2001-2002 Yamaha Fz-1 Service Repair Workshop Manual Download

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FZS1000N (C) SERVICE MANUAL 2001 by Yamaha Motor Corporation, U.S.A. First edition, January 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-14-48
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NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: S This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully. S Designs and specifications are subject to change without notice.
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IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle.
CAUTION:
NOTE:
A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.
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HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS on the following page. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (Periodic Checks and Adjustments), where the sub-section title(-s) appears.
(In Chapter 3, Periodic Checks and Adjustments, the sub-section title appears at the top of each page, instead of the section title.)
3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced (see SYMBOLS). 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially. 6 2 1
3 4 5 8
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SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis 8 Electrical system 9 Troubleshooting
GEN INFO
3
SPEC
4
CHK ADJ
5 6
ENG
COOL
7
CARB
8
CHAS
9
ELEC
10
Symbols 10 to 17 indicate the following.

10 11 12 13 14 15 16 17
TRBL SHTG
11 12
Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data
13
14
15
16
17
18
19
20
Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18 19 20 21 22 23
21
22
23
Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap base grease Molybdenum disulfide grease
24
25
Symbols 24 to 25 in the exploded diagrams indicate the following:

24 Apply locking agent (LOCTITER) 25 Replace the part
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TABLE OF CONTENTS
GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURETORS CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING
GEN INFO
1 2 3 4 5 6 7 8 9
SPEC
CHK ADJ
ENG
COOL
CARB
CHAS
ELEC
TRBL SHTG
GEN INFO
CHAPTER 1 GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2 1-2 1-3 1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
GEN INFO
MOTORCYCLE IDENTIFICATION
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GEN INFO
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
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VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head.
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MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
1-1
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GEN INFO
PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the SPECIAL TOOLS section. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been mated through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all 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.
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REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
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lip
lip spring
oil grease
GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and apply grease onto the oil seal lips with greace.
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LOCK WASHERS/PLATES AND COTTER PINS 1. After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.
1-2
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GEN INFO
BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturers marks or numbers are visible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips. Oil bearings liberally when installing, if appropriate. 1 Oil seal
CAUTION:
Do not spin the bearing with compressed air because this will damage the bearing surfaces.
1 Bearing
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CIRCLIPS 1. Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1 , make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4 Shaft
1-3
CHECKING THE CONNECTIONS

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GEN INFO
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead 1 S coupler 2 S connector 3 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect several times. 3. Check: S all connections Loose connection ! Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. 4. Connect: S lead S coupler S connector NOTE: Make sure that all connections are tight. 5. Check: S continuity (with a pocket tester) Pocket tester measurement YU-03112-C NOTE: S If there is no continuity, clean the terminals. S When checking the wire harness, perform steps 1 to 3. S As a quick remedy, use a contact revitalizer available at most part stores.
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SPECIAL TOOLS
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GEN INFO
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Tool name/Function Alternator Rotor Puller YM-01080-A This tool is used to remove the generator rotor. Universal Magneto & Rotor Holder YU-01235 This tool is used to hold the generator rotor when removing or installing the generator rotor bolt or pickup coil rotor bolt. Piston Pin Puller YU-01304 This tool is used to remove the piston pins. Fuel Level Gauge YU-01312-A This tool is used to measure the fuel level in the float chamber. Radiator Pressure Tester YU-24460-01 Radiator Pressure Tester Adapter YU-33984 Radiator Pressure Tester Radiator Pressure Tester Adapter These tools are used to check the cooling system. Spanner Wrench YU-33975 This tool is used to loosen or tighten the steering stem ring nuts. Steering Nut Wrench YU-1268 This tool is used to loosen the steering stem ring nuts. Damper Rod Holder YM-01447 This tool is used to hold the damper rod assembly when loosening or tightening the damper rod assembly bolt.
1-5
Illustration
SPECIAL TOOLS
GEN INFO
Illustration
Tool No.
Tool name/Function Oil Filter Wrench
YU-38411 This tool is needed to loosen or tighten the oil filter cartridge. Rod Holder YM-01434 This tool is used to support the damper adjusting rod. Rod Puller Rod puller YM-01437 Driver YM-33963 43 mm Adapters YM-8020-A
This tool is used to pull up the front fork damper rod. Driver 43 mm Adapters This tool is used to install the front forks oil seal and dust seal. Micrometers (50 X 75 mm)
YU-03008 This tool is used to measure the piston skirt diameter. Carburetor Synchronizer YU-8030 This guide is used to synchronize the carburetors. Compression Gauge Set Compression Gauge Set YU-33223
Compression Gauge Adapter
These tools are used to measure engine compression. Pocket Tester Measurement
YU-03112-C This tool is used to check the electrical system. Inductive Self-Powered Tachometer YU-8036-B This tool is used to check engine speed.
1-6
SPECIAL TOOLS
GEN INFO
Illustration
Tool No.
Tool name/Function Battery Powered Timing Light
YM-33277-A This tool is used to check the ignition timing. Valve Spring Compressor YM-04019 Adapter YM-4108 YM-4114 40 and 50 mm Bearing Driver YM-4058 Water Pump Seat Installer YM-33221 Valve Spring Compressor Set, Quick Release Adapter These tools are used to remove or install the valve assemblies. 40 and 50 mm Bearing Driver Water Pump Seal Installer These tools are used to install the water pump seal. Universal Clutch Holder (Grabbit) YM-91042 This tool is used to hold the clutch boss when removing or installing the clutch boss nut. Valve Guide Remover (4) Valve Guide Remover (4.5) YM-04111 YM-4116 This tool is used to remove or install the valve guides. Valve Guide Installer (4) Valve Guide Installer (4.5) YM-04112 YM-4117 This tool is used to install the valve guides. Valve Guide Reamer (4) Valve Guide Reamer (4.5) YM-04113 YM-4118 This tool is used to rebore the new valve guides. Dynamic Spark Tester YM-34487 This tool is used to check the ignition system components. Yamaha bond No. 1215 ACC-1100105-01 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
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SPEC
CHAPTER 2. SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 2-18 2-19 2-22
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23 CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24 COOLING SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 ENGINE OIL LUBRICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 LUBRICATION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
SPEC
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Model code Standard 5LV5 (USA except for California) 5LV6 (CDN) 5LV7 (California) 2,125 mm (83.7 in) 765 mm (30.1 in) 1,190 mm (46.9 in) 820 mm (32.3 in) 1,450 mm (57.1 in) 140 mm (5.5 in) 2,900 mm (114.2 in) 231 kg (509 lb) 232 kg (512 lb) (for california) 208 kg (459 lb) 209 kg (461 lb) (for california) 189 kg (417 lb) 188 kg (415 lb) (for california) Limit
Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo, rider, passenger, and accessories)
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ENGINE SPECIFICATIONS
SPEC
Limit
Item Engine Engine type Displacement Cylinder arrangement Bore X stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Engine oil Lubrication system Recommended oil Standard Liquid-cooled, 4-stroke, DOHC 998 cm3 Forward-inclined parallel 4-cylinder 74 X 58 mm (2.91 X 2.28 in) 11.4 : 1 1,050 X 1,150 r/min 30 kPa (225 mmHg, 8.86 in Hg) 1,450 kPa (14.5 kg/cm2, 206 psi) at 400 r/min Unleaded fuel (for USA) Regular unleaded gasoline (for CDN) 21 L (18.5 Imp qt, 22.2 US qt) 4.0 L (3.52 Imp qt, 4.22 US qt) Wet sump Yamalube 4 (20W40) or SAE 20W40 type SE motor oil
Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure (hot) Relief valve opening pressure
3.7 L (3.2 Imp qt, 3.8 US qt) 2.8 L (2.4 Imp qt, 2.9 US qt) 3.0 L (2.6 Imp qt, 3.1 US qt) 45 kPa (0.45 kg/cm2, 6.40 psi) at 1,100 r/min 490 X 570 kPa (4.9 X 5.7 kg/cm2, 69.7 X 81.1 psi)
2-2
Item Oil filter Oil filter type Bypass valve opening pressure Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max. impeller shaft tilt Starting system type Spark plugs Model (manufacturer) X quantity Spark plug gap Cylinder head Max. warpage Standard Cartridge (paper) 180 X 220 kPa (1.8 X 2.2 kg/cm2, 25.6 X 31.3 psi) Trochoidal 0.09 X 0.15 mm (0.004 X 0.006 in) 0.03 X 0.08 mm (0.001 X 0.003 in)
SPEC
Limit
2.4 L (2.11 Imp qt, 2.53 US qt) 95 X 125 kPa (0.95 X 1.25 kg/cm2, 13.1 X 17.8 psi) 340 mm (13.4 in) 238 mm (9.4 in) 24 mm (0.94 in) 0.3 L (0.26 Imp qt, 0.32 US qt) Single-suction centrifugal pump 68/43 X 28/28 (1.581) 0.15 mm (0.006 in) Electric starter CR9E/U27ESR-N (NGK/DENSO) X 4 0.7 X 0.8 mm (0.028 X 0.031 in) 0.1 mm (0.004 in)
2-3
Item Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Intake camshaft lobe dimensions Standard
SPEC
Limit
Chain drive (right) 24.500 X 24.521 mm (0.9646 X 0.9654 in) 24.459 X 24.472 mm (0.9630 X 0.9635 in) 0.028 X 0.062 mm (0.0011 X 0.0024 in)
Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions
32.5 X 32.6 mm (1.2795 X 1.2835 in) 24.95 X 25.05 mm (0.9823 X 0.9862 in) 7.45 X 7.65 mm (0.2933 X 0.3012 in)
32.4 mm (1.2756 in) 24.85 mm (0.9783 in)
Measurement A Measurement B Measurement C Max. camshaft runout
32.95 X 33.05 mm (1.2972 X 1.3012 in) 24.95 X 25.05 mm (0.9823 X 0.9862 in) 7.75 X 7.95 mm (0.3051 X 0.3126 in)
32.85 mm (1.2933 in) 24.85 mm (0.9783 in) 0.03 mm (0.0012 in)
2-4
Item Timing chain Model/number of links Tensioning system Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions RH2015/130 Automatic Standard
SPEC
Limit
0.11 X 0.20 mm (0.0043 X 0.0079 in) 0 21 X 0.25 0.21 0 25 mm (0 (0.0083 0083 X 0 0.0098 0098 in)
Head Diameter
Face Width
Seat Width
Margin Thickness
Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust
22.9 X 23.1 mm (0.9016 X 0.9094 in) 24.4 X 24.6 mm (0.9606 X 0.9685 in) 1.76 X 2.90 mm (0.0693 X 0.1142 in) 1.76 X 2.90 mm (0.0693 X 0.1142 in) 0.9 X 1.1 mm (0.035 X 0.043 in) 0.9 X 1.1 mm (0.035 X 0.043 in) 0.5 X 0.9 mm (0.020 X 0.035 in) 0.5 X 0.9 mm (0.020 X 0.035 in) 3.975 X 3.900 mm (0.1565 X 0.1535 in) 4.465 X 4.480 mm (0.1758 X 0.1764 in) 4.000 X 4.012 mm (0.1575 X 0.1580 in) 4.500 X 4.512 mm (0.1772 X 0.1776 in) 3.945 mm (0.1553 in) 4.43 mm (0.1744 in) 4.05 mm (0.1594 in) 4.55 mm (0.1791 in)
0.010 X 0.037 mm (0.0004 X 0.0015 in) 0.020 X 0.047 mm (0.0008 X 0.0019 in)
0.08 mm (0.0031 in) 0.10 mm (0.0039 in)
2-5
Item Valve stem runout SSS Standard
SPEC
Limit 0.01 mm (0.0004 in)
Valve seat width Intake Exhaust Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt
0.9 X 1.1 mm (0.035 X 0.043 in) 0.9 X 1.1 mm (0.035 X 0.043 in) 38.90 mm (1.53 in) 40.67 mm (1.60 in) 34.50 mm (1.36 in) 35.00 mm (1.38 in)
SSS SSS SSS SSS SSS SSS
82 X 96 N (8.2 X 9.6 kg, 18.4 X 25.4 lb) SSS 110 X 126 N SSS (11.0 X 12.6 kg, 24.7 X 28.3 lb)
Intake Exhaust Winding direction (top view) Intake Exhaust
SSS SSS Clockwise Clockwise
2.5_ /1.7 mm (2.5_ /0.067 in) 2.5_ /1.8 mm (2.5_ /0.071 in) SSS SSS
2-6
Item Cylinders Cylinder arrangement Bore X stroke Compression ratio Bore Max. taper Max. out-of-round Pistons Piston-to-cylinder clearance Diameter D Standard
SPEC
Limit
Forward-inclined, parallel 4-cylinder 74 X 58 mm (2.91 X 2.28 in) 11.4 : 1 74.00 X 74.01 mm (2.9134 X 2.9138 in) 0.05 mm (0.0016 in) 0.05 mm (0.0016 in) 0.030 X 0.055 mm (0.001 X 0.002 in) 73.955 X 73.970 mm (2.9118 X 2.9122 in) 0.12 mm (0.005 in)
Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pins Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring
5 mm (0.20 in) 17.002 X 17.013 mm (0.6694 X 0.6698 in) 0.5 mm (0.0197 in) Intake side 16.991 X 17.000 mm (0.6689 X 0.6693 in) 0.002 X 0.022 mm (0.00008 X 0.00087 in) 17.043 mm (0.6710 in)
16.971 mm (0.6681 in) 0.072 mm (0.0028 in)
Ring type Dimensions (B X T) End gap (installed) Ring side clearance
Barrel 0.90 X 2.75 mm (0.035 X 0.108 in) 0.32 X 0.44 mm (0.010 X 0.020 in) 0.030 X 0.065 mm (0.0012 X 0.0026 in)
2-7
Item 2nd ring Standard
SPEC
Limit
Ring type Dimensions (B X T) End gap (installed) Ring side clearance Oil ring
Taper 0.8 X 2.8 mm (0.031 X 0.110 in) 0.43 X 0.58 mm (0.017 X 0.023 in) 0.020 X 0.055 mm (0.0008 X 0.0022 in)
Dimensions (B X T) End gap (installed) Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code Crankshaft
1.5 X 2.6 mm (0.059 X 0.101 in) 0.10 X 0.35 mm (0.004 X 0.014 in) 0.031 X 0.055 mm (0.0012 X 0.0022 in) 1 = Violet 2 = Black 0 = White 1 = Blue
Width A Width B Max. runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code
52.40 X 57.25 mm (2.063 X 2.254 in) 300.75 X 302.65 mm (11.84 X 11.92 in) 0.03 mm (0.0012 in) 0.160 X 0.262 mm (0.006 X 0.010 in) 0.029 X 0.053 mm (0.0011 X 0.0021 in) 1 = Pink/violet 1 = Pink/blue 3 = Pink/brown 0 = Pink/white 2 = Pink/black
Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play (at the end of the clutch lever)
Wet, multiple disc Cam (pull rod type) Cable operation Left-hand operation 10 X 15 mm (0.39 X 0.59 in)
2-8
Item Friction plates Thickness Plate quantity Thickness Plate quantity Clutch plates Thickness Plate quantity Max. warpage Clutch springs Free length Spring quantity Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Max. main axle runout Max. drive axle runout Shifting mechanism Shift mechanism type Max. shift fork guide bar bending Installed shift rod length Air filter type Fuel pump Pump type Model (manufacturer) Output pressure Standard 2.92 X 3.08 mm (0.115 X 0.121 in) 8 3.42 X 3.58 mm (0.135 X 0.141 in) 1 1.9 X 2.1 mm (0.075 X 0.083 in) 8
SPEC
Limit 2.82 mm (0.111 in) 3.32 mm (0.131 in)
0.1 mm (0.004 in) 50 mm (1.97 in) 6 Constant mesh, 6-speed Spur gear 68/43 (1.581) Chain drive 44/16 (2.750) Left-foot operation 35/14 (2.500) 35/19 (1.842) 30/20 (1.500) 28/21 (1.333) 30/25 (1.200) 29/26 (1.115) 0.08 mm (0.003 in) 0.08 mm (0.003 in) Guide bar 0.1 mm (0.004 in) 260 mm (10.2 in) Dry element Electrical 4SV (MITSUBISHI) 20 kPa (0.2 kg/cm2, 2.8 psi)
2-9
Item Carburetors Model (manufacturer) X quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat size Starter jet 1 Starter jet 2 Throttle valve size Fuel level (above the line on the float chamber) Max. EXUP cable free play (at the EXUP valve pulley) Standard BSR37 (MIKUNI) X 4 3 X 5 mm (0.12 X 0.20 in) 5LV5 40 Carburetors 1 and 4: #132.5 Carburetors 2 and 3: #130 #80 Carburetor 1 and 4: 5D129-3/5 Carburetor 2 and 3: 5D130-3/5 P-OM #85 1.0 #15 0.9 0.9 0.9 2.0 1.5 #42.5 0.8 #115 3.0 X 4.0 mm (0.118 X 0.157 in) 1.5 mm (0.059 in)
SPEC
Limit
2-10
CHASSIS SPECIFICATIONS
SPEC
Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg 90 X 201 kg High-speed riding Min. tire tread depth Standard Double cradle 26_ 104 mm (4.09 in) Cast wheel 17 X MT3.50 Aluminum 140 mm (5.51 in) SSS SSS SSS SSS SSS SSS SSS SSS SSS 1 mm (0.04 in) 0.5 mm (0.02 in) SSS SSS SSS SSS 1 mm (0.04 in) 0.5 mm (0.02 in) SSS SSS SSS SSS SSS SSS 1.0 mm (0.04 in) Limit
Cast wheel 17 X MT5.50 Aluminum 135 mm (5.31 in) SSS SSS
Tubeless 120/70 ZR17 (58W) MEZ4Y FRONT (METZELER) BT020F U (BRIDGESTONE) 250 kPa (2.5 kgf/cm2, 36 psi) 250 kPa (2.5 kgf/cm2, 36 psi) 250 kPa (2.5 kgf/cm2, 36 psi) SSS
2-11
Item Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg 90 X 201 kg High-speed riding Min. tire tread depth Front brakes Brake type Operation Recommended fluid Brake discs Diameter X thickness Min. thickness Max. deflection Brake pad lining thickness 5.5 mm (0.22 in) Standard Tubeless 180/55 ZR17 (73W) MEZ4Y (METZELER) BT020R U (BRIDGESTONE) 270 kPa (2.7 kgf/cm2, 39 bar) 290 kPa (2.9 kgf/cm2, 42 bar) 290 kPa (2.9 kgf/cm2, 42 bar)
SPEC
Limit
1.0 mm (0.04 in) Dual-disc brake Right-hand-operation DOT 4 298 X 5 mm (11.7 X 0.20 in) 4.5 mm (0.18 in) 0.1 mm (0.004 in) 0.5 mm (0.02 in)
Master cylinder inside diameter Caliper cylinder inside diameter Rear brake Brake type Operation Brake pedal position (from the top of the brake pedal to the top of the rider footrest) Recommended fluid Brake discs Diameter X thickness Min. thickness Max. deflection Brake pad lining thickness
14 mm (0.05 in) 30.2 mm (1.19 in) and 27 mm (1.06 in) Single-disc brake Right-foot operation 35 X 40 mm (1.38 X 1.57 in) DOT 4 267 X 5 mm (10.51 X 0.20 in) 4.5 mm (0.18 in) 0.1 mm (0.004 in) 0.5 mm (0.02 in)
5.5 mm (0.22 in)
Master cylinder inside diameter Caliper cylinder inside diameter
12.7 mm (0.5 in) 42.9 mm (1.69 in)
2-12
Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate (K1) Spring rate (K2) Spring stroke (K1) Spring stroke (K2) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *from the fully turned-in position Standard Telescopic fork Coil sprin 140 mm (5.51 in) 344.0 mm (13.5 in) 66.0 mm (2.60 in) 320.0 mm (12.6 in) 7.8 N/mm (0.78 kg/mm, 43.7 lb/in) 11.8 N/mm (1.2 kg/mm, 67.2 lb/in) 0 X 64 mm (0 X 2.52 in) 64 X 140 mm (2.52 X 5.51 in) No Suspension oil 01 or equivalent 435 cm3 (15.3 Imp oz, 14.7 US oz) 140 mm (5.51 in)
SPEC
Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS
5 (fully turned out position) 2 1
SSS SSS SSS SSS SSS SSS SSS SSS SSS
17 7 1
21 6 1
2-13
Item Steering Steering bearing type Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard spring preload gas/air pressure Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *from the fully turned-in position Swingarm Free play (at the end of the swingarm) Radial Axial Drive chain Model (manufacturer) Link quantity Drive chain slack Maximum ten-link section Standard Angular ball bearings Swingarm (link suspension) Coil spring/gas-oil damper 65 mm (2.56 in)
SPEC
Limit
182.5 mm (7.19 in) 163 mm (6.42 in) 73.6 N/mm (7.5 kg/mm, 420 lb/in) 0 X 65 mm (0 X 2.56 in) No 1,200 kPa (12 kg/cm2, 170.7 psi)
1 6 11
20 10 3
1 7 12
1 mm (0.04 in) 1 mm (0.04 in) 50ZVM (DAIDO) 116 40 X 50 mm (1.57 X 1.97 in) 150.1 mm (5.91 in)
152.5 mm (6.00 in)
2-14
ELECTRICAL SPECIFICATIONS
SPEC
Item System voltage Ignition system Ignition system type Ignition timing Advanced timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug caps Material Resistance Throttle position sensor standard resistance Charging system System type Model (manufacturer) Normal output Stator coil resistance/color Rectifier/regulator Regulator type Model ( (manufacture) ) No-load regulated voltage Rectifier capacity Withstand voltage Battery Battery type Battery voltage/capacity Headlight type Bulbs (voltage/wattage X quantity) Headlight Auxiliary light Tail/brake light Front turn signal light Rear turn signal light Meter light 12 V Transistorized coil ignition 5_ BTDC at 1,100 r/min 55_ BTDC at 5,000 r/min Throttle position sensor and electrical 248 X 372 /Gy-B TNDF69 (DENSO) Standard SSS SSS SSS SSS SSS SSS SSS Limit
J0313 (DENSO) 6 mm (0.24 in) 1.87 X 2.53 12 X 18 k Rubber 10 k 4 X 6 k AC magneto F4T361 (MITSUBISHI) 14 V/365 W at 5,000 r/min 0.27 X 0.33 at 20_C (68_F)/W-W Semiconductor short circuit SH650C-11 ( (SHINDENGEN) ) 14.1 X 14.9 V 18 A 200 V GT14B-4 12 V/12AH Halogen bulb 12 V 60 W/55 W X 2 12 V 5 W X 2 12 V 5 W/21 W X 2 12 V 8 W/27 W X 2 12 V 27 W X 2 12 V 2 W X 3
SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS
SSS SSS SSS SSS SSS SSS
2-15
Item Indicator light (voltage /wattage X quantity) Neutral indicator light High beam indicator light Oil level indicator light Turn signal indicator light Fuel indicator light Water temperature indicator light Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut Starter relay Model (manufacturer) Amperage Coil resistance Horn Horn type Model (manufacturer) X quantity Max. amperage Turn signal relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Oil level switch Model (manufacturer) Fuel sender Model (manufacturer) Resistance Sidestand /fuel pump relay Model (manufacturer) Coil resistance Fuel pump maximum amperage Radiator fan Model (manufacturer) Thermo switch Model (manufacturer) Standard
SPEC
Limit
14 V 1.4 W X 1 14 V 1.4 W X 1 14 V 1.4 W X 1 14 V 1.4 W X 2 12 V 2 W X 1 LED Constant mesh SM-13 (MITSUBA) 0.8 kW 12.5 mm (0.49 in) 7.65 X 10.01 N (780 X 1,021 gf, 27.5 X 36.0 oz) 0.025 X 0.035 28 mm (1.10 in) 0.7 mm (0.03 in) MS5F-631 (JIDECO) 180 A 4.18 X 4.62 Plain YF-12 (NIKKO) X 1 3A Full-transistor FE246BH (DENSO) No 75 X 95 cycles/min. 27 W X 2 + 3.4 W 5LV (DENSO) 5LV (NIPPON SEIKI) 4 X 100 at 25_C (77_F) 5EB-20 (OMRON) 180 1.2 A 4XV (TOYO RADIATOR) 5JJ (NIPPON THERMOSTAT)
2-16
SSS SSS SSS SSS SSS SSS SSS SSS SSS 4 mm (0.16 in) SSS SSS 27 mm (1.06 in) SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS
Item Fuses (amperage quantity) Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Turn signal relay fuse Backup fuse (odometer) Reserve fuse 30 A 20 A 20 A 20 A 10 A 10 A 10 A 30 A 20 A 10 A 1 1 1 1 1 1 1 1 1 1 Standard
SPEC
Limit
2-17
TIGHTENING TORQUES
EAS00030
SPEC
GENERAL TIGHTENING TORQUE SPECIFICATIONS

This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.
A: Distance between flats B: Outside thread diameter A (Nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm B (Bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm General tightening torques Nm 6 15 30 55 85 130 m kg 0.6 1.5 3.0 5.5 8.5 13.0 ft lb 4.3 11 22 40 61 94
2-18
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES Item Spark plugs Cylinder head Cylinder head Cylinder head Camshaft caps Cylinder head cover Cylinder head (exhaust pipe) Connecting rod caps Generator rotor Crankshaft sprocket Cap bolt (timing chain tensioner) Camshaft sprocket Water pump inlet pipe Water pump outlet pipe Oil/water pump assembly driven sprocket Oil pump Oil cooler Engine oil drain bolt Oil strainer housing Oil/water pump assembly driven sprocket cover Oil delivery pipe Oil filter bolt Oil filter cartridge Oil pipe Oil strainer cover Air cleaner cap and air cleaner Frame and air cleaner Air cleaner cover and air cleaner Ring nut and cylinder head Exhaust pipe and muffler Emission check bolt EXUP pulley cover EXUP cable bracket EXUP pulley and shaft arm Exhaust joint Exhaust pipe assembly Air induction system pipe Crankcase (cylinder head) Crankcase Crankcase Crankcase Crankcase Fastener Nut Cap nut Bolt Bolt Bolt Stud bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Screw Bolt Screw Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Band Stud bolt Bolt Bolt Bolt Bolt Thread Qty y size M10 M10 M10 M6 M6 M6 M8 M8 M10 M10 M6 M7 M6 M6 M6 M6 M20 M14 M6 M6 M6 M20 M20 M6 M6 M6 M6 M6 M8 M8 M8 M6 M6 M5 M4 M8 M10 M9 M6 M6 M8 4 8 2 2 28 6 8 8 1 1 1 4 1 1 1 1 1 1 2 1 1 1 1 2 2 4 3 6 8 3 4 3 3 1 2 1 4 10 10 2 14 2 14 12 24 Tightening torque Nm 13 50 50 12 10 12 15 mSkg 1.3 5.0 5.0 1.2 1.0 1.2 1.5
SPEC
Remarks ftSlb 9.4 36 36 8.7 7.2 8.7 11
36 3.6 25 65 + 60_ 6.5 + 60_ 47 + 60_ 60 6.0 43 6.4 24 10 10 15 12 35 43 10 12 10 70 17 10 10 6 7 2 20 20 10 10 10 10 3 20 3.5 10 0.64 2.4 1.0 1.0 1.5 1.2 3.5 4.3 1.0 1.2 1.0 7.0 1.7 1.0 1.0 0.6 0.7 0.2 2.0 2.0 1.0 1.0 1.0 1.0 0.3 2.0 0.35 1.0 See note 1.4 1.2 2.4 10 8.7 17 4.6 17 7.2 7.2 11 8.7 25 31 7.2 8.7 7.2 51 12 7.2 7.2 4.3 5.1 1.4 14 14 7.2 7.2 7.2 7.2 2.2 14 2.5 7.2
2-19
TIGHTENING TORQUES
Thread size M6 M6 M6 M6 M6 M6 M6 M8 M6 M6 M20 M6 M22 M6 M6 M8 M6 M6 M6 M6 M6 M5 M10 M6 Tightening torque Nm 9 4 2 8 8 5 5 1 1 3 1 6 1 3 2 1 1 2 1 1 3 2 1 2 1 12 10 10 12 12 12 10 15 10 12 90 8 85 12 10 22 6.5 6.5 10 10 14 7 20 10 15 mSkg 1.2 1.0 1.0 1.2 1.2 1.2 1.0 1.5 1.0 1.2 9.0 0.8 8.5 1.2 1.0 2.2 0.65 0.65 1.0 1.0 1.4 0.7 2.0 1.0 1.5
SPEC
Remarks ftSlb 8.7 7.2 7.2 8.7 8.7 8.7 7.2 11 7.2 8.7 65 5.8 61 8.7 7.2 16 4.7 4.7 7.2 7.2 10 5.1 14 7.2 11 Use a lock washer. Use a lock washer.
Item AC magneto cover Drive sprocker cover Plate Clutch cover Timing chain cap bolt Shift shaft cover Breather plate Timing mark accessing screw Starter clutch idle gear shaft Starter one-way clutch Clutch boss Clutch spring Drive sprocket Main axle bearing housing Shift lever stopper Stopper screw Shift rod Shift rod Shift rod joint Shift arm AC magneto stator coil Ignitor unit Neutral switch Pick up coil Thermo unit
Fastener Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Nut Screw Bolt Screw Nut Nut Bolt Bolt Screw Screw Bolt
Qty y
Left thread
NOTE: 1. First, tighten the bolt to approximately 14.7 Nm (1.5 mSkg, 11 ftSlb) with a torque wrench. 2. Retighten the bolt to 14.7 Nm (1.5 mSkg, 11 ftSlb), and tighten another 45 X 50_.
2-20
TIGHTENING TORQUES
Crankcase tightening sequence:
SPEC
2-21
TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES Item Upper bracket pinch bolt Upper bracket cap nut Upper bracket and handlebar holder Handlebar holder Lower bracket pinch bolt Lower bracket ring nut Front brake master cylinder Front brake hose union bolt Engine mounting Engine mounting bolt/nut Engine mounting bolt/nut Frame and down tube Clutch cable lock nut Ignition coil and stay Pivot shaft Rear shock absorber (upper) Rear shock absorber and relay arm Relay arm and frame Relay arm and connecting arm Connecting arm and swing arm Drive chain guard Drive chain case Fuel cock Fuel sender Side cover Coolant reservoir tank Front wheel axle Front wheel axle pinch bolt Front brake caliper Front brake disk Front brake bleed screw Rear brake torque rod Rear wheel sprocket Drive chain adjusting nut Rear brake caliper Rear wheel axle Rear brake hose union bolt Rear brake bleed screw Rear brake disk Rider footrest bracket and frame Rear brake reservoir tank Rear brake master cylinder Rider footrest and bracket Passenger footrest bracket and frame Passenger footrest bracket and muffler Thread size M8 M22 M10 M8 M25 M6 M10 M10 M8 M10 M8 M6 M18 M10 M10 M10 M12 M12 M6 M6 M6 M5 M6 M6 M16 M8 M10 M6 M8 M8 M10 M8 M10 M24 M10 M8 M8 M8 M6 M8 M10 M8 M10 Tightening Nm 30 110 32 23 23 18 10 30 55 33 89 7 7 125 40 40 40 48 48 7 7 7 4 4 4 72 23 40 18 6 23 69 16 40 150 30 6 23 30 4 23 55 28 48 m kg 3.0 11 3.2 2.3 2.3 1.8 1.0 3.0 5.5 3.3 8.9 0.7 0.7 12.5 4.0 4.0 4.0 4.8 4.8 0.7 0.7 0.7 0.4 0.4 0.4 7.2 2.3 4.0 1.8 0.6 2.3 6.9 1.6 4.0 15 3.0 0.6 2.3 3.0 0.4 2.3 5.5 2.8 4.8
SPEC
ft lb 22 80 23 17 17 13 7.2 22 40 24 64 5.1 5.1 90 29 29 29 35 35 5.1 5.1 5.1 2.9 2.9 2.9 52 17 29 13 4.3 17 50 12 29 108 22 4.3 17 22 2.9 17 40 20 35
Remarks
See note
NOTE: 1. First, tighten the ring nut to approximately 52 Nm (5.2 m kg, 38 ft lb) with a torque wrench, then loosen the ring nut completely. 2. Retighten the ring nut to specification.
2-22
LUBRICATION POINTS AND LUBRICANT TYPES

