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9-2

INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND-

HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING

TRBL

SHTG

ELECTRICAL SYSTEMS
Battery

Faulty battery

Discharged battery

Spark plugs

Incorrect spark plug gap

Incorrect spark plug heat range

Fouled spark plug

Worn or damaged electrode

Worn or damaged insulator

Faulty spark plug cap

Ignition coils

Broken or shorted primary or secondary coils

Faulty spark plug lead

Damaged ignition coil

Ignition system

Faulty ignition unit

Faulty pickup coil

FUEL SYSTEM
Carburetors

Faulty diaphragm

Incorrect fuel level

Loose or clogged main jet

Fuel pump

Faulty fuel pump

JUMPS OUT OF GEAR
Shift shaft

Incorrect shift pedal position

Incorrectly returned stopper lever

Shift forks

Worn shift fork

Shift drum

Incorrect axial play

Worn shift drum groove

Transmission

Worn gear dog

EB901000

INCORRECT ENGINE IDLING SPEED

ENGINE
Cylinders and cylinder head

Incorrect valve clearance

Damaged valve train components

Air filter

Clogged air filter element

FUEL SYSTEM
Carburetors

Faulty starter plunger

Loose or clogged pilot jet

Loose or clogged pilot air jet

Damaged or loose carburetor joint

Incorrectly synchronized carburetors

Incorrectly adjusted engine idling speed
(throttle stop screw)

Incorrect throttle cable free play

Flooded carburetor

EB902000

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to “STARTING PROBLEMS”.
ENGINE
Air filter

Clogged air filter element

Air intake system

Clogged air ducts

EB903000

FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft

Incorrectly adjusted shift rod

Bent shift shaft

Shift drum and shift forks

Foreign object in a shift drum groove

Seized shift fork

Bent shift fork guide bar

Transmission

Seized transmission gear

Foreign object between transmission gears

Incorrectly assembled transmission

Содержание YZF-R6

Страница 1: ......

Страница 2: ......

Страница 3: ...ZF R6 SERVICE MANUAL 1998 by Yamaha Motor Co Ltd First edition August 1998 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly p...

Страница 4: ...prove all of its models Modifications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual wher...

Страница 5: ...e top of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s ap pears 3 Sub section titles appear in smaller print than the section title 4 To help identify par...

Страница 6: ...al system 9 Troubleshooting Symbols 10 to 17 indicate the following 10 Serviceable with engine mounted 11 Filling fluid 12 Lubricant 13 Special tool 14 Tightening torque 15 Wear limit clearance 16 Eng...

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

Страница 8: ......

Страница 9: ...GEN INFO 1...

Страница 10: ...RMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 USING A DYNAMOMETER 1 3 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1...

Страница 11: ...GEN INFO...

Страница 12: ...CYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe EB100020 MODEL CODE The model code label 1 is a...

Страница 13: ...all of the parts and place them in trays in the order of disas sembly This will speed up assembly and al low for the correct installation of all parts 5 Keep all parts away from any source of fire EB1...

Страница 14: ...02040 BEARINGS AND OIL SEALS 1 Install bearings and oil seals so that the manufacturer s marks or numbers are vis ible When installing oil seals lubricate the oil seal lips with a light coat of lithiu...

Страница 15: ...s Connect and disconnect sev eral times 3 Check all connections Loose connection Connect properly If the pin 1 on the terminal is flattened bend it up 4 Connect lead coupler connector Make sure that a...

Страница 16: ...r intake port located under the headlight The system also delivers air pressure from the air filter case to the carburetor side The air pressure is operated to the fuel level in the carburetor to supp...

Страница 17: ...rough the notch depend ing on its area at b section This flow rate is larger than the case of 2 4 When the valve is set as high lift In the same way as the regular thermostat control the coolant flows...

Страница 18: ...ince the plug top ignition coil is equipped in which the plug cap ignition coil are inte grated High tension cord was cut an end to use and ignition energy loss has become lower 3 Spark plug The 2 pol...

Страница 19: ...hold the generator rotor when removing or installing the generator ro tor bolt or pickup coil rotor bolt 90890 01304 Piston pin puller This tool is used to remove the piston pins 90890 01312 Fuel lev...

Страница 20: ...al driver 90890 01376 Fork seal driver attachment 90890 01374 Fork seal driver weight Fork seal driver attachment This tool is used to install the front fork s oil seal and dust seal 90890 03008 Micro...

Страница 21: ...etor angle driver This tool is used to turn the pilot screw when adjusting the engine idling speed Valve spring compressor 90890 04019 Attachment 90890 04108 Valve spring compressor Attachment These t...

Страница 22: ...is used to install the valve guides 90890 04113 Valve guide reamer This tool is used to rebore the new valve guides 90890 06754 Ignition checker This tool is used to check the ignition system compone...

Страница 23: ...GEN INFO...

Страница 24: ...SPEC 2...

Страница 25: ...ION TABLE 2 18 TIGHTENING TORQUES 2 18 GENERAL TIGHTENING TORQUES 2 18 ENGINE TIGHTENING TORQUES 2 19 CHASSIS TIGHTENING TORQUES 2 22 LUBRICATION POINTS AND LUBRICANT TYPES 2 23 ENGINE LUBRICATION POI...

Страница 26: ...SPEC...

Страница 27: ...eight Seat height Wheelbase Minimum ground clearance Minimum turning radius 2025 mm except for NOR SWE FIN AUS NZL 2075 mm for NOR SWE FIN AUS NZL 690 mm 1105 mm 820 mm 1380 mm 135 mm 3400 mm Weight W...

Страница 28: ...linder 65 5 44 5 mm 12 4 1 1 250 1 350 r min 24 0 kPa 0 24 kg cm2 1550 kPa 15 5 kgf cm2 at 400 r min Fuel Recommended fuel Fuel tank capacity Total including reserve Reserve only Regular gasoline 17 L...

Страница 29: ...03 0 09 mm 0 03 0 08 mm 0 15 mm 0 15 mm Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction...

Страница 30: ...ntake camshaft lobe dimensions Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions Measurement A Measurement B Measurement C Max camshaft runout Chain drive right 23 000 23 021...

Страница 31: ...alve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve stem to valve guide clearance Intake Exhaus...

Страница 32: ...g direction top view Intake Exhaust 37 0 mm 38 4 mm 41 7 mm 30 0 mm 32 5 mm 36 1 mm 69 79 N 7 0 8 0 kgf 114 132 N 11 6 13 4 kgf 160 184 N 16 3 18 7 kgf SSS SSS Clockwise Clockwise 35 mm 36 5 mm 39 5 m...

Страница 33: ...Ring type Dimensions B T End gap installed Ring side clearance 2nd ring Ring type Dimensions B T End gap installed Ring side clearance Oil ring Dimensions B T End gap installed 0 025 0 050 mm 65 460 6...

Страница 34: ...0 058 mm 0 White 1 Blue 2 Black 3 Brown 4 Green 0 03 mm Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play at the end of the clutch lever Fricti...

Страница 35: ...02 mm 0 02 mm Shifting mechanism Shift mechanism type Max shift fork guide bar bending installed shift rod length Cam drum 242 mm 0 05 mm Air filter type Dry element Fuel pump Pump type Model manufac...

Страница 36: ...2 10 ENGINE SPECIFICATIONS SPEC Item Standard Limit Starter jet 1 Starter jet 2 Butterfly valve size Fuel level below the line on the float chamber 50 0 6 110 17 5 18 5 mm...

Страница 37: ...SSS SSS SSS 1 mm 0 5 mm Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max radial wheel runout Max lateral wheel runout Cast wheel 17 MT5 50 Aluminum 120 mm SSS SSS SSS SSS SSS SSS...

Страница 38: ...on Brake pad lining thickness Master cylinder inside diameter Caliper cylinder inside diameter Dual disc brake Right hand operation DOT 4 298 5 mm 5 5 mm 14 mm 30 2 mm and 27 mm 4 5 mm 0 1 mm 0 5 mm R...

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

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

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

Страница 42: ...e Model manufacturer quantity Max amperage Plain YF 12 NIKKO 1 3 A Flasher relay Relay type Model manufacturer Self cancelling device built in Turn signal blinking frequency Wattage Full transistor FE...

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

Страница 44: ...eral tightening torques 10 mm 12 mm 14 mm 18 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm Nm mSkg 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 0 EB201000 CONVERSION TABLE All specification data in thi...

Страница 45: ...haft sprocket Oil pump Oil cooler Engine oil drain bolt Oil pump assembly driven sprocket cover Oil pipe Oil filter bolt Oil filter cartridge Exhaust pipes Muffler clamp Exhaust pipe emission check bo...

Страница 46: ...hift rod locknut Oil level switch Shift arm Stator coil Ignitor unit Neutral switch Pickup coil Thermo unit Thermo switch Bolt Bolt Bolt Bolt Nut Bolt Nut Screw Bolt Bolt Nut Bolt Bolt Bolt Bolt Screw...

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

Страница 48: ...ket Rear master cylinder Rear brake hose union bolts Sidestand Front wheel axle Rear wheel axle nut Front brake caliper and front fork Rear brake caliper and bracket Brake disc and wheel Rear wheel sp...

Страница 49: ...er pump impeller shaft Oil pump rotors inner and outer Oil pump housing Oil strainer Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears wheel and pin...

Страница 50: ...ive hub mating surface Rear brake pedal Sidestand pivoting point and metal to metal moving parts Throttle grip inner surface Brake lever pivoting point and metal to metal moving parts Clutch lever piv...

Страница 51: ...2 25 OIL FLOW DIAGRAMS SPEC 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil pipe 5 Oil strainer 6 Oil pump OIL FLOW DIAGRAMS...

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

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

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

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

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

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

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

Страница 59: ...oute the headlight lead through the plastic guide C Route the right handlebar switch lead in front of the front fork inner tube D Route the throttle cables between the brake hose and right handlebar s...

Страница 60: ...e with a band Locate the end of band to forward H Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie Cut the end of locking tie And then rout...

Страница 61: ...rame D Route the coolant hose under the heat protector plate CABLE ROUTING SPEC E Route the clutch cable through the guide on the ra diator F Fasten the clutch cable to the coolant hose protec tor wit...

Страница 62: ...h the wireharness with the throttle cable pully Route the wireharness under the radiator hose D Route the wireharness through the slit of rear fender E Route the rear turn signal light leads left and...

Страница 63: ...position sensor connector 11 Handlebar switch left connec tors 12 Neutral switch lead 13 Fuel pump connector 14 Rear brake switch lead 15 Starter motor lead CABLE ROUTING SPEC 16 Battery negative cabl...

Страница 64: ...and right main switch lead throttle position sensor lead rear brake switch lead and pickup coil lead with them CABLE ROUTING SPEC H Route the starter motor lead under the wirehar ness I Fasten the sta...

Страница 65: ...ter motor lead with a steel band on the engine S Route the fuel tank breather hose and fuel tank drain hose over the wireharness T Route the starter cable with slot of the heat protec tion plate CABLE...

Страница 66: ...SPEC...

Страница 67: ...CHK ADJ 3...

Страница 68: ...KING THE IGNITION TIMING 3 23 MEASURING THE COMPRESSION PRESSURE 3 24 CHECKING THE ENGINE OIL LEVEL 3 26 CHANGING THE ENGINE OIL 3 27 MEASURING THE ENGINE OIL PRESSURE 3 29 ADJUSTING THE CLUTCH CABLE...

Страница 69: ...7 CHECKING THE FRONT FORK 3 50 ADJUSTING THE FRONT FORK LEGS 3 51 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3 53 CHECKING THE TIRES 3 55 CHECKING THE WHEELS 3 57 CHECKING AND LUBRICATING THE CABLES 3...

Страница 70: ...0 km or 42 months which ever comes first 5 Air filter element Clean or replace if necessary 6 Clutch Check operation Adjust or replace cable 7 Front brake Check operation fluid level and vehicle for f...

Страница 71: ...0 km or 24 months whichever comes first 21 Carburetors Check engine idling speed synchronization and starter operation Adjust if necessary 22 Engine oil Check oil level and vehicle for oil leakage Cor...

Страница 72: ...Removing the rider and passenger seats Passenger seat Rider seat 1 1 Remove the parts in the order listed For installation reverse the removal procedure 7Nm 0 7 m kg RIDER AND PASSENGER SEATS CHK ADJ...

Страница 73: ...tank overflow hose Fuel tank breather hose Fuel tank 1 2 1 1 1 1 1 Remove the parts in the order listed Refer to SEATS Disconnect Before disconnecting the fuel hose set the fuel cock OFF For installa...

Страница 74: ...ar cowling Bottom cowling left Bottom cowling right Front cowling inner panel left Front cowling inner panel right Side cowling inner panel left Side cowling inner panel right 1 1 1 1 1 1 1 Remove the...

Страница 75: ...t Q ty Remarks 8 9 10 11 12 Left side cowling Right side cowling Windshield Rear view mirror Front cowling 1 1 1 2 1 For installation reverse the removal procedure 5 Nm 0 5 m kg 5 Nm 0 5 m kg COWLINGS...

Страница 76: ..._ with a screwdriver then pull the fastener out INSTALLATION 1 Install Sside cowlings Srear cowling To install the quick fastener push its pin so that it protrudes from the fastener head then insert t...

Страница 77: ...nel right Crankcase breather hose Air vent hose Hoses Drain cup Air filter case balance hose Clamp screw Bolt Surge tank joint left Surge tank joint right Air filter case Clamp Quick fastener 1 1 2 1...

Страница 78: ...3 9 AIR FILTER CASE AND IGNITION COILS CHK ADJ Order Job Part Q ty Remarks 13 14 15 Heat protector plate Ignition coil coupler Ignition coil 1 4 4 For installation reverse the removal procedure...

Страница 79: ...ts center in with a screwdriver then pull the fastener out INSTALLATION 1 Install heat protector plate To install the quick fastener push its pin so that it protrudes from the fastener head then inser...

Страница 80: ...d the piston must be at top dead center TDC on the compression stroke 1 Remove rider seat fuel tank Refer to SEATS and FUEL TANK air filter case heat protector plate Refer to AIR FILTER CASE AND IGNIT...

Страница 81: ...when the camshaft lobes are turned away from each other c Measure the valve clearance with a thick ness gauge 1 SIf the valve clearance is incorrect record the measured reading SMeasure the valve cle...

Страница 82: ...r the timing chain opening with a rag to prevent the valve pad from falling into the crankcase Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the c...

Страница 83: ...ed again and the above steps should be repeated if the measurement is still incorrect e Install the new valve pad 1 and the valve lift er 2 Lubricate the valve pad with molybdenum dis ulfide grease Lu...

Страница 84: ...0 225 230 235 240 0 88 0 92 195 200 205 210 215 220 225 230 235 240 0 93 0 97 200 205 210 215 220 225 230 235 240 0 98 1 02 205 210 215 220 225 230 235 240 1 03 1 07 210 215 220 225 230 235 240 1 08 1...

Страница 85: ...rocedure Note the following points 8 Install timing chain guide exhaust side timing chain tensioner pickup coil rotor cover cylinder head cover spark plugs ignition coils Refer to CAMSHAFTS in chapter...

Страница 86: ...03094 Vacuum gauge attachment 90890 03060 Engine tachometer 90793 80009 5 Start the engine and let it warm up for several minutes 6 Measure engine idling speed Out of specification Adjust Refer to ADJ...

Страница 87: ...e at engine idling speed 24 0 kPa 0 24 kg cm2 The difference in vacuum pressure between two carburetors should not exceed 1 33 kPa 10 mm Hg 8 Measure engine idling speed Out of specification Adjust 9...

Страница 88: ...COILS 5 Measure engine idling speed Out of specification Adjust Engine idling speed 1 250 1 350 r min 6 Adjust engine idling speed a Turn the pilot screw 1 in until it is lightly seated b Turn the pi...

Страница 89: ...31 ADJUSTING THE THROTTLE CABLE FREE PLAY Prior to adjusting the throttle cable free play the engine idling speed and carburetor synchro nization should be adjusted properly 1 Measure throttle cable f...

Страница 90: ...Throttle cable free play in increased Direction Throttle cable free play is decreased e Tighten the locknuts If the specified throttle cable free play cannot be obtained on the carburetor side of the...

Страница 91: ...l counterdockwise 5 to 6 turns would be adequate c Pull out the coil upward Never pry the coupler with a screw driver d Press the coil in the plug hole by hand as fa ras it will go e Turn the coil clo...

Страница 92: ...gauge Out of specification Regap Spark plug gap 0 6 0 7 mm 8 Install spark plug Before installing the spark plug clean the spark plug and gasket surface EB303050 CHECKING THE IGNITION TIMING Prior to...

Страница 93: ...he required firing range b on the pickup coil rotor Incorrect firing range Check the ignition system The ignition timing is not adjustable EB303060 MEASURING THE COMPRESSION PRES SURE The following pr...

Страница 94: ...6 Measure compression pressure Out of specification Refer to steps c and d Compression pressure at sea level Minimum 1300 kPa 13 0 kg cm2 13 0 bar Standard 1550 kPa 15 5 kg cm2 15 5 bar Maximum 1600 k...

Страница 95: ...oil applied into the cylinder Reading Diagnosis Higher than without oil Piston wear or damage Repair Same as without oil Piston ring s valve s cylinder head gasket or piston possibly defective Repair...

Страница 96: ...a grade of CD c or higher and do not use oils labeled ENERGY CONSERV ING II d or higher Do not allow foreign materials to enter the crankcase 4 Start the engine warm it up for several min utes and the...

Страница 97: ...the groove of the oil filter car tridge c Tighten the new oil filter cartridge to specifi cation with an oil filter wrench Oil filter cartridge 17 Nm 1 7 m kg 7 Check engine oil drain bolt washer Dam...

Страница 98: ...t up for several min utes and then turn it off When the engine is cold the engine oil will have a higher viscosity causing the engine oil pressure to increase Therefore be sure to measure the engine o...

Страница 99: ...oil gallery bolt EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Measure clutch cable free play a Out of specification Adjust Clutch cable free play at the end of the clutch lever 10 15 mm 2 Adjust cl...

Страница 100: ...ove the excess oil The air filter should be wet but not dripping 4 Check air filter element Damage Replace 5 Install air filter element air filter case cover Never operate the engine without the air f...

Страница 101: ...to CARBURETORS in chapter 6 3 Install carburetor assembly Refer to CARBURETORS in chapter 6 EB303181 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses 1...

Страница 102: ...ers front cowling fuel tank 2 Loosen clamps on the inside of the front cowling 3 Remove air intake system air ducts 1 4 Clean air intake system air ducts a Thoroughly flush out the air intake system a...

Страница 103: ...B303200 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex haust pipes and gaskets 1 Remove radiator assembly Refer to RADIATOR in chapter 5 2 Check exhaust pipe 1 muffler 2...

Страница 104: ...t If water is used instead of coolant check and correct the antifreeze concentration of the coolant Use only distilled water Soft water may be used if distilled water is not available 3 Start the engi...

Страница 105: ...ant reservoir 4 Install coolant reservoir bolts reservoir cover 5 Remove radiator cap 1 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot f...

Страница 106: ...hylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1 1 antifreeze water Quantity Total amount 2 15 L Coolant reservoir capacity 0 44 L Handling notes for coolan...

Страница 107: ...nt comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 11 Install radiator cap 12 Fill coolant reservoir with the recommended coolant to...

Страница 108: ...the arrow mark 2 on the brake lever hold er Position 1 Distance is the largest Position 5 Distance is the smallest After adjusting the brake lever position make sure that the pin on the brake lever ho...

Страница 109: ...le d c Tighten the locknut 1 to specification Locknut 16 Nm 1 6 m kg A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system Before the vehicle is operated the...

Страница 110: ...se the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemica...

Страница 111: ...Rear brake EB304050 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by movement of the brake pedal The rear brake light switch is properly adjusted when the brake light...

Страница 112: ...C BRAKE SYS TEM Bleed the hydraulic brake system whenev er the brake system was disassembled a brake hose was loosened disconnected or replaced the brake fluid level is very low brake operation is fau...

Страница 113: ...ss the brake pedal and hold it in position g Loosen the bleed screw Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to ful...

Страница 114: ...od length increases Direction Installed shift rod length decreases c Tighten both locknuts d Make sure that the installed shift rod length is within specification EB304092 ADJUSTING THE DRIVE CHAIN SL...

