ring NOTE ...

Page 203: ...o its original cylinder numbering order starting from the left 1 to 4 Å Piston head New 3 Offset piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring Å Intake side 4 Lubricate piston piston rings cylinder with the recommended lubricant 5 Lubricate bolt threads nut seats with the recommended lubricant ACHTUNG CAUTION MOLYKOTE G n paste is a special grease which sho...

Page 204: ...onto the connecting rod NOTE Align the projections on the big end bearings with the notches in the con necting rods and connecting rod caps Be sure to reinstall each big end bear ing in its original place While compressing the piston rings with piston ring compressor 1 install the connecting rod assembly into the cylinder with the other hand Make sure that the Y marks a on the connecting rods face...

Page 205: ...until the connecting rod bolt has stretched by between 0 170 and 0 175 mm ACHTUNG CAUTION If the connecting rod nut cannot eventu ally be tightened to about 50 Nm 5 0 m kg 36 ft lb too much MOLYKOTE G n paste may have been applied Loosen the connecting rod nut and check the loosening torque If the loos ening torque is less than 40 Nm 4 0 m kg 29 ft lb too much MOLYKOTE G n paste was applied In tha...

Page 206: ...ankshaft assembly Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Connecting rod caps Refer to CONNECTING RODS AND PISTONS 1 Crankshaft 1 2 Crankshaft journal lower bearing 5 3 Crankshaft journal upper bearing 5 For installation reverse the removal procedure ...

Page 207: ...haft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crank shaft CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1 Measure crankshaft journal to crankshaft jour nal bearing clearance Out of specification Replace the crankshaft journal bearings ACHTUNG CAUTION Do not interchange the crankshaft jour nal bearings To obtain the correct crankshaft journal to crankshaft jou...

Page 208: ...ot put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings into the lower crankcase and assemble the crankcase NOTE Align the projections a on the crank shaft journal lower bearings with the notches b in the lower crankcase Do not move the crankshaft until the clearance measurement has been completed f Tighten the bolts to specification in th...

Page 209: ...k shaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same size for all of the bearings For example if the crankcase J1 and crankshaft web J1 numbers are 8 and 3 respectively then the bearing size for J1 is Bearing size for J1 ...

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

Page 211: ...shift drum assembly and shift forks Remove the parts in the order listed Crankcase Separate Refer to CRANKCASE Stopper lever Refer to SHIFT SHAFT 1 Drive axle assembly 1 2 Circlip 1 3 Oil seal 1 4 Bearing 1 5 Shift drum retainer 1 6 Shift fork guide bar 2 7 Spring 4 8 Shift fork L 1 9 Shift fork R 1 ...

Page 212: ...ENG 4 80 TRANSMISSION Order Job Part Q ty Remarks 10 Shift drum assembly 1 11 Shift fork C 1 12 Main axle assembly 1 For installation reverse the removal procedure ...

Page 213: ...g the main axle assem bly Remove the parts in the order listed 1 2nd pinion gear 1 2 Toothed lock washer 1 3 Toothed lock washer retainer 1 4 6th pinion gear 1 5 Toothed spacer 1 6 Toothed washer 2 7 Circlip 2 8 3rd 4th pinion gears 1 9 5th pinion gear 1 Collar 1 ...

Page 214: ...ENG 4 82 TRANSMISSION Order Job Part Q ty Remarks A Main axle 1st pinion gear 1 B Bearing 1 C Main axle bearing housing 1 For installation reverse the removal procedure ...

Page 215: ...Disassembling the drive axle assem bly Remove the parts in the order listed 1 Washer 1 2 1st wheel gear 1 3 Spacer 1 4 5th wheel gear 1 5 Circlip 3 6 Washer 3 7 3rd wheel gear 1 8 Toothed spacer 2 9 Toothed lock washer 1 Toothed lock washer retainer 1 ...

Page 216: ...ENG 4 84 TRANSMISSION Order Job Part Q ty Remarks A 4th wheel gear 1 B 6th wheel gear 1 C 2nd wheel gear 1 D Spacer 1 E Drive axle 1 F Bearing 1 G Spacer 1 For installation reverse the removal procedure ...

Page 217: ...rankcase surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase EB413400 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check shift fork cam follower 1 shift fork pawl 2 Bends damage scoring wear Replace the shift fork 2 Check shift fork guide bar Roll the shift fork guide bar on a flat surface Bends Replace WA...

Page 218: ...g 2 Damage pitting Replace the shift drum assembly EB413422 CHECKING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the main axle Maximum main axle runout 0 08 mm 0 003 in 2 Measure drive axle runout with a centering device and dial gauge 1 Out of specification Replace the drive axle Maximum drive axle runout 0 08 mm 0 003 in 3 Che...

Page 219: ...ive axle assembly NOTE Install the shift forks so that the embossed marks C R and L are facing toward the right side of the engine 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...

Page 220: ...cowling Refer to COWLINGS in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Coolant reservoir breather hose 1 2 Coolant reservoir hose 1 3 Coolant reservoir 1 4 Thermo switch 1 5 Thermostat assembly breather hose 1 Disconnect 6 Water pump inlet pipe 1 7 Water pump breather hose 1 8 Radiator outlet pipe breather hose 1 9 Water pump inlet hose 1 10 Radiator outlet pipe 1 5 ...

Page 221: ... 13 Lower radiator 1 14 Lower radiator breather hose 1 15 Radiator joint hose 1 16 Plastic band 1 17 Oil cooler outlet hose 1 Disconnect 18 Radiator inlet hose 1 19 Horn 1 20 Upper radiator 1 21 Radiator fan 1 22 Upper radiator bracket 2 23 Lower radiator bracket 1 For installation reverse the removal procedure 5 ...

Page 222: ... and rubber cover Refer to AIR FILTER CASE AND IGNI TION COIL PLATE in chapter 3 Carburetor assembly Refer to CARBURETORS in chapter 6 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Fuel tank and air filter case cover Refer to FUEL TANK AND AIR FIL TER in chapter 3 Air filter case Refer to ELECTRONIC FUEL INJEC TION in chapter 6 1 Thermostat assembly 1 2 Thermostat assembly inlet hose 1 ...

Page 223: ...THERMOSTAT Order Job Part Q ty Remarks 3 Thermostat assembly breather hose 1 4 Coolant temperature sensor 1 5 Copper washer 1 6 Plastic band 1 7 Thermostat assembly inlet pipe 1 For installation reverse the removal procedure ...

Page 224: ...DIATOR AND THERMOSTAT EB502010 Order Job Part Q ty Remarks Disassembling the thermostat assembly Remove the parts in the order listed 1 Thermostat housing cover 1 2 Thermostat 1 3 Thermostat housing 1 For assembly reverse the disassembly procedure ...

Page 225: ...e 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap a Install the radiator cap tester 1 and adapter 2 onto the radiator cap 3 b Apply the specified pressure for ten seconds and make sure that there is no drop in pressure Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 3 51 7 78 psi Radiator cap tester 90890 01325 Adapter 90890 01352 4 Check rad...

Page 226: ...d thermometer s indi cated temperature 1 Thermostat 2 Thermometer 3 Water 4 Container Å Fully closed ı Fully open NOTE If the accuracy of the thermostat is in doubt replace it A faulty thermostat could cause serious overheating or overcooling 2 Check thermostat housing cover thermostat housing Cracks damage Replace EB502030 ASSEMBLING THE THERMOSTAT ASSEMBLY 1 Install thermostat housing 1 thermost...

