2007 r 1 Service Manual

7/31/2019 2007 r 1 Service Manual

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YZFR1WYZFR1WC

SERVICEMANUAL

LIT-11616-20-534C8-28197-10


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EAS20040

YZFR1W/YZFR1WCSERVICEMANUAL2006byYamahaMotorCorporation,U.S.A.Firstedition,October2006Allrightsreserved.AnyreproductionorunauthorizedusewithoutthewrittenpermissionofYamahaMotorCorporation,U.S.A.isexpresslyprohibited.PrintedinU.S.A.P/NLIT-11616-20-53


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EAS20070

NOTICE

ThismanualwasproducedbytheYamahaMotorCompany,Ltd.primarilyforusebyYamahadealersandtheirqualifiedmechanics.Itisnotpossibletoincludealltheknowledgeofamechanicinonemanual.Therefore,anyonewhousesthisbooktoperformmaintenanceandrepairsonYamahavehiclesshouldhaveabasicunderstandingofmechanicsandthetechniquestorepairthesetypesofvehicles.Repairandmaintenanceworkattemptedbyanyonewithoutthisknowledgeislikelytorenderthevehicleunsafeandunfitforuse.Thismodelhasbeendesignedandmanufacturedtoperformwithincertainspecificationsinregardtoperformanceandemissions.Properservicewiththecorrecttoolsisnecessarytoensurethatthevehiclewilloperateasdesigned.Ifthereisanyquestionaboutaserviceprocedure,itisimperativethatyoucontactaYamahadealerforanyserviceinformationchangesthatapplytothismodel.This

policyisintendedtoprovidethecustomerwiththemostsatisfactionfromhisvehicleandtoconformtofederalenvironmentalqualityobjectives.YamahaMotorCompany,Ltd.iscontinuallystrivingtoimproveallofitsmodels.ModificationsandsignificantchangesinspecificationsorprocedureswillbeforwardedtoallauthorizedYamahadealersandwillappearinfutureeditionsofthismanualwhereapplicable.

NOTE:

ThisServiceManualcontainsinformationregardingperiodicmaintenancetotheemissioncontrol

system.Pleasereadthismaterialcarefully.Designsandspecificationsaresubjecttochangewithoutnotice.EAS20080

IMPORTANTMANUALINFORMATION

Particularlyimportantinformationisdistinguishedinthismanualbythefollowing.TheSafetyAlertSymbolmeansATTENTION!BECOMEALERT!YOURSAFETYISINVOLVED!FailuretofollowWARNINGinstructionscouldresultinsevereinjuryordeathtothevehicleoperator,abystanderorapersoncheckingorrepairingthevehicle.

ACAUTIONindicatesspecialprecautionsthatmustbetakentoavoiddamage

WARNINGCAUTION:

tothevehicle.NOTE:


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ANOTEprovideskeyinformationtomakeprocedureseasierorclearer.


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EAS20090

HOWTOUSETHISMANUAL

Thismanualisintendedasahandy,easy-to-readreferencebookforthemechanic.Comprehensiveexplanationsofallinstallation,removal,disassembly,assembly,repairandcheckproceduresarelaidoutwiththeindividualstepsinsequentialorder.

Themanualisdividedintochaptersandeachchapterisdividedintosections.Thecurrentsectiontitleisshownatthetopofeachpage1.Sub-sectiontitlesappearinsmallerprintthanthesectiontitle2.Tohelpidentifypartsandclarifyproceduresteps,thereareexplodeddiagramsatthestartofeachremovalanddisassemblysection3.Numbersaregivenintheorderofthejobsintheexplodeddiagram.Anumberindicatesadisassemblystep4.Symbolsindicatepartstobelubricatedorreplaced5.RefertoSYMBOLS.Ajobinstructionchartaccompaniestheexplodeddiagram,providingtheorderof

jobs,namesofparts,notesinjobs,etc6.Jobsrequiringmoreinformation(suchasspecialtoolsandtechnicaldata)aredescribedsequentially7.


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EAS20100

16.Replacethepart

SYMBOLS

Thefollowingsymbolsareusedinthismanualforeasierunderstanding.

NOTE:

Thefollowingsymbolsarenotrelevanttoeveryvehicle.

123456

TR..78

GME

91011121314

BLSM1516

LTNew1.Serviceablewithenginemounted2.Fillingfluid3.Lubricant

4.Specialtool5.Tighteningtorque6.Wearlimit,clearance7.Enginespeed8.Electricaldata9.Engineoil10.Gearoil11.Molybdenum-disulfideoil12.Wheel-bearinggrease13.Lithium-soap-basedgrease14.Molybdenum-disulfidegrease15.Applylockingagent(LOCTITE)


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EAS20110

TABLEOFCONTENTS

GENERALINFORMATION

SPECIFICATIONS

PERIODICCHECKSANDADJUSTMENTS

CHASSIS

ENGINE

COOLINGSYSTEM

FUELSYSTEM

ELECTRICALSYSTEM

TROUBLESHOOTING


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GENERALINFORMATION

IDENTIFICATION..........................................................................................1-1

VEHICLEIDENTIFICATIONNUMBER...................................................1-1

MODELLABEL.......................................................................................1-1

FEATURES...................................................................................................1-2FISYSTEM.............................................................................................1-3

IMPORTANTINFORMATION.....................................................................1-12

PREPARATIONFORREMOVALANDDISASSEMBLY........................1-12REPLACEMENTPARTS.......................................................................1-12GASKETS,OILSEALSANDO-RINGS................................................1-12LOCKWASHERS/PLATESANDCOTTERPINS.................................1-12BEARINGSANDOILSEALS...............................................................1-13CIRCLIPS.............................................................................................1-13

CHECKINGTHECONNECTIONS.......................................................

......1-14

SPECIALTOOLS........................................................................................1-15

1


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IDENTIFICATION

EAS20130

IDENTIFICATION

EAS20140

VEHICLEIDENTIFICATIONNUMBER

Thevehicleidentificationnumber1isstampedintotherightsideofthesteeringheadpipe.

EAS20150

MODELLABEL

Themodellabel1isaffixedtotheframe.Thisinformationwillbeneededtoorderspareparts.

1-1


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FEATURES

EAS20170

FEATURES

OUTLINEOFTHEFISYSTEM

Themainfunctionofafuelsupplysystemistoprovidefueltothecombustionchamberattheoptimumair-fuelratioinaccordancewiththeengineoperatingconditionsandtheatmospherictemperature.Intheconventionalcarburetorsystem,theair-fuelratioofthemixturethatissuppliedtothecombustionchamberiscreatedbythevolumeoftheintakeairandthefuelthatismeteredbythejetusedintherespectivecarburetor.Despitethesamevolumeofintakeair,thefuelvolumerequirementvariesbytheengineoperatingconditions,suchasacceleration,deceleration,oroperatingunderaheavyload.Carburetorsthatmeterthefuelthroughtheuseofjetshavebeenprovidedwithvariousauxiliary

devices,sothatanoptimumair-fuelratiocanbeachievedtoaccommodatetheconstantchangesintheoperatingconditionsoftheengine.Astherequirementsfortheenginetodelivermoreperformanceandcleanerexhaustgasesincrease,itbecomesnecessarytocontroltheair-fuelratioinamorepreciseandfinelytunedmanner.Toaccommodatethisneed,thismodelhasadoptedanelectronicallycontrolledfuelinjection(FI)system,inplaceoftheconventionalcarburetorsystem.Thissystemcanachieveanoptimumair-fuelratiorequiredbytheengineatalltimesbyusingamicroprocessortha

tregulatesthefuelinjectionvolumeaccordingtotheengineoperatingconditionsdetectedbyvarioussensors.TheadoptionoftheFIsystemhasresultedinahighlyprecisefuelsupply,improvedengineresponse,betterfueleconomy,andreducedexhaustemissions.

1.Intakeairtemperaturesensor2.Enginetroublewarninglight3.Airinductionsystemsolenoid4.Atmosphericpressuresensor5.Throttlepositionsensor(forthrottlecable

pulley)6.Throttleservomotor7.Throttlepositionsensor(forthrottlevalves)8.Intakefunnelservomotor9.Injector10.Intakeairpressuresensor11.Fuelpump12.Leananglesensor13.ECU(enginecontrolunit)14.Startingcircuitcut-offrelay


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15.Speedsensor16.EXUPservomotor17.O2sensor18.Crankshaftpositionsensor19.Coolanttemperaturesensor20.Sparkplug21.Ignitioncoil22.Cylinderidentificationsensor

1-2


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FEATURES

EAS4C81010

FISYSTEM

Thefuelpumpdeliversfueltothefuelinjectorviathefuelfilter.Thepressureregulatormaintainsthefuelpressurethatisappliedtothefuelinjectoratonly324kPa(3.24kg/cm2,46.1psi).Accordingly,whentheenergizingsignalfromtheECUenergizesthefuelinjector,thefuelpassageopens,causingthefueltobeinjectedintotheintakemanifoldonlyduringthetimethepassageremainopen.Therefore,thelongerthelengthoftimethefuelinjectorisenergized(injectionduration),thegreaterthevolumeoffuelthatissupplied.Conversely,theshorterthelengthoftimethefuelinjectorisenergized(injectionduration),thelesserthevolumeoffuelthatissupplied.TheinjectiondurationandtheinjectiontimingarecontrolledbytheECU.Signalsthatareinputfromthethrottlepositionsensor(forthrottlevalves),throttlepositionsensor(fo

rthrottlecablepulley),crankshaftpositionsensor,intakeairpressuresensor,intakeairtemperaturesensor,coolanttemperaturesensor,atmosphericpressuresensor,cylinderidentificationsensor,leananglesensor,speedsensorandO2sensorenabletheECUtodeterminetheinjectionduration.Theinjectiontimingis

determinedthroughthesignalsfromthecrankshaftpositionsensor.Asaresult,thevolumeoffuelthatisrequiredbytheenginecanbesuppliedatalltimesinaccordancewiththedrivingconditions.

1.Fuelpump2.Injector3.Cylinderidentificationsensor4.ECU(enginecontrolunit)5.Throttlepositionsensor(forthrottlevalves)6.Throttlepositionsensor(forthrottlecablepulley)7.Speedsensor8.Intakeairtemperaturesensor9.Leananglesensor10.O2sensor11.Catalyticconverter

12.Coolanttemperaturesensor13.Crankshaftpositionsensor14.Intakeairpressuresensor15.Throttleservomotor16.Throttlebody17.Atmosphericpressuresensor18.Airfiltercase19.Intakefunnelservomotor

A.Fuelsystem


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B.AirsystemC.Controlsystem1-3


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FEATURES

EAS4C81011

YCC-T(YamahaChipControlledThrottle)YCC-I(YamahaChipControlledIntake)

Mechanismcharacteristics

YamahadevelopedtheYCC-TandYCC-Isystememployingthemostadvancedelectroniccontroltechnologies.Electroniccontrolthrottlesystemshavebeenusedonautomobiles,butYamahahasdevelopedafaster,morecompactsystemspecificallyfortheneedsofasportsmotorcycle.TheYamaha-developedsystemhasahigh-speedcalculatingcapacitythatproducescomputationsofrunningconditionsevery1/1000thofasecond.TheYCC-TsystemisdesignedtorespondtothethrottleactionoftheriderbyhavingtheECUinstantaneouslycalculatetheidealthrottlevalveopeningandgeneratesignalstooperatethemotor-driventhrottlevalvesandthusactivelycontroltheintakeairvolume.

TheECUcontainsthreeCPUswithacapacityaboutfivetimesthatofconventionalunits,makingitpossibleforthesystemtorespondextremelyquicklytotheslightestadjustmentsmadebytherider.Inparticular,optimizedcontrolofthethrottlevalveopeningprovidestheoptimumvolumeofintakeairforeasy-to-usetorque,eveninahigh-revvingengine.TheYCC-Isystemcalculatesthevaluefromtheenginerevolutionnumberandthrottleopeningrate,activatestheintakeairfunnelwiththeelectroniccontrolmotordrivetocontroltheintakepipelengthinordertogainthehighpoweroutputinallrevolutionrangesfromlowspeedstohighspeeds.

AimsandadvantagesofusingYCC-Tsystem

IncreasedenginepowerByshorteningtheairintakepath,higherenginespeedispossible.Increasedenginepower.ImproveddriveabilityAirintakevolumeiscontrolledaccordingtotheoperatingconditions.Improvedthrottleresponsetomeetenginerequirement.Drivingforceiscontrolledattheoptimallevelaccordingtothetransmissiongearpositionandenginespeed.Improvedthrottlecontrol.

EnginebrakingcontrolDuetothethrottlecontrol,optimalenginebrakingismadepossible.Simplifiedidlespeedcontrol(ISC)mechanismThebypassmechanismandISCactuatorareeliminated.Asimplemechanismisusedtomaintainasteadyidlespeed.ReducedweightComparedtousingasub-throttlemechanism,weightisreduced.A.Tothrottlegrip1.Throttlepositionsensor(forthrottlecable


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pulley)2.Throttleservomotor3.Throttlepositionsensor(forthrottlevalves)4.Throttlevalves5.Throttlecablepulleywithlinkageguard1-4


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FEATURES

AimsandadvantagesofusingYCC-Isystem

ImprovementoftheenginepowercharacteristicsThehighpowerdesigninallrangesisnowprovidedbyhavingbothtwofeaturesoftheshortintakefunctiontoensurethepoweratthehighspeedrevolutionofengine,andthelongintakefunctiontoensurethepowerinthepracticaluserange.IntakepipelengthswitchingcontrolusingthemotorTheintakepipelengthswitchingoperationinaminutetimeisnowavailablebymeansofthemotordriveusingtheelectroniccontrol.Thesmoothpowercharacteristicisprovided,whichdoesnotletanoperatorfeeltheswitchingactionbytheoptimizationofitsswitchingrevolutionnumberandthemostsuitableapplicationofengineatthetimeofchangingtherevolution.A.Downposition(longintake)(LowrpmtoMidrpm)B.Upposition(shortintake)

(Highrpm)1-5


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FEATURES

YCC-T/YCC-Isystemoutline

19.Intakefunnelservomotordriver20.Intakefunnelservomotor

1.Throttlepositionsensor(forthrottlecablepulley)2.Throttleservomotor3.Throttlepositionsensor(forthrottlevalves)4.ECU(enginecontrolunit)5.ETVmainCPU(32bit)6.ETVsubCPU(16bit)7.FICPU(32bit)8.Throttleservomotordriver9.Throttleservomotordriveroperationsensing/shutoffcircuit

10.Throttleservomotordriveroperationsensingfeedback/emergencystop11.Emergencystop12.Enginerevolution(pulsesignal)13.Sensorinput14.Neutralswitch15.Crankshaftpositionsensor16.Speedsensor17.Coolanttemperaturesensor18.Atmosphericpressuresensor

1-6


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FEATURES

YCC-T/YCC-Icontroloutline

1.Throttlepositionsensor(forthrottlecablepulley)2.Throttlepositionsensor(forthrottlevalves)3.Crankshaftpositionsensor4.Speedsensor5.Coolanttemperaturesensor6.Neutralswitch7.Atmosphericpressuresensor8.Acceleratorposition(twosignals)9.Throttleposition(twosignals)10.Enginerevolution11.Vehiclespeed12.Coolanttemperature13.Neutral/Ingear14.Atmosphericpressure15.Throttleservomotor16.ECU(enginecontrolunit)

17.Basemap18.Idlespeedcontrol19.Calculatedthrottlevalveopeningangle20.Basemap21.Airfunnelposition(Calculationvalue)22.Intakefunnelservomotor

1-7


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FEATURES

EAS4C81024

Toswitchthespeedometerandodometer/INSTRUMENTFUNCTIONS

tripmeterdisplaysbetweenkilometersandmiles,presstheSELECTbuttonforatleast

Multi-functionmeterunit

onesecond.

1.Clock2.Speedometer3.SELECTbutton4.RESETbutton5.Tachometer6.Coolanttemperaturedisplay/airintaketemperature

display7.Odometer/tripmeters/fuelreservetripmeter/stopwatch8.ShifttimingindicatorlightEWA4C81008

WARNINGBesuretostopthevehiclebeforemakinganysettingchangestothemulti-functionmeterunit.

Themulti-functionmeterunitisequippedwiththefollowing:

aspeedometer(whichshowstheridingspeed)atachometer(whichshowsenginespeed)anodometer(whichshowsthetotaldistancetraveled)twotripmeters(whichshowthedistancetraveledsincetheywerelastsettozero)afuelreservetripmeter(whichshowsthedistancetraveledsincethefuellevelwarninglightcameon)aclockacoolanttemperaturedisplay

anairintaketemperaturedisplayaself-diagnosisdeviceadisplaybrightnessandshifttimingindicatorlightcontrolmodeNOTE:

BesuretoturnthekeytoONbeforeusingtheSELECTandRESETbuttons.Tachometer


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1.Tachometer2.TachometerredzoneTheelectrictachometerallowstheridertomonitortheenginespeedandkeepitwithintheidealpowerrange.WhenthekeyisturnedtoON,thetachometerneedlewillsweeponceacrossther/minrangeandthenreturntozeror/mininordertotesttheelectricalcircuit.

ECA4C81017

CAUTION:

Donotoperatetheengineinthetachometerredzone.Redzone:13750r/minandabove

Clockmode

1.ClockTurnthekeytoON.

Tosettheclock

1.PushtheSELECTbuttonandRESETbuttontogetherforatleasttwoseconds.2.Whenthehourdigitsstartflashing,pushtheRESETbuttontosetthehours.3.PushtheSELECTbutton,andtheminutedigitswillstartflashing.1-8


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FEATURES

4.PushtheRESETbuttontosettheminutes.5.PushtheSELECTbuttonandthenreleaseittostarttheclock.Odometer,tripmeter,andstopwatchmodes

1.Odometer/tripmeter/fuelreservetripmeterPushtheSELECTbuttontoswitchthedisplaybetweentheodometermodeODOandthetripmetermodesTRIPAandTRIPBandthestopwatchmodeinthefollowingorder:TRIPA.TRIPB.ODO.Stopwatch.TRIPAIfthefuellevelwarninglightcomeson,theodometerdisplaywillautomaticallychangetothefuelreservetripmetermodeF-TRIPandstartcountingthedistancetraveledfromthatpoint.Inthatcase,pushtheSELECTbuttontoswitchthedisplaybetweenthevarioustrip-

meter,odometer,andstopwatchmodesinthefollowingorder:F-TRIP.Stopwatch.TRIPA.TRIPB.ODO.F-TRIPToresetatripmeter,selectitbypushingtheSELECTbutton,andthenpushtheRESETbuttonforatleastonesecond.Ifyoudonotresetthefuelreservetripmetermanually,itwillresetitselfautomaticallyandthedisplaywillreturntothepriormodeafterrefuelingandtraveling5km(3mi).

Stopwatchmode

Tochangethedisplaytothestopwatchmode,selectitbypushingtheSELECTbutton.(Thestopwatchdigitswillstartflashing.)ReleasetheSELECTbutton,andthenpushitagainforafewsecondsuntilthestopwatchdigitsstopflashing.Standardmeasurement

1.PushtheRESETbuttontostartthestopwatch.2.PushtheSELECTbuttontostopthestopwatch.

3.PushtheSELECTbuttonagaintoresetthestopwatch.Split-timemeasurement

1.PushtheRESETbuttontostartthestopwatch.2.PushtheRESETbuttonorstartswitchtomeasuresplit-times.(Thecolon:


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willstartflashing.)3.PushtheRESETbuttonorstartswitchtomeasuresplit-times.(Thecolon:willstartflashing.)4.PushtheSELECTbuttontoresetthestopwatch.NOTE:

Tochangethedisplaybacktothepriormode,pushtheSELECTbuttonforafewseconds.

Coolanttemperaturedisplay

1.CoolanttemperaturedisplayThecoolanttemperaturedisplayindicatesthetemperatureofthecoolant.PushtheRESETbuttontoswitchthecoolanttemperaturedisplaytotheairintaketemperaturedisplay.

NOTE:

Whenthecoolanttemperaturedisplayisselected,Cisdisplayedforonesecond,andthenthecoolanttemperatureisdisplayed.

ECA4C81018

CAUTION:

Donotoperatetheengineifitisoverheated.

1-9


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FEATURES

AirintaketemperaturedisplayDisplaybrightnessandshifttimingindica

1.AirintaketemperaturedisplayTheairintaketemperaturedisplayindicatesthetemperatureoftheairdrawnintotheairfiltercase.PushtheRESETbuttontoswitchthecoolanttemperaturedisplaytotheairintaketemperaturedisplay.

NOTE:

Eveniftheairintaketemperatureissettobedisplayed,thecoolanttemperaturewarninglightcomesonwhentheengineoverheats.WhenthekeyisturnedtoON,thecoolanttemperatureisautomaticallydisplayed,eveniftheairintaketemperaturewasdisplayedpriortoturningthekeytoOFF.

Whentheairintaketemperaturedisplayisselected,Aisdisplayedbeforethetemperature.Self-diagnosisdevice

1.ErrorcodedisplayThismodelisequippedwithaself-diagnosisdeviceforvariouselectricalcircuits.Ifanyofthosecircuitsaredefective,theenginetroublewarninglightwillcomeon,andthenthedisplaywillindicateatwo-digiterrorcode.

torlightcontrolmode

1.Displaybrightness2.Shifttimingindicatorlightactivation/deactivation3.Shifttimingindicatorlight4.BrightnesslevelThismodecyclesthroughfivecontrolfunctions,allowingyoutomakethefollowingsettingsintheorderlistedbelow.Displaybrightness:

Thisfunctionallowsyoutoadjustthebrightnessofthedisplaysandtachometertosuittheoutsidelightingconditions.Shifttimingindicatorlightactivity:

Thisfunctionallowsyoutochoosewhetherornottheindicatorlightshouldbeactivatedandwhetheritshouldflashorstayonwhenactivated.Shifttimingindicatorlightactivation:Thisfunctionallowsyoutoselecttheenginespeedatwhichtheindicatorlightwillbeactivated.Shifttimingindicatorlightdeactivation:Thisfunctionallowsyoutoselecttheenginespeedatwhichtheindicatorlightwillbe


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deactivated.Shifttimingindicatorlightbrightness:Thisfunctionallowsyoutoadjustthebrightnessoftheindicatorlighttosuityourpreference.NOTE:

Inthismode,therightdisplayshowsthecurrentsettingforeachfunction(excepttheshifttimingindicatorlightactivityfunction).

Toadjustthebrightnessofthemultifunctionmeterdisplaysandtachometer

1.TurnthekeytoOFF.2.PushandholdtheSELECTbutton.3.TurnthekeytoON,andthenreleasetheSELECTbuttonafterfiveseconds.1-10


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FEATURES

4.PushtheRESETbuttontoselectthedesiredbrightnesslevel.5.PushtheSELECTbuttontoconfirmtheselectedbrightnesslevel.Thecontrolmodechangestotheshifttimingindicatorlightactivityfunction.Tosettheshifttimingindicatorlightactivityfunction

1.PushtheRESETbuttontoselectoneofthefollowingindicatorlightactivitysettings:Theindicatorlightwillstayonwhenactivated.(Thissettingisselectedwhentheindicatorlightstayson.)Theindicatorlightwillflashwhenactivated.(Thissettingisselectedwhentheindicatorlightflashesfourtimespersecond.)

Theindicatorlightisdeactivated;inotherwords,itwillnotcomeonorflash.(Thissettingisselectedwhentheindicatorlightflashesonceeverytwoseconds.)2.PushtheSELECTbuttontoconfirmtheselectedindicatorlightactivity.Thecontrolmodechangestotheshifttimingindicatorlightactivationfunction.rytwoseconds.)Tosettheshifttimingindicatorlightactivationfunction

NOTE:

Theshifttimingindicatorlightactivationfunctioncanbesetbetween7000r/minand15000r/min.From7000r/minto12000r/min,theindicatorlightcanbesetinincrementsof500r/min.From12000r/minto15000r/min,theindicatorlightcanbesetinincrementsof200r/min.

1.PushtheRESETbuttontoselectthedesiredenginespeedforactivatingtheindicatorlight.

2.PushtheSELECTbuttontoconfirmtheselectedenginespeed.Thecontrolmodechangestotheshifttimingindicatorlightdeactivationfunction.Tosettheshifttimingindicatorlightdeactivationfunction

NOTE:


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Theshifttimingindicatorlightdeactivationfunctioncanbesetbetween7000r/minand15000r/min.From7000r/minto12000r/min,theindicatorlightcanbesetinincrementsof500r/min.From12000r/minto15000r/min,theindicatorlightcanbesetinincrementsof200r/min.Besuretosetthedeactivationfunctiontoahigherenginespeedthanfortheactivationfunction,otherwisetheshifttimingindicatorlightwillremaindeactivated.1.PushtheRESETbuttontoselectthedesiredenginespeedfordeactivatingtheindicatorlight.2.PushtheSELECTbuttontoconfirmtheselectedenginespeed.Thecontrolmodechangestotheshifttimingindicatorlightbrightnessfunction.Toadjusttheshifttimingindicatorlightbrightness

1.

PushtheRESETbuttontoselectthedesiredindicatorlightbrightnesslevel.2.PushtheSELECTbuttontoconfirmtheselectedindicatorlightbrightnesslevel.Therightdisplaywillreturntotheodometerortripmetermode.1-11


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IMPORTANTINFORMATION

EAS20180

IMPORTANTINFORMATION

EAS20190

PREPARATIONFORREMOVALANDDISASSEMBLY

1.Beforeremovalanddisassembly,removealldirt,mud,dustandforeignmaterial.2.Useonlythepropertoolsandcleaningequipment.Referto"SPECIALTOOLS"onpage1-15.3.Whendisassembling,alwayskeepmatedpartstogether.Thisincludesgears,cylinders,pistonsandotherpartsthathave

beenmatedthroughnormalwear.Matedpartsmustalwaysbereusedorreplacedasanassembly.4.Duringdisassembly,cleanallofthepartsandplacethemintraysintheorderofdisassembly.Thiswillspeedupassemblyandallowforthecorrectinstallationofallparts.5.Keepallpartsawayfromanysourceoffire.EAS20200

REPLACEMENTPARTS

UseonlygenuineYamahapartsforallreplacements.UseoilandgreaserecommendedbyYamahaforalllubricationjobs.Otherbrandsmaybesimilarinfunctionandappearance,butinferiorinquality.