EAS00031
SPEC

ENGINE Lubrication point Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Water pump impeller shaft Oil pump rotors (inner and outer) Oil strainer Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Cylinder head cover mating surface Crankcase mating surface Clutch cover (crankcase mating surface) Generator rotor cover (crankcase mating surface) Yamaha bond No.1215 Yamaha bond No.1215 Yamaha bond No.1215 Yamaha bond No.1215 Lubricant
2-23

EAS00032
SPEC
CHASSIS Lubrication point Steering bearings, steering seal lips and ball race cover lips Pivot shaft Swing arm pivoting points and connecting arm bearings Connecting arm oil seal lips Swing arm oil seal lips Relay arm bearings Relay arm oil seal lips Rear shock absorber upper bolt Front wheel oil seal lips Rear wheel oil seal lips Clutch hub oil seal lips Throttle cable end Starter cable end and starter lever Rear brake pedal moving point Shift pedal moving point Side stand moving point Passenger footrest ball joint and moving point Engine mounting bracket collar and oil seal lips Mainstand moving point Lubricant
2-24
COOLING SYSTEM DIAGRAMS

EAS00033
SPEC

1 2 3 4 Radiator cap Thermostat housing Radiator Water pump
2-25

1 2 3 4 5 Radiator cap Thermostat housing Radiator Oil cooler Water jacket joint
SPEC
2-26

1 Radiator cap 2 Thermostat 3 Thermo unit
SPEC
2-27

1 Radiator
SPEC
2-28
ENGINE OIL LUBRICATION CHART
SPEC
ENGINE OIL LUBRICATION CHART
Exhaust camshaft
Intake camshaft
Main gallery
Oil filter
Main axle
Oil cooler Relief valve
Strainer
Drive axle
2-29
LUBRICATION DIAGRAMS
EAS00034
SPEC
1 2 3 4 5 6 Oil cooler Oil filter cartridge Drain bolt Oil level switch Oil strainer Oil pump
2-30
1 2 3 4 5 Intake camshaft Exhaust camshaft Oil cooler Oil strainer Oil pump
SPEC
2-31
1 2 3 4 Intake camshaft Exhaust camsahft Oil filter cartridge Oil level switch
SPEC
2-32
1 Cylinder head 2 Crankshaft
SPEC
2-33
1 Main axle 2 Oil delivery pipe 3 Drive axle
SPEC
2-34
CABLE ROUTING
EAS00035
SPEC
CABLE ROUTING
A Fasten the handlebar switch lead (right) and handlebar with a plastic band. B Route the handlebar switch lead (right) backward the throttle cable and right side the brake hose guide. C Fasten the handlebar switch lead (left) and handlebar with a plastic band. D Fasten the handlebar switch lead (left), main switch lead, clutch cable and starter cable with a plastic band. Clamp beneath the horn lead branching position. Do not fasten the horn lead. E Route the main switch lead front and left side the another leads. F Route the horn lead outside the motorcycle body, and fasten with the under bracket. Do not loose between the horn and under bracket. G Route the brake hose through the brake hose guide. H Route the throttle cable 1 and 2 backward the brake hose, and left side the brake hose guide.
2-35
CABLE ROUTING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SPEC
Fuel pump lead Fuel pump EXUP cable Handlebar switch lead (right) Throttle cable 1 Throttle cable 2 Water-carburetor hose Fan motor lead Coolant reservoir tank over flow hose Fuel tank drain hose Fuel tank breather hose White paint mark Rear brake light switch lead Neutral switch lead Speedo sensor lead Pickup coil lead
17 Handle crown 18 Handlebar switch lead 19 Brake hose guide
A Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speed sensor lead, rear brake light switch lead and fuel pump with a plastic clamp. B Fasten the fuel hose, pickup coil lead, neutral switch lead and speed sensor lead with a plastic clamp under the fuel hose. C Put the EXUP cable into the air box cover. D Route the T.P.S. lead inward the EXUP cable. E Fasten the water-carburetor hose with a plastic band. F Route the coolant hose over the frame. G Fasten the handlebar switch lead and frame with a plastic guide. H Align the white tape mark of the handlebar switch lead (right) with the tank rail welding bead and clamp down throttle cables 1 and 2.
2-36
CABLE ROUTING
I Route the water-carburetor hose between the frame cross pipe and fan motor lead. J To the carburetor K Fasten the T.P.S. lead with a steel clamp. L Fasten the coolant hose with a plastic band. M Fasten the pickup coil lead with a steel clamp. N Pass the coolant reservoir tank overflow hose, fuel tank drain hose and fuel tank breather hose through the frame hose holder from the inside of the vehicle to the outside. At this time, pull the fuel tank drain hose and fuel tank breather hose so that the white paint marks are within a 20 mm (0.79 in) range. O Route the EXUP cable forward the another hoses, and upward the engine mounting bracket. P Fasten the rear brake light switch lead with a plastic guide.
SPEC
Q Insert the all couplers into the rubber cover. R Route the rear brake light switch lead inside the another leads. S Route the neutral switch lead and speed sensor lead left side the coolant reservoir hose. T Route the coolant reservoir hose left side the engine mounting bracket. U Route the coolant reservoir hose forward the neutral switch lead and speed sensor lead. V Route the coolant reservoir hose backward the another hoses. W Route the EXUP cable forward the another hoses. X Route the EXUP cable forward the frame cross pipe. Y Route the fuel tank drain hose and fuel tank breather hose forward the neutral switch lead and speed sensor lead.
2-37
CABLE ROUTING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
SPEC
Starter cable Clutch cable Handlebar switch lead (left) Main switch lead EXUP servo motor Starting circuit cutoff relay Starter motor lead Fan motor relay Air cleaner case drain hose Sidestand switch lead oil level switch lead ACgenerator lead Water-head pipe Water-carburetor hose Throttle cable 2 Throttle cable 1 EXUP cable
A Fasten the main switch lead and handlebar switch lead with a plastic guide. B Fasten the water-head hose and water-carburetor hose with a plastic band. C Fasten the clutch cable with a plastic band. D Fasten the clutch cable with a steel clamp. E Fasten the wire harness with a plastic band. F To the fuel sender. G Route the fuel sender lead inside the seat rail. H Route the battery negative lead forward the frame stay. I Route the main harness inside the rear fender groove. J Fasten the wire harness, sidestand switch lead, oil level switch and flame with a plastic band. Do not fasten the Acgenerator lead (white). K Route the starter motor lead and battery negative lead inside the plastic band. L Route the all hoses outside the fuel hose. M Route the fuel hose through the steel guide.
2-38
CABLE ROUTING
N Fasten the sidestand switch lead, oil level switch lead, ACgenerator lead, starter motor lead, battery negative lead and air cleaner case drain hose with a plastic clamp. O Fasten the sidestand switch lead, oil level switch lead, ACgenerator lead and air filter case drain hose with a plastic clamp. P Fasten the sidestand switch lead and frame with a plastic clamp. Q Route the air cleaner box drain hose inside the sidestand switch lead, and put the end of the hose backward. R Fasten the sidestand switch lead and frame with a plastic clamp. S Fasten the sidestand switch lead, oil level switch lead and air filter case drain hose with a plastic clamp. Do not crush the air filter case drain hose. T Route the high tension cable (#1) outside the starter cable and water-carburetor hose, and under the clutch cable
SPEC
and rectifier regulator lead. U Route the water carburetor hose outside the coolant hose. V Route the starter cable outside the coolant hose, and upper the water-carburetor hose. W Route the high tension cable (#2, 3) forward the EXUP cable and high tension cable (#4). X Route the throttle cable between the water-head hose, and upper the EXUP cable. Y Route the high tension cable (#4) between the waterhead hose. Z Taillight lead and flasher light lead (right) should not be stick out from the gap between the rear fender and taillight. AA Route the flasher light lead through the hole on the rear fender. AB Route the wire harness in the groove.
2-39
CABLE ROUTING
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
SPEC
Clutch cable Handlebar switch lead Main switch lead Starter cable Thermo unit lead Throttle cable 1 Throttle cable 2 Handlebar switch lead (right) Coolant reservoir hose Ignition coil Fuel hose Fan motor lead EXUP servo motor lead Rectifier/ regulator lead White paint mark Main harness
17 18 19 20 21 22 23 24 25 26 27 28 29 30
Ignition coil lead Battery Emergency engine stop switch Flasher relay Fuse box Igniter unit Flasher light lead Taillight lead Alarm coupler (free) Starter relay Battery positive lead Fan motor lead Battery negative lead Starting circuit cutoff relay
2-40
CABLE ROUTING
A Fasten the flasher light lead and headlight lead with a plastic clamp. B Route the rectifier / regulator lead upper the fan motor lead and EXUP servomotor lead. C Route the throttle cable right side the fan motor lead, EXUP servo motor lead and thermo unit lead. D Fasten the flasher light lead with a plastic clamp. E Route the all leads between the frame cross pipe and bracket. F Do not excessively bend the throttle cable. G Route the coolant reservoir hose under the frame cross pipe. H Fasten the ignition coil and ignition coil lead with a plastic clamp. I Route the T.P.S. lead under the air vent hose. J Fasten the EXUP cable with a plastic band.
SPEC
K Fasten the fuel hose and air induction system hose with a plastic clamp. L Route the coolant reservoir hose under the frame cross pipe. M Fasten the fuel hose and frame with a plastic band. N Put the fuel tank drain hose into the frontward nipple on the fuel tank. O Put the fuel tank breather hose into the backward nipple on the fuel tank. P Route the coolant reservoir hose under the air vent hose and air induction system hose. Q Route the air vent hose upper the main harness. R All coupler into the rubber cover. S Fasten the Rectifier / regulator lead with a plastic band in the main harness.
2-41
CABLE ROUTING
SPEC
T Fasten the ignition coil lead and frame cross pipe AA Put the seat lock cable into the groove on the rear fender. with a plastic clamp. Do not fasten the red / black AB Fasten the battery positive lead with a plastic band. lead and orange lead. U Fasten the handlebar switch lead (left / right), main switch lead, EXUP servo motor lead, fan motor lead and thermo unit lead with a plastic clamp. Locate the end of clamp to downward. Ensure that the throttle cable and high tension cable do not come into contact with each other. V Fasten the rectifier / regulator stay and rectifier / regulator lead with a plastic clamp. W Route the wire harness under the rectifier/regulator. X Fasten the battery negative lead with a battery band. Y Insert the ground lead coupler in the battery band. Z Fasten the taillight lead and flasher light lead, and put in the groove on the taillight bracket.
2-42
CHK ADJ
CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . . 3-1 FRONT COWLING/SEAT/SIDE COVER/FUEL TANK . . . . . . . . . . . . . . 3-3 FRONT COWLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 SEAT, SIDE COVER AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE EXUP CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3-5 3-10 3-12 3-13 3-15 3-16 3-17 3-19 3-20 3-22 3-23 3-24 3-24 3-25 3-25 3-26 3-26 3-27 3-29 3-30 3-33 3-33 3-34 3-35 3-36 3-36 3-37 3-37 3-38 3-39 3-41 3-41 3-43
CHK ADJ
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DIGITAL CLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 3-45 3-47 3-50 3-50 3-50 3-50 3-51 3-51 3-56 3-58 3-59 3-59
INTRODUCTION PERIODIC MAINTENANCE/LUBRICATION INTERVALS

EAS00036
CHK ADJ
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INITIAL No. ITEM ROUTINE 600 mi (1,000 km) or 1 month 4,000 mi (7,000 km) or 6 months ODOMETER READINGS 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or 30 months
Valve clearance (See page 3-5) Spark plugs (See page 3-15) Crankcase ventilation system (See page 3-25) Fuel line (See page 3-24) Fuel filter (See page 3-24) Exhaust system (See page 3-25) Carburetor synchronization (See page 3-10) Idle speed (See page 3-12) Evaporative emission control system (For California only) (See page 3-26) Air induction system (See page 7-14)
S Check and adjust valve clearance when engine is cold. S Check condition. S Adjust gap and clean. S Replace every 8,000 mi (13,000 km) or 12 months. S Check ventilation hose for cracks or damage. S Replace if necessary. S Check fuel hoses and vacuum hose for cracks or damage. S Replace if necessary. S Replace every 20,000 mi (31,000 km) or 30 months. S Check for leakage. S Retighten if necessary. S Replace gasket(s) if necessary. S Adjust synchronization of carburetors. S Check and adjust engine idle speed. S Adjust cable free play. S Check control system for damage. S Replace if necessary. S Check the air cut valve and read valve for damage. S Replace the entire air induction system if necessary.
Every 26,600 mi (42,000 km)
Replace.
Replace.
Replace.
10
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL No. ITEM ROUTINE 600 mi (1,000 km) or 1 month 4,000 mi (7,000 km) or 6 months ODOMETER READINGS 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months Replace. 20,000 mi (31,000 km) or 30 months
Engine oil (See page 3-20) Engine oil filter cartridge (See page 3-20) * Air filter element (See page 3-23) Cooling system (See page 3-29) 3 29) (See page 3-30) Brake system (See page 3-35) (See page 3-36)
S Replace (warm engine before draining). (See NOTE) S Replace at initial 600 mi (1,000 km) or 1 month, and thereafter every 8,000 mi (13,000 km) or 12 months. S Clean with compressed air. S Replace if necessary. S Check hose for cracks or damage. S Replace if necessary. S Replace coolant every 24 months. #3 S Check operation, pad wear, and fluid leakage. (See NOTE) S Correct if necessary.
3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INITIAL No. ITEM ROUTINE 600 mi (1,000 km) or 1 month 4,000 mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months
CHK ADJ
16,000 mi (25,000 km) or 24 months Repack. Repack. Repack. 20,000 mi (31,000 km) or 30 months
ODOMETER READINGS
6 7
* *
Clutch (See page 3-22) Control cable (See page 3-50) Swingarm pivot bearing (See page 4-68) (See page 4-69) Rear suspension link pivots (See page 4-69) Shock absorber assembly (See page 4-64) Front fork (See page 3-43) Steering bearings (See page 3-41) (See page 4-59) Brake and clutch lever pivot shafts (See page 3-50) Brake and shift pedal pivot shafts (See page 3-50) Drive chain (See page 3-39) (See page 3-69) Wheel bearings (See page 4-4) Sidestand and centerstand pivots (See page 3-50) Sidestand switch (See page 8-21) Chassis fasteners (See page 2-22)
S Check operation. S Adjust or replace cable. S Apply chain lube thoroughly. #1 S Check bearing assembly for looseness. S Moderately repack every 16,000 mi (25,000 km) or 24 months. #2 S Check operation. S Moderately repack every 16,000 mi (25,000 km) or 24 months. #2 S Check operation and for oil leakage. S Replace if necessary. S Check operation and for oil leakage. S Repair if necessary. S Check bearing assembly for looseness. S Moderately repack every 16,000 mi (25,000 km) or 24 months. #2 S Lubricate. #2
10
11
12
13
14
S Lubricate. #2 S Check chain slack / alignment condition. S Adjust and lubricate chain thoroughly. #1 S Check bearings for smooth operation. S Check operation. S Lubricate. #2 S Check and clean or replace if necessary. S Check all chassis fitting and fasteners. S Correct if necessary.
15
Every 600 mi (1,000 km) or after washing the motorcycle or riding in the rain.
16
17
18 19
* *
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. #1: Yamaha chain lube #2: Lithium-soap-based grease (all-purpose grease) #3: Ethylene glycol anti-freeze coolant NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months. NOTE: D The air filter needs more frequent service if you are riding in unusually wet or dusty areas. D Hydraulic brake service S Regularly check and, if necessary, correct the brake fluid level. S Every two years replace the internal components of the brake master cylinder and caliper, and change the brake fluid. S Replace the brake hoses every four years and if cracked or damaged. D Engine oil type S Yamalube 4 (20W-40) or engine oil SAE 20W-40 (API SE) for temperatures of 5 _C (40 _F) or above. S Yamalube 4 (10W-30) or engine oil SAE 10W-30 (API SE) for temperatures of 15 _C (60 _F) or below.
3-2
FRONT COWLING
EAS00038
CHK ADJ
FRONT COWLING/SEAT/SIDE COVER/FUEL TANK

FRONT COWLING
Order 1 2 3 4 5 6
Job/Part Removing the fron cowling Inner panel Headlight/meter coupler Front cowling assembly Back view mirror Meter unit Headlight unit
Qty 2 1/1 1 2 1 1
Remarks Remove the parts in the order listed. Disconnect.
For installation, reverse the removal procedure.
3-3
SEAT, SIDE COVER AND FUEL TANK

EAS00040
CHK ADJ
SEAT, SIDE COVER AND FUEL TANK
19 Nm (1.9 mDkg), 14 ftDlb
10 Nm (1.0 mDkg), 7.2 ftDlb
4 Nm (0.4 mDkg, 2.9 ftDlb) 10 Nm (1.0 mDkg, 7.2 ftDlb)
Order
Job/Part Removing the seat, side cover and fuel tank Seat Side cover (left and right) Fuel sender coupler Fuel tank Fuel tank breather hose Fuel tank drain hose Fuel hose
Qty
Remarks Remove the parts in the order listed.
1 2 3 4 5 6 7
1 2 1 1 1 1 1
Disconnect. NOTE: Befor disconnecting the fuel hose, turn the fuel cock off.
8 9
Grab bar Rear cowling
1 1 For installation, reverse the removal procedure.
3-4
ADJUSTING THE VALVE CLEARANCE

EAS00045
CHK ADJ
ENGINE
ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: DValve clearance adjustment should be made on a cold engine, at room temperature. DWhen the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: Dcylinder head cover Refer to CYLINDER HEAD COVER in chapter 5.
2. Measure: Dvalve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.11 X 0.20 mm (0.0043 X 0.0079 in) Exhaust valve 0.21 X 0.25 mm (0.0083 X 0.0098 in) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the pickup rotor with the crankcase mating surface b . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thickness gauge 1 . NOTE: DIf the valve clearance is incorrect, record the measured reading. DMeasure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 ! #2 ! #4 ! #3
3-5
CHK ADJ
A Front d. For each cylinder, starting with cylinder #1 at TDC, turn the crankshaft clockwise as specified in the following table. B Degrees that the crankshaft is turned clockwise C Cylinder D Combustion cycle
#2 Cylinder #4 Cylinder #3 Cylilnder
180_ 360_ 540_
3. Remove: S intake camshaft S exhaust camshaft NOTE: S Refer to REMOVING THE CAMSHAFTS in chapter 5. S When removing the timing chain and camshafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase.
4. Adjust: S valve clearance a. Remove the valve lifter 1 and the valve pad 2 with a valve lapper 3 .
3-6
CHK ADJ
NOTE: Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. b. Select the proper valve pad from the following table. Valve pad thickness range 1.20 X Nos. 2.40 mm 120 X 240 (0.047 X 0.094 in) Available valve pads 25 thicknesses in 0.05 mm (0.0020 in) increments
NOTE: The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original. c. Round off the original valve pad number according to the following table. Last digit 0 or 2 5 8 Rounded value 0 5 10
EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect.
3-7

VALVE PAD SELECTION TABLE INTAKE
Measured clearance #
CHK ADJ
INSTALLED PAD NUMBER

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 125 130 135 140 145 150 155 160 165 170 120 125 130 135 140 145 150 155 160 165 170 175 120 125 130 135 140 145 150 155 160 165 170 175 180 Specification 130 135 140 145 150 155 160 165 170 175 180 185 190 135 140 145 150 155 160 165 170 175 180 185 190 195 140 145 150 155 160 165 170 175 180 185 190 195 200 145 150 155 160 165 170 175 180 185 190 195 200 205 150 155 160 165 170 175 180 185 190 195 200 205 210 155 160 165 170 175 180 185 190 195 200 205 210 215 160 165 170 175 180 185 190 195 200 205 210 215 220 165 170 175 180 185 190 195 200 205 210 215 220 225 170 175 180 185 190 195 200 205 210 215 220 225 230 175 180 185 190 195 200 205 210 215 220 225 230 235 180 185 190 195 200 205 210 215 220 225 230 235 240 185 190 195 200 205 210 215 220 225 230 235 240 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 240 175 180 185 190 195 200 205 210 215 220 225 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 235 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 235 240 240
0.00 X 0.02 0.03 X 0.07 0.08 X 0.10 0.11 X 0.20 exa 0.21 X 0.22 0.23 X 0.27 ! 0.28 X 0.32 0.33 X 0.37 0.38 X 0.42 0.43 X 0.47 0.48 X 0.52 0.53 X 0.57 0.58 X 0.62 0.63 X 0.67 0.68 X 0.72 0.73 X 0.77 0.78 X 0.82 0.83 X 0.87 0.88 X 0.92 0.93 X 0.97 0.98 X 1.02 1.03 X 1.07 1.08 X 1.12 1.13 X 1.17 1.18 X 1.22 1.23 X 1.27 1.28 X 1.32 1.33 X 1.37
125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
EXAMPLE: VALVE CLEARANCE: 0.11 X 0.20 mm (0.0043 X 0.0079 in) Installed is 150 Measured clearance is 0.25 mm (0.0098 in) Replace 150 pad with 160 pad
EXHAUST
Measured clearance #
INSTALLED PAD NUMBER

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 120 125 120 125 130 120 125 130 135 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 125 130 135 140 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 125 130 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 150 155 160 165 155 160 165 170 160 165 170 175 165 170 175 180 Specification 175 180 185 190 180 185 190 195 185 190 195 200 190 195 200 205 195 200 205 210 200 205 210 215 205 210 215 220 210 215 220 225 215 220 225 230 220 225 230 235 225 230 235 240 230 235 240 235 240 240 165 170 175 180 185 195 200 205 210 215 220 225 230 235 240 170 175 180 185 190 200 205 210 215 220 225 230 235 240 175 180 185 190 195 205 210 215 220 225 230 235 240 180 185 190 195 200 210 215 220 225 230 235 240 185 190 195 200 205 215 220 225 230 235 240 190 195 200 205 210 220 225 230 235 240 195 200 205 210 215 200 205 210 215 220 205 210 215 220 225 210 215 220 225 230 215 220 225 230 235
0.00 X 0.02 0.03 X 0.07 0.08 X 0.10 0.13 X 0.17 0.18 X 0.20 0.21 X 0.30 exa 0.31 X 0.32 0.33 X 0.37 ! 0.38 X 0.42 0.43 X 0.47 0.48 X 0.52 0.53 X 0.57 0.58 X 0.62 0.63 X 0.67 0.68 X 0.72 0.73 X 0.77 0.78 X 0.82 0.83 X 0.87 0.88 X 0.92 0.93 X 0.97 0.98 X 1.02 1.30 X 1.07 1.08 X 1.12 1.13 X 1.17 1.18 X 1.22 1.23 X 1.27 1.28 X 1.32 1.33 X 1.37 1.38 X 1.42 1.43 X 1.47
225 230 235 240 230 235 240 235 240 240
EXAMPLE: VALVE CLEARANCE: 0.21 X 0.30 mm (0.0083 X 0.0118 in) Installed is 175 Measured clearance is 0.35 mm (0.0138 in) Replace 175 pad with 185 pad
3-8
CHK ADJ
e. Install the new valve pad 1 and the valve lifter 2 . NOTE: Apply molybdenum disulfide oil to the valve pad and the valve lifter. 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 camshafts, timing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 m kg, 7.2 ft lb) NOTE: Refer to INSTALLING THE CAMSHAFTS in chapter 4. Lubricate the camshaft caps, camshaft lobes and camshaft journals. First, install the exhaust camshaft. Align the camshaft marks with the camshaft cap marks. Rotate the crankshaft clockwise several turns to seat the parts. g. Measure the valve clearance again. h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 5. Install: cylinder head cover Refer to CYLINDER HEAD COVER in chapter 5. 6. Install: all removed parts NOTE: For installation, reverse the removal procedure. Note the following points.
3-9
SYNCHRONIZING THE CARBURETORS

EAS00050
CHK ADJ
SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, 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: vacuum cap
3. Install: carburetor synchronizer 1 inductive self-powered tachometer 2 (to the spark plug lead of cyl. #1) Carburetor synchronizer YU-8030 Inductive self-powered tachometer YU-8036-B 4. Start the engine and let it warm up for several minutes. 5. Check: engine idling speed Out of specification Adjust. Refer to ADJUSTING THE ENGINE IDLING SPEED. Engine idling speed 1,050 X 1,150 r/min
3-10
SYNCHRONIZING THE CARBURETORS
CHK ADJ
6. Adjust: carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same. c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in either direction until both gauges read the same. Vacuum pressure at engine idling speed 30 kPa (225 mm Hg, 8.86 in Hg) NOTE: The difference in vacuum pressure between two carburetors should not exceed 1.33 kPa (10 mm Hg, 0.39 in Hg).
7. Measure: engine idling speed Out of specification Adjust. 8. Stop the engine and remove the measuring equipment. 9. Adjust: throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in) 10. Install: vacuum cap
3-11
ADJUSTING THE ENGINE IDLING SPEED

EAS00052
CHK ADJ
ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes. 2. Install: inductive self-powered tachometer (to the spark plug lead of cyl. #1) Inductive self-powered tachometer YU-8036-B 3. Measure: engine idling speed Out of specification
Adjust.
Engine idling speed 1,050 X 1,150 r/min
4. Adjust: engine idling speed a. Turn the throttle stop screw 1 in direction a or b until the specified engine idling speed is obtained. Direction a Direction b Engine idling speed is increased. Engine idling speed is decreased.
3-12
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK ADJ
5. Adjust: throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in)
EAS00055
ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly.
1. Check: throttle cable free play a Out of specification Adjust. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in) 2. Remove: seat fuel tank
3-13
ADJUSTING THE THROTTLE CABLE FREE PLAY

3. Adjust: throttle cable free play
CHK ADJ
NOTE: When the motorcycle is accelerating, the accelerator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. c. Loosen the locknut 4 on the accelerator cable. d. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained. Direction a Direction b Throttle cable free play is increased. Throttle cable free play is decreased.
e. Tighten the locknuts. NOTE: If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.
Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Direction a Direction b Throttle cable free play is increased. Throttle cable free play is decreased.
c. Tighten the locknut.
WARNING
After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.
3-14
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS
4. Install: fuel tank seat
CHK ADJ
EAS00059
CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: spark plug cap 2. Remove: spark plug
CAUTION:
Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 3. Check: spark plug type Incorrect Change. Spark plug type (manufacturer) CR9E (NGK) U27ESR-N (DENSO) 4. Check: electrode 1 Damage/wear Replace the spark plug. insulator 2 Abnormal color Replace the spark plug. Normal color is a medium-to-light tan color. 5. Clean: spark plug (with a spark plug cleaner or wire brush) 6. Measure: spark plug gap a (with a wire gauge) Out of specification
Regap.
Spark plug gap 0.7 X 0.8 mm (0.028 X 0.031 in)
3-15
CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING

7. Install: spark plug
CHK ADJ
13 Nm (1.3 m kg, 9.4 ft lb)
NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: spark plug cap
EAS00063
CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion.
1. Remove: timing plug 1
2. Install: battery powered timing light 1 inductive self-powered tachometer 2 (to the spark plug lead of cyl. #1) Battery powered timing light YM-33277-A Inductive self-powered tachometer YU-8036-B 3. Check: ignition timing a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1,050 X 1,150 r/min
3-16
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE
CHK ADJ
b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range Check the ignition system. NOTE: The ignition timing is not adjustable.
4. Remove: timing light engine tachometer 5. Install: timing plug

EAS00065
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 specification Adjust. Refer to ADJUSTING THE VALVE CLEARANCE. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Disconnect: spark plug cap 4. Remove: spark plug
CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders.
5. Install: compression gauge 1 Compression gauge set YU-33223 Compression gauge adapter YU-33223-3
3-17
MEASURING THE COMPRESSION PRESSURE
CHK ADJ
6. Measure: compression pressure Above the maximum pressure Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again. Refer to the following table. Compression pressure (with oil applied into cylinder) Reading Higher than without oil Diagnosis Piston ring(-s) wear or damage Repair. Piston, valves, cylinder head gasket or piston possibly defective Repair. Compression pressure (at sea level)
Same as without oil
Compression pressure (at sea level): Standard: 1,450 kPa (14.5 kg/cm2, 206 psi) Minimum: 1,260 kPa (12.6 kg/cm2, 179 psi) Maximum: 1,620 kPa (16.2 kg/cm2, 230 psi) a. Turn the main switch to ON. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.
WARNING
To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm2,14.2 psi).
7. Install: spark plug 8. Connect: spark plug cap

3-18
13 Nm (1.3 m kg, 9.4 ft lb)
CHECKING THE ENGINE OIL LEVEL

EAS00071
CHK ADJ
CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright.
2. Check: engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b . Below the minimum level mark Add the recommended engine oil to the proper level. Recommended engine oil Yamalube 4 (20W40) or SAE 20W40 type SE motor oil
CAUTION:
Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. Do not allow foreign materials to enter the crankcase. NOTE: API Service SE, SF and SG type or equivalent (e.g., SF-SE, SF-SE-CC, SF-SE-SD). 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
3-19
CHANGING THE ENGINE OIL

EAS00073
CHK ADJ
CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place a container under the engine oil drain bolt.
3. Remove: engine oil filler cap 1 engine oil drain bolt 2 (along with the gasket) 4. Drain: engine oil (completely from the crankcase) 5. If the oil filter cartridge is also to be replaced, perform the following procedure.
a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench YU-38411
b. Apply a thin coat of engine oil onto the O-ring 1 of the new oil filter cartridge.
CAUTION:
Make sure that the O-ring 1 is positioned correctly in the groove of the oil filter cartridge.
3-20
CHANGING THE ENGINE OIL
CHK ADJ
c. Tighten the new oil filter cartridge to specification with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m kg, 12 ft lb) 6. Check: engine oil drain bolt gasket Damage Replace. 7. Install: engine oil drain bolt
43 Nm (4.3 m kg, 31 ft lb)
8. Fill: crankcase (with the specified amount of the recommended engine oil) Quantity Total amount 3.7 L (3.2 Imp qt, 3.8 US qt) Without oil filter cartridge replacement 2.8 L (2.4 Imp qt, 2.9 US qt) With oil filter cartridge replacement 3.0 L (2.6 Imp qt, 3.1 US qt) 9. Install: engine oil filler cap 10. Start the engine, warm it up for several minutes, and then turn it off. 11. Check: engine (for engine oil leaks) 12. Check: engine oil level Refer to CHECKING THE ENGINE OIL LEVEL. 13. 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 damage or leakage. Refer to OIL PAN AND OIL PUMP in chapter 5. d. Start the engine after solving the problem(-s) and check the engine oil pressure again. e. Tighten the oil gallery bolt to specification.
3-21
CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY
CHK ADJ
Oil gallery bolt 10 Nm (1.0 mSkg, 7.2 ftSlb)
EAS00078
ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 2. Adjust: S clutch cable free play Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is obtained. Direction a Direction b Clutch cable free play is increased. Clutch cable free play is decreased
c. Tighten the locknut. NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. Engine side a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified clutch cable free play is obtained. Direction a Direction b Clutch cable free play is increased. Clutch cable free play is decreased
c. Tighten the locknut.