Page 227: ...ng system with the specified amount of the rec ommended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below the specified pressure Replace the radiator cap Refer to CHECKING THE RADIATOR ...

Page 228: ...RADIATOR AND THERMO STAT Exhaust pipe assembly Refer to ENGINE in chapter 4 Engine oil Drain Refer to CHANGING THE ENGINE OIL in chapter 3 1 Oil cooler outlet hose 1 2 Bolt 1 3 Gasket 1 4 Oil cooler 1 5 Oil cooler inlet hose 1 6 Water pump outlet pipe 1 7 Water jacket joint inlet hose 1 8 Water jacket joint 1 For installation reverse the removal procedure ...

Page 229: ...EB501020 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 oil cooler 1 gasket 2 bolt 3 NOTE Before installing the oil cooler lubri cate the oil cooler bolt and O ring with a thin coat of engine oil Make sure that the O ring is positioned properly Align the projection a on the oil cooler with the projec...

Page 230: ...COOLANT in chapter 3 crankcase with the specified amount of the rec ommended engine oil Refer to CHANGING THE ENGINE OIL 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 231: ...ly and oil pump rotor Refer to OIL PAN AND OIL PUMP in chapter 4 1 Water pump cover 1 2 O ring 1 3 Pin 2 4 Impeller shaft along with the impel ler 1 NOTE The water pump and oil pump are combined into one unit oil water pump assembly It is not necessary to remove the impeller shaft unless the coolant level is extremely low or coolant leaks from the oil pan ...

Page 232: ...5 13 COOL WATER PUMP Order Job Part Q ty Remarks 5 Water pump seal 1 6 Oil seal 1 7 Bearing 1 For installation reverse the removal procedure ...

Page 233: ...e of the water pump housing 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver NOTE Do not scratch the impeller shaft EB503032 CHECKING THE WATER PUMP 1 Check water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 Cracks damage wear Replace 2 Check water pump seal oil seal water pump in...

Page 234: ...AUTION Never lubricate the water pump seal surface with oil or grease NOTE Install the water pump seal with the special tools Before installing the water pump seal apply Yamaha bond No 1215 2 to the water pump housing 3 Å Push down Mechanical seal installer 4 90890 04078 Middle driven shaft bearing driver 5 90890 04058 Yamaha bond No 1215 90890 85505 New 3 Install rubber damper 1 rubber damper hol...

Page 235: ... impeller shaft tilt Out of specification Repeat steps 3 and 4 ACHTUNG CAUTION Make sure that the rubber damper and rubber damper holder are flush with the impeller 1 Straightedge 2 Impeller Max impeller shaft tilt 0 15 mm 0 006 in ...

Page 236: ... case Remove the parts in the order listed Air filter case cover Refer to FUEL TANK AND AIR FIL TER in chapter 3 1 Crankcase breather hose 1 Disconnect 2 Fuel hose 3 3 Injector 2 sub lead coupler 3 Disconnect 4 Pressure sensor hose 2 Disconnect 5 Plastic band 1 6 Injector 2 assembly 1 7 Spacer 6 8 Air funnel 4 9 Air funnel bracket 4 10 Fuel hose joint pipe 1 6 ...

Page 237: ... Q ty Remarks 11 Intake air temperature sensor 1 12 Copper washer 1 13 Air filter case breather hose 1 Disconnect 14 Negative pressure hose 1 Disconnect 15 Air funnel rubber seat 4 16 Air filter case 1 For installation reverse the removal procedure 6 ...

Page 238: ...rt Q ty Remarks Removing the injector 2 Remove the parts in the order listed 1 Intake air pressure sensor coupler 1 2 Atmospheric pressure sensor cou pler 1 3 Cylinder 1 injector 2 coupler 1 4 Cylinder 2 injector 2 coupler 1 5 Cylinder 3 injector 2 coupler 1 6 Cylinder 4 injector 2 coupler 1 7 Pressure sensor hose 2 8 Intake air pressure sensor 1 9 Atmospheric pressure sensor 1 10 Pressure sensor ...

Page 239: ...ector 2 cover 8 16 Injector 2 4 17 O ring 4 18 Seal 4 19 Seal 4 20 Fuel distributor 1 For installation reverse the removal procedure T R 30 Nm 3 0 m kg 22 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib T R 5 Nm 0 5 m kg 3 6 ft Ib T R 8 Nm 0 8 m kg 5 8 ft Ib 4 1 2 3 4 5 6 7 10 9 8 11 20 12 14 11 12 13 15 19 16 18 17 LT LT LT LT LT LT ...

Page 240: ...Fuel hose 1 2 Throttle position sensor coupler 1 3 Cylinder 4 injector 1 coupler 1 4 Cylinder 3 injector 1 coupler 1 5 Cylinder 2 injector 1 coupler 1 6 Cylinder 1 injector 1 coupler 1 7 Starter cable 1 Disconnect 8 Throttle cable 2 Disconnect 9 Throttle stop screw 1 Disconnect 10 Throttle body assembly 1 11 Left plate 4 12 Right plate 4 ...

Page 241: ...6 6 EFI ELECTRONIC FUEL INJECTION Order Job Part Q ty Remarks 13 Gasket 4 14 Spacer 16 For installation reverse the removal procedure ...

Page 242: ... and throttle body Remove the parts in the order listed 1 Negative pressure hose 1 2 Pressure regulator 1 3 Union bolt 1 4 Washer 2 5 Injector fuel pipe 1 1 6 Injector fuel pipe 2 1 7 Washer 1 8 Fuel distributor 1 9 Injector 1 4 10 O ring 4 11 Seal 4 12 Seal 4 13 Rear connecting plate 1 ...

Page 243: ...ks 14 Throttle position sensor 1 15 Throttle cable holder 1 16 Starter link lever screw 4 17 Starter link 1 18 Starter link lever 4 19 Front connecting plate 1 20 Throttle body 4 21 Starter plunger 4 22 Air screw 4 For installation reverse the removal procedure ...

Page 244: ... Check injector 1 injector 2 Damage Replace CHECKING THE THROTTLE BODY 1 Check throttle body Cracks damage Replace the throttle body assembly 2 Check fuel passages Obstruction Clean a Wash the throttle body in a petro leum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of passages with com pressed air ...

Page 245: ...osition sensor installed on the throttle body a Disconnect the throttle position sen sor coupler from the throttle position sensor b Connect the pocket tester Ω 1k to the throttle position sensor c Measure the maximum throttle posi tion sensor resistance Out of specification Replace the throttle position sensor Positive tester probe blue terminal 1 Negative tester probe black blue terminal 2 Maxim...

Page 246: ...fication or the resistance changes abruptly Go to step 2 below Positive tester probe yellow terminal 3 Negative tester probe black blue terminal 2 Throttle position sensor resis tance 520 900 Ω 4 0 6 0 kΩ at 20 C 68 F yellow black blue 2 Check throttle position sensor removed from the throttle body a Disconnect the throttle position sen sor coupler from the throttle position sensor b Remove the th...

Page 247: ...ot change or it changes abruptly Replace the throttle position sensor The slot is worn or broken Replace the throttle position sensor NOTE Check mainly that the resistance changes gradually when turning the throttle since the readings from closed to wide open throttle may differ slightly from those specified Maximum throttle position sensor resistance 4 0 6 0 kΩ at 20 C 68 F blue black blue Positi...

Page 248: ...0 750 Ω Lift the throttle body assembly slightly out of the intake manifolds Loosen the throttle position sensor screws 4 Connect the pocket tester Ω 100 to the throttle position sensor e Adjust the throttle position sensor angle so that the measured resistance is within the specified range After adjusting the throttle position sen sor angle tighten the throttle position sensor screws Positive tes...

Page 249: ...injector fuel pipe 3 2 from the fuel distributor d Connect the mity vac 3 onto the neg ative pressure hose from the pressure regulator e Install the pressure gauge 4 and adapter 5 with the washers and injector fuel pipe 3 onto the fuel dis tributor f Install the fuel tank Refer to FUEL TANK AND AIR FIL TER in chapter 3 g Start the engine h Measure the fuel pressure Mity vac 90890 06756 Pressure ga...

Page 250: ...sure in relation to the vacuum pressure as described below NOTE The vacuum pressure should not exceed 100 kPa 1 mmHg 0 04 in Hg Faulty Replace the pressure regula tor Increase the vacuum pressure Fuel pressure is decreased Decrease the vacuum pressure Fuel pressure is increased ...

Page 251: ... order listed 1 Brake hose holder left and right 2 2 Brake caliper left and right 2 3 Wheel axle pinch bolt 4 Loosen 4 Front wheel axle 1 5 Front wheel 1 6 Collar left and right 2 7 Oil seal cover left and right 2 8 Brake disc left and right 2 For installation reverse the removal procedure NOTE Place the motorcycle on a suitable stand so that the front wheel is ele vated 7 ...

Page 252: ... DISCS EB700010 Order Job Part Q ty Remarks Disassembling the front wheel Remove the parts in the order listed 1 Oil seal left and right 2 2 Wheel bearing left and right 2 3 Spacer 1 For assembly reverse the disassembly procedure 7 ...

Page 253: ...move left brake caliper right brake caliper NOTE Do not squeeze the brake lever when removing the brake calipers 3 Elevate front wheel NOTE Place the motorcycle on a suitable stand so that the front wheel is elevated EB700400 CHECKING THE FRONT WHEEL 1 Check wheel axle Roll the wheel axle on a flat surface Bends Replace WARNING WARNING Do not attempt to straighten a bent wheel axle 2 Check tire fr...

Page 254: ... the oil seals 1 with a flat head screwdriver NOTE To prevent damaging the wheel place a rag 2 between the screwdriver and the wheel surface c Remove the wheel bearings 3 with a general bearing puller d Install the new wheel bearings and oil seals in the reverse order of disas sembly ACHTUNG CAUTION Do not contact the wheel bearing center race 4 or balls 5 Contact should be made only with the oute...

Page 255: ...ure that the front wheel is stationary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc Max brake disc deflection Front 0 1 mm 0 004 in Rear 0 1 mm 0 004 in 3 Measure brake disc thickness Measure the brake disc thickness at a few different locations Out of specification Replace ...

Page 256: ...THE FRONT WHEEL 1 Lubricate wheel axle oil seal lips Recommended lubricant Lithium soap base grease 2 Install brake discs NOTE Apply locking agent LOCTITE 648 to the threads of the brake disc bolts Tighten the brake disc bolts in stages and in a crisscross pattern T R 18 Nm 1 8 m kg 13 ft lb 3 Tighten wheel axle 1 wheel axle pinch bolt 2 ACHTUNG CAUTION Before tightening the wheel axle nut push do...

Page 257: ...scs installed 1 Remove balancing weight s 2 Find front wheel s heavy spot a Place the front wheel on a suitable balancing stand b Spin the front wheel c When the front wheel stops put an X1 mark at the bottom of the wheel d Turn the front wheel 90 so that the X1 mark is positioned as shown e Release the front wheel f When the front wheel stops put an X2 mark at the bottom of the wheel g Repeat ste...

Page 258: ...n the front wheel 90 so that the heavy spot is positioned as shown c If the heavy spot does not stay in that position install a heavier weight d Repeat steps b and c until the front wheel is balanced 4 Check front wheel static balance a Turn the front wheel and make sure that it stays at each position shown b If the front wheel does not remain stationary at all of the positions rebalance it ...

Page 259: ... wheel Remove the parts in the order listed 1 Brake caliper 1 2 Locknut left and right 2 Loosen 3 Adjusting bolt left and right 2 Loosen 4 Wheel axle nut 2 5 Washer 1 6 Rear wheel axle 1 7 Rear wheel 1 8 Brake caliper bracket 1 For installation reverse the removal procedure NOTE Place the motorcycle on a suitable stand so that the rear wheel is ele vated ...

Page 260: ...ke disc and rear wheel sprocket Remove the parts in the order listed 1 Brake disc 1 2 Rear wheel sprocket 1 3 Oil seal cover left and right 2 4 Spacer left and right 2 5 Oil seal 1 6 Bearing 1 7 Rear wheel drive hub 1 8 Rear wheel drive hub damper 6 9 Rear wheel 1 For installation reverse the removal procedure ...

Page 261: ...ND REAR WHEEL SPROCKET Order Job Part Q ty Remarks Disassembling the rear wheel Remove the parts in the order listed 1 Spacer 1 2 Bearing 1 3 Spacer 1 4 Oil seal 1 5 Circlip 1 6 Bearing 1 For assembly reverse the disassembly procedure ...

Page 262: ...rear wheel is elevated 2 Remove brake caliper NOTE Do not depress the brake pedal when removing the brake caliper 3 Remove wheel axle nut washer wheel axle rear wheel NOTE Push the rear wheel forward and remove the drive chain from the rear wheel sprocket EB701400 CHECKING THE REAR WHEEL 1 Check wheel axle rear wheel wheel bearings oil seals brake disc Refer to FRONT WHEEL 2 Check tire rear wheel ...

Page 263: ...HECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check rear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprocket b Correct 1 Drive chain roller 2 Rear wheel sprocket 2 Replace rear wheel sprocket a Remove the self locking nuts and the rear wheel sprocket b Clean the rear wheel drive hub with a clean cloth especially the surfaces that c...

Page 264: ... 1 97 in 3 Tighten wheel axle wheel axle nut brake caliper bolts WARNING WARNING Make sure that the brake hose is routed properly EB701900 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE After replacing the tire wheel or both the rear wheel static balance should be adjusted Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed 1 Adjust rear wheel static balance R...

Page 265: ...s Removing the front brake pads Remove the parts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Bleed screw 1 For installation reverse the removal procedure ...

Page 266: ...der Job Part Q ty Remarks Removing the rear brake pads Remove the parts in the order listed 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 1 4 Brake pad 2 5 Brake pad shim 2 6 Bleed screw 2 For installation reverse the removal procedure ...

Page 267: ...e only clean or new brake fluid for cleaning brake components Brake fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid coming into contact with the eyes as it can cause serious injury First aid for brake fluid entering the eyes Flush with water for 15 minutes and get immediate medical attention EB702112 REPLACING THE F...

Page 268: ...nstall new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open con tainer b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim onto each new brake pads e Install new brake pads and a n...

Page 269: ...RAKE 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 EB702113 REPLACING THE REAR BRAKE PADS NOTE When replacing the brake pads it is not necessary to disconnect the brake hose or disassemble the brake caliper 1 Remove brake caliper 1 2 Remove brake pad clips 1 brake pad pins 2 brake pad s...

Page 270: ...ring NOTE Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open con tainer b Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger c Tighten the bleed screw d Install a new brake pad shim onto each new brake pad T R Bleed screw...

Page 271: ...g 29 ft lb 6 Check brake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake pedal operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 ...

Page 272: ...ake calipers Remove the parts in the order listed The following procedure applies to both of the front brake calipers Brake fluid Drain 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal procedure FRONT AND REAR BRAKES ...

Page 273: ...ts in the order listed The following procedure applies to both of the front brake calipers 1 Brake pad clip 2 2 Brake pad pin 1 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 4 6 Brake caliper piston seal 8 7 Bleed screw 1 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 274: ... Q ty Remarks Removing the rear brake caliper Remove the parts in the order listed Brake fluid Drain 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake caliper 1 For installation reverse the removal procedure FRONT AND REAR BRAKES ...

Page 275: ...rear brake caliper Remove the parts in the order listed 1 Brake pad clip 4 2 Brake pad pin 2 3 Brake pad spring 1 4 Brake pad 2 5 Brake caliper piston 2 6 Brake caliper piston seal 4 7 Bleed screw 2 For assembly reverse the disassembly procedure FRONT AND REAR BRAKES ...

Page 276: ...and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side pistons from the brake cali per WARNING WARNING Never try to pry out the brake caliper pistons Do not loosen the bolts 3 c Remove the brake calip...

Page 277: ...efully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper piston with a piece of wood a b Blow compressed air into the brake hose joint opening b to force out the left side piston from the brake caliper WARNING WARNING Never try to pry out the brake caliper pistons Do not loosen the bolt 3 c Remove the brake caliper piston seals d Repeat the previou...

Page 278: ...assages brake caliper body Obstruction Blow out with com pressed air WARNING WARNING Whenever a brake caliper is disassem bled replace the brake caliper piston seals Å Front ı Rear Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassem bled Å ı 2 Check rear brak...

Page 279: ... replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHTUNG CAUTION When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touches the projection b on the b...

Page 280: ...brake fluid reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ACHTUNG CAUTION Brake fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Recommended brake fluid DOT 4 6 Check brake fluid level Below the mi...

Page 281: ...n seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers brake hose 2 union bolt 3 WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHTUNG CAUTION When installing the brake hose onto the brake caliper 1 make sure that the brake pipe a touches the projection b on the brake caliper 2 Remove brake cali...

Page 282: ...brake fluid reser voir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock ACHTUNG CAUTION Brake fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt brake fluid immediately 5 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Recommended brake fluid DOT 4 6 Check brake fluid level Below the mi...

Page 283: ...e order listed Brake fluid Drain 1 Brake fluid reservoir cap stopper 1 2 Brake fluid reservoir cap 1 3 Brake fluid reservoir diaphragm holder 1 4 Brake fluid reservoir diaphragm 1 5 Brake fluid reservoir 1 6 Brake fluid reservoir hose 1 7 Circlip 1 8 Hose joint 1 9 Brake lever 1 10 Front brake switch connector 2 Disconnect 11 Union bolt 1 12 Copper washer 3 ...

Page 284: ...4 CHAS FRONT AND REAR BRAKES Order Job Part Q ty Remarks 13 Brake hose 2 14 Brake master cylinder holder 1 15 Brake master cylinder 1 16 Front brake switch 1 For installation reverse the removal procedure ...

Page 285: ... Order Job Part Q ty Remarks Disassembling the front brake mas ter cylinder Remove the parts in the order listed 1 Dust boot 1 2 Circlip 1 3 Brake master cylinder kit 1 4 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 286: ...ake fluid Drain 1 Brake fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir 1 5 Plastic clamp 1 6 Plastic locking tie 1 7 Brake fluid reservoir hose 1 8 Hose joint 1 9 Oil seal 1 10 Union bolt 1 11 Copper washer 2 12 Brake hose 1 13 Brake master cylinder 1 For installation reverse the removal procedure ...

Page 287: ...RAKES EB702203 Order Job Part Q ty Remarks Disassembling the rear brake mas ter cylinder Remove the parts in the order listed 1 Brake master cylinder kit 1 2 Brake master cylinder 1 For assembly reverse the disassembly procedure ...

Page 288: ...e brake hose EB702220 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 NOTE To collect any remaining brake fluid place a container under the master cylin der and the end of the brake hose 3 3 1 1 2 2 EB702243 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to both of the brake master cylinders 1 Check brake master c...

Page 289: ...e fluid reservoir diaphragm 2 Cracks damage Replace 4 Check brake hoses Cracks damage wear Replace Å EB702283 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING WARNING Before installation all internal brake components should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake components Recommended brake fluid DOT 4 ...

Page 290: ... 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 New T R 30 Nm 3 0 m kg 22 ft lb 3 Fill brake fluid reservoir with the specified amount of the rec ommended brake fluid WARNING WARNING Use only the designated brake fluid Other brake fluids may cause the rub ber seals to deteriorate causing leak age and poor brake perfor...

Page 291: ...HECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 EB702290 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1 Install copper washers brake hoses union bolt WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHTUNG CA...

Page 292: ...gnificantly lower the boiling point of the brake fluid and could cause vapor lock ACHTUNG CAUTION Brake fluid may damage painted sur faces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 Recommended brake fluid DOT 4 4 Check brake fluid level Below the minimum level mark a Add the recommend...

Page 293: ...ve the parts in the order listed Clutch fluid Drain 1 Clutch fluid reservoir cap 1 2 Clutch fluid reservoir diaphragm holder 1 3 Clutch fluid reservoir diaphragm 1 4 Clutch fluid reservoir 1 5 Clutch fluid reservoir hose 1 6 Dust seat 1 7 Circlip 1 8 Hose joint 1 9 Clutch lever 1 10 Clutch switch coupler 1 11 Union bolt 1 ...

Page 294: ... HYDRAULIC CLUTCH Order Job Part Q ty Remarks 12 Copper washer 2 13 Clutch hose 1 14 Clutch master cylinder holder 1 15 Clutch master cylinder 1 16 Clutch switch 1 For installation reverse the removal procedure ...

Page 295: ...CH Order Job Part Q ty Remarks Disassembling the clutch master cylinder Remove the parts in the order listed 1 Push rod 1 2 Clutch master cylinder kit 1 3 Clutch master cylinder 1 For assembly reverse the disassembly procedure ...

Page 296: ... cleaning clutch components Clutch fluid may damage painted sur faces and plastic parts Therefore always clean up any split fluid imme diately Avoid clutch fluid coming into contact with the eyes as it can cause serious injury First aid for clutch fluid entering the eyes Flush with water for 15 minutes and get immediate medical attention EAS00308 CHECKING THE CLUTCH MASTER CYLINDER 1 Check clutch ...

Page 297: ...l internal clutch components must be cleaned and lubricated with clean or new clutch fluid Never use solvents on internal clutch components Recommended clutch fluid Brake fluid DOT 4 1 Install clutch master cylinder 1 NOTE Install the clutch master cylinder holder with the UP mark facing up Align the end of the clutch master cyl inder holder with the punch mark a in the handlebar First tighten the...

Page 298: ...uid Brake fluid DOT 4 WARNING WARNING Use only the designated clutch fluid Other clutch fluids may cause the rub ber seals to deteriorate causing leak age and poor clutch performance Refill with the same type of clutch fluid that is already in the system Mixing clutch fluids may result in a harmful chemical reaction leading to poor clutch performance When refilling be careful that water does not e...

Page 299: ...fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 6 Check clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 a a HYDRAULIC CLUTCH ...

Page 300: ...r Remove the parts in the order listed Bottom cowling Refer to COWLINGS in chapter 3 Clutch fluid Drain 1 Starter knob 1 2 Union bolt 1 3 Copper washer 2 4 Clutch hose 1 5 Clutch release cylinder assembly 1 6 Dowel pin 2 For installation reverse the removal procedure HYDRAULIC CLUTCH ...