Страница 115: ...in slack a Loosen the wheel axle nut 1 b Loosen both locknuts 2 c Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is ob tained Direction Drive chain slack is redu...

Страница 116: ...refore use only kerosine to clean the drive chain Wipe the drive chain dry and thor oughly lubricate it with engine oil or chain lubri cant that is suitable for O ring chains Do not use any other lubr...

Страница 117: ...s from the upper bracket 6 Remove steering stem nut 1 washer 2 upper bracket 3 7 Adjust steering head a Remove the lock washer 1 the upper ring nut 2 and the washer 3 b Loosen the lower ring nut 4 and...

Страница 118: ...stall the washer 3 f Install the upper ring nut 2 g Finger tighten the upper ring nut 2 then align the slots of both ring nuts If necessary hold the lower ring nut and tighten the upper ring nut until...

Страница 119: ...e the steering head tension again as described above h Repeat the above procedure until the steer ing head tension is within specification i Grasp the bottom of the front fork legs and gently rock the...

Страница 120: ...and loss of stability Securely support the motorcycle so that there is no danger of it falling over Spring preload Grooves are provided to indicate the ad justment position Never go beyond the maximum...

Страница 121: ...softer Adjusting positions Minimum 12 clicks out Standard 6 clicks out Maximum 1 clicks out from the fully turned in position Compression damping Never go beyond the maximum or minimum adjustment posi...

Страница 122: ...or minimum adjustment positions 1 Adjust spring preload Adjust the spring preload with the special wrench and extension bar included in the own er s tool kit a Turn the adjusting ring 1 in direction a...

Страница 123: ...ion is softer Adjusting positions Minimum 25 clicks out Standard 9 clicks out Maximum 1 click out from the fully turned in position Compression damping Never go beyond the maximum or minimum adjustmen...

Страница 124: ...the anticipated riding speed Operation of an overloaded motorcycle could cause tire damage an accident or an injury NEVER OVERLOAD THE MOTORCYCLE Basic weight with oil and a full fuel tank 188 kg Max...

Страница 125: ...he wheel groove Patching a punctured tube is not recom mended If it is absolutely necessary to do so use great care and replace the tube as soon as possible with a good quality replacement A Tire B Wh...

Страница 126: ...the rim Failure to do so could lead to an accident with possible injury to the rider or damage to the motor cycle For tires with a direction of rotation mark 1 Install the tire with the mark pointing...

Страница 127: ...bricate Recommended lubricant Engine oil or a suitable cable lubricant Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit able lubing device EB304210 LUBR...

Страница 128: ...lectrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medical attenti...

Страница 129: ...inals 1 Remove Srider seat Refer to SEATS 2 Disconnect Sbattery leads from the battery terminals First disconnect the negative lead 2 then the positive lead 1 3 Remove Sbattery 4 Measure Sbattery char...

Страница 130: ...ed on the motorcycle disconnect the negative lead from the battery terminal STo reduce the chance of sparks do not plug in the battery charger until the battery charger leads are connected to the batt...

Страница 131: ...charg ing amperage after 5 min utes replace the battery If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the am per...

Страница 132: ...Charge the battery until the charging voltage reaches 15 V This type of battery charger cannot charge an MF battery A variable voltage charger is recommended Leave the battery unused for more than 30...

Страница 133: ...bricate battery terminals Recommended lubricant Dielectric grease 10 Install rider seat Refer to SEATS EB305040 CHECKING THE FUSES The following procedure applies to all of the fuses To avoid a short...

Страница 134: ...circuit Item Amperage Q ty Main fuse 30 A 1 Headlight fuse 20 A 1 Signaling system fuse 20 A 1 Ignition fuse 15 A 1 Radiator fan motor fuse 7 5 A 1 Backup fuse odometer 7 5 A 1 Never use a fuse with...

Страница 135: ...cts and your hands away from the bulb until it has cooled down 4 Install headlight bulb New Secure the new headlight bulb with the head light bulb holder Avoid touching the glass part of the head ligh...

Страница 136: ...justing screw 1 in direction a or b Direction Headlight beams is raised Direction Headlight beams is low ered 2 Adjust headlight beam horizontally a Turn the adjusting knob 1 in direction a or b Left...

Страница 137: ...CHK ADJ...

Страница 138: ...ENG 4...

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

Страница 140: ...OIL PAN 4 58 CRANKCASE 4 59 OIL BAFFLE PLATES AND OIL FILTER BOLT 4 61 DISASSEMBLING THE CRANKCASE 4 62 CHECKING THE CRANKCASE 4 63 CHECKING THE BEARINGS AND OIL SEALS 4 63 CHECKING THE SPROCKETS AND...

Страница 141: ...Shift rod Shift arm Drive sprocket cover Nut Lock washer Drive sprocket 2 1 1 1 1 1 1 Remove the parts in the order listed Refer to CHANGING THE COOLANT For installation reverse the remove procedure...

Страница 142: ...mbly Muffler Exhaust pipe assembly Exhaust pipe gasket 1 1 4 Remove the parts in the order listed Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to RADIATOR in c...

Страница 143: ...and joints Engine oil and oil filter cartridge Oil cooler Disconnect the parts in the order listed Refer to FUEL TANK in chapter 3 Refer to AIR FILTER CASE AND IGNITION COILS in chapter 3 Refer to CAR...

Страница 144: ...ead Battery positive lead Startor coil assembly coupler Pickup coil coupler Engine earth Clutch wire and holder Crankcase breather hose Separator 1 1 1 1 1 1 1 1 First disconect the negative lead then...

Страница 145: ...Rear mounting bolts Engine mounting adjust bolts 4 2 2 2 2 2 2 Remove The Parts In The Order Listed For Installation Reverse The Removal Procedure NOTE Use the point shaft wrench to loosen the engine...

Страница 146: ...bolts 8 Lubricate the rear mounting bolt threads with lithium soap base grease Do not fully tighten the nuts and bolts 2 Tighten self locking nut front mounting bolts button head bolt pinch bolt M8 M...

Страница 147: ...embly Spark plugs Cylinder head cover Cylinder head cover gasket Timing chain guide top side 4 1 1 1 Remove the parts in the order listed Refer to CARBURETORS in chapter 6 Refer to RADIATOR in chapter...

Страница 148: ...asket Dowel pin Intake camshaft Exahust camshaft Timing chain guide exhaust side 1 1 1 4 2 1 1 1 Remove the parts in the order listed Refer to PICKUP COIL AND PICK UP COIL COVER During removal the dow...

Страница 149: ...9 10 11 12 Intake camshaft sproket Exhaust camshaft sproket Pin Timing chain guide intake side 1 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE CAMSHAFTS 10 Nm 1 0 m kg...

Страница 150: ...ace b TDC on the compression stroke can be found when the camshaft lobes are turned away from each other 2 Remove timing chain tensioner 3 Remove camshaft cap dowel pins To prevent damage to the cylin...

Страница 151: ...mshaft a 32 50 mm b 25 02 mm 3 Measure camshaft runout Out of specification Replace Max camshaft runout 0 06 mm 4 Measure camshaft journal to camshaft cap clear ance Out of specification Measure the c...

Страница 152: ...t 10 Nm 1 0 m kg d Remove the camshaft caps and then mea sure the width of the Plastigauge 1 5 Measure camshaft journal diameter a Out of specification Replace the cam shaft Within specification Repla...

Страница 153: ...CHECKING THE TIMING CHAIN TENSIONER 1 Check timing chain tensioner Cracks damage rough movement Re place a Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand...

Страница 154: ...cap The brim 1 of intake camshaft is not pro cessed The groove is processed around the brim 1 of exhaust cameshaft as illustration a Turn the crankshaft clockwise b When piston 1 is at TDC on the com...

Страница 155: ...rewdriver 1 until if stops C With the screwdriver still inserted into the timing chain tensioner install the timing chain tensioner 2 gasket and float cham ber air vent hose holder 3 onto the cylinder...

Страница 156: ...r to the installation steps above 7 Measure valve clearance Out of specification Adjust Refer to ADJUSTING THE VALVE CLEAR ANCE in chapter 3 8 Install cylinder head cover gasket cylinder head cover Ap...

Страница 157: ...mp senser lead Front mounting bolt Cylinder head Cylinder head gasket Dowel pin 1 1 2 Remove the parts in the order listed Refer to CAMSHAFTS Disconnect Disconnect Refer to ENGINE Refer to REMOVING IN...

Страница 158: ...r carbon deposits with a rounded scraper Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads valve seats 2 Check cylinder head Damage scratches Replace cylinder head...

Страница 159: ...head using a figure eight sanding pattern To ensure an even surface rotate the cylinder head several times EAS00223 INSTALLING THE CYLINDER HEAD 1 Install cylinder head gasket cylinder head cylinder...

Страница 160: ...take valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve gui...

Страница 161: ...alve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide 8 8 16...

Страница 162: ...the valves properly seal 1 Remove valve lifter 1 valve pad 2 Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place 2 Check valve for le...

Страница 163: ...seal 5 lower spring seat 6 Identify the position of each part very carefully so that it can be reinstalled in its original place EAS00239 CHECKING THE VALVES AND VALVE GUIDES The following procedure a...

Страница 164: ...lve guide bore the valve guide with a valve guide reamer 3 to obtain the proper valve stem to valve guide clearance After replacing the valve guide reface the valve seat Valve guide remover Intake 4 0...

Страница 165: ...replace the valve guide If the valve is removed or replaced always re place the oil seal Valve stem runout 0 04 mm EAS00240 CHECKING THE VALVE SEATS The following procedure applies to all of the valv...

Страница 166: ...ve seat After replacing the cylinder head or replacing the valve and valve guide the valve seat and valve face should be lapped a Apply a coarse lapping compound a to the valve face Do not let the lap...

Страница 167: ...e valve through the valve guide and onto the valve seat to make a clear impres sion j Measure the valve seat width c again If the valve seat width is out of specification reface and lap the valve seat...

Страница 168: ...the valve spring Max Spring tilt Intake valve spring inner 1 6 mm Intake valve spring outer 1 7 mm Exhaust valve spring 1 8 mm EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to a...

Страница 169: ...o the following em bossed marks Install the valve spring with the larger pitch a facing up b Smaller pitch 4 Install valve cotters 1 Install the valve cotters by compressing the valve spring with the...

Страница 170: ...pad with the recommended lubricant Recommended lubricant Molybdenum disulfide oil 7 Install valve pad valve lifter The valve lifter must move smoothly when ro tated with a finger Each valve lifter and...

Страница 171: ...cowling and right side cowling Engine oil Generator cover Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGI...

Страница 172: ...lutch cable holder Pickup coil coupler Pickup coil cover Pickup coil cover gasket Dowel pin Pickup coil Pickup rotor 1 1 1 1 1 2 1 1 Disconnect For installation reverse the removal procedure Refer to...

Страница 173: ...lly loosened remove them 2 Remove pickup coil rotor bolt 1 plain washer 2 pickup coil rotor 3 While holding the generator rotor 4 with the ro tor holding tool 5 loosen the pickup coil rotor bolt Sheav...

Страница 174: ...coil rotor bolt Sheave holder 90890 01701 3 Apply sealant onto the pickup coil lead grommet Yamaha bond No 1215 90890 85505 4 Install pickup coil cover clutch cable holder When installing the pickup c...

Страница 175: ...enerator rotor cover gasket Dowel pin Stator coil assembly lead holder Stator coil assembly 1 1 1 2 1 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to COWLINGS...

Страница 176: ...1 12 13 Generator rotor bolt Plain washer Generator rotor Starter one way assy Idler gear shaft Idler hear Starter clutch gear 1 1 1 1 1 1 1 For installation reverse the removal proceduer Refer to REM...

Страница 177: ...ts are fully loosened remove them 2 Remove generator rotor bolt 1 Plain washer While holding the generator rotor 2 with the sheave holder 3 loosen the generator rotor bolt Do not allow the sheave hold...

Страница 178: ...e defective parts 3 Check Starter clutch operation a Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch b When turning the starter clutch drive gear clockwise A th...

Страница 179: ...the crankshaft and the generator rotor hub with lacquer tinner 2 Tighten generator rotor bolt 3 While holding the generator rotor 2 with the sheave holder 3 tighten the generator rotor bolt Do not all...

Страница 180: ...Drive sprocket cover sift rod and sift arm Shift shaft cover Shift shaft cover gasket Dowel pin Oil seal Sift shaft 1 1 2 1 1 Remove the parts in the order listed Drain Refer to CHNGING THE COOLANT i...

Страница 181: ...8 9 10 11 12 13 14 Shift shaft spring Collar Stopper lever spring Circrip Washer Stopper lever Collar Washer Shift shaft spring stopper 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedur...

Страница 182: ...S00334 INSTALLING THE SHIFT SHAFT 1 Install shift shaft spring stopper 1 stopper lever spring 2 washer stopper lever 3 Apply LOCTITE to the threads of the shift shaft spring stopper Hook the ends of t...

Страница 183: ...t side cowling Engine oil Coolant Therm bypass hose Clutch cable 1 1 Remove the parts in the order listed Refer to COWLINGS in chapter 3 Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer...

Страница 184: ...TCH ENG Order Job Part Q ty Remarks 3 4 5 Clutch cover Clutch cover gasket Dowel pin 1 1 2 Refer to REMOVING INSTALLING THE CLUTCH For installation reverse the removal procedure 12 Nm 1 2 m kg 12 Nm 1...

Страница 185: ...assembling the clutch cover assembly Circlip Plain washer Pull lever Pull lever spring Oil seal Bearing 2 2 1 1 1 2 Disassemble the parts in the order listed Refer to INSTALLING THE CLUTCH For assembl...

Страница 186: ...ession spling Pressure plate Pull rod Bearing Friction plate Clutch plate Clutch plate Clutch boss nut Look washer Clutch boss 6 1 1 1 8 7 1 1 1 1 Remove the parts in the order listed Refer to REMOVIN...

Страница 187: ...4 47 CLUTCH ENG Order Job Part Q ty Remarks 11 Thrust plate 1 For installation reverse the removal procedure 70 Nm 7 0 m kg 8 Nm 0 8 m kg...

Страница 188: ...the clutch boss 2 with the clutch holding tool 3 loosen the clutch boss nut Clutch holding tool 90890 04086 4 Remove clutch boss nut 1 lock washer 2 clutch boss 3 thrust plate 4 EAS00280 CHECKING THE...

Страница 189: ...PRINGS The following procedure applies to all of the clutch springs 1 Check clutch spring Damage Replace the clutch springs as a set 2 Measure clutch spring free length a Out of specification Replace...

Страница 190: ...cause er ratic clutch operation EAS00286 CHECKING THE PRESSURE PLATE 1 Check pressure plate 1 Cracks damage Replace bearing 2 Damage wear Replace EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1...

Страница 191: ...t 4 Lubricate friction plates clutch plates with the recommended lubricant Recommended lubricant Engine oil 5 Install friction plates clutch plates First install a friction plate and then alternate be...

Страница 192: ...tages and in a criss cross pattern 8 Install clutch cover When installing the clutch cover push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch co...

Страница 193: ...t pipe assembly Oil level switch couplar Oil level switch 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE ENGINE OIL in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3...

Страница 194: ...n Oil strainer Oil pipe Oil delivery pipe Gear cover Dowel pin Oil pump assembly Relief valve assembly 1 1 1 2 1 1 1 1 2 1 1 Refer to INSTALLING THE OIL STRAINER Refer to INSTALLING THE OIL PUMP For i...

Страница 195: ...p assembly Oil pump rotor housing Dowel pin Oil pump inner rotor Oil pump outer rotor Dowel pin Washer Oil pump cover Driver gear 1 2 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly...

Страница 196: ...ove them EAS00364 CHECKING THE OIL PUMP 1 Check oil pump driven gear 1 rotor housing 2 Cracks damage wear Replace the defec tive part s 2 Measure inner rotor to outer rotor tip clearance a outer rotor...

Страница 197: ...E OIL DELIVERY PIPE AND OIL PIPE 1 Check oil delivery pipe 1 oil pipe 2 Damage Replace Obstruction Wash and blow out with com pressed air EAS00368 CHECKING THE OIL STRAINER 1 Check oil strainer 1 Dama...

Страница 198: ...LING THE OIL PUMP 1 Install oil pump 1 Install the oil pump assembly drive chain onto the oil pump assembly driven sprocket EAS00378 INSTALLING THE OIL STRAINER 1 Install oil strainer 1 The arrow a on...

Страница 199: ...d pickup rotor Clutch assembly Water pump assembly Oil pan and oil pump Remove the parts in the order listed Refer to ENGINE Refer to CYLINDER HEAD Refer to STARTER CLUTCH AND GENERATOR Refer to SHIFT...

Страница 200: ...art Q ty Remarks 1 2 3 4 5 Timing chain Oil pump drive chain guide Oil pump drive chain Lower crankcase Dowel pin 1 1 1 1 3 Refer to DISASSEMBLY ASSEMBLY THE CRANKCASE For installation reverse the rem...

Страница 201: ...mission Oil baffle plate Oil baffle plate Oil delivery pipe Bearing Lower crankcase Oil filter bolt Upper crankcase 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to TRANSMISSION For instala...

Страница 202: ...ers embossed on the crankcase in dicate the crankcase tightening sequence 2 Remove crankcase bolts 3 Remove lower crankcase Tap on one side of the crankcase with a soft face hammer Tap only on reinfor...

Страница 203: ...ck bearings Clean and lubricate the bearings then rotate the inner race with your finger Rough movement Replace 2 Check oil seals Damage wear Replace CHECKING THE SPROCKETS AND CHAINS 1 Check cranksha...

Страница 204: ...15 90890 85505 Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear ings Do not apply sealant to within 2 3 mm of the crankshaft journal bearings 3 Install dow...

Страница 205: ...ubricate seal botts 18 12 Tighten the bolts in the tightening sequence cast on the crankcase M8 85 mm bolts 1 X 7 10 M8 115 mm bolts 8 9 M8 65 mm bolts 11 12 M6 65 mm bolts 13 14 17 27 M6 55 mm bolts...

Страница 206: ...wer crankcase Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin Piston Connecting rod 4 4 4 8 4 4 4 Remove the parts in the order listed Separate Refer to CRANK...

Страница 207: ...RODS AND PISTONS ENG Order Job Part Q ty Remarks 8 9 10 Top ring 2nd ring Oil ring 4 4 4 For installation reverse the removal procedure Refer to REMOVING INSTALLING THE CONNECTING RODS AND PISTONS 15...

Страница 208: ...pin 2 piston 3 connecting rod Do not use a hammer to drive the piston pin out For reference during installation put identifi cation marks on the piston crown Before removing the piston pin deburr the...

Страница 209: ...Measure cylinder bore C by taking side to side and front to back measurements of the cylinder Then find the average of the measure ments Cylinder bore gauge 90890 03017 Cylinder bore C 65 50 65 51 mm...

Страница 210: ...tons and piston rings as a set EAS00263 CHECKING THE PISTON RINGS 1 Measure piston ring side clearance Out of specification Replace the piston and piston rings as a set Before measuring the piston rin...

Страница 211: ...0 mm Limit 0 85 mm Oil ring 0 10 0 35 mm ABS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis ton pins 1 Check piston pin Blue discoloration grooves Replace the piston p...

Страница 212: ...rankshaft pin to big end bearing clearance 0 028 0 052 mm The following procedure applies to all of the connecting rods Do not interchange the big end bearings and connecting rods To obtain the correc...

Страница 213: ...both the connecting rod and connecting rod cap are aligned e Tighten the connecting rod nuts SWhen tightening the connecting rod nuts be sure to use an F type torque wrench SAfter tightening the conn...

Страница 214: ...tration For example if the connecting rod P1 and the crankshaft web P1 numbers are 5 and 1 respectively then the bearing size for P1 is P1 connecting rod P1 crank shaft 5 1 4 BIG END BEARING COLOR COD...

Страница 215: ...is pointing up Refer to the illustra tion Reinstall each piston into its original cylinder numbering order starting from the left 1 to 4 3 Offset piston ring end gaps a Top ring b Lower oil ring rail...

Страница 216: ...nnecting rod caps SBe sure to reinstall each big end bearing in its original place SWhile compressing the piston rings with one hand install the connecting rod assembly into the cylinder with the othe...

Страница 217: ...hten the nut further to reach the specified angle 90_ When the nut is tightened more than the specified angle do not loosen the nut and then retighten it Replace the bolt with a new one and perform th...

Страница 218: ...and pistons Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing 1 5 5 Remove the parts in the order listed Separate Refer to CRANKCASE Refer to CONNECTING RODS AND PISTONS Fo...

Страница 219: ...mm 2 Check crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches wear Replace the crankshaft CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1 Measure crankshaft journal to cranksha...

Страница 220: ...stigauge 2 on each crankshaft journal Do not put the Plastigauge over the oil hole in the crankshaft journal e Install the crankshaft journal lower bearings into the lower crankcase and assemble the c...

Страница 221: ...into the lower crankcase are used to determine the replace ment crankshaft journal bearing sizes J1 J5 refer to the bearings shown in the crankshaft illustration If J1 J5 are the same use the same si...

Страница 222: ...Install crankshaft journal upper bearings into the upper lower crankcase Align the projections a on the crankshaft jour nal upper bearings with the notches b in the upper crankcase Be sure to install...

Страница 223: ...ion Crankcase lower Shift shaft and stopper lever Drive axle assembly Circlip Oil seal Bearing Shift bar stopper Shift fork guide bar 1 1 1 1 1 2 Remove the parts in the order listed Separate Refer to...

Страница 224: ...10 11 12 Spring Shift fork L Shift fork R Shift drum assembly Shift fork C Main axle assembly 4 1 1 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE TRANSMISSION Refer to...

Страница 225: ...Disassembling the main axle assembly Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip 1 1 1 1 1 1 1 1 1 1 Remove t...

Страница 226: ...4 86 TRANSMISSION ENG Order Job Part Q ty Remarks Washer 5th pinion gear Collar Main axle Bearing housing Bearing 1 1 1 1 1 1 For installation reverse the removal procedure 11 12 13 14 15 16...

Страница 227: ...bling the drive axle assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear 1 1 1 1 1 1 1 1 1 1 1 Rem...

Страница 228: ...ty Remarks Collar Washer Circrip 6th wheel gear Circrip washer 2nd wheel gear Collar Collar Oil seal Bearing Circrip Drive axle 1 1 1 1 1 1 1 1 1 1 1 1 1 For installation reverse the removal procedure...

Страница 229: ...until they contact the crank case surface c Continue tightening the bolts until the main axle assembly comes free from the upper crankcase EAS00421 CHECKING THE SHIFT FORKS The following procedure ap...

Страница 230: ...drum bearing 2 Damage pitting Replace the shift drum assembly EAS00425 CHECKING THE TRANSMISSION 1 Measure main axle runout with a centering device and dial gauge 1 Out of specification Replace the m...

Страница 231: ...bly shift fork R shift fork L springs shift fork guide bars drive axle assembly Carefully position the shift forks so that they are installed correctly into the transmission gears Install shift fork C...

Страница 232: ...ENG...

Страница 233: ...COOL 5...

Страница 234: ...NG THE RADIATOR 5 4 OIL COOLER 5 5 CHECKING THE OIL COOLER 5 7 INSTALLING THE OIL COOLER 5 7 THERMOSTAT 5 9 CHECKING THE THERMOSTAT 5 11 INSTALLING THE THERMOSTAT 5 11 WATER PUMP 5 13 DISASSEMBLING TH...

Страница 235: ...COOL...

Страница 236: ...cowling and side cowlings Coolant Coolant reserver hose Breather hose Radiator outlet hose 1 2 1 Remove the parts in the order listed Refer to SEATS and FUEL TANK in chapter 3 Refer to AIRFILTER CASE...

Страница 237: ...8 9 Radiator inlet hose Oil cooler outlet hose Thermo switch coupler Radiator fan motor coupler Radiator Radiator fan 1 1 1 1 1 1 Disconnect Disconnect Disconnect For installation reverse the removal...

Страница 238: ...asure radiator cap opening pressure Below the specified pressure Replace the radiator cap Radiator cap opening pressure 110 140 kPa 1 1 1 4 kg cm2 1 1 1 4 bar a Install the radiator cap tester 1 and a...

Страница 239: ...he specified amount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 2 Check cooling system Leaks Repair or replace any faulty part 3 Measure radiator cap opening pressure Below...

Страница 240: ...ly Exaust pipe assembly Engine oil Oil cooler outlet hose Bolt Washer Oil cooler 1 1 1 1 Remove the parts in the order listed Refer to RADIATOR Refer to ENGINE in chapter 4 Drain Refer to CHANGING THE...

Страница 241: ...Q ty Remarks 5 6 7 8 9 10 Oil cooler inlet hose Water jacket joint Water jacket joint hose Water pump outlet pipe Water pump outlet hose Water pump inlet hose 1 1 1 1 1 1 For installation reverse the...

Страница 242: ...Replace EBS00459 INSTALLING THE OIL COOLER 1 Clean mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thinner 2 Install O ring New oil cooler 1 washer 2 New bolt 3...

Страница 243: ...OLANT in chapter 3 crankcase with the specified amount of the recom mended engine oil Refer to CHANGING THE ENGINE OIL in chapter 3 5 Check cooling system Leaks Repair or replace any faulty part 6 Mea...

Страница 244: ...d fuel tank Coolant Air filter case Carburetor assembly Remove the parts in the order listed Refer to SEAT and FUEL TANK in chapter 3 Drain Refer to CHANGING THE COOLANT in chapter 3 Refer to AIRFILTE...

Страница 245: ...RMOSTAT COOL Order Job Part Q ty Remarks 1 2 3 4 Radiator inlet hose Carburator outlet hose Thermostat cover Thermostat 1 1 1 1 For installation revers the removal procedure Refer to INSTALLING THE TH...

Страница 246: ...dicated tempera ture 1 Thermostat 2 Thermometer 3 Water 4 Container A Fully closed B Fully opens If the accuracy of the thermostat is in doubt re place it A faulty thermostat could cause serious overh...

Страница 247: ...mount of the recom mended coolant Refer to CHANGING THE COOLANT in chapter 3 4 Check cooling system Leaks Repair or replace any faulty part 5 Measure radiator cap opening pressure Below the specified...

Страница 248: ...assembly Coolant Water pump inlet hose Water pump outlet hose Water pump hose Clutch wire and holder Water pump 1 1 1 1 1 Remove the parts in the order listed Drain Refer to CHANGING THE COOLANT in c...

Страница 249: ...Water pump cover O ring Impeller shaft along with the impeller Water pump seal Oil seal Bearing Circlip 1 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly pr...

Страница 250: ...eal from the outside of the water pump housing 3 Water pump housing 3 Remove rubber damper holder 1 rubber damper 2 from the impeller with a thin flat head screwdriver Do not scratch the impeller shaf...

Страница 251: ...er pump seal 1 New Never lubricate the water pump seal surface with oil or grease Install the water pump seal with the special tools Before installing the water pump seal apply Yamaha bond No 1215 2 t...

Страница 252: ...UTION 4 Measure impeller shaft tilt Out of specification Repeat steps 3 and 4 Make sure that the rubber damper and rub ber damper holder are flush with the impel ler Max impeller shaft tilt 0 15 mm 1...

Страница 253: ...COOL...

Страница 254: ...CARB 6...

Страница 255: ...RS 6 7 ASSEMBLING THE CARBURETORS 6 9 INSTALLING THE CARBURETORS 6 11 MEASURING AND ADJUSTING THE FUEL LEVEL 6 12 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR 6 13 CHECKING THE FUEL PUMP 6 16 C...

Страница 256: ...CARB...

Страница 257: ...Air filter case and heat protector plate Starter cable Fuel hose Throttle position sensor coupler Throttle stop screw 1 1 1 1 Remove the parts in the order listed Refer to Seats and FUEL TANK in chap...

Страница 258: ...CARB Order Job Part Q ty Remarks 5 6 7 8 9 10 Therm bypass hose Carburetor joint clamp screw Throttle cable Carburetor assembly Carburetor joint Side cover 2 4 2 1 4 2 For installation reverse the re...

Страница 259: ...er link Connecting bolt Connecting bolt Hose joint Spring Fuel feed pipe Fuel feed pipe Pipe Throttle stop screw Throttle position sensor Water pipe 1 1 1 2 2 2 1 2 1 1 2 Remove the parts in the order...

Страница 260: ...6 4 Order Job Part Q ty Remarks 12 13 14 15 Balance pipe Balance pipe bracket Throttle cable bracket Carburetor 2 1 1 4 For installation reverse the removal procedure CARBURETORS CARB...

Страница 261: ...r cover Piston valve spring Jet needle holder Jet needle kit Piston valve Pilot screw Fuel drain bolt Float chamber Float pivot pin 1 1 1 1 1 1 1 1 1 1 1 Disassemble the parts in the order listed The...

Страница 262: ...6 6 CARBURETORS CARB Order Job Part Q ty Remarks Float Needle valve Main jet Main jet holder Pilot jet 1 1 1 1 1 For assembly reverse the disassembly procedure 12 13 14 15 16...

Страница 263: ...lean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt...

Страница 264: ...dle kit 1 main jet 2 main jet holder 3 pilot jet 4 pilot screw 5 starter plunger 6 Bends damage wear Replace Obstruction Clean Blow out the jets with compressed air 10 Check piston valve movement Inse...

Страница 265: ...assembling the carburetors wash all of the parts in a petroleumbased sol vent Always use a new gasket 1 Install pilot screw kit 1 Pilot screw setting 2 turns out 2 Install piston valve 1 jet needle j...

Страница 266: ...spring 2 and synchronizing screw 3 4 Install starter plunger link 1 Install the starter plunger link 1 onto each start er plunger 5 Tighten connecting bolts Place the carburetor assembly on a surface...

Страница 267: ...G THE CARBU RETORS in chapter 3 2 Adjust engine idling speed Engine idling speed 1250 1350 r min Refer to ADJUSTING THE ENGINE ID LING SPEED in chapter 3 3 Adjust throttle cable free play Throttle cab...

Страница 268: ...gauge 90890 01312 d Loosen the fuel drain bolt 3 e Hold the fuel level gauge vertically next to the line 4 on the float chamber f Measure the fuel level a Fuel level readings should be equal on both...

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

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

Страница 271: ...n the throttle position sensor screws 1 e Adjust the throttle position sensor angle ac cording to the following table The angle of the throttle position sensor is indi cated by the r min which are dis...

Страница 272: ...tank to fuel pump fuel hose to the fuel tank and then set the fuel cock to ON d Place a container under the end of the fuel hose 2 e Start the engine and check if fuel flows from the fuel hose 2 Fuel...

