FZS1000(N) Service Manual

EAS00000

FZS1000 (N)SERVICE MANUAL

2000 by Yamaha Motor Co.Ltd.First edition, December 2000

All rights reserved. Any reproduction orunauthorized use without the written

permission of Yamaha Motor Co., Ltd. isexpressly prohibited.

NOTE:

CAUTION:

EAS00003

NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu-al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehiclesshould 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 ve-hicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard toperformance and emissions. Proper service with the correct tools in necessary to ensure that the ve-hicle will operate as designed. If there is any question about a service procedure, it is imperative thatyou contact a Yamaha dealer for any service information changes that apply to this model. This policyis intended to provide the customer with the most satisfaction from his vehicle and to conform with fed-eral environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers andwill appear in future editions of this manual where applicable.

This Service Manual contains information regarding periodic maintenance to the emission controlsystem. Please read this material carefully.

Designs and specifications are subject to change without notice.

EAS00004

IMPORTANT INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

126

4

5

7

3

8

EAS00007

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.1

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage 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 eachpage, 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 eachremoval and disassembly section.5

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly 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 ofparts, notes in jobs, etc.8

Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

22

1

3

5

7

9

2

4

8

6

24 25

2321

19 2018

16 1715

1413

11 12

10

GENINFO SPEC

ENG

CARB ELEC

COOL

CHKADJ

TRBLSHTG

CHAS

EAS00008

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 9 indicate the subject of eachchapter.1 General information2 Specifications3 Periodic checks and adjustments4 Chassis5 Engine6 Cooling system7 Carburetor(-s)8 Electrical system9 Troubleshooting

Symbols 10 to 17 indicate the following.10 Serviceable with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening torque15 Wear limit, clearance16 Engine speed17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.18 Engine oil19 Gear oil20 Molybdenum disulfide oil21 Wheel bearing grease22 Lithium soap base grease23 Molybdenum disulfide greaseSymbols 24 to 25 in the exploded diagrams indi-cate the following:24 Apply locking agent (LOCTITE)25 Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS ANDADJUSTMENTS

CHASSIS

ENGINE

COOLING SYSTEM

CARBURETORS

ELECTRICAL SYSTEM

TROUBLESHOOTING

GENINFO 1SPEC 2

3CHAS 4ENG 5

COOL 6CARB 7ELEC 8TRBLSHTG 9

CHKADJ

EAS00012

TABLE OF CONTENTS

GENINFO

CHAPTER 1GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2. . . . . . . . . . REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-2. . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENINFO

1-1

MOTORCYCLE IDENTIFICATIONGENINFO

EAS00014

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEAS00017

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head.

EAS00018

MODEL CODEThe model code label 1 is affixed to the frame.This information will be needed to order spareparts.

1-2

IMPORTANT INFORMATIONGENINFO

springlip

oilgrease

lip

EAS00020

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DIS-ASSEMBLY1. 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 matedparts together. This includes gears, cylin-ders, pistons and other parts that have beenmated through normal wear. Mated partsmust always be reused or replaced as an as-sembly.

4. During disassembly, clean all of the partsand place them in trays in the order of disas-sembly. This will speed up assembly and al-low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EAS00021

REPLACEMENT PARTS1. Use only genuine Yamaha parts for all re-

placements. Use oil and grease recom-mended by Yamaha for all lubrication jobs.Other brands may be similar in function andappearance, but inferior in quality.

EAS00022

GASKETS, OIL SEALS AND O-RINGS1. When overhauling the engine, replace all

gaskets, seals and O-rings. All gasket sur-faces, oil seal lips and O-rings must becleaned.

2. During reassembly, properly oil all matingparts and bearings and apply grease ontothe oil seal lips with greace.

EAS00023

LOCK WASHERS/PLATES AND COTTERPINS1. After removal, replace all lock wash-

ers/plates 1 and cotter pins. After the bolt ornut has been tightened to specification, bendthe lock tabs along a flat of the bolt or nut.

1-3

IMPORTANT INFORMATIONGENINFO

CAUTION:

EAS00024

BEARINGS AND OIL SEALS1. Install bearings and oil seals so that the

manufacturers marks or numbers are vis-ible. When installing oil seals, apply a lightcoat of lithium soap base grease onto the oilseal lips. Oil bearings liberally when instal-ling, if appropriate.

1 Oil seal

Do not spin the bearing with compressed airbecause this will damage the bearing sur-faces.

1 Bearing

EAS00025

CIRCLIPS1. Before reassembly, check all circlips careful-

ly and replace damaged or distorted circlips.Always replace piston pin clips after one use.When installing a circlip 1 , make sure thatthe sharp-edged corner 2 is positioned op-posite the thrust 3 that the circlip receives.

4 Shaft

1-4

CHECKING THE CONNECTIONSGENINFO

NOTE:

NOTE:

NOTE:

EAS00026

CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: lead 1coupler 2connector 3

2. Check: leadcouplerconnectorMoisture Dry with an air blower.Rust/stains Connect and disconnect sev-eral times.

3. Check:all connectionsLoose connection Connect properly.

If the pin 1 on the terminal is flattened, bend itup.

4. Connect: leadcouplerconnector

Make sure that all connections are tight.

5. Check:continuity(with a pocket tester)

Pocket tester90890-03112

If there is no continuity, clean the terminals.When checking the wire harness, performsteps 1 to 3.

As a quick remedy, use a contact revitalizeravailable at most part stores.

1-5

SPECIAL TOOLSGENINFO

EAS00027

SPECIAL TOOLSThe following special tools are necessary for complete and accurate tune-up and assembly. Use onlythe appropriate special tools as this will help prevent damage caused by the use of inappropriate toolsor 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 Illustration

90890-01080

Rotor puller

This tool is used to remove the generator rotor.

90890-01235

Rotor holding tool

This tool is used to hold the generator rotorwhen removing or installing the generatorrotor bolt or pickup coil rotor bolt.

90890-01304

Piston pin puller set

This tool is used to remove the piston pins.

90890-01312

Fuel level gauge

This tool is used to measure the fuel level inthe float chamber.

Radiator captester90890-01325Adapter90890-01352

Radiator cap testerAdapter

These tools are used to check the coolingsystem.

90890-01403

Steering nut wrench

This tool is used to loosen or tighten thesteering stem ring nuts.

90890-01447

Damper rod holder

This tool is used to hold the damper rod as-sembly when loosening or tightening thedamper rod assembly bolt.

1-6



90890-01426

Oil filter wrench

This tool is needed to loosen or tighten theoil filter cartridge.

90890-01434

Rod holder

This tool is used to support the damper ad-justing rod.

Rod puller90890-01437Rod puller attachment90890-01436

Rod pullerRod puller attachment

These tools are used to pull up the frontfork damper rod.

Fork seal driverweight90890-01367Fork seal driverattachment (43)90890-01374

Fork seal driver weightFork seal driver attachment (43)

This tool is used to install the front forks oilseal and dust seal.

90890-03008

Micrometer (50 75 mm)

This tool is used to measure the piston skirtdiameter.

Vacuum gauge90890-03094Vacuum gaugeattachment90890-03060

Vacuum gaugeVacuum gauge attachment

This guide is used to synchronize the car-buretors.

Compressiongauge90890-03081Compressiongauge adapter90890-04136

Compression gaugeCompression gauge adapter

These tools are used to measure enginecompression.

90890-03112

Pocket tester

This tool is used to check the electrical sys-tem.

90890-03113

Engine tachometer

This tool is used to check engine speed.

1-7



90890-03141

Timing light

This tool is used to check the ignition tim-ing.

90890-03173

Carburetor angle driver 2

This tool is used to turn the pilot screwwhen adjusting the engine idling speed.

Valve spring com-pressor90890-04019Attachmenht90890-0410890890-04114

Valve spring compressorValve spring compressor attachment

These tools are used to remove or installthe valve assemblies.

Middle driven shaftbearing driver90890-04058Mechanical sealinstaller90890-04078

Middle driven shaft bearing driverMechanical seal installer

These tools are used to install the waterpump seal.

90890-04086

Universal clutch holder

This tool is used to hold the clutch bosswhen removing or installing the clutch bossnut.

90890-0411190890-04116

Valve guide remover (4)Valve guide remover (4.5)

This tool is used to remove or install thevalve guides.

90890-0411290890-04117

Valve guide installer (4)Valve guide installer (4.5)

This tool is used to install the valve guides.

90890-0411390890-04118

Valve guide reamer (4)Valve guide reamer (4.5)

This tool is used to rebore the new valveguides.

90890-06754

Ignition checker

This tool is used to check the ignition sys-tem components.