Page 301: ... Remarks Disassembling the clutch release cylinder Remove the parts in the order listed 1 Dust seal 1 2 Clutch release cylinder piston 1 3 Spring 1 4 Oil seal 1 5 Bleed screw 1 For assembly reverse the disassembly procedure HYDRAULIC CLUTCH ...

Page 302: ...Be careful not to get injured when the piston is expelled from the clutch release cylinder Never try to pry out the clutch release cylinder piston b Remove the clutch release cylinder oil seal EAS00314 CHECKING THE CLUTCH RELEASE CYLINDER 1 Check clutch release cylinder body 1 Cracks damage Replace the clutch release cylinder clutch release cylinder 2 clutch release cylinder piston 3 Rust scratche...

Page 303: ...ing is essential to insure safe motorcycle operation Refer to CABLE ROUTING ACHTUNG CAUTION When installing the clutch hose onto the clutch release cylinder make sure that the pipe a touches the projection b 2 Fill clutch fluid reservoir with the specified amount of the rec ommended clutch fluid WARNING WARNING Use only the designated clutch fluid Other clutch fluids may cause the rub ber seals to...

Page 304: ...e always clean up any spilt clutch fluid immedi ately 3 Bleed clutch system Refer to BLEEDING THE HYDRAULIC CLUTCH SYSTEM in chapter 3 4 Check clutch fluid level Below the minimum level mark a Add the recommended clutch fluid to the proper level Refer to CHECKING THE CLUTCH FLUID LEVEL in chapter 3 5 Check clutch lever operation Soft or spongy feeling Bleed the clutch system Refer to BLEEDING THE ...

Page 305: ...nt fork legs Remove the parts in the order listed The following procedure applies to both of the front fork legs Bottom cowling and front cowling Refer to COWLINGS in chapter 3 Front wheel Refer to FRONT WHEEL AND BRAKE DISCS 1 Front fender 1 2 Upper bracket pinch bolt 1 Loosen 3 Cap bolt 1 Loosen 4 Handlebar pinch bolt 2 5 Lower bracket pinch bolt 3 6 Front fork leg 1 For installation reverse the...

Page 306: ...arts in the order listed The following procedure applies to both of the front fork legs 1 Cap bolt O ring 1 1 2 Straight key 1 3 Washer 1 4 Damper adjusting rod 1 5 Nut 1 6 Spring seat 1 7 Spacer 1 8 Fork spring 1 9 Outer tube 1 0 Dust seal 1 A Oil seal clip 1 B Oil seal 1 C Washer 1 FRONT FORK ...

Page 307: ...7 57 CHAS Order Job Part Q ty Remarks D Damper rod assembly 1 E Inner tube 1 For assembly reverse the disassembly procedure FRONT FORK ...

Page 308: ...s lightly Refer to ADJUSTING THE FRONT FORK LEGS in chapter 3 1 1 3 Loosen upper bracket pinch bolt 1 cap bolt 2 with the front fork cap bolt wrench handlebar pinch bolts lower bracket pinch bolts WARNING WARNING Before loosening the upper and lower bracket pinch bolts and handlebar pinch bolt support the front fork leg 4 Remove front fork leg Front fork cap bolt wrench 90890 01472 1 1 2 2 EB70311...

Page 309: ...t straight key washer and damper adjusting rod e Remove the rod holder and fork spring compressor WARNING WARNING The fork spring is compressed f Remove the nut spring seat and spacer Fork spring compressor 90890 01441 Rod holder 90890 01434 2 Drain fork oil NOTE Stroke the damper rod 1 several times while draining the fork oil 3 Remove outer tube from inner tube 4 Remove dust seal oil seal clip 1...

Page 310: ...this may dangerously weaken it 2 Measure spring free length a Out of specification Replace Spring free length limit 240 mm 9 45 in 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil passages with compressed air ACHTUNG CAUTION The front fork leg has a built in damper adjusting rod and a very sophisticated internal construction which are particularly sensitive to for eign ...

Page 311: ...e to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Install damper rod assembly 1 ACHTUNG CAUTION Allow the damper rod assembly to slide slowly down the inner tube 2 until it protrudes from the bottom of the inner tube Be careful not to damage the inner tube NOTE Be sure that...

Page 312: ...Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag 5 to protect the oil seal during installation 5 Install outer tube onto the inner tube Damper rod holder 90890 01473 T R 48 Nm 4 8 m kg 35 ft lb 6 Install washer oil seal 1 with the fork seal driver 2 Fork seal driver 90890 01442 7 Install oil seal clip ...

Page 313: ...fect on front fork performance When disassembling and assembling the front fork leg do not allow any for eign material to enter the front fork Rod puller 90890 01437 Adapter 90890 01436 Quantity each front fork leg 460 cm3 16 2 Imp oz 15 6 US oz Recommended oil Yamaha fork and shock oil 01 or equivalent 12 After filling the front fork leg slowly stroke the damper rod 1 up and down at least ten tim...

Page 314: ...ait ten minutes until the oil has settled and the air bubbles have dispersed NOTE Be sure to bleed the front fork leg of any residual air 15 Measure front fork leg oil level a Out of specification Correct Front fork leg oil level from the top of the outer tube with the outer tube fully down and without the spring 170 mm 6 69 in 16 Install fork spring 1 spacer 2 spring seat 3 nut 4 damper adjusting...

Page 315: ...he rod puller and adapter h Install the damper adjusting rod washer straight key and cap bolt and then finger tighten the cap bolt NOTE Make sure that the spring preload adjusting bolt at the top of cap bolt is fully but lightly tightened Insert the cap bolt fully into the damper rod i Hold the cap bolt and tighten the nut j Remove the rod holder and fork spring compressor WARNING WARNING The fork...

Page 316: ... bolt 2 Tighten lower bracket pinch bolt 1 2 3 NOTE Tighten the lower bracket pinch bolts 1 2 and 3 in the given order and in two stages Finally tighten the pinch bolt 1 once more handlebar pinch bolt cap bolt upper bracket pinch bolt WARNING WARNING Make sure that the brake hoses are routed properly 3 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE FRONT FORK LEGS...

Page 317: ... 13 12 17 16 16 18 17 19 20 15 14 9 2 5 6 3 4 T R 13 Nm 1 3 m kg 9 4 ft Ib 15 Order Job Part Q ty Remarks Removing the handlebars Remove the parts in the order listed 1 Clutch switch coupler 1 Disconnect 2 Left handlebar switch 1 3 Clutch master cylinder holder 1 4 Clutch master cylinder 1 5 Left grip end 1 6 Handlebar grip 1 7 Right grip end 1 8 Throttle cable housing 1 9 Throttle cable 2 10 Thro...

Page 318: ...5 14 9 2 5 6 3 4 T R 13 Nm 1 3 m kg 9 4 ft Ib 15 Order Job Part Q ty Remarks 11 Front brake switch connector 2 Disconnect 12 Right handlebar switch 1 13 Brake master cylinder holder 1 14 Brake master cylinder 1 15 Handlebar pinch bolt 4 16 Upper bracket bolt 2 17 Upper bracket pinch bolt 2 18 Steering stem nut 1 19 Upper bracket 1 20 Left handlebar 1 21 Right handlebar 1 For installation reverse t...

Page 319: ... cracks damage Replace WARNING WARNING Do not attempt to straighten bent han dlebars as this may dangerously weaken them EB704704 INSTALLING THE HANDLEBARS 1 Install brake master cylinder holder 1 ACHTUNG CAUTION Install the brake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt NOTE Align the mating surfaces of the brake master cylinder holder wit...

Page 320: ...ole b in the right handlebar a a b b 1 1 2 2 4 Install clutch master cylinder holder 1 ACHTUNG CAUTION Install the clutch master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt NOTE Align the slit in the clutch master cylin der holder with the punch mark a in the left handlebar UP UP UP 1 1 a a 5 Install left handlebar switch 1 NOTE Align the projection ...

Page 321: ...f the left handlebar c Wipe off any excess rubber adhesive with a clean rag WARNING WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried 7 Adjust throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3 Throttle cable free play at the flange of the throttle grip 3 5 mm 0 12 0 20 in HANDLEBARS ...

Page 322: ...20 LS LS 19 Order Job Part Q ty Remarks Removing the lower bracket Remove the parts in the order listed Front wheel Refer to FRONT WHEEL AND BRAKE DISCS Front fork legs Refer to FRONT FORK 1 Main switch coupler 2 Disconnect 2 Upper bracket bolt 2 3 Left handlebar assembly 1 4 Right handlebar assembly 1 5 Steering stem nut 1 6 Upper bracket 1 7 Brake hose holder bolt 2 8 Lock washer 1 9 Upper ring ...

Page 323: ... 4 2 2 5 6 1 8 9 11 13 14 15 18 10 3 16 14 17 12 7 20 LS LS 19 Order Job Part Q ty Remarks 11 Lower ring nut 1 12 Lower bracket 1 13 Bearing cover 1 14 Bearing inner race 2 15 Upper bearing 1 16 Lower bearing 1 17 Dust seal 1 18 Bearing outer race 2 19 Upper bearing housing 1 20 Lower bearing housing 1 For installation reverse the removal procedure STEERING HEAD ...

Page 324: ...he special tool 2 WARNING WARNING Securely support the lower bracket so that there is no danger of it falling Ring nut wrench 90890 01403 EB705401 CHECKING THE STEERING HEAD 1 Wash bearing balls bearing races Recommended cleaning solvent Kerosine 2 Check bearing balls 1 bearing races 2 Damage pitting Replace 3 Check upper bracket lower bracket along with the steering stem Bends cracks damage Repla...

Page 325: ...ithium soap base grease 3 Install upper bracket steering stem nut NOTE Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK NOTE Temporarily tighten the upper and lower bracket pinch bolts and handlebar pinch bolts 5 Tighten steering stem nut lower bracket pinch bolt upper bracket pinch bolt upper bracket bolt handlebar pinch bolt T R 115 Nm 11 5 m kg 85 ft lb T ...

Page 326: ...elf locking nut bolt 1 1 3 Self locking nut bolt 2 2 4 Self locking nut bolt 1 1 5 Rear shock absorber assembly 1 6 Self locking nut bolt 1 1 7 Connecting arm 2 8 Spacer oil seal bearing 2 4 2 9 Sidestand 1 10 Self locking nut bolt spacer 1 1 1 11 Relay arm 1 12 Spacer oil seal bearing 3 6 3 For installation reverse the removal procedure REAR SHOCK ABSORBER ASSEMBLY ...

Page 327: ...t the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pressure Do not deform or damage the rear shock absorber or gas cylinder in any way If the rear shock absorber gas cylinder or both are damaged damp ing performance will suffer EB706111 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER Gas pressure mus...

Page 328: ...not drop down 2 2 2 2 1 1 3 Remove rear shock absorber assembly upper bolt 1 rear shock absorber assembly NOTE Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm 1 1 EB706401 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1 Check rear shock absorber rod Bends damage Replace the rear shock absorber assembly rear shock absorber Gas leaks oil lea...

Page 329: ...onnecting arms rear shock absorber assembly NOTE When installing the rear shock absorber assembly lift up the swingarm 3 Tighten relay arm to frame nut relay arm to connecting arm nut connecting arm to swingarm nut rear shock absorber assembly upper nut rear shock absorber assembly lower nut Recommended lubricant Molybdenum disulfide grease T R 40 Nm 4 0 m kg 29 ft lb T R 40 Nm 4 0 m kg 29 ft lb T...

Page 330: ...ter 4 Rear wheel Refer to REAR WHEEL BRAKE DISC AND REAR WHEEL SPROCKET Rear shock absorber assembly Refer to REAR SHOCK ABSORBER ASSEMBLY 1 Spacer 1 2 Adjusting bolt locknut 2 2 3 Left drive chain puller 1 4 Right drive chain puller 1 5 Drive chain guard 1 1 6 Drive chain guard 3 1 7 Brake hose holder 3 8 Pivot shaft nut washer 1 1 9 Right pivot shaft boss 1 SWINGARM AND DRIVE CHAIN ...

Page 331: ...haft 1 11 Left pivot shaft boss 1 12 Swingarm 1 13 Spacer 2 14 Drive chain 1 15 Drive chain guard 2 1 16 Drive chain guide 1 17 Dust cover 2 18 Bearing 2 19 Spacer 1 20 Bearing 2 For installation reverse the removal procedure SWINGARM AND DRIVE CHAIN ...

Page 332: ...d 2 Measure swingarm side play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play Å by moving the swingarm from side to side c If the swingarm side play is out of specification check the spacers bear ings washers and dust covers d Check the swingarm vertical move ment ı by moving the swingarm up and down If swingarm vertical movement ...

Page 333: ...CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace NOTE If the swingarm must be replaced the drive chain must be cut with a drive chain cutter 2 Check pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING WARNING Do not attempt to straighten a bent pivot shaft 3 Wash pivot shaft dust covers spacer bearings Recommended cleaning solvent Kerosine SWINGARM AND DRIVE ...

Page 334: ...ten link section push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and A as shown Perform this measurement at two or three different places Max ten link drive chain sec tion 150 1 mm 5 91 in 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 a...

Page 335: ... O rings A coarse brush can also damage the O rings Therefore use only kero sine to clean the drive chain 4 Check O rings 1 Damage Replace the drive chain drive chain rollers 2 Damage wear Replace the drive chain drive chain side plates 3 Cracks damage wear Replace the drive chain 5 Lubricate drive chain Recommended lubricant Engine oil or chain lubricant suitable for O ring chains 6 Check drive s...

Page 336: ...chain pullers onto the swingarm so that the sides stamped IN face toward the inside i e the rear wheel 4 Install rear shock absorber assembly rear wheel Refer to REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL 5 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 Recommended lubricant Molybdenum disulfide grease Drive chain slack 40 50 mm 1 57 1 97 in T R 125 Nm 12 5 m kg 90...

Page 337: ...e air pressure sensor 9 Atmospheric pressure sensor 0 Turn signal relay A Relay unit B ECU C CDI unit D Fuse box E Fall detection switch F Starter relay G Main fuse H Main relay I Battery J Rectifier regulator K Rear brake light switch L Neutral switch M Speed sensor N Sidestand switch O Stator coil assembly P Oil level switch Q Pickup coil R Radiator fan S Horn T Coolant temperature sender U Ther...

Page 338: ... 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 illus tration NOTE indicates a continuity of electric ity between switch terminals i e a closed circuit at the re...

Page 339: ... switch 1 Main switch 2 Light switch 3 Pass switch 4 Dimmer switch 5 Turn signal switch 6 Horn switch 7 Clutch switch 8 Engine stop switch 9 Start switch 0 Front brake light switch A Oil level switch B Rear brake light switch C Fuse D Neutral switch E Sidestand switch 1 L Y L B L L R R Br L OFF ON P L R L Br L R L Y L B 3 4 5 Br W R Y P L B Dg Y G Ch B Y L Y PASS R Y Y 6 7 Y G B P BLUE BLACK BLACK...

Page 340: ...re shown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be detached before removing the bulb The majority of these bulbs can be removed from their respective socket by turning them counterclockwise Bulb C is used for turn signal and tail brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise B...

Page 341: ...e of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continuity with the pocket tester No continuity Replace NOTE Before checking for continuity set the pocket tester to 0 and to the Ω 1 range a Connect the tester positive probe to ter minal 1 and the tester negat...

Page 342: ...ings indicate no continu ity 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 battery terminals to the respective cou pler terminals as shown WARNING WARNING A wire that is used as a jumper lead must have at least the same ca...

Page 343: ... B B B B B R G B1 B Y B R W R B R G R B L R R L Br G W R L L Y W B B L Gy Gy B R L L R L W B L L B Br W Br Y L P W P B2 B2 R PB BLACK B3 B3 W2 Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G W G Y G L G Br W W Y B L L Y Lg R G Y W Y L R Y B L Y B Sb Sb R G G W W Y Ch L W Br P P G Y Ch Dg B Dg B B B B B...

Page 344: ... replace Check the spark plug Re gap or replace Measure the ignition spark gap Ignition system is OK Measure the ignition coil resis tance Replace Measure the pickup coil resis tance Replace Check the main switch Replace Check the engine stop switch Replace the right handlebar switch Check the neutral switch Replace Check the diode Replace Check the sidestand switch Replace Check the relay unit Re...

Page 345: ...E IGNITION SPARK GAP The following procedure applies to all of the spark plugs Disconnect the ignition coil from the spark plug Connect the ignition checker 1 as shown 2 Ignition coil Set the main switch to ON Measure the ignition spark gap a Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs Is there a spark and is the spark gap within specifi...

Page 346: ...coupler from the wire harness Connect the pocket tester Ω 100 to the pickup coil coupler Measure the pickup coil resistance Is the pickup coil OK Yes Good No Replace Tester positive probe orange cylinder 1 1 gray cylinder 2 gray green cylinder 3 orange green cylinder 4 Tester negative probe black 2 Primary coil resistance 0 16 0 21 Ω at 20 C 68 F Tester positive probe orange cylinder 1 1 gray cyli...

Page 347: ...ster negative probe blue white 1 No conti nuity L W L Y 1 2 CHECKING THE RELAY UNIT Remove the relay unit from the coupler Connect the pocket tester Ω 1 to the relay unit terminals as shown Check the starting circuit cutoff relay for continuity NOTE When you switch the tester s positive and negative probes the readings in the above chart will be reversed Are the tester readings correct Yes Good No...

Page 348: ... R B R R G 4 B L Y B B Br L Br Br L B B B R G B1 B Y B R W R B R G R B L R R L Br G W R L L Y W B B L Gy Gy B R L L R L W B L L B Br W Br Y L P W P B2 B2 R PB BLACK B3 B3 W2 Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G W G Y G L G Br W W Y B L L Y Lg R G Y W Y L R Y B L Y B Sb Sb R G G W W Y Ch L W ...

Page 349: ...replace Check the starter motor Repair or replace Check the relay unit Replace Check the starter relay Replace Check the diodes Replace Check the main switch Replace Check the engine stop switch Replace the right handlebar switch Check the neutral switch Replace Check the sidestand switch Replace Check the clutch switch Replace Check the start switch Replace the right handlebar switch Check the en...

Page 350: ...elay unit terminals as shown Check the relay unit for continuity as fol lows NOTE When you switch the tester s positive and negative probes the readings in the above chart will be reversed Are the tester readings correct Yes Good No Replace Battery positive terminal red black 1 Battery negative terminal black yellow 2 Tester positive probe blue white 3 Tester negative probe black 4 Tester positive...

Page 351: ... Remove the diodes from the couplers Connect the pocket tester Ω 1 to the diode as show Check the diodes for continuity NOTE When you switch the tester s positive and negative probes the readings in the above chart will be reversed Are the tester readings correct Yes Good No Replace the defective diode s Tester positive probe brown 1 Tester negative probe blue white 2 Continu ity Tester positive p...

Page 352: ... R W Lg Y L W B W R L R B L W W G Lg L R L B Sb B Y B B R L Y R B R R G 4 B L Y B B Br L Br Br L B B B R G B1 B Y B R W R B R G R B L R R L Br G W R L L Y W B B L Gy Gy B R L L R L W B L L B Br W Br Y L P W P B2 B2 R PB BLACK B3 B3 W2 Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G W G Y G L G Br W W Y...

Page 353: ...g special tool s The battery is not being charged Check the main fuse for continu ity Replace Check the condition of the bat tery Recharge or replace Measure the charging voltage The charging circuit is OK Measure the stator coil assembly resistance Replace Check the entire charging sys tem s wiring Repair or replace Replace the rectifier regulator Engine tachometer 90890 06760 Pocket tester 90890...

Page 354: ...arging voltage within specifica tion Yes OK No Measure the stator coil assembly resistance Tester positive probe battery positive terminal Tester negative probe battery negative terminal Charging voltage 12 V at 1 100 r min MEASURING THE STATOR COIL ASSEMBLY RESISTANCES Disconnect the generator coupler from the wire harness Connect the pocket tester Ω 1 to the stator coil assembly coupler as shown...

Page 355: ... L Y R B R R G 4 B L Y B B Br L Br Br L B B B B B R G B1 B Y B R W R B R G R B L R R L Br G W R L L Y W B B L Gy Gy B R L L R L W B L L B Br W Br Y L P W P B2 B2 R PB BLACK B3 B3 W2 Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G W G Y G L G Br W W Y B L L Y Lg R G Y W Y L R Y B L Y B Sb Sb R G G W W Y...

Page 356: ...ght or meter light Check the main and headlight fuses for continuity Replace Check the condition of the bat tery Recharge or replace Check the bulbs and bulb sockets Replace Check the LED s of the indicator light Replace the meter assembly Check the main switch Replace Check the lights switch Replace the left handlebar switch Check the dimmer switch Replace the left handlebar switch Check the pass...

Page 357: ... Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G W G Y G L G Br W W Y B L L Y Lg R G Y W Y Y B L Y B Sb Sb R G G W W Y Ch L W Br P P G Y Ch Dg B Dg B B B B B B Dg Ch Br L R Y L Y B Y Br L Br L Br L Br R Y R W B2 Gy Gy B B3 R B G B L B O B Gy R Lg R Y R G R Br R R W R Y Lg Y W1 W2 BLACK BLACK BLACK BLAC...

Page 358: ...ce the meter assembly Check the relay unit Check the continuity of the thermistor in the fuel pump OK OK OK OK OK OK OK OK OK OK No good No good No good No good Replace Replace Replace Replace Replace Replace Replace Recharge or replace Recharge or replace No good No good No good No good No good No good No good No good No good No good OK OK BAD OK Check the horn switch Check the horn Replace Repla...

Page 359: ...sed Are the tester readings correct Yes Good No Replace CHECKING THE OIL LEVEL SWITCH Drain the engine oil Remove the oil level switch Connect the pocket tester Ω 1 to the oil level switch connector as shown Check the oil level switch for continuity as follows Are the oil level switch readings correct Yes Good No Replace Tester positive probe sky blue 1 Tester negative probe blue red 2 Continu ity...

Page 360: ... L R B L W W G Lg L R L B Sb B Y B B R L Y R B R R G 4 B L Y B B Br L Br Br L B B B R G B1 B Y B R W R B R G R B L R R L Br G W R L L Y W B B L Gy Gy B R L L R L W B L L B Br W Br Y L P W P B2 B2 R PB BLACK B3 B3 W2 Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G W G Y G L G Br W W Y B L L Y Lg R G Y W...

Page 361: ...he radiator fan motor fails to turn The coolant temperature meter needle fails to move when the engine is warm Check the main and radiator fan motor fuses for continuity Replace Check the condition of the bat tery Recharge or replace Check the main switch Replace Check the radiator fan motor Replace Check the thermo switch Replace Check the entire cooling system s wiring Repair or replace Pocket t...

Page 362: ...indicated in the table WARNING WARNING Handle the thermo switch with special care Never subject the thermo switch to strong shocks If the thermo switch is dropped replace it ÅThe thermo switch circuit is open and the radiator fan is off ıThe thermo switch circuit is closed and the radiator fan is on Does the thermo switch operate properly as described above Yes OK No Replace Test step Coolant temp...

Page 363: ...8 27 ELEC ...

Page 364: ... W P L R Y Br W R W Lg Y L W B W R L R B L W W G Lg L R L B Sb B Y B B R L Y R B R R G 4 B L Y B B Br L Br Br L B B B R G B1 B Y B R W R B R G R B L R R L Br G W R L L Y W B B L Gy Gy B R L L R L W B L L B Br W Br Y L P W P B2 B2 R PB BLACK B3 B3 W2 Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G W G Y...

Page 365: ...ll detection switch YSpeed sensor yFuel pump zMain relay Engine stop switch åElectronic fuel injection system fuse ECU fuse TROUBLESHOOTING NOTE Before troubleshooting remove the following part s 1 bottom cowling 2 front cowling Troubleshoot with the following special tool s The condition code is displayed by the tachometer Check the condition code list to identify the faulty part Refer to ELECTRI...

Page 366: ...t to light up and the engine trouble symbol to blink When the engine is started the condition code is no longer displayed and the engine speed appears Normally when the main switch is set to ON the warning light comes on for 1 4 seconds and then goes off The warning light also comes on while the start switch is pushed When the engine is not running the warning light flashes once every 0 16 second ...

Page 367: ...s 2 First condition code 13 intake air pressure sensor 3 Second condition code 42 speed sensor 4 1st digit of condition code for 1 0 second 5 10 000 r min for 0 5 second 6 2nd digit of condition code for 1 0 second 5 10 Time seconds 5 0 10 Revolution 103 r min 4 6 5 1 2 4 6 5 1 1 3 Repeat Main switch is turnd on ...

Page 368: ...9 9 in Hg The motorcycle can be ridden 14 Intake air pressure sensor hose and negative pressure hose Improper connec tion Bending 15 Throttle position sensor Disconnected Short circuit The ECU stays set to a wide throt tle opening The motorcycle can be ridden 16 Throttle position sensor Locked 21 Coolant tempera ture sensor Disconnected Short circuit The ECU stays set to a coolant temperature of 8...

Page 369: ...n be selected while either of the diagnosis mode operation methods is being performed CO diagnosis switch box method Remove the bottom cowling and the front cowling Refer to COWLINGS in chapter 3 Remove the protection cap 1 from the EFI test coupler 2 Connect the CO diagnosis switch box 3 to the EFI test coupler 2 Turn the main switch to ON Turn the engine stop switch to Within 4 seconds press the...

Page 370: ...nosis code 31 is selected pressing the UP switch once selects diagnosis code 00 Release the MODE switch to start the test for the selected diagnosis code NOTE To select another diagnosis code hold down the MODE switch and press either the UP switch or the DOWN switch Example First select diagnosis code 29 in either of the following ways Hold down the MODE switch press the UP switch 29 times and th...

Page 371: ...s mode Select a diagnosis code by pressing the start switch Refer to the diagnosis code list First press the start switch once to select diagnosis code 01 Afterwards each press of the start switch increases the diagnosis code number by one If diagnosis code 31 is selected pressing the start switch once selects diagnosis code 00 Turn the engine stop switch to to start the test for the selected diag...

Page 372: ...displays the throttle position sensor signal 1 300 r min 0 68 V 5 900 r min 2 93 V 05 Throttle position sensor The tachometer displays the mini mum throttle position sensor signal 5 500 r min 0 68 V 10 000 r min 1 25 V 06 Intake air temper ature The tachometer displays the intake air temperature signal 4 800 r min 20 C 5 700 r min 30 C 07 Coolant tempera ture The tachometer displays the coolant te...

Page 373: ...er 1 CO diagnosis switch box method Within one second after the MODE switch is released the ignition coil for the selected cylin der is operated once every sec ond for the next five seconds During this time the warning light lights up for 0 5 second once every second Test coupler adapter method Within one second after the engine stop switch is turned to the ignition coil for the selected cylinder ...

Page 374: ...ons The condition code of any fixed mal function is recorded in the ROM and displayed by the tachometer Refer to the condition code list in USER MODE for details on the condition codes Condition codes 11 44 30 ROM Clearing the condition code record Selecting this diagnosis code clears the condition code record of mal functions stored in the ROM If an error has occurred in a sensor signal it was re...

Page 375: ...olts from the exhaust pipe assembly Install the exhaust attachment 1 and CO tester 2 to the exhaust pipe assembly Attach the engine tachometer to the igni tion coil for cylinder 1 Refer to SYNCHRONIZING THE THROT TLE BODIES in chapter 3 Remove the protection cap 3 from the EFI test coupler 4 Connect the CO diagnosis switch box 5 to the EFI test coupler 4 Start the engine and let it warm up for sev...

Page 376: ...down the MODE switch while pressing either the UP switch or the DOWN switch Release the MODE switch to start the CO emission adjustment for the selected cyl inder The warning light flashes once every 0 5 second and the tachometer dis plays the engine speed While watching the CO tester press the UP switch or DOWN switch to adjust the CO emission NOTE If the UP switch is pressed when the CO emission...

Page 377: ... ELECTRICAL CONTROL SYSTEM Adjust all four cylinders to specification To select a different cylinder hold down the MODE switch while pressing either the UP switch or the DOWN switch Standard CO concentration 3 5 ...

Page 378: ...Rear turn signal light left m Front turn signal light right n Front turn signal light left o Tail brake light p Rear brake light switch q Left handlebar switch r Clutch switch s Lights switch t Pass switch u Dimmer switch v Turn signal switch w Horn switch x Turn signal relay y Fuel pump z Main relay Right handlebar switch Front brake light switch Engine stop switch Start switch å Electronic fuel ...

Page 379: ...R Y Br W R W Lg Y L W B W R L R B L W W G Lg L R L B Sb B Y B B R L Y R B R R G 4 B L Y B B Br L Br Br L B B B B B R G B1 B Y B R W R B R G R B L R R L Br G W R L L Y W B B L Gy Gy B R L L R L W Br Br G B L L B Br W Br Y L P W P B2 B2 R PB BLACK B3 B3 W2 Y G L G Br G Br R Gy R Br Br O B G Y L B G B G R Y R W G Y B R B O B R L L B Gy O O Lg R B B B B B Gy Gy G Gy G Gy G O G O G O G Gy Gy Gy G Br G ...

Page 380: ......

Page 381: ...PRINTED IN JAPAN 98 12 0 5 1 CR PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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