3-22
CLEANING THE AIR FILTER ELEMENT

EAS00086
CHK ADJ
CLEANING THE AIR FILTER ELEMENT 1. Remove: seat fuel tank side cover cover 1
2. Remove: air filter case cover 1 air filter element
3. Clean: air filter element Apply compressed air to the outer surface of the air filter element.
4. Check: air filter element Damage Replace. 5. Install: air filter element air filter case cover
CAUTION:
Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating.
3-23
CLEANING THE AIR FILTER ELEMENT / CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS / CHECKING THE FUEL HOSES AND FUEL FILTER
CHK ADJ
NOTE: When installing the air filter element into the air filter case cover, be sure their sealing surfaces are aligned to prevent any air leaks. 6. Install: cover side cover fuel tank seat
EAS00095
CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS The following procedure applies to all of the carburetor joints and intake manifolds. 1. Remove: seat fuel tank air filter case panel 1
2. Check: carburetor joint 1 intake manifold 2 Cracks/damage Replace. Refer to CARBURETORS in chapter 6. 3. Install: air chamber cover fuel tank seat
EAS00097
CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1. Remove: seat fuel tank side cover
2. Check: fuel hose 1 Cracks/damage Replace. fuel filter 2 Damage/dirt Replace.
3-24
CHECKING THE FUEL HOSES AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM
CHK ADJ
NOTE: Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. The arrow mark a on the fuel filter should face to the side of the fuel pump 1 . 3. Install: side cover fuel tank seat
EAS00098
CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: seat fuel tank 2. Check: crankcase breather hose 1 Cracks/damage Replace. Loose connection Connect properly.
CAUTION:
Make sure that the crankcase breather hose is routed correctly. 3. Install: fuel tank seat
EAS00099
CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: exhaust pipe 1 muffler 2 Cracks/damage Replace. gasket 3 Exhaust gas leaks Replace. 2. Check: tightening torque Exhaust pipe nut 4 20 Nm (2.0 m kg, 14 ft lb) Exhaust pipe and muffler bolt 5 20 Nm (2.0 m kg, 14 ft lb) Exhaust pipe and bracket bolt 6 20 Nm (2.0 m kg, 14 ft lb) Muffler and muffler bracket bolt 7 48 Nm (4.8 m kg, 35 ft lb)
3-25
CHECKING THE CANISTER/ ADJUSTING THE EXUP CABLES
CHK ADJ
CHECKING THE CANISTER (for California only) 1. Remove: S seat S fuel tank 2. Check: S hose and canister Cracks/damage ! Replace. S vent hose Obstruction ! Clean. 3. Install: S fuel tank S seat
EAS00101
ADJUSTING THE EXUP CABLES 1. Remove: S seat S fuel tank 2. Remove: S EXUP valve pulley cover 1
3. Check: S EXUP operation a. Disconnect the EXUP servomotor connector 1. b. Connect the battery to the EXUP servomotor connector and check if the servomotor operates properly. Battery positive lead ! black/yellow 2 Battery negative lead ! black/red 3
CAUTION:
To avoid damaging the servomotor, do not leave the battery connected to it for more than a few seconds. c. Check that the EXUP valve operates properly. d. Connect the EXUP servomotor connector.
3-26
ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL

4. Check: EXUP cable free play a
CHK ADJ
EXUP cable free play 1.5 mm (0.06 in) max.
5. Adjust: EXUP cable free play a. Loosen both locknuts 1 . b. Insert a 4 mm long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover. c. Turn both adjusting bolts 2 counterclockwise until there is no EXUP cable free play. d. Turn both adjusting bolts 1/2 of a turn clockwise. e. Tighten both locknuts and then remove the pin. 6. Install: EXUP valve pulley cover
10 Nm (1.0 m kg, 7.2 ft lb)
7. Install: fuel tank seat
EAS00102
CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Check: coolant level The coolant level should be between the maximum level mark a and minimum level marks b . Below the minimum level mark Add the recommended coolant to the proper level.
3-27
CHECKING THE COOLANT LEVEL CAUTION:
CHK ADJ
Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and correct the antifreeze concentration of the coolant. Use only distilled water. Soft water may be used if distilled water is not available. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles.
3-28
CHECKING THE COOLING SYSTEM

EAS00104
CHK ADJ
CHECKING THE COOLING SYSTEM 1. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 water jacket inlet joint 6 water pump outlet joint 7 Cracks/damage Replace. Refer to COOLING SYSTEM in chapter 6.
3-29
CHANGING THE COOLANT

EAS00105
CHK ADJ
CHANGING THE COOLANT 1. Remove seat fuel tank front cowling rear suspension Refer to REAR SHOCK ABSORBER ASSEMBLY in chapter 4. 2. Disconnect: coolant reservoir hose 1 3. Drain: coolant (from the coolant reservoir)
4. Remove: radiator cap 1
WARNING
A hot radiator is under pressure. Therefore, 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 radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, press down on the radiator cap, while still pressing down turn it counterclockwise, and then remove it. The following procedure applies to all of the coolant drain bolts and copper washers. 5. Remove: coolant drain bolt 1 (along with the copper washer) 6. Drain: coolant (from the engine and radiator)
3-30
CHANGING THE COOLANT

7. Check: copper washer 1 coolant drain bolt 2 Damage Replace. 8. Install: coolant drain bolt
CHK ADJ
7 Nm (0.7 m kg, 5.1 ft lb)
9. Connect: coolant reservoir hose 10. Fill: cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol anti freeze containing corrosion inhibi tors for aluminum engines Mix ratio 50% antifreeze/50% water Quantity Total amount 2.4 L (2.11 Imp qt, 2.53 US qt) Coolant reservoir capacity 0.3 L (0.26 Imp qt, 0.32 US qt) From minimum to maximum level mark 0.2 L (0.18 Imp qt, 0.21 US qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care.
WARNING
If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. If coolant is swallowed, induce vomiting and get immediate medical attention.
3-31
CHANGING THE COOLANT CAUTION:
CHK ADJ
S 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. S Use only distilled water. Soft water may be used if distilled water is not available. S If coolant comes into contact with painted surfaces, immediately wash them with water. S Do not mix different types of antifreeze. 11. Install: S radiator cap
12. Fill: S coolant reservoir (with the recommended coolant to the maximum level mark a ) 13. Install: S coolant reservoir cap 14. Start the engine, warm it up for several minutes, and then turn it off. 15. Check: S coolant level Refer to CHECKING THE COOLANT LEVEL. NOTE: Before checking the coolant level, wait a few minutes until it settles. 16. Install: S rear suspension Refer to REAR SHOCK ABSORBER ASSEMBLY in chapter 4. S fuel tank S seat
3-32
ADJUSTING THE FRONT BRAKE

EAS00107
CHK ADJ
CHASSIS
ADJUSTING THE FRONT BRAKE 1. Adjust: brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder. Distance a is the largest. Distance a is the smallest.
Position #1 Position #5
WARNING
After adjusting the brake lever position, make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial. A soft or spongy feeling in the brake lever can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system . Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake lever position, make sure that there is no brake drag.
3-33
ADJUSTING THE REAR BRAKE

EAS00110
CHK ADJ
ADJUSTING THE REAR BRAKE 1. Check: brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 40 mm (1.57 in) 2. Adjust: brake pedal position a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Direction b Brake pedal is raised. Brake pedal is lowered.
WARNING
After adjusting the brake pedal position, check that the end of the adjusting bolt 2 is visible through the hole c . c. Tighten the locknut 1 to specification. Locknut 18 Nm (1.8 m kg, 13 ft lb)
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 . Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system.
CAUTION:
After adjusting the brake pedal position, make sure that there is no brake drag.
3-34
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL
CHK ADJ
3. Adjust: rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH.
EAS00115
CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright.
A
2. Check: brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Recommended brake fluid DOT 4
A Front brake B Rear brake B
WARNING
Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure that the top of the reservoir is horizontal.
3-35
CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH
A
EAS00122
CHK ADJ
CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: front brake pad rear brake pad Wear indicator groove 1 almost disappeared ! Replace the brake pads as a set. Refer to REPLACING THE FRONT BRAKE PADS and REPLACING THE REAR BRAKE PADS in chapter 4. A Front brake B Rear brake
EAS00128
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 so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. Direction a Direction b Brake light comes on sooner. Brake light comes on later.
3-36
CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM

EAS00131
CHK ADJ
CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check: brake hose 1 Cracks/damage/wear ! Replace. 2. Check: brake hose clamp 2 Loose connection ! Tighten. 3. Hold the motorcycle upright and apply the brake. 4. Check: brake hose 1 Activate the brake several times. Brake fluid leakage ! Replace the damaged hose. Refer to FRONT AND REAR BRAKES in chapter 4.
EAS00134
BLEEDING THE HYDRAULIC BRAKE SYSTEM
WARNING
Bleed the hydraulic brake system whenever: the system was disassembled, a brake hose was loosened or removed, the brake fluid level is very low, brake operation is faulty. 1. Remove: reservoir cap 1 diaphragm 2 NOTE: Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.
3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL

2. Bleed: hydraulic brake system
CHK ADJ
a. Add the recommended brake fluid to the proper level. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2 . A Front B Rear d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. g. Loosen the bleed screw. This will release the tension 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 specification. Bleed screw 6 Nm (0.6 m kg, 4.3 ft lb) k. Fill the reservoir to the proper level. Refer to CHECKING THE BRAKE FLUID LEVEL.
WARNING
After bleeding the hydraulic brake system, check the brake operation.
EAS00110
ADJUSTING THE SHIFT PEDAL 1. Check: shift pedal position (distance a from the top of the rider footrest to the top of the shift pedal) Out of specification ! Adjust. Shift pedal position (below the top of the rider footrest) 40 mm (1.57 in)
3-38
ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK

2. Adjust: adjusting bolt length
CHK ADJ
a. Loosen both locknuts 1 . b. Turn the adjusting bolt 2 in direction a or b to obtain the correct shift pedal position. Direction a Direction b Shift pedal is raised. Shift pedal is lowered.
Tighten both locknuts.
EAS00140
ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain.
CAUTION:
A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Check: drive chain slack a Out of specification ! Adjust. Drive chain slack 40 X 50 mm (1.57 X 1.97 in)
3-39
ADJUSTING THE DRIVE CHAIN SLACK

4. Adjust: drive chain slack a. b. c. d.
CHK ADJ
Loosen the brake caliper bracket bolt. Loosen the wheel axle nut 1 . Loosen both locknuts 2 . Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is obtained. Drive chain is tightened. Drive chain is loosened.
Direction a Direction b
NOTE: To maintain the proper wheel alignment, adjust both sides evenly. e. Tighten both locknuts to specification. Locknut 16 Nm (1.6 m kg, 12 ft lb) f. Tighten the wheel axle nut to specification. Wheel axle nut 150 Nm (15 m kg, 108 ft lb)
3-40
LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD
EAS00142
CHK ADJ
LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber O-rings between each side plate. Steam cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only 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 forO-ring chains
EAS00146
CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Check: steering head Grasp the bottom of the front fork legs and gently rock the front fork. Looseness or binding ! Adjust the steering head. 3. Remove: front cowling assembly Refer to FRONT COWLING. upper bracket Refer to HANDLEBAR and STEERING HEAD in chapter 4. 4. Adjust: steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 .
3-41
CHECKING AND ADJUSTING THE STEERING HEAD
CHK ADJ
b. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5 . NOTE: Set the torque wrench at a right angle to the spanner wrench. Spanner wrench YU-33975 Lower ring nut (initial tightening torque) 52 Nm (5.2 m kg, 38 ft lb) c. Loosen the lower ring nut 6 completely, then tighten it to specification.
WARNING
Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 m kg, 13 ft lb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and inspect the upper and lower bearings. Refer to STEERING HEAD AND HANDLEBAR in chapter 4.
e. Install the rubber washer 7 . f. Install the upper ring nut 8 . g. Finger tighten the upper ring nut 8 , then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer 9 . NOTE: Make sure that the lock washer tabs a sit correctly in the ring nut slots b .
5. Install: upper bracket front cowling assembly
3-42
CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK / ADJUSTING THE FRONT FORK LEGS
CHK ADJ
Steering stem nut 110 Nm (11 m kg, 80 ft lb) Upper bracket pinch bolt 30 Nm (3.0 m kg, 22 ft lb) Handlebar holder bolt 23 Nm (2.3 m kg, 17 ft lb)
EAS00149
CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. 2. Check: inner tube Damage/scratches ! Replace. oil seal Oil leakage ! Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Unsmooth operation ! Repair. Refer to FRONT FORK in chapter 4.
EAS00155
ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
WARNING
Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. Securely support the motorcycle so that there is no danger of it falling over. Spring preload
CAUTION:
Grooves are provided to indicate the adjustment position. Never go beyond the maximum or minimum adjustment positions.
3-43
ADJUSTING THE FRONT FORK LEGS

1. Adjust: S spring preload
CHK ADJ
a. Turn the adjusting bolt 1 in direction a or b. Direction a Spring preload is increased (suspension is harder). Spring preload is decreased (suspension is softer).
Direction b
Adjusting positions Standard: 2 Minimum: 5* Maximum: 1 *fully turned out position
Rebound damping
CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or b. Direction a Rebound damping p g is increased (suspension is harder). Rebound damping p g is decreased (suspension is softer).
Direction b
Adjusting positions Standard: 7 clicks out* Minimum: 17 clicks out* Maximum: 1 clicks out* *: from the fully turned-in position
3-44
ADJUSTING THE FRONT FORK LEGS/ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
Compression damping
CHK ADJ
CAUTION:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or b. Direction a Compression damping is increased (suspension is harder). Compression damping is decreased (suspension is softer).
Direction b
EAS00158
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
WARNING
Securely support the motorcycle so that there is no danger of it falling over. Spring preload
CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: spring preload NOTE: Adjust the spring preload with the special wrench and extension bar included in the owners tool kit.
3-45
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK ADJ
a. Turn the adjusting ring 1 in direction a or b. b. Align the desired position on the adjusting ring with the stopper 2 . Direction a Spring preload is (s spension is increased (suspension harder). Spring preload is spension decreased (s (suspension is softer).
Direction b
Adjusting positions Standard: 6 Minimum: 1 Maximum: 11
Rebound damping
CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: rebound damping a. Turn the adjusting knob 1 in direction a or b. Direction a Rebound damping is (s spension is increased (suspension harder). Rebound damping is (s spension is decreased (suspension softer).
Direction b
3-46
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ CHECKING THE TIRES

Compression damping
CHK ADJ
CAUTION:
Never go beyond the maximum or minimum adjustment positions.
1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or b. Direction a Compression damping is increased (suspension is harder). Compression damping is decreased (suspension is softer).
Direction b
Adjusting positions Standard: 7 clicks in Minimum: 1 clicks in Maximum: 12 clicks in *: from the fully turned-out position
EAS00162
CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: tire pressure Out of specification ! Regulate.
WARNING
The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. Operation of an overloaded motorcycle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE MOTORCYCLE.
3-47
CHECKING THE TIRES

Basic weight (with oil and a full fuel tank) Maximum load* Cold tire pressure Up to 90 kg load*
CHK ADJ
231 kg (509 lb) 232 kg (512 lb) (california) 189 kg (417 lb) 188 kg (415 lb) (california)
Front tire
Rear tire
250 kPa 270 kPa (2.5 kgf/cm2, (2.7 kgf/cm2, 36 psi) 39 psi)
250 kPa 290 kPa 90 kg X 2, (2.9 kgf/cm2, (2.5 kgf/cm maximum load* 36 psi) 42 psi) High speed riding 250 kPa 290 kPa (2.5 kgf/cm2, (2.9 kgf/cm2, 36 psi) 42 psi)
*: total of cargo, rider, passenger and accessories
WARNING
It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately. 2. Check: tire surfaces Damage/wear ! Replace the tire. Minimum tire tread depth 1.0 mm (0.04 in)
1 Tire tread depth 2 Side wall 3 Wear indicator
WARNING
Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. When using a tube tire, be sure to install the correct tube. Always replace a new tube tire and a new tube as a set. To avoid pinching the tube, make sure that the wheel rim band and tube are centered in the wheel groove. Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. A Tire B Wheel
3-48
CHECKING THE TIRES

Tube wheel
CHK ADJ
Tube tire only
Tubeless wheel Tube or tubeless tire After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer METZELER BRIDGESTONE Rear tire Manufacturer METZELER BRIDGESTONE Type Tubeless Tubeless Size 180/55 ZR17 (73 W) 180/55 ZR17 (73 W) Type Tubeless Tubeless Size 120/70 ZR17 (58 W) 120/70 ZR17 (58 W)
WARNING
New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km (62 mi) should be traveled at normal speed before any highspeed riding is done.
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 installation point.
3-49
CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION
EAS00170
CHK ADJ
CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.
WARNING
Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: cable sheath Damage ! Replace. 2. Check: cable operation Unsmooth operation ! Lubricate. Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubing device.
EAS00171
LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant lithium soap base grease
EAS00172
LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant lithium soap base grease
EAS00174
LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant lithium soap base grease
3-50
CHECKING AND CHARGING THE BATTERY

EAS00178
CHK ADJ
ELECTRICAL SYSTEM
WARNING
Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries. Charge batteries in a well-ventilated area. Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). DO NOT SMOKE when charging or handling batteries. KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. First aid in case of bodily contact: External SKIN Wash with water. EYES Flush with water for 15 minutes and get immediate medical attention. Internal Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.
CAUTION:
This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. Charging time, charging amperage and charging voltage for a MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.
3-51
CHK ADJ
NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: S seat 2. Disconnect: S battery leads (from the battery terminals)
CAUTION:
First, disconnect the negative lead 1 , then the positive lead 2 . 3. Remove: S battery 4. Check: S battery charge a. Connect a pocket tester to the battery terminals. Tester positive lead ! battery positive Tester positive lead ! terminal Tester negative lead ! battery negative Tester negative lead ! terminal
Relationship between the open-circuit voltage and the charging time at 20_C
Open-circuit voltage (V)
13.0 12.5 12.0 11.5
NOTE: S The charge state of a MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). S No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.
5 6.5 10 Charging time (hours) These values vary with the temperature, the condition of the battery plates, and the electrolyte level.
b. Check the charge of the battery, as shown in the charts and the following example. Example c. Open-circuit voltage = 12.0 V d. Charging time = 6.5 hours e. Charge of the battery = 20 X 30%
3-52

Charging Open-circuit voltage (V) Ambient temperature 20_C
CHK ADJ
5. Charge: S battery (refer to the appropriate charging method illustration)
WARNING
Do not quick charge a battery.
Time (minutes) Check the open-circuit voltage.
CAUTION:
S Make sure that the battery vent is free of obstructions. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. S If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. S When charging a battery, be sure to remove it from the motorcycle. (If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal.) S To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. S Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. S 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 contact area and a weak clip spring may cause sparks. S If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! S As shown in the following illustration, the open-circuit voltage of a MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.
Open-circuit voltage (V)
Ambient temperature 20_C
Charging condition of the battery (%)
3-53

Charging method using a variable voltage charger Measure the open-circuit voltage prior to charging. Connect a charged and AMP meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery.
CHK ADJ
NOTE: Voltage should be measured 30 minutes after the machine is stopped.
NOTE: Set the charging voltage at 16 X 17 V. (If the setting is lower, charging will be insufficient. If too high, the battery will be over-charged.)
YES
NO
By turning the charging voltage adjust dial, set the charging voltage at 20 X 24 V. Adjust the voltage so that the current is at the standard charging level. YES Monitor the amperage for 3 X 5 minutes to check if the standard charging current is reached. NO
Set the time according to the charging time suitable for the open-circuit voltage. Refer to Battery condition checking steps.
If the current does not exceed the standard charging current after 5 minutes, replace the battery.
If charging requires more than 5 hours, it is advisable to check the charging current after a lapse of 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging current. Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.
3-54

Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging.
CHK ADJ
NOTE: Voltage should be measured 30 minutes after the machine is stopped.
Connect a charger and AMP meter to the battery and start charging.
YES
Make sure that the current is higher than the standard charging current written on the battery.
NO
Charge the battery until the batterys charging voltage is 15 V. Charge the battery until the batterys charging voltage is 15 V.
NOTE: Set the charging time at 20 hours (maximum).
This type of battery charger cannot charge the MF battery. A variable voltage charger is recommended.
Measure the battery open-circuit voltage after leaving the battery unused for more than 30 minutes. 12.8 V or more --- Charging is complete. 12.7 V or less --- Recharging is required. Under 12.0 V --- Replace the battery.
3-55
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES

6. Check: battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: battery
CHK ADJ
8. Connect: battery leads (to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the negative lead 2 . 9. Check: battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly. 10. Lubricate: battery terminals Recommended lubricant Dielectric grease 11. Install: seat
EAS00181
CHECKING THE FUSES The following procedure applies to all of the fuses.
CAUTION:
To avoid a short circuit, always turn the main switch to OFF when checking or replacing a fuse. 1. Remove: seat 2. Check: fuse a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to 1.
3-56
CHECKING THE FUSES
CHK ADJ
Pocket tester measurement YU-03112-C b. If the pocket tester indicates , replace the fuse. 3. Replace: blown fuse a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. Fuses Main fuse Headlight fuse Signaling system fuse Ignition fuse Turn signal relay fuse Digital clock fuse Radiator fan fuse Reserve fuse Reserve fuse Reserve fuse Amperage rating Quantity 30A 20A 20A 20A 10 A 10A 10A 30A 20 A 10 A 1 1 1 1 1 1 1 1 1 1
WARNING
Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: seat
3-57
REPLACING THE HEADLIGHT BULBS

EAS00183
CHK ADJ
REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: headlight coupler 1 bulb cover 2
2. Remove: headlight bulb holder 1 3. Remove: headlight bulb 2
WARNING
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: headlight bulb New Secure the new headlight bulb with the headlight bulb holder.
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 clean it with a cloth moistened with alcohol or lacquer thinner. 5. Install: headlight bulb holder 6. Install: bulb cover 7. Connect: headlight coupler
3-58
ADJUSTING THE HEADLIGHT BEAMS/ ADJUSTING THE DIGITAL CLOCK

EAS00185
CHK ADJ
ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b. Direction a Direction b Headlight beam is raised. Headlight beam is lowered.
2. Adjust: headlight beam (horizontally) a. Turn the adjusting knob 1 in direction a or b. Left headlight Direction a Direction b Headlight beam moves to the right. Headlight beam moves to the left.
Right headlight Direction a Direction b Headlight beam moves to the left. Headlight beam moves to the right.
EAS00187
ADJUSTING THE DIGITAL CLOCK NOTE: This digital clock constantly displays the time. 1. Adjust: digital clock 1 a. Hold down the RESET button 2 and SELECT button 3 . b. Push the RESET button 2 to set the hour. And push the SELECT button. c. Push the RESET button 2 to set the minutes. And push the SELECT button. NOTE: When setting the time (e.g., after reconnecting the battery), first set the clock to 1:00 AM, then set it to the correct time.
3-59
CHAS
CHAPTER 4 CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . . CHECKING AND REPLACING THE REAR WHEEL SPROCKET . CHECKING THE BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING AND DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING AND DISASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-2 4-3 4-4 4-4 4-5 4-7 4-7 4-8 4-10 4-10 4-13 4-14 4-14 4-14 4-15 4-16 4-16 4-17 4-17 4-19 4-21 4-24 4-26 4-28 4-28 4-29 4-30 4-33 4-35 4-37 4-39 4-40 4-41 4-42 4-44
CHAS
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46 4-48 4-48 4-50 4-51 4-55 4-56 4-57 4-57 4-58 4-60 4-61 4-61 4-62 4-63 4-64 4-64 4-65 4-66 4-66 4-67 4-69 4-70 4-70 4-71 4-73 4-73
FRONT WHEEL AND BRAKE DISCS

EAS00514
CHAS
CHASSIS
72 Nm (7.2 m kg, 52 ft lb)
40 Nm (4.0 m kg, 29 ft lb)
18 Nm (1.8 m kg, 13 ft lb)
Order
Job/Part Removing the front wheel and brake discs
Qty
Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
1 2 3 4 5 6 7 8
Brake hose holder (left and right) Brake caliper (left and right) Wheel axle pinch bolt Front wheel axle Front wheel Collar (left and right) Oil seal cover (left and right) brake disc (left and right)
2 2 1 1 1 2 2 2
Loosen.
4-1

EAS00518
CHAS
FRONT WHEEL
Order
1 2 3
Job/Part Disassembling the front wheel Oil seal (left and right) Wheel bearing (left and right) Spacer
Qty 2 2 1
Remarks Disassemble the parts in the order listed.
For assembly, reverse the disassembly procedure.
4-2

EAS00521
CHAS
REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: brake hose holders left brake caliper right brake caliper NOTE: Do not squeeze the brake lever when removing the brake calipers. 3. Loosen: wheel axle pinch bolt front wheel axle 4. Elevate: front wheel NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 5. Remove: front wheel axle 6. Remove: front wheel
4-3

EAS00523
CHAS
DISASSEMBLING THE FRONT WHEEL 1. Remove: oil seals wheel bearings a. Clean the outside of the front wheel hub. b. Remove 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 with a general bearing puller.
EAS00525
CHECKING THE FRONT WHEEL 1. Check: wheel axle Roll the wheel axle on a flat surface. Bends ! Replace.
WARNING
Do not attempt to straighten a bent wheel axle. 2. Check: tire front wheel Damage/wear ! Replace. Refer to CHECKING THE TIRES in chapter 3.
3. Measure: front wheel radial runout 1 front wheel lateral runout 2 Over the specified limits ! Replace. Front wheel radial runout limit 1 mm (0.04 in) Front wheel lateral runout limit 0.5 mm (0.02 in)
4-4
CHAS
4. Check: wheel bearings Front wheel turns roughly or is loose ! Replace the wheel bearings. oil seals Damage/wear ! Replace.
5. Replace: wheel bearings New oil seals New a. Clean the outside of the front wheel hub. b. Remove 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 disassembly.
CAUTION:
Do not contact the wheel bearing center race 1 or balls 2 . Contact should be made only with the outer race 3 . NOTE: Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal.
EAS00531
CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: brake disc Damage/galling ! Replace.
4-5
CHAS
2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.1 mm (0.004 in) a. Place the motorcycle on a suitable stand so that the wheel is elevated. b. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure 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 2 X 3 mm (0.08 X 0.12 in) below the edge of the brake disc. 3. Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) 4.5 mm (0.18 in) 4. Adjust: S brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 18 Nm (1.8 mSkg, 13 ftSlb) LOCTITER d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.
4-6

EAS00539
CHAS
ASSEMBLING THE FRONT WHEEL 1. Install: wheel bearings New oil seals New a. Install the new wheel bearings and oil seals in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race 1 or balls 2 . Contact should be made only with the outer race 3 . NOTE: Use a shocket 4 that matches the diameter of the wheel bearing outer race and oil seal.
EAS00544
INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate: wheel axle oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: 72 Nm (7.2 m kg, 52 ft lb) wheel axle 1 wheel axle pinch bolt 2
23 Nm (2.3 m kg, 17 ft lb)
CAUTION:
Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly. 3. Install: brake caliper
40 Nm (4.0 m kg, 29 ft lb)
WARNING
Make sure that the brake hose is routed properly.
4-7

EAS00549
CHAS
ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake discs installed. 1. Remove: S balancing weight(-s) NOTE: Place the front wheel on a suitable balancing stand.
2. Find: S front wheels heavy spot a. Spin the front wheel. b. When the front wheel stops, put an X1 mark at the bottom of the wheel. c. Turn the front wheel 90_ so that the X1 mark is positioned as shown. d. Release the front wheel. e. When the wheel stops, put an X2 mark at the bottom of the wheel. f. Repeat steps (b) through (d) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest is the front wheels heavy spot X.
3. Adjust: S front wheel static balance a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot X. NOTE: Start with the lightest weight.
4-8
CHAS
b. Turn the front wheel 90_ so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that position, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced. 4. Check: S 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.
4-9
REAR WHEEL AND BRAKE DISC

EAS00551
CHAS

REAR WHEEL
150 Nm (15 m kg, 108 ft lb)
40 Nm (4.0 m kg, 29 ft lb)
Order
Job/Part Removing the rear wheel
Qty
Remarks Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
1 2 3 4 5 6 7 8
Brake caliper Brake torque rod Lock nut Adjusting nut Wheel axle nut Washer Wheel axle Rear wheel assembly
1 1 2 2 1 1 1 1
Loosen. Loosen.
4-10

EAS00560
CHAS
Order
1 2 3 4 5 6
Job/Part Disassembling the rear wheel Spacer Bearing Spacer Oil seal Circlip Bearing
Qty 1 1 1 1 1 1
4-11
CHAS
18 Nm (1.8 m kg, 13 ft lb)
69 Nm (6.9 m kg, 50 ft lb)
Order
Job/Part Removing the brake disc and rear wheel sprocket Brake disc Rear wheel sprocket Collar (left and right) Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper
Qty
1 2 3 4 5 6 7
1 1 2 1 1 1 6 For installation, reverse the removal procedure.
4-12

EAS00561
CHAS
REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: brake caliper 1 NOTE: Do not depress the brake pedal when removing the brake caliper.
3. Loosen: brake torque rod 4. Loosen: locknut 1 adjusting nut 2 5. Remove: wheel axle nut 3 wheel axle rear wheel NOTE: Push the rear wheel forward and remove the drive chain from the rear wheel sprocket.
6. Remove: left collar 1 rear wheel drive hub 2 rear wheel drive hub damper right collar
4-13