1-8



90890-85505

Yamaha bond No. 1215

This bond is used to seal two mating sur-faces (e.g., crankcase mating surfaces).

SPEC

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-23. . . . . . . . . . . . . . . . ENGINE 2-23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 2-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM DIAGRAMS 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE OIL LUBRICATION CHART 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION DIAGRAMS 2-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard LimitModel code 5VL1 (A) (B) (D) (DK) (E) (GB) (GR) (I)

(N) (NL) (S) (SF) (CH) (P)5LV2 (F)5LV3 (D)5LV4 (AUS)

DimensionsOverall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,125 mm765 mm1,190 mm820 mm1,450 mm140 mm2,900 mm

WeightWet (with oil and a full fuel tank)Dry (without oil and fuel)Maximum load (total of cargo, rider,passenger, and accessories)

231 kg208 kg189 kg

2-2

ENGINE SPECIFICATIONS SPEC

ENGINE SPECIFICATIONSItem Standard Limit

EngineEngine typeDisplacementCylinder arrangementBore strokeCompression ratioEngine idling speedVacuum pressure at engine idlingspeedStandard compression pressure(at sea level)

Liquid-cooled, 4-stroke, DOHC998 cm3Forward-inclined parallel 4-cylinder74 58 mm11.4 : 11,050 1,150 r/min30 kPa (225 mm Hg)

1,450 kPa (14.5 kg/cm2) at 400 r/min

FuelRecommended fuelFuel tank capacityTotal (including reserve)Reserve only

Regular unleaded gasoline

21 L4.0 L

Engine oilLubrication systemRecommended oil

QuantityTotal amountWithout oil filter cartridgereplacementWith oil filter cartridge replacement

Oil pressure (hot)

Relief valve opening pressure

Wet sump

SAE20W40SE or SAE10W30SE

3.7 L2.8 L

3.0 L45 kPa at 1,100 r/min(0.45 kg/cm2 at 1,100 r/min)490 570 kPa (4.9 5.7 kg/cm2)

2-3


Item Standard LimitOil filterOil filter typeBypass valve opening pressure

Cartridge (paper)180 220 kPa (1.8 2.2 kg/cm2)

Oil pumpOil pump typeInner-rotor-to-outer-rotor-tipclearanceOuter-rotor-to-oil-pump-housingclearance

Trochoid0.09 0.15 mm

0.03 0.08 mm

Cooling systemRadiator capacityRadiator cap opening pressureRadiator coreWidthHeightDepth

Coolant reservoirCapacity

Water pumpWater pump typeReduction ratioMax. impeller shaft tilt

2.4 L95 125 kPa (0.95 1.25 kg/cm2)

340 mm238 mm24 mm

0.3 L

Single-suction centrifugal pump68/43 28/28 (1.581)

0.15 mmStarting system type Electric starterSpark plugsModel (manufacturer) quantitySpark plug gap

CR9E/U27ESR-N (NGK/DENSO) 40.7 0.8 mm

Cylinder headMax. warpage 0.1 mm

2-4


Item Standard LimitCamshaftsDrive systemCamshaft cap inside diameterCamshaft journal diameterCamshaft-journal-to-camshaft-cap clearanceIntake camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Exhaust camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Max. camshaft runout

Chain drive (right)24.500 24.521 mm24.459 24.472 mm0.028 0.062 mm

32.5 32.6 mm24.95 25.05 mm7.45 7.65 mm

32.95 33.05 mm24.95 25.05 mm7.75 7.95 mm

32.4 mm24.85 mm

32.85 mm24.85 mm

0.03 mm

2-5


Head Diameter Face Width Seat Width Margin Thickness

Item Standard LimitTiming chainModel/number of linksTensioning system

RH2015/130Automatic

Valves, valve seats, valve guidesValve clearance (cold)IntakeExhaust

Valve dimensions

0.11 0.20 mm0.21 0.25 mm

Valve head diameter AIntakeExhaust

Valve face width BIntakeExhaust

Valve seat width CIntakeExhaust

Valve margin thickness DIntakeExhaust

Valve stem diameterIntakeExhaust

Valve guide inside diameterIntakeExhaust

Valve-stem-to-valve-guide clearanceIntakeExhaust

Valve stem runout

Valve seat widthIntakeExhaust

22.9 23.1 mm24.4 24.6 mm

1.76 2.90 mm1.76 2.90 mm

0.9 1.1 mm0.9 1.1 mm

0.5 0.9 mm0.5 0.9 mm

3.975 3.990 mm4.465 4.480 mm

4.000 4.012 mm4.500 4.512 mm

0.010 0.037 mm0.020 0.047 mm

0.9 1.1 mm0.9 1.1 mm

3.945 mm4.43 mm

4.05 mm4.55 mm

0.08 mm0.10 mm0.01 mm

2-6


Item Standard LimitValve springsFree lengthIntakeExhaust

Installed length (valve closed)IntakeExhaust

Compressed spring force(installed)IntakeExhaust

Spring tilt

Intake

Exhaust

Winding direction (top view)IntakeExhaust

38.9 mm40.67 mm

34.5 mm35 mm

82 96 N (8.36 9.79 kg)110 126 N (11.22 12.85 kg)

ClockwiseClockwise

2.5 /1.7 mm2.5 /1.8 mm

CylindersCylinder arrangementBore strokeCompression ratioBoreMax. taperMax. out-of-round

Forward-inclined, parallel 4-cylinder74 58 mm11.4 : 174.00 74.01 mm

0.05 mm0.05 mm

2-7


Item Standard LimitPistonPiston-to-cylinder clearanceDiameter D

Height HPiston pin bore (in the piston)DiameterOffsetOffset direction

Piston pinsOutside diameterPiston-pin-to-piston-pin-boreclearance

Piston ringsTop ring

Ring typeDimensions (B T)End gap (installed)Ring side clearance

2nd ring

Ring typeDimensions (B T)End gap (installed)Ring side clearance

Oil ring

Dimensions (B T)End gap (installed)

0.030 0.055 mm73.955 73.970 mm

5 mm

17.002 17.013 mm

Intake side

16.991 17.000 mm0.002 0.022 mm

Barrel0.90 2.75 mm0.32 0.44 mm0.030 0.065 mm

Taper0.8 2.80.43 0.58 mm0.020 0.055 mm

1.5 2.6 mm0.10 0.35

0.12 mm

17.043

16.9710.072 mm

2-8


Item Standard LimitConnecting rodsCrankshaft-pin-to-big-end-bearingclearanceBearing color code

0.031 0.055 mm

1 = Violet 0 = White 1 = Blue 2 = Black

Crankshaft

Width AWidth BMax. runout CBig end side clearance DCrankshaft-journal-to-crankshaft-journal-bearing clearanceBearing color code

52.40 57.25 mm300.75 302.65 mm

0.160 0.262 mm0.029 0.053 mm

1 = Pink/violet 0 = Pink/white1 = Pink/blue 2 = Pink/black3 = Pink/brown

0.03 mm

ClutchClutch typeClutch release methodClutch release method operationOperationClutch cable free play (at the endof the clutch lever)Friction platesThicknessPlate quantityThicknessPlate quantity

Clutch platesThicknessPlate quantityMax. warpage

Clutch springsFree lengthSpring quantity

Wet, multiple discCam (pull rod type)Cable operationLeft-hand operation10 15 mm

2.92 3.08 mm83.42 3.58 mm1

1.9 2.1 mm8

50 mm6

2.82 mm

3.32 mm

0.1 mm

2-9


Item Standard LimitTransmissionTransmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios1st gear2nd gear3rd gear4nd gear5th gear6th gear

Max. main axle runoutMax. drive axle runout

Constant mesh, 6-speedSpur gear68/43 (1.581)Chain drive44/16 (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 mm0.08 mm

Shifting mechanismShift mechanism typeMax. shift fork guide bar bendingInstalled shift rod length

Guide bar

260 mm

0.1 mm

Air filter type Dry element Fuel pumpPump typeModel (manufacturer)Output pressure

Electrical4SV (MITSUBISHI)20 kPa (0.2 kg/cm2)

2-10


Item Standard LimitCarburetorsModel (manufacturer) quantityThrottle cable free play (at theflange of the throttle grip)ID markMain jet

Main air jetJet needle

Needle jetPilot air jet

BSR37 (MIKUNI) 43 5 mm

5LV1 00Carburetors 1 and 4: #132.5Carburetors 2 and 3: #130#80Carburetor 1 and 4: 5D129-3/5Carburetor 2 and 3: 5D130-3/5P-OM#85

Pilot outletPilot jetBypass 1Bypass 2Bypass 3Pilot screw turns outValve seat sizeStarter jet 1Starter jet 2Throttle valve sizeFuel level (above the line on thefloat chamber)