EAS20210

GASKETS,OILSEALSANDO-RINGS

1.

Whenoverhaulingtheengine,replaceallgaskets,sealsandO-rings.Allgasketsurfaces,oilseallipsandO-ringsmustbecleaned.2.Duringreassembly,properlyoilallmatingpartsandbearingsandlubricatetheoilseallipswithgrease.1.Oil2.Lip


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3.Spring4.GreaseEAS20220

LOCKWASHERS/PLATESANDCOTTERPINS

Afterremoval,replacealllockwashers/plates1andcotterpins.Aftertheboltornuthasbeentightenedtospecification,bendthelocktabsalongaflatoftheboltornut.

1-12


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CHECKINGTHECONNECTIONS

EAS20250

CHECKINGTHECONNECTIONS

Checktheleads,couplers,andconnectorsforstains,rust,moisture,etc.

1.Disconnect:Pockettester90890-03112AnalogpockettesterYU-03112-C

LeadNOTE:

CouplerIfthereisnocontinuity,cleantheterminals.ConnectorWhencheckingthewireharness,perform

2.Check:steps(1)to(3).

LeadAsaquickremedy,useacontactrevitalizerCoupleravailableatmostpartstores.

ConnectorMoisture.Drywithanairblower.Rust/stains.Connectanddisconnectseveraltimes.

3.Check:AllconnectionsLooseconnection.Connectproperly.NOTE:

Ifthepin1ontheterminalisflattened,benditup.

4.Connect:LeadCoupler

ConnectorNOTE:

Makesureallconnectionsaretight.

5.Check:Continuity(withthepockettester)1-14


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SPECIALTOOLS

EAS20260

SPECIALTOOLS

Thefollowingspecialtoolsarenecessaryforcompleteandaccuratetune-upandassembly.Useonlytheappropriatespecialtoolsasthiswillhelppreventdamagecausedbytheuseofinappropriatetoolsorimprovisedtechniques.Specialtools,partnumbersorbothmaydifferdependingonthecountry.Whenplacinganorder,refertothelistprovidedbelowtoavoidanymistakes.

NOTE:

ForU.S.A.andCanada,usepartnumberstartingwithYM-,YU-,orACC-.Forothers,usepartnumberstartingwith90890-.Toolname/ToolNo.IllustrationReferencepagesPistonpinpullerset

90890-01304PistonpinpullerYU-013045-71Radiatorcaptester90890-01325RadiatorpressuretesterYU-24460-016-3Radiatorcaptesteradapter90890-01352RadiatorpressuretesteradapterYU-33984

6-3Steeringnutwrench90890-01403SpannerwrenchYU-339753-28,4-60Damperrodholder90890-01423DampingrodholderYM-014234-52,4-53Oilfilterwrench90890-01426

YU-384113-12

1-15


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SPECIALTOOLS

Toolname/ToolNo.IllustrationReferencepagesRodholder90890-01434DamperrodholderdoubleendedYM-014344-51,4-56Rodpuller90890-01437UniversaldampingrodbleedingtoolsetYM-A87034-55,4-56Rodpullerattachment(M12)90890-01435UniversaldampingrodbleedingtoolsetYM-A87034-55,4-56Forkspringcompressor90890-01441YM-01441

4-51,4-56Forksealdriver90890-01442Adjustableforksealdriver(3646mm)YM-014424-54Vacuumgauge90890-03094CarburetorsynchronizerYU-444563-7Compressiongauge90890-03081

EnginecompressiontesterYU-332233-10Extension90890-041363-10

1-16


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SPECIALTOOLS

Toolname/ToolNo.IllustrationReferencepagesValvespringcompressor90890-04019YM-040195-23,5-29Valvespringcompressorattachment90890-04108Valvespringcompressoradapter(22mm)YM-041085-23,5-29Middledrivenshaftbearingdriver90890-04058Bearingdriver(40mm)YM-040586-11Mechanicalsealinstaller90890-04078WaterpumpsealinstallerYM-33221-A

6-11Universalclutchholder90890-04086YM-910425-47,5-51Valveguideremover(5)90890-04097Valveguideremover(5.0mm)YM-040975-25Valveguideremover(4.5)90890-04116Valveguideremover(4.5mm)

YM-041165-25Valveguideinstaller(5)90890-04098Valveguideinstaller(5.0mm)YM-040985-25

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SPECIALTOOLS

Toolname/ToolNo.IllustrationReferencepagesValveguideinstaller(4.5)90890-04117Valveguideinstaller(4.5mm)YM-041175-25Valveguidereamer(5)90890-04099Valveguidereamer(5.0mm)YM-040995-25Valveguidereamer(4.5)90890-04118Valveguidereamer(4.5mm)YM-041185-25Ignitionchecker90890-06754Opamapet-4000sparkchecker

YU-344878-84YamahabondNo.1215(ThreeBondNo.1215)90890-855055-67,6-11Pivotshaftwrench90890-01471FramespannersocketYM-014715-7Pivotshaftwrenchadapter90890-01476

5-7Pockettester90890-03112AnalogpockettesterYU-03112-C1-14,5-41,8-75,8-76,8-77,8-80,8-81,8-82,8-83,8-84,8-85,8-86,8-87,8-88,8-89,8-90,8-91,8-92

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SPECIALTOOLS

Toolname/ToolNo.IllustrationReferencepagesOilpressuregaugeadapter90890-031393-13Valvelapper90890-04101ValvelappingtoolYM-A89983-5Fuelpressureadapter90890-03176YM-031767-6Pressuregauge90890-03153YU-031533-13,7-6Camshaftwrench90890-04143

YM-041435-11,5-16Ringnutwrench90890-01507YM-015074-67,4-69Damperrodholder(22mm)90890-013654-68,4-69

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SPECIFICATIONS

GENERALSPECIFICATIONS......................................................................2-1ENGINESPECIFICATIONS..........................................................................2-2CHASSISSPECIFICATIONS........................................................................2-8ELECTRICALSPECIFICATIONS...............................................................2-10TIGHTENINGTORQUES............................................................................2-12GENERALTIGHTENINGTORQUESPECIFICATIONS.......................2-12ENGINETIGHTENINGTORQUES......................................................2-13CHASSISTIGHTENINGTORQUES....................................................2-17LUBRICATIONPOINTSANDLUBRICANTTYPES..................................2-20ENGINE................................................................................................2-20CHASSIS..............................................................................................2-21

LUBRICATIONSYSTEMCHARTANDDIAGRAMS.................................2-23ENGINEOILLUBRICATIONCHART...................................................2-23LUBRICATIONDIAGRAMS..................................................................2-25COOLINGSYSTEMDIAGRAMS...............................................................2-35CABLEROUTING......................................................................................2-39

2


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GENERALSPECIFICATIONS

EAS20280

GENERALSPECIFICATIONS

ModelModel4C84(U.S.A.)4C85(California)DimensionsOveralllengthOverallwidthOverallheightSeatheightWheelbaseGroundclearanceMinimumturningradius2060mm(81.1in)720mm(28.3in)1110mm(43.7in)835mm(32.9in)1415mm(55.7in)

135mm(5.31in)3400mm(133.9in)WeightWithoilandfuelMaximumload200kg(441lb)195kg(430lb)

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ENGINESPECIFICATIONS

EAS20290


Engine

EnginetypeLiquidcooled4-stroke,DOHC

Displacement998.0cm

CylinderarrangementForward-inclinedparallel4-cylinder

Borestroke77.053.6mm(3.032.11in)

Compressionratio12.70:1

Standardcompressionpressure(atsealevel)1480kPa/350r/min(210.5psi/350r/min)(14.8

kgf/cm/350r/min)

StartingsystemElectricstarter

FuelRecommendedfuelPremiumunleadedgasolineonlyFueltankcapacity18.0L(4.76USgal)(3.96Imp.gal)Fuelreserveamount3.2L(0.85USgal)(0.70Imp.gal)

Engineoil

LubricationsystemWetsumpTypeYAMALUBE4,SAE10W30orSAE20W40

RecommendedengineoilgradeAPIservice,SGtypeorhigher,JASOstandard

MA

EngineoilquantityTotalamount3.83L(4.05USqt)(3.37Imp.qt)Withoutoilfiltercartridgereplacement2.90L(3.07USqt)(2.55Imp.qt)Withoilfiltercartridgereplacement3.10L(3.28USqt)(2.73Imp.qt)

Oilfilter

OilfiltertypeFormed

Oilpump

OilpumptypeTrochoidInner-rotor-to-outer-rotor-tipclearance0.0100.100mm(0.00040.0039in)Limit0.18mm(0.0071in)Outer-rotor-to-oil-pump-housingclearance0.0900.190mm(0.00350.0074in)Limit0.26mm(0.0102in)Oil-pump-housing-to-inner-and-outer-rotorclearance0.060.13mm(0.00240.0051in)


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Limit0.20mm(0.0079in)Bypassvalveopeningpressure80.0120.0kPa(11.617.4psi)(0.801.20

kgf/cm)Reliefvalveoperatingpressure600.0680.0kPa(87.098.6psi)(6.006.80kgf/cm)

Coolingsystem

Radiatorcapacity(includingallroutes)2.76L(2.92USqt)(2.43Imp.qt)

Coolantreservoircapacity(uptothemaximum

levelmark)0.25L(0.26USqt)(0.22Imp.qt)

Radiatorcapopeningpressure108137kPa(15.419.5psi)(1.081.37kgf/

cm)

RadiatorcoreWidth374.0mm(14.72in)Height257.8mm(10.15in)Depth24.0mm(0.94in)

WaterpumpWaterpumptypeSinglesuctioncentrifugalpumpReductionratio65/4325/32(1.181)

Sparkplug(s)

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Manufacturer/modelSparkpluggapNGK/CR9EK0.60.7mm(0.0240.028in)CylinderheadVolumeWarpagelimit*14.0014.80cm(0.850.90cu.in)0.10mm(0.0039in)

Camshaft

DrivesystemChaindrive(right)Camshaftcapinsidediameter24.50024.521mm(0.96460.9654in)Camshaftjournaldiameter24.45924.472mm(0.96300.9635in)Camshaft-journal-to-camshaft-capclearance0.0280.062mm(0.00110.0024in)

Camshaftlobedimensions

IntakeA34.45034.550mm(1.35631.3602in)Limit34.350mm(1.3524in)IntakeB25.17025.270mm(0.99090.9949in)Limit25.070mm(0.9870in)ExhaustA33.55033.650mm(1.32091.3248in)Limit33.450mm(1.3169in)ExhaustB25.19225.292mm(0.99180.9957in)Limit25.092mm(0.9879in)

Camshaftrunoutlimit0.030mm(0.0012in)

TimingchainModel/numberoflinksRH2020/124TensioningsystemAutomatic

Valveclearance(cold)Intake0.110.20mm(0.00430.0079in)Exhaust0.260.30mm(0.01020.0118in)

ValvedimensionsValveheaddiameterA(intake)30.9031.10mm(1.21651.2244in)

ValveheaddiameterA(exhaust)24.9025.10mm(0.98030.9882in)

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ValvefacewidthB(intake)1.2002.480mm(0.04720.0976in)ValvefacewidthB(exhaust)1.6252.900mm(0.06400.1142in)

ValveseatwidthC(intake)0.901.10mm(0.03540.0433in)ValveseatwidthC(exhaust)0.901.10mm(0.03540.0433in)

ValvemarginthicknessD(intake)1.101.50mm(0.04330.0591in)ValvemarginthicknessD(exhaust)0.500.90mm(0.01970.0354in)

Valvestemdiameter(intake)4.9754.990mm(0.19590.1965in)Limit4.960mm(0.1953in)Valvestemdiameter(exhaust)4.4604.475mm(0.17560.1762in)Limit4.425mm(0.1742in)Valveguideinsidediameter(intake)5.0005.012mm(0.19690.1973in)

Limit5.050mm(0.1988in)Valveguideinsidediameter(exhaust)4.5004.512mm(0.17720.1776in)Limit4.550mm(0.1791in)Valve-stem-to-valve-guideclearance(intake)0.0100.037mm(0.00040.0015in)Limit0.080mm(0.0032in)Valve-stem-to-valve-guideclearance(exhaust)0.0250.052mm(0.00100.0020in)Limit0.100mm(0.0039in)Valvestemrunout0.010mm(0.0004in)

Cylinderheadvalveseatwidth(intake)0.901.10mm(0.03540.0433in)Cylinderheadvalveseatwidth(exhaust)0.901.10mm(0.03540.0433in)