EAS00565
CHAS
CHECKING THE REAR WHEEL 1. Check: wheel axle rear wheel wheel bearings oil seals Refer to FRONT WHEEL. 2. Check: tire rear wheel Damage/wear ! Replace. Refer to CHECKING THE TIRES in chapter 3. 3. Measure: rear wheel radial runout rear wheel lateral runout Refer to FRONT WHEEL.
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB 1. Check: rear wheel drive hub 1 Cracks/damage ! Replace. rear wheel drive hub dampers 2 Damage/wear ! Replace.
EAS00568
CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: rear wheel sprocket More than 1/4 tooth a wear ! Replace the rear wheel sprocket, the drive sprocket and the drive chain as a set. Bent teeth ! Replace the rear wheel sprocket, the drive sprocket and the drive chain as a set. 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 contact the sprocket. c. Install the new rear wheel sprocket.
4-14
CHAS
Rear wheel sprocket self-locking nut 69 Nm (6.9 m kg, 50 ft lb) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern.
EAS00531
CHECKING THE BRAKE DISC 1. Check: brake disc Damage/galling ! Replace. 2. Measure: brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.1 mm (0.004 in) NOTE: Place the motorcycle on a suitable stand so that the wheel is elevated. a. Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. b. Remove the brake caliper. c. Hold the dial gauge at a right angle against the brake disc surface. d. Measure the deflection 2 X 3 mm below the edge of the brake disc.
3. Measure: brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) 4.5 mm (0.18 in)
4-15

4. Adjust: S brake disc deflection
CHAS
a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 18 Nm (1.8 mSkg, 13 ftSlb) LOCTITER d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.
EAS00572
INSTALLING THE REAR WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: S wheel axle nut 150 Nm (15 mSkg, 108 ftSlb) S brake caliper bolts
40 Nm (4.0 mSkg, 29 ftSlb)
EAS00575
ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: S rear wheel static balance Refer to FRONT WHEEL.
4-16
FRONT AND REAR BRAKES

EAS00577
CHAS

FRONT BRAKE PADS
40 Nm (4.0 m kg, 29 ft lb)
6 Nm (0.6 m kg, 4.3 ft lb)
Order 1 2 3 4 5 6
Job/Part Removing the front brake pads Brake pad clip Brake pad pin Brake pad spring brake pad Brake pad shim Bleed scrw
Qty 2 1 1 2 2 1
4-17
CHAS
40 Nm (4.0 m kg, 29 ft lb)
6 Nm (0.6 m kg, 4.3 ft lb)
Order 1 2 3 4 5 6
Job/Part Removing the rear brake pads Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw
Qty 4 2 1 2 2 2
4-18

EAS00579
CHAS
CAUTION:
Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: Never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Never use solvents on internal brake components. Use only clean or new brake fluid for cleaning brake components. Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt 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.
EAS00582
REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove: brake hose holder 1 brake caliper 2
4-19

2. Remove: brake pad clips 1 brake pad pins 2 brake pad spring 3
CHAS
3. Remove: brake pads 1 (along with the brake pad shims)
4. Measure: brake pad wear limit Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm (0.02 in)
5. Install: brake pad shims (onto the brake pads) brake pads brake pad spring 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 container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 m kg, 4.3 ft lb)
4-20
CHAS
d. Install new brake pad shims onto the new brake pads. e. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation.
6. Install: brake pad pins brake pad clips brake caliper 40 Nm (4.0 m kg, 29 ft lb) 7. 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. 8. Check: brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS 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 spring 3 brake pads (along with the brake pad shims)
4-21
CHAS
3. Measure: brake pad wear limit Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm (0.02 in)
4. Install: brake pad shims (onto the brake pads) brake pads brake pad spring NOTE: Always install new brake pads, brake pad shims, brake pad pins, brake pad clips, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 m kg, 4.3 ft lb) d. Install a new brake pad shim 3 onto each new brake pad 4 . e. Install new brake pads and a new brake pad spring.
4-22

5. Install: brake pad pins brake pad clips brake caliper
CHAS
40 Nm (4.0 m kg, 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 lever operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
4-23

EAS00584
CHAS
FRONT BRAKE MASTER CYLINDER
10 Nm (1.0 m kg, 7.2 ft lb)
30 Nm (3.0 m kg, 22 ft lb)
Order
Job/Part Removing the front brake master cylinder Brake fluid Brake lever Brake switch lead Brake switch Union bolt Brake hose/copper washer Master cylinder bracket Master cylinder
Qty
Remarks Remove the parts in the order listed. Drain.
1 2 3 4 5 6 7
1 2 1 1 1/2 1 1
Refer to REMOVING/ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER section. For installation, reverse the removal procedure.
4-24

EAS00585
CHAS
Order
Job/Part Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring
Qty
1 2 3 4
1 1 1 1 For assembly, reverse the disassembly procedure.
4-25

EAS00586
CHAS
REAR BRAKE MASTER CYLINDER
4 Nm (0.4 mSkg, 2.9 ftSlb)
Order
Job/Part Removing the rear brake master cylinder Side cover (right) Brake fluid Master cylinder bolt Union bolt Brake hose/copper washer Clip/hose Cotter pin Pin Washer Master cylinder
Qty
Drain. 2 1 1/2 2/1 1 1 1 1 For installation, reverse the removal procedure. Refer to REMOVING/ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER section.
1 2 3 4 5 6 7 8
4-26

EAS00587
CHAS
Order
Job/Part Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring
Qty
1 2 3 4
1 1 1 1 For assembly, reverse the disassembly procedure.
4-27

EAS00588
CHAS
REMOVING AND DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system.
1. Disconnect: brake switch coupler (from the brake switch) 2. Remove: union bolt 1 copper washers 2 brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 3. Remove: master cylinder bracket master cylinder 4. Remove: master cylinder boot circlip 5. Remove: master cylinder kit spring
EAS00589
REMOVING AND DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Remove: side cover (right)
2. Remove: union bolt 1 copper washers 2 brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose.
4-28

3. Remove: clip hose cotter pin pin washer 4. Remove: master cylinder 5. Remove: master cylinder boot circlip 6. Remove: master cylinder kit spring
CHAS
EAS00592
CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: brake master cylinder body Damage/scratches/wear ! Replace. brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air. A Front B Rear 2. Check: brake master cylinder kit seals 1 Damage/scratches/wear ! Replace. C Front D Rear
3. Check: rear brake fluid reservoir 1 Cracks/damage ! Replace. rear brake fluid reservoir diaphragm 2 Cracks/damage ! Replace.
4-29
CHAS
4. Check: front brake master cylinder reservoir 1 Cracks/damage ! Replace. front brake master cylinder reservoir diaphragm 2 Damage/wear ! Replace.
5. Check: brake hoses Cracks/damage/wear ! Replace.
EAS00598
ASSEMBLING AND INSTALLING FRONT BRAKE MASTER CYLINDER
THE
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 1. Install: spring master cylinder kit 2. Install: circlip master cylinder boot
4-30

3. Install: S brake master cylinder 1
CHAS
NOTE: S Install the brake master cylinder holder with the UP mark facing up. S Align the end of the brake master cylinder holder with the punch mark a on the handlebar. S First, tighten the upper bolt, then the lower bolt. 4. Install: S copper washers 1 New S brake hose 2 S union bolt 3 30 Nm (3.0 mSkg, 22 ftSlb)
CAUTION:
When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a on the brake master cylinder.
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to CABLE ROUTING. NOTE: S While holding the brake hose, tighten the union bolt as shown. S Turn the handlebar 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. 5. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4
4-31
FRONT AND REAR BRAKES WARNING
CHAS
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 6. Bleed: brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
7. 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. 8. Check: brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
4-32

EAS00608
CHAS
ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: spring master cylinder kit 2. Install: circlip master cylinder boot 3. Install: master cylinder 4. Install: washer pin cotter pin hose clip
5. Install: copper washers 1 New brake hose 2 union bolt 3 30 Nm (3.0 m kg, 22 ft lb)
CAUTION:
When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a as shown.
WARNING
Proper brake hose routing is essential to insure safe motorcycle operation. Refer to CABLE ROUTING.
6. Fill: brake fluid reservoir (to the maximum level mark a ) Recommended brake fluid DOT 4
4-33
CHAS
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 7. Bleed: brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
8. 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.
9. Adjust: brake pedal position a Refer to ADJUSTING THE REAR BRAKE in chapter 3. Brake pedal position (below the top of the rider footrest) 40 mm (1.57 in) 10. Adjust: rear brake light operation timing Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH in chapter 3.
4-34

EAS00613
CHAS
FRONT BRAKE CALIPERS
6 Nm (0.6 m kg, 4.3 ft lb)
40 Nm (4.0 m kg, 29 ft lb) 30 Nm (3.0 m kg, 22 ft lb)
Order
Job/Part Removing the front brake calipers Brake fluid Union bolt Copper washer Brake hose Brake caliper
Qty
1 2 3 4
1 2 1 1 For installation, reverse the removal procedure.
4-35

EAS00615
CHAS
6 Nm (0.6 m kg, 4.3 ft lb)
Order
Job/Part Disassembling the front brake calipers
Qty
Remarks Disassemble the parts in the order listed. The following procedure applies to both of the front brake calipers.
1 2 3 4 5 6 7
Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw
2 1 1 2 4 8 1 For assembly, reverse the disassembly procedure.
4-36

EAS00616
CHAS
REAR BRAKE CALIPER
30 Nm (3.0 m kg, 22 ft lb)
40 Nm (4.0 m kg, 29 ft lb)
Order
Job/Part Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake caliper
Qty
1 2 3 4
4-37

EAS00617
CHAS
6 Nm (0.6 m kg, 4.3 ft lb)
Order
1 2 3 4 5 6 7
Job/Part Disassembling the rear brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw
Qty 4 2 1 2 2 4 2
4-38

EAS00625
CHAS
DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system.
1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
2. Remove: S brake caliper pistons 1 S 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 caliper.
WARNING
S Never try to pry out the brake caliper pistons. S Do not loosen the bolts 3 . c. Remove the brake caliper piston seals. d. Repeat the previous steps to force out the right side pistons from the brake caliper.
4-39

EAS00628
CHAS
DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system.
1. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
2. Remove: S brake caliper pistons 1 S 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
S Never try to pry out the brake caliper pistons. S Do not loosen the bolts 3 . c. Remove the brake caliper piston seals. d. Repeat the previous steps to force out the right side piston from the brake caliper.
4-40

EAS00633
CHAS
CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads Piston seals Brake hoses Brake fluid If necessary Every two years Every two years Every two years and whenever the brake is disassembled.
1. Check: S brake caliper pistons 1 Rust/scratches/wear ! Replace the brake caliper. S brake caliper cylinders 2 Scratches/wear ! Replace the brake caliper. S brake calipers Cracks/damage ! Replace. S brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed Air.
WARNING
Whenever a brake caliper Is disassembled, replace the brake caliper piston seals.
A Front B Rear
2. Check: S brake caliper brackets 1 Cracks/damage ! Replace.
4-41

EAS00638
CHAS
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers.
WARNING
S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake components as they will cause the piston seals to swell and distort. S Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4
1. Install: S brake caliper (temporarily) S copper washers 1 New S brake hose 2 S union bolt 3 30 Nm (3.0 mSkg, 22 ftSlb)
WARNING
CAUTION:
When installing the brake hose onto the brake caliper, make sure that the brake pipe a touches the projection b on the brake caliper. 2. Remove: S brake caliper 3. Install: S brake pads S brake pad pins S brake pad clips S brake hose holder S brake caliper 40 Nm (4.0 mSkg, 29 ftSlb) Refer to REPLACING THE BRAKE PADS.
4-42
CHAS
4. Fill: S brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4
WARNING
S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S 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. S When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: S brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3. 6. Check: S 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: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
4-43

EAS00644
CHAS
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER
WARNING
S Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. S Never use solevents on internal brake components as they will cause the piston seals to swell and distort. S Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 1. Install: S brake caliper 1 (temporarily) S copper washers New S brake hose 2 S union bolt 3 30 Nm (3.0 mSkg, 22 ftSlb)
WARNING
CAUTION:
When installing the brake hose onto the brake caliper, make sure that the brake pipe a touches the projection b on the brake caliper. 2. Remove: S brake caliper 3. Install: S brake pads S brake pad pin S brake pad clips S brake caliper 40 Nm (4.0 mSkg, 29 ftSlb) Refer to REPLACING THE BRAKE PADS. 4. Fill: S brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4
4-44
CHAS
S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S 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. S 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.
CAUTION:
Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed: S brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
6. Check: S 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: S brake pedal operation Soft or spongy feeling ! Bleed the brake system. Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3.
4-45
FRONT FORK
EAS00647
CHAS
FRONT FORK
30 Nm (3.0 mSkg, 22 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb)
Order
Job/Part Removing the front fork Front wheel
Qty
Remarks Remove the parts in the order listed. Refer to FRONT WHEEL AND BRAKE DISCS.
1 2 3 4 5
Front fender Upper bracket pinch bolt Cap bolt Lower bracket pinch bolt Front fork assembly (left/right)
1 2 2 4 1/1
Loosen. Loosen. Loosen.
Refer to REMOVING/ INSTALLING THE FRONT FORK LEGS section.
4-46
FRONT FORK
EAS00648
CHAS
Order
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16
Job/Part Disassembly the front fork Cap bolt O-ring Spacer Spring seat Fork spring Damper adjusting rod Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod Inner tube Oil seal Washer Slide metal Oil flow stopper
Qty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

4-47
FRONT FORK
EAS00649
CHAS
REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Loosen: S upper bracket pinch bolt 1 S cap bolt 2 S lower bracket pinch bolt 3
WARNING
Before loosening the upper and lower bracket pinch bolts, support the front fork leg. 3. Remove: S front fork leg
EAS00653
DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: S cap bolt 1 (from the damper adjusting rod) S nut 2 NOTE: Remove the cap bolt with the piston rod holder 3. Rod holder YM-01434
4-48
FRONT FORK
2. Remove: S spacer 1 S spring seat 2 S spring 3 S damper adjusting rod 4 3. Drain: S fork oil
CHAS
4. Remove: S oil seal clip 1 (with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
5. Remove: S damper rod bolt S damper rod 1 NOTE: While holding the damper rod with the damper rod holder 2 , loosen the damper rod bolt. Damper rod holder YM-01447
6. Remove: S inner tube a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully.
4-49
FRONT FORK CAUTION:
CHAS
S Excessive force will damage the oil seal and bushing. A damaged oil seal or bushing must be replaced. S Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged.
EAS00657
CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace.
WARNING
Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: S spring free length a Over the specified limit ! Replace. Spring free length limit 344.0 mm (13.5 in)
3. Check: S damper rod Damage/wear ! Replace. Obstruction ! Blow out all of the oil passages with compressed air. S oil flow stopper Damage ! Replace.
CAUTION:
S The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. S When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 4. Check: S cap bolt O-ring Damage/wear ! Replace.
4-50
FRONT FORK
EAS00660
CHAS
ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
WARNING
S Make sure that the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor handling and a loss of stability. NOTE: S When assembling the front fork leg, be sure to replace the following parts: -inner tube bushing -outer tube bushing -oil seal -dust seal S Before assembling the front fork leg, make sure that all of the components are clean. 1. Install: S damper rod 1
CAUTION:
Allow the damper rod 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: Install the oil flow stopper with a flat surface part a downward. 2. Lubricate: S inner tubes outer surface Recommended lubricant Suspension oil 01 or equivalent 3. Tighten: S damper rod bolt 1
35 Nm (3.5 mSkg, 25 ftSlb) LOCTITE
NOTE: While holding the damper rod with the damper rod holder 2 , tighten the damper rod bolt. Damper rod holder YM-01447
4-51
FRONT FORK
CHAS
4. Install: S oil seal 1 (with the driver 2 and 43 mm adapter 3 ) Driver YM-33963 43 mm Adapters YM-8020-A
CAUTION:
Make sure that the numbered side of the oil seal faces up. NOTE: S Before installing the oil seal, apply lithium soap base grease onto its lips. S Apply fork oil onto the outer surface of the inner tube. S Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. 5. Install: S oil seal clip NOTE: Adjust the oil seal clip so that it fits into the outer tubes groove. 6. Fill: S front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.44 L (435 cm3) (15.3 Imp oz, 14.7 US oz) Recommended oil Yamaha suspension oil 01 or equivalent
CAUTION:
S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. S When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. NOTE: Be sure to bleed the front fork.
4-52
FRONT FORK
CHAS
7. Install: S rod puller 1 (onto the damper rod 2 ) Rod puller YM-01437
8. After filling the front fork leg, slowly stroke the damper rod 1 up and down (at least ten times) to distribute the fork oil. NOTE: Be sure to stroke the damper rod slowly because the fork oil may spurt out.
9. Slowly stroke the inner tube 2 up and down to distribute the fork oil once more (1 stroke = about 150 mm (5.9 in)). NOTE: Be careful not to stroke the inner tube over 150 mm (5.9 in) as this will cause air to enter. If the inner tube is stroke more than 150 mm (5.9 in), repeat steps (10) and (11). 10. Before checking the fork oil level, wait 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.
11. Measure: S front fork leg oil level a Out of specification ! Correct. Front fork leg oil level (from the top of the inner tube and damper rod, with the inner tube fully compressed, and without the spring) 140 mm (5.51 in)
4-53
FRONT FORK
12. Install: S spring 1 S spring seats 2 S spacer 3 S nut 4 S damper adjusting rod 5 S cap bolt 6
CHAS
a. Install the fork spring, spring seats, and spacer. NOTE: Install the fork spring with the larger pitch a facing up.
b smaller pitch b. Install the rod puller onto the damper rod.
c. Pull up the rod puller and install the rod holder 1 between the rod puller 2 and the spacer. NOTE: Use the side of the rod holder that is marked B. Rod holder YM-01434 d. Remove the rod puller. e. Install the damper adjusting rod locknut. f. Tighten the damper adjusting rod locknut. Damper adjusting rod locknut 25 Nm (2.5 mSkg, 18 ftSlb) g. Install the damper adjusting rod and cap bolt, and finger tighten it. h. Remove the rod holder.
CAUTION:
The spring is compressed.
4-54
FRONT FORK
EAS00662
CHAS
INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder.
2. Tighten: S lower bracket pinch bolt 1
25 Nm (2.5 mSkg, 18 ftSlb) S cap bolt 2 S upper bracket pinch bolt 3 30 Nm (3.0 mSkg, 22 ftSlb)
WARNING
Make sure that the brake hoses are routed properly. 3. Adjust: S spring preload S rebound damping S compression damping Refer to ADJUSTING THE FRONT FORK in chapter 3.
4-55
HANDLEBAR
EAS00664
CHAS
HANDLEBAR
26 Nm (2.6 mSkg, 19 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb)
Order 1 2 3 4 5 6 7 8 9 10 11 12 13
Job/Part Removing the handlebar Front brake master cylinder Right handlebar switch Throotle cable Grip end (right) Throttle grip Grip end (left) Left grip Left handlebar switch Starter cable Clutch cable Clutch lever Handlebar holder Handlebar
Qty 1 1 1 1 1 1 1 1 1 1 1 2 1
4-56
HANDLEBAR
EAS00666
CHAS
REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over.
2. Remove: S throttle cable housing 1 S throttle grip 2
3. Remove: S handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
EAS00668
CHECKING THE HANDLEBAR 1. Stand the motorcycle on a level surface.
WARNING
2. Check: S handlebar Bends/cracks/damage ! Replace.
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
4-57
HANDLEBAR
3.Install: S handlebar grip
CHAS
a. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
WARNING
Do not touch the handlebar grip until the rubber adhesive has fully dried.
EAS00672
INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. 2. Install: S handlebar 1 S upper handlebar holders 2
CAUTION:
S First, tighten the bolts on the front side of the handlebar holder, then on the rear side. S Turn the handlebar all the way to the left and right. If there is any contact with the fuel tank, adjust the handlebar position. NOTE: Align the match marks a in the handlebar with the upper surface of the lower handlebar holders.
3. Install: S throttle grip 1 S throttle cables NOTE: Align the pins a on the right handlebar switch with the holes b in the handlebar.
4-58
HANDLEBAR
5. Install: S left handlebar switch
CHAS
NOTE: Align the pins a on the right handlebar switch with the holes b in the handlebar.
6. Install: S clutch lever holder NOTE: Align the slit in the clutch lever holder with the punch mark a in the left handlebar. 7. Install: S brake master cylinder Refer to ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER. 8. Adjust: S 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 X 5 mm (0.12 X 0.20 in)
4-59
STEERING HEAD
EAS00676
CHAS
STEERING HEAD
110 Nm (11.0 mSkg, 80 ftSlb)
1st 52 Nm (5.2 mSkg, 38 ftSlb) 2nd 18 Nm (1.8 mSkg, 13 ftSlb)
Order
Job/Part Removing the steering head Front wheel Front fork Handlebar Front brake hose bracket Horn/bracket Brake hose joint Upper bracket cap nut Upper bracket Lock washer Upper ring nut Rubber washer Lower ring nut Dust cover Steering bearing (upper) Lower bracket Steering bearing (lower)
Qty
Remarks Remove the parts in the order listed. Refer to FRONT WHEEL Refer to FRONT FORK Refer to HANDLEBAR
1 2 3 4 5 6 7 8 9 10 11 12 13
1 1/1 1 1 1 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.

4-60
STEERING HEAD
EAS00677
CHAS
REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface.
WARNING
2. Remove: S lower ring nut 1 (with the special tool 2 ) Steering nut wrench YU-1268
WARNING
Securely support the lower bracket so that there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD 1. Wash: S bearings S bearing races Recommended cleaning solvent Kerosine 2. Check: S bearings 1 S bearing races 2 Damage/pitting ! Replace.
3. Replace: S bearings S bearing races a. Remove the bearing races 1 from the steering head pipe with a long rod 2 and hammer.
4-61
STEERING HEAD
CHAS
b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new bearing races.
CAUTION:
If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearings and bearing races as a set. S Whenever the steering head is disassembled, replace the rubber seal. 4. Check: S upper bracket S lower bracket (along with the steering stem) Bends/cracks/damage ! Replace.
EAS00683
INSTALLING THE STEERING HEAD 1. Lubricate: S upper bearing S lower bearing S bearing races Recommended lubricant Lithium soap base grease 2. Install: S lower ring nut 1 S rubber washer 2 S upper ring nut 3 S lock washer 4 Refer to CHECKING AND ADJUSTING THE STEERING HEAD in chapter 3. 3. Install: S upper bracket S steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: S front fork legs Refer to FRONT FORK. NOTE: Temporarily tighten the upper and lower bracket pinch bolts.
4-62
REAR SHOCK ABSORBER ASSEMBLY

EAS00685
CHAS
Order
Job/Part Removing the rear shock absorber assembly Rear wheel Side cover (left/right) Connecting arm Relay arm Rear shock absorber
Qty
Remarks Remove the parts in the order listed. Refer to REAR WHEEL
1 2 3 4
1/1 1 1 1 For installation, reverse the removal procedure.
4-63

EAS00687
CHAS
HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER
WARNING
This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder. S Do not tamper or attempt to open the rear shock absorber or gas cylinder. S 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 pressure. S Do not deform or damage the rear shock absorber or gas cylinder in any way. If the rear shock absorber, gas cylinder or both are damaged, damping performance will suffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER a. Gas pressure must be released before disposing of a rear shock absorber and gas cylinder. To release the gas pressure, drill a 2 X 3 mm (0.08 X 0.12 in) hole through the gas cylinder at a point 15 X 20 mm (0.59 X 0.79 in) from its end as shown.
WARNING
Wear eye protection to prevent eye damage from released gas or metal chips.
4-64

EAS00694
CHAS
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
2. Remove: S connecting arm bolt 1 S relay arm bolt 2 S rear shock absorber assembly lower bolt 3 NOTE: While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down.
3. Remove: S rear shock absorber assembly upper bolt 1 S rear shock absorber assembly NOTE: Raise the swingarm and then remove the rear shock absorber assembly from between the swingarm and relay arm.
4-65

EAS00696
CHAS
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. S spring Damage/wear ! Replace the rear shock absorber assembly. S bushings Damage/wear ! Replace. S dust seals Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace.
EAS00698
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 2. Install: S rear shock absorber assembly Rear shock absorber assembly upper nut 40 Nm (4.0 mSkg, 29 ftSlb) Rear shock absorber assembly lower nut 40 Nm (4.0 mSkg, 29 ftSlb) Relay-arm-to-frame-nut 40 Nm (4.0 mSkg, 29 ftSlb) NOTE: S When installing the rear shock absorber assembly, lift up the swingarm. S Install the connecting arm front bolt from the right.
4-66
SWINGARM AND DRIVE CHAIN

EAS00700
CHAS
125 Nm (12.5 mSkg, 90 ftSlb)
Order
Job/Part Removing the swing arm and drive chain Rear wheel Rear shock absorber assembly
Qty
Remarks Remove the parts in the order listed. Refer to REAR WHEEL Refer to REAR SHOCK ABSORBER ASSEMBLY
1 2 3
Rear brake caliper Brake hose holder Side protector (left/right)
1 2 1/1 NOTE: Remove the side protector assembly. Do not remove the center cap. 1 1 1 1 2 2
4-67
4 5 6 7 8 9
Pivot shaft Swing arm Drive chain case Drive chain guard Dust cover Oil seal
CHAS
125 Nm (12.5 mSkg, 90 ftSlb)
Order 10 11 12 13 14 15 16
Job/Part Bearing Spacer Shoft pedal assembly Drive sprocket cover Drive chain guide Drive sprocket Drive chain
Qty 2 1 1 1 1 1 1
Remarks
4-68

EAS00703
CHAS
REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S connecting arm bolt 1 S relay arm bolt 2 S rear shock absorber assembly lower bolt 3 NOTE: When removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down. 3. Check: S swingarm side play A S swingarm vertical movement B a. Check the tightening torque of the pivot shaft nut. Pivot shaft nut 125 Nm (12.5 mSkg, 90 ftSlb) b. Check the swingarm side play A by moving the swingarm from side to side. c. If the swingarm side play is out of specification, check the spacers, bearings, washers, and dust covers. Swingarm side play (at the end of the swingarm) 1.0 mm (0.04 in) d. Check the swingarm vertical movement B by moving the swingarm up and down. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.
4-69

EAS00704
CHAS
REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: S foot rest (left) S drive sprocket cover S drive chain guide 1 S drive sprocket 2
EAS00707
CHECKING THE SWINGARM 1. Check: S swingarm Bends/cracks/damage ! Replace.
2. Check: S pivot shaft Roll the pivot shaft on a flat surface. Bends ! Replace.
WARNING
Do not attempt to straighten a bent pivot shaft. 3. Wash: S pivot shaft S dust covers S spacer S washers S bearings Recommended cleaning solvent Kerosine
4-70
CHAS
4. Check: S dust covers 1 S spacer 2 S oil seals 3 Damage/wear ! Replace. S bearings 4 Damage/pitting ! Replace.
5. Check: S connecting arms 1 S relay arm 2 Damage/wear ! Replace. S bearings 3 S oil seals 4 Damage/pitting ! Replace. S spacers 5 Damage/scratches ! Replace.
EAS00709
CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain, the drive sprocket and the rear wheel sprocket as a set. Ten-link drive chain section limit (maximum) 150.1 mm (5.91 in) NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension. S Measure the length between drive chain roller 1 and 11 as shown. S Perform this measurement at two or three different places.
2. Check: S drive chain Stiffness ! Clean and lubricate or replace.
4-71

3. Clean: S drive chain
CHAS
a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosine and remove any remaining dirt. c. Remove the drive chain from the kerosine and completely dry it.
CAUTION:
This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chains internals, and solvents will deteriorate the Orings. A coarse brush can also damage the O-rings. Therefore, use only kerosine to clean the drive chain.
4. Check: S O-rings 1 Damage ! Replace the drive chain. S drive chain rollers 2 Damage/wear ! Replace the drive chain. S drive chain side plates 3 Damage/wear ! Replace the drive chain. Cracks ! Replace the drive chain and make sure that the battery breather hose is properly routed away from the drive chain and below the swingarm. 5. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check: S drive sprocket S rear wheel sprocket More than 1/4 tooth a wear ! Replace the drive chain, the drive sprocket and the rear wheel sprocket as a set. Bent teeth ! Replace the drive chain, the drive sprocket and the rear wheel sprocket as a set. b Correct 1 Drive chain roller 2 Drive chain sprocket
4-72

EAS00713
CHAS
INSTALLING THE DRIVE CHAIN 1. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Install: S drive chain 1 S drive sprocket 2 S lock washer 3 New S drive sprocket nut 4 S drive chain guide 5
NOTE: While applying the rear brake, tighten the drive sprocket nut. 3. Bend the lock washer tab a along a flat side of the nut.
EAS00711
INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: S relay arm 48 Nm (4.8 mSkg, 35 ftSlb) S left connecting arm S right connecting arm
4-73
CHAS
NOTE: Install the connecting arm front bolt 1 from the right. 3. Install: S rear shock absorber assembly S rear wheel Refer to INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY and REAR WHEEL. 4. Adjust: S drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3. Drive chain slack 40 X 50 mm (1.57 X 1.97 in)
CAUTION:
A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits.
4-74
ENG
CHAPTER 5 OVERHAULING THE ENGINE
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET AND EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . LEADS AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEADS . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-2 5-3 5-4 5-5 5-5 5-6 5-8 5-9 5-11 5-11 5-12 5-16 5-17 5-17 5-18 5-19 5-21 5-22 5-24 5-26 5-27 5-27
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29 REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 INSTATLLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 PICKUP COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 REMOVING THE PLCKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-34 INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-34
ENG
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PULL LEVER AND PULL ROD . . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERATOR ROTOR COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT AND CONNECTING RODS . . . . CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . CHECKING THE SPROCKETS AND CHAINS . . . . . . . . . . . . . . . . . . INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING ROD AND PISTON . . . . . . . . . . . ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 5-36 5-38 5-40 5-40 5-42 5-42 5-43 5-43 5-43 5-43 5-44 5-45 5-48 5-48 5-49 5-49 5-49 5-50 5-53 5-53 5-54 5-54 5-54 5-54 5-55 5-55 5-56 5-57 5-57 5-59 5-60 5-61 5-62 5-63 5-64 5-65 5-66 5-67 5-72 5-72 5-73 5-73 5-74 5-76
ENG
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-78 5-78 5-83 5-83 5-84 5-84 5-85
ENG
ENGINE
EAS00188
ENG
OVERHAULING THE ENGINE

ENGINE
DRIVE SPROCKET AND EXHAUST PIPE
10 Nm (1.0 m kg, 7.2 ft lb)
20 Nm (2.0 m kg, 14 ft lb) 85 Nm (8.5 m kg, 61 ft lb) 20 Nm (2.0 m kg, 14 ft lb)
Order
Job/Part Removing the drive sprocket and exhaust pipe Carburetor Plug code Ignition coil Radiator Water hose Air iduction system
Qty
Remarks Remove the parts in the order listed. Refer to CARBURETORS in chapter 7. Refer to RADIATOR in chapter 6. Refer to AIR INDUCTION SYSTEM in chapter 7.
1 2 3 4 5 6 7
Side cover (left) Stator coil coupler/oil level switch Shit rod Drive sprocket cover Drive sprocket Water outlet hose Exhaust pipe
1 1/1 1 1 1 1 1 For installation, reverse the removal procedure.