1.0#150.90.90.92.01.5#42.50.8#1153.0 4.0 mm

Max. EXUP cable free play (at theEXUP valve pulley)

1.5 mm

2-11

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONSItem Standard Limit

FrameFrame typeCaster angleTrail

Double cradle26104 mm

Front wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 MT3.50Aluminum140 mm

1 mm0.5 mm

Rear wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 MT5.50Aluminum135 mm

1 mm0.5 mm

Front tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg90 201 kgHigh-speed riding

Min. tire tread depth

Tubeless120/70 ZR17 (58W)MEZ4Y FRONT (METZELER)BT020F U (BRIDGESTONE)

250 kPa (2.5 kgf/cm2, 2.5 bar)250 kPa (2.5 kgf/cm2, 2.5 bar)250 kPa (2.5 kgf/cm2, 2.5 bar)

1.6 mm

2-12


Item Standard LimitRear tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg90 201 kgHigh-speed riding

Min. tire tread depth

Tubeless180/55 ZR17 (73W)MEZ4Y (METZELER)BT020R U (BRIDGESTONE)

270 kPa (2.7 kgf/cm2, 2.7 bar)290 kPa (2.9 kgf/cm2, 2.9 bar)290 kPa (2.9 kgf/cm2, 2.9 bar)

1.6 mmFront brakesBrake typeOperationRecommended fluidBrake discsDiameter thicknessMin. thicknessMax. deflectionBrake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Dual-disc brakeRight-hand-operationDOT 4

298 5 mm

5.5 mm

14 mm30.2 mm and 27 mm

4.5 mm0.1 mm0.5 mm

Rear brakeBrake typeOperationBrake pedal position (from the topof the brake pedal to the top of therider footrest)Recommended fluidBrake discsDiameter thicknessMin. thicknessMax. deflectionBrake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Single-disc brakeRight-foot operation35 40 mm

DOT 4

267 5 mm

5.5 mm

12.7 mm42.9 mm

4.5 mm0.1 mm0.5 mm

2-13


Item Standard LimitFront suspensionSuspension typeFront fork typeFront fork travelSpringFree lengthSpacer lengthInstalled lengthSpring rate (K1)Spring rate (K2)Spring stroke (K1)Spring stroke (K2)

Optional spring availableFork oilRecommended oilQuantity (each front fork leg)Level (from the top of the innertube, with the inner tube fullycompressed, and without thefork spring)

Spring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjustingpositionsMinimum*Standard*Maximum*

Compression damping adjustingpositionsMinimum*Standard*Maximum*

*from the fully turned-in position

Telescopic forkCoil spring/oil damper140 mm

344.0 mm78.5 mm320.0 mm8.1 N/mm (0.83 kg/mm)11.8 N/mm (1.2 kg/mm)0 55 mm55 140 mmNo

Suspension oil 01 or equivalent440 cm3140 mm

841

1771

2161

2-14


Item Standard LimitSteeringSteering bearing type Angular ball bearings

Rear suspensionSuspension typeRear shock absorber assemblytypeRear shock absorber assemblytravelSpringFree lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableStandard spring preload gas/airpressureSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjustingpositionsMinimum*Standard*Maximum*

Compression damping adjustingpositionsMinimum*Standard*Maximum*

*from the fully turned-in position

Swingarm (link suspension)Coil spring/gas-oil damper

65 mm

182.5 mm163 mm73.6 N/mm (7.5 kgf/mm)0 65 mmNo1,200 kPa (12 kgf/cm2)

1611

20103

1712

SwingarmFree play (at the end of theswingarm)RadialAxial

1 mm1 mm

Drive chainModel (manufacturer)Link quantityDrive chain slackMaximum ten-link section

50ZVM (DAIDO)11640 50 mm150.1 mm

152.5 mm

2-15

ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONSItem Standard Limit

System voltage 12 V Ignition systemIgnition system typeIgnition timingAdvanced timingAdvancer typePickup coil resistance/colorTransistorized coil ignition unitmodel (manufacturer)

Transistorized coil ignition5 BTDC at 1,100 r/min55 BTDC at 5,000 r/minThrottle position sensor and electrical248 372 /Gy-BTNDF66 (DENSO)

Ignition coilsModel (manufacturer)Minimum ignition spark gapPrimary coil resistanceSecondary coil resistance

J0313 (DENSO)6 mm1.87 2.53 12 18 k

Spark plug capsMaterialResistance

Rubber10 k

Throttle position sensor standardresistance 4 6 k Charging systemSystem typeModel (manufacturer)Normal outputStator coil resistance/color

AC magnetoF4T361 (MITSUBISHI)14 V/365 W at 5,000 r/min0.27 0.33 at 20C/W-W

Rectifier/regulatorRegulator typeModel (manufacture)

Semiconductor short circuitSH650C-11 (SHINDENGEN)

( )No-load regulated voltageRectifier capacityWithstand voltage

( )14.1 14.9 V18 A200 V

BatteryBattery typeBattery voltage/capacity

GT14B-412 V/12AH

Headlight type Halogen bulbBulbs (voltage/wattage quantity)HeadlightAuxiliary lightTail /brake lightTurn signal lightMeter light

12 V 60 W/55 W 212 V 5 W 212 V 5 W/21 W 212 V 21 W 412 V 2 W 3

2-16


Item Standard LimitIndicator light(voltage/wattage quantity)Neutral indicator lightHigh beam indicator lightOil level indicator lightTurn signal indicator lightFuel indicator lightWater temperature indicator light

14 V 1.4 W 114 V 1.4 W 114 V 1.4 W 114 V 1.4 W 212 V 2 W 1LED

Electric starting systemSystem typeStarter motorModel (manufacturer)Power outputBrushesOverall lengthSpring force

Commutator resistanceCommutator diameterMica undercut

Constant mesh

SM-13 (MITSUBA)0.8 kW

12.5 mm7.65 10.01 N (780 1,021 gf)0.025 0.035 28 mm0.7 mm

4 mm

27 mm

Starter relayModel (manufacturer)AmperageCoil resistance

MS5F-631 (JIDECO)180 A4.18 4.62

HornHorn typeModel (manufacturer) quantityMax. amperage

PlainYF-12 (NIKKO) 13 A

Turn signal relayRelay typeModel (manufacturer)Self-cancelling device built-inTurn signal blinking frequencyWattage

Full-transistorFE246BH (DENSO)No75 95 cycles/min.21 W 2 + 3.4 W

Oil level switchModel (manufacturer) 5LV (DENSO)

Fuel senderModel (manufacturer)Resistance

5LV (NIPPON SEIKI)4 100 at 25C

Sidestand/fuel pump relayModel (manufacturer)Coil resistance

5EB-20 (OMRON)180

Fuel pump maximum amperage 1.2 A Radiator fanModel (manufacturer) 4XV (TOYO RADIATOR)

Thermo switchModel (manufacturer) 5JJ (NIPPON THERMOSTAT)

2-17


Item Standard LimitFuses (amperage quantity)Main fuseHeadlight fuseSignaling system fuseIgnition fuseRadiator fan fuseTurn signal relay fuseBackup fuse (odometer)Reserve fuse

30 A 120 A 120 A 120 A 110 A 110 A 110 A 130 A 120 A 110 A 1

2-18

TIGHTENING TORQUES SPEC

A(Nut)

10 mm12 mm14 mm17 mm19 mm22 mm

B(Bolt)

6 mm8 mm

10 mm12 mm14 mm16 mm

General tighteningtorques

Nm6

15305585

130

mkg0.61.53.05.58.5

13.0

EAS00029

TIGHTENING TORQUEGENERAL TIGHTENING TORQUESThis chart specifies tightening torques for stan-dard fasteners with a standard ISO thread pitch.Tightening torque specifications for specialcomponents or assemblies are provided foreach chapter of this manual. To avoid warpage,tighten multi-fastener assemblies in a criss-cross pattern and progressive stages until thespecified tightening torque is reached. Unlessotherwise specified, tightening torque specifi-cations require clean, dry threads. Compo-nents should be at room temperature.