Страница 273: ...truction Clean Damage Replace 4 Install fuel cock fuel filter fuel tank EAS00506 CHECKING THE FUEL COCK OPERATION After installing the fuel cock check its opera tion 1 Check that the fuel cock lever i...

Страница 274: ...CARB...

Страница 275: ...CHAS 7...

Страница 276: ...NT AND REAR BRAKES 7 14 FRONT BRAKE PADS 7 14 REAR BRAKE PADS 7 15 REPLACING THE FRONT BRAKE PADS 7 16 REPLACING THE REAR BRAKE PADS 7 18 FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 7 21 REA...

Страница 277: ...AD 7 61 INSTALLING THE STEERING HEAD 7 62 REAR SHOCK ABSORBER ASSEMBLY 7 64 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER 7 65 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 7 65 REMOVING THE...

Страница 278: ...left and right 2 2 1 1 1 2 2 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the front wheel is elevated Loosen NOTE Refer to INSTALLING THE FRONT WHEEL 72 Nm 7...

Страница 279: ...Disassembling the front wheel Oil seals left and right Wheel bearings left and right Spacer 2 2 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 FRONT WHEEL...

Страница 280: ...Remove Brake hose holders left brake caliper right brake caliper wheel axle Do not squeeze the brake lever when removing the brake calipers 3 Elevate front wheel Place the motorcycle on a suitable sta...

Страница 281: ...rings New oil seals New a Clean the outside of the front wheel hub b Remove the oil seals 1 with a flat head screwdriver To prevent damaging the wheel place a rag 2 between the screwdriver and the whe...

Страница 282: ...front brake disc deflection turn the handlebars to the left or right to ensure that the front wheel is station ary c Remove the brake caliper d Hold the dial gauge at a right angle against the brake d...

Страница 283: ...INSTALLING THE FRONT WHEEL 1 Lubricate wheel axle oil seal lips Recommended lubricant Lithium soap base grease 2 Tighten wheel axle 1 wheel axle pinch bolt 2 Before tightening the wheel axle nut push...

Страница 284: ...l the marks come to rest at the same spot h The spot where all the marks come to rest is the front wheel s heavy spot X 3 Adjust Sfront wheel static balance a Install a balancing weight 1 onto the rim...

Страница 285: ...et bolt Brake caliper bracket 1 2 2 1 1 1 1 1 1 1 1 Remove the parts in the order listed Place the motorcycle on a suitable stand so that the rear wheel is elevated Loosen Loosen Make sure that the ta...

Страница 286: ...Spacers left and right Oil seal Bearing Rear wheel drive hub Rear wheel drive hub dampers Rear wheel 1 1 2 1 1 1 5 1 Remove the parts in the order listed For installation reverse the removal procedur...

Страница 287: ...assembling the rear wheel Spacer Bearing Spacer Oil seal Circlip Bearing 1 1 1 1 1 1 Disassemble the parts in the order listed For assembly reverse the disassembly procedure 1 2 3 4 5 6 REAR WHEEL BRA...

Страница 288: ...Remove brake caliper Do not depress the brake pedal when removing the brake caliper 3 Remove wheel axle nut washer wheel axle adjusting blocks brake caliper bracket rear wheel Push the rear wheel forw...

Страница 289: ...68 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check rear wheel sprocket More than 1 4 tooth a wear Replace the rear wheel sprocket Bent teeth Replace the rear wheel sprock et b Correct 1 Drive c...

Страница 290: ...eel axle nut brake caliper 3 Adjust drive chain slack a Drive chain slack 40 50 mm Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 4 Tighten wheel axle nut brake caliper bolts Make sure that the...

Страница 291: ...rake pad shims Bleed screw 2 1 1 2 2 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Refer to REPLACING THE FRONT BRAKE PADS 40 Nm 4 0 m kg 6...

Страница 292: ...liper bolts Brake pads Brake pad shims Bleed screw 2 2 4 1 Remove the parts in the order listed Refer to REPLACING THE REAR BRAKE PADS 27 Nm 2 7 m kg 6 Nm 0 6 m kg 40 Nm 4 0 m kg For installation reve...

Страница 293: ...e only clean or new brake fluid for clean ing brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fluid c...

Страница 294: ...Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b Loos...

Страница 295: ...d to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in c...

Страница 296: ...pads Always install new brake pads brake pad shims and a brake pad spring as a set a Connect a clear plastic hose 1 tightly to the bleed screw 2 Put the other end of the hose into an open container b...

Страница 297: ...rake fluid level Below the minimum level mark a Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 7 Check brake pedal operation Soft or spongy fe...

Страница 298: ...diaphragm Brake fluid reservoir Brake fluid reservoir hose Circlip Dust cover Hose joint Brake lever Front brake switch connector Union bolt Copper washer 1 1 11 1 1 1 1 1 1 2 1 3 Remove the parts in...

Страница 299: ...inder holder Brake master cylinder Front brake switch 2 1 1 1 For installation reverse the removal procedure Refer to INSTALLING THE FRONT BRAKE MASTER SYLINDER 1 2 3 4 5 6 8 7 9 10 11 12 13 14 13 14...

Страница 300: ...mbling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder 1 1 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2...

Страница 301: ...iaphragm Brake fluid reservoir Brake fluid reservoir hose Hose joint Union bolt Copper washer Brake hose Brake master cylinder 1 1 1 1 1 1 1 2 1 1 Remove the parts in the order listed Drain Refer to I...

Страница 302: ...isassembling the rear brake master cylinder Brake master cylinder kit Brake master cylinder 1 1 Remove the parts in the order listed For assembly reverse the disassembly procedure 1 2 16 Nm 1 6 m kg F...

Страница 303: ...and the end of the brake hose EAS00589 REMOVING THE REAR BRAKE MASTER CYLINDER 1 Remove union bolt 1 copper washers 2 brake hose 3 button head bolts 4 To collect any remaining brake fluid place a cont...

Страница 304: ...s damage Replace brake fluid reservoir diaphragm 2 Cracks damage Replace 4 Check brake hoses Cracks damage wear Replace EAS00607 INSTALLING THE FRONT BRAKE MASTER CYLINDER Before installation all inte...

Страница 305: ...as shown Turn the handlebars to the left and to the right to make sure that the brake hose does not touch other parts e g wire harness cables leads Correct if necessary 3 Fill brake fluid reservoir wi...

Страница 306: ...d to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in c...

Страница 307: ...oiling point of the brake fluid and could cause vapor lock Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 3 Bleed brake system Re...

Страница 308: ...ose Brake caliper 1 2 1 1 Remove the parts in the order listed The following procedure applies to both of the front brake calipers Drain Refer to INSTALLING THE FRONT BRAKE CALIPERS 6 Nm 0 6 m kg 30 N...

Страница 309: ...e caliper piston Brake caliper piston seal Bleed screw 2 1 1 2 4 8 1 Disassemble the parts in the order listed The following procedure applies to both of the front brake calipers Refer to REMOVING THE...

Страница 310: ...uid Union bolt Copper washer Brake hose Brake caliper 1 2 1 1 Remove the parts in the order listed Drain Refer to INSTALLING THE REAR BRAKE CALIPERS 30 Nm 3 0 m kg 27 Nm 2 7 m kg For installation reve...

Страница 311: ...r Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 2 2 4 1 Disassemble the parts in the order listed Refer to REMOVING THE REAR BRAKE CALIPERS 1 2 3 4 For assembly reverse the disa...

Страница 312: ...e end of the brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Secure the right side brake caliper pistons with a piece...

Страница 313: ...brake hose into a container and pump out the brake fluid carefully 2 Remove brake caliper pistons 1 brake caliper piston seals 2 a Blow compressed air into the brake hose joint opening a to force out...

Страница 314: ...enever the brake is disassembled 1 Check brake caliper pistons 1 Rust scratches wear Replace the brake caliper brake caliper cylinders 2 Scratches wear Replace the brake cali per brake calipers 3 Crac...

Страница 315: ...the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake caliper 1 temporarily copper washers...

Страница 316: ...nce When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage...

Страница 317: ...they will cause the piston seals to swell and distort Whenever a brake caliper is disassembled replace the brake caliper piston seals Recommended brake fluid DOT 4 1 Install brake pads brake caliper...

Страница 318: ...nce When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock Brake fluid may damage...

Страница 319: ...er bracket pinch bolts Cap bolts Lower bracket pinch bolts Front fork legs 1 2 2 1 1 2 2 4 2 Remove the parts in the order listed The following procedure applies to both of the front fork legs Refer t...

Страница 320: ...er Washer Fork spring Copper washer Damper rod assembly bolt Damper rod assembly 1 1 1 1 1 1 1 1 1 1 Remove the parts in the order listed The following procedure applies to both of the front fork legs...

Страница 321: ...ust seal Oil seal clip Oil seal Washer Outer tube bushing Inner tube Oil lock piece 1 1 1 1 1 1 1 For assembly reverse the disassembly procedure Refer to DISASSEMBLING ASSEMBLING THE FRONT FORK LEGS 2...

Страница 322: ...cap bolt 2 handlebar pinch bolt 1 lower bracket pinch bolt upper bracket bolt 4 handlebar 5 Before loosening the upper and lower bracket pinch bolts and handlebar pinch bolt support the front fork leg...

Страница 323: ...ressed f Remove the spacer and nut g Remove the fork spring 2 Drain fork oil Stroke the damper rod 1 several times while draining the fork oil 3 Remove dust seal oil seal clip 1 oil seal washer with a...

Страница 324: ...2 Measure spring free length a Out of specification Replace Spring free length limit 251 8 mm Limit 246 mm 3 Check damper rod 1 Damage wear Replace Obstruction Blow out all of the oil pas sages with...

Страница 325: ...ont fork leg be sure to replace the following parts inner tube bushing outer tube bushing oil seal dust seal Before assembling the front fork leg make sure that all of the components are clean 1 Insta...

Страница 326: ...ide of the oil seal faces up Before installing the oil seal lubricate its lips with lithium soap base grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal...

Страница 327: ...ch front fork leg 476 cm3 Recommended oil Yamaha fork and suspension oil 01 or equivalent Be sure to use the recommended fork oil Other oils may have an adverse effect on front fork performance When d...