5-1
ENGINE
EAS00189
ENG
LEADS AND HOSES
Order 1 2 3 4 5
Job/Part Removing the leads and hoses Cover Clutch cable Nuetral switch/speed sensor/pickup coil lead Water head pipe Coolant outlet hose
Qty
Remarks
Remove the parts in the order listed. 1 1 1/1/1 Disconnect. 1 1 For installation, reverse the removal procedure.
5-2
ENGINE
EAS00191
ENG
ENGINE
55 Nm (5.5 m kg, 40 ft lb)
55 Nm (5.5 m kg, 40 ft lb)
24 Nm (2.4 m kg, 17 ft lb)
24 Nm (2.4 m kg, 17 ft lb) 33 Nm (3.3 m kg, 24 ft lb)
Order 1 2 3 4 5 6
Job/Part Removing the engine Down tube Engine mounting bolt (front) Engine bracket Engine mounting bolt (rear upper) Engine mounting bolt (rear lower) Engine
Qty 1 2 1 1 1 1
5-3
ENGINE
EAS00192
ENG
INSTALLING THE ENGINE 1. Install: engine mount bolt 1 engine mount bolt 2 engine mount bolts 3 engine bracket 4 engine mount bolt 5 down tube 6 NOTE: Do not fully tighten the bolts. 2. Tighten the bolts in the following order. Engine mount bolt 1 55 Nm (5.5 m kg, 40 ft Engine mount bolt 2 55 Nm (5.5 m kg, 40 ft Engine mount bolt 3 33 Nm (3.3 m kg, 24 ft Engine mount bolt 5 55 Nm (5.5 m kg, 40 ft Down tube 6 24 Nm (2.4 m kg, 17 ft lb) lb) lb) lb) lb)
3. Install: shift arm 1
10 Nm (10 m kg, 7.2 ft lb)
NOTE: Align the punch mark a in the shift shaft with the slot in the shift arm. Align the bottom edge of the shift pedal with the mark on the frame-to-swingarm bracket.
5-4
CAMSHAFT
EAS00194
ENG
CAMSHAFT
CYLINDER HEAD COVER
13 Nm (1.3 m kg, 9.4 ft lb)
12 Nm (1.2 m kg, 8.7 ft lb)
Order
Job/Part Removing the cylinder head cover Carburetor assembly Radiator assembly and thermostat assembly Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide (top side)
Qty
Remarks Remove the parts in the order listed. Refer to CARBURETORS in chapter 7. Refer to RADIATOR and THERMOSTAT ASSEMBLY in chapter 6.
1 2 3 4
5-5
CAMSHAFT
EAS00196
ENG
CAMSHAFTS
10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
24 Nm (2.4 m kg, 17 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
Order
Job/Part Removing the camshafts Pickup coil rotor cover Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft
Qty
Remarks Remove the parts in the order listed. Refer to PICKUP COIL.
1 2 3 4 5 6 7 8 9
1 1 1 3 6 3 6 1 1
NOTE: During removal, the dowel pins may still be connected to the camshaft caps.
5-6
CAMSHAFT
ENG
10 Nm (1.0 m kg, 7.2 ft lb)
24 Nm (2.4 m kg, 17 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
Order 10 11 12 13
Job/Part Intake camshaft sprocket Exhaust camshaft sprocket Pin Timing chain guide (intake side)
Qty 1 1 1 1
Remarks
5-7
CAMSHAFT
EAS00198
ENG
REMOVING THE CAMSHAFTS 1. Remove: pickup rotor coil cover 2. Align: T mark on the pickup coil rotor a (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the T mark a with the crankcase mating surface b . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
3. Loosen: camshaft sprocket bolts 1
4. Loosen: cap bolt 1 5. Remove: timing chain tensioner 2 gasket
6. Remove: camshaft sprocket 1 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 2 .
5-8
CAMSHAFT
ENG
7. Remove timing chain guide (exhaust side) 1 camshaft caps dowel pins
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. 8. Remove: intake camshaft 1 exhaust camshaft 2
EAS00204
CHECKING THE CAMSHAFTS 1. Check: camshaft lobes Blue discoloration/pitting/scratches Replace the camshaft.
2. Measure: camshaft lobe dimensions a and b Out of specification Replace the camshaft. Camshaft lobe dimension limit Intake a 32.4 mm (1.2756 in) b 24.85 mm (0.9783 in) Exhaust a 32.85 mm (1.2933 in) b 24.85 mm (0.9783 in)
5-9
CAMSHAFT
ENG
3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout Less than 0.03 mm (0.0012 in)
4. Measure: S camshaft-journal-to-camshaft-cap clearance Out of specification Measure the camshaft journal diameter. Camshaft-journal-to-camshaftcap clearance 0.028 X 0.062 mm (0.0011 X 0.0024 in) a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of PlastigaugeR 1 onto the camshaft journal as shown. c. Install the dowel pins and camshaft caps. NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. S Do not turn the camshaft when measuring the camshaft journal-to-camshaft cap clearance with the PlastigaugeR. Camshaft cap bolt 10 Nm (1.0 mSkg, 7.2 ftSlb) d. Remove the camshaft caps and then measure the width of the Plastigauge 1 .
5. Measure: S camshaft journal diameter a Out of specification ! Replace the camshaft. Within specification ! Replace the cylinder head and the camshaft caps as a set. Camshaft journal diameter 24.459 X 24.472 mm (0.9630 X 0.9635 in)
5-10
CAMSHAFT
EAS00208
ENG
CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: R timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set.
2. Check: R camshaft sprocket More than 1/4 tooth a wear ! Replace the camshaft sprockets and the timing chain as a set. a 1 / 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3. Check: R timing chain guide (exhaust side) 1 R timing chain guide (intake side) 2 R timing chain guide (top side) 3 Damage/wear ! Replace the defective part(-s).
EAS00210
CHECKING THE TIMING CHAIN TENSIONER 1. Check: R timing chain tensioner Cracks/damage ! Replace.
5-11
CAMSHAFT
ENG
2. Check: R one-way cam operation Rough movement ! Replace the timing chain tensioner housing. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops. b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough movement, replace the timing chain tensioner.
3. Check: R cap bolt R copper washer R spring R gasket R timing chain tensioner rod Damage/wear ! Replace the defective part(-s).
EAS00217
INSTALLING THE CAMSHAFTS 1. Install: R exhaust camshaft 1 R intake camshaft 2 NOTE: Install the camshafts with the punch mark a facing up.
2. Install: R dowel pins R intake camshaft caps R exhaust camshaft caps NOTE: Make sure that the punch marks a on the camshafts are aligned with the arrow marks b on the camshaft caps. Out of alignment ! Reinstall.
5-12
CAMSHAFT
3. Install: R camshaft cap bolts
ENG
10 Nm (1.0 mR kg, 7.2 ftR lb)
NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out.
CAUTION:
The camshaft cap bolts must be tightened evenly or damage to the cylinder head, camshaft caps, and camshafts will result.
4. Install: R intake camshaft sprocket R exhaust camshaft sprocket a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the T mark a on the pickup coil rotor with the crankcase mating surface b . c. Place the timing chain onto both camshaft sprockets and then install the camshaft sprockets onto the camshafts. NOTE: When installing the camshaft sprockets, start with the exhaust camshaft and be sure to keep the timing chain as tight as possible on the exhaust side.
CAUTION:
Do not turn the crankshaft when installing the camshaft to avoid damage or improper valve timing.
5-13
CAMSHAFT
ENG
d. Turn both camshafts opposite each other so that the punch marks c in the camshaft are aligned with the arrow marks d in the camshaft caps as shown. e. While holding the camshafts, temporarily tighten the camshaft sprocket bolts.
5. Install: R timing chain tensioner a. While lightly pressing the timing chain tensioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1 . b. With the timing chain tensioner rod turned all the way into the timing chain tensioner housing (with the thin screwdriver still installed), install the gasket and the timing chain tensioner 2 onto the cylinder block.
WARNING
Always use a new gasket. c. Tighten the timing chain tensioner bolts 3 to the specified torque. Timing chain tensioner bolt 10 Nm (1.0 mR kg, 7.2 ftR lb) d. Remove the screwdriver, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Timing chain cap bolt 12 Nm (1.2 mR kg, 8.7 ftR lb) 6. Turn: R crankshaft (several turns clockwise)
5-14
CAMSHAFT
ENG
7. Check: R T mark a Make sure that the T mark a on the pickup coil rotor is aligned with the crankcase mating surface b .
R camshaft punch marks c Make sure that the marks c on the camshaft are aligned with the arrow marks d in the comshaft caps. Out of alignment ! Adjust. Refer to the installation steps above.
8. Measure: R valve clearance Out of specification ! Adjust. Refer to ADJUSTING THE VALVE CLEARANCE in chapter 3. 9. Install: R timing mark accessing screw R crankshaft end cover
15 Nm (15 mR kg, 11 ftR lb)
5-15
CYLINDER HEAD
EAS00221
ENG
CYLINDER HEAD
Order
Job/Part Removing the cylinder head Engine Intake and exhaust camshafts Cylinder head Cylinder head gasket Dowel pin
Qty
Remarks Remove the parts in the order listed. Refer to ENGINE. Refer to CAMSHAFTS.
1 2 3
1 1 2 For installation, reverse the removal procedure.
5-16
CYLINDER HEAD
EAS00223
ENG
REMOVING THE CYLINDER HEADS 1. Remove: R cylinder head nuts R cylinder head cap nuts R cylinder head bolts NOTE: R Loosen the nuts in the proper sequence as shown. R Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
EAS00230
CHECKING THE CYLINDER HEADS The following procedure applies to all of the cylinder heads. 1. Eliminate: R carbon deposits (from the combustion chambers with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: R spark plug threads R valve seats 2. Check: R cylinder head Damage/scratches ! Replace. R cylinder head water jacket Mineral deposits/rust ! Eliminate. 3. Measure: R cylinder head warpage Out of specification ! Resurface the cylinder head. Cylinder head warpage Less than 0.1 mm (0.004 in) a. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. b. Measure the warpage. c. If the limited is exceeded, resurface the cylinder head as follows. d. Place a 400 X 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times.
5-17
CYLINDER HEAD
EAS00233
ENG
INSTALLING THE CYLINDER HEAD 1. Install: R gasket New 1 R dowel pins 2 2. Install: R cylinder head NOTE: Pass the timing chain through the timing chain cavity.
3. Tighten: R cylinder head nuts 1 X 10 20 Nm (2.0 mR kg, 14 ftR lb) 1st 50 Nm (5.0 mR kg, 36 ftR lb) 2nd 11 12 R cylinder head bolt
12 Nm (1.2 mR kg, 8.7 ftR lb)
NOTE: R First, tighten the nuts 1 X 10 to approximately 20 Nm (2.0 mR kg, 14 ftR lb) with a torque wrench. R Retighten the nuts to 50 Nm (5.0 mR kg, 36 ftR lb). NOTE: R Apply engine oil onto the threads of the cylinder head nuts. R Tighten the cylinder head nuts in the proper tightening sequence as shown and torque them in two stages. 4. Install: R exhaust camshaft R intake camshaft Refer to INSTALLING THE CAMSHAFTS.
5-18
VALVES AND VALVE SPRINGS

EAS00236
ENG
Order
Job/Part Removing the valves and valve springs Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide
Qty
Remarks Remove the parts in the order listed. Refer to CYLINDER HEAD.
1 2 3 4 5 6 7 8 9
12 12 24 12 12 12 12 12 12
5-19
ENG
Order 10 11 12 13 14 15 16 17 18
Job/Part Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide
Qty 8 8 16 8 8 8 8 8 8
Remarks
5-20

EAS00237
ENG
REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal.
1. Remove: R valve lifter 1 R 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: R valve sealing 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 properly seal. NOTE: There should be no leakage at the valve seat 1 .
3. Remove: R valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and adapter 3 . Valve spring compressor set, Quick release YM-04019 Adapter Intake valve YM-4114 Exhaust valve YM-4108
5-21

4. Remove: R upper spring seat 1 R valve spring 2 R oil seal 3 R lower spring seat 4 R valve 5
ENG
NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: R valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter A Valve stem diameter B Out of specification ! Replace the valve guide. Valve-stem-to-valve-guide clearance Intake 0.010 X 0.037 mm (0.0004 X 0.0015 in) <Limit>: 0.08 mm (0.0031 in) Exhaust 0.020 X 0.047 mm (0.0008 X 0.0019 in) <Limit>: 0.1 mm (0.0039 in)
5-22

2. Replace: S valve guide
ENG
NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C in an oven.
a. Remove the valve guide with a valve guide remover 1 . b. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . c. After 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) YM-04111 Exhaust (4.5 mm) YM-4116 Valve guide installer Intake (4.0 mm) YM-04112 Exhaust (4.5 mm) YM-4117 Valve guide reamer Intake YM-04113 Exhaust YM4118
5-23
ENG
3. Eliminate: R carbon deposits (from the valve face and valve seat) 4. Check: R valve face Pitting/wear ! Grind the valve face. R valve stem end Mushroom shape or diameter larger than the body of the valve stem ! Replace the valve. 5. Measure: R valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 0.5 X 0.9 mm (0.020 X 0.035 in)
6. Measure: R valve stem runout Out of specification ! Replace the valve. NOTE: R When installing a new valve, always replace the valve guide. R If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm (0.0004 in)
EAS00240
CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1. Eliminate: R carbon deposits (from the valve face and valve seat) 2. Check: R valve seat Pitting/wear ! Replace the cylinder head. 3. Measure: R valve seat width a Out of specification ! Replace the cylinder head. Valve seat width Intake: 0.9 X 1.1 mm (0.035 X 0.043 in) Exhaust: 0.9 X 1.1 mm (0.035 X 0.043 in)
5-24
ENG
a. Apply Mechanics blueing dye (Dykem) 1 onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed.
4. Lap: R valve face R valve seat NOTE: 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.
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 face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hand. e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanics blueing dye (Dykem) onto the valve face. h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impression. j. Measure the valve seat width a again. If the valve seat width is out of specification, reface and lap the valve seat.
5-25

EAS00241
ENG
CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: R valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length Intake spring 38.9 mm (1.53 in) Exhaust spring 40.67 mm (1.60 in)
2. Measure: R compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force Intake 8.2 X 9.6 kg at 34.5 mm (18.4 X 25.4 lb at 1.36 in) Exhaust 11.0 X 12.6 kg at 35.0 mm (24.7 X 28.3 lb at 1.38 in)
3. Measure: R valve spring tilt a Out of specification ! Replace the valve spring. Spring tilt limit Intake 1.7 mm (0.067 in) Exhaust 1.8 mm (0.071 in)
5-26

EAS00242
ENG
CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: R valve lifter Damage/scratches ! Replace the valve lifters and cylinder head.
EAS00245
INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: R valve stem end (with an oil stone)
2. Lubricate: R valve stem 1 R oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil
3. Install: R valve 1 R lower spring seat 2 R oil seal 3 R valve spring 4 R upper spring seat 5 (into the cylinder head) NOTE: Install the valve spring with the larger pitch a facing up.
b Smaller pitch
NOTE: Make sure that each valve is installed in its original place. Refer to the following embossed marks. Right and left intake valve(-s): 4XV: Middle intake valve(-s): 4XV. Exhaust valve(-s): 5LV
5-27

4. Install: R valve cotters 1
ENG
NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and adapter 3 . Valve spring compressor set, Quick release YM-04019 Adapter Intake valve YM-4114 Exhaust valve YM-4108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
CAUTION:
Hitting the valve tip with excessive force could damage the valve. 6. Install: R valve pad 1 R valve lifter 2 NOTE: R Apply molybdenum disulfide oil onto the valve lifter and valve pad. R The valve lifter must move smoothly when rotated with a finger. R Each valve lifter and valve pad must be reinstalled in its original position.
5-28
GENERATOR
EB410000
ENG
GENERATOR
65 Nm (6.5 mSkg, 47 ftSlb) + 60_
Order
Job/Part Removing the stator coil assembly Rider seat and fuel tank Bottom cowling Engine oil
Qty
Remarks Remove the parts in the order listed. Refer to SEATS and FUEL TANK in chapter 3. Refer to COWLINGS in chapter 3. Drain. Refer to CHANGING THE ENGINE OIL in chapter 3.
1 2 3 4 5 6 7 8
Generator rotor cover Generator rotor cover gasket Dowel pin Generator rotor bolt Generator rotor Stator coil assembly coupler Stator coil assembly lead holder Stator coil assembly
1 1 2 1 1 1 1 1
Disconnect.
5-29
GENERATOR
ENG
REMOVING THE GENERATOR 1. Remove: R generator rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: R generator rotor bolt 1 R washer NOTE: While holding the generator rotor 2 with the universal magneto & rotor holder 3 , loosen the generator rotor bolt. Universal magneto & rotor holder YU-01235 3. Remove: R generator rotor 1 (with the alternator roter puller 2 and rotor holding tool 3 ) Alternator roter puller YM-01080-A INSTALLING THE GENERATOR 1. Apply: R sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 ACC-11001-05-01 2. Install: R generator rotor R washer R generator rotor bolt
WARNING
Always use a new generator rotor bolt.
CAUTION:
R Clean the tapered portion of the crankshaft and the generator rotor hub with lacquer thinner. R Lubricate the generator rotor bolt threads with engine oil.
5-30
GENERATOR
ENG
3. Tighten: S generator rotor bolt 1 New

65 Nm (6.5 mSkg, 47 ftSlb) + 60_
NOTE: S While holding the generator rotor 2 with the universal magneto & rotor holder 3 , tighten the generator rotor bolt. S After tightening to 65 Nm (6.5 mSkg, 47 ftSlb), tighten another 60_. Universal magneto & rotor holder YU-01235 4. Install: S generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern.
5-31
PICKUP COIL
ENG
PICKUP COIL
60 Nm (6.0 mR kg, 43 ftR lb)
12 Nm (1.2 mR kg, 8.7 ftR lb)
10 Nm (1.0 mR kg, 7.2 ftR lb)
15 Nm (1.5 mR kg, 11 ftR lb)
Order
Job/Part Removing the pickup coil and pickup coil rotor Rider seat and fuel tank Bottom cowling and right side cowling Engine oil
Qty
Remarks Remove the parts in the order listed. Refer to SEATS and FUEL TANK in chapter 3. Refer to COWLINGS in chapter 3. Drain. Refer to CHANGING THE ENGINE OIL in chapter 3. Refer to GENERATOR.
1 2 3 4
Generator rotor cover Pickup coil lead holder Pickup coil rotor cover Pickup coil rotor cover gasket Dowel pin
1 1 1 2
5-32
PICKUP COIL
ENG
60 Nm (6.0 mR kg, 43 ftR lb)
12 Nm (1.2 mR kg, 8.7 ftR lb)
10 Nm (1.0 mR kg, 7.2 ftR lb)
15 Nm (1.5 mR kg, 11 ftR lb)
Order 5 6 7
Job/Part Pickup coil coupler Pickup coil Pickup coil rotor
Qty 1 1 1 Disconnect.
Remarks
5-33
PICKUP COIL
ENG
REMOVING THE PICKUP COIL ROTOR 1. Remove: R pickup coil lead holder 1 R pickup coil rotor cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: R pickup coil rotor bolt 1 R washer R pickup coil rotor 2 NOTE: While holding the generator rotor 3 with the universal magneto & rotor holder 4 , loosen the pickup coil rotor bolt. Universal magneto & rotor holder YU-01235
INSTALLING THE PICKUP COIL ROTOR 1. Install: R pickup coil rotor 1 R washer R pickup coil rotor bolt NOTE: When installing the pickup coil rotor, align the pin 2 in the crankshaft sprocket with the groove a in the pickup coil rotor.
5-34
PICKUP COIL
2. Tighten: R pickup coil rotor bolt 1
ENG
60 Nm (6.0 mR kg, 43 ftR lb)
NOTE: While holding the generator rotor 2 with the universal magneto & rotor holder 3 , tighten the pickup coil rotor bolt. Universal magneto & rotor holder YU-01235
3. Apply: R sealant (onto the pickup coil lead grommet) Yamaha bond No. 1215 ACC-11001-05-01
4. Install: R pickup coil rotor cover R pickup coil lead holder NOTE: R When installing the pickup coil rotor cover, align the timing chain guide (intake side) pin 1 with the hole 2 in the pickup coil rotor cover. R Tighten the pickup coil rotor cover bolts in stages and in a crisscross pattern.
5-35
CLUTCH
EAS00273
ENG
CLUTCH
CLUTCH COVER
Order
Job/Part Removing the clutch cover Engine oil
Qty
Remarks Remove the parts in the order listed. Drain. Refer to CHANGING THE ENGINE OIL in chapter 3.
1 2 3 4
Clutch cable Clutch cover Clutch cover gasket Dowel pin
5-36
CLUTCH
EB405010
ENG
Order 1 2 3 4 5 6
Job/Part Removing the pull lever shaft Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing
Qty 2 1 1 1 1 2
5-37
CLUTCH
EAS00274
ENG
CLUTCH
Order 1 2 3 4 5 6 7 8 9 10
Job/Part Removing the clutch Clutch cover Pull rod Friction plate Clutch plate Friction plate Clutch plate Friction plate Friction plate Clutch damper spring Clutch damper spring seat
Qty 1 1 1 2 4 6 3 1 1 1
Select. Color code: Black Color code: Blue Refer to INSTALLING THE CLUTCH.
5-38
CLUTCH
ENG
Order 11 12 13 14 15 16 17 18 19 20 21
Job/Part Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear
Qty 1 1 1 1 1 1 1 1 1 1 1
Remarks
5-39
CLUTCH
EAS00277
ENG
REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: R clutch boss nut 1 NOTE: While holding the clutch boss 2 with the universal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder YM-91042
3. Remove: R clutch boss nut 1 R lock washer 2 R clutch boss 3
EAS00280
CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: R friction plate Damage/wear ! Replace the friction plates as a set.
5-40
CLUTCH
ENG
2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness Friction plate a 3.42 X 3.58 mm (0.135 X 0.141 in) <Limit>: 3.32 mm (0.131 in) Friction plate b 2.92 X 3.08 mm (0.115 X 0.121 in) <Limit>: 2.82 mm (0.111 in) 3. Measure: S assembly width a Out of specification ! Adjust. Assembly width 43.1 X 43.9 mm (1.70 X 1.73 in) a. Assembly width adjusted by clutch plate 1 and 2 . b. Select the clutch plate from the following table. Clutch plate 1 Part No. 168-16325-00 31A-16325-00 168-16324-00 Clutch plate 2 Part No. 31A-16325-00 168-16324-00 Thickness 2.0 mm (0.08 in) 2.3 mm (0.09 in) STD Thickness 1.6 mm (0.06 in) 2.0 mm (0.08 in) 2.3 mm (0.09 in) STD
NOTE: When adjusting the clutch assembly width [by replacing the clutch plate(s)], be sure to replace the clutch plate 1 first. After replacing the cltuch plate 1 , if specifications cannot be met, replace the clutch plate 2 .
5-41
CLUTCH
EAS00281
ENG
CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: R clutch plate Damage ! Replace the clutch plates as a set.
2. Measure: R clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification ! Replace the clutch plates as a set. Clutch plate warpage limit Less than 0.1 mm (0.004 in)
EAS00282
CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: R clutch spring Damage ! Replace the clutch springs as a set.
2. Measure: R clutch spring free length Out of specification ! Replace the clutch springs as a set. Clutch spring free length 50 mm (1.97 in) <Limit>: 47.5 mm (1.87 in)
5-42
CLUTCH
EAS00284
ENG
CHECKING THE CLUTCH HOUSING 1. Check: R 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 erratic clutch operation. 2. Check: R bearing Damage/wear ! Replace the clutch housing.
EAS00285
CHECKING THE CLUTCH BOSS 1. Check: R clutch boss splines Damage/pitting/wear ! Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation.
EAS00286
CHECKING THE PRESSURE PLATE 1. Check: R pressure plate 1 Cracks/damage ! Replace. R bearing 2 Damage/wear ! Replace.
EAS00287
CHECKING THE PULL LEVER AND PULL ROD 1. Check: R pull lever 1 R pull rod 2 Damage/wear ! Replace the pull rod and pull lever pinion gear as a set.
5-43
CLUTCH
ENG
2. Check: R pull rod bearing Damage/wear ! Replace.
EAS00351
CHECKING THE STARTER CLUTCH 1. Check: R starter clutch rollers Damage/wear ! Replace.
2. Check: R starter clutch idle gear R starter clutch drive gear R starter clutch gear Burrs/chips/roughness/wear the defective part(-s).
Replace
3. Check: R starter clutch gears contacting surfaces Damage/pitting/wear ! Replace the starter clutch gear.
5-44
CLUTCH
4. Check: starter clutch operation
ENG
a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch drive gear clockwise A , the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear counterclockwise B , it should turn freely. If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must be replaced.
EAS00299
INSTALLING THE CLUTCH 1. Install: clutch housing NOTE: Make sure that the slots a in the clutch housing align with the tabs b on the oil/water pump assembly drive sprocket. Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly. Make sure that the starter clutch gear teeth and starter clutch idle gear teeth mesh correctly.
2. Install: lock washer New clutch boss nut 1

90 Nm (9.0 m kg, 65 ft lb)
NOTE: While holding the clutch boss 2 with the universal clutch holder 3 , tighten the clutch boss nut. Universal clutch holder YM-91042
5-45
CLUTCH
ENG
3. Bend the lock washer tab along a flat side of the nut. 4. Lubricate: S friction plates S clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 5. Install: S friction plates S clutch plates NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate.
a. Install the clutch damper spring seat 1 , clutch damper spring 2 and friction plate (smaller size) 3 . b. Install the clutch plate and friction plate at following the illustrated. Friction plate 4 : Color code/Blue Friction plate 5 : Color code/Black Clutch plate 6 : 2.0 mm Clutch plate 7 : Select. Refer to CHECKING THE FRICTION PLATE
6. Measure: S assembly width a Out of specification ! Adjust. Refer to CHECKING THE FRICTION PLATE. Assembly width 43.1 X 43.9 mm (1.70 X 1.73 in)
5-46
CLUTCH
7. Install: pressure plate 1
ENG
NOTE: Align the punch mark b in the pressure plate with the punch mark a in the clutch boss.
8. Install: clutch springs clutch spring bolts

8 Nm (0.8 m kg, 5.8 ft lb)
NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern.
9. Install: pull lever NOTE: Align the punch mark a in the pull lever shaft with the mark b on the clutch cover.
10. Install: dowel pins gasket New clutch cover
12 Nm (1.2 m kg, 8.7 ft lb)
NOTE: When installing the clutch cover, push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover. Make sure that the pull rod groove c and pull lever shaft groove d are engaged. Tighten the clutch cover bolts in stages and in a crisscross pattern.
5-47
SHIFT SHAFT
EAS00326
ENG
SHIFT SHAFT
GENERATOR ROTOR COVER
12 Nm (1.2 m kg, 8.7 ft lb)
Order
Job/Part Removing the shift shaft and stopper lever Drive sprocket cover Shift shaft cover Shift shaft cover gasket Dowel pin Shift shaft Shift shaft spring Spacer Stopper lever spring Stopper lever Collar Shift shaft spring stopper
Qty
Remarks Remove the parts in the order listed. Refer to ENGINE.
1 2 3 4 5 6 7 8 9 10
1 1 2 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
5-48
SHIFT SHAFT
EAS00328
ENG
CHECKING THE SHIFT SHAFT 1. Check: shift shaft 1 Bends/damage/wear ! Replace. shift shaft spring 3 Damage/wear ! Replace.
EAS00330
CHECKING THE STOPPER LEVER 1. Check: stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
EAS00331
INSTALLING THE SHIFT SHAFT 1. Install: shift shaft spring stopper 1

22 Nm (2.2 m kg, 16 ft lb)
stopper lever spring 2 stopper lever 3 NOTE: Apply LOCTITE to the threads of the shift shaft spring stopper. Hook the ends of the stopper lever spring onto the stopper lever and the crankcase boss. Mesh the stopper lever with the shift drum segment assembly.
2. Install: shift shaft 1 spacer NOTE: Lubricate the oil seal lips with lithium soap base grease. Install the end of the shift shaft spring onto the shift shaft spring stopper 2 .
5-49
OIL PAN AND OIL PUMP

EAS00356
ENG
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb)
43 Nm (4.3 m kg, 31 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
Order
Job/Part Removing the oil pan and oil pump Engine oil
Qty
Remarks Remove the parts in the order listed. Drain. Refer to CHANGING THE ENGINE OIL in chapter 3. Drain. Refer to CHANGING THE COOLANT in chapter 3. Refer to RADIATOR in chapter 6. Refer to ENGINE. Disconnect.
Coolant
1 2 3 4 5 6
Radiator assembly and water pump outlet pipe Exhaust pipe assembly Oil level switch connector Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin
1 1 1 1 1 2
5-50

EB411001
ENG
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb)
43 Nm (4.3 m kg, 31 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
Order 7 8 9 10 11 12 13 14
Job/Part Drain pipe Oil strainer Oil pipe Oil delivery pipe Oil/water pump assembly drive sprocket cover Dowel pin Oil/water pump assembly Relief valve assembly
Qty 1 1 1 1 1 1 1 1
Remarks
5-51

EAS00360
ENG
10 Nm (1.0 m kg, 7.2 ft lb)
15 Nm (1.5 m kg, 11 ft lb)
Order
1 2 3 4 5 6 7 8
Job/Part Disassembling the oil pump Oil/water pump assembly driven sprocket Washer Oil pump housing Bearing Pin Oil pump outer rotor Oil pump inner rotor Pin
Qty 1 1 1 1 2 1 1 1
5-52

EAS00362
ENG
REMOVING THE OIL PAN 1. Remove: oil level switch 1 oil pan 2 engine oil drain bolt 3 gasket dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
EAS00364
CHECKING THE OIL PUMP 1. Check: oil pump drive gear 1 oil pump driven gear 2 oil pump housing oil pump housing cover Cracks/damage/wear ! Replace the defective part(-s). 2. Measure: inner-rotor-to-outer-rotor-tip clearance a outer-rotor-to-oil-pump-housing clearance b oil-pump-housing-to-inner-rotor-and-outerrotor clearance c Out of specification ! Replace the oil pump. 1 Inner rotor 2 Outer rotor 3 Oil pump housing Inner-rotor-to-outer-rotor-tip clearance 0.09 X 0.15 mm (0.004 X 0.006 in) <Limit>: 0.23 mm (0.009 in) Outer-rotor-to-oil-pump-housing clearance 0.03 X 0.08 mm (0.001 X 0.003 in) <Limit>: 0.15 mm (0.006 in) Oil-pump-housing-to-inner-rotorand-outer-rotor clearance 0.06 X 0.11 mm (0.002 X 0.004 in) <Limit>: 0.18 mm (0.007 in) 3. Check: oil pump operation Unsmooth ! Repeat steps (1) and (2) or replace the defective part(-s).
5-53

EAS00365
ENG
CHECKING THE RELIEF VALVE 1. Check: relief valve body 1 relief valve 2 spring 3 O-ring 4 Damage/wear ! Replace the defective part(-s).
EAS00366
CHECKING THE OIL DELIVERY PIPE 1. Check: oil delivery pipe 1 oil pipe 2 Damage ! Replace. Obstruction ! Wash and blow out with compressed air.
EAS00368
CHECKING THE OIL STRAINER 1. Check: oil strainer 1 Damage ! Replace. Contaminants ! Clean with engine oil.
EAS00374
ASSEMBLING THE OIL PUMP 1. Lubricate: inner rotor outer rotor oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil
5-54

2. Install: pin 1 inner rotor 2 outer rotor 3 oil pump housing 4
ENG
Oil pump housing screw 10 Nm (1.0 m kg, 7.2 ft lb) NOTE: When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the inner rotor 2 . 3. Check: oil pump operation Refer to CHECKING THE OIL PUMP.
EAS00376
INSTALLING THE OIL PUMP 1. Install: oil pump 12 Nm (1.2 m kg, 8,7 ft lb) NOTE: Install the oil/water pump drive chain 1 onto the oil/water pump driven sprocket 2 .
EAS00378
INSTALLING THE OIL STRAINER 1. Install: oil strainer housing 1

10 Nm (1.0 m kg, 7.2 ft lb) LOCTITE
NOTE: The arrow a on the oil strainer housing must point towards the front of the engine.
5-55

EAS00380
ENG
INSTALLING THE OIL PAN 1. Install: dowel pins gasket New oil pan 1 10 Nm (10 m kg, 7.2 ft lb) oil level switch 2
10 Nm (10 m kg, 7.2 ft lb)
engine oil drain bolt 3

43 Nm (4.3 m kg, 31 ft lb)
WARNING
Always use new copper washers. NOTE: Tighten the oil pan bolts in stages and in a crisscross pattern. Lubricate the oil level switchs O-ring with engine oil.
5-56
CRANKCASE
EAS00381
ENG
CRANKCASE
CRANKCASE
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
Order
Job/Part Removing the crankcase Engine Cylinder head Pickup coil and pickup coil rotor Stator coil assembly Clutch housing and starter clutch idle gear Oil/water pump assembly Timing chain Crankshaft sprocket Pin Oil/water pump assembly drive chain guide Oil/water pump assembly drive chain
Qty
Remarks Remove the parts in the order listed. Refer to ENGINE. Refer to CYLINDER HEAD. Refer to PICKUP COIL. Refer to GENERATOR. Refer to CLUTCH. Refer to OIL PAN AND OIL PUMP.
1 2 3 4 5
1 1 1 1 1
5-57
CRANKCASE
ENG
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
Order 6 7 8 9 10
Job/Part Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin
Qty 1 1 1 1 3
Remarks
5-58
CRANKCASE
EAS00382
ENG
CONNECTING RODS AND PISTONS

36 Nm (3.6 m kg, 25 ft lb)
Order
Job/Part Removing the connecting rods and pistons Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing Top ring 2nd ring Oil ring
Qty
1 2 3 4 5 6 7 8 9 10
4 4 8 4 4 4 4 4 4 4 For installation, reverse the removal procedure.
5-59
CRANKCASE
CRANKSHAFT
ENG
Order
Job/Part Removing the crankshaft assembly Crankcase Connecting rod caps
Qty
Remarks Remove the parts in the order listed. Separate. Refer to CRANKCASE. Refer to CONNECTING RODS AND PISTONS.
1 2 3
Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing
1 5 5 For installation, reverse the removal procedure.
5-60
CRANKCASE
EAS00384
ENG
DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: crankcase bolts NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). The numbers embossed on the crankcase indicate the crankcase tightening sequence. 3. Remove: lower crankcase
CAUTION:
Tap on one side of the crankcase with a softface hammer. Tap only on reinforced portions of the crankcase, not on the crankcase mating surfaces. Work slowly and carefully and make sure that the crankcase halves separate evenly. M9 125 mm bolts: 1 X 10 M8 125 mm bolts: 21 X 22 M6 100 mm bolts: 11 X 20 , 23 X 28 4. Remove: dowel pins O-ring 5. Remove: crankshaft journal lower bearing (from the lower crankcase) NOTE: Identify the position of each crankshaft journal lower bearing so that it can be reinstalled in its original place.
5-61
CRANKCASE
EAS00393
ENG
REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: connecting rod cap 1 big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
2. Remove: piston pin clips 1 piston pin 2 piston 3
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 clips groove and the pistons pin bore area. If both areas are deburred and the piston pin is still difficult to remove, remove it with the piston pin puller 1 . Piston pin puller YU-01304
5-62
CRANKCASE
3. Remove: top ring 2nd ring oil ring
ENG
NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown.
EAS00387
REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: crankshaft assembly 1 crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.
5-63
CRANKCASE
EAS00256
ENG
CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: piston wall cylinder wall Vertical scratches ! Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: piston-to-cylinder clearance a. Measure cylinder bore C with the cylinder bore gauge. NOTE: Measure cylinder bore C by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements. 74.00 X 74.01 mm (2.9134 X 2.9138 in) 74.06 mm (2.9157 in) 0.05 mm (0.0016 in) 0.05 mm (0.0016 in)
Cylinder bore C Wear limit Taper limit T Out of round R
C = maximum of D1 X D6 T = maximum of D1 or D2 maximum of D5 or D6 R = maximum of D1 D3 or D5 minimum of D2 D4 or D6
b. If out of specification, replace the cylinder, and the piston and piston rings as a set.
5-64
CRANKCASE
ENG
c. Measure piston skirt diameter P with the micrometer. a 5 mm (0.20 in) from the bottom edge of the piston. Piston size P 73.955 X 73.970 mm (2.9118 X 2.9122 in) d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore C Piston skirt diameter P Piston-to-cylinder clearance 0.030 X 0.055 mm (0.001 X 0.002 in) <Limit>: 0.12 mm (0.005 in) f. If out of specification, replace the cylinder, and the piston 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. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) 2nd ring 0.020 X 0.055 mm (0.0008 X 0.0022 in)
5-65
CRANKCASE
2. Install: piston ring (into the cylinder)
ENG
NOTE: Level the piston ring in the cylinder with the piston crown as shown.
a 5 mm (0.20 in) 3. Measure: piston ring end gap Out of specification ! Replace the piston ring.
NOTE: The oil ring expander spacers end gap cannot be measured. If the oil ring rails gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.32 X 0.44 mm (0.010 X 0.020 in) 2nd ring 0.43 X 0.58 mm (0.017 X 0.023 in) Oil ring 0.10 X 0.35 mm (0.004 X 0.014 in)
EAS00266
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 lubrication system.
2. Measure: piston pin outside diameter Out of specification ! Replace the piston pin. Piston pin outside diameter 16.991 X 17.000 mm (0.6689 X 0.6693 in)
5-66
CRANKCASE
ENG
3. Measure: piston pin bore inside diameter Out of specification Replace the piston. Piston pin bore inside diameter 17.002 X 17.013 mm (0.6694 X 0.6698 in) 4. Calculate: piston-pin-to-piston clearance Out of specification ! Replace the piston pin and piston as a set. Piston-pin-to-piston clearance = Piston pin bore size Piston pin outside diameter Piston-pin-to-piston clearance 0.002 X 0.022 mm (0.00008 X 0.00087 in) <Limit>: 0.072 mm (0.0028 in)
EAS00395
CHECKING THE CRANKSHAFT AND CONNECTING RODS 1. Measure: crankshaft runout Out of specification ! Replace the crankshaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: crankshaft journal surfaces crankshaft pin surfaces bearing surfaces Scratches/wear ! Replace the crankshaft. 3. Measure: crankshaft-journal-to-crankshaft-journalbearing clearance Out of specification ! Replace the crankshaft journal bearings. Crankshaft-journal-to-crankshaftjournal-bearing clearance 0.029 X 0.053 mm (0.0011 X 0.0021 in)
5-67
CRANKCASE CAUTION:
ENG
Do not interchange the crankshaft journal bearings. To obtain the correct crankshaftjournal-to-crankshaft-journal-bearing clearance and prevent engine damage, the crankshaft journal bearings must be installed in their original positions. a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench.
c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a of the crankshaft journal upper bearings with the notches b in the crankcase. d. Put a piece of Plastigauge 2 on each crankshaft journal. NOTE: Do not put the Plastigauge over the oil hole in the crankshaft journal.
e. Install the crankshaft journal lower bearings 1 into the lower crankcase and assemble the crankcase halves. NOTE: Align the projections a of the crankshaft journal lower bearings with the notches b in the crankcase. Do not move the crankshaft until the clearance measurement has been completed.
5-68
CRANKCASE
ENG
f. Tighten the bolts to specification in the tightening sequence cast on the crankcase. Crankcase bolt Bolt 1 X 10 1st: 15 Nm (1.5 mSkg, 11 ftSlb) 2nd: 15 Nm (1.5 mSkg, 11 ftSlb) + 45 X 50_ Bolt 11 X 15 , 17 X 20 , 23 , 25 X 28 12 Nm (1.2 mSkg, 8.7 ftSlb) Bolt 16 , 24 14 Nm (1.4 mSkg, 10 ftSlb) Bolt 21 X 22 24 Nm (24 mSkg, 17 ftSlb) NOTE: Lubricate the crankcase bolt threads with engine oil. g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge width c on each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings.
4. Select: S crankshaft journal bearings (J1 X J5) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes. S J1 X J5 refer to the bearings shown in the crankshaft illustration. S If J1 X 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 6 and 2 respectively, then the bearing size for J1 is: Bearing size for J1: J1 (crankcase) J1 (crankshaft web) 2 = 6 2 2 = 2 (Pink/black)
5-69
CRANKCASE
ENG
CRANKSHAFT JOURNAL BEARING COLOR CODE 1 0 1 2 3 Pink/violet Pink/white Pink/blue Pink/black Pink/brown
5. Measure: crankshaft-pin-to-big-end-bearing clearance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.031 X 0.055 mm (0.0012 X 0.0022 in) The following procedure applies to all of the connecting rods.
CAUTION:
Do not interchange the big end bearings and connecting rods. To obtain the correct crankshaft-pin-to-big-end-bearing clearance and prevent engine damage, the big end bearings must be installed in their original positions. a. Clean the big end bearings, crankshaft pins, and bearing portions of the connecting rods. b. Install the big end upper bearing into the connecting rod and the big end lower bearing into the connecting rod cap.
NOTE: Align the projections a on the big end bearings with the notches b in the connecting rod and connecting rod cap.
5-70
CRANKCASE
ENG
c. Put a piece of Plastigauge 1 on the crankshaft pin. d. Assemble the connecting rod halves. NOTE: Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Apply molybdenum disulfide grease onto the bolts, threads, and nut seats. Make sure that the Y mark c on the connecting rod faces towards the left side of the crankshaft. Make sure that the characters d on both the connecting rod and connecting rod cap are aligned. e. Tighten the connecting rod nuts.
CAUTION:
When tightening the connecting rod nuts, be sure to use an F-type torque wrench. Without pausing, tighten the connecting rod nuts to the specified torque. Apply continuous torque between 2.0 and 3.6 m kg. Once you reach 2.0 m kg, DO NOT STOP TIGHTENING until the specified torque is reached. If the tightening is interrupted between 2.0 and 3.6 m kg, loosen the connecting rod nut to less than 2.0 m kg and start again. Refer to INSTALLING THE CONNECTING RODS. Connecting rod nut 36 Nm (3.6 m kg, 25 ft lb) f. Remove the connecting rod and big end bearings. Refer to REMOVING THE CONNECTING RODS. g. Measure the compressed Plastigauge width on the crankshaft pin. If the clearance is out of specification, select replacement big end bearings.
5-71
CRANKCASE
ENG
6. Select: big end bearings (P1 X P4) NOTE: The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. P1 X P5 refer to the bearings shown in the crankshaft illustration.
For example, if the connecting rod P1 and the crankshaft web P1 numbers are 4 and 1 respectively, then the bearing size for P1 is: Bearing size for P1: P1 (connecting rod) P1 (crankshaft) 2 = 4 1 2 = 1 (Blue) BIG END BEARING COLOR CODE 1 0 1 2 Violet White Blue Black
EAS00399
CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: crankcase Cracks/damage ! Replace. oil delivery passages Obstruction ! Blow out with compressed air.
EAS00401
CHECKING THE BEARINGS AND OIL SEALS 1. Check: bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 2. Check: oil seals Damage/wear ! Replace.
5-72
CRANKCASE
ENG
CHECKING THE SPROCKETS AND CHAINS 1. Check: crankshaft sprocket 1 oil/water pump assembly drive sprocket 2 Cracks/damage/wear ! Replace the defective part(-s).
2. Check: timing chain 1 Damage/stiffness ! Replace the timing chain and crankshaft sprocket as a set. oil/water pump assembly drive chain 2 Damage/stiffness ! Replace the oil/water pump assembly drive chain and oil/water pump assembly drive sprocket as a set.
EAS00407
INSTALLING THE CRANKSHAFT 1. Install: crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase. Be sure to install each crankshaft journal upper bearing in its original place. 2. Install: crankshaft
5-73
CRANKCASE
EAS00268
ENG
INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons. 1. Install: top ring 1 2nd ring 2 upper oil ring rail 3 oil ring expander 4 lower oil ring rail 5 NOTE: Be sure to install the piston rings so that the manufacturers marks or numbers a face up.
2. Install: piston 1 (onto the respective connecting rod 2 ) piston pin 3 piston pin clip New 4 NOTE: Apply engine oil onto the piston pin. Make sure that the Y mark a on the connecting rod faces left when the arrow mark b on the piston is pointing up. Refer to the illustration. Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4). 3. Lubricate: piston piston rings cylinder (with the recommended lubricant) Recommended lubricant Engine oil 4. Offset: piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander
5-74
CRANKCASE
ENG
5. Lubricate: crankshaft pins big end bearings connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6. Install: big end bearings connecting rod assembly (into the cylinder and onto the crankshaft pin). connecting rod cap (onto the connecting rod) NOTE: Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps. Be sure to reinstall each big end bearing in its original place. While compressing the piston rings with one hand, install the connecting rod assembly into the cylinder with the other hand. Make sure that the Y marks a on the connecting rods face towards the left side of the crankshaft. Make sure that the characters b on both the connecting rod and connecting rod cap are aligned. 7. Align: bolt heads (with the connecting rod caps) 8. Tighten: connecting rod nuts
36 Nm (3.6 m kg, 25 ft lb)
CAUTION:
When tightening the connecting rod nuts, be sure to use an F-type torque wrench. Without pausing, tighten the connecting rod nuts to the specified torque. Apply continuous torque between 2.0 and 3.6 m kg. Once you reach 2.0 m kg DO NOT STOP TIGHTENING until the specified torque is reached. If the tightening is interrupted between 2.0 and 3.6 m kg, loosen the connecting rod nut to less than 2.0 m kg and start again.
5-75
CRANKCASE
EAS00414
ENG
ASSEMBLING THE CRANKCASE 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil
2. Apply: sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. 3. Install: dowel pin
4. Install: crankshaft journal lower bearings 1 (into the lower crankcase) NOTE: Align the projections a on the crankshaft journal lower bearings with the notches b in the crankcase. Install each crankshaft journal lower bearing in its original place. 5. Set the shift drum assembly and transmission gears in the neutral position.
5-76
CRANKCASE
ENG
6. Install: S upper crankcase 1 (onto the lower crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. 7. Install: S crankcase bolts NOTE: S Lubricate the bolt threads with engine oil. S Tighten the bolts in increasing numerical order. S Install washers on bolts 1 X 10 . M9 M8 M6 125 mm bolts: 1 X 10 125 mm bolts: 21 X 22 100 mm bolts: 11 X 20 , 23 X 28 Crankcase bolt Bolt 1 X 10 1st: 15 Nm (1.5 mSkg, 11 ftSlb) 2nd: 15 Nm (1.5 mSkg, 11 ftSlb) + 45 X 50_ Bolt 11 X 15 , 17 X 20 , 23 , 25 X 28 12 Nm (1.2 mSkg, 8.7 ftSlb) Bolt 16 , 24 14 Nm (1.4 mSkg, 10 ftSlb) Bolt 21 X 22 24 Nm (24 mSkg, 17 ftSlb)
5-77
TRANSMISSION
EAS00419
ENG
TRANSMISSION
TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS
12 Nm (1.2 m kg, 8.7 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
Order
Job/Part Removing the transmission, shift drum assembly, and shift forks Crankcase Stopper lever Drive axle assembly Circlip Oil seal Bearing Shift drum retainer Shift fork guide bar Spring Shift fork L Shift fork R
Qty
Remarks Remove the parts in the order listed. Separate. Refer to CRANKCASE. Refer to SHIFT SHAFT.
1 2 3 4 5 6 7 8 9
1 1 1 1 1 2 4 1 1 For installation, reverse the removal procedure.
5-78
TRANSMISSION
ENG
Order
Job/Part Disassembling the main axle assembly 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gears 5th pinion gear Collar
Qty
Remarks Disassembly the parts in the order listed.
1 2 3 4 5 6 7 8 9
10
1 1 1 1 1 2 2 1 1 1
5-79
TRANSMISSION
ENG
Order
11 12 13
Job/Part Main axle/1st pinion gear Bearing Main axle bearing housing
Qty 1 1 1
Remarks
5-80
TRANSMISSION
ENG
Order
Job/Part Disassembling the drive axle assembly Washer 1st wheel gear Spacer 5th wheel gear Circlip Washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer
Qty
Remarks Disassembly the parts in the order listed.
1 2 3 4 5 6 7 8 9
10
1 1 1 1 3 3 1 2 1 1
5-81
TRANSMISSION
ENG
Order
11 12 13 14 15 16 17
Job/Part 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer
Qty 1 1 1 1 1 1 1
Remarks
5-82
TRANSMISSION
EAS00420
ENG
REMOVING THE TRANSMISSION 1. Remove: main axle assembly 1 (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crankcase surface. c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase.
EAS00421
CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 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.
WARNING
Do not attempt to straighten a bent shift fork guide bar.
3. Check: shift fork movement (on the shift fork guide bar) Rough movement ! Replace the shift forks and shift fork guide bar as a set.
5-83
TRANSMISSION
EAS00422
ENG
CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: shift drum grooves Damage/scratches/wear ! Replace the shift drum. shift drum segment 1 Damage/wear ! Replace. shift drum bearing 2 Damage/pitting ! Replace.
EAS00425
CHECKING THE TRANSMISSION 1. Measure: main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle. Main axle runout limit 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. Drive axle runout limit 0.08 mm (0.003 in)
3. Check: transmission gears Blue discoloration/pitting/wear ! Replace the defective gear(-s). transmission gear dogs Cracks/damage/rounded edges ! Replace the defective gear(-s). 4. Check: transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: transmission gear movement Rough movement ! Replace the defective part(-s). 6. Check: circlips Damage/bends/looseness ! Replace.
5-84
TRANSMISSION
EAS00428
ENG
INSTALLING THE TRANSMISSION main axle assembly shift fork C shift drum assembly shift fork R shift fork L springs shift fork guide bars drive axle assembly NOTE: Carefully position the shift forks so that they are installed correctly into the transmission gears. Install shift fork C into the groove in the 3rd and 4th pinion gear on the main axle. Install shift fork L into the groove in the 6th wheel gear and shift fork R into the groove in the 5th wheel gear on the drive axle. Make sure that the drive axle bearing circlip is inserted into the grooves in the upper crankcase. 2. Check: transmission Rough movement ! Repair. NOTE: Oil each gear, shaft, and bearing thoroughly.
5-85
COOL
CHAPTER 6 COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6-6 6-6 6-7 6-8 6-10 6-10 6-11
COOL
RADIATOR
EAS00454
COOL
COOLING SYSTEM
RADIATOR
Order
Job/Part Removing the radiator Coolant Water inlet hose Carburetor hose Oil cooler hose Water outlet hose Radiator Fan motor
Qty
1 2 3 4 5 6
1 1 1 1 1 1 For installation, reverse the removal procedure.
6-1
RADIATOR
EAS00455
COOL
CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radiator. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: S radiator hoses S radiator pipes Cracks/damage ! Replace.
3. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap. Radiator cap opening pressure 95 X 125 kPa (0.95 X 1.25 kg/cm2, 13.1 X 17.8 psi) a. Install the radiator pressure tester 1 and radiator pressure adapter 2 to the radiator cap 3. Radiator pressure tester YU-24460-01 Radiator pressure tester adapter YU-33984 b. Apply the specified pressure for ten seconds and make sure that there is no drop in pressure. 4. Check: S radiator fan Damage ! Replace. Malfunction ! Check and repair. Refer to COOLING SYSTEM in chapter 8.
6-2
RADIATOR
EAS00456
COOL
INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT in chapter 3.
2. Check: S cooling system Leaks ! Repair or replace any faulty part. a. Attach the radiator pressure tester 1 to the radiator. Radiator pressure tester YU-24460-01 b. Apply 100 kPa (1.0 kg/cm2, 14.2 psi) of pressure. c. Measure the indicated pressure with the gauge.
6-3
THERMOSTAT
EAS00460
COOL
THERMOSTAT
Order
Job/Part Removing the thermostat Front cowling Coolant reservoir hose Water inlet hose Water outlet hose Thermostat housing
Qty
Remarks Remove the parts in the order listed. Refer to FRONT COWLING in chapter 3.
1 2 3 4
6-4
THERMOSTAT
EAS00461
COOL
Order
1 2 3 4
Job/Part
Qty
Disassembling the thermostat housing Thermostat housing cover 1 Thermostat /O-ring 1/1 Thermostat housing 1 Thermo unit 1
6-5
THERMOSTAT
EAS00462
COOL
CHECKING THE THERMOSTAT 1. Check: S thermostat Does not open at 71 X 85_C (160 X 185_F) ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermometers indicated temperature.
1 2 3 4 A B
Thermometer Water Thermostat Container Closes Opens
NOTE: If the accuracy of the thermostat is in doubt, replace it. A faulty thermostat could cause serious overheating or overcooling.
2. Check: S thermostat housing cover 1 S thermostat housing 2 Cracks/damage ! Replace.
EAS00464
ASSEMBLING THE THERMOSTAT 1. Install: S thermostat housing 1 S thermostat 2 S O-ring New S thermostat housing cover NOTE: Install the thermostat with its breather hole a facing up.
6-6
THERMOSTAT
2. Install: thermo unit 1
COOL
15 Nm (1.5 m kg, 11 ft lb)
CAUTION:
Use extreme care when handling the thermo unit. Replace any part that was dropped or subjected to a strong impact.
EAS00466
INSTALLING THE THERMOSTAT 1. Fill: cooling system (with the specified amount of the recommended coolant) Refer to CHANGING THE COOLANT in chapter 3. 2. Check: cooling system Leaks ! Repair or replace any faulty part.
6-7
WATER PUMP
EAS00469
COOL
WATER PUMP
10 Nm (1.0 m kg, 7.2 ft lb)
Order
Job/Part Disassembling the water pump
Qty
Remarks Disassemble the parts in the order listed. 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. Refer to OIL PAN AND OIL PUMP in chapter 5.
1 2 3 4
Oil/water pump assembly and oil pump rotor Water pump cover O-ring Pin Impeller shaft (along with the impeller)
1 1 2 1
6-8
WATER PUMP
COOL
10 Nm (1.0 m kg, 7.2 ft lb)
Order
5 6 7
Job/Part Water pump seal Oil seal Bearing
Qty 1 1 1
Remarks
6-9
WATER PUMP
EAS00470
COOL
DISASSEMBLING THE WATER PUMP 1. Remove: water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing.
2 Water pump housing
2. Remove: oil sesal 1 bearing 2 NOTE: Tap out the bearing and oil seal from the outside of the water pump housing.
3 Water pump housing
3. Remove: rubber damper holder 1 rubber damper 2 (from the impeller, with a thin, flat-head screwdriver) NOTE: Do not scratch the impeller shaft.
EAS00473
CHECKING THE WATER PUMP 1. Check: water pump housing cover 1 water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5 2. Check: water pump seal oil seal water pump inlet pipe Crack/damage/wear ! Replace bearing Roughness ! Replace.
6-10
WATER PUMP
EAS00475
COOL
ASSEMBLING THE WATER PUMP 1. Install: oil seal New 1 (to the water pump housing 2 ) NOTE: Install the oil seal with a socket that matches its outside diameter. Before installing the oil seal, apply tap water or coolant onto its outer surface.
2. Install: water pump seal New 1
CAUTION:
Never apply oil or grease onto the water pump seal surface. NOTE: Install the water pump seal with the water pump seal installers. Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Water pump seal installer 4 YM-33221 40 and 50 mm Bearing driver 5 YM-4058 Yamaha bond No.1215 ACC-11001-05-01
A Push down
6-11
WATER PUMP
COOL
3. Install: rubber damper New 1 rubber damper holder New 2 NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface.
4. Measure: tilt Out of specification ! Repeat steps (3) and (4).
CAUTION:
Make sure that the rubber damper and rubber damper holder are flush with the impeller. Tilt limit 0.15 mm (0.006 in)
1 Straightedge 2 Impeller
6-12
CARB
CHAPTER 7 CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . 7-1 7-1 7-6 7-8 7-9 7-10 7-11 7-13 7-14 7-14 7-14 7-15 7-16
CARB
CARBURETORS
CARB
CARBURETORS
CARBURETORS
AIR FILTER CASE
Order
Job/Part Removing the air filter case Seat, fueltank and sidecovers
Qty
Remarks Remove the parts in the order listed. Refer to FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK section in chapter 3. Refer to CHANGING THE COOLANT section.
Drain the coolant 1 2 3 4 5 Air filter case panel (left/right) Battery negative lead Battery positive lead Battery Stay 1/1 1 1 1 1
7-1
CARBURETORS
EAS00481
CARB
Order
Job/Part Removing the carburetors Throttle position sensor lead Air filter joint screw Carburetors joint screw Carburetor inlet/outlet hose Carburetors assembly Starter cable Throttle cable
Qty
Remarks Remove the parts in the order listed. Disconnect.
1 2 3 4 5 6
4 4 1/1 1 1 2 For installation, reverse the removal procedure.
7-2
CARBURETORS
EAS00482
CARB
Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Job/Part Separating the carburetor Throttle stop screw Coolant hose Starter plunger link Connecting bolt Spacer Connecting bolt Spacer Fuel inlet pipe Fuel feed pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Throttle position sensor bracket Carburetor
Qty 1 1 1 1 1 1 3 1 2 2 2 2 1 1 4

7-3
CARBURETORS
EAS00484
CARB
Order
Job/Part Disassembling the carburetor
Qty
Remarks Disassemble the parts in the order listed. NOTE: The following procedure applies to all of the carburetors.
1 2 3 4 5 6 7 8 9
Starter plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Fuel drain bolt Float pin
1 1 1 1 1 1 1 1 1
7-4
CARBURETORS
CARB
Order
10 11 12 13 14 15 16
Job/Part Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet
Qty 1 1 1 1 1 1 1
Remarks
7-5
CARBURETORS
EAS00486
CARB
CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace.
2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic-carburetorcleaning solution. b. Blow out all of the passages and jets with compressed air.
3. Check: S float chamber body 1 Dirt ! Clean. 4. Check: S float chamber rubber gasket 2 Cracks/damage/wear ! Replace.
5. Check: S float 1 Damage ! Replace.
6. Check: S needle valve 1 S needle valve seat 2 Damage/obstruction/wear ! Replace the needle valve, needle valve seat and O-ring as a set. 7. Check: S O-ring 3 Damage/wear ! Replace the needle valve, needle valve seat and O-ring as a set.
7-6
CARBURETORS
CARB
8. Check: S piston valve 1 Damage/scratches/wear! Replace. S rubber diaphragm 2 Cracks/tears ! Replace.
9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 Cracks/damage ! Replace.
10. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S main jet holder 4 S pilot jet 5 Bends/damage/wear ! Replace. Obstruction ! Clean. Blow out the jets with compressed air.
11. Check: S piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness ! Replace the piston valve. 12. Check: S fuel feed pipes S hose joint Cracks/damage ! Replace. Obstruction ! Clean. Blow out the pipes with compressed air. 13. Check: S fuel feed hoses S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air.
7-7
CARBURETORS
EAS00489
CARB
ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors.
CAUTION:
S Before assembling the carburetors, wash all of the parts in a petroleum-based solvent. S Always use a new gasket. 1. Install: S jet needle kit
2. Install: S needle jet 1 S pilot jet 2 S main jet 3
3. Measure: S float height a Out of specification ! Adjust. Float height 12.5 X 13.5 mm (0.49 X 0.53 in) a. Hold the carburetor upside down. b. Measure the distance from the mating surface of the float chamber (with the gasket removed) to the top of the float. NOTE: The float arm should rest on the needle valve without depressing it. c. If the float height is not within specification, check the needle valve seat and needle valve.
7-8
CARBURETORS
CARB
d. If either the needle valve seat or needle valve is worn, replace them both. e. If both the needle valve seat and needle valve are fine, adjust the float height by bending the float tang 1 . f. Check the float height again.
4. Install: S piston valve S piston valve spring S vacuum chamber cover NOTE: Align the tab a on the piston valve diaphragm with the recess b in the carburetor body. 5. Install: S connecting bracket NOTE: After installing the connecting bracket, check that the throttle cable lever and starter plunger link operate smoothly.
EAS00493
INSTALLING THE CARBURETORS 1. Adjust: S carburetor synchronization Refer to SYNCHRONIZING THE CARBURETORS in chapter 3. 2. Adjust: S engine idling speed Engine idling speed 1,050 X 1,150 r/min Refer to ADJUSTING THE ENGINE IDLING SPEED in chapter 3.
3. Adjust: S throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in) Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY in chapter 3.
7-9
CARBURETORS
EAS00495
CARB
MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust. Fuel level (below the line on the float chamber) 3.0 X 4.0 mm (0.118 X 0.157 in) a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Install the fuel level gauge 1 to the fuel drain pipe 2 . Fuel level gauge YU-01312-A d. Loosen the fuel drain screw. e. Hold the fuel level gauge vertically next to the line on the float chamber 3 . f. Measure the fuel level a on both sides of the carburetor assembly. NOTE: The fuel level readings should be equal on both sides.
2. Adjust: S fuel level a. Remove the carburetor assembly. b. Check the needle valve seat and needle valve. c. If either is worn, replace them as a set. d. If both are fine, adjust the float level by slightly bending the float tang 1 . e. Install the carburetor assembly. f. Measure the fuel level again. g. Repeat steps (a) to (f) until the fuel level is within specification.
7-10
CARBURETORS
EAS00500
CARB
THE
CHECKING AND ADJUSTING THROTTLE POSITION SENSOR
NOTE: S Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. S When installing the throttle position sensor, adjust its angle according to the RPM which is displayed on the tachometer. Refer to the adjustment procedure below. 1. Check: S throttle position sensor a. Disconnect the throttle position sensor coupler. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester ( 1k) to the throttle position sensor. Tester positive lead ! Black/blue 1 Tester negative lead ! Blue 2 d. Check the throttle position sensor maximum resistance. Out of specification ! Replace the throttle position sensor. Throttle position sensor maximum resistance 4 X 6 k at 20_C (68_F) e. Install the throttle position sensor onto the carburetor. f. Connect the pocket tester ( 1k) to the throttle position sensor. Tester positive lead ! Yellow 3 Tester negative lead ! Blue 2 g. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range. Out of specification ! Replace the throttle position sensor. Throttle position sensor resistance 0.4 X 5.4 k at 20_C (68_F)
7-11
CARBURETORS
CARB
2. Adjust: throttle position sensor angle a. Turn the main switch to ON. b. Disconnect the throttle position sensor coupler. c. Reconnect the throttle position sensor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode. d. Loosen the throttle position sensor screws 1. e. Adjust the throttle position sensor angle according to the following table: NOTE: The angle of the throttle position sensor is indicated by the RPM which are displayed on the tachometer. Throttle position sensor angle Too small Correct Too large
Tachometer reading 0 r/min 1 5,000 r/min 2 10,000 r/min 3
f. After adjusting the throttle position sensor angle, tighten the throttle position sensor screws. NOTE: To exit the throttle position sensor adjustment mode, start the engine or turn the main switch to OFF.
7-12
CARBURETORS
EAS00504
CARB
CHECKING THE FUEL PUMP 1. Check: fuel pump 1 a. Place a container under the end of the fuel hose. b. Start the engine and check if fuel flows from the fuel hose 2 . Fuel flows. Fuel does not flow. Fuel pump is OK. Replace the fuel pump.
c. Stop the engine and check if the fuel stops flowing from the fuel hose 2 . Fuel stops flowing. Fuel flows. Fuel pump is OK. Replace the fuel pump.
7-13
AIR INDUCTION SYSTEM