A: Distance between flatsB: Outside thread diameter

2-19

TIGHTENING TORQUES SPECENGINE TIGHTENING TORQUES

Item Fastener Threadsize Qty

Tighteningtorque Remarks

size yNm mkgf

Spark plugsCylinder headCylinder headCylinder headCamshaft capsCylinder head coverCylinder head (exhaust pipe)Connecting rod capsGenerator rotorCrankshaft sprocketCap bolt (timing chain tensioner)Camshaft sprocketWater pump inlet pipeWater pump outlet pipeOil /water pump assembly drivensprocket

Oil pumpOil coolerEngine oil drain boltOil strainer housingOil /water pump assembly drivensprocket cover

Oil delivery pipeOil filter boltOil filter cartridgeOil pipeAir cleaner cap and air cleanerFrame and air cleanerAir cleaner cover and air cleanerRing nut and cylinder headExhaust pipe and mufflerEmission check boltEXUP pulley coverEXUP cable bracketEXUP pulley and shaft armExhaust jointExhaust pipe assemblyAir induction system pipeCrankcase (cylinder head)

NutCap nut

BoltBoltBolt

Stud boltNutBoltBoltBoltBoltBoltBoltBoltBoltBolt

BoltBoltBoltBolt

BoltScrewBolt

ScrewNutBoltBoltBoltBoltBoltBoltBolt

BandStud bolt

M10M10M10M6M6M6M8M8

M10M10M6M7M6M6M6M6

M20M14M6M6M6

M20M20M6M6M6M6M8M8M8M6M6M5M4M8

M10

4822

28688111411

1

1112

1

1112436834331214

10

1350501210121536

65 + 60606.424101015

1235431012

10701710672

2020101010103

203.510

1.35.05.01.21.01.21.53.6

6.5 + 606.0

0.642.41.01.01.5

1.23.54.31.01.2

1.07.01.71.00.60.70.22.02.01.01.01.01.00.32.0

0.351.0

Crankcase Bolt M9 10 See noteCrankcaseCrankcaseCrankcase

BoltBoltBolt

M6M6M8

2142

141224

1.41.22.4

2-20


NOTE:

Item Fastener Threadsize Qty

Tighteningtorque Remarks

size yNm mkgf

AC magneto coverDrive sprocker coverPlateClutch coverTiming chain cap boltShift shaft coverBreather plateTiming mark accessing screwStarter clutch idle gear shaftStarter one-way clutchClutch bossClutch springDrive sprocketMain axle bearing housingShift lever stopperStopper screwShift rodShift rodShift rod jointShift armAC magneto stator coilIgnitor unitNeutral switchPick up coilThermo unit

BoltBoltBoltBoltBoltBoltBoltBoltBoltBoltNutBoltNut

ScrewBolt

ScrewNutNutBoltBolt

ScrewScrew

Bolt

M6M6M6M6M6M6M6M8M6M6

M20M6

M22M6M6M8M6M6M6M6M6M5

M10M6

94288551131

61

321121132121

12101012121210151012

908

851210226.56.51010147

201015

1.21.01.01.21.21.21.01.51.01.2

9.00.88.51.21.02.2

0.650.651.01.01.40.72.01.01.5

Use a lockwasher.

Use a lockwasher.

Left thread

1. First, tighten the bolt to approximately 14.7 Nm (1.5 mkg) with a torque wrench.2. Retighten the bolt to 14.7 Nm (1.5 mkg), and tighten another 45 50.

2-21


Crankcase tightening sequence:

2-22


NOTE:

CHASSIS TIGHTENING TORQUES

Item Thread sizeTightening

RemarksItem Thread sizeNm mkgf

Remarks

Upper bracket pinch boltUpper bracket cap nutUpper bracket and handlebar holderHandlebar holderLower bracket pinch boltLower bracket ring nutFront brake master cylinderFront brake hose union boltEngine mountingEngine mounting bolt /nutEngine mounting bolt /nutFrame and down tube

Clutch cable lock nutIgnition coil and stayPivot shaftRear shock absorber (upper)Rear shock absorber and relay armRelay arm and frameRelay arm and connecting armConnecting arm and swing armDrive chain guardDrive chain caseFuel cockFuel senderSide coverCoolant reservoir tankFront wheel axleFront wheel axle pinch boltFront brake caliperFront brake diskFront brake bleed screwRear brake torque rodRear wheel sprocketDrive chain adjusting nutRear brake caliperRear wheel axleRear brake hose union boltRear brake bleed screwRear brake diskRider footrest bracket and frameRear brake reservoir tankRear brake master cylinderRider footrest and bracketPassenger footrest bracket and framePassenger footrest bracket and muffler

M8M22M10M8

M25M6

M10

M10M8

M10M8M6

M18M10M10M10M12M12M6M6M6M5M6M6

M16M8

M10M6M8M8

M10M8

M10M24M10M8M8M8M6M8

M10M8

M10

30110322323181030

55338977

1254040404848777444

722340186

23691640

150306

23304

23552848

3.0113.22.32.31.8103.0

5.53.38.90.70.7

12.54.04.04.04.84.80.70.70.70.40.40.47.22.34.01.80.62.36.91.64.0153.00.62.33.00.42.35.52.84.8

See note

1. First, tighten the ring nut to approximately 52 Nm (5.2 mkg) with a torque wrench, then loosen thering nut completely.

2. Retighten the ring nut to specification.

2-23

LUBRICATION POINTS AND LUBRICANT TYPES SPECEAS00031

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

Lubrication point LubricantOil seal lipsO-ringsBearingsCrankshaft pinsPiston surfacesPiston pinsConnecting rod bolts and nutsCrankshaft journalsCamshaft lobesCamshaft journalsValve stems (intake and exhaust)Valve stem ends (intake and exhaust)Water pump impeller shaftOil pump rotors (inner and outer)Oil strainerStarter clutch idle gear inner surfaceStarter clutch assemblyPrimary driven gearTransmission gears (wheel and pinion)Main axle and drive axleShift drumShift forks and shift fork guide barsShift shaftShift shaft boss

Cylinder head cover mating surface Yamaha bondNo.1215

Crankcase mating surface Yamaha bondNo.1215

Clutch cover (crankcase mating surface) Yamaha bondNo.1215Generator rotor cover (crankcase mating surface) Yamaha bondNo.1215

2-24

LUBRICATION POINTS AND LUBRICANT TYPES SPECEAS00032

CHASSISLubrication point Lubricant

Steering bearings, steering seal lips and ball race cover lipsPivot shaftSwing arm pivoting points and connecting arm bearingsConnecting arm oil seal lipsSwing arm oil seal lipsRelay arm bearingsRelay arm oil seal lipsRear shock absorber upper boltFront wheel oil seal lipsRear wheel oil seal lipsClutch hub oil seal lipsThrottle cable endStarter cable end and starter leverRear brake pedal moving pointShift pedal moving pointSide stand moving pointPassenger footrest ball joint and moving pointEngine mounting bracket collar and oil seal lipsMainstand moving point

2-25

COOLING SYSTEM DIAGRAMS SPEC

1 Radiator cap2 Thermostat housing3 Radiator4 Water pump

EAS00033

COOLING SYSTEM DIAGRAMS

2-26

COOLING SYSTEM DIAGRAMS SPEC1 Radiator cap2 Thermostat housing3 Radiator4 Oil cooler5 Water jacket joint

2-27

COOLING SYSTEM DIAGRAMS SPEC1 Radiator cap2 Thermostat3 Thermo unit

2-28

COOLING SYSTEM DIAGRAMS SPEC1 Radiator

2-29

Oilcooler

Exhaustcamshaft

Intakecamshaft

Main gallery

Oil filter

Main axle

Drive axleStrainer Relief

valve

ENGINE OIL LUBRICATION CHART SPEC

ENGINE OIL LUBRICATION CHART

2-30

1 Oil cooler2 Oil filter cartridge3 Drain bolt4 Oil level switch5 Oil strainer6 Oil pump

LUBRICATION DIAGRAMS SPECEAS00034

LUBRICATION DIAGRAMS

2-31

LUBRICATION DIAGRAMS SPEC1 Intake camshaft2 Exhaust camshaft3 Oil cooler4 Oil strainer5 Oil pump

2-32

LUBRICATION DIAGRAMS SPEC1 Intake camshaft2 Exhaust camsahft3 Oil filter cartridge4 Oil level switch

2-33

LUBRICATION DIAGRAMS SPEC1 Cylinder head2 Crankshaft

2-34

LUBRICATION DIAGRAMS SPEC1 Main axle2 Oil delivery pipe3 Drive axle

2-35

CABLE ROUTING SPEC

F Route the horn lead outside the motorcycle body,and fasten with the under bracket. Do not loose be-tween the horn and under bracket.

G Route the brake hose through the brake hoseguide.

H Route the throttle cable 1 and 2 backward the brakehose, and left side the brake hose guide.

A Fasten the handlebar switch lead (right) and han-dlebar with a plastic band.

B Route the handlebar switch lead (right) backwardthe throttle cable and right side the brake hoseguide.

C Fasten the handlebar switch lead (left) and handle-bar with a plastic band.

D Fasten the handlebar switch lead (left), main switchlead, clutch cable and starter cable with a plasticband. Clamp beneath the horn lead branching posi-tion. Do not fasten the horn lead.

E Route the main switch lead front and left side theanother leads.

EAS00035

CABLE ROUTING

2-36

1 Fuel pump lead2 Fuel pump3 EXUP cable4 Handlebar switch lead (right)5 Throttle cable 16 Throttle cable 27 Water-carburetor hose8 Fan motor lead9 Coolant reservoir tank over flow

hose10 Fuel tank drain hose11 Fuel tank breather hose12 White paint mark13 Rear brake light switch lead14 Neutral switch lead15 Speedo sensor lead16 Pickup coil lead

CABLE ROUTING SPEC17 Handle crown18 Handlebar switch lead19 Brake hose guide

A Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speedsensor lead, rear brake light switch lead and fuel pump with a plasticclamp.

B Fasten the fuel hose, pickup coil lead, neutral switch lead and speedsensor 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.

2-37

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 en-

gine mounting bracket.U Route the coolant reservoir hose forward the neu-

tral 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 breath-

er hose forward the neutral switch lead and speedsensor lead.

I Route the water-carburetor hose between theframe cross pipe and fan motor lead.

J To the carburetorK 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 throughthe frame hose holder from the inside of the vehicleto the outside. At this time, pull the fuel tank drainhose and fuel tank breather hose so that the whitepaint marks are within a 20 mm 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 plasticguide.

CABLE ROUTING SPEC

2-38

A Fasten the main switch lead and handlebar switch lead with a plasticguide.

B Fasten the water-head hose and water-carburetor hose with a plasticband.

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.

CABLE ROUTING SPEC1 Starter cable2 Clutch cable3 Handlebar switch lead (left)4 Main switch lead5 EXUP servo motor6 Starting circuit cutoff relay7 Starter motor lead8 Fan motor relay9 Air cleaner case drain hose10 Sidestand switch lead11 oil level switch lead12 ACgenerator lead13 Water-head pipe14 Water-carburetor hose15 Throttle cable 216 Throttle cable 117 EXUP cable

2-39

CABLE ROUTING SPECand rectifier regulator lead.

U Route the water carburetor hose outside the coolanthose.

V Route the starter cable outside the coolant hose, and up-per the water-carburetor hose.

W Route the high tension cable (#2, 3) forward the EXUPcable 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 water-head hose.

Z Taillight lead and flasher light lead (right) should not bestick out from the gap between the rear fender and tail-light.

AA Route the flasher light lead through the hole on the rearfender.

AB Route the wire harness in the groove.

N Fasten the sidestand switch lead, oil level switch lead,ACgenerator lead, starter motor lead, battery negativelead 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 aplastic clamp.

P Fasten the sidestand switch lead and frame with a plasticclamp.

Q Route the air cleaner box drain hose inside the sidestandswitch lead, and put the end of the hose backward.

R Fasten the sidestand switch lead and frame with a plasticclamp.

S Fasten the sidestand switch lead, oil level switch lead andair filter case drain hose with a plastic clamp. Do not crushthe air filter case drain hose.

T Route the high tension cable (#1) outside the starter cableand water-carburetor hose, and under the clutch cable

2-40

17 Ignition coil lead18 Battery19 Emergency engine stop switch20 Flasher relay21 Fuse box22 Igniter unit23 Flasher light lead24 Taillight lead25 Alarm coupler (free)26 Starter relay27 Battery positive lead28 Fan motor lead29 Battery negative lead30 Starting circuit cutoff relay

CABLE ROUTING SPEC1 Clutch cable2 Handlebar switch lead3 Main switch lead4 Starter cable5 Thermo unit lead6 Throttle cable 17 Throttle cable 28 Handlebar switch lead (right)9 Coolant reservoir hose10 Ignition coil11 Fuel hose12 Fan motor lead13 EXUP servo motor lead14 Rectifier / regulator lead15 White paint mark16 Main harness

2-41

CABLE ROUTING SPECK 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.

A Fasten the flasher light lead and headlight lead witha plastic clamp.

B Route the rectifier / regulator lead upper the fan mo-tor lead and EXUP servomotor lead.

C Route the throttle cable right side the fan motorlead, 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.

2-42

AA Put the seat lock cable into the groove on the rearfender.

AB Fasten the battery positive lead with a plastic band.

CABLE ROUTING SPECT Fasten the ignition coil lead and frame cross pipe

with a plastic clamp. Do not fasten the red/blacklead and orange lead.

U Fasten the handlebar switch lead (left / right), mainswitch lead, EXUP servo motor lead, fan motor leadand thermo unit lead with a plastic clamp.

V Fasten the rectifier / regulator stay and rectifier / reg-ulator lead with a plastic clamp.

W Route the wire harness under the rectifier / regula-tor.

X Fasten the battery negative lead with a batteryband.

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.

CHKADJ

CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTS

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

PERIODIC MAINTENANCE/LUBRICATION INTERVALS 3-1. . . . . . . . . . .

FRONT COWLING/SEAT/SIDE COVER/FUEL TANK 3-3. . . . . . . . . . . . . . FRONT COWLING 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SEAT, SIDE COVER AND FUEL TANK 3-4. . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-5. . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE CARBURETORS 3-10. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED 3-12. . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-13. . . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IGNITION TIMING 3-16. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-17. . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-19. . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL 3-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY 3-22. . . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT 3-23. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR JOINTS AND

INTAKE MANIFOLDS 3-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL HOSES AND FUEL FILTER 3-24. . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE 3-25. . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-25. . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE EXUP CABLES 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM 3-29. . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT 3-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-35. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE PADS 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-36. . . . . . . . . . . . . . . CHECKING THE BRAKE HOSES 3-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-37. . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK 3-39. . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN 3-41. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-41. . . . . . . . . . CHECKING THE FRONT FORK 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT FORK LEGS 3-43. . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-45. . . . . . CHECKING THE TIRES 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHKADJ

CHECKING AND LUBRICATING THE CABLES 3-50. . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-50. . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-50. . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEMS 3-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-51. . . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS 3-58. . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS 3-59. . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DIGITAL CLOCK 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

INTRODUCTIONPERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHKADJ

NOTE:

EAS00036

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.EAS00037

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

The annual checks must be performed every year, except if a kilometer-based maintenanceis performed instead.

From 50,000 km, repeat the maintenance intervals starting from 10,000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special

tools, data and technical skills.

NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUAL

NO. ITEM CHECK OR MAINTENANCE JOB1 10 20 30 40 CHECK

1 * Fuel line (See page 3-24) Check fuel hoses for cracks or damage.

2 * Fuel filter(See page 3-24) Check condition.

3 Spark plugs(See page 3 15) Check condition. Clean and regap. 3 (See page 3-15) Replace.

4 * Valves (See page 3-5)

Check valve clearance. Adjust. Every 40,000 km

5 Air filter element Clean.

5 Air filter element(See page 3-23) Replace.

6 Clutch (See page 3-22) Check operation. Adjust.

7 *Front brake(See page 3-35)

Check operation, fluid level and vehiclefor fluid leakage. (See NOTE) 7 (See page 3 35)

(See page 3-36) Replace brake pads. Whenever worn to the limit

8 *Rear brake(See page 3-35)

Check operation, fluid level and vehiclefor fluid leakage. (See NOTE) 8 (See page 3 35)

(See page 3-36) Replace brake pads. Whenever worn to the limit

9 * Brake hoses Check for cracks or damage.

9 * (See page 3-37) Replace. (See NOTE) Every 4 years

10 * Wheels (See page 4-4) Check runout and for damage.

11 * Tires (See page 3-47) Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

12 * Wheel bearings(Seep age 4-4) Check bearing for looseness or damage.

13 *Swingarm (See page 4 68)

Check operation and for excessive play. 13 * (See page 4-68)

(See page 4-69) Lubricate with lithium-soap-based grease. Every 50,000 km

14Drive chain(See page 3-39)(See page 4-69)

Check chain slack. Make sure that the rear wheel is properly

aligned. Clean and lubricate.

Every 1,000 km and after washing themotorcycle or riding in the rain.

15 *Steering bearings(See page 3-41)

Check bearing play and steering forroughness. 15 (See page 3 41)

(See page 4-59) Lubricate with lithium-soap-based grease. Every 20,000 km

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSCHKADJ

NOTE:

NO ITEM CHECK OR MAINTENANCE JOBODOMETER READING ( 1,000 km) ANNUALNO. ITEM CHECK OR MAINTENANCE JOB

1 10 20 30 40 CHECK

16 * Chassis fasteners(See page 2-22) Make sure that all nuts, bolts and

screws and properly tightened.

17Sidestand/centerstand(Seep age 3-50)

Check operation. Lubricate.

18 * Sidestand switch(See page 8-21) Check operaiton.