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Valvespring

InnerspringFreelength(intake)39.79mm(1.57in)Freelength(exhaust)38.42mm(1.51in)Installedlength(intake)35.50mm(1.40in)Installedlength(exhaust)33.00mm(1.30in)SpringrateK1(intake)42.91N/mm(245.02lb/in)(4.38kgf/mm)SpringrateK2(intake)56.23N/mm(321.07lb/in)(5.73kgf/mm)SpringrateK1(exhaust)40.10N/mm(228.97lb/in)(4.09kgf/mm)SpringrateK2(exhaust)51.85N/mm(296.06lb/in)(5.29kgf/mm)Installedcompressionspringforce(intake)171197N(38.4444.29lbf)(17.4420.09

kgf)at35.50mm(1.398in)Installedcompressionspringforce(exhaust)202232N(45.4152.15lbf)(20.6023.66

kgf)at33.00mm(1.299in)Springtilt(intake)*2.5/1.7mmSpringtilt(exhaust)*2.5/1.7mm

Windingdirection(intake)ClockwiseWindingdirection(exhaust)Clockwise

CylinderBore77.00077.010mm(3.03153.0319in)Taperlimit0.050mm(0.0020in)Outofroundlimit0.050mm(0.0020in)PistonPiston-to-cylinderclearance0.0100.035mm(0.00040.0014in)

Limit0.12mm(0.0047in)DiameterD76.97576.990mm(3.03053.0311in)HeightH12.0mm(0.47in)

OffsetOffsetdirection0.50mm(0.0197in)IntakesidePistonpinboreinsidediameterPistonpinoutsidediameter17.00217.013mm(0.66940.6698in)16.99117.000mm(0.66890.6693in)

PistonringTopringRingtypeDimensions(BT)Barrel0.902.75mm(0.040.11in)

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Endgap(installed)0.150.25mm(0.00590.0098in)Ringsideclearance0.0300.065mm(0.00120.0026in)2ndringRingtypeTaperDimensions(BT)0.802.75mm(0.030.11in)

Endgap(installed)0.300.45mm(0.01180.0177in)Ringsideclearance0.0200.055mm(0.00080.0022in)OilringDimensions(BT)1.502.25mm(0.060.09in)

Endgap(installed)0.100.40mm(0.00390.0157in)ConnectingrodOilclearance(usingplastigauge)Bearingcolorcode0.0340.058mm(0.00130.0023in)

1.Blue2.Black3.Brown4.Green

Crankshaft

WidthA55.2056.60mm(2.1732.228in)WidthB298.75300.65mm(11.7611.84in)RunoutlimitC0.030mm(0.0012in)BigendsideclearanceD0.1600.262mm(0.00630.0103in)

Journaloilclearance(usingplastigauge)Bearingcolorcode

0.0140.037mm(0.00060.0015in)0.White1.Blue2.Black3.Brown4.GreenClutchClutchtypeClutchreleasemethodClutchleverfreeplayFrictionplatethicknessWearlimitPlatequantityClutchplatethicknessPlatequantityWarpagelimitClutchspringfreelength

SpringquantityWet,multiple-discOuterpull,rackandpinionpull10.015.0mm(0.390.59in)2.903.10mm(0.1140.122in)2.80mm(0.1102in)9pcs1.902.10mm(0.0750.083in)8pcs0.10mm(0.0039in)


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43.80mm(1.72in)6pcsTransmissionTransmissiontypePrimaryreductionsystemPrimaryreductionratioSecondaryreductionsystemConstantmesh6-speedSpurgear65/43(1.512)Chaindrive2-6


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Secondaryreductionratio45/17(2.647)OperationLeftfootoperation

Gearratio

1st38/15(2.533)2nd33/16(2.063)3rd37/21(1.762)4th35/23(1.522)5th30/22(1.364)6th33/26(1.269)Mainaxlerunoutlimit0.08mm(0.0032in)Driveaxlerunoutlimit0.08mm(0.0032in)

Shiftingmechanism

ShiftmechanismtypeShiftdrumandguidebarShiftforkguidebarbendinglimit0.100mm(0.0039in)Shiftforkthickness5.805.88mm(0.22830.2315in)

Airfilter

AirfilterelementOil-coatedpaperelement

Fuelpump

PumptypeElectricalModel/manufacturer4C8/DENSOMaximumconsumptionamperage6.0AOutputpressure324.0kPa(46.1psi)(3.24kgf/cm)

Fuelinjector

Model/quantity297500-1110/4ManufacturerDENSO

Throttlebody

Type/quantity45EIDW/1ManufacturerMIKUNIIDmark4C8100(U.S.A.)

4C8510(California)Throttlevalvesize#50

Throttlepositionsensor

Resistance2.03.0k.Outputvoltage(atidle)0.630.73V

Idlingcondition

Engineidlingspeed11501250r/minIntakevacuum22.0kPa(6.5inHg)(165mmHg)Watertemperature95.0105.0C(203.00221.00F)Oiltemperature80.090.0C(176.00194.00F)Throttlecablefreeplay3.05.0mm(0.120.20in)


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2-7


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CHASSISSPECIFICATIONS

EAS20300


ChassisFrametypeCasterangleDiamond24.00Trail102.0mm(4.02in)FrontwheelWheeltypeCastwheelRimsize17M/CMT3.50RimmaterialAluminumWheeltravel120.0mm(4.72in)Radialwheelrunoutlimit1.0mm(0.04in)Lateralwheelrunoutlimit0.5mm(0.02in)RearwheelWheeltypeCastwheelRimsize17M/CMT6.00

RimmaterialAluminumWheeltravel130.0mm(5.12in)Radialwheelrunoutlimit1.0mm(0.04in)Lateralwheelrunoutlimit0.5mm(0.02in)FronttireTypeTubelessSize120/70ZR17M/C(58W)Manufacturer/modelPIRELLI/DIABLOCORSAEManufacturer/modelMICHELIN/PilotPOWERWearlimit(front)0.8mm(0.03in)ReartireTypeTubelessSize190/50ZR17M/C(73W)

Manufacturer/modelPIRELLI/DIABLOCORSALManufacturer/modelMICHELIN/PilotPOWERWearlimit(rear)0.8mm(0.03in)Tireairpressure(measuredoncoldtires)Loadingcondition090kg(0198lb)Front250kPa(36psi)(2.50kgf/cm)(2.50bar)Rear290kPa(42psi)(2.90kgf/cm)(2.90bar)Loadingcondition90195kg(198430lb)Front250kPa(36psi)(2.50kgf/cm)(2.50bar)Rear290kPa(42psi)(2.90kgf/cm)(2.90bar)High-speedridingFront250kPa(36psi)(2.50kgf/cm)(2.50bar)Rear290kPa(42psi)(2.90kgf/cm)(2.90bar)

FrontbrakeTypeDualdiscbrakeOperationRighthandoperationFrontbrakeleverfreeplay2.311.5mm(0.090.45in)

Frontdiscbrake

Discoutsidediameterthickness310.05.0mm(12.200.20in)Brakediscthicknesslimit4.5mm(0.18in)Brakediscdeflectionlimit0.10mm(0.0039in)


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Brakepadliningthickness(inner)4.5mm(0.18in)Limit0.8mm(0.03in)Brakepadliningthickness(outer)4.5mm(0.18in)Limit0.8mm(0.03in)

2-8


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Mastercylinderinsidediameter16.00mm(0.63in)Calipercylinderinsidediameter24.05mm3(0.95in3)RecommendedfluidDOT4RearbrakeTypeSinglediscbrakeOperationRightfootoperationBrakepedalfreeplay4.39.3mm(0.170.37in)ReardiscbrakeDiscoutsidediameterthickness220.05.0mm(8.660.20in)Brakediscthicknesslimit4.5mm(0.18in)Brakediscdeflectionlimit0.15mm(0.0059in)Brakepadliningthickness(inner)6.0mm(0.24in)Limit1.0mm(0.04in)Brakepadliningthickness(outer)6.0mm(0.24in)Limit1.0mm(0.04in)Mastercylinderinsidediameter12.7mm(0.50in)Calipercylinderinsidediameter38.18mm(1.50in)RecommendedfluidDOT4SteeringSteeringbearingtype

Locktolockangle(left)Locktolockangle(right)Angularbearing27.027.0FrontsuspensionTypeTelescopicforkSpring/shockabsorbertypeCoilspring/oildamperFrontforktravel120.0mm(4.72in)Forkspringfreelength237.5mm(9.35in)Limit232.8mm(9.17in)Collarlength100.0mm(3.94in)Installedlength223.0mm(8.78in)

SpringrateK19.07N/mm(51.79lb/in)(0.92kgf/mm)SpringstrokeK10.0120.0mm(0.004.72in)Innertubeouterdiameter43.0mm(1.69in)Innertubebendinglimit0.2mm(0.01in)OptionalspringavailableNoRecommendedoilSuspensionoil01Quantity513.0cm(17.34USoz)(18.09Imp.oz)Level101.0mm(3.98in)RearsuspensionTypeSwingarm(linksuspension)Spring/shockabsorbertypeCoilspring/gas-oildamperRearshockabsorberassemblytravel65.0mm(2.56in)Springfreelength179.5mm(7.07in)

Installedlength166.5mm(6.56in)SpringrateK193.00N/mm(531.03lb/in)(9.48kgf/mm)SpringstrokeK10.065.0mm(0.002.56in)OptionalspringavailableNoEnclosedgas/airpressure(STD)1200kPa(170.7psi)(12.0kgf/cm)DrivechainType/manufacturer50VA8/DAIDOLinkquantity118Drivechainslack30.040.0mm(1.181.57in)15-linklengthlimit239.3mm(9.42in)


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2-9


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ELECTRICALSPECIFICATIONS

EAS20310


VoltageSystemvoltage12VIgnitionsystemIgnitionsystemIgnitiontiming(B.T.D.C.)Transistorizedcoilignition(digital)5.0/1050r/minEnginecontrolunitModel/manufacturerTBDF42/DENSOIgnitioncoilModel/manufacturerMinimumignitionsparkgapPrimarycoilresistanceSecondarycoilresistanceF6T568/MITSUBISHI6.0mm(0.24in)

0.851.15Oat20C(68F)5.026.79kOat20C(68F)ACmagnetoModel/manufacturerStandardoutputStatorcoilresistanceF4T850/MITSUBISHI14.0V40.0A5000r/min0.140.18Oat20C(68F)Rectifier/regulatorRegulatortypeModel/manufacturerRegulatedvoltage(DC)

RectifiercapacityWithstandvoltageSemiconductor-shortcircuitFH012AA/SHINDENGEN14.214.8V50.0A40.0VBatteryModelYTZ10SVoltage,capacitySpecificgravityManufacturer12V,8.6Ah

1.310GYMTenhourrateamperage0.90AHeadlightBulbtypeHalogenbulbBulbvoltage,wattagequantityHeadlightAuxiliarylightTail/brakelightFrontturnsignal/positionlight


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RearturnsignallightLicenseplatelightMeterlighting12V,55.0W412V,5.0W2LED12V,21.0W/5.0W212V,21.0W212V,5.0W1LEDIndicatorlightNeutralindicatorlightTurnsignalindicatorlightOillevelwarninglightHighbeamindicatorlightFuellevelwarninglightCoolanttemperaturewarninglightEnginetroublewarninglightShifttimingindicatorlightLEDLEDLEDLEDLED

LEDLEDLEDElectricstartingsystemSystemtypeConstantmesh2-10


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StartermotorModel/manufacturerPoweroutputArmaturecoilresistance5VY/YAMAHA0.90kW0.00900.0110.BrushoveralllengthLimitBrushspringforceCommutatordiameterLimitMicaundercut(depth)10.8mm(0.43in)7.19mm(0.28in)5.287.92N(19.0128.51oz)(538808gf)24.5mm(0.96in)23.5mm(0.93in)1.50mm(0.06in)Starterrelay

Model/manufacturerAmperageCoilresistance2768093-A/JIDECO180.0A4.184.62.HornHorntypeQuantityModel/manufacturerMaximumamperageCoilresistancePlane

1pcsYF-12/NIKKO3.0A1.151.25.Performance105113dB/2mTurnsignalrelayRelaytypeModel/manufacturerBuilt-in,self-cancelingdeviceTurnsignalblinkingfrequencyWattageFulltransistorFE246BS/DENSO

No75.095.0cycles/min21W2.0+3.4WOillevelgaugeModel/manufacturer5VY/SOMICISHIKAWAServomotorModel/manufacturer5VY/YAMAHAFusesMainfuse50.0AHeadlightfuse


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SignalingsystemfuseIgnitionfuseRadiatorfanfuse25.0A7.5A15.0A15.0A2BackupfuseElectricthrottlevalvefuse7.5A7.5AReservefuse25.0AReservefuse15.0AReservefuse7.5A

2-11


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TIGHTENINGTORQUES

EAS20320

TIGHTENINGTORQUES

EAS20330

GENERALTIGHTENINGTORQUESPECIFICATIONS

ThischartspecifiestighteningtorquesforstandardfastenerswithastandardISOthreadpitch.Tighteningtorquespecificationsforspecialcomponentsorassembliesareprovidedforeachchapterofthismanual.Toavoidwarpage,tightenmulti-fastenerassembliesinacrisscrosspatternandprogressivestagesuntilthespecifiedtighteningtorqueisreached.Unlessotherwisespecified,tighteningtorquespecificationsrequireclean,drythreads.Componentsshouldbeatroomtemperature.