EAS00507
CARB

AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. The required temperature for burning the unburned exhaust gases is approximately 600 to 700_C (1112 to 1292_F).
EAS00508
AIR CUTOFF VALVE The air cutoff valve is operated by the intake gas pressure through the piston valve diaphragm. Normally, the air cutoff valve is open to allow fresh air to flow into the exhaust port. During sudden deceleration (the throttle valve suddenly closes), negative pressure is generated and the air cutoff valve is closed in order to prevent after-burning. Additionally, at high engine speeds and when the pressure decreases, the air cutoff valve automatically closes to guard against a loss of performance due to self-EGR.
VIEW 1. (NO FLOW) VIEW 1. (NO FLOW) When decelerating (the throttle closes), the valve will close. VIEW 2. (FLOW) During normal operation the valve is open. A From the air cleaner B To the reed valve C To the carburetor joint
VIEW 2. (FLOW)
7-14

EAS00509
CARB
AIR INDUCTION SYSTEM DIAGRAMS
1 2 3 4 A B C D E
Reed valve Air cleaner Air cutoff valve Carburetor joint (cylinder #4) To the air cutoff valve To cylinder #1 To cylinder #2 To cylinder #3 To cylinder #4
7-15

EAS00510
CARB
CHECKING THE AIR INDUCTION SYSTEM 1. Check: _hoses Loose connection ! Connect properly. Cracks/damage ! Replace. _pipes Cracks/damage ! Replace.
2. Check: _fibre reed 1 _fibre reed stopper _reed valve seat Cracks/damage ! Replace the reed valve.
3. Measure: _fibre reed bending limit a Out of specification ! Replace the reed valve. Fibre reed bending limit 0.2 mm (0.008 in)
1 Surface plate
4. Check: _air cutoff valve Cracks/damage ! Replace.
7-16
ELEC
CHAPTER 8 ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 INSTRUMENT FUENCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6 CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8 CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . . TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 8-10 8-10 8-11 8-12
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14 ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8-17 8-17 8-18 8-19 8-22 8-24 8-25
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-27 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-28 LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-30 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31 SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37 COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-44 FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46 8-46 8-47 8-48 8-50
ELEC
EXUP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51 CIRCUT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-52 SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-57
ELECTRICAL COMPONENTS
EAS00729
ELEC
ELECTRICAL
ELECTRICAL COMPONENTS
1 2 3 4 5 6
Main switch Fuel sender Rear brake switch Battery Ignitor unit Starter relay
7 8 9 10 11
Starting circuit cutoff relay Flasher relay Speed sensor Sidestand switch Neutral switch
12 13 14 15 16 17 18
Oil level gauge Ignition coil Rectifier/ Regulator Thermo unit Horn Emargency stop switch Fan motor relay
8-1
ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS
ELEC

1 2 3 4 5
Thermo unit T.P.S. Starter motor Pickup rotor Pickup coil
8-2

1 2 3 4 5 6 7 8 9
ELEC
Ignitor unit Fuse box Battery Fuel pump Fuel pump coupler Brake light switch coupler Newtral switch coupler Pickup coil coupler Speed sensor coupler
8-3

1 2 3 4
ELEC
Ignition coil #2.3 Ignition coil #1.4 Rectifier/ regulator Stator coil
8-4

1 2 3 4 5 6 7 8 9
ELEC
Emargency stop switch Flasher relay Starter relay Fan motor relay Starting circuit cutoff relay Stator coil coupler Sidestand switch coupler Fuel sender coupler Oil level switch coupler
8-5
INSTRUMENT FUNCTIONS
ELEC
INDICATOR LIGHTS Turn indicator light This indicator flashes when the turn switch is moved to the left or right. Neutral indicator light This indicator comes on when the transmission is in neutral. High beam indicator light This indicator comes on when the headlight high beam is used.
1 Turn indicator light (left) 2 Turn indicator light (right) 3 Neutral indicator light
4 High beam indicator light
WARNING LIGHT Oil evel warning light This warning light comes on when the engine oil level is low. If this symbol flashes, stop the engine immediately and fill it with oil to the specified level. Coolant temperature warning light This warning light comes on when the coolant temperature is too high. Fuel level warning light When the fuel level drops below approximately 5.5 L, this light will come on.When this light comes on, fill the fuel tank at the first opportunity.
1 Oil level warning light 3 Fuel level warning light
2 Coolant temperature warning light
CAUTION:
Do not run the motorcycle until you know it has sufficient engine oil. Do not run the motorcycle if the engine is overheated. NOTE: Even if the oil is filled to the specified level, the warning light may flicker when riding on a slope or during sudden acceleration or deceleration, but this is normal.
8-6
DIGITAL CLOCK
ELEC
1 SELECT button 2 RESET button
Clock To set the clock: 1. Push both the SELECT 1 and RESET 2 buttons for at least two seconds. 2. When the hour digits start flashing, push the RESET button 2 to set the hours. 3. Push the SELECT button 1 to change the minutes. 4. When the minute digits start flashing, push the RESET button 2 to set the minutes. 5. Push the SELECT button 1 to start the clock. NOTE: After setting the clock, be sure to push the SELECT button 1 before turning the main switch to OFF, otherwise the clock will not be set.
8-7
CHECKING SWITCH CONTINUITY

EAS00730
ELEC
CHECKING SWITCH CONTINUITY

Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
CAUTION:
Never insert the tester probes into the coupler terminal slots 1 . Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester measurement YU-03112-C NOTE: Before checking for continuity, set the pocket tester to 0 and to the X 1 range. When checking for continuity, switch back and forth between the switch positions a few times. The terminal connections for switches (e.g., main switch, engine stop switch) are shown in an illustration similar to the one on the left. The switch positions a are shown in the far left column and the switch lead colors b are shown in the top row in the switch illustration. NOTE: indicates a continuity of electricity between switch terminals (i.e., a closed circuit at the respective switch position). The example illustration on the left shows that: There is continuity between blue/red and red when the switch is set to P. There is continuity between blue/red and blue when the switch is set to ON.
8-8
CHECKING THE SWITCHES

EAS00731
ELEC
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to CHECKING SWITCH CONTINUITY. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
1 2 3 4 5 6
Main switch Dimmer switch Horn switch Clutch switch Hazard switch Turn signal switch
7 8 9 10 11 12
Front brake switch Engine stop switch Start switch Rear brake switch Fuse Side stand switch 8-9
13 Neutral switch 14 Oil level switch
CHECKING THE BULBS AND BULB SOCKETS

EAS00732
ELEC
BULBS AND
CHECKING THE BULB SOCKETS
Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect. Incorrect continuity reading ! Repair or replace the bulb, bulb socket or both.
TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left. Bulbs A 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 B is used for turn signal and tail/brake lights and can be removed from the socket by pushing and turning the bulb counterclockwise. Bulbs C are used for meter and indicator lights and can be removed from their respective socket by carefully pulling them out.
8-10
ELEC
CHECKING THE CONDITION OF THE BULBS The following procedure applies to all of the bulbs. 1. Remove: bulb
WARNING
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
CAUTION:
Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler. 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 clean it with a cloth moistened with alcohol or lacquer thinner. 2. Check: bult (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester measurement YU-03112-C NOTE: Before checking for continuity, set the pocket tester to 0 and to the X 1 range.
a. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 2 , and check the continuity. b. Connect the tester positive probe to terminal 1 and the tester negative probe to terminal 3 , and check the continuity. c. If either of the readings indicate no continuity, replace the bulb.
8-11
ELEC
CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester measurement YU-03112-C NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following.
a. Install a good bulb into the bulb socket. b. Connect the pocket tester probes to the respective leads of the bulb socket. c. Check the bulb socket for continuity. If any of the readings indicate no continuity, replace the bulb socket. CHECKING THE LEDs The following procedures applies to all of the LEDs. 1. Check: LED (for proper operation) Improper operation ! Replace. a. Disconnect the meter assembly coupler (meter assembly side). b. Connect two jumper leads 1 from the battery terminals to the respective coupler terminal as shown.
WARNING
A wire that is used as a jumper lead must have at least the same capacity of the battery lead, otherwise the jumper lead may burn. This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity. c. When the jumper leads are connected to the terminals the respective LED should illuminate. Does not light ! Replace the meter assembly.
8-12
IGNITION SYSTEM
EAS00735
ELEC
IGNITION SYSTEM
CIRCUIT DIAGRAM
1 5 7 15 16 17 18 40 54
Main switch Battery Fuse (main) Ignitor Ignition coil Spark plug Pickup coil Engine stop switch Fuse (ignition)
8-13
IGNITION SYSTEM
EAS00737 EAS00739
ELEC
TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Check: 1. Main and ignition fuses 2. Battery 3. Spark plugs 4. Ignition spark gap 5. Spark plug cap resistance 6. Ignition coil resistance 7. Main switch 8. Engine stop switch 9. Pickup coil resistance 10. Wiring connections (of the entire ignition system) NOTE: Before troubleshooting, remove the following part(-s): 1) Seat 2) Fuel tank 3) Side cover S Troubleshoot with the following special tool(-s). Dynamic spark tester YM-34487 Pocket tester measurement YU-03112-C
EAS00738
2. Battery S Check the condition of the battery. Refer to CHECKING THE BATTERY in CHAPTER 3. Minimum open-circuit voltage 12.8 V or more at 20_C (68_F) S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery.
EAS00741
3. Spark plugs The following procedure applies to all of the spark plugs. S Check the condition of the spark plug. S Check the spark plug type. S Measure the spark plug gap. Refer to CHECKING THE SPARK PLUGS in CHAPTER 3. Standard spark plug CR9E (NGK) U27ESR-N (DENSO) Spark plug gap 0.7 X 0.8 mm (0.028 X 0.031 in) S Is the spark plug in good condition, it is of the correct type, and is its gap within specification? YES NO Re-gap or replace the spark plug.
1. Main and ignition fuses S Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in CHAPTER 3. S Are the main and ignition fuses OK? YES NO Replace the fuse(s).
8-14
IGNITION SYSTEM
EAS00743
ELEC
4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the dynamic spark tester 1 as shown. S Set the main switch to ON. S Measure the ignition spark gap a . S Crank the engine by pushing the starter switch and gradually increase the spark gap until a misfire occurs.
Spark plug cap resistance 10 k at 20_C (68_F) S Is the spark plug cap OK? YES NO Replace the spark plug cap.
EAS00747
6. Ignition coil resistance The following procedure applies to all of the ignition coils. S Disconnect the ignition coil leads from the wire harness. S Connect the pocket tester ( 1) to the ignition coil as shown. Positive tester probe ! red/black Negative tester probe ! orange (gray)
Minimum ignition spark gap 6.0 mm (0.24 in) S Is there a spark and is the spark gap within specification? NO YES The ignition system is OK.
EAS00745
S Measure the primary coil resistance. Primary coil resistance 1.87 X 2.53 at 20_C (68_F) S Connect the pocket tester ( ignition coil as shown. 1k) to the
5. Spark plug cap resistance The following procedure applies to all of the spark plug caps. S Remove the spark plug cap from the spark plug lead. S Connect the pocket tester ( 1k) to the spark plug cap as shown. S Measure the spark plug cap resistance.
Posltlve tester probe ! spark plug lead Negative tester probe ! spark plug lead
S Measure the secondary coil resistance.
8-15
IGNITION SYSTEM
EAS00748
ELEC
Secondary coil resistance 12 X 18 k at 20_C (68_F) S Is the ignition coil OK? YES NO Replace the ignition coil.
9. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester ( 100) to the pickup coil terminal as shown. Positive tester probe ! gray 1 Negative tester probe ! black 2
EAS00749
7. Main switch S Check the main switch for continuity. Refer to CHECKING THE SWITCHES. S Is the main switch OK? YES NO S Measure the pickup coil resistance. Replace the main switch.
EAS00750
Pickup coil resistance 248 X 372 at 20_C (68_F) (between gray and black) S Is the pickup coil OK? YES NO Replace the pickup coil.
8. Engine stop switch S Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. S Is the engine stop switch OK? YES NO
EAS00754
Replace the right handlebar switch.
10. Wiring S Check the entire ignition systems wiring. Refer to CIRCUIT DIAGRAM. S Is the ignition systems wiring properly connected and without defects? NO Properly connect or repair the ignition systems wiring. YES Replace the ignitor unit.
8-16
ELECTRIC STARTING SYSTEM

EAS00755
ELEC

CIRCUIT DIAGRAM
1 5 6 7 8 9 10 19 40 41 46 54
Main switch Battery Starter relay Fuse (main) Starter motor Starting circuit cutoff relay Side stand switch Neutral switch Engine stop switch Start switch Clutch switch Fuse (ignition)
8-17

EAS00756
ELEC
STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to and the main switch is set to ON (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed). The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed). The starting circuit cutoff relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cutoff relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cutoff relay is closed and the engine can be started by pressing the start switch. WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR
1 Battery 2 Fuse (main) 3 Main switch 4 Fuse (ignition) 5 Engine stop switch 6 Starting circuit cutoff relay 7 Diode 8 Clutch switch 9 Sidestand switch 10 Neutral switch
11 Start switch 12 Starter relay 13 Starter motor
8-18

EAS00757 EAS00739
ELEC
TROUBLESHOOTING The starter motor fails to turn. Check: 1. Main and ignition fuses 2. Battery 3. Starter motor 4. Starting circuit cutoff relay 5. Starter relay 6. Main switch 7. Engine stop switch 8. Neutral switch 9. Sidestand switch 10. Clutch switch 11. Start switch 12. Wiring connections (of the entire starting system) NOTE: S Before troubleshooting, remove the following part(-s): 1) Seat 2) Fuel tank 3) Side cover S Troubleshoot with the following special tool(-s). Pocket tester measurement YU-03112-C
EAS00738
EAS00758
3. Starter motor S Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3 .
1. Main and ignition fuses S Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in CHAPTER 3. S Are the main and ignition fuses OK? YES NO
WARNING
S A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn. S This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity. S Does the starter motor turn? YES NO Repair or replace the starter motor.
Replace the fuse (s).
8-19

EAS00759
ELEC
4. Starting circuit cutoff relay Disconnect the starting circuit cutoff relay coupler from the wire harness. Connect the pocket tester ( X 1) and battery (12 V) to the starting circuit cutoff relay coupler as shown. Positive battery lead ! red/black 1 Negative battery lead ! black/yellow 2 Positive tester probe ! blue/white 3 Negative tester probe ! black 4 Does the starter relay have continuity between red and red? YES NO Replace the starter relay.
EAS00749
6. Main switch Check the main switch for continuity. Refer to CHECKING THE SWITCHES. Does the starting circuit cutoff relay have continuity between blue/white and black? YES NO Replace the starting circuit cutoff relay.
EAS00761 EAS00750
Is the main switch OK? YES NO Replace the main switch.
5. Starter relay Disconnect the starter relay coupler from the wireharness. Connect the pocket tester ( X 1) and battery (12 V) to the starter relay coupler as shown. Positive battery lead ! blue/white 1 Negative battery lead ! red/white 2 Positive tester probe ! red 3 Negative tester probe ! red 4
7. Engine stop switch Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. Is the engine stop switch OK? YES NO Replace the right handlebar switch.
8-20

EAS00751 EAS00766
ELEC
8. Neutral switch Check the neutral switch for continuity. Refer to CHECKING THE SWITCHES. Is the neutral switch OK? YES NO Replace the neutral switch.
EAS00752
12. Wiring Check the entire starting systems wiring. Refer to CIRCUIT DIAGRAM. Is the starting systems wiring properly connected and without defects? YES The starting system circuit is OK? NO Properly connect or repair the starting systems wiring.
9. Sidestand switch Check the sidestand switch for continuity. Refer to CHECKING THE SWITCHES. Is the sidestand switch OK? YES NO Replace the sidestand switch.
EAS00763
10. Clutch switch Check the clutch switch for continuity. Refer to CHECKING THE SWITCHES. Is the clutch switch OK? YES NO Replace the clutch switch.
EAS00764
11. Start switch Check the start switch for continuity. Refer to CHECKING THE SWITCHES. Is the start switch OK? YES NO Replace the right handlebar switch.
8-21

EAS00767
ELEC
STARTER MOTOR
Order
Job/Part Removing the starter motor Carburetor Starter motor lead Starter motor/O-ring
Qty
Remarks Remove the parts in the order listed. Refer to CARBURETOR in chapter 7.
1 2
1 1/1 For installation, reverse the removal procedure.
8-22

EAS00768
ELEC
Order
1 2 3 4 5 6 7 8 9
10 11 12
Job/Part Disassembling the starter motor Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set Brush seat (along with the brushes) Armature assembly Brush holder (along with the brushes) O-ring Starter motor yoke
Qty 1 1 1 1 1 1 1 1 1 1 2 1
Remarks Disassemble the parts in the order listed. Refer to ASSEMBLING THE STARTER MOTOR. NOTE: Be sure to remove the installation nut on brush #1 first.
For assembly reverse the disassembly procedure.
8-23

EAS00769
ELEC
CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600-grit sandpaper.
2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm (1.06 in)
3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. Mica undercut 0.7 mm (0.03 in) NOTE: The mica must be undercut to ensure proper operation of the commutator. 4. Measure: S armature assembly resistances (commutator and insulation) Out of specification ! Replace the starter motor. a. Measure the armature assembly resistances with the pocket tester. Pocket tester measurement YU-03112-C Armature coil Commutator resistance 1 0.025 X 0.035 at 20_C (68_F) Insulation resistance 2 Above 1M at 20_C (68_F)
8-24
ELEC
b. If any resistance is out of specification, replace the starter motor.
5. Measure: brush length a Out of specification ! Replace the brushes as a set. Brush length wear limit 4 mm (0.16 in)
6. Measure: brush spring force Out of specification ! Replace the brush springs as a set. Brush spring force 7.65 X 10.01 N (780 X 1,021 gf, 27.5 X 36.0 oz)
7. Check: gear teeth Damage/wear ! Replace the gear.
EAS00772
ASSEMBLING THE STARTER MOTOR 1. Install: armature brush seat 1 NOTE: Align the tab a on the brush seat with the slot b in the starter motor rear cover.
8-25
ELEC
2. Install: starter motor front cover 1 starter motor rear cover 2 O-ring 3 New NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.
8-26
CHARGING SYSTEM
EAS00773
ELEC
CHARGING SYSTEM
CIRCUIT DIAGRAM
2 3 5 7
Rectifire/ reguretor AC magneto Battery Fuse (main)
8-27
CHARGING SYSTEM
EAS00774
ELEC
NO S Clean the battery terminals. S Recharge or replace the battery.
TROUBLESHOOTING The battery is not being charged. Check: 1. Main fuse 2. Battery 3. Charging voltage 4. Stator coil resistance 5. Wiring connections (of the entire charging system) NOTE: S Before troubleshooting, remove the following part(-s): 1) Seat 2) Fuel tank 3) Side cover S Troubleshoot with the following special tool(-s). Inductive self-powered tachometer YU-8036-B Pocket tester measurement YU-03112-C
YES
EAS00775
3. Charging voltage S Connect the inductive self-powered tachometer to the spark plug lead of cylinder #1. S Connect the pocket tester (DC 20 V) to the battery as shown. Positive tester probe ! positive battery terminal Negative tester probe ! negative battery terminal
EAS00738
1. Main fuses S Check the fuses for continuity. Refer to CHECKING THE FUSES in CHAPTER 3. S Are the fuses OK? YES NO Replace the fuse (s).
EAS00739
S Start the engine and let it run at approximately 5,000 r/min. S Measure the charging voltage. Charging voltage 14 V at 5,000 r/min NOTE: Make sure the battery is fully charged. S Is the charging voltage within specification? NO YES The charging circuit is OK.
2. Battery S Check the condition of the battery. Refer to CHECKING THE BATTERY in CHAPTER 3. Minimum open-circuit voltage 12.8 V or more at 20_C (68_F) S Is the battery OK?
8-28
CHARGING SYSTEM
EAS00776
ELEC
4. Stator coil resistance S Remove the generator cover. S Connect the pocket tester ( 1) to the stator coils as shown. Positive tester probe ! white 1 Negative tester probe ! white 2 Positive tester probe ! white 3 Negative tester probe ! white 1
S Measure the stator coil resistances. Stator coil resistance 0.27 X 0.33 at 20_C (68_F) S Is the stator coil OK? YES NO Replace the stator coil assembly.
EAS00779
5. Wiring S Check the wiring connections of the entire charging system. Refer to CIRCUIT DIAGRAM. S Is the charging systems wiring properly connected and without defects? YES Replace the rectifier/regulator. NO Properly connect or repair the charging systems wiring.
8-29
LIGHTING SYSTEM
EAS00780
ELEC
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1 5 7 31 34 44 48
Main switch Battery Fuse (main) Hi-beam indicator light Meter light Dimmer switch Front turn signal light (left)
49 52 53 54 56 61
Front turn signal light (right) Headlight Tail/ brake light Fuse (ignition) Fuse (headlight) Headlight relay (dimmer)
8-30
LIGHTING SYSTEM
EAS00781
ELEC
NO S Clean the battery terminals. S Recharge or replace the battery.
TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. Check: 1. Main, ignition and headlight fuses 2. Battery 3. Main switch 4. Dimmer switch 5. Headlight relay (dimmer) 6. Wiring connections (of the entire charging system) NOTE: S Before troubleshooting, remove the following part(-s): 1) Seat 2) Fuel tank 3) Side cover S Troubleshoot with the following special tool(-s). Pocket tester measurement YU-03112-C
EAS00738
YES
EAS00749
3. Main switch S Check the main switch for continuity. Refer to CHECKING THE SWITCHES. S Is the main switch OK? YES NO Replace the main switch.
EAS00784
4. Dimmer switch S Check the dimmer switch for continuity. Refer to CHECKING THE SWITCHES. S Is the dimmer switch OK? YES NO The dimmer switch is faulty. Replace the left handlebar switch.
1. Main, ignition and headlight fuses S Check the main, ignition and headlight fuses for continuity. Refer to CHECKING THE FUSES in CHAPTER 3. S Are the main, ignition and headlight fuses OK? YES NO Replace the fuse (s).
EAS00739
8-31
LIGHTING SYSTEM
5. Headlight relay (dimmer) Disconnect the headlight relay (dimmer) from the coupler. Connect the pocket tester ( X 1) and battery (12 V) to the headlight relay (dimmer) coupler as shown. Low-beam Positive tester probe ! red/yellow 1 Negative tester probe ! black/green 2
EAS00787
ELEC
6. Wiring Check entire lighting systems wiring. Refer to CIRCUIT DIAGRAM. Is the lighting systems wiring properly connected and without defects? YES Check the condition of each of the lighting systems circuits. Refer to CHECKING THE LIGHTING SYSTEM. NO Properly connect or repair the lighting systems wiring.
Hi-beam Positive battery lead ! yellow 1 Negative battery lead ! black 2 Positive tester probe ! red/yellow 3 Negative tester probe ! black/yellow 4
Does the headlight rrelay (dimmer) have continuity? YES NO Replace the headlight relay (dimmer).
8-32
LIGHTING SYSTEM
EAS00788
ELEC
CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 1. Headlight buld and scocket Check the headlight bulb and socket for continuity. Are the headlight bulb and socket OK? YES NO Replace the headlight bulb, socket or both
Set the main switch to ON. Set the dimmer switch to or . Measure the voltage (12 V) (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the headlight coupler is faulty and must be repaired.
EAS00789
2. Voltage Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light couplers as shown.
A When the dimmer switch is set to B When the dimmer switch is seto to
2. The meter light fails to come on. 1. Meter light bulb and socket Check the meter light bulb and socket for continuity. Are the meter light bulb and socket OK? YES NO Replace the meter light bulb, socket of both.
. .
Headlight Positive tester probe ! black/yellow 1 or black/green 2 Negative tester probe ! black 3 High beam indicator light Positive tester probe ! black/yellow 4 Negative tester probe ! black 5 Headlight coupler (wire harness side)
2. Vollage Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe ! blue 1 Negative tester probe ! black 2
Meter light coupler (wire harness side)
8-33
LIGHTING SYSTEM
Set the main switch to ON. Measure the voltage (12 V) of blue 1 on the meter light coupler (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter light coupler is faulty and must be repaired.
ELEC
Set the main switch to ON. Measure the voltage (12 V) of blue/red 1 on the tail/brake light coupler (tail/brake light side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
EAS00790
3. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket Chek the tail/brake light bulb and socket for continuity. Are the tail/brake light bulb and socket OK? YES NO Replace the tail/brake light bulb, socket or both.
2. Voltage Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe ! blue/red 1 Negative tester probe ! black 2
8-34
SIGNAL SYSTEM
EAS00793
ELEC
SIGNAL SYSTEM
CIRCUIT DIAGRAM
8-35
SIGNAL SYSTEM
1 5 7 9
19 23 24 25 27 29 32 33 35 36 37 39 42 45 47 48 49 50 51 53 54 55 60
ELEC
Main switch Battery Fuse (main) Starting circuit cutoff relay Neutral switch Fuel level warning light Oil level warning light Neutral indicator light Combination meter Fuel gauge Turn signal indicator light (left) Turn signal indicator light (right) Oil level gauge Fuel sender Turn signal relay Front brake light switch Horn Horn switch Turn signal switch Front turn signal light (left) Front turn signal light (right) Rear turn signal light (left) Rear turn signal light (right) Tail/ brake light Fuse (ignition) Fuse (turn signal) Rear brake light switch
8-36
SIGNAL SYSTEM
EAS00794 EAS00749
ELEC
TROUBLESHOOTING S Any of the following fail to come on: turn signal light, brake light or indicator light. S The horn fails to sound. Check: 1. Main, signal and ignition fuses 2. Battery 3. Main switch 4. Wiring connections (of the entire signal system) NOTE: S Before troubleshooting, remove the following part(s): 1) Seat 2) Fuel tank 3) Front cowling 4) Side cover S Troubleshoot with the following special tool(s). Pocket tester measurement YU-03112-C
EAS00738
EAS00795
4. Wiring S Check the entire signal systems wiring. Refer to CIRCUIT DIAGRAM. S Is the signaling systems wiring properly connected and without defects? YES Check the condition of each of the signaling systems circuits. Refer to CHECKING THE SIGNALING SYSTEM. NO Properly connect or repair the signaling systems wiring.
1. Main, signal and ignition fuses S Check the main, signal and ignition fuses for continuity. Refer to CHECKING THE FUSES in CHAPTER 3. S Are the main, signal and ignition fuses OK? YES NO Replace the fuse (s).
EAS00739
EAS00796
CHECKING THE SIGNAL SYSTEM 1. The horn fails to sound. 1. Horn switch S Check the horn switch for continuity. Refer to CHECKING THE SWITCHES. S Is the horn switch OK? YES NO Replace the left handlebar switch.
2. Voltage YES NO S Clean the battery terminals. S Recharge or replace the battery. S Connect the pocket tester (DC 20 V) to the horn connector at the horn terminal as shown.
8-37
SIGNAL SYSTEM
Positive tester probe ! brown 1 Negative tester probe ! black 4. Voltage
ELEC
Connect the pocket tester (DC 20 V) to the horn connector at the black terminal as shown. Positive tester probe ! black 1 Negative tester probe ! ground
Set the main switch to ON. Push the horn switch. Measure the voltage (12 V) of pink at the horn terminal. Is the voltage within specification? YES NO The wiring circuit from the main switch to the horn connector is faulty and must be repaired. Set the main switch to ON. Measure the voltage (12 V) of black 1 at the horn terminal. Is the voltage within specification? YES Repair or replace the horn.
EAS00797
NO Replace the horn.
3. Horn Disconnect the black connector at the horn terminal. Connect a jumper lead 1 to the horn terminal and ground the jumper lead. Set the main switch to ON. Push the horn switch. Does the horn sound?
2. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket. Check the tail/brake light bulb and socket for continuity. Are the tail/brake light bulb and socket OK? YES NO Replace the tail/brake light bulb, socket or both. 2. Brake switches Check the brake light switches for continuity. Refer to CHECKING THE SWITCHES.
NO
YES The horn is OK.
Is the brake light switch OK? YES NO Replace the brake light switch.
8-38
SIGNAL SYSTEM
3. Voltage Connect the pocket tester (DC 20 V) to the tail/brake light coupler (wire harness side) as shown. Positive tester probe ! yellow 1 Negative tester probe ! black 2 2. Turn signal switch
ELEC
Check the turn signal switch for continuity. Refer to CHECKING THE SWITCHES. Is the turn signal switch OK? YES NO Replace the left handlebar switch. 3. Voltage Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness side) as shown.
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 1 on the tail/brake light coupler (wire harness side). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the tail/brake light coupler is faulty and must be repaired.
Positive tester probe ! brown 1 Negative tester probe ! ground
Set the main switch to ON. Measure the voltage (12 V) on brown 1 at the turn signal relay coupler (wire harness side). Is the voltage within specification? YES NO The wiring circuit from the main switch to the turn signal relay coupler is faulty and must be repaired.
EAS00799
3. The turn signal light, turn signal indicator light or both fail to blink. 1. Turn signal indicator light bulb and socket Check the turn signal light bulb and socket for continuity. Are the turn signal light bulbs and socket OK? YES NO Replace the turn signal light bulb, socket or both.
8-39
SIGNAL SYSTEM
4. Voltage Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown. Positive tester probe ! brown/white 1 Negative tester probe ! ground
A B
ELEC
Set the main switch to ON. Set the turn signal switch to or . Measure the voltage (12 V) of the chocolate 1 or dark green 2 at the turn signal light connector (wire harness side). Is the voltage within specification? Set the main switch to ON. Set the turn signal switch to or . Measure the voltage (12 V) on brown/white 1 at the turn signal relay coupler (wire harness side). Is the voltage within specification? YES NO
EAS00800
YES This circuit is OK.
NO The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired.
The turn signal relay is faulty and must be replaced.
4. The neutral indicator light fails to come on. 1. Neutral indicator light bulb and socket Check the neutral indicator light bulb and socket for continuity.
5. Voltage Connect the pocket tester (DC 20 V) to the turn signal light connector (wire harness side) as shown.
A Rear turn signal light B Turn signal indicator light
Are the neutral indicator light bulb and socket OK? YES NO Replace the neutral indicator light bulb, socket or both. 2. Neutral switch Check the neutral switch for continuity. Refer to CHECKING THE SWITCHES. Is the neutral switch OK? YES NO Replace the neutral switch.
8-40
Left turn signal light Positive tester probe ! chocolate 1 Negative tester probe ! ground Right turn signal light Positive tester probe ! dark green 2 Negative tester probe ! ground
SIGNAL SYSTEM
3. Voltage Connect the pocket tester (DC 20 V) to the meter light bulb coupler (wire harness side) as shown. Positive tester probe ! brown 1 Negative tester probe ! ground 2. Engine oil level switch
ELEC
Drain the engine oil and remove the engine oil level switch from the oil pan. Check the engine oil level switch for continuity. Refer to CHECKING THE SWITCHES. Is the engine oil level switch OK? YES NO Replace the engine oil level switch.
EAS00795
3. Wiring Set the main switch to ON. Measure the voltage (12 V). Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the meter light bulb coupler is faulty and must be repaired. Check the entire signal systems wiring. Refer to CIRCUIT DIAGRAM. Is the signaling systems wiring properly connected and without defects? YES Replace the meter unit. NO Properly connect or repair the signaling systems wiring.
EAS00802
5. The oil level warning light fails to come on. 1. Oil level warning light bulb and socket Check the oil level warning light bulb and socket for continuity. Are the oil level warning light bulb and socket OK? YES NO Replace the oil level warning light bulb, socket or both.
8-41
SIGNAL SYSTEM
EAS00804
ELEC
5. The fuel level gauge fails to operate. 1. Fuel sender S Remove the fuel sender from the fuel tank. S Connect the pocket tester to the fuel sender coupler (wire harness side) as shown. Positive tester probe ! green 1 Negative tester probe ! black 2
S Set the main switch to ON. S Measure the voltage (12 V) of brown 1 on the meter light coupler (wire harness side). S Is the voltage within specification? YES NO Check the wiring connections of the entire signaling system.
3. Fuel level gauge S Set the main switch to ON. S Move the float up 1 or down 2 . S Check that the fuel level gauge needle moves to F or E.
S Measure the fuel sender resistances. Fuel sender resistance (up position 1) 3 ) ( 4 X 10 at 20_C (68_F) Fuel sender resistance (down position 4 ) ( 10) 90 X 100 at 20_C (68_F) S Is the fuel sender OK? YES Replace sender. the NO fuel
NOTE: Before reading the fuel level gauge, leave the float in one position (either up or down) for at least three minutes. S Does the fuel level gauge needle move appropriately? YES NO Replace the fuel level gauge.
2. Voltage S Connect the pocket tester (DC 20 V) to the meter light coupler (wire harness side) as shown. Positive tester probe ! brown 1 Negative tester probe ! black 2
4. Wiring S Check the entire signaling systems wiring. Refer to CIRCUIT DIAGRAM.
8-42
COOLING SYSTEM
EAS00807
ELEC
COOLING SYSTEM
CIRCUIT DIAGRAM
1 5 7 21 27 28 57 58 59
Main switch Battery Fuse (main) Thermo unit Combination meter Water temp warning light Fues (fan) Fan motor relay Fan motor
8-43
COOLING SYSTEM
EAS00808
ELEC
TROUBLESHOOTING S The radiator fan motor fails to turn. S The water temperature gauge needle fails to move when the engine is warm. Check: 1. Main and radiator fan motor fuses 2. Battery 3. Main switch 4. Radiator fan motor 5. Thermo unit 6. Wiring connections (the entire cooling system) NOTE: S Before troubleshooting, remove the following part(-s). 1) Seat 2) Fuel tank S Troubleshoot with the following special tool(s). Pocket tester measurement YU-03112-C
EAS00738
S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery.
EAS00749
EAS00809
4. Radiator fan motor S Disconnect the rediator fan motor coupler from the wire harness. S Connect the battery (12 V) as shown. Positive battery lead ! blue 1 Negative battery lead ! black 2
1. Main and radiator fan motor fuses S Check the main and radiator fan motor fuses for continuity. Refert to CHECKING THE FUSES in CHAPTER 3. S Are the main and radiator fan motor fuses OK? YES NO Replace the fuse (s).
EAS00739
2. Battery S Check the condition of the battery. Refer to CHECKING THE BATTERY in CHAPTER 3. Minimum open-circuit voltage 12.8 V or more at 20_C
S Does the rediator fan motor turn? YES NO The radiator fan motor is faulty and must be replaced.
8-44
COOLING SYSTEM
EAS00812 EAS00759
ELEC
5. Thermo unit S Remove the thermo unit from the thermostat housing. S Connect the pocket tester ( 1) to the termo unit 1 as shown. S Immerse the termo unit in a container filled with coolant 2 . NOTE: Make sure the termo unit terminals do not get wet. S Place a thermometer 3 in the coolant. S Slowly heat the coolant, and then let it cool to the specified temperature indicated in the table. S Check the thermo unit for continuity at the temperatures indicated in the table.
6. Fan motor relay S Disconnect the fan motor relay coupler from the wire harness. S Connect the pocket tester ( 1) and battery (12 V) to the fan mtor relay coupler as shown. Positive battery terminal ! brown 1 Negative battery terminal ! green/black 2 Positive tester probe ! brown 3 Negative tester probe ! blue 4
S Does the fan motor relay have continuity between brown and blue? YES Termo unit resistance 80_C (176_F): 3.41 X 4.00 105_C (221_F): 1.65 X 1.86 NO Replace the fan motor relay.
WARNING
S Handle the termo unit with special care. S Never subject the thermo unit to strong shocks. If the thermo unit is dropped, replace it. Thermo unit 15 Nm (1.5 mSkg, 11 ftSlb) Three bond sealock 10 S Does the thetmo unit operate properly? YES NO Replace the thermo unit. This circuit is OK. Properly connect or repair the cooling systems wiring.
EAS00813
7. Wiring S Check the entire cooling systems wiring. Refer to CIRCUIT DIAGRAM. S Is the cooling systems wiring properly connected and without defects? YES NO
8-45
FUEL PUMP SYSTEM