19 * Front fork (See page 3-43) Check operation and for oil leakage.

20 *Rear shockabsorberassembly (See page 4-64)

Check operation and shock absorber foroil leakage.

21 *

Rear suspensionrelay arm andconnecting arm

Check operation. 21 * connecting arm

pivoting points(See page 4-69) Lubricate with lithium-soap-based grease.

22 *Carburetors(See page 3-10)(See page 3-12)

Check starter (choke) operation. Adjust engine idling speed and

synchronization.

23 Engine oil (See page 3-20) Change.

24Engine oil filtercartridge (See page 3-20)

Replace.

25 *Cooling system(See page 3-29)

Check coolant level and vehicle. forcoolant leakage 25 (See page 3 29)

(See page 3-30) Change. Every 3 years

26 *Front and rearbrake switches(See page 3-36)(See page 8-38)

Chck operation.

27Moving parts andcables (See page 2-24)(See page 3-50)

Lubricate.

28 *Air inductionsystem(See page 7-16)

Check the air cut valve and reed valve fordamage.

Replace the entire air induction system ifnecessary.

29 *

Lights, signalsand switches(See page 3-59)(See page 8-30)(See page 8-35)

Check operation. Adjust headlight beam.

*: It is recommended that these items be serviced by a Yamaha dealer.

The air filter needs more frequent service if you are riding in unusually wet or dusty areas. Hydraulic brake service

Regularly check and, if necessary, correct the brake fluid level. Every two years replace the internal components of the brake master cylinders and calipers, and

change the brake fluid. Replace the brake hoses every four years and if cracked or damaged.

3-3

FRONT COWLINGCHKADJ

Order Job/Part Qty Remarks

123456

Removing the fron cowlingInner panelHeadlight/meter couplerFront cowling assemblyBack view mirrorMeter unitHeadlight unit

21/11211

Remove the4 parts in the order listed.

Disconnect.

For installation, reverse the removalprocedure.

EAS00038

FRONT COWLING/SEAT/SIDE COVER/FUEL TANKFRONT COWLING

3-4

SEAT, SIDE COVER AND FUEL TANKCHKADJ

Order Job/Part Qty Remarks

1234567

89

Removing the seat, side cover andfuel tankSeatSide cover (left and right)Fuel sender couplerFuel tankFuel tank breather hoseFuel tank drain hoseFuel hose

Grab barRear cowling

1211111

11

Remove the parts in the order listed.

Disconnect.

Befor disconnecting the fuel hose, turnthe fuel cock off.

For installation, reverse the removalprocedure.

NOTE:

10 Nm (1.0 mkg)

19 Nm (1.9 mkg)

4 Nm (0.4 mkg)

10 Nm (1.0 mkg)

EAS00040

SEAT, SIDE COVER AND FUEL TANK

3-5

ADJUSTING THE VALVE CLEARANCECHKADJ

NOTE:

NOTE:

NOTE:

EAS00045

ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.

Valve clearance adjustment should be madeon a cold engine, at room temperature.

When the valve clearance is to be measured oradjusted, the piston must be at top dead center(TDC) on the compression stroke.

1. Remove:cylinder head coverRefer to CYLINDER HEAD COVER inchapter 5.

2. Measure:valve clearanceOut of specification Adjust.

Valve clearance (cold)Intake valve

0.11 0.20 mmExhaust valve

0.21 0.25 mm

a. Turn the crankshaft clockwise.b. When piston #1 is at TDC on the compres-

sion stroke, align the TDC mark a on thepickup rotor with the crankcase mating sur-face b .

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

c. Measure the valve clearance with a thick-ness gauge 1 .

If the valve clearance is incorrect, record themeasured reading.

Measure the valve clearance in the followingsequence.

Valve clearance measuring sequenceCylinder #1 #2 #4 #3

3-6


NOTE:

A Frontd. For each cylinder, starting with cylinder #1 at

TDC, turn the crankshaft clockwise as speci-fied in the following table.

B Degrees that the crankshaft is turned clockwiseC CylinderD Combustion cycle

#2 Cylinder 180#4 Cylinder 360#3 Cylilnder 540

3. Remove: intake camshaftexhaust camshaft

Refer to DISASSEMBLING THE ENGINE CAMSHAFT AND CYLINDER HEAD in chap-ter 5.

When removing the timing chain and cam-shafts, fasten a wire to the timing chain to re-trieve it if it falls into the crankcase.

4. Adjust:valve clearance

a. Remove the valve lifter 1 and the valve pad2

with a valve lapper 3 .

Valve lapper9089004101

3-7


NOTE:

NOTE:

NOTE:

Cover the timing chain opening with a rag toprevent the valve pad from falling into thecrankcase.

Make a note of the position of each valve lifter1

and valve pad 2 so that they can beinstalled in the correct place.

b. Select the proper valve pad from the follow-ing table.

Valve padthickness range

Available valvepads

Nos.120 240

1.20 2.40 mm

25 thicknessesin 0.05 mmincrements

The thickness a of each valve pad is markedin hundredths of millimeters on the side thattouches the valve lifter.

Since valve pads of various sizes are originallyinstalled, the valve pad number must berounded in order to reach the closest equiva-lent to the original.

c. Round off the original valve pad number ac-cording to the following table.

Last digit Rounded value0 or 2 0

5 58 10

EXAMPLE:Original valve pad number = 148 (thickness=1.48 mm (0.058 in))Rounded value = 150d. Locate the rounded number of the original

valve pad and the measured valve clearancein the valve pad selection table. The pointwhere the column and row intersect is thenew valve pad number.

The new valve pad number is only an approxi-mation. The valve clearance must be measuredagain and the above steps should be repeated ifthe measurement is still incorrect.

3-8


Measuredclearance

exa

INSTALLED PAD NUMBER

EXAMPLE:VALVE CLEARANCE: 0.11 0.20 mm

Installed is 150Measured clearance is 0.25 mmReplace 150 pad with 160 pad

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.08 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.11 0.20 Specification0.21 0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.23 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.28 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.33 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73 0.77 180 185 190 195 200 205 210 215 220 225 230 235 2400.78 0.82 185 190 195 200 205 210 215 220 225 230 235 2400.83 0.87 190 195 200 205 210 215 220 225 230 235 2400.88 0.92 195 200 205 210 215 220 225 230 235 2400.93 0.97 200 205 210 215 220 225 230 235 2400.98 1.02 205 210 215 220 225 230 235 2401.03 1.07 210 215 220 225 230 235 2401.08 1.12 215 220 225 230 235 2401.13 1.17 220 225 230 235 2401.18 1.22 225 230 235 2401.23 1.27 230 235 2401.28 1.32 235 2401.33 1.37 240

Measuredclearance

exa

EXAMPLE:VALVE CLEARANCE: 0.21 0.30 mm

Installed is 175Measured clearance is 0.35 mmReplace 175 pad with 185 pad

INSTALLED PAD NUMBER120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 2150.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 2200.08 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.13 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.18 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.21 0.30 Specification0.31 0.32 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.33 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.78 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.83 0.87 180 185 190 195 200 205 210 215 220 225 230 235 2400.88 0.92 185 190 195 200 205 210 215 220 225 230 235 2400.93 0.97 190 195 200 205 210 215 220 225 230 235 2400.98 1.02 195 200 205 210 215 220 225 230 235 2401.30 1.07 200 205 210 215 220 225 230 235 2401.08 1.12 205 210 215 220 225 230 235 2401.13 1.17 210 215 220 225 230 235 2401.18 1.22 215 220 225 230 235 2401.23 1.27 220 225 230 235 2401.28 1.32 225 230 235 2401.33 1.37 230 235 2401.38 1.42 235 2401.43 1.47 240

VALVE PAD SELECTION TABLEINTAKE

EXHAUST

3-9


NOTE:

NOTE:

NOTE:

e. Install the new valve pad 1 and the valve lift-er 2 .

Apply molybdenum disulfide to the valve pad.Lubricate the valve lifter with molybdenum dis-ulfide oil.

The valve lifter must turn smoothly when ro-tated by hand.

Install the valve lifter and the valve pad in thecorrect place.

f. Install the exhaust and intake camshafts,timing chain and camshaft caps.

Camshaft cap bolt10 Nm (1.0 mkg)

Refer to ASSEMBLING AND ADJUSTINGTHE ENGINE CYLINDER HEAD AND CAM-SHAFT in chapter 4.

Lubricate the camshaft bearings, camshaftlobes and camshaft journals.

First, install the exhaust camshaft.Align the camshaft marks with the camshaftcap marks.

Rotate the crankshaft clockwise several turnsto seat the parts.

g. Measure the valve clearance again.h. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust-ment steps until the specified clearance isobtained.