Страница 328: ...measuring the fork oil level wait ten minutes until the oil has settled and the air bubbles have dispersed Be sure to bleed the front fork leg of any residual air 14 Measure front fork leg oil level a...

Страница 329: ...ut 1 and the spacer 4 Use the side of the rod holder that is marked B Fork spring compressor 90890 01441 Rod holder 90890 01434 g Remove the rod puller and adapter h Install the nut 1 and position it...

Страница 330: ...both of the front fork legs 1 Install front fork leg Temporarily tighten the upper and lower bracket pinch bolts Make sure that the inner fork tube is flush with the top of the handlebar 2 Tighten lo...

Страница 331: ...Clutch cable Clutch lever holder Right grip end Throttle cable Throttle grip 1 1 2 1 1 1 1 1 1 2 1 Remove the parts in the order listed Disconnect Refer to INSTALLING THE HANDLEBARS Disconnect Discon...

Страница 332: ...r Brake master cylinder Handlebar pinch bolt Upper bracket bolt Upper bracket pinch bolt Steering stem nut Left handlebar Right handlebar Upper bracket 2 1 1 1 2 2 2 1 1 1 1 Disconnect Refer tp INSTAL...

Страница 333: ...ebar switch clutch lever holder Blow compressed air between the left handle bar and the handlebar grip and gradually push the grip off the handlebar 3 Remove grip end right handle switch 1 throttle gr...

Страница 334: ...es of the brake master cylinder holder with the punch mark a in the right handlebar There should be 2 mm of clearance between the right handlebar switch and the brake mas ter cylinder holder 2 Install...

Страница 335: ...r grip over the end of the left handlebar c Wipe off any excess rubber adhesive with a clean rag Do not touch the handlebar grip until the rubber adhesive has fully dried 6 Adjust clutch cable free pl...

Страница 336: ...Lower bracket panel Brake hose holder bolt Lock washer Upper ring nut Rubber washer 2 2 1 1 1 1 1 1 2 1 1 1 Remove the parts in the order listed Refer to FRONT WHEEL AND BRAKE DISCS Refer to FRONT FOR...

Страница 337: ...er Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race 1 1 1 2 1 1 1 2 Refer to CHECK AND ADJUSTING THE STEERING HEAD in chapter 3 For installation reverse the removal procedur...

Страница 338: ...r bracket ring nuts 1 with the special tool 2 Ring nut wrench 90890 01403 Securely support the lower bracket so that there is no danger of it falling EAS00682 CHECKING THE STEERING HEAD 1 Wash bearing...

Страница 339: ...s and bearing races as a set Whenever the steering head is disassembled replace the dust seal 4 Check upper bracket lower bracket along with the steering stem Bends cracks damage Replace EAS00683 INST...

Страница 340: ...pper bracket steering stem nut Temporarily tighten the steering stem nut 4 Install front fork legs Refer to FRONT FORK Temporarily tighten the upper and lower bracket pinch bolts and handlebar pinch b...

Страница 341: ...assembly Coller oil seal bearing Relay arm Coller oil seal bearing Connecting arm Coller oil seal bearing 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 2 1 1 1 2 1 Remove the parts in the order listed Refer to...

Страница 342: ...orber or gas cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pres sure Do not de...

Страница 343: ...r bolt hold the swingarm so that it does not drop down 3 Remove rear shock absorber assembly upper bin 1 rear shock absorber assembly Raise the swingarm and then remove the rear shock absorber assembl...

Страница 344: ...e spacers Damage scratches Replace EAS00698 INSTALLING THE REAR SHOCK ABSORB ER ASSEMBLY 1 Lubricate bearings oil seals spacers Recommended lubricant Lithium soap base grease 2 Install connecting arm...

Страница 345: ...sembly Adjusting bolt locknut Drive chain guard Rear fender Flap Pivot shaft nut washer Pivot shaft Swingarm 2 2 1 1 1 1 1 1 1 Remove the parts in the order listed Refer to ENGINE in chapter 4 Refer t...

Страница 346: ...14 15 16 17 Pivot shaft adjust bolt Drive chain Dust cover Oil seal Bush Shim Drive chain guide Bush Left bearing Right bearing 2 1 1 1 1 1 1 1 1 1 Refer to REMOVING INSTALLING THE SWINGARM For instal...

Страница 347: ...EC573000 REMOVING THE SWINGARM 1 Remove Bolt connecting rod 1 Connecting rod 2 Remove the bolt while holding the swingarm 2 Loosen Pivot shaft adjust bolt 1 Loosen the pivot shaft adjust bolt using a...

Страница 348: ...Pivot shaft nut 95 Nm 9 5m kg b Measure the swingarm side play A by mov ing the swingarm from side to side c If the swingarm side play is out of specifica tion check the spacers bearings washers and...

Страница 349: ...ft on a flat surface Bends Replace Do not attempt to straighten a bent pivot shaft 5 Wash pivot shaft pivot shaft adjust bolt dust covers spacer bearings Recommended cleaning solvent Kerosine 6 Check...

Страница 350: ...mm While measuring the ten link section push down on the drive chain to increase its tension Measure the length between drive chain roller 1 and 11 as shown Perform this measurement at two or three d...

Страница 351: ...can also damage the O rings Therefore use only kerosine to clean the drive chain Don t soak drive drain in kerosine more them ten minutes O ring is damage by kero sine 4 Check O rings 1 Damage Replace...

Страница 352: ...pivot shaft nut Use the pivot shaft wrench 2 to tighten the piv ot adjust bolt to finger tightness Pivot shaft wrench 90890 1471 3 Install rear shock absorber assembly rear wheel Refer to REAR SHOCK A...

Страница 353: ...CHAS...

Страница 354: ...ELEC 8...

Страница 355: ...ON OF THE BULBS 8 8 CHECKING THE CONDITION OF THE BULB SOCKETS 8 10 CHECKING THE LEDs 8 10 IGNITION SYSTEM 8 11 CIRCUIT DIAGRAM 8 11 TROUBLESHOOTING 8 12 ELECTRIC STARTING SYSTEM 8 16 CIRCUIT DIAGRAM...

Страница 356: ...37 CHECKING THE SIGNALING SYSTEM 8 38 COOLING SYSTEM 8 45 CIRCUIT DIAGRAM 8 45 TROUBLESHOOTING 8 46 FUEL PUMP SYSTEM 8 49 CIRCUIT DIAGRAM 8 49 FUEL PUMP CIRCUIT OPERATION 8 50 TROUBLESHOOTING 8 51 CHE...

Страница 357: ...8 Flasher relay 9 CDI unit 10 Starter relay 11 Main fuse 12 Oil level relay 13 Battery 14 Rectifier regulator 15 Rear brake light switch 16 Neutral switch 17 Speed sensor 18 Sidestand switch 19 Stator...

Страница 358: ...n When this light comes on fill the fuel tank at the first opportunity OIL LEVEL COOLANT TEMPERATURE WARNING LIGHT This warning light has two functions The light will come on and symbol will flash if...

Страница 359: ...shes and the indicator light comes on Stop the engine and allow it to cool Refer to OVERHEATING in chapter 9 COMBINATION METER This combination meter is equipped with the fol lowing SA speedometer SAn...

Страница 360: ...r at least one second The display will return to TRIP 1 If you do not reset the fuel reserve trip meter manually it will automatically reset and return to TRIP 1 after refueling and the motorcycle has...

Страница 361: ...ng for continuity switch back and forth between the switch positions a few times The terminal connections for switches e g main switch engine stop switch are shown in an illustration similar to the on...

Страница 362: ...eck each switch for damage or wear proper connections and also for continuity between the termi nals Refer to CHECKING SWITCH CONTINUITY Damage wear Repair or replace the switch Improperly connected P...

Страница 363: ...3 Dimmer switch 4 Turn signal switch 5 Horn switch 6 Clutch switch 7 Light switch for Europe 8 Engine stop switch 9 Start switch 10 Front brake light switch 11 Rear brake light switch 12 Neutral swit...

Страница 364: ...hown in the illustration on the left Bulbs A and B are used for headlights and usually use a bulb holder which must be de tached before removing the bulb The majority of these bulbs can be removed fro...

Страница 365: ...ife of the bulb and the luminous flux will be adverse ly affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 2 Check bulb for continui...

Страница 366: ...et for continuity If any of the readings indicate no continuity replace the bulb socket CHECKING THE LEDs The following procedure applies to all of the LEDs 1 Check LED for proper operation a Disconne...

Страница 367: ...y 11 Sidestand switch 14 CDI unit 15 Ignition coil 1 16 Ignition coil 2 17 Ignition coil 3 18 Ignition coil 4 19 Spark plugs 20 Pick up coil 21 Neutral switch 56 Ignition fuse 63 Engine stop switch 66...

Страница 368: ...YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHECKING THE FUSES in chap ter 3 SAre the main and ignition fuses OK EB802011 TROUBLESHO...

Страница 369: ...increase the spark gap until a misfire occurs Min ignition spark gap 6 mm SIs there a spark and is the spark gap within specification NO The ignition system is OK YES EB802409 6 Ignition coil resista...

Страница 370: ...r to CHECKING THE SWITCHES SIs the main switch OK YES Replace the main switch NO 8 Main switch EB802412 SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs the engine stop...

Страница 371: ...Tester positive probe blue yellow Tester negative probe sky blue 2 1 Continuity No continuity NOTE When you switch the and leads of the digital pocket tester the readings in the above chart will be r...

Страница 372: ...lay 8 Starter motor 9 Starting circuit cutoff relay 11 Sidestand switch 21 Neutral switch 38 Clutch switch 56 Ignition fuse 63 Engine stop switch 64 Start switch 65 Diode 1 ELECTRIC STARTING SYSTEM EL...

Страница 373: ...relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cutoff relay is open so current cannot reach the starter motor When...

Страница 374: ...e vicinity SDoes the starter motor turn EB802401 ELECTRIC STARTING SYSTEM ELEC NOTE YES NO Replace the fuse s 1 Main and ignition fuses SCheck the main and ignition fuses for conti nuity Refer to CHEC...

Страница 375: ...r Connect the pocket tester 1 to the relay terminals as shown Measure the starting circuit cutoff relay for continuity as follows YES Replace the starting circuit cutoff relay NO Tester positive probe...

Страница 376: ...ES Is the engine stop switch OK YES Replace the right handlebar switch NO 8 Engine stop switch EB802413 Check the neutral switch for continuity Refer to CHECKING THE SWITCHES Is the neutral switch OK...

Страница 377: ...t switch OK YES Replace the right handlebar switch NO 13 Start switch Properly connect or repair the starting system s wiring EB803406 Check the sidestand switch for continuity Refer to CHECKING THE S...

Страница 378: ...assembly Throttle stop screw 1 1 1 Remove the parts in the order listed Refer to SEATS in chapter 3 Refer to FUEL TANK in chapter 3 Refer to CARBURETORS in chapter 6 Drain Refer to CHANGING THE COOLA...

Страница 379: ...or front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set O ring Brush holder set O ring Armature assembly Starter motor yoke 1 1 1 1 1 1 1 1 2 1 1 1 1 Remove the part...

Страница 380: ...aw blade which has been grounded to fit the commuta tor Mica undercut 0 7 mm The mica must be undercut to ensure proper operation of the commutator 4 Measure Sarmature assembly resistances commuta tor...

Страница 381: ...9 52 gf 7 Check gear teeth Damage wear Replace the gear 8 Check bearing oil seal Damage wear Replace the defective part s EB803701 ASSEMBLING THE STARTER MOTOR 1 Install brush seat 1 Align the tab a...

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

Страница 383: ...ry positive terminal Tester negative probe battery negative terminal SStart the engine and let it run at approximate ly 5 000 r min SMeasure the charging voltage NOTE YES NO Replace the fuse 1 Main fu...

Страница 384: ...place the rectifier regulator YES 5 Wiring Properly connect or repair the charging system s wiring EB804401 4 Stator coil assembly resistances SRemove the generator cover SConnect the pocket tester 1...

Страница 385: ...32 Illumination light 34 Pass switch 35 Dimmer switch 45 Headlight 46 Auxiliary light 47 Headlight relay Hi 48 Headlight relay LO 49 Tail brake light 53 Headlight fuse 54 Signaling system fuse 62 Ligh...

Страница 386: ...tch for Europe NOTE YES NO Replace the fuse s 1 Main signaling system and headlight fuses SCheck the main signaling system and headlight fuses for continuity Refer to CHECKING THE FUSES in chap ter 3...

Страница 387: ...f the lighting system s circuits Refer to CHECKING THE LIGHTING SYSTEM Check the headlight bulb and socket for con tinuity Refer to CHECKING THE BULBS AND BULB SOCKETS Are the headlight bulb and socke...

Страница 388: ...from the cou pler Connect the pocket tester 1 and bat tery 12 V to the headlight relay terminals as shown Tester positive probe yellow green Tester negative probe red yellow 1 2 4 3 YES Replace the he...

Страница 389: ...on the meter assembly coupler wire harness side Is the voltage within specification 1 YES The wiring circuit from the main switch to the tail brake light coupler is faulty and must be repaired NO This...

Страница 390: ...h to the auxiliary light connectors is faulty and must be re paired NO This circuit is OK Set the main switch to ON Set the light switch to or Measure the voltage 12 V of blue red on the auxiliary lig...

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

Страница 392: ...light 27 Neutral indicator light 28 Tachometer 29 Combination meter 31 Turn signal indicator light 36 Horn switch 37 Horn 39 Turn signal switch 40 Flasher relay 41 Front turn signal light L 42 Front...

Страница 393: ...m s wiring Refer to CIRCUIT DIAGRAM SIs the signaling system s wiring properly con nected and without defects YES Properly connect or repair the signaling system s wiring Check the condition of each o...

Страница 394: ...horn switch Does the horn sound NO 4 Voltage Connect the pocket tester DC 20 V to the horn connector at the black terminal as shown Tester positive probe black Tester negative probe ground 1 Set the...

Страница 395: ...coupler is faulty and must be repaired NO This circuit is OK Set the main switch to ON Pull in the brake lever or push down on the brake pedal Measure the voltage 12 V of yellow at the tail brake ligh...

Страница 396: ...1 5 Voltage Connect the pocket tester DC 20 V to the turn signal relay coupler wire harness side as shown The turn signal relay is faulty and must be replaced NO YES 1 Set the main switch to ON Set th...

Страница 397: ...Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe brown Tester negative probe sky blue 1 2 1 2 Replace the neutral switch NO 2 Neutral s...

Страница 398: ...positive probe red blue Tester negative probe black 1 2 3 4 4 Voltage Connect the pocket tester DC 20 V to the meter assembly coupler wire harness side as shown Tester positive probe brown Tester neg...

Страница 399: ...circuit OK Set the main switch to ON Measure the voltage 12 V Is the voltage within specification NO EAS00805 7 The clock fails to come on 1 Voltage Connect the pocket tester 20 V DC to the clock coup...

Страница 400: ...ive probe blue Tester negative probe blue black 1 2 3 Voltage Connect the pocket tester 20 V DC to the speedometer bulb socket coupler wire har ness side as shown NO YES Set the main switch to ON Meas...

Страница 401: ...use 23 Thermo unit 26 Oil level coolant temperature warning light 29 Combination meter 50 Radiator fan motor 51 Thermo switch 52 Radiator fan motor fuse 54 Signaling system fuse COOLING SYSTEM ELEC EB...

Страница 402: ...oupler from the wire harness SConnect the battery 12 V as shown YES The radiator fan mo tor is faulty and must be replaced Battery positive lead blue Battery negative lead black 1 2 SDoes the radiator...

Страница 403: ...oolant SSlowly heat the coolant then let it cool to the specified temperature as indicated in the table SCheck the thermo switch for continuity at the temperatures indicated in the table 6 Thermo swit...

Страница 404: ...dicated below 7 Thermo unit Handle the temperature sender with spe cial care Never subject the temperature sender to strong shocks If the temperature sender is dropped replace it WARNING Temperature s...

Страница 405: ...witch 5 Battery 6 Main fuse 9 Starting circuit cutoff relay 10 Fuel pump 14 CDI unit 54 Signaling system fuse 56 Ignition fuse 63 Engine stop switch FUEL PUMP SYSTEM ELEC EB808000 FUEL PUMP SYSTEM CIR...

Страница 406: ...EC 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 CDI unit 7 Starting circuit cutoff relay 8 Fuel pump EB808010 FUEL PUMP CIRCUIT OPERATION The CDI unit includes the contro...

Страница 407: ...he battery Refer to CHECKING AND CHARGING THE BATTERY in chapter 3 SIs the battery OK NO EB802412 4 Engine stop switch SCheck the engine stop switch for continuity Refer to CHECKING THE SWITCHES SIs t...

Страница 408: ...wire harness SConnect the pocket tester 1 to the fuel pump coupler fuel pump side as shown Tester positive probe blue black Tester negative probe black 1 2 Tester positive probe red Tester negative pr...

Страница 409: ...accidentally spill gasoline wipe it up immediately with dry rags If gasoline touches the engine when it is hot a fire may occur Therefore make sure that the engine is completely cool before performin...

Страница 410: ...N irrespective of whether the engine is running or not Circuit Defect s System response Condition code Throttle posi tion sensor Disconnected Short circuit Locked The ignitor unit stays set to the wid...

Страница 411: ...ce the throttle position sensor Replace the CDI unit EB812401 SELF DIAGNOSIS ELEC NOTE 13 Throttle position sensor 14 CDI unit EB812010 TROUBLESHOOTING The tachometer starts to display the self diagno...

Страница 412: ...2 Fuel sender Disconnect the fuel sender coupler from the wire harness Connect the pocket tester W 1 to the fuel sender coupler as shown YES Tester positive probe green Tester negative probe black 1 C...

Страница 413: ...8 57 Replace or replace the wire harness NO 3 Wire harness Check the wire harness for continuity Refer to CIRCUIT DIAGRAM Is the wire harness OK YES Replace the CDI unit SELF DIAGNOSIS ELEC EB812405...

Страница 414: ...ELEC...

Страница 415: ...TRBL SHTG 9...

Страница 416: ...PERFORMANCE 9 2 ENGINE 9 2 FUEL SYSTEM 9 2 FAULTY GEAR SHIFTING 9 2 SHIFTING IS DIFFICULT 9 2 SHIFT PEDAL DOES NOT MOVE 9 2 JUMPS OUT OF GEAR 9 2 FAULTY CLUTCH 9 3 CLUTCH SLIPS 9 3 CLUTCH DRAGS 9 3 O...

Страница 417: ...HEADLIGHT DOES NOT LIGHT 9 5 HEADLIGHT BULB BURNT OUT 9 5 TAIL BRAKE LIGHT DOES NOT LIGHT 9 5 TAIL BRAKE LIGHT BULB BURNT OUT 9 5 TURN SIGNAL DOES NOT LIGHT 9 5 TURN SIGNAL BLINKS SLOWLY 9 5 TURN SIGN...

Страница 418: ...ng guide for troubleshooting does not cover all the possible causes of trouble It should be helpful however as a guide to basic troubleshooting Refer to the relative procedure is this manual for check...

Страница 419: ...dog EB901000 INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder head Incorrect valve clearance Damaged valve train components Air filter Clogged air filter element FUEL SYSTEM Carburetors Fau...

Страница 420: ...it EB904000 FAULTY CLUTCH CLUTCH SLIPS Clutch Incorrectly assembled clutch Incorrectly adjusted clutch cable Loose or fatigued clutch spring Worn friction plate Worn clutch plate Engine oil Incorrect...

Страница 421: ...teering head pipe Incorrectly installed bearing race EB907000 POOR BRAKING PERFORMANCE Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper piston seal...

Страница 422: ...rn Faulty main switch Faulty horn switch Faulty battery Blown damaged or incorrect fuse Faulty wire harness EB910000 FAULTY LIGHTING AND SIGNALING SYSTEMS HEADLIGHT DOES NOT LIGHT Wrong headlight bulb...

Страница 423: ...TRBL SHTG...

Страница 424: ...l light R 43 Rear turn signal light L 44 Rear turn signal light R 45 Headlight 46 Auxiliary light 47 Headlight relay Hi 48 Headlight relay Lo 49 Tail brake light 50 Radiator fan motor 51 Thermo switch...

Страница 425: ...ht L 42 Front turn signal light R 43 Rear turn signal light L 44 Rear turn signal light R 45 Headlight 47 Headlight relay Hi 48 Headlight relay Lo 49 Tail brake light 50 Radiator fan motor 51 Thermo s...

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