EAS00814
ELEC
FUEL PUMP SYSTEM

CIRCUIT DIAGRAM
1 5 7 9 11 15 40 54
Main switch Battery Fuse (main) Starting circuit cutoff relay Fuel pump Ignitor Engine stop switch Fuse (ignition)
8-46
FUEL PUMP SYSTEM

EAS00815
ELEC
FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump.
1 2 3 4 5 6 7 8
Battery Main fuse Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump
8-47
FUEL PUMP SYSTEM

EAS00816 EAS00749
ELEC
TROUBLESHOOTING If the fuel pump fails to operate. Check: 1. Main and ignition fuses 2. Battery 3. Main switch 4. Engine stop switch 5. Starting circuit cutoff relay (the fuel pump relay) 6. Fuel pump 7. Wiring connections (the entire fuel system) NOTE: S Before troubleshooting, remove the following part(-s): 1) Seat 2) Fuel tank 3) Side cover Troubleshoot with the following special tool(s). Pocket tester measurement YU-03112-C
EAS00738
3. Main switch S Check the main switch for continuity. Refer to CHECKING THE SWITCHES. S Is the main switch OK? YES Replace switch.
EAS00750
NO the main
4. Engine stop switch S Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. S Is the engine stop switch OK? YES NO Replace the right handlebar switch.
EAS00759
1. Main, and ignition fuses S Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in CHAPTER 3. S Are the main and ignition fuses OK? YES NO Replace the fuse (s).
EAS00739
5. Starting circuit cutoff relay S Disconnect the starting circuit cutoff relay coupler from the wire harness. S Connect the pocket tester ( 1) and battery (12 V) to the starting circuit cutoff relay coupler as shown. Positive battery lead red/black 1 Negative battery lead blue/red 2 Positive tester probe red/black 3 Negative tester probe black/blue 4
8-48
S Does the starting circuit cutoff relay have continuity between red/black and black/blue? YES NO Replace the starting circuit cutoff relay.
FUEL PUMP SYSTEM

EAS00817
ELEC
6. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester ( 1) to the fuel pump coupler as shown. Positive tester probe black/blue 1 Negative tester probe black 2
S Measure the fuel pump resistance. Fuel pump resistance 4 X 30 at 20_C (68_F) S Is the fuel pump OK? YES Replace pump.
EAS00818
NO the fuel
7. Wiring S Check the entire fuel pump systems wiring. Refer to CIRCUIT DIAGRAM. S Is the fuel systems wiring properly connected and without defects? YES Replace the ignitor unit. NO Properly connect or repair the fuel systems wiring.
8-49
FUEL PUMP SYSTEM

EAS00819
ELEC
CHECKING THE FUEL PUMP
WARNING
Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: Stop the engine before refuelling. Do not smoke, and keep away from open flames, sparks, or any other source of fire. If you do accidentally spill gasoline, wipe it up immediately with dry rags. If gasoline touches the engine when it is not, a fire may occur. Therefore, make sure that the engine is completely cool before performing the following test.
1. Check: fuel pump operation a. Fill the fuel tank. b. Put the end of the fuel hose into an open container. c. Turn the fuel cock to ON. d. Connect the battery (12 V) to the fuel pump coupler as shown. Positive battery lead black/blue 1 Negative battery lead black 2 e. If fuel flows out of the fuel hose, the fuel pump is OK. If fuel does not flow, replace the fuel pump.
B/L
8-50
EXUP SYSTEM
EAS00827
ELEC
EXUP SYSTEM
CIRCUIT DIAGRAM
1 5 7 12 15 54
Main switch Battery Fuse (main) EXUP servomotor Ignitor Fuse (ignition)
8-51
EXUP SYSTEM
EAS00828 EAS00829
ELEC
TROUBLESHOOTING When the engine speed changes, the EXUP servomotor does not operate. Procedure 1 Check: 1. EXUP servomotor operation (with the EXUP servomotor coupler connected to the wire harness) 2. Voltage 3. EXUP servomotor operation (with the EXUP servomotor coupler disconnected from the wire harness) 4. EXUP servomotor resistance (potentiometer resistance) 5. Wiring connections (the entire EXUP system) Procedure 2 Check: 1. Main and turn signal fuses 2. Battery 3. Main switch 4. Neutral switch 5. Engine stop switch 6. Wiring connections (the entire EXUP system) NOTE: Before troubleshooting, remove the following part(s): 1) Seat 2) Fuel tank Troubleshoot with the following special tool(s). Pocket tester measurement YU-03112-C
Procedure 1 1. EXUP servomotor operation (with the EXUP servomotor coupler connected to the wire harness) Disconnect the EXUP cables at the EXUP servomotor pulley side. Start the engine and rev it to 5,000 r/min. Does the EXUP servomotor pulley turn? YES NO Check that the EXUP cables are properly installed. If the connections are correct, check the EXUP valve and cables. Refer to EXHAUST SYSTEM in chapter 5.
EAS00830
2. Voltage Connect the pocket tester (DC 20 V) to the EXUP servomotor coupler as shown. Positive tester probe black/red 1 Negative tester probe black/yellow 2
Set the main switch to ON. Measure the voltage (12 V) between black/red 1 and black/yellow 2 . Is the voltage within specification? YES NO Go to Procedure 2.
8-52
EXUP SYSTEM
EAS00831
ELEC
3. EXUP servomotor operation (with the servomotor coupler disconnected to the wire harness) Disconnect the EXUP cables from the EXUP servomotor pulley. Disconnect the EXUP servomotor coupler from the wire harness. Connect the battery leads to the EXUP servomotor coupler as shown. Positive battery lead black/yellow 1 Negative battery lead black/red 2
Positive tester probe blue 1 Negative tester probe white/red 2 While slowly turning the EXUP servomotor pulley, measure the EXUP servomotor resistance. EXUP servomotor resistance (when the pulley is turned once) 0 X approximately 7.5 k (blue white/red) Is the EXUP servomotor OK?
Check that the EXUP servomotor pulley rotates several times.
YES
NO The EXUP servomotor is faulty and must be replaced.
CAUTION:
To prevent damaging the EXUP servomotor, perform this test within a few seconds of connecting the battery. Does the EXUP servomotor pulley turn? YES NO Replace the EXUP servomotor.
EAS00832
EAS00833
5. Wiring Check the entire EXUP systems wiring. Refer to CIRCUIT DIAGRAM. Is the EXUP systems wiring properly connected and without defects? YES Replace the ignitor unit. NO Properly connect or repair the EXUP systems wiring.
4. EXUP servomotor resistance (potentiometer resistance) Disconnect the EXUP servomotor coupler from the wire harness. Connect the pocket tester ( 1 k) to the EXUP servomotor coupler.
8-53
EXUP SYSTEM
Procedure 2
EAS00738 EAS00750
ELEC
4. Engine stop switch S Check the engine stop switch for continuity. Refer to CHECKING THE SWITCHES. S Is the engine stop switch OK? YES NO Replace the right handlebar switch.
EAS00833
1. Main and ignition fuses S Check the main and ignition fuses for continuity. Refer to CHECKING THE FUSES in chapter 3. S Are the main and ignition fuses OK? YES NO Replace the fuse(s).
EAS00739
5. Wiring 2. Battery S Check the condition of the battery. Refer to CHECKING AND CHARGING THE BATTERY in chapter 3. Minimum open-circuit voltage 12.8 V or more at 20_C (68_F) S Is the battery OK? YES NO S Clean the battery terminals. S Recharge or replace the battery.
EAS00749
S Check the entire EXUP systems wiring. Refer to CIRCUIT DIAGRAM. S Is the EXUP systems wiring properly connected and without defects? YES Replace the ignitor unit. NO Properly connect or repair the EXUP systems wiring.
3. Main switch S Check the main switch for continuity. Refer to CHECKING THE SWITCHES. S Is the main switch OK? YES Replace switch. the NO main
8-54
SELF-DIAGNOSIS SELF-DIAGNOSIS
ELEC
The FZS1000 features a self-diagnosing system for the following circuit(-s): Throttle position sensor EXUP Speed sensor Emargency stop switch If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to ON (irrespective of whether the engine is running or not) Circuit Throttle position sensor Defect(-s) Disconnected Short-circuit Locked System response The ignitor unit stays set to the wide-open throttle ignition timing. The motorcycle can be ridden. The tachometer displays the condition code. Condition code 3,000 r/min
EXUP
Improper connection Short-circuit
The EXUP valve stays in the open 7,000 r/min position for three seconds and then the servomotor shuts off. The motorcycle can be ridden. The tachometer displays the condition code. The servomotors power supply is constantly inteerupted so that it will not burn out. The motorcycle can be ridden. The tachometer displays the condition code. The tachometer displays the condition code. The tachometer displays the condition code. Ignition system cutoff. 4,000 r/min 9,000 r/min
Servomotor is locked.
Speed sensor Emargency stop switch
Improper connection Disconnected Short-circuit Fail angle
8-55
SELF-DIAGNOSIS
Tachometer display sequence
Revolution ( 103 r / min)
ELEC
1 0 r / min ... 3 seconds 2 Condition code ... 2.5 seconds 3 Engine speed ... 3 seconds
Tachometer display
Engine speed
Time (seconds)
When more than one item is being monitored, the tachometer needle displays the condition codes in ascending order, cycling through the sequence repeatedly. If the engine is stopped, the engine speed 3 is 0 r/min.
8-56
SELF-DIAGNOSIS
TROUBLESHOOTING The tachometer starts to display the selfdiagnosis sequence. Check: 1. Throttle position sensor 2. EXUP 3. Speed sensor 4. Emargency stop switch NOTE: Before troubleshooting, remove the following part(-s): 1) Rider seat 2) Fuel tank 3) Air filter case Troubleshoot with the following special tool(-s). Pocket tester measurement YU-03112-C 1. Throttle position sensor CIRCUIT DIAGRAM 1. Wire harness
ELEC
Check the wire harness for continuity. Refer to CIRCUIT DIAGRAM. Is the wire harness OK? YES NO Repair or replace the wire harness.
2. Throttle position sensor Check the throttle position sensor for continuity. Refer to CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR in chapter 6. Is the throttle position sensor OK? YES Replace the ignitor unit. NO Replace the throttle position sensor.
13 Throttle position sensor 15 Ignitor unit
8-57
SELF-DIAGNOSIS
2. EXUP CIRCUIT DIAGRAM 2. EXUP servomotor
ELEC
Check the EXUP servomotor for continuity. Refer to EXUP SYSTEM. Is the EXUP servomotor OK? YES Replace the ignitor unit. NO Replace the EXUP servomotor.
12 EXUP servomotor 15 Ignitor unit
1. Wire harness Check the wire harness for continuity. Refer to CIRCUIT DIAGRAM. Is the wire harness OK? YES NO Repair or replace the wire harness.
8-58
SELF-DIAGNOSIS
3. Speed sensor CIRCUIT DIAGRAM 1. Wire harness
ELEC
Check the wire harness for continuity. Refer to CIRCUIT DIAGRAM. Is the wire harness OK? YES Replace the speed sensor. BAD Replace the ignitor unit. Repair or replace the wire harness. NO
15 lgnitor unit 20 Speed sensor
8-59
SELF-DIAGNOSIS
4. Emargency stop switch CIRCUIT DIAGRAM 1. Wire harness
ELEC
Check the wire harness for continuity. Refer to CIRCUIT DIAGRAM. Is the wire harness OK? YES Replace the emargency stop switch. BAD Replace the ignitor unit. Repair or replace the wire harness. NO
14 Emargency stop switch 15 lgnitor unit
8-60
TRBL SHTG
CHAPTER 9 TROUBLESHOOTING
STARTING PROBLEMS ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 INCORRECT ENGINE IDLING SPEED ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3 FAULTY CLUTCH CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 OVERHEATING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4 9-4 9-4 9-4 9-4
OVERCOOLING COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 FAULTY FRONT FORK LEGS LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
TRBL SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7 9-7 9-7 9-7 9-7 9-7 9-7 9-7 9-7
TROUBLESHOOTING
EAS00844
TRBL SHTG
TROUBLESHOOTING
NOTE: The following 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 in this manual for checks, adjustments, and replacement of parts.
STARTING PROBLEMS
ENGINE Cylinder(s) and cylinder head(s) S Loose spark plug S Loose cylinder head or cylinder S Damaged cylinder head gasket S Damaged cylinder gasket S Worn or damaged cylinder S Incorrect valve clearance S Improperly sealed valve S Incorrect valve-to-valve-seat contact S Incorrect valve timing S Faulty valve spring S Seized valve Piston(s) and piston ring(s) S Improperly installed piston ring S Damaged, worn or fatigued piston ring S Seized piston ring S Seized or damaged piston Air filter S Improperly installed air filter S Clogged air filter element Crankcase and crankshaft S Improperly assembled crankcase S Seized crankshaft
FUEL SYSTEM Fuel tank S Empty fuel tank S Clogged fuel filter S Clogged fuel strainer S Clogged fuel tank drain hose S Clogged rollover valve S Clogged rollover valve hose S Deteriorated or contaminated fuel Fuel pump S Faulty fuel pump S Faulty fuel pump relay Fuel cock S Clogged or damaged fuel hose
Carburetor(s) S Deteriorated or contaminated fuel S Clogged pilot jet S Clogged pilot air passage S Sucked-in air S Damaged float S Worn needle valve S Improperly installed needle valve seat S Incorrect fuel level S Improperly installed pilot jet S Clogged starter jet S Faulty starter plunger S Improperly adjusted starter cable
9-1
TROUBLESHOOTING
ELECTRICAL SYSTEMS Battery S Discharged battery S Faulty battery Fuse(s) S Blown, damaged or incorrect fuse S Improperly installed fuse Spark plug(s) S Incorrect spark plug gap S Incorrect spark plug heat range S Fouled spark plug S Worn or damaged electrode S Worn or damaged insulator S Faulty spark plug cap Ignition coil(s) S Cracked or broken ignition coil S Broken or shorted primary or secondary coils S Faulty spark plug lead
EAS00846
TRBL SHTG
Ignition system S Faulty ignitor unit S Faulty pickup coil S Broken generator rotor woodruff key Switches and wiring S Faulty main switch S Faulty engine stop switch S Broken or shorted wiring S Faulty neutral switch S Faulty start switch S Faulty sidestand switch S Faulty clutch switch S Improperly grounded circuit S Loose connections Starting system S Faulty starter motor S Faulty starter relay S Faulty starting circuit cutoff relay S Faulty starter clutch
INCORRECT ENGINE IDLING SPEED

ENGINE Cylinder(s) and cylinder head(s) S Incorrect valve clearance S Damaged valve train components Air filter S Clogged air filter element FUEL SYSTEM Carburetor(s) S Faulty starter plunger S Loose or clogged pilot jet S Loose or clogged pilot air jet S Damaged or loose carburetor joint S Improperly synchronized carburetors S Improperly adjusted engine idling speed (throttle stop screw) S Improper throttle cable free play S Flooded carburetor S Faulty air induction system ELECTRICAL SYSTEMS Battery S Discharged battery S Faulty battery Spark plug(s) S Incorrect spark plug gap S Incorrect spark plug heat range S Fouled spark plug S Worn or damaged electrode S Worn or damaged insulator S Faulty spark plug cap Ignition coil(s) S Broken or shorted primary or secondary coils S Faulty spark plug lead S Cracked or broken ignition coil Ignition system S Faulty ignitor unit S Faulty pickup coil S Broken generator rotor woodruff key
9-2
TROUBLESHOOTING
EAS00848
TRBL SHTG
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to STARTING PROBLEMS. ENGINE Air filter S Clogged air filter element FUEL SYSTEM Carburetor(s) S Faulty diaphragm S Incorrect fuel level S Loose or clogged main jet Fuel pump S Faulty fuel pump
EAS00850
FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT Refer to CLUTCH DRAGS. SHIFT PEDAL DOES NOT MOVE Shift shaft S Improperly adjusted shift rod S Bent shift shaft. Shift drum and shift forks S Foreign object in a shift drum groove S Seized shift fork S Bent shift fork guide bar Transmission S Seized transmission gear S Foreign object between transmission gears S Improperly assembled transmission JUMPS OUT OF GEAR Shift shaft S Incorrect shift pedal position S Improperly returned stopper lever Shift forks S Worn shift fork Shift drum S Incorrect axial play S Worn shift drum groove Transmission S Worn gear dog
9-3
TROUBLESHOOTING
EAS00851
TRBL SHTG
FAULTY CLUTCH
CLUTCH SLIPS Clutch S Improperly assembled clutch S Improperly adjusted clutch cable S Loose or fatigued clutch spring S Worn friction plate S Worn clutch plate Engine oil S Incorrect oil level S Incorrect oil viscosity (low) S Deteriorated oil CLUTCH DRAGS Clutch S Unevenly tensioned clutch springs S Warped pressure plate S Bent clutch plate S Swollen friction plate S Bent clutch push rod S Broken clutch boss S Burnt primary driven gear bushing S Match marks not aligned Engine oil S Incorrect oil level S Incorrect oil viscosity (high) S Deteriorated oil
EAS00855
OVERHEATING
ENGINE Clogged coolant passages S Cylinder head(s) and piston(s) S Heavy carbon buildup Engine oil S Incorrect oil level S Incorrect oil viscosity S Inferior oil quality COOLING SYSTEM Coolant S Low coolant level Radiator S Damaged or leaking radiator S Faulty radiator cap S Bent or damaged radiator fin Water pump S Damaged or faulty water pump S Thermostat S Thermostat stays closed S Oil cooler S Clogged or damaged oil cooler S Hose(s) and pipe(s) S Damaged hose S Improperly connected hose S Damaged pipe S Improperly connected pipe FUEL SYSTEM Carburetor(s) S Incorrect main jet setting S Incorrect fuel level S Damaged or loose carburetor joint Air filter S Clogged air filter element CHASSIS Brake(s) S Dragging brake ELECTRICAL SYSTEMS Spark plug(s) S Incorrect spark plug gap S Incorrect spark plug heat range Ignition system S Faulty ignitor unit
9-4
TROUBLESHOOTING
EAS00856
TRBL SHTG
OVERCOOLING
COOLING SYSTEM Thermostat S Thermostat stays open
EAS00857
POOR BRAKING PERFORMANCE

S Worn brake pad S Worn brake disc S Air in hydraulic brake system S Leaking brake fluid S Faulty brake caliper seal S Loose union bolt S Damaged brake hose S Oil or grease on the brake disc S Oil or grease on the brake pad S Incorrect brake fluid level
EAS00861
FAULTY FRONT FORK LEGS

LEAKING OIL S Bent, damaged or rusty inner tube S Cracked or damaged outer tube S Improperly installed oil seal S Damaged oil seal lip S Incorrect oil level (high) S Loose damper rod bolt S Damaged damper rod bolt copper washer S Cracked or damaged cap bolt O-ring MALFUNCTION S Bent or damaged inner tube S Bent or damaged outer tube S Damaged fork spring S Worn or damaged outer tube bushing S Bent or damaged damper rod S Incorrect oil viscosity S Incorrect oil level
9-5
TROUBLESHOOTING
EAS00862
TRBL SHTG
UNSTABLE HANDLING
Handlebar S Bent or improperly installed handlebar Steering head components S Improperly installed upper bracket S Improperly installed lower bracket (improperly tightened ring nut) S Bent steering stem S Damaged ball bearing or bearing race Front fork leg(s) S Uneven oil levels (both front fork legs) S Unevenly tensioned fork spring (both front fork legs) S Broken fork spring S Bent or damaged inner tube S Bent or damaged outer tube Swingarm S Worn bearing or bushing S Bent or damaged swingarm Rear shock absorber assembly(-ies) S Faulty rear shock absorber spring S Leaking oil or gas Tire(s) S Uneven tire pressures (front and rear) S Incorrect tire pressure S Uneven tire wear Wheel(s) S Incorrect wheel balance S Deformed cast wheel S Damaged wheel bearing S Bent or loose wheel axle S Excessive wheel runout Frame S Bent frame S Damaged steering head pipe S Improperly installed bearing race
9-6
TROUBLESHOOTING
EAS00866
TRBL SHTG
FAULTY LIGHTING OR SIGNALING SYSTEM

HEADLIGHT DOES NOT LIGHT S Wrong headlight bulb S Too many electrical accessories S Hard charging S Incorrect connection S Improperly grounded circuit S Poor contacts (main or light switch) S Burnt-out headlight bulb HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Faulty battery S Faulty rectifier/regulator S Improperly grounded circuit S Faulty main switch S Headlight bulb life expired TAIL/BRAKE LIGHT DOES NOT LIGHT S Wrong tail/brake light bulb S Too many electrical accessories S Incorrect connection S Burnt-out tail/brake light bulb TAIL/BRAKE LIGHT BULB BURNT OUT S Wrong tail/brake light bulb S Faulty battery S Incorrectly adjusted rear brake light switch S Tail/brake light bulb life expired TURN SIGNAL DOES NOT LIGHT S Faulty turn signal switch S Faulty turn signal relay S Burnt-out turn signal bulb S Incorrect connection S Damaged or faulty wire harness S Improperly grounded circuit S Faulty battery S Blown, damaged or incorrect fuse TURN SIGNAL BLINKS SLOWLY S Faulty turn signal relay S Faulty main switch S Faulty turn signal switch S Incorrect turn signal bulb TURN SIGNAL REMAINS LIT S Faulty turn signal relay S Burnt-out turn signal bulb TURN SIGNAL BLINKS QUICKLY S Incorrect turn signal bulb S Faulty turn signal relay S Burnt-out turn signal bulb HORN DOES NOT SOUND S Improperly adjusted horn S Damaged or faulty horn S Faulty main switch S Faulty horn switch S Faulty battery S Blown, damaged or incorrect fuse S Faulty wire harness
9-7
YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN
PRINTED IN U.S.A.

2001-2002 Yamaha Fz-1 Service Repair Workshop Manual Download

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EAS00001

HOW TO USE THIS MANUAL

Symbols 10 to 17 indicate the following.

Symbols 24 to 25 in the exploded diagrams indicate the following:

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

CHECKING THE CONNECTIONS

CHECKING THE CONNECTIONS

Tool name/Function Oil Filter Wrench

Tool name/Function Battery Powered Timing Light

Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions

32.4 mm (1.2756 in) 24.85 mm (0.9783 in)

Measurement A Measurement B Measurement C Max. camshaft runout

32.85 mm (1.2933 in) 24.85 mm (0.9783 in) 0.03 mm (0.0012 in)

0.08 mm (0.0031 in) 0.10 mm (0.0039 in)

SSS SSS SSS SSS SSS SSS

Intake Exhaust Winding direction (top view) Intake Exhaust

SSS SSS Clockwise Clockwise

16.971 mm (0.6681 in) 0.072 mm (0.0028 in)

Ring type Dimensions (B X T) End gap (installed) Ring side clearance

Cast wheel 17 X MT5.50 Aluminum 135 mm (5.31 in) SSS SSS

5.5 mm (0.22 in)

Master cylinder inside diameter Caliper cylinder inside diameter

12.7 mm (0.5 in) 42.9 mm (1.69 in)

5 (fully turned out position) 2 1

SSS SSS SSS SSS SSS SSS SSS SSS SSS

152.5 mm (6.00 in)

SSS SSS SSS SSS SSS SSS

GENERAL TIGHTENING TORQUE SPECIFICATIONS

Remarks ftSlb 9.4 36 36 8.7 7.2 8.7 11

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

COOLING SYSTEM DIAGRAMS

ENGINE OIL LUBRICATION CHART

ENGINE OIL LUBRICATION CHART

Oil cooler Relief valve

17 Handle crown 18 Handlebar switch lead 19 Brake hose guide

INTRODUCTION PERIODIC MAINTENANCE/LUBRICATION INTERVALS

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

Every 26,600 mi (42,000 km)

GENERAL MAINTENANCE AND LUBRICATION CHART

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

FRONT COWLING/SEAT/SIDE COVER/FUEL TANK

Remarks Remove the parts in the order listed. Disconnect.

For installation, reverse the removal procedure.

SEAT, SIDE COVER AND FUEL TANK

SEAT, SIDE COVER AND FUEL TANK

19 Nm (1.9 mDkg), 14 ftDlb

10 Nm (1.0 mDkg), 7.2 ftDlb

4 Nm (0.4 mDkg, 2.9 ftDlb) 10 Nm (1.0 mDkg, 7.2 ftDlb)

Remarks Remove the parts in the order listed.

Grab bar Rear cowling

1 1 For installation, reverse the removal procedure.

ADJUSTING THE VALVE CLEARANCE

ADJUSTING THE VALVE CLEARANCE