A.DistancebetweenflatsB.OutsidethreaddiameterA(nut)B(bolt)GeneraltighteningtorquesNmmkgftlb10mm6mm60.64.312mm8mm151.51114mm10mm303.02217mm12mm555.54019mm14mm858.561

22mm16mm13013.094

2-12


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TIGHTENINGTORQUES

EAS20340

ENGINETIGHTENINGTORQUES

ItemThreadsizeQtyTighteningtorqueRemarksSparkplugsM10413Nm(1.3mkg,9.4ftlb)Cylinderheadnut(2pieces)M102SeeNOTEECylinderheadnut(8pieces)M108SeeNOTEECylinderheadboltM6212Nm(1.2mkg,8.7ftlb)CamshaftcapboltM62010Nm(1.0mkg,7.2ftlb)ECylinderheadcoverboltM6612Nm(1.2mkg,8.7ftlb)Cylinderheadstudbolt(exhaustpipe)M8815Nm(1.5mkg,11ftlb)AirinductionsystemcapboltM6410Nm(1.0mkg,7.2ftlb)LTCamshaftsprocketboltM7424Nm(2.4mkg,17ftlb)Cylinderheadandthrottlebodyclamp

M6710Nm(1.0mkg,7.2ftlb)Connectingrodcapbolt(1st)M8820Nm(2.0mkg,14ftlb)MConnectingrodcapbolt(final)M88specifiedangle150MGeneratorrotorboltM10160Nm(6.0mkg,43ftlb)ETimingchaintensionerboltM6210Nm(1.0mkg,7.2ftlb)WaterpumpoutletpipeboltM6110Nm(1.0mkg,7.2ftlb)LTWaterpumpinletpipebolt(waterpumpside)M6110Nm(1.0mkg,7.2ftlb)LTWaterpumpinletpipebolt(frontside)M6110Nm(1.0mkg,7.2ftlb)

Oil/waterpumpdrivesprocketboltM6115Nm(1.5mkg,11ftlb)LTWaterpumpboltM6212Nm(1.2mkg,8.7ftlb)LTThermostatcovernutM6210Nm(1.0mkg,7.2ftlb)ThermostatinletpipeboltM6110Nm(1.0mkg,7.2ftlb)OilcoolerboltM20163Nm(6.3mkg,46ftlb)EEngineoildrainboltM14143Nm(4.3mkg,31ftlb)OilpipeboltM6210Nm(1.0mkg,7.2ftlb)LTOilstrainerboltM6310Nm(1.0mkg,7.2ftlb)LTOildeliverypipeboltM6310Nm(1.0mkg,7.2ftlb)LTOilfilterunionboltM20170Nm(7.0mkg,51ftlb)OilfilterM20117Nm(1.7mkg,12ftlb)E

OilpanboltM61412Nm(1.2mkg,8.7ftlb)AirfiltercasescrewM592.0Nm(0.2mkg,1.4ftlb)AirfiltercaseandfunnelscrewM522.5Nm(0.25mkg,1.8ftlb)ThrottlebodyandthrottlebodyjointclampM543.0Nm(0.3mkg,2.2ftlb)ThrottlebodyandfunnelboltM666.0Nm(0.6mkg,4.3ftlb)ThrottlecableadjustingboltM524.0Nm(0.4mkg,2.9ftlb)Cylinderheadandexhaustpipenut


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M8820Nm(2.0mkg,14ftlb)

2-13


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TIGHTENINGTORQUES

ItemThreadsizeQtyTighteningtorqueRemarksExhaustpipeandmufflerboltM8220Nm(2.0mkg,14ftlb)ExhaustpipeandEXUPvalveboltM6512Nm(1.2mkg,8.7ftlb)ExhaustvalvepipebracketboltM8120Nm(2.0mkg,14ftlb)EXUPpulleyandshaftarmnutM616.5Nm(0.65mkg,4.7ftlb)EXUPvalvepulleycoverboltM6210Nm(1.0mkg,7.2ftlb)EXUPvalveandEXUPvalvepipeboltM6110Nm(1.0mkg,7.2ftlb)EXUPcablebracketboltM6110Nm(1.0mkg,7.2ftlb)EXUPcablenutM626.5Nm(0.65mkg,4.7ftlb)EXUPservomotorcoverboltM522Nm(0.2mkg,1.4ftlb)EXUPservomotorboltM626.0Nm(0.6mkg,4.3ftlb)CatalystpipebracketandrearframeM8120Nm(2.0mkg,14ftlb)

CatalystpipeandEXUPvalvepipeboltM8120Nm(2.0mkg,14ftlb)CatalystpipeandcatalystpipebracketboltM8120Nm(2.0mkg,14ftlb)CatalystpipeprotectorM646.5Nm(0.65mkg,4.7ftlb)MufflerandrearframeboltM8223Nm(2.3mkg,17ftlb)MufflerprotectorboltM6410Nm(1.0mkg,7.2ftlb)CrankcasestudboltM10108.0Nm(0.8mkg,5.8ftlb)ECrankcasebolt(mainjournal)M910SeeNOTEECrankcaseboltM6210Nm(1.0mkg,7.2ftlb)ECrankcaseboltM6810Nm(1.0mkg,7.2ftlb)E

CrankcaseboltM8124Nm(2.4mkg,17ftlb)ELTCrankcaseboltM8524Nm(2.4mkg,17ftlb)EGeneratorrotorcoverboltM6412Nm(1.2mkg,8.7ftlb)GeneratorrotorcoverboltM8322Nm(2.2mkg,16ftlb)DrivesprocketcoverboltM6312Nm(1.2mkg,8.7ftlb)LTCrankcasecoverboltM6310Nm(1.0mkg,7.2ftlb)ClutchcoverboltM6712Nm(1.2mkg,8.7ftlb)ClutchcoverboltM6112Nm(1.2mkg,8.7ftlb)LTPickuprotorcoverboltM6612Nm(1.2mkg,8.7ftlb)BreathercoverboltM6412Nm(1.2mkg,8.7ftlb)BreatherplateboltM6310Nm(1.0mkg,7.2ftlb)LTPlateboltM6112Nm(1.2mkg,8.7ftlb)LT

PlateboltM6112Nm(1.2mkg,8.7ftlb)LTPickuprotorcoverblindboltM8115Nm(1.5mkg,11ftlb)OillevelplugM2011.5Nm(0.15mkg,1.1ftlb)GeneratorrotorcoverplugM2018.0Nm(0.8mkg,5.8ftlb)Maingalleryplug(oilreturn)M1638.0Nm(0.8mkg,5.8ftlb)MaingalleryplugM2018.0Nm(0.8mkg,5.8ftlb)

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TIGHTENINGTORQUES

ItemThreadsizeQtyTighteningtorqueRemarksOilreturnpipeboltM6210Nm(1.0mkg,7.2ftlb)LTOilreturnplugM12224Nm(2.4mkg,17ftlb)LTACmagnetoleadboltM6110Nm(1.0mkg,7.2ftlb)LTStatorcoilscrewM6314Nm(1.4mkg,10ftlb)LTGeneratorrotorcoverscrewM6310Nm(1.0mkg,7.2ftlb)LTThermostatassemblystayboltM6210Nm(1.0mkg,7.2ftlb)StarterclutchidlergearboltM6110Nm(1.0mkg,7.2ftlb)LTClutchbossnutM201115Nm(11.5mkg,83ftlb)UsealockwasherEClutchspringboltM6610Nm(1.0mkg,7.2ftlb)DrivesprocketnutM22185Nm(8.5mkg,61ftlb)UsealockwasherLTBearingplateboltM6312Nm(1.2mkg,8.7ftlb)LTShiftbarstopperplateboltM6210Nm(1.0mkg,7.2ftlb)LTStopperscrewM8122Nm(2.2mkg,16ftlb)LT

ShiftrodnutM616.5Nm(0.65mkg,4.7ftlb)LeftthreadShiftrodnutM616.5Nm(0.65mkg,4.7ftlb)JointrodboltM6110Nm(1.0mkg,7.2ftlb)LTShiftarmboltM6110Nm(1.0mkg,7.2ftlb)NeutralswitchM10120Nm(2.0mkg,14ftlb)CoolanttemperaturesensorM12118Nm(1.8mkg,13ftlb)CylinderidentificationsensorboltM618.0Nm(0.8mkg,5.8ftlb)LTAtmosphericpressuresensorscrewM527.0Nm(0.7mkg,5.0ftlb)CrankshaftpositionsensorboltM6110Nm(1.0mkg,7.2ftlb)LT

OillevelswitchboltM6210Nm(1.0mkg,7.2ftlb)

NOTE:

Cylinderheadnut(2pieces)1.First,tightentheboltsto10Nm(1.0mkg,7.2ftlb)withatorquewrenchfollowingthetighteningorder.2.Second,tightentheboltsto25Nm(2.5mkg,18ftlb)withatorquewrenchfollowingthetighteningorder.

3.Third,tightentheboltsto40Nm(4.0mkg,29ftlb)withatorquewrenchfollowingthetighteningorder.4.Final,tightentheboltsto55Nm(5.5mkg,40ftlb)withatorquewrenchfollowingthetighteningorder.Cylinderheadnut(8pieces)1.


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First,tightentheboltsto10Nm(1.0mkg,7.2ftlb)withatorquewrenchfollowingthetighteningorder.2.Second,tightentheboltsto25Nm(2.5mkg,18ftlb)withatorquewrenchfollowingthetighteningorder.2-15


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TIGHTENINGTORQUES

3.Final,tightentheboltsto40Nm(4.0mkg,29ftlb)withatorquewrenchfollowingthetighteningorder.Crankcasebolt(mainjournal)1.First,tightentheboltstoapproximately20Nm(2.0mkg,14ftlb)withatorquewrenchfollowingthetighteningorder.2.Loosenalltheboltsonebyonefollowingthetighteningorderandthentightenthemto20Nm(2.7mkg,14ftlb)again.3.Retightentheboltsfurthertoreachthespecifiedangle(56-61).Cylinderheadtighteningsequence:

Crankcasetighteningsequence:

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TIGHTENINGTORQUES

EAS20350

CHASSISTIGHTENINGTORQUES

ItemThreadsizeQtyTighteningtorqueRemarksUpperbracketpinchboltM8226Nm(2.6mkg,19ftlb)SteeringstemnutM281113Nm(11.3mkg,82ftlb)HandlebarpinchboltM8217Nm(1.7mkg,12ftlb)HandlebarboltM6213Nm(1.3mkg,9.4ftlb)CapboltM46223Nm(2.3mkg,17ftlb)LowerringnutM302SeeNOTELowerbracketpinchboltM8423Nm(2.3mkg,17ftlb)BrakemastercylinderreservoircapscrewM411.2Nm(0.12mkg,0.9ftlb)FrontbrakehoseunionboltM10330Nm(3.0mkg,22ftlb)Frontbrakemastercylinderholderbolt

M6213Nm(1.3mkg,9.4ftlb)Meterassemblyandcowlingstayscrew31.3Nm(0.13mkg,0.9ftlb)Headlightandcowlingstayscrew60.8Nm(0.08mkg,0.6ftlb)Frontcowlingandheadlightscrew51.5Nm(0.15mkg,1.1ftlb)SidecowlingbracketandframeboltM625.0Nm(0.5mkg,3.6ftlb)UndercowlingandengineboltM635.0Nm(0.5mkg,3.6ftlb)RearviewmirrornutM647.0Nm(0.7mkg,5.1ftlb)Frontcowlingandintakeairductpanelscrew

M521.3Nm(0.13mkg,0.9ftlb)GripendboltM624.0Nm(0.4mkg,2.9ftlb)HornbracketboltM6211Nm(1.1mkg,8.0ftlb)CoolantreservoirboltM625.0Nm(0.5mkg,3.6ftlb)LeftfrontenginemountingboltM10145Nm(4.5mkg,33ftlb)RightfrontenginemountingboltM10145Nm(4.5mkg,33ftlb)Enginemountselflockingnut(upper)M10151Nm(5.1mkg,37ftlb)SeeNOTEEEnginemountselflockingnut

(lower)M10151Nm(5.1mkg,37ftlb)SeeNOTEEEnginemountingadjustbolt(upper)M1617.0Nm(0.7mkg,5.1ftlb)SeeNOTE


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Enginemountingadjustbolt(lower)M1617.0Nm(0.7mkg,5.1ftlb)SeeNOTEClutchcablelocknut(engineside)M817.0Nm(0.7mkg,5.1ftlb)MainframeandrearframeboltM10441Nm(4.1mkg,30ftlb)SeeNOTELTPivotshaftM3017.0Nm(0.7mkg,5.1ftlb)LSPivotshaftringnutM30165Nm(6.5mkg,47ftlb)PivotshaftnutM201105Nm(10.5mkg,76ftlb)

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TIGHTENINGTORQUES

ItemThreadsizeQtyTighteningtorqueRemarksConnectingarmnut(connectingarmandframe)M10144Nm(4.4mkg,32ftlb)Relayarmnut(relayarmandconnectingarm)M10144Nm(4.4mkg,32ftlb)Relayarmnut(relayarmandswingarm)M10144Nm(4.4mkg,32ftlb)RearshockabsorberassemblylowernutM10144Nm(4.4mkg,32ftlb)RearshockabsorberupperbracketnutM10144Nm(4.4mkg,32ftlb)Rearshockabsorberassemblyuppernut

M10192Nm(9.2mkg,67ftlb)DrivechainguardboltM627.0Nm(0.7mkg,5.1ftlb)DrivechainguideboltM6113Nm(1.3mkg,9.4ftlb)DrivechainadjustinglocknutM8216Nm(1.6mkg,12ftlb)FuelpumpboltM564.0Nm(0.4mkg,2.9ftlb)Fueltankbolt(front)M617.0Nm(0.7mkg,5.1ftlb)FueltankbracketboltM627.0Nm(0.7mkg,5.1ftlb)Fueltankbolt(rear)M647.0Nm(0.7mkg,5.1ftlb)FueltanksidecoverscrewM524.0Nm(0.4mkg,2.9ftlb)RiderseatboltM627.0Nm(0.7mkg,5.1ftlb)SeatlockassemblyboltM6210Nm(1.0mkg,7.2ftlb)UppertailcoverboltM514.0Nm(0.4mkg,2.9ftlb)BatteryboxboltM627.0Nm(0.7mkg,5.1ftlb)

LeananglesensorboltM422.0Nm(0.2mkg,1.4ftlb)FootrestbracketboltM8428Nm(2.8mkg,20ftlb)RearbrakemastercylinderboltM8223Nm(2.3mkg,17ftlb)RearbrakehoseunionboltM10230Nm(3.0mkg,22ftlb)SidestandandbracketnutM10161Nm(6.1mkg,44ftlb)LTSidestandbracketandframeboltM10263Nm(6.3mkg,46ftlb)LTFrontwheelaxleboltM14191Nm(9.1mkg,66ftlb)RearwheelaxlenutM241150Nm(15.0mkg,108ftlb)FrontbrakecaliperboltM10435Nm(3.5mkg,25ftlb)FrontbrakediscboltM61018Nm(1.8mkg,13ftlb)LTRearbrakediscboltM8530Nm(3.0mkg,22ftlb)LTRearwheelsprocketnutM106100Nm(10.0mkg,72ftlb)BrakecaliperbleedscrewM836.0Nm(0.6mkg,4.3ftlb)

FrontwheelaxlepinchboltM8421Nm(2.1mkg,15ftlb)SeeNOTE

NOTE:

Lowerringnut1.First,tightenthelowerringnutapproximately52Nm(5.2mkg,38ftlb)byusingthetorque


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wrench,thenloosentheringnutcompletely.2.Retightenthelowerringnut18Nm(1.8mkg,13ftlb).2-18


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TIGHTENINGTORQUES

EnginemountingadjustboltandenginemountselflockingnutReferto"INSTALLINGTHEENGINE"onpage5-7.Frontwheelaxlepinchbolt1.Insertthefrontwheelaxlefromtherightsideandtightenitwiththeflangeboltfromtheleftsideto91Nm(9.1mkg,65.8ftlb).2.Intheorderfromthepinchbolt2.pinchbolt1.pinchbolt2,tighteneachboltto21Nm(2.1mkg,15ftlb)withoutperformingtemporarytightening.3.Checkthattheendfaceoftheaxleheadandtheendfaceoftheforksideareflush-mounted.Iftheyareoutofalignment,makesuretofitthembyaddingtheexternalforcebyhandorwithaplastichammer,etc.Iftheendfaceoftheaxleisnotparalleltotheendfaceofthefork,alignthemsothatonepointoftheaxlecircumferenceispositionedontheendfaceofthefork.

Atthisstage,itcanbeacceptediftheendfaceoftheaxlebecomespartiallyconcavetotheendfaceofthefork.4.Intheorderfromthepinchbolt4.pinchbolt3.pinchbolt4,tighteneachboltto21Nm(2.1mkg,15ftlb)withoutperformingtemporarytightening.Mainframeandrearframebolt1.Checktheclearancebetweenrearframeandmainframebythicknessgauge1.Insertadjustingshim(s)toeliminatethegapaccordingtothechartasshownbelow.ThicknessShim(s)

Under0.5mm(Under0.01969in)NONE0.511.0mm(0.020080.03937in)Oneshimontheleftside1.011.5mm(0.039760.05906in)Twoshimsontheleftside1.512.0mm(0.059450.07874in)Threeshimsontheleftside2.012.5mm(0.079130.09843in)Threeshimsontheleftsideandoneshimontherightside2.513.0mm(0.098820.11811in)Threeshimsontheleftsideandtwoshimsontherightside

Shim:0.5mm(0.02in)

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LUBRICATIONPOINTSANDLUBRICANTTYPES

EAS20360


EAS20370

ENGINE

LubricationpointLubricantOilseallipsLSO-ringsLSBearingsECrankshaftpinsEPistonsurfacesEPistonpinsEConnectingrodboltsMCrankshaftjournalsECamshaftlobesMCamshaftjournalsMValvestems(intakeandexhaust)M

Valvestemends(intakeandexhaust)EWaterpumpimpellershaftEOilpumprotors(innerandouter)EOilpumphousingEOilstrainerEClutch(pullrod)LSStarterclutchidlegearinnersurfaceEStarterclutchassemblyEPrimarydrivengearETransmissiongears(wheelandpinion)MMainaxleanddriveaxleMShiftdrumEShiftforksandshiftforkguidebarsE

CylinderheadcovermatingsurfaceYamahabondNo.1215CylinderheadcoversemicircularYamahabondNo.1215CrankcasematingsurfaceYamahabondNo.1215CrankcasecovermatingsurfaceYamahabondNo.1215Generatorrotorcover(statorcoilassemblyleadgrommet)

YamahabondNo.1215

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EAS20380

CHASSIS

LubricationpointLubricantSteeringbearingsandbearingraces(upperandlower)LSThrottlegripinnersurfaceLSBrakeleverpivotingpointandmetal-to-metalmovingpartsLSClutchleverpivotingpointandmetal-to-metalmovingpartsLSEnginemountbolts(rearupperandlower)LSRelayarm,connectingrodandrearshockabsorbercollarLSPivotshaftLSSwingarmpivotbearingLSSwingarmheadpipeend,oilsealandbushLSOilseal(relayarm,connectingarmandrearshockabsorber)LSSeatlockassemblymovingpartsLSSidestandpivotingpintandmetal-to-metalmovingpartsLSLinkandsidestandswitchcontactpointLSSidestandhookandspringLSShiftshaftjointLS

Frontwheeloilseal(rightandleft)LSFrontaxleshaftLSRearwheeloilsealLSRearwheeldrivehuboilsealLSRearwheeldrivehubmatingsurfaceLS

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2-22


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LUBRICATIONSYSTEMCHARTANDDIAGRAMS

EAS20390


EAS20400

ENGINEOILLUBRICATIONCHART

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1.Oilstrainer2.Oilpump3.Reliefvalve4.Oilcooler5.Oilfilter6.Maingallery7.ACmagnetodrivegearshower8.Shiftfork(upper)9.Mainaxle10.Missionshower11.Driveaxle12.ACmagnetoaxle13.Pistoncooler14.Chaintensioner15.Intakecamshaft16.Exhaustcamshaft2-24


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LUBRICATIONSYSTEMCHARTANDDIAGRAMS2-25EAS20410LUBRICATIONDIAGRAMS


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1.Intakecamshaft2.Exhaustcamshaft3.Oilfiltercartridge4.Oillevelswitch2-26


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LUBRICATIONSYSTEMCHARTANDDIAGRAMS2-27


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1.Intakecamshaft2.Exhaustcamshaft3.Crankshaft4.Oilcooler5.Reliefvalve6.Oilpipe7.Oilstrainer8.Oilpump2-28


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2-29


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1.Oilfiltercartridge2.Oillevelswitch3.Oilpump4.Oilstrainer5.Oilpipe6.Oilcooler2-30


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LUBRICATIONSYSTEMCHARTANDDIAGRAMS2-31A-AAA


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1.Mainaxle2.Oildeliverypipe3.Driveaxle2-32


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LUBRICATIONSYSTEMCHARTANDDIAGRAMS2-33


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1.Cylinderhead2.Crankshaft2-34


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COOLINGSYSTEMDIAGRAMS2-35EAS20420COOLINGSYSTEMDIAGRAMS


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COOLINGSYSTEMDIAGRAMS

1.Waterpump2.Radiator3.Radiatorfan2-36


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COOLINGSYSTEMDIAGRAMS2-37


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COOLINGSYSTEMDIAGRAMS

1.Radiatorcap2.Radiator3.Oilcooler4.Thermostat2-38


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CABLEROUTING

EAS20430

CABLEROUTING

2-39


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CABLEROUTING

1.Groundlead2.Meterlead3.Headlightstay4.Rightheadlightlead(highbeam)5.Rightauxiliarylightlead6.Intakeairtemperaturesensorcoupler7.Headlightlead8.LeftAuxiliarylightlead9.Leftheadlightlead(highbeam)10.Rightconsolepanel11.Rightintakeairduct12.Leftintakeairduct13.LeftconsolepanelA.Inserttotheriboftheheadlight.(Eitherlocationoftherightandleftrelaysisacceptable.)B.Theleadshouldnotstretchtoomuch.Directionofthegroundterminalcanbeeithertopsideorflipside.

C.Makesuretoinsertthecouplerandboottothestayhole.D.Thespeedometerleadshouldnotbestrained.E.TotheheadlightstayholeF.Routebytherearsideofthevehicleawayfromtherightauxiliarylightlead.G.Connectafterpassingovertheuppersideoftheduct.H.TotheturnsignallightI.

Pastethelatchoftheclamptobepositionedtowardtherearsideofthevehicle.J.Thereshouldbenoslackwhenclamping.Pointthetipoftheclamp(excessivepart)tothefrontsideofthevehicle.Fastentheheadlightleadwithaclamp.K.Clamptheheadlightlead.Cutthetipoftheclamp.L.TothewireharnessM.Routebytherearsideofthevehicleawayfromtheleftauxiliarylightlead.N.FeedaleadwirethroughtheUshapecutout

oftheconsolepanel.2-40


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CABLEROUTING

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CABLEROUTING

1.Righthandlebarswitchlead2.Clutchcable3.Mainswitchlead4.Lefthandlebarswitchlead5.Hornlead6.Horn7.Throttlecables8.Brakehose9.Throttlecable(returnside)10.Throttlecable(pullside)A.Routetheclutchcablesoastogetalongthefrontsideofthemainswitchafterpassingitthroughtheguide.B.Passthemainswitchleadthroughtheguidewire.C.Passthelefthandlebarswitchleadthroughtheguidewire.D.Passtheclutchswitchleadthroughoutside

ofthelefthandlebarswitchlead.E.Pointthetipoftheband(excessivepart)totheleftsideofthevehicleandcutthesurplussection.F.Clampthesectionbetween0and20mm(0and0.79in)fromthesplitoftheunderbracket.G.Clamptheleadsinsidethefrontforkofthevehicle.Pointtheexitofthehornleadtotheleftfrontforkside.H.Fitintheclampfromtheinnersidetotheoutersideofthevehiclesothatthereturn

sideispositionedupperandthepullsideislowerattheuppersideofthevehicleabovethebrakehose.I.0to30mm(0to1.18in)J.Routetwothrottlecablesbehindthebrakehose,passbetweentheinsideoftheunderbracketsuppersidefrontfork.K.20to40mm(0.8to1.6in)L.Pointthetipoftheband(excessivepart)totherightsideofthevehicleandcutthesurplussection.

M.Passthelefthandlebarswitchleadthroughuppersideofthesteeringdamperbracket.N.Cuttheclamptipleaving2to4mm(0.08to0.16in).O.Outsideofthevehicle.P.Insideofthevehicle.2-42


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CABLEROUTING

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CABLEROUTING

1.Wireharness2.Crankshaftpositionsensorlead3.Bracket4.Ignitioncoillead5.Righthandlebarswitchlead6.Radiatorfanmotorlead7.Heatprotector8.Rightradiatorfanmotorlead9.Coolantreservoirtank10.Coolantreservoirdrainhose11.Hoseclamp12.O2sensorlead13.Rearbrakelightswitch14.Protector15.Rightintakeairduct16.Rightairoutletgrille17.Cover18.Waterhose19.Clutchcable

20.Radiatorstayguide21.RadiatorA.Clampitafterpassingbetweentheframeandradiatorstay.Aligntheclamppositionwiththetapingsectionsofrighthandlebarswitchlead.Pointthetipoftheclamp(excessivepart)tothefrontsideofthevehicle.Fastentherighthandlebarswitchleadwithaclamp.B.Passtheclutchcablethroughinsideofthewaterhose.

Routetheradiatorfanmotorleadbytheoutsideoftheclutchcableafterroutingitbytheinnersideofthewaterhose.C.Routethecoolantreservoirdrainhosebytheoutsideofthewaterhoseafterroutingitbytheinnersideoftheradiatorcapmountingsection.D.Checkthattheradiatorfanmotorleadisfixedwiththeguideoftheradiatorstay.E.Clampsothattheclamptopendissetalongwiththebottomendofthehoseclamp.

Pointthetipoftheclamp(excessivepart)tothefrontsideofthevehicle.Fastentheclutchcablewithaclamp.F.Clampsothatthecoolantreservoirdrainhoseispositionedatthefrontsideofthevehiclebyaligningtheprotectorendpartofthecoolantreservoirdrainhosewiththeradiatorbottomend.Fastentheclutchcableandcoolantreservoir


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drainhosewithaclamp.G.TotheengineH.Clampthecoolantreservoirdrainhosetothelowersideofthevehicle.Fastentheclutchcableandcoolantreservoirdrainhosewithaclamp.I.80to100mm(3.15to3.94in)J.Cuttheclamptipleaving2to4mm(0.08to0.16in).K.RoutetherearbrakelightswitchleadbytheoutersideofthevehiclethantheO2sensorleadandpushitintothematingsurfacesectionoftheclutchcover.L.Pointthetipoftheclamp(excessivepart)tothelowerfrontsideofthevehicle.Fastentherighthandlebarswitchlead,radiatorfanmotorleadandignitioncoilleadwithaclamp.M.Pointthetipoftheclamp(excessivepart)totheuppersideofthevehicle.Fastentherighthandlebarswitchlead,radiatorfanmotorleadandignitioncoil

leadwithaclamp.N.Passtherighthandlebarswitchleadandradiatorfanmotorleadbetweentheframeandheatprotector.O.Clampsothatthereisnoslackattheleftsideofthevehicle.Fastentheairinductionsystemsolenoidlead,cylinderidentificationsensorlead,ignitioncoilleadandairinductionsystemsolenoidhosewithaclamp.P.Thecouplerfortheairinductionsystemsolenoidleadandcylinderidentificationsensorleadshouldbeconnectedabove

theignitioncoilsubwireharnessanditshouldnotdroponthecylinderheadcoverbehindtheignitioncoil.Q.Clamptheclutchcablesothatitiswithinthisspecifiedclamp(90).R.Routetheleadtobepositionedbytheinnersideofthevehiclethanthetipoftheclamp(excessivepart.)S.Itshouldnotentertheinnersideofthevehiclethantheradiatorstayguide.2-44


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CABLEROUTING

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CABLEROUTING

1.Leftradiatorfanmotorlead2.Heatprotector3.Lefthandlebarswitchlead4.Mainswitchlead5.Bracket6.EXUPservomotorlead7.Cover8.Fueltankdrainhoseandfueltankbreatherhose9.Waterpipe10.Sidestandswitchlead11.Oillevelswitchlead12.ACmagnetolead13.Headlightlead14.Fuseboxstay15.Fusebox16.Wireharness17.Cover18.Leftairoutletgrille19.Leftintakeairduct

20.Waterhose21.Stay22.Fueltankdrainhose23.Fueltankbreatherhose24.Chaincasecover25.Intakeairtemperaturesensorlead26.HeadlightleadandleftturnsignallightleadA.Clamptheleadssothattheyarepositionedinnerofthevehiclethanthewasherpositionafterroutingthembetweentheframeandradiatorstay.Aligntheclamppositionwiththetapingsectionsofleads.

Pointthetipoftheclamp(excessivepart)tothelowerfrontsideofthevehicle.Whattheclampfastensatthisstagearethehandlebarswitchandmainswitchleads.B.Checkthattheradiatorfanmotorleadisfixedwiththeguideoftheradiatorstay.C.Passthemainswitchleadandlefthandlebarswitchleadbetweentheframeandtheheatprotector.D.Pointthetipoftheclamp(excessivepart)

tothelowerfrontsideofthevehicle.Fastenthelefthandlebarswitchleadandmainswitchleadwithaclamp.E.Foldbacktheclampandsecureitafterpassingtheleadthroughtheclamp.F.TotheEXUPservomotorG.Passthefueltankdrainhoseandfueltankbreatherhosethroughtheholeofthecoverfromtheoutsideofthewaterpipeafter


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passingthewaterhosethroughfirst.AnydirectionofthehosecutedgecanbeacceptedH.40to60mm(1.57to2.36in)I.Routethesidestandswitchleadbytheinsideofthewaterhoseandwaterpipe.J.Routetheoillevelswitchleadbytheinsideofthewaterhoseandwaterpipe.K.Thereshouldbenoexposureofbaredconductorsduetothedisplacementofthetube.L.Routebytheoutsideofvehicleawayfromthewaterhose.M.Pointthetipoftheclamp(excessivepart)tothefrontinsideofthevehicle.Fastenthewireharnessandleftradiatorfanmotorleadwithaclamp.N.Aligntheclamppositionwiththetapingsectionsofheadlightlead.Pointthetipoftheclamp(excessivepart)totherearinsideofthestay.Fastentheheadlightlead,intakeairtemperature

sensorleadandwireharnesswithaclamp.O.TotheintakeairtemperaturesensorP.Pointthetipoftheclamp(excessivepart)tothefrontinsideofthevehicle.Fastenthewireharnessandleftradiatorfanmotorleadwithaclamp.Q.AligntheclamppositionwiththetapingsectionsofwireharnessPointthetipoftheclamp(excessivepart)totheinsideofthevehicle.Fastenthewireharnessandleftradiatorfanmotorleadwithaclamp.

R.Routethewaterhosesothatitisplacedattheoutermostpositionfinallyafterroutingotherleadsandhosesintheguide.S.Alignthemoldedpartofthefueltankdrainhoseandfueltankbreatherhosewiththestay.T.Canberoutedinanyorder.2-46


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CABLEROUTING

2-47


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CABLEROUTING

1.Throttlecables2.Rectifier/regulator3.Rectifier/regulatorlead4.Rightairoutletgrille5.Airinductionsystemsolenoidhose6.Intakefunnelservomotorlead7.O2sensorlead8.Rearbrakelightswitchlead9.Crankshaftpositionsensorlead10.Enginegroundlead11.Batterynegativelead12.Neutralswitchlead13.Speedsensorlead14.Oillevelswitchlead15.Sidestandswitchlead16.Fueltankdrainhose17.ACmagnetolead18.Pulleycoverrib19.Atmosphericpressuresensor20.Leftairoutletgrille

21.Leftradiatorfanmotorlead22.Cover223.Wireharness24.Throttlepositionsensor(forthrottlevalves)lead25.Atmosphericpressuresensorlead26.Frame27.Locatingdamper28.Throttlebody

A.Totherighthandlebarswitchlead.B.Passitsothatthereisnotorsionthrough

theclampwhichinsertedtothecover.C.TotheengineD.Passtherectifier/regulatorleadthroughthenotchholeofthecover.E.TothethrottlebodyF.TotheintakefunnelservomotorG.Intakefunnelservomotorleadshouldberoutedbythefrontandoutersidethantheairinductionsystemsolenoidhose.H.Clampthewireharnesswindinginandinsertittotheframehole.

I.Afterconnectingthecoupler,makesuretoinsertitbetweenthedeliverypipeandthermostat.J.Forroutingthefuelhoses,refertothefueltanksection.K.TothestartermotorL.TotheairfiltercaseM.Pointthetipoftheclamp(cutthetipoftheclampleaving2to4mm(0.08to0.16in).)


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totheinsideofthevehicle.Fastenthewireharnessandcrankshaftpositionsensorleadwithaclamp.N.Allhosesandleadsshouldberoutedoverthevehiclesuppersideabovetheheatprotector.O.TothefuelpumpP.TothespeedsensorQ.Clampthewireharnesswindinginandinsertittotheframehole.R.Installtheleadssothattheenginegroundleadispositionedlowerandthebatterynegativeleadtobeupper.Installtheprotrusionofeachleadtobeabovethevehicle.S.Itshouldnotbepositionedontheharness.T.Routeitunderthewireharness,speedsensorlead,O2sensorleadandrearbrakelightswitchlead.U.Pointthetipoftheclamp(cutthetipofthe

clampleaving2to4mm(0.08to0.16in).)totheinsideofthevehicle.Fastenthewireharness,oillevelswitchleadandsidestandswitchleadwithaclamp.V.AligntheclamppositionwiththetapingsectionsPointthetipoftheclamp(cutthetipoftheclampleaving2to4mm(0.08to0.16in).)totheuppersideofthevehicle.FastentheACmagnetoleadwithaclamp.W.RoutetheACmagnetoleadbytheoutside

ofthepulleycoverrib.X.Clampthewireharnesswindinginandinsertittotheframehole.Y.PasstheACmagnetoleadthroughthenotchholeofthecover2.Z.TothethrottlecableleverAA.TotheradiatorAB.ClamptheACmagnetolead.AC.Tothethrottlepositionsensor(forthrottlevalves)AD.Routeeachleadlowerthantheframeplate.

Leadsshouldberoutedinrandomorder.Clampcanbeinsertedinanydirection.AE.Routeeachleadhigherthantheframeplate,passittotheinsideofthevehiclefromthehole.Leadsshouldberoutedinrandomorder.Clampcanbeinsertedinanydirection.AF.Passthesidestandswitchleadbehindthecanisterstay,andthroughtherearsideofthevehicle.


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AG.Passtheoillevelswitchleadbehindthecanisterstay,andthroughtherearsideofthevehicle.AH.Passthefueltankdrainhosebehindthecanisterstay,andthroughtherearsideofthevehicle.AI.Passthewireharnessbehindthecanisterstay,andthroughtheupsideofthevehicle.AJ.Forroutingtheclamp,refertothecanistersection.

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CABLEROUTING

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CABLEROUTING

1.Starterrelaylead2.Startermotorlead3.Batterypositivelead4.Leananglesensor5.Turnsignalrelay6.Mainfuse7.Turnsignallight/licenseplatelightlead8.Tail/brakelightlead9.Tail/brakelightbracket10.Lowertailcover11.Seatlockcable12.Antisafetyalarmcoupler13.Startingcircuitcut-offrelay14.Batterynegativelead15.Starterrelay16.Rearframe17.Reararmbracket18.Wireharness

19.Batterybox120.Battery21.ECU(enginecontrolunit)22.Cover23.Batterybox224.Licenseplatelightlead25.Turnsignallightlead26.MudguardA.Pointthetipoftheclamp(excessivepart)totheinnerdownsideofthevehicleandclampatthejunctionofthewireharness.Fastenthebatterynegativelead,wireharnessandstartermotorleadwithaclamp.

B.Pointthetipoftheclamp(excessivepart)totheinsideofthevehicle.Fastenthewireharnesswithaclamp.C.Holddowntheclamptipsafterpassingeachlead.D.Inserttheleadstotherearframehole.E.Inserttheclampfromthevehiclefronttotherearsideandfasteneachleads,couplerandonionheadtothetail/brakelightbracket,andthenpointthetipoftheclamp(excessivepart)tothelowerfrontsideof

thevehicle.F.Itshouldbesetintherearframenottobecaughtinthesheetbottomorthecovers.G.Passthebatterynegativeleadthroughinsideofthebatteryband.H.Batterynegativeleadshouldnotrunonthereararmbracket.I.Allleadsshouldbepositionedlowerthan


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thetail/brakelightbracket.2-50


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CABLEROUTING

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CABLEROUTING

1.Fueltank2.O-ring3.Fuelhose4.Fueltankdrainhose5.Fueltankbreatherhose6.Airfilterstay7.Clip8.Fueltankbracket9.Fuelhoseclamp10.FuelpumpassemblyA.InstallthelipofO-ringfacingupward.B.Installthepartpointingthewhitepaintpartofthehosetotheleftsideofthevehicle.C.Pointtheclipgriptotheinsideofthevehicle.

D.Fuelpipingconnectorattachmentdirections.(fuelpumpside)Alwaysusehandstoconnect/disconnecttheconnectorwithoutusingtool.E.Inserttheconnectoruntiltheclicksoundisheardandcheckthattheconnectordoesnotcomeoff.Makesurethatnoforeignmatteriscaughtinthesealingsection.(Itisprohibitedtowearthecottonworkglovesorequivalentcoverings.)F.

AfteritemEmentionedaboveisfinished,checkthattheclampisinsertedfromthedownsidea,bandcsectionsareperfectlyequipped.G.Thispartworksasadropoutstopper.H.Fuelpipingconnectorattachmentdirections.(engineside)Alwaysusehandstoconnect/disconnecttheconnectorwithoutusingtool.I.AfterStepHasaboveisfinished,checkthattheconnectoriscompletelyattachedbyslidingthedoublelock(orangepart)d

ontheconnectorasshownintheillustrationandseeingifittouchesfirmlyornot.2-52


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CABLEROUTING

ForCalifornia

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CABLEROUTING

1.Frame2.Canisterstay3.Fueltankdrainhose4.Clip5.Pipe36.Clamp7.Rivet8.Rollovervalveassembly9.Pipe410.Canisterhose11.Canisterassembly12.BracketA.InsertthehoseuntilitreachestheR-bottomofthepipe.B.Installthepartpointingthewhitepaintmarktothefrontsideofthevehicle.C.Pointtheclipgriptotheuppersideofthevehicle.

D.TothethrottlebodyE.Theknoboftheclipcanbepositionedinanydirection.F.Installthepartpointingthewhitepaintmarktotheleftsideofthevehicle.G.Installthepartpointingtheyellowpaintmarktotheleftsideofthevehicle.H.Pointtheclipgriptothedownsideofthevehicle.I.Insertthehosesothatitstipofthenipple

doesnotprotrude.2-54


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CABLEROUTING

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PERIODICCHECKSANDADJUSTMENTS

PERIODICMAINTENANCE.........................................................................3-1INTRODUCTION....................................................................................3-1

ENGINE.........................................................................................................3-4ADJUSTINGTHEVALVECLEARANCE................................................3-4SYNCHRONIZINGTHETHROTTLEBODIES.......................................3-7ADJUSTINGTHETHROTTLECABLEFREEPLAY..............................3-8CHECKINGTHESPARKPLUGS...........................................................3-9MEASURINGTHECOMPRESSIONPRESSURE...............................3-10CHECKINGTHEENGINEOILLEVEL.................................................3-11CHANGINGTHEENGINEOIL.............................................................3-11MEASURINGTHEENGINEOILPRESSURE.....................................3-13

ADJUSTINGTHECLUTCHCABLEFREEPLAY................................3-14REPLACINGTHEAIRFILTERELEMENT...........................................3-14CHECKINGTHETHROTTLEBODYJOINTS......................................3-15CHECKINGTHEFUELLINE...............................................................3-15CHECKINGTHECRANKCASEBREATHERHOSE............................3-16CHECKINGTHEEXHAUSTSYSTEM.................................................3-16ADJUSTINGTHEEXUPCABLES.......................................................3-17CHECKINGTHEEXUPSERVOMOTOR.............................................3-18CHECKINGTHECOOLANTLEVEL....................................................3-18

CHECKINGTHECOOLINGSYSTEM.................................................3-19CHANGINGTHECOOLANT................................................................3-19

CHASSIS....................................................................................................3-22ADJUSTINGTHEFRONTDISCBRAKE.............................................3-22ADJUSTINGTHEREARDISCBRAKE...............................................3-22CHECKINGTHEBRAKEFLUIDLEVEL..............................................3-23

CHECKINGTHEFRONTBRAKEPADS..............................................3-24CHECKINGTHEREARBRAKEPADS................................................3-24CHECKINGTHEFRONTBRAKEHOSES...........................................3-24CHECKINGTHEREARBRAKEHOSE...............................................3-24ADJUSTINGTHEREARBRAKELIGHTSWITCH..............................3-25BLEEDINGTHEHYDRAULICBRAKESYSTEM.................................3-25ADJUSTINGTHESHIFTPEDAL.........................................................3-26


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ADJUSTINGTHEDRIVECHAINSLACK............................................3-27LUBRICATINGTHEDRIVECHAIN......................................................3-27CHECKINGANDADJUSTINGTHESTEERINGHEAD......................3-28CHECKINGTHEFRONTFORK..........................................................3-29ADJUSTINGTHEFRONTFORKLEGS..............................................3-30ADJUSTINGTHEREARSHOCKABSORBERASSEMBLY................3-31CHECKINGTHETIRES.......................................................................3-33CHECKINGTHEWHEELS..................................................................3-35CHECKINGANDLUBRICATINGTHECABLES..................................3-35LUBRICATINGTHELEVERS...............................................................3-35LUBRICATINGTHEPEDAL.................................................................3-35LUBRICATINGTHESIDESTAND.........................................................3-35LUBRICATINGTHEREARSUSPENSION..........................................3-35

3


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ELECTRICALSYSTEM..............................................................................3-36CHECKINGANDCHARGINGTHEBATTERY.....................................3-36CHECKINGTHEFUSES......................................................................3-36REPLACINGTHEHEADLIGHTBULBS...............................................3-36ADJUSTINGTHEHEADLIGHTBEAMS..............................................3-37


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PERIODICMAINTENANCE

EAS20450

PERIODICMAINTENANCE

EAS20460

INTRODUCTION

Thischapterincludesallinformationnecessarytoperformrecommendedchecksandadjustments.Iffollowed,thesepreventivemaintenanceprocedureswillensuremorereliablevehicleoperation,alongerservicelifeandreducetheneedforcostlyoverhaulwork.Thisinformationappliestovehiclesalreadyinserviceaswellastonewvehiclesthatarebeingpreparedforsale.Allservicetechniciansshouldbefamiliarwiththisentirechapter.

Periodicmaintenancechartfortheemissioncontrolsystem

NO.ITEMROUTINEINITIALODOMETERREADINGS600mi(1000km)or1month4000mi(7000km)or6months8000mi(13000km)or

12months12000mi(19000km)or18months16000mi(25000km)or24months20000mi(31000km)or30months

1*FuellineCheckfuelhosesforcracksordamage.Replaceifnecessary.vvvvv2*Sparkplugs


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Checkcondition.Adjustgapandclean.Replaceevery8000mi(13000km)or12months.vReplace.vReplace.v3*ValveclearanceCheckandadjustvalveclearancewhenengineiscold.Every26600mi(42000km)4*CrankcasebreathersystemCheckbreatherhoseforcracksordamage.Replaceifnecessary.vvvvv5*FuelinjectionAdjustsynchronization.vv

vvv6*ExhaustsystemCheckforleakage.Tightenifnecessary.Replacegasket(s)ifnecessary.vvvvv7*

Evaporativeemissioncontrolsystem(ForCaliforniaonly)Checkcontrolsystemfordamage.Replaceifnecessary.vv8*AirinductionsystemChecktheaircut-offvalve,reedvalve,andhosefordamage.Replaceanydamagedpartsif

necessary.vv

*Sincetheseitemsrequirespecialtools,dataandtechnicalskills,haveaYamahadealerperformtheservice.Generalmaintenanceandlubricationchart


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NO.ITEMROUTINEINITIALODOMETERREADINGS600mi(1000km)or1month4000mi(7000km)or6months8000mi(13000km)or12months12000mi(19000km)or18months16000mi(25000km)or24months20000mi(31000km)

or30months1*AirfilterelementCheckconditionanddamage.Replaceifnecessary.vvvvv2*ClutchCheckoperation.Adjustorreplacecable.

vvvvvv3*FrontbrakeCheckoperation,fluidlevel,andforfluidleakage.Replacebrakepadsifnecessary.vvv

vvv

3-1


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PERIODICMAINTENANCE

NO.ITEMROUTINEINITIALODOMETERREADINGS600mi(1000km)or1month4000mi(7000km)or6months8000mi(13000km)or12months12000mi(19000km)or18months16000mi(25000km)

or24months20000mi(31000km)or30months4*RearbrakeCheckoperation,fluidlevel,andforfluidleakage.Replacebrakepadsifnecessary.vvv

vvv5*BrakehosesCheckforcracksordamage.vvvvvReplace.Every4years6*WheelsCheckrunoutandfordamage.Replaceifnecessary.

vvvvv7*TiresChecktreaddepthandfordamage.Replaceifnecessary.Checkairpressure.


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Correctifnecessary.vvvvv8*WheelbearingsCheckbearingsforsmoothoperation.Replaceifnecessary.vvvvv9*SwingarmpivotbearingsCheckbearingassembliesforlooseness.Moderatelyrepackwithlithiumsoap-basedgrease.vRepack.

10DrivechainCheckchainslack,alignmentandcondition.AdjustandlubricatechainwithaspecialO-ringchainlubricantthoroughly.Every500mi(800km)andafterwashingthevehicleorridingintherain11*SteeringbearingsCheckbearingassembliesforlooseness.Moderatelyrepackwithlithiumsoap-basedgreaseevery16000mi(25000km)or24

months.vvvvRepack.v12*SteeringdamperCheckoperationandforoilleakage.vvvv

v13*ChassisfastenersCheckallchassisfittingandfasteners.Correctifnecessary.vvvvv


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14BrakeandclutchleverpivotshaftsApplylithium-soap-basedgrease(all-purposegrease)lightly.vvvvv15ShiftpedalrodpivotsApplylithium-soap-basedgrease(all-purposegrease)lightly.vvvvv16SidestandpivotCheckoperation.

Applylithium-soap-basedgrease(all-purposegrease)lightly.vvvvv17*SidestandswitchCheckoperationandreplaceifnecessary.vv

vvvv18*FrontforkCheckoperationandforoilleakage.Replaceifnecessary.vvvvv

19*ShockabsorberassemblyCheckoperationandforoilleakage.Replaceifnecessary.vvvv


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v20*RearsuspensionlinkpivotsCheckoperation.Correctifnecessary.vv21EngineoilChange(warmenginebeforedraining).vvvvvv22*EngineoilfiltercartridgeReplace.vvv

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PERIODICMAINTENANCE

NO.ITEMROUTINEINITIALODOMETERREADINGS600mi(1000km)or1month4000mi(7000km)or6months8000mi(13000km)or12months12000mi(19000km)or18months16000mi(25000km)

or24months20000mi(31000km)or30months23*CoolingsystemCheckhosesforcracksordamage.Replaceifnecessary.vvv

vvChangewithethyleneglycolantifreezecoolantevery24months.Change.24*EXUPsystemCheckoperation,cablefreeplayandpulleyposition.vvvv

v25*FrontandrearbrakeswitchesCheckoperation.vEvery12000mi(19000km)26*ControlcablesApplyYamahachainandcablelubeorengineoilSAE10W-30thoroughly.


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vvvvvv27*ThrottlegriphousingandcableCheckoperationandfreeplay.Adjustthethrottlecablefreeplayifnecessary.Lubricatethethrottlegriphousingandcable.vvvvv28*Lights,signalsandswitchesCheckoperation.Adjustheadlightbeam.

vvvvvv

*Sincetheseitemsrequirespecialtools,dataandtechnicalskills,haveaYamahadealerperformtheservice.NOTE:

From24000mi(37000km)or36months,repeatthemaintenanceintervalsstartingfrom8000mi(13000km)or12months.

NOTE:

AirfilterThismodelsairfilterisequippedwithadisposableoil-coatedpaperelement,whichmustnotbecleanedwithcompressedairtoavoiddamagingit.Theairfilterelementneedstobereplacedmorefrequentlywhenridinginunusuallywetordustyareas.

HydraulicbrakeserviceAfterdisassemblingthebrakemastercylindersandcalipers,alwayschangethefluid.Regularlycheckthebrakefluidlevelsandfillthereservoirsasrequired.Everytwoyearsreplacetheinternalcomponentsofthebrakemastercylindersandcalipers,andchangethebrakefluid.Replacethebrakehoseseveryfouryearsandifcrackedordamaged.3-3


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ENGINE

EAS20470

ENGINE

EAS20490

ADJUSTINGTHEVALVECLEARANCE

Thefollowingprocedureappliestoallofthevalves.

NOTE:

Valveclearanceadjustmentshouldbemadeonacoldengine,atroomtemperature.Whenthevalveclearanceistobemeasuredoradjusted,thepistonmustbeattopdeadcenter(TDC)onthecompressionstroke.1.Remove:

RiderseatReferto"GENERALCHASSIS"onpage41.FueltankReferto"FUELTANK"onpage7-1.AirfiltercaseReferto"GENERALCHASSIS"onpage41.LowercowlingsSidecowlingsReferto"GENERALCHASSIS"onpage41.ThrottlebodyassemblyReferto"THROTTLEBODIES"onpage74.Aircut-offvalveReferto"AIRINDUCTIONSYSTEM"on

page7-9.RadiatorRadiatorfanmotorReferto"RADIATOR"onpage6-1.2.Remove:IgnitioncoilsSparkplugsCylinderheadcoverCylinderheadcovergasketReferto"CAMSHAFTS"onpage5-9.3.Remove:

Pickuprotorcover14.Measure:ValveclearanceOutofspecification.Adjust.Valveclearance(cold)

Intake0.110.20mm(0.00430.0079in)


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Exhaust0.260.30mm(0.01020.0118in)

..............................

a.Turnthecrankshaftcounterclockwise.b.Whenpiston#1isatTDConthecompressionstroke,aligntheTDCmarkaonthegeneratorrotorwiththemarkbonthecrankcase.NOTE:

TDConthecompressionstrokecanbefoundwhenthecamshaftlobesareturnedawayfromeachother.

c.Measurethevalveclearancewithathicknessgauge2.NOTE:

Ifthevalveclearanceisincorrect,recordthemeasuredreading.Measurethevalveclearanceinthefollowingsequence.3-4


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ENGINE

Whenremovingthetimingchainandcamshafts,fastenthetimingchainwithawiretoret

2007 r 1 Service Manual

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