5. Install:cylinder head coverRefer to CYLINDER HEAD COVER inchapter 5.

6. Install:all removed parts

For installation, reverse the removal procedure.Note the following points.

3-10

SYNCHRONIZING THE CARBURETORSCHKADJ

NOTE:

NOTE:

EAS00050

SYNCHRONIZING THE CARBURETORS

Prior to synchronizing the carburetors, the valveclearance and the engine idling speed shouldbe properly adjusted and the ignition timingshould be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.

2. Remove:vacuum cap

3. Install:vacuum gauge attachmentvacuum gauge 1engine tachometer 2(to the spark plug lead of cyl. #1)

Vacuum gauge90890-03094

Vacuum gauge attachment90890-03060

Engine tachometer90890-03113

4. Start the engine and let it warm up for severalminutes.

5. Check:engine idling speedOut of specification Adjust.Refer to ADJUSTING THE ENGINE IDLINGSPEED.

Engine idling speed1,050 1,150 r/min

3-11

SYNCHRONIZING THE CARBURETORSCHKADJ

NOTE:

NOTE:

6. Adjust:carburetor synchronization

a. Synchronize carburetor #1 to carburetor #2by turning the synchronizing screw 1 in ei-ther direction until both gauges read thesame.

After each step, rev the engine two or threetimes, each time for less than a second, andcheck the synchronization again.

b. Synchronize carburetor #4 to carburetor #3by turning the synchronizing screw 2 in ei-ther direction until both gauges read thesame.

c. Synchronize carburetor #2 to carburetor #3by turning the synchronizing screw 3 in ei-ther direction until both gauges read thesame.

Vacuum pressure at engine idling speed

30 kPa (225 mm Hg)

The difference in vacuum pressure betweentwo carburetors should not exceed 1.33 kPa (10mm Hg).

7. Measure:engine idling speedOut of specification Adjust.

8. Stop the engine and remove the measuringequipment.

9. Adjust: throttle cable free playRefer to ADJUSTING THE THROTTLECABLE FREE PLAY.

Throttle cable free play (at the flange of the throttle grip)

3 5 mm

10. Install:vacuum cap

3-12

ADJUSTING THE ENGINE IDLING SPEEDCHKADJ

NOTE:

EAS00052

ADJUSTING THE ENGINE IDLING SPEED

Prior to adjusting the engine idling speed, thecarburetor synchronization should be adjustedproperly, the air filter should be clean, and theengine should have adequate compression.

1. Start the engine and let it warm up for severalminutes.

2. Install:engine tachometer(to the spark plug lead of cyl. #1)


3. Measure:engine idling speedOut of specification Adjust.


4. Adjust:engine idling speed

a. Turn the pilot screw 1 in or out until it is light-ly seated.

b. Turn the pilot screw out the specified numberof turns.

Carburetor angle driver 2908900-03173

Pilot screw2 turns out

3-13

ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAY

CHKADJ

a

b

NOTE:

c. Turn the throttle stop screw 2 in direction aor b until the specified engine idling speed isobtained.

Direction Engine idling speed is in-creased.

Direction Engine idling speed isdecreased.5. Adjust: throttle cable free playRefer to ADJUSTING THE THROTTLECABLE FREE PLAY.

Throttle cable free play (at theflange of the throttle grip)

3 5 mm

EAS00055

ADJUSTING THE THROTTLE CABLE FREEPLAY

Prior to adjusting the throttle cable free play, theengine idling speed and carburetor synchro-nization should be adjusted properly.

1. Check: throttle cable free play aOut of specification Adjust.

Throttle cable free play (at theflange of the throttle grip)

3 5 mm

2. Remove:seat fuel tank

3-14

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

NOTE:

a

b

NOTE:

a

b

WARNING

3. Adjust: throttle cable free play

When the motorcycle is accelerating, the accel-erator cable 1 is pulled.

Carburetor sidea. 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 isobtained.

Direction Throttle cable free play isincreased.

Direction Throttle cable free play isdecreased.e. Tighten the locknuts.

If the specified throttle cable free play cannot beobtained on the carburetor side of the cable, usethe adjusting nut on the handlebar side.

Handlebar sidea. Loosen the locknut 1 .b. Turn the adjusting nut 2 in direction a or b

until the specified throttle cable free play isobtained.

Direction Throttle cable free play isincreased.

Direction Throttle cable free play isdecreased.c. Tighten the locknut.

After adjusting the throttle cable free play,turn the handlebar to the right and to the leftto ensure that this does not cause the en-gine idling speed to change.

3-15

ADJUSTING THE THROTTLE CABLE FREE PLAY/CHECKING THE SPARK PLUGS

CHKADJ

CAUTION:

4. Install: fuel tankseat

EAS00059

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Disconnect:spark plug cap

2. Remove:spark plug

Before removing the spark plugs, blow awayany dirt accumulated in the spark plug wellswith compressed air to prevent it from fal-ling into the cylinders.

3. Check:spark plug typeIncorrect Change.

Spark plug type (manufacturer)CR9E (NGK)U27ESR-N (DENSO)

4. Check:electrode 1Damage/wear Replace the spark plug.

insulator 2Abnormal 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 gap0.7 0.8 mm

3-16

CHECKING THE SPARK PLUGS/CHECKING THE IGNITION TIMING

CHKADJ

13 Nm (1.3 mkg)NOTE:

NOTE:

7. Install:spark plug

Before installing the spark plug, clean the sparkplug and gasket surface.

8. Connect:spark plug cap

EAS00063

CHECKING THE IGNITION TIMING

Prior to checking the ignition timing, check thewiring connections of the entire ignition system.Make sure that all connections are tight and freeof corrosion.

1. Remove: timing plug 1

2. Install: timing light 1engine tachometer 2(to the spark plug lead of cyl. #1)

Timing light90890-03141


3. Check: ignition timing

a. Start the engine, warm it up for several min-utes, and then let it run at the specified en-gine idling speed.


3-17

CHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSURE

CHKADJ

NOTE:

NOTE:

CAUTION:

b. Check that the mark a is within the requiredfiring range b on the pickup coil rotor.Incorrect firing range Check the ignitionsystem.

The ignition timing is not adjustable.

4. Remove: timing lightengine tachometer

5. Install: timing plug

EAS00065

MEASURING THE COMPRESSION PRES-SUREThe following procedure applies to all of the cyl-inders.

Insufficient compression pressure will result in aloss of performance.

1. Measure:valve clearanceOut of specification Adjust.Refer to ADJUSTING THE VALVE CLEAR-ANCE.

2. Start the engine, warm it up for several min-utes, and then turn it off.

3. Disconnect:spark plug cap

4. Remove:spark plug

Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders.

5. Install:compression gauge 1

Compression gauge90890-03081

Compression gauge adapter90890-04136

3-18

MEASURING THE COMPRESSION PRESSURECHKADJ

WARNING

NOTE:

13 Nm (1.3 mkg)

6. Measure:compression pressureAbove the maximum pressure Inspect thecylinder head, valve surfaces, and pistoncrown for carbon deposits.Below the minimum pressure Squirt a fewdrops of oil into the affected cylinder andmeasure again.

Refer to the following table.

Compression pressure(with oil applied into cylinder)

Reading DiagnosisHigher thanwithout oil

Piston ring(-s) wear ordamage Repair.

Same aswithout oil

Piston valves, cylinderhead gasket or pistonpossibly defective Repair.Compression pressure(at sea level)

Compression pressure (at sealevel):Standard:

1,450 kPa (14.5 kg/cm2)Minimum:

1,260 kPa (12.6 kg/cm2)Maximum:

1,620 kPa (16.2 kg/cm2)

a. Turn the main switch to ON.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilizes.

To prevent sparking, ground all spark plugleads before cranking the engine.

The difference in compression pressure be-tween cylinders should not exceed 100 kPa (1kg/cm2).

7. Install:spark plug

8. Connect:spark plug cap

3-19

CHECKING THE ENGINE OIL LEVELCHKADJ

NOTE:

CAUTION:

NOTE:

EAS00069

CHECKING THE ENGINE OIL LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.

2. Let the engine idle for a few minutes.

3. Check:engine oil levelThe engine oil level should be between theminimum level marks a and maximum levelmarks b .Below the minimum level mark Add therecommended engine oil to the proper level.

Recommended engine oilRefer to the chart for the engineoil grade which is best suitedfor certain atmospheric temper-atures.API standard

SE or higher gradeACEA standard

G4 or G5

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD a or higher and donot use oils labeled ENERGY CONSERV-ING II b or higher.

Do not allow foreign materials to enter thecrankcase.


5. Check the engine oil level again.

Before checking the engine oil level, wait a fewminutes until the oil has settled.

3-20

CHANGING THE ENGINE OILCHKADJ

CAUTION:

EAS00073

CHANGING THE ENGINE OIL1. Start the engine, warm it up for several min-

utes, and then turn it off.2. Place a container under the engine oil drain

bolt.

3. Remove:engine oil filler cap 1engine 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 oilfilter wrench 2 .

Oil filter wrench90890-01426

b. Apply a thin coat of engine oil onto the O-ring1

of the new oil filter cartridge.

Make sure that the O-ring 1 is positionedcorrectly in the groove of the oil filter car-tridge.

3-21

CHANGING THE ENGINE OILCHKADJ

43 Nm (4.3 mkg)

c. Tighten the new oil filter cartridge to specifi-cation with an oil filter wrench.

Oil filter cartridge17 Nm (1.7 mkg)

6. Check:engine oil drain bolt gasketDamage Replace.

7. Install:engine oil drain bolt

8. Fill:crankcase(with the specified amount of the recom-mended engine oil)

QuantityTotal amount

3.7 LWithout oil filter cartridgereplacement

2.7 LWith oil filter cartridge replace-ment

3.0 L

9. Install:engine oil filler cap


11. Check:engine(for engine oil leaks)

12. Check:engine oil levelRefer to CHECKING THE ENGINE OILLEVEL.

13. Check:engine oil pressure

a. Slightly loosen the oil gallery bolt 1 .b. Start the engine and keep it idling until en-

gine 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 filtercartridge and the oil pump for damage orleakage. Refer to OIL PAN AND OIL PUMPin 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.

3-22

CHANGING THE ENGINE OIL/ADJUSTING THE CLUTCH CABLE FREE PLAY

CHKADJ

a

b

NOTE:

a

b

Oil gallery bolt10 Nm (1.0 mkg)

EAS00078

ADJUSTING THE CLUTCH CABLE FREEPLAY1. Check:clutch cable free play aOut of specification Adjust.

Clutch cable free play (at the endof the clutch lever)

10 15 mm

2. Adjust:clutch cable free play

Handlebar sidea. Loosen the locknut 1 .b. Turn the adjusting bolt 2 in direction a or b

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play isincreased.

Direction Clutch cable free play isdecreasedc. Tighten the locknut.

If the specified clutch cable free play cannot beobtained on the handlebar side of the cable, usethe adjusting nut on the engine side.

Engine sidea. Loosen the locknuts 1 .b. Turn the adjusting bolt 2 in direction a or b

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play isincreased.

Direction Clutch cable free play isdecreasedc. Tighten the locknuts.

3-23

CLEANING THE AIR FILTER ELEMENTCHKADJ

CAUTION:

EAS00086

CLEANING THE AIR FILTER ELEMENT1. Remove:seat fuel tankside covercover 1

2. Remove:air filter case cover 1air filter element

3. Clean:air filter elementApply compressed air to the outer surface ofthe air filter element.

4. Check:air filter elementDamage Replace.

5. Install:air filter elementair filter case cover

Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the air filter element will also affectthe carburetor tuning, leading to poor en-gine performance and possible overheat-ing.

3-24

CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS/

CHECKING THE FUEL HOSES AND FUEL FILTERCHKADJ

NOTE:When installing the air filter element into the airfilter case cover, be sure their sealing surfacesare aligned to prevent any air leaks.

6. Install:coverside cover fuel tankseat

EAS00095

CHECKING THE CARBURETOR JOINTSAND INTAKE MANIFOLDSThe following procedure applies to all of the car-buretor joints and intake manifolds.1. Remove:seat fuel tankair filter case panel 1

2. Check:carburetor joint 1 intake manifold 2Cracks/damage Replace.Refer to CARBURETOR in chapter 6.

3. Install:air chamber cover fuel tankseat

EAS00097

CHECKING THE FUEL HOSES AND FUELFILTERThe following procedure applies to all of the fuelhoses.1. Remove:seat fuel tankside cover

2. Check: fuel hose 1Cracks/damage Replace.

fuel filter 2Damage/dirt Replace.

3-25

CHECKING THE FUEL HOSES AND FUEL FILTER/CHECKING THE CRANKCASE BREATHER HOSE/

CHECKING THE EXHAUST SYSTEMCHKADJ

NOTE:

CAUTION:

Drain and flush the fuel tank if abrasive dam-age to any components of the fuel line is evi-dent.

The arrow mark a on the fuel filter should faceto the side of the fuel pump 1 .

3. Install:side cover fuel tankseat

EAS00098

CHECKING THE CRANKCASE BREATHERHOSE1. Remove:seat fuel tank

2. Check:crankcase breather hose 1Cracks/damage Replace.Loose connection Connect properly.

Make sure that the crankcase breather hoseis routed correctly.


EAS00099

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes and gaskets.1. Check:exhaust pipe 1muffler 2Cracks/damage Replace.

gasket 3Exhaust gas leaks Replace.

2. Check: tightening torque

Exhaust pipe nut 420 Nm (2.0 mkg)

Exhaust pipe and muffler bolt 520 Nm (2.0 mkg)

Exhaust pipe and bracket bolt 620 Nm (2.0 mkg)

Muffler and muffler bracket bolt 748 Nm (4.8 mkg)

3-26

ADJUSTING THE EXUP CABLESCHKADJ

CAUTION:

EAS00101

ADJUSTING THE EXUP CABLES1. Remove:seat fuel tank

2. Remove:EXUP valve pulley cover 1

3. Check:EXUP operation

a. Disconnect the EXUP servomotor connector1 .

b. Connect the battery to the EXUP servomotorconnector and check if the servomotor oper-ates properly.

Battery positive lead black/yellow 2Battery negative lead black/red 3

To avoid damaging the servomotor, do notleave the battery connected to it for morethan a few seconds.

c. Check that the EXUP valve operates properly.d. Connect the EXUP servomotor connector.

3-27

ADJUSTING THE EXUP CABLES/CHECKING THE COOLANT LEVEL

CHKADJ

10 Nm (1.0 mkg)

NOTE:

4. Check:EXUP cable free play a

EXUP cable free play1.5 mm 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 theEXUP valve cover.

c. Turn both adjusting bolts 2 counterclock-wise until there is no EXUP cable free play.

d. Turn both adjusting bolts 1/2 of a turn clock-wise.

e. Tighten both locknuts and then remove thepin.

6. Install:EXUP valve pulley cover


EAS00102

CHECKING THE COOLANT LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.

2. Check:coolant levelThe coolant level should be between themaximum level mark a and minimum levelmarks b .Below the minimum level mark Add therecommended coolant to the proper level.

3-28

CHECKING THE COOLANT LEVELCHKADJ

CAUTION:

NOTE:

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused instead of coolant, check and correctthe antifreeze concentration of the coolant.

Use only distilled water. Soft water may beused if distilled water is not available.


4. Check:coolant level

Before checking the coolant level, wait a fewminutes until it settles.

3-29

CHECKING THE COOLING SYSTEMCHKADJ

EAS00104

CHECKING THE COOLING SYSTEM1. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3oil cooler inlet hose 4oil cooler outlet hose 5water jacket inlet joint 6water pump outlet joint 7Cracks/damage Replace.Refer to COOLING SYSTEM in chapter 5.

3-30

CHANGING THE COOLANTCHKADJ

WARNING

EAS00105

CHANGING THE COOLANT1. Removeseat fuel tank front cowling rear suspensionRefer to REAR SHOCK ABSORBER AS-SEMBLY in chapter 4.

2. Disconnect:coolant reservoir hose 1

3. Drain:coolant(from the coolant reservoir)

4. Remove: radiator cap 1

A hot radiator is under pressure. Therefore,do not remove the radiator cap when the en-gine is hot. Scalding hot fluid and steam maybe blown out, which could cause serious in-jury. When the engine has cooled, open theradiator cap as follows:Place a thick rag or a towel over the radiatorcap and slowly turn the radiator cap coun-terclockwise toward the detent to allow anyresidual pressure to escape. When the his-sing sound has stopped, press down on theradiator cap, while still pressing down turn itcounterclockwise, and then remove it.

The following procedure applies to all of thecoolant drain bolts and copper washers.

5. Remove:coolant drain bolt 1(along with the copper washer)

6. Drain:coolant(from the engine and radiator)

3-31

CHANGING THE COOLANTCHKADJ

7 Nm (0.7 mkg)

WARNING

7. Check:copper washer 1coolant drain bolt 2Damage Replace.

8. Install:coolant drain bolt

9. Connect:coolant reservoir hose

10. Fill:cooling system(with the specified amount of the recom-mended coolant)

FZS1000(N) Service Manual

Documents

Transcript of FZS1000(N) Service Manual