US Fazer 1000 Service Manual

EAS00001

FZS1000N (C)SERVICE MANUAL

2001 by Yamaha MotorCorporation, U.S.A.

First edition, January 2001All rights reserved. Any reproduction

or unauthorized use without the writtenpermission of Yamaha Motor Corporation,

U.S.A. is expressly prohibited.Printed in U.S.A.

P/N LIT-11616-14-48

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.

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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

ELECCHAS

COOL

CHKADJ

TRBLSHTG

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 Engine5 Cooling system6 Carburetor(-s)7 Chassis8 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 grease

Symbols 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

ENGINE

COOLING SYSTEM

CARBURETORS

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

GENINFO 1SPEC 2

3ENG 4

COOL 5CARB 6CHAS 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 been”mated” 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

manufacturer’s 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 tester measurementYU-03112-C

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

YM-01080-A

Alternator Rotor Puller

This tool is used to remove the generator rotor.

YU-01235

Universal Magneto & Rotor Holder

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

YU-01304

Piston Pin Puller

This tool is used to remove the piston pins.

YU-01312-A

Fuel Level Gauge

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

RadiatorPressure TesterYU-24460-01RadiatorPressureTester AdapterYU-33984

Radiator Pressure TesterRadiator Pressure Tester Adapter

These tools are used to check the coolingsystem.

YU-33975

Spanner Wrench

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

YU-1268

Steering Nut Wrench

This tool is used to loosen the steering stemring nuts.

YM-01447

Damper Rod Holder

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

1-6



YU-38411

Oil Filter Wrench

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

YM-01434

Rod Holder

This tool is used to support the damperadjusting rod.

Rod pullerYM-01437

Rod Puller

This tool is used to pull up the front forkdamper rod.

DriverYM-3396343 mmAdaptersYM-8020-A

Driver43 mm Adapters

This tool is used to install the front fork’s oilseal and dust seal.

YU-03008

Micrometers (50 75 mm)

This tool is used to measure the piston skirtdiameter.

YU-8030

Carburetor Synchronizer

This guide is used to synchronize thecarburetors.

CompressionGauge SetYU-33223

Compression Gauge SetCompression Gauge Adapter

These tools are used to measure enginecompression.

YU-03112-C

Pocket Tester Measurement

This tool is used to check the electricalsystem.

YU-8036-B

Inductive Self-Powered Tachometer

This tool is used to check engine speed.

1-7



YM-33277-A

Battery Powered Timing Light

This tool is used to check the ignitiontiming.

Valve SpringCompressorYM-04019AdapterYM-4108YM-4114

Valve Spring Compressor Set, QuickReleaseAdapter

These tools are used to remove or installthe valve assemblies.

40 and 50 mmBearing DriverYM-4058Water PumpSeat InstallerYM-33221

40 and 50 mm Bearing DriverWater Pump Seal Installer

These tools are used to install the waterpump seal.

YM-91042

Universal Clutch Holder (Grabbit)

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

YM-04111YM-4116

Valve Guide Remover (ø4)Valve Guide Remover (ø4.5)

This tool is used to remove or install thevalve guides.

YM-04112YM-4117

Valve Guide Installer (ø4)Valve Guide Installer (ø4.5)

This tool is used to install the valve guides.

YM-04113YM-4118

Valve Guide Reamer (ø4)Valve Guide Reamer (ø4.5)

This tool is used to rebore the new valveguides.

YM-34487

Dynamic Spark Tester

This tool is used to check the ignitionsystem components.

ACC-11001-05-01

Yamaha bond No. 1215

This bond is used to seal two matingsurfaces (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

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard Limit

Model code 5LV5 (USA except for California)5LV6 (CDN)5LV7 (California)

DimensionsOverall lengthOverall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2,125 mm (83.7 in)765 mm (30.1 in)1,190 mm (46.9 in)820 mm (32.3 in)1,450 mm (57.1 in)140 mm (5.5 in)2,900 mm (114.2 in)

WeightWet (with oil and a full fuel tank)

Dry (without oil and fuel)

Maximum load (total of cargo, rider,passenger, and accessories)

231 kg (509 lb)232 kg (512 lb) (for california)208 kg (459 lb)209 kg (461 lb) (for california)189 kg (417 lb)188 kg (415 lb) (for california)

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 cm3

Forward-inclined parallel 4-cylinder74 58 mm (2.91 2.28 in)11.4 : 11,050 1,150 r/min30 kPa (225 mmHg, 8.86 in Hg)

1,450 kPa(14.5 kg/cm2, 206 psi) at 400 r/min

FuelRecommended fuel

Fuel tank capacityTotal (including reserve)Reserve only

Unleaded fuel (for USA)Regular unleaded gasoline (for CDN)

21 L (18.5 Imp qt, 22.2 US qt)4.0 L (3.52 Imp qt, 4.22 US qt)

Engine oilLubrication systemRecommended oil

QuantityTotal amountWithout oil filter cartridgereplacementWith oil filter cartridgereplacement

Oil pressure (hot)

Relief valve opening pressure

Wet sump

Yamalube 4 (20W40) or SAE 20W40 typeSE motor oil

3.7 L (3.2 Imp qt, 3.8 US qt)2.8 L (2.4 Imp qt, 2.9 US qt)

3.0 L (2.6 Imp qt, 3.1 US qt)

45 kPa (0.45 kg/cm2, 6.40 psi) at1,100 r/min490 570 kPa(4.9 5.7 kg/cm2, 69.7 81.1 psi)

2-3


Item Standard Limit

Oil filterOil filter typeBypass valve opening pressure

Cartridge (paper)180 220 kPa(1.8 2.2 kg/cm2, 25.6 31.3 psi)

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

Trochoidal0.09 0.15 mm (0.004 0.006 in)

0.03 0.08 mm (0.001 0.003 in)

Cooling systemRadiator capacityRadiator cap opening pressure

Radiator coreWidthHeightDepth

Coolant reservoirCapacity

Water pumpWater pump typeReduction ratioMax. impeller shaft tilt

2.4 L (2.11 Imp qt, 2.53 US qt)95 125 kPa(0.95 1.25 kg/cm2, 13.1 17.8 psi)

340 mm (13.4 in)238 mm (9.4 in)24 mm (0.94 in)

0.3 L (0.26 Imp qt, 0.32 US qt)

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

0.15 mm(0.006 in)

Starting system type Electric starter

Spark plugsModel (manufacturer) quantitySpark plug gap

CR9E/U27ESR-N (NGK/DENSO) 40.7 0.8 mm (0.028 0.031 in)

Cylinder headMax. warpage 0.1 mm

(0.004 in)

2-4


Item Standard Limit

CamshaftsDrive systemCamshaft cap inside diameter

Camshaft journal diameter

Camshaft-journal-to-camshaft-cap clearanceIntake camshaft lobe dimensions

Measurement A

Measurement B

Measurement CExhaust camshaft lobedimensions

Measurement A

Measurement B

Measurement CMax. camshaft runout

Chain drive (right)24.500 24.521 mm(0.9646 0.9654 in)24.459 24.472 mm(0.9630 0.9635 in)0.028 0.062 mm (0.0011 0.0024 in)

32.5 32.6 mm (1.2795 1.2835 in)

24.95 25.05 mm (0.9823 0.9862 in)

7.45 7.65 mm (0.2933 0.3012 in)

32.95 33.05 mm (1.2972 1.3012 in)

24.95 25.05 mm (0.9823 0.9862 in)

7.75 7.95 mm (0.3051 0.3126 in)

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

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

0.03 mm(0.0012 in)

2-5


Head Diameter Face Width Seat Width Margin Thickness

Item Standard Limit

Timing chainModel/number of linksTensioning system

RH2015/130Automatic

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

0.11 0.20 mm (0.0043 0.0079 in)0 21 0 25 mm (0 0083 0 0098 in)Intake

ExhaustValve dimensions

0.21 0.25 mm (0.0083 0.0098 in)

Valve head diameter AIntakeExhaust

Valve face width BIntakeExhaust

Valve seat width CIntakeExhaust

Valve margin thickness DIntakeExhaust

Valve stem diameterIntake

Exhaust

Valve guide inside diameterIntake

Exhaust

Valve-stem-to-valve-guideclearanceIntake

Exhaust

22.9 23.1 mm (0.9016 0.9094 in)24.4 24.6 mm (0.9606 0.9685 in)

1.76 2.90 mm (0.0693 0.1142 in)1.76 2.90 mm (0.0693 0.1142 in)

0.9 1.1 mm (0.035 0.043 in)0.9 1.1 mm (0.035 0.043 in)

0.5 0.9 mm (0.020 0.035 in)0.5 0.9 mm (0.020 0.035 in)

3.975 3.900 mm (0.1565 0.1535 in)

4.465 4.480 mm (0.1758 0.1764 in)

4.000 4.012 mm (0.1575 0.1580 in)

4.500 4.512 mm (0.1772 0.1776 in)

0.010 0.037 mm (0.0004 0.0015 in)

0.020 0.047 mm (0.0008 0.0019 in)

3.945 mm(0.1553 in)4.43 mm(0.1744 in)

4.05 mm(0.1594 in)4.55 mm(0.1791 in)

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

2-6


Item Standard Limit

Valve stem runout

Valve seat widthIntakeExhaust

Valve springsFree lengthIntakeExhaust

Installed length (valve closed)IntakeExhaust

Compressed spring force(installed)IntakeExhaust

Spring tilt

Intake

Exhaust

Winding direction (top view)IntakeExhaust

0.9 1.1 mm (0.035 0.043 in)0.9 1.1 mm (0.035 0.043 in)

38.90 mm (1.53 in)40.67 mm (1.60 in)

34.50 mm (1.36 in)35.00 mm (1.38 in)

82 96 N (8.2 9.6 kg, 18.4 25.4 lb)110 126 N(11.0 12.6 kg, 24.7 28.3 lb)

ClockwiseClockwise

0.01 mm(0.0004 in)

2.5 /1.7 mm(2.5 /0.067 in)2.5 /1.8 mm(2.5 /0.071 in)

2-7


Item Standard Limit

CylindersCylinder arrangementBore strokeCompression ratioBoreMax. taper

Max. out-of-round

Forward-inclined, parallel 4-cylinder74 58 mm (2.91 2.28 in)11.4 : 174.00 74.01 mm (2.9134 2.9138 in)

0.05 mm(0.0016 in)0.05 mm(0.0016 in)

PistonsPiston-to-cylinder clearance

Diameter D

Height HPiston pin bore (in the piston)Diameter

OffsetOffset direction

Piston pinsOutside diameter

Piston-pin-to-piston-pin-boreclearance

Piston ringsTop ring

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

0.030 0.055 mm (0.001 0.002 in)

73.955 73.970 mm(2.9118 2.9122 in)

5 mm (0.20 in)

17.002 17.013 mm(0.6694 0.6698 in)0.5 mm (0.0197 in)Intake side

16.991 17.000 mm(0.6689 0.6693 in)0.002 0.022 mm(0.00008 0.00087 in)

Barrel0.90 2.75 mm (0.035 0.108 in)0.32 0.44 mm (0.010 0.020 in)0.030 0.065 mm (0.0012 0.0026 in)

0.12 mm(0.005 in)

17.043 mm(0.6710 in)

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

2-8


Item Standard Limit

2nd ring

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

Oil ring

Taper0.8 2.8 mm (0.031 0.110 in)0.43 0.58 mm (0.017 0.023 in)0.020 0.055 mm (0.0008 0.0022 in)

Dimensions (B T)End gap (installed)

1.5 2.6 mm (0.059 0.101 in)0.10 0.35 mm (0.004 0.014 in)

Connecting rodsCrankshaft-pin-to-big-end-bearingclearanceBearing color code

0.031 0.055 mm (0.0012 0.0022 in)

–1 = Violet 0 = White 1 = Blue2 = Black

Crankshaft

Width AWidth BMax. runout C

Big end side clearance DCrankshaft-journal-to-crankshaft-journal-bearing clearanceBearing color code

52.40 57.25 mm (2.063 2.254 in)300.75 302.65 mm (11.84 11.92 in)

0.160 0.262 mm (0.006 0.010 in)0.029 0.053 mm (0.0011 0.0021 in)

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

0.03 mm(0.0012 in)

ClutchClutch typeClutch release methodClutch release method operationOperationClutch cable free play (at the end of theclutch lever)

Wet, multiple discCam (pull rod type)Cable operationLeft-hand operation10 15 mm (0.39 0.59 in)

2-9


Item Standard Limit

Friction platesThickness

Plate quantityThickness

Plate quantityClutch platesThicknessPlate quantityMax. warpage

Clutch springsFree lengthSpring quantity

2.92 3.08 mm (0.115 0.121 in)

83.42 3.58 mm (0.135 0.141 in)

1

1.9 2.1 mm (0.075 0.083 in)8

50 mm (1.97 in)6

2.82 mm(0.111 in)

3.32 mm(0.131 in)

0.1 mm(0.004 in)

TransmissionTransmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios1st gear2nd gear3rd gear4th gear5th gear6th gear

Max. main axle runout

Max. 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 mm(0.003 in)0.08 mm(0.003 in)

Shifting mechanismShift mechanism typeMax. shift fork guide bar bending

Installed shift rod length

Guide bar

260 mm (10.2 in)

0.1 mm(0.004 in)

Air filter type Dry element

Fuel pumpPump typeModel (manufacturer)Output pressure

Electrical4SV (MITSUBISHI)20 kPa (0.2 kg/cm2, 2.8 psi)

2-10


Item Standard Limit

CarburetorsModel (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 (0.12 0.20 in)

5LV5 40Carburetors 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 (0.118 0.157 in)

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

1.5 mm (0.059 in)

2-11

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

FrameFrame typeCaster angleTrail

Double cradle26104 mm (4.09 in)

Front wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runout

Max. lateral wheel runout

Cast wheel

17 MT3.50Aluminum140 mm (5.51 in)

1 mm(0.04 in)0.5 mm(0.02 in)

Rear wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runout

Max. lateral wheel runout

Cast wheel

17 MT5.50Aluminum135 mm (5.31 in)

1 mm(0.04 in)0.5 mm(0.02 in)

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, 36 psi)250 kPa (2.5 kgf/cm2, 36 psi)250 kPa (2.5 kgf/cm2, 36 psi)

1.0 mm(0.04 in)

2-12


Item Standard Limit

Rear 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, 39 bar)290 kPa (2.9 kgf/cm2, 42 bar)290 kPa (2.9 kgf/cm2, 42 bar)

1.0 mm(0.04 in)

Front brakesBrake typeOperationRecommended fluidBrake discsDiameter thicknessMin. thickness

Max. deflection

Brake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Dual-disc brakeRight-hand-operationDOT 4

298 5 mm (11.7 0.20 in)

5.5 mm (0.22 in)

14 mm (0.05 in)30.2 mm (1.19 in) and 27 mm (1.06 in)

4.5 mm(0.18 in)0.1 mm(0.004 in)0.5 mm(0.02 in)

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

Max. deflection

Brake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Single-disc brakeRight-foot operation35 40 mm (1.38 1.57 in)

DOT 4

267 5 mm (10.51 0.20 in)

5.5 mm (0.22 in)

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

4.5 mm(0.18 in)0.1 mm(0.004 in)0.5 mm(0.02 in)

2-13


Item Standard Limit

Front 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 sprin140 mm (5.51 in)

344.0 mm (13.5 in)66.0 mm (2.60 in)320.0 mm (12.6 in)7.8 N/mm (0.78 kg/mm, 43.7 lb/ in)11.8 N/mm (1.2 kg/mm, 67.2 lb/ in)0 64 mm (0 2.52 in)64 140 mm (2.52 5.51 in)No

Suspension oil “01” or equivalent435 cm3 (15.3 Imp oz, 14.7 US oz)140 mm (5.51 in)

5 (fully turned out position)21

1771

2161

2-14


Item Standard Limit

SteeringSteering 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 (2.56 in)

182.5 mm (7.19 in)163 mm (6.42 in)73.6 N/mm (7.5 kg/mm, 420 lb/ in)0 65 mm (0 2.56 in)No1,200 kPa (12 kg/cm2, 170.7 psi)

1611

20103

1712

SwingarmFree play (at the end of theswingarm)Radial

Axial

1 mm (0.04 in)1 mm (0.04 in)

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

50ZVM (DAIDO)11640 50 mm (1.57 1.97 in)150.1 mm (5.91 in) 152.5 mm

(6.00 in)

2-15

ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS

Item 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 Ω /Gy-BTNDF69 (DENSO)

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

J0313 (DENSO)6 mm (0.24 in)1.87 2.53 Ω12 18 kΩ

Spark plug capsMaterialResistance

Rubber10 kΩ

Throttle position sensor standardresistance 4 6 kΩ

Charging systemSystem typeModel (manufacturer)Normal outputStator coil resistance/color

AC magnetoF4T361 (MITSUBISHI)14 V/365 W at 5,000 r/min0.27 0.33 Ω at 20C (68F)/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 bulb

Bulbs (voltage/wattage quantity)HeadlightAuxiliary lightTail /brake lightFront turn signal lightRear turn signal lightMeter light

12 V 60 W/55 W 212 V 5 W 212 V 5 W/21 W 212 V 8 W/27 W 212 V 27 W 212 V 2 W 3

2-16


Item Standard Limit

Indicator 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 length

Spring force

Commutator resistanceCommutator diameter

Mica undercut

Constant mesh

SM-13 (MITSUBA)0.8 kW

12.5 mm (0.49 in)

7.65 10.01 N(780 1,021 gf, 27.5 36.0 oz)0.025 0.035 Ω28 mm (1.10 in)

0.7 mm (0.03 in)

4 mm(0.16 in)

27 mm(1.06 in)

Starter relayModel (manufacturer)AmperageCoil resistance

MS5F-631 (JIDECO)180 A4.18 4.62 Ω

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.27 W 2 + 3.4 W

Oil level switchModel (manufacturer) 5LV (DENSO)

Fuel senderModel (manufacturer)Resistance

5LV (NIPPON SEIKI)4 100 Ω at 25C (77F)

Sidestand/fuel pump relayModel (manufacturer)Coil resistance

5EB-20 (OMRON)180 Ω

Fuel pump maximum amperage 1.2 A

Radiator fanModel (manufacturer) 4XV (TOYO RADIATOR)

Thermo switchModel (manufacturer) 5JJ (NIPPON THERMOSTAT)

2-17


Item Standard Limit

Fuses (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 mm

12 mm

14 mm

17 mm

19 mm

22 mm

B(Bolt)

6 mm

8 mm

10 mm

12 mm

14 mm

16 mm

General tighteningtorques

Nm

6

15

30

55

85

130

m kg

0.6

1.5

3.0

5.5

8.5

13.0

ft lb

4.3

11

22

40

61

94

EAS00030

GENERAL TIGHTENING TORQUESPECIFICATIONSThis 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


ENGINE TIGHTENING TORQUES

Item Fastener Threadsize Q’ty

Tighteningtorque Remarkssize y

Nm mkg ftlb

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 assemblydriven sprocket

Oil pumpOil coolerEngine oil drain boltOil strainer housingOil /water pump assemblydriven sprocket cover

Oil delivery pipeOil filter boltOil filter cartridgeOil pipeOil strainer coverAir cleaner cap and aircleanerFrame and air cleanerAir cleaner cover and aircleanerRing 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)

–Nut

Cap nutBoltBoltBolt

Stud bolt

NutBoltBolt

Bolt

BoltBoltBolt

Bolt

BoltBolt

–Bolt

Bolt

BoltBolt

–BoltBolt

Screw

Bolt

Screw

NutBoltBoltBoltBoltBoltBoltBolt

BandStud bolt

M10M10M10M6M6M6

M8

M8M10M10

M6

M7M6M6

M6

M6M20M14M6

M6

M6M20M20M6M6

M6

M6

M6

M8M8M8M6M6M5M4M8–

M10

4822

286

8

811

1

411

1

1112

1

11122

4

3

6

834331214

10

135050121012

15

3665 + 60

60

6.4

241010

15

12354310

12

1070171010

6

7

2

2020101010103

203.510

1.35.05.01.21.01.2

1.5

3.66.5 + 60

6.0

0.64

2.41.01.0

1.5

1.23.54.31.0

1.2

1.07.01.71.01.0

0.6

0.7

0.2

2.02.01.01.01.01.00.32.0

0.351.0

9.436368.77.28.7

11

2547 + 60

43

4.6

177.27.2

11

8.725317.2

8.7

7.251127.27.2

4.3

5.1

1.4

14147.27.27.27.22.2142.57.2

Crankcase Bolt M9 10 See note

CrankcaseCrankcaseCrankcase

BoltBoltBolt

M6M6M8

2142

141224

1.41.22.4

108.717

2-20


NOTE:

Item FastenerThread

size Q’tyTightening

torque Remarkssize yNm mkg ftlb

AC magneto coverDrive sprocker coverPlateClutch coverTiming chain cap boltShift shaft coverBreather plateTiming mark accessing screwStarter clutch idle gear shaftStarter one-way clutch

Clutch boss

Clutch spring

Drive sprocket

Main axle bearing housingShift lever stopperStopper screwShift rodShift rodShift rod jointShift armAC magneto stator coilIgnitor unitNeutral switchPick up coilThermo unit

BoltBoltBoltBoltBoltBoltBoltBoltBoltBolt

Nut

Bolt

Nut

ScrewBolt

ScrewNutNutBoltBolt

ScrewScrew

–Bolt

–

M6M6M6M6M6M6M6M8M6M6

M20

M6

M22

M6M6M8M6M6M6M6M6M5

M10M6–

9428855113

1

6

1

321121132121

12101012121210151012

90

8

85

1210226.56.51010147

201015

1.21.01.01.21.21.21.01.51.01.2

9.0

0.8

8.5

1.21.02.2

0.650.651.01.01.40.72.01.01.5

8.77.27.28.78.78.77.2117.28.7

65

5.8

61

8.77.2164.74.77.27.2105.1147.211

Use a lockwasher.

Use a lockwasher.

Left thread

1. First, tighten the bolt to approximately 14.7 Nm (1.5 mkg, 11 ftlb) with a torque wrench.2. Retighten the bolt to 14.7 Nm (1.5 mkg, 11 ftlb), and tighten another 45 50.

2-21


Crankcase tightening sequence:

2-22


NOTE:

CHASSIS TIGHTENING TORQUES

Item Thread sizeTightening

RemarksItem Thread sizeNm m kg ft lb

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

3.0113.22.32.31.81.03.0

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

2280231717137.222

4024645.15.19029292935355.15.15.12.92.92.9521729134.317501229

108224.317222.917402035

See note

1. First, tighten the ring nut to approximately 52 Nm (5.2 m kg, 38 ft lb) with a torque wrench, thenloosen the ring nut completely.

2. Retighten the ring nut to specification.

2-23

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS00031

LUBRICATION POINTS AND LUBRICANT TYPESENGINE

Lubrication point Lubricant

Oil seal lips

O-rings

Bearings

Crankshaft pins

Piston surfaces

Piston pins

Connecting rod bolts and nuts

Crankshaft journals

Camshaft lobes

Camshaft journals

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Water pump impeller shaft

Oil pump rotors (inner and outer)

Oil strainer

Starter clutch idle gear inner surface

Starter clutch assembly

Primary driven gear

Transmission gears (wheel and pinion)

Main axle and drive axle

Shift drum

Shift forks and shift fork guide bars

Shift shaft

Shift shaft boss

Cylinder head cover mating surface Yamaha bondNo.1215

Crankcase mating surface Yamaha bondNo.1215

Clutch cover (crankcase mating surface) Yamaha bondNo.1215

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

2-24

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EAS00032

CHASSIS

Lubrication point Lubricant

Steering bearings, steering seal lips and ball race cover lips

Pivot shaft

Swing arm pivoting points and connecting arm bearings

Connecting arm oil seal lips

Swing arm oil seal lips

Relay arm bearings

Relay arm oil seal lips

Rear shock absorber upper bolt

Front wheel oil seal lips

Rear wheel oil seal lips

Clutch hub oil seal lips

Throttle cable end

Starter cable end and starter lever

Rear brake pedal moving point

Shift pedal moving point

Side stand moving point

Passenger footrest ball joint and moving point

Engine mounting bracket collar and oil seal lips

Mainstand moving point

2-25

COOLING SYSTEM DIAGRAMS SPEC

1 Radiator cap2 Thermostat housing3 Radiator4 Water pump

EAS00033

COOLING SYSTEM DIAGRAMS

2-26


1 Radiator cap2 Thermostat housing3 Radiator4 Oil cooler5 Water jacket joint

2-27


1 Radiator cap2 Thermostat3 Thermo unit

2-28


1 Radiator

2-29

Oilcooler

Exhaustcamshaft

Intakecamshaft

Main gallery

Oil filter

Main axle

Drive axleStrainer

Reliefvalve

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 SPEC

EAS00034

LUBRICATION DIAGRAMS

2-31


1 Intake camshaft2 Exhaust camshaft3 Oil cooler4 Oil strainer5 Oil pump

2-32


1 Intake camshaft2 Exhaust camsahft3 Oil filter cartridge4 Oil level switch

2-33


1 Cylinder head2 Crankshaft

2-34


1 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 SPEC

17 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 (0.79 in) range.

O Route the EXUP cable forward the another hoses,and upward the engine mounting bracket.

P Fasten the rear brake light switch lead with a 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 SPEC

1 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 SPEC

and rectifier regulator lead.U Route the water carburetor hose outside the coolant

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

per the water-carburetor hose.W Route the high tension cable (#2, 3) forward the EXUP

cable and high tension cable (#4).X Route the throttle cable between the water-head hose,

and upper the EXUP cable.Y Route the high tension cable (#4) between the water-

head hose.Z Taillight lead and flasher light lead (right) should not be

stick 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 SPEC

1 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 SPEC

K Fasten the fuel hose and air induction system hosewith a plastic clamp.

L Route the coolant reservoir hose under the framecross 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 SPEC

T Fasten the ignition coil lead and frame cross pipewith 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. Locatethe end of clamp to downward. Ensure that thethrottle cable and high tension cable do not comeinto contact with each other.

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

W Route the wire harness under the rectifier/regulator.X Fasten the battery negative lead with a battery

band.Y Insert the ground lead coupler in the battery band.Z Fasten the taillight lead and flasher light lead, and

put in the groove on the taillight bracket.

CHKADJ

CHAPTER 3PERIODIC CHECKS AND ADJUSTMENTS

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

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERAL MAINTENANCE AND LUBRICATION CHART 3-1. . . . . . . . . .

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

ENGINE 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. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CANISTER 3-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHKADJ

ADJUSTING THE FRONT FORK LEGS 3-43. . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-45. . . . . . CHECKING THE TIRES 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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.

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS

No. ITEM ROUTINE 600 mi(1,000 km)

or1 month

4,000 mi(7,000 km)

or6 months

8,000 mi(13,000 km)

or12 months

12,000 mi(19,000 km)

or18 months

16,000 mi(25,000 km)

or24 months

20,000 mi(31,000 km)

or30 months

1 * Valve clearance(See page 3-5)

Check and adjust valve clearancewhen engine is cold. Every 26,600 mi (42,000 km)

2 Spark plugs(See page 3-15)

Check condition. Adjust gap and clean. Replace every 8,000 mi (13,000 km)

or 12 months.

√ Replace. √ Replace. √

3 *Crankcaseventilation system(See page 3-25)

Check ventilation hose for cracks ordamage.

Replace if necessary.√ √ √ √ √

4 * Fuel line(See page 3-24)

Check fuel hoses and vacuum hosefor cracks or damage.

Replace if necessary.√ √ √ √ √

5 * Fuel filter(See page 3-24)

Replace every 20,000 mi (31,000 km)or 30 months. Replace.

6 * Exhaust system(See page 3-25)

Check for leakage. Retighten if necessary. Replace gasket(s) if necessary.

√ √ √ √ √

7 *Carburetorsynchronization(See page 3-10)

Adjust synchronization of carburetors. √ √ √ √ √ √

8 * Idle speed(See page 3-12)

Check and adjust engine idle speed. Adjust cable free play. √ √ √ √ √

9 *

Evaporativeemission controlsystem (ForCalifornia only)(See page 3-26)

Check control system for damage. Replace if necessary. √ √

10 *Air inductionsystem(See page 7-14)

Check the air cut valve and read valvefor damage.

Replace the entire air inductionsystem if necessary.

√ √ √ √ √

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform theservice.

GENERAL MAINTENANCE AND LUBRICATION CHART



or1 month

4,000 mi(7,000 km)

or6 months

8,000 mi(13,000 km)

or12 months

12,000 mi(19,000 km)

or18 months

16,000 mi(25,000 km)

or24 months

20,000 mi(31,000 km)

or30 months

1 Engine oil(See page 3-20)

Replace (warm engine beforedraining). (See NOTE) √ √ √ √ √ √

2Engine oil filtercartridge(See page 3-20)

Replace at initial 600 mi (1,000 km) or1 month, and thereafter every8,000 mi (13,000 km) or 12 months.

√ √ √

3 * Air filter element(See page 3-23)

Clean with compressed air. Replace if necessary. √ √ √ √ √

4 *Cooling system(See page 3-29)

Check hose for cracks or damage. Replace if necessary. √ √ √ √ √

4 (See page 3 29)(See page 3-30)

Replace coolant every 24 months. #3 Replace.

5 *Brake system(See page 3-35)(See page 3-36)

Check operation, pad wear, and fluidleakage. (See NOTE)

Correct if necessary.√ √ √ √ √ √

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSCHKADJ

NOTE:

NOTE:



or1 month

4,000 mi(7,000 km)

or6 months

8,000 mi(13,000 km)

or12 months

12,000 mi(19,000 km)

or18 months

16,000 mi(25,000 km)

or24 months

20,000 mi(31,000 km)

or30 months

6 * Clutch(See page 3-22)

Check operation. Adjust or replace cable. √ √ √ √ √ √

7 * Control cable(See page 3-50) Apply chain lube thoroughly. #1 √ √ √ √ √ √

8 *

Swingarm pivotbearing(See page 4-68)(See page 4-69)

Check bearing assembly forlooseness.

Moderately repack every 16,000 mi(25,000 km) or 24 months. #2

√ √Repack.

9 *Rear suspensionlink pivots(See page 4-69)

Check operation. Moderately repack every 16,000 mi

(25,000 km) or 24 months. #2√ √

Repack.

10 *Shock absorberassembly(See page 4-64)

Check operation and for oil leakage. Replace if necessary. √ √ √ √ √

11 * Front fork(See page 3-43)

Check operation and for oil leakage. Repair if necessary. √ √ √ √ √

12 *Steering bearings(See page 3-41)(See page 4-59)

Check bearing assembly forlooseness.

Moderately repack every 16,000 mi(25,000 km) or 24 months. #2

√ √ √ √Repack. √

13Brake and clutchlever pivot shafts(See page 3-50)

Lubricate. #2 √ √ √ √ √

14Brake and shiftpedal pivot shafts(See page 3-50)

Lubricate. #2 √ √ √ √ √

15 *Drive chain(See page 3-39)(See page 3-69)

Check chain slack / alignmentcondition.

Adjust and lubricate chain thoroughly.#1

Every 600 mi (1,000 km) or after washing the motorcycleor riding in the rain.

√

16 * Wheel bearings(See page 4-4) Check bearings for smooth operation. √ √ √ √ √

17 *

Sidestand andcenterstandpivots(See page 3-50)

Check operation. Lubricate. #2 √ √ √ √ √

18 * Sidestand switch(See page 8-21)

Check and clean or replace ifnecessary. √ √ √ √ √ √

19 * Chassis fasteners(See page 2-22)

Check all chassis fitting and fasteners. Correct if necessary. √ √ √ √ √

* Since these items require special tools, data and technical skills, have a Yamaha dealer perform theservice.

#1: Yamaha chain lube#2: Lithium-soap-based grease (all-purpose grease)#3: Ethylene glycol anti-freeze coolant

From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi(7,000 km) or 6 months.

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 cylinder and caliper, andchange the brake fluid.

Replace the brake hoses every four years and if cracked or damaged. Engine oil type

Yamalube 4 (20W-40) or engine oil SAE 20W-40 (API SE) for temperatures of 5 C (40 F) orabove.

Yamalube 4 (10W-30) or engine oil SAE 10W-30 (API SE) for temperatures of 15 C (60 F) orbelow.

3-3

FRONT COWLINGCHKADJ

Order Job/Part Q’ty Remarks

123456

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

21/11211

Remove the 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


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


Disconnect.

Befor disconnecting the fuel hose, turnthe fuel cock off.


NOTE:

10 Nm (1.0 mkg), 7.2 ftlb

19 Nm (1.9 mkg), 14 ftlb

4 Nm (0.4 mkg,2.9 ftlb)

10 Nm (1.0 mkg,7.2 ftlb)

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 mm(0.0043 0.0079 in)

Exhaust valve0.21 0.25 mm(0.0083 0.0098 in)

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 clockwise

C Cylinder

D Combustion cycle

#2 Cylinder 180

#4 Cylinder 360

#3 Cylilnder 540

3. Remove: intake camshaftexhaust camshaft

Refer to “REMOVING THE CAMSHAFTS” inchapter 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 .

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(0.047

0.094 in)

25 thicknessesin 0.05 mm(0.0020 in)increments

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 value

0 or 2 0

5 5

8 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


120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 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

INSTALLED PAD NUMBER

EXAMPLE:VALVE CLEARANCE: 0.11 0.20 mm(0.0043 0.0079 in)

Installed is 150Measured clearance is 0.25 mm (0.0098 in)Replace 150 pad with 160 pad

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

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

Measuredclearance

exa

EXAMPLE:VALVE CLEARANCE: 0.21 0.30 mm(0.0083 0.0118 in)

Installed is 175Measured clearance is 0.35 mm (0.0138 in)Replace 175 pad with 185 pad

INSTALLED PAD NUMBER

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 oil to the valvepad and the valve lifter.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 m kg, 7.2 ft lb)

Refer to “INSTALLING THE CAMSHAFTS” inchapter 4.Lubricate the camshaft caps, camshaft lobesand 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:carburetor synchronizer 1inductive self-powered tachometer 2(to the spark plug lead of cyl. #1)

Carburetor synchronizerYU-8030

Inductive self-powered tachometerYU-8036-B

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, 8.86 in Hg)

The difference in vacuum pressure betweentwo carburetors should not exceed 1.33 kPa (10mm Hg, 0.39 in 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 (0.12 0.20 in)

10. Install:vacuum cap

3-12

ADJUSTING THE ENGINE IDLING SPEEDCHKADJ

NOTE:

a

b

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:inductive self-powered 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 throttle stop screw 1 in direction aor b until the specified engine idling speed isobtained.

Direction Engine idling speed isincreased.

Direction Engine idling speed isdecreased.

3-13

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

CHKADJ

NOTE:

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 (0.12 0.20 in)

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.


3 5 mm (0.12 0.20 in)

2. Remove:seatfuel 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 cap2. 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 (0.028 0.031 in)

3-16

CHECKING THE SPARK PLUGS/CHECKING THE IGNITION TIMING

CHKADJ

13 Nm (1.3 m kg, 9.4 ft lb)

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:battery powered timing light 1inductive self-powered tachometer 2(to the spark plug lead of cyl. #1)

Battery powered timing lightYM-33277-A


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 gauge setYU-33223

Compression gauge adapterYU-33223-3

3-18

MEASURING THE COMPRESSION PRESSURECHKADJ

WARNING

NOTE:

13 Nm (1.3 m kg, 9.4 ft lb)

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 Diagnosis

Higher 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, 206 psi)Minimum:

1,260 kPa (12.6 kg/cm2, 179 psi)Maximum:

1,620 kPa (16.2 kg/cm2, 230 psi)

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

until the reading on the compression 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/cm2,14.2 psi).

7. Install:spark plug

8. Connect:spark plug cap

3-19

CHECKING THE ENGINE OIL LEVELCHKADJ

NOTE:

CAUTION:

NOTE:

NOTE:

EAS00071

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. 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 oilYamalube 4 (20W40) or SAE20W40 type SE motor oil

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives.Do not allow foreign materials to enter thecrankcase.

API Service “SE”, “SF” and “SG” type or equiva-lent (e.g., “SF-SE”, “SF-SE-CC”, “SF-SE-SD”).


4. 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 wrenchYU-38411

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 m kg, 31 ft lb)

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

Oil filter cartridge17 Nm (1.7 m kg, 12 ft lb)

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 L (3.2 Imp qt, 3.8 US qt)Without oil filter cartridgereplacement

2.8 L (2.4 Imp qt, 2.9 US qt)With oil filter cartridge replace-ment

3.0 L (2.6 Imp qt, 3.1 US qt)

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 PUMP”in chapter 5.

d. Start the engine after solving the problem(-s)and check the engine oil pressure again.

e. Tighten the oil gallery bolt to specification.

3-22

CHANGING THE ENGINE OIL/ADJUSTING THE CLUTCH CABLE FREE PLAY

CHKADJ

a

b

NOTE:

a

b

Oil gallery bolt10 Nm (1.0 mkg, 7.2 ftlb)

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 (0.39 0.59 in)

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 isdecreased


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 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 isdecreased


3-23

CLEANING THE AIR FILTER ELEMENTCHKADJ

CAUTION:

EAS00086

CLEANING THE AIR FILTER ELEMENT1. Remove:

seatfuel 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 FILTER

CHKADJ

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 coverfuel tankseat

EAS00095

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

seatfuel tankair filter case panel 1

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

3. Install:air chamber coverfuel tankseat

EAS00097

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

seatfuel 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 SYSTEM

CHKADJ

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 coverfuel tankseat

EAS00098

CHECKING THE CRANKCASE BREATHERHOSE1. Remove:

seatfuel 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 m kg, 14 ft lb)

Exhaust pipe and muffler bolt 520 Nm (2.0 m kg, 14 ft lb)

Exhaust pipe and bracket bolt 620 Nm (2.0 m kg, 14 ft lb)

Muffler and muffler bracket bolt 748 Nm (4.8 m kg, 35 ft lb)

3-26

CHECKING THE CANISTER/ADJUSTING THE EXUP CABLES

CHKADJ

CAUTION:

CHECKING THE CANISTER(for California only)1. Remove:seat fuel tank

2. Check:hose and canisterCracks/damage Replace.

vent hoseObstruction Clean.

3. Install: fuel tankseat

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 m kg, 7.2 ft lb)

NOTE:

4. Check:EXUP cable free play a

EXUP cable free play1.5 mm (0.06 in) max.

5. Adjust:EXUP cable free play

a. Loosen both locknuts 1 .b. Insert a 4 mm long pin through the notch in

the EXUP valve pulley and into the hole in 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.


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 1radiator inlet hose 2radiator 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 6.

3-30

CHANGING THE COOLANTCHKADJ

WARNING

EAS00105

CHANGING THE COOLANT1. Remove

seatfuel tankfront cowlingrear 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


7 Nm (0.7 m kg, 5.1 ft lb)

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)

Recommended antifreezeHigh-quality ethylene glycol anti freeze containing corrosion inhibi tors for aluminum engines

Mix ratio 50% antifreeze/50% water

QuantityTotal amount

2.4 L (2.11 Imp qt, 2.53 US qt)Coolant reservoir capacity

0.3 L (0.26 Imp qt, 0.32 US qt)From minimum to maximumlevel mark

0.2 L (0.18 Imp qt, 0.21 US qt)

Handling notes for coolantCoolant is potentially harmful and should behandled with special care.

If coolant splashes in your eyes, thorough-ly wash them with water and consult a doc-tor.If coolant splashes on your clothes, quick-ly wash it away with water and then withsoap and water.If coolant is swallowed, induce vomitingand get immediate medical attention.

3-32


CAUTION:

NOTE:

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused instead of coolant, check, and if nec-essary, correct the antifreeze concentra-tion of the coolant.

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

If coolant comes into contact with paintedsurfaces, immediately wash them with wa-ter.

Do not mix different types of antifreeze.

11. Install: radiator cap

12. Fill:coolant reservoir

(with the recommended coolant to the maxi-mum level mark a )13. Install:coolant reservoir cap


15. Check:coolant levelRefer to “CHECKING THE COOLANT LEV-EL”.

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

16. Install: rear suspensionRefer to “REAR SHOCK ABSORBER AS-SEMBLY” in chapter 4.

fuel tankseat

3-33

ADJUSTING THE FRONT BRAKECHKADJ

NOTE:

a

a

WARNING

CAUTION:

EAS00107

CHASSISADJUSTING THE FRONT BRAKE1. Adjust:

brake lever position(distance a from the throttle grip to the brakelever)

a. While pushing the brake lever forward, turnthe adjusting dial 1 until the brake lever is inthe desired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the brake lever hold-er.

Position #1 Distance is the larg-est.

Position #5 Distance is the small-est.

After adjusting the brake lever position,make sure that the pin on the brake leverholder is firmly inserted in the hole in theadjusting dial.A soft or spongy feeling in the brake levercan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem . Air in the brake system will con-siderably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, check and, if nec-essary, bleed the brake system.

After adjusting the brake lever position,make sure that there is no brake drag.

3-34

ADJUSTING THE REAR BRAKECHKADJ

a

b

WARNING

WARNING

CAUTION:

EAS00110

ADJUSTING THE REAR BRAKE1. Check:

brake pedal position(distance a from the top of the rider footrestto the top of the brake pedal)Out of specification Adjust.

Brake pedal position (below thetop of the rider footrest)

40 mm (1.57 in)

2. Adjust:brake pedal position

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

until the specified brake pedal position is ob-tained.

Direction Brake pedal is raised.

Direction Brake pedal is lowered.

After adjusting the brake pedal position,check that the end of the adjusting bolt 2 isvisible through the hole c .

c. Tighten the locknut 1 to specification.

Locknut18 Nm (1.8 m kg, 13 ft lb)

A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem . Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident. Therefore, check and, if neces-sary, bleed the brake system.

After adjusting the brake pedal position,make sure that there is no brake drag.

3-35

ADJUSTING THE REAR BRAKE/CHECKING THE BRAKE FLUID LEVEL

CHKADJ

A

B

NOTE:

WARNING

CAUTION:

NOTE:

3. Adjust:rear brake light switchRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”.

EAS00115

CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.


2. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.

Recommended brake fluidDOT 4

A Front brakeB Rear brake

Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

In order to ensure a correct reading of the brakefluid level, make sure that the top of the reser-voir is horizontal.

3-36

A

B

CHECKING THE BRAKE PADS/ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHKADJ

NOTE:

a

b

EAS00122

CHECKING THE BRAKE PADSThe following procedure applies to all of thebrake pads.1. Operate the brake.2. Check:

front brake padrear brake padWear indicator groove 1 almost disap-peared Replace the brake pads as a set.Refer to “REPLACING THE FRONT BRAKEPADS” and “REPLACING THE REARBRAKE PADS” in chapter 4.

A Front brake

B Rear brakeEAS00128

ADJUSTING THE REAR BRAKE LIGHTSWITCH

The rear brake light switch is operated by move-ment of the brake pedal.The rear brake light switch is properly adjustedwhen the brake light comes on just before thebraking effect starts.

1. Check:rear brake light operation timingIncorrect Adjust.

2. Adjust:rear brake light operation timing

a. Hold the main body 1 of the rear brake lightswitch so that it does not rotate and turn theadjusting nut 2 in direction a or b until therear brake light comes on at the proper time.

Direction Brake light comes onsooner.

Direction Brake light comes on lat-er.

3-37

CHECKING THE BRAKE HOSES/BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHKADJ

WARNING

NOTE:

EAS00131

CHECKING THE BRAKE HOSESThe following procedure applies to all of thebrake hoses and clamps.1. Check:

brake hose 1Cracks/damage/wear Replace.

2. Check:brake hose clamp 2Loose connection Tighten.

3. Hold the motorcycle upright and apply thebrake.

4. Check:brake hose 1Activate the brake several times.Brake fluid leakage Replace the damagedhose.Refer to “FRONT AND REAR BRAKES” inchapter 4.

EAS00134

BLEEDING THE HYDRAULIC BRAKE SYS-TEM

Bleed the hydraulic brake system whenev-er:the system was disassembled,a brake hose was loosened or removed,the brake fluid level is very low,brake operation is faulty.

1. Remove:reservoir cap 1diaphragm 2

Be careful not to spill any brake fluid or allowthe brake master cylinder reservoir or brakefluid reservoir to overflow.When bleeding the hydraulic brake system,make sure that there is always enough brakefluid before applying the brake. Ignoring thisprecaution could allow air to enter the hydrau-lic brake system, considerably lengthening thebleeding procedure.If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.

3-38

BLEEDING THE HYDRAULIC BRAKE SYSTEM /ADJUSTING THE SHIFT PEDAL

CHKADJ

WARNING

2. Bleed:hydraulic brake system

a. Add the recommended brake fluid to theproper level.

b. Install the diaphragm (brake master cylinderreservoir or brake fluid reservoir).

c. Connect a clear plastic hose 1 tightly to thebleed screw 2 .

A FrontB Reard. Place the other end of the hose into a con-

tainer.e. Slowly apply the brake several times.f. Fully squeeze the brake lever or fully de-

press the brake pedal and hold it in position.g. Loosen the bleed screw.

This will release the tension and cause thebrake lever to contact the throttle grip or thebrake pedal to fully extend.

h. Tighten the bleed screw and then release thebrake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 m kg, 4.3 ft lb)

k. Fill the reservoir to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL”.

After bleeding the hydraulic brake system,check the brake operation.

EAS00110

ADJUSTING THE SHIFT PEDAL1. Check:

shift pedal position(distance a from the top of the rider footrestto the top of the shift pedal)Out of specification Adjust.

Shift pedal position (below the top of the rider footrest)

40 mm (1.57 in)

3-39

ADJUSTING THE SHIFT PEDAL/ADJUSTING THE DRIVE CHAIN SLACK

CHKADJ

a

b

NOTE:

CAUTION:

WARNING

NOTE:

2. Adjust:adjusting bolt length

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

to obtain the correct shift pedal position.

Direction Shift pedal is raised.

Direction Shift pedal is lowered.

Tighten both locknuts.

EAS00140

ADJUSTING THE DRIVE CHAIN SLACK

The drive chain slack must be checked at thetightest point on the chain.

A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip and damage the swin-garm or cause an accident. Therefore, keepthe drive chain slack within the specifiedlimits.

1. Stand the motorcycle on a level surface.

Securely support the motorcycle so thatthere is no danger of it falling over.

Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.

2. Rotate the rear wheel several times andcheck the drive chain to locate its tightestpoint.

3. Check:drive chain slack aOut of specification Adjust.

Drive chain slack40 50 mm (1.57 1.97 in)

3-40

ADJUSTING THE DRIVE CHAIN SLACKCHKADJ

a

b

NOTE:

4. Adjust:drive chain slack

a. Loosen the brake caliper bracket bolt.b. Loosen the wheel axle nut 1 .c. Loosen both locknuts 2 .d. Turn both adjusting nuts 3 in direction a or

b until the specified drive chain slack is ob-tained.

Direction Drive chain is tightened.

Direction Drive chain is loosened.

To maintain the proper wheel alignment, adjustboth sides evenly.

e. Tighten both locknuts to specification.

Locknut16 Nm (1.6 m kg, 12 ft lb)

f. Tighten the wheel axle nut to specification.

Wheel axle nut150 Nm (15 m kg, 108 ft lb)

3-41

LUBRICATING THE DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEAD

CHKADJ

WARNING

NOTE:

EAS00142

LUBRICATING THE DRIVE CHAINThe drive chain consists of many interactingparts. If the drive chain is not maintained proper-ly, it will wear out rapidly. Therefore, the drivechain should be serviced, especially when themotorcycle is used in dusty areas.This motorcycle has a drive chain with smallrubber O-rings between each side plate. Steamcleaning, high-pressure washing, certain sol-vents, and the use of a coarse brush can dam-age these O-rings. Therefore, use only kerosineto clean the drive chain. Wipe the drive chain dryand thoroughly lubricate it with engine oil orchain lubricant that is suitable for O-ring chains.Do not use any other lubricants on the drivechain since they may contain solvents thatcould damage the O-rings.

Recommended lubricantEngine oil or chain lubricant suitable forO-ring chains

EAS00146

CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the motorcycle on a level surface.


Place the motorcycle on a suitable stand so thatthe front wheel is elevated.

2. Check:steering headGrasp the bottom of the front fork legs andgently rock the front fork.Looseness or binding Adjust the steeringhead.

3. Remove:front cowling assemblyRefer to “FRONT COWLING”.upper bracketRefer to “HANDLEBAR” and “STEERINGHEAD” in chapter 4.

4. Adjust:steering head

a. Remove the lock washer 1 , the upper ringnut 2 , and the rubber washer 3 .

3-42

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

NOTE:

WARNING

NOTE:

b. Loosen the lower ring nut 4 and then tightenit to specification with a spanner wrench 5 .

Set the torque wrench at a right angle to thespanner wrench.

Spanner wrenchYU-33975

Lower ring nut (initial tightening torque)

52 Nm (5.2 m kg, 38 ft lb)

c. Loosen the lower ring nut 6 completely, thentighten it to specification.

Do not overtighten the lower ring nut.

Lower ring nut (final tighteningtorque)

18 Nm (1.8 m kg, 13 ft lb)

d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and inspect the upper andlower bearings.Refer to “STEERING HEAD AND HAN-DLEBAR” in chapter 4.

e. Install the rubber washer 7 .f. Install the upper ring nut 8 .g. Finger tighten the upper ring nut 8 , then

align the slots of both ring nuts. If necessary,hold the lower ring nut and tighten the upperring nut until their slots are aligned.

h. Install the lock washer 9 .

Make sure that the lock washer tabs a sit cor-rectly in the ring nut slots b .

5. Install:upper bracketfront cowling assembly

3-43

CHECKING AND ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK/ADJUSTING THE FRONT FORK LEGS

CHKADJ

WARNING

WARNING

CAUTION:

Steering stem nut110 Nm (11 m kg, 80 ft lb)

Upper bracket pinch bolt30 Nm (3.0 m kg, 22 ft lb)

Handlebar holder bolt23 Nm (2.3 m kg, 17 ft lb)

EAS00149

CHECKING THE FRONT FORK1. Stand the motorcycle on a level surface.


2. Check:inner tubeDamage/scratches Replace.oil sealOil leakage Replace.

3. Hold the motorcycle upright and apply thefront brake.

4. Check:operationPush down hard on the handlebar severaltimes and check if the front fork reboundssmoothly.Unsmooth operation Repair.Refer to “FRONT FORK” in chapter 4.

EAS00155

ADJUSTING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Always adjust both front fork legs evenly.Uneven adjustment can result in poor han-dling and loss of stability.Securely support the motorcycle so thatthere is no danger of it falling over.

Spring preload

Grooves are provided to indicate the ad-justment position.Never go beyond the maximum or mini-mum adjustment positions.

3-44

ADJUSTING THE FRONT FORK LEGSCHKADJ

a

b

CAUTION:

a

b

1. Adjust:spring preload

a. Turn the adjusting bolt 1 in direction a orb .

DirectionSpring preload isincreased (suspension isharder).

DirectionSpring preload isdecreased (suspension issofter).

Adjusting positionsStandard: 2Minimum: 5*Maximum: 1

*fully turned out position

Rebound damping

Never go beyond the maximum or minimumadjustment positions.

1. Adjust: rebound damping

a. Turn the adjusting screw 1 in direction a orb .

Rebound damping isDirection

p gincreased (suspension isharder).

Rebound damping isDirection

p gdecreased (suspension issofter).

Adjusting positionsStandard: 7 clicks out*Minimum: 17 clicks out*Maximum: 1 clicks out*

*: from the fully turned-in position

3-45

ADJUSTING THE FRONT FORK LEGS/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

CHKADJ

CAUTION:

a

b

WARNING

CAUTION:

NOTE:

Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension issofter).



EAS00158

ADJUSTING THE REAR SHOCK ABSORB-ER ASSEMBLY


Spring preload


1. Adjust:spring preload

Adjust the spring preload with the specialwrench and extension bar included in the own-er’s tool kit.

3-46

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

a

b

CAUTION:

a

b

a. Turn the adjusting ring 1 in direction a orb .

b. Align the desired position on the adjustingring with the stopper 2 .

DirectionSpring preload isincreased (s spension isDirection increased (suspension isharder).

DirectionSpring preload isdecreased (s spensionDirection decreased (suspensionis softer).

Adjusting positionsStandard: 6Minimum: 1Maximum: 11

Rebound damping


1. Adjust:rebound damping

a. Turn the adjusting knob 1 in direction a orb .

DirectionRebound damping isincreased (s spension isDirection increased (suspension isharder).

DirectionRebound damping isdecreased (s spension isDirection decreased (suspension issofter).



3-47

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES

CHKADJ

CAUTION:

a

b

WARNING

Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension issofter).

Adjusting positionsStandard: 7 clicks inMinimum: 1 clicks inMaximum: 12 clicks in

*: from the fully turned-out position

EAS00162

CHECKING THE TIRESThe following procedure applies to both of thetires.1. Measure:

tire pressureOut of specification Regulate.

The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.The tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated ridingspeed.Operation of an overloaded motorcyclecould cause tire damage, an accident or aninjury.

NEVER OVERLOAD THE MOTORCYCLE.

3-48

CHECKING THE TIRESCHKADJ

WARNING

WARNING

Basic weight(with oil and afull fuel tank)

231 kg (509 lb)232 kg (512 lb)

(california)

Maximumload*

189 kg (417 lb)188 kg (415 lb)

(california)

Cold tire pressure Front tire Rear tire

Up to 90 kgload*

250 kPa(2.5 kgf/cm2,

36 psi)


39 psi)

90 kg maximum load*


36 psi)


42 psi)

Highspeed riding


36 psi)


42 psi)

*: total of cargo, rider, passenger and accesso-ries

It is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately.

2. Check:tire surfacesDamage/wear Replace the tire.

Minimum tire tread depth1.0 mm (0.04 in)

1 Tire tread depth2 Side wall3 Wear indicator

Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire fail-ure and personal injury from sudden defla-tion.When using a tube tire, be sure to install thecorrect tube.Always replace a new tube tire and a newtube as a set.To avoid pinching the tube, make sure thatthe wheel rim band and tube are centered inthe wheel groove.Patching a punctured tube is not recom-mended. If it is absolutely necessary to doso, use great care and replace the tube assoon as possible with a good quality re-placement.

A Tire B Wheel

3-49

CHECKING THE TIRESCHKADJ

WARNING

NOTE:

Tube wheel Tube tire only

Tubeless wheel Tube or tubeless tire

After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. The front and rear tiresshould always be by the same manufactur-er and of the same design. No guaranteeconcerning handling characteristics canbe given if a tire combination other thanone approved by Yamaha is used on thismotorcycle.

Front tire

Manufacturer Type Size

METZELER Tubeless 120/70ZR17 (58 W)

BRIDGESTONE Tubeless 120/70ZR17 (58 W)

Rear tire

Manufacturer Type Size

METZELER Tubeless 180/55ZR17 (73 W)

BRIDGESTONE Tubeless 180/55ZR17 (73 W)

New tires have a relatively low grip on theroad surface until they have been slightlyworn. Therefore, approximately 100 km (62mi) should be traveled at normal speed be-fore any highspeed riding is done.

For tires with a direction of rotation mark 1 :Install the tire with the mark pointing in thedirection of wheel rotation.Align the mark 2 with the valve installationpoint.

3-50

CHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/

LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION

CHKADJ

WARNING

NOTE:

EAS00170

CHECKING AND LUBRICATING THECABLESThe following procedure applies to all of thecable sheaths and cables.

Damaged cable sheaths may cause thecable to corrode and interfere with its move-ment. Replace damaged cable sheaths andcables as soon as possible.

1. Check:cable sheathDamage Replace.

2. Check:cable operationUnsmooth operation Lubricate.

Recommended lubricantEngine oil or a suitable cablelubricant

Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suit-able lubing device.

EAS00171

LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.

Recommended lubricantlithium soap base grease

EAS00172

LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.


EAS00174

LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metalmoving parts of the rear suspension.


3-51

CHECKING AND CHARGING THE BATTERYCHKADJ

WARNING

CAUTION:

EAS00178

ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY

Batteries generate explosive hydrogen gasand contain electrolyte which is made of poi-sonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures:Wear protective eye gear when handling orworking near batteries.Charge batteries in a well-ventilated area.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes).DO NOT SMOKE when charging or han-dling batteries.KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.

First aid in case of bodily contact:ExternalSKIN – Wash with water.EYES – Flush with water for 15 minutes andget immediate medical attention.

InternalDrink large quantities of water or milk fol-lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medical atten-tion.

This is a sealed battery. Never remove thesealing caps because the balance betweencells will not be maintained and battery per-formance will deteriorate.Charging time, charging amperage andcharging voltage for a MF battery are differ-ent from those of conventional batteries.The MF battery should be charged as ex-plained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when chargingthe battery.

3-52


Relationship between the open-circuit voltageand the charging time at 20C

Ope

n-ci

rcui

t vol

tage

(V

)

These values vary with the temperature, the condition ofthe battery plates, and the electrolyte level.

13.0

12.5

12.0

11.5

5 6.5 10Charging time (hours)

NOTE:

CAUTION:

NOTE:

Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the electrolyte.Therefore, the charge of the battery has to bechecked by measuring the voltage at the batteryterminals.

1. Remove:seat

2. Disconnect:battery leads(from the battery terminals)

First, disconnect the negative lead 1 , thenthe positive lead 2 .

3. Remove:battery

4. Check:battery charge

a. Connect a pocket tester to the battery termi-nals.

Tester positive lead battery positive Tester positive lead terminalTester negative lead battery negative Tester negative lead terminal

The charge state of a MF battery can bechecked by measuring its open-circuit voltage(i.e., the voltage when the positive terminal isdisconnected).

No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown inthe charts and the following example.

Examplec. Open-circuit voltage = 12.0 Vd. Charging time = 6.5 hourse. Charge of the battery = 20 30%

3-53


ChargingAmbient temperature 20C

Ope

n-ci

rcui

t vol

tage

(V

)

Check the open-circuitvoltage.

Time (minutes)

Ambienttemperature20C

Ope

n-ci

rcui

t vol

tage

(V

)

Charging condition of the battery (%)

WARNING

CAUTION:

5. Charge:battery(refer to the appropriate charging method il-lustration)

Do not quick charge a battery.

Make sure that the battery vent is free of ob-structions.

Never remove the MF battery sealing caps.Do not use a high-rate battery charger.They force a high-amperage current intothe battery quickly and can cause batteryoverheating and battery plate damage.

If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

When charging a battery, be sure to removeit from the motorcycle. (If charging has tobe done with the battery mounted on themotorcycle, disconnect the negative leadfrom the battery terminal.)

To reduce the chance of sparks, do notplug in the battery charger until the batterycharger leads are connected to the battery.

Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.

Make sure that the battery charger leadclips are in full contact with the battery ter-minal and that they are not shorted. A cor-roded battery charger lead clip may gener-ate heat in the contact area and a weak clipspring may cause sparks.

If the battery becomes hot to the touch atany time during the charging process, dis-connect the battery charger and let the bat-tery cool before reconnecting it. Hot batter-ies can explode!

As shown in the following illustration, theopen-circuit voltage of a MF battery stabi-lizes about 30 minutes after charging hasbeen completed. Therefore, wait 30 min-utes after charging is completed beforemeasuring the open-circuit voltage.

3-54


Measure the open-circuitvoltage prior to charging.

Connect a charged andAMP meter to the batteryand start charging.

Make sure that the currentis higher than the standardcharging current written onthe battery.

By turning the chargingvoltage adjust dial, set thecharging voltage at 20 24 V.

Adjust the voltage so that thecurrent is at the standardcharging level.

Monitor the amperage for3 5 minutes to check if thestandard charging current isreached.

Set the time according to thecharging time suitable for theopen-circuit voltage.Refer to “Battery conditionchecking steps”.

If the current does notexceed the standardcharging current after 5minutes, replace the battery.

If charging requires more than 5 hours, it is advisable to check thecharging current after a lapse of 5 hours. If there is any change in theamperage, readjust the voltage to obtain the standard chargingcurrent.

Measure the battery open-circuit voltage after leaving the batteryunused for more than 30 minutes.12.8 V or more --- Charging is complete.12.7 V or less --- Recharging is required.Under 12.0 V --- Replace the battery.

YES NO

YES

NO

NOTE:Voltage should be measured 30minutes after the machine is stopped.

NOTE:Set the charging voltage at 16 17 V.(If the setting is lower, charging will beinsufficient. If too high, the battery willbe over-charged.)

Charging method using a variable voltage charger

3-55


Measure the open-circuitvoltage prior to charging.

Connect a charger andAMP meter to the batteryand start charging.

Make sure that the currentis higher than the standardcharging current written onthe battery.

Charge the battery until the battery’scharging voltage is 15 V. Charge thebattery until the battery’s chargingvoltage is 15 V.

This type of battery charger cannotcharge the MF battery. A variablevoltage charger is recommended.

Measure the battery open-circuitvoltage after leaving the batteryunused for more than 30 minutes.12.8 V or more --- Charging iscomplete.12.7 V or less --- Recharging isrequired.Under 12.0 V --- Replace the battery.

Set the charging time at 20 hours(maximum).

YES NO

NOTE:Voltage should be measured 30minutes after the machine is stopped.

NOTE:

Charging method using a constant voltage charger

3-56

CHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES

CHKADJ

CAUTION:

CAUTION:

NOTE:

6. Check:battery ventObstruction Clean.Damage Replace.

7. Install:battery

8. Connect:battery leads(to the battery terminals)

First, connect the positive lead 1 , then thenegative lead 2 .

9. Check:battery terminalsDirt Clean with a wire brush.Loose connection Connect properly.

10. Lubricate:battery terminals

Recommended lubricantDielectric grease

11. Install:seat

EAS00181

CHECKING THE FUSESThe following procedure applies to all of thefuses.

To avoid a short circuit, always turn the mainswitch to “OFF” when checking or replacinga fuse.

1. Remove:seat

2. Check:fuse

a. Connect the pocket tester to the fuse andcheck the continuity.

Set the pocket tester selector to “Ω 1”.

3-57

CHECKING THE FUSESCHKADJ

WARNING


b. If the pocket tester indicates “∞”, replace thefuse.

3. Replace:blown fuse

a. Turn off the ignition.b. Install a new fuse of the correct amperage

rating.c. Turn on the switches to verify if the electrical

circuit is operational.d. If the fuse immediately blows again, check

the electrical circuit.

Fuses Amperage rating Quantity

Main fuse 30A 1

Headlight fuse 20A 1

Signalingsystem fuse

20A 1

Ignition fuse 20A 1

Turn signalrelay fuse

10 A 1

Digital clockfuse

10A 1

Radiator fanfuse

10A 1

Reserve fuse 30A 1

Reserve fuse 20 A 1

Reserve fuse 10 A 1

Never use a fuse with an amperage ratingother than that specified. Improvising or us-ing a fuse with the wrong amperage ratingmay cause extensive damage to the electri-cal system, cause the lighting and ignitionsystems to malfunction and could possiblycause a fire.

4. Install:seat

3-58

REPLACING THE HEADLIGHT BULBSCHKADJ

WARNING

CAUTION:

EAS00183

REPLACING THE HEADLIGHT BULBSThe following procedure applies to both of theheadlight bulbs.1. Disconnect:

headlight coupler 1bulb cover 2

2. Remove:headlight bulb holder 1

3. Remove:headlight bulb 2

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

4. Install:headlight bulb NewSecure the new headlight bulb with the head-light bulb holder.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

5. Install:headlight bulb holder

6. Install:bulb cover

7. Connect:headlight coupler

3-59

ADJUSTING THE HEADLIGHT BEAMS/ADJUSTING THE DIGITAL CLOCK

CHKADJ

a

b

a

b

a

b

NOTE:

NOTE:

EAS00185

ADJUSTING THE HEADLIGHT BEAMSThe following procedure applies to both of theheadlights.1. Adjust:

headlight beam (vertically)


Direction Headlight beam is raised.

Direction Headlight beam is lowered.

2. Adjust:headlight beam (horizontally)

a. Turn the adjusting knob 1 in direction a orb .Left headlight

Direction Headlight beam moves tothe right.

Direction Headlight beam moves tothe left.

Right headlight

Direction Headlight beam moves tothe left.

Direction Headlight beam moves tothe right.

EAS00187

ADJUSTING THE DIGITAL CLOCK

This digital clock constantly displays the time.

1. Adjust:digital clock 1

a. Hold down the “RESET” button 2 and “SE-LECT” button 3 .

b. Push the “RESET” button 2 to set the hour.And push the “SELECT” button.

c. Push the “RESET” button 2 to set the min-utes. And push the “SELECT” button.

When setting the time (e.g., after reconnectingthe battery), first set the clock to 1:00 AM, thenset it to the correct time.

CHAS

CHAPTER 4CHASSIS

FRONT WHEEL AND BRAKE DISCS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT WHEEL 4-4. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT WHEEL 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE 4-8. . . . . . . . . .

REAR WHEEL AND BRAKE DISC 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR WHEEL 4-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR WHEEL 4-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL 4-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB 4-14. . . . . . . . . . . . . . . . . . CHECKING AND REPLACING THE REAR WHEEL SPROCKET 4-14.CHECKING THE BRAKE DISC 4-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REAR WHEEL 4-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE 4-16. . . . . . . . . . . .

FRONT AND REAR BRAKES 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 4-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 4-19. . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 4-21. . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER 4-24. . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER 4-26. . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING AND DISASSEMBLING THE FRONT BRAKE

MASTER CYLINDER 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING AND DISASSEMBLING THE REAR BRAKE

MASTER CYLINDER 4-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE MASTER

CYLINDERS 4-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE

MASTER CYLINDER 4-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE REAR BRAKE MASTER CYLINDER 4-33. . . . . . . . FRONT BRAKE CALIPERS 4-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 4-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT BRAKE CALIPERS 4-39. . . . . . . . . . . . . DISASSEMBLING THE REAR BRAKE CALIPER 4-40. . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 4-41. . . . . . . . ASSEMBLING AND INSTALLING THE FRONT BRAKE

CALIPERS 4-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING AND INSTALLING THE REAR BRAKE

CALIPER 4-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAS

FRONT FORK 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 4-48. . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 4-50. . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 4-51. . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 4-55. . . . . . . . . . . . . . . . . . . . . . .

HANDLEBAR 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBAR 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 4-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET 4-61. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 4-61. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 4-62. . . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER ASSEMBLY 4-63. . . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND

GAS CYLINDER 4-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND

GAS CYLINDER 4-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4-65. . . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-66. . . . . . . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-66. . . . . .

SWINGARM AND DRIVE CHAIN 4-67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 4-69. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE DRIVE CHAIN 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM 4-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

FRONT WHEEL AND BRAKE DISCS CHAS


12345678

Removing the front wheel and brakediscs

Brake hose holder (left and right)Brake caliper (left and right)Wheel axle pinch boltFront wheel axleFront wheelCollar (left and right)Oil seal cover (left and right)brake disc (left and right)

22111222


Place the motorcycle on a suitable standso that the front wheel is elevated.

Loosen.


NOTE:

72 Nm (7.2 m kg, 52 ft lb)

40 Nm (4.0 m kg, 29 ft lb)

18 Nm (1.8 m kg, 13 ft lb)

EAS00514

CHASSISFRONT WHEEL AND BRAKE DISCS

4-2



Disassembling the front wheelOil seal (left and right)Wheel bearing (left and right)Spacer

221

Disassemble the parts in the order listed.

For assembly, reverse the disassemblyprocedure.

123

EAS00518

FRONT WHEEL

4-3


WARNING

NOTE:

NOTE:

NOTE:

EAS00521

REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.



2. Remove:brake hose holdersleft brake caliperright brake caliper

Do not squeeze the brake lever when removingthe brake calipers.

3. Loosen:wheel axle pinch boltfront wheel axle

4. Elevate:front wheel


5. Remove:front wheel axle

6. Remove:front wheel

4-4


NOTE:

WARNING

EAS00523

DISASSEMBLING THE FRONT WHEEL1. Remove:

oil sealswheel bearings

a. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-head

screwdriver.

To prevent damaging the wheel, place a rag 2between the screwdriver and the wheel surface.

c. Remove the wheel bearings with a generalbearing puller.

EAS00525

CHECKING THE FRONT WHEEL1. Check:

wheel axleRoll the wheel axle on a flat surface.Bends Replace.

Do not attempt to straighten a bent wheelaxle.

2. Check:tirefront wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” in chapter3.

3. Measure:front wheel radial runout 1front wheel lateral runout 2Over the specified limits Replace.

Front wheel radial runout limit1 mm (0.04 in)

Front wheel lateral runout limit0.5 mm (0.02 in)

4-5


NOTE:

CAUTION:

NOTE:

4. Check:wheel bearingsFront wheel turns roughly or is loose Re-place the wheel bearings.oil sealsDamage/wear Replace.

5. Replace:wheel bearings Newoil seals New

a. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-head

screwdriver.

To prevent damaging the wheel, place a rag 2between the screwdriver and the wheel surface.

c. Remove the wheel bearings 3 with a gener-al bearing puller.

d. Install the new wheel bearings and oil sealsin the reverse order of disassembly.

Do not contact the wheel bearing center race1 or balls 2 . Contact should be made onlywith the outer race 3 .

Use a socket 4 that matches the diameter ofthe wheel bearing outer race and oil seal.

EAS00531

CHECKING THE BRAKE DISCSThe following procedure applies to all of thebrake discs.1. Check:

brake discDamage/galling Replace.

4-6


NOTE:

2. Measure:brake disc deflection Out of specification Correct the brake discdeflection or replace the brake disc.

Brake disc deflection limit(maximum)

0.1 mm (0.004 in)

a. Place the motorcycle on a suitable stand sothat the wheel is elevated.

b. Before measuring the front brake disc deflec-tion, turn the handlebar to the left or right toensure that the front wheel is stationary.

c. Remove the brake caliper.d. Hold the dial gauge at a right angle against

the brake disc surface.e. Measure the deflection 2 3 mm (0.08

0.12 in) below the edge of the brake disc.

3. Measure:brake disc thickness Measure the brake disc thickness at a fewdifferent locations.Out of specification Replace.

Brake disc thickness limit(minimum)

4.5 mm (0.18 in)

4. Adjust:brake disc deflection

a. Remove the brake disc.b. Rotate the brake disc by one bolt hole.c. Install the brake disc.

Tighten the brake disc bolts in stages and in acrisscross pattern.

Brake disc bolt18 Nm (1.8 mkg, 13 ftlb)LOCTITE

d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment

steps until the brake disc deflection is withinspecification.

f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.

4-7


CAUTION:

NOTE:

72 Nm (7.2 m kg, 52 ft lb)

23 Nm (2.3 m kg, 17 ft lb)

CAUTION:

40 Nm (4.0 m kg, 29 ft lb)

WARNING

EAS00539

ASSEMBLING THE FRONT WHEEL1. Install:

wheel bearings Newoil seals New

a. Install the new wheel bearings and oil sealsin the reverse order of disassembly.

Do not contact the wheel bearing inner race1 or balls 2 . Contact should be made onlywith the outer race 3 .

Use a shocket 4 that matches the diameter ofthe wheel bearing outer race and oil seal.

EAS00544

INSTALLING THE FRONT WHEELThe following procedure applies to both brakediscs.1. Lubricate:

wheel axleoil seal lips

Recommended lubricantLithium soap base grease

2. Tighten:wheel axle 1wheel axle pinch bolt 2

Before tightening the wheel axle nut, pushdown hard on the handlebar several times andcheck if the front fork rebounds smoothly.

3. Install:brake caliper

Make sure that the brake hose is routedproperly.

4-8


NOTE:

NOTE:

NOTE:

EAS00549

ADJUSTING THE FRONT WHEEL STATICBALANCE

After replacing the tire, wheel or both, the frontwheel static balance should be adjusted.

Adjust the front wheel static balance with thebrake discs installed.

1. Remove:balancing weight(-s)

Place the front wheel on a suitable balancingstand.

2. Find: front wheel’s heavy spot

a. Spin the front wheel.b. When the front wheel stops, put an “X1” mark

at the bottom of the wheel.c. Turn the front wheel 90 so that the “X1” mark

is positioned as shown.d. Release the front wheel.e. When the wheel stops, put an “X2” mark at

the bottom of the wheel.f. Repeat steps (b) through (d) several times

until all the marks come to rest at the samespot.

g. The spot where all the marks come to rest isthe front wheel’s heavy spot “X”.

3. Adjust: front wheel static balance

a. Install a balancing weight 1 onto the rim ex-actly opposite the heavy spot “X”.

Start with the lightest weight.

4-9


b. Turn the front wheel 90 so that the heavyspot is positioned as shown.

c. If the heavy spot does not stay in that posi-tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheelis balanced.

4. Check: front wheel static balance

a. Turn the front wheel and make sure that itstays at each position shown.

b. If the front wheel does not remain stationaryat all of the positions, rebalance it.

4-10

REAR WHEEL AND BRAKE DISC CHAS


12345678

Removing the rear wheel

Brake caliperBrake torque rodLock nutAdjusting nutWheel axle nutWasherWheel axleRear wheel assembly

11221111


Place the motorcycle on a suitable standso that the rear wheel is elevated.

Loosen.


NOTE:

Loosen.

40 Nm (4.0 m kg, 29 ft lb)

150 Nm (15 m kg, 108 ft lb)

EAS00551

REAR WHEEL AND BRAKE DISCREAR WHEEL

4-11


Disassembling the rear wheelSpacerBearingSpacerOil sealCirclipBearing

111111



123456


EAS00560

4-12



1234567

Removing the brake disc and rearwheel sprocketBrake discRear wheel sprocketCollar (left and right)Oil sealBearingRear wheel drive hubRear wheel drive hub damper

1121116



18 Nm (1.8 m kg, 13 ft lb)

69 Nm (6.9 m kg, 50 ft lb)

4-13


WARNING

NOTE:

NOTE:

NOTE:

EAS00561

REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.



2. Remove:brake caliper 1

Do not depress the brake pedal when removingthe brake caliper.

3. Loosen:brake torque rod

4. Loosen:locknut 1adjusting nut 2

5. Remove:wheel axle nut 3wheel axlerear wheel

Push the rear wheel forward and remove thedrive chain from the rear wheel sprocket.

6. Remove:left collar 1rear wheel drive hub 2rear wheel drive hub damperright collar

4-14


EAS00565

CHECKING THE REAR WHEEL1. Check:

wheel axlerear wheelwheel bearingsoil sealsRefer to “FRONT WHEEL”.

2. Check:tirerear wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” in chapter3.

3. Measure:rear wheel radial runoutrear wheel lateral runoutRefer to “FRONT WHEEL”.

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB1. Check:

rear wheel drive hub 1Cracks/damage Replace.rear wheel drive hub dampers 2Damage/wear Replace.

EAS00568

CHECKING AND REPLACING THE REARWHEEL SPROCKET1. Check:

rear wheel sprocketMore than 1/4 tooth a wear Replace therear wheel sprocket, the drive sprocket andthe drive chain as a set.Bent teeth Replace the rear wheel sprock-et, the drive sprocket and the drive chain as aset.

b Correct1 Drive chain roller2 Rear wheel sprocket2. Replace:

rear wheel sprocket

a. Remove the self-locking nuts and the rearwheel sprocket.

b. Clean the rear wheel drive hub with a cleancloth, especially the surfaces that contact thesprocket.

c. Install the new rear wheel sprocket.

4-15


NOTE:

NOTE:

Rear wheel sprocket self-lockingnut

69 Nm (6.9 m kg, 50 ft lb)

Tighten the self-locking nuts in stages and in acrisscross pattern.

EAS00531

CHECKING THE BRAKE DISC1. Check:

brake discDamage/galling Replace.

2. Measure:brake disc deflection Out of specification Correct the brake discdeflection or replace the brake disc.

Brake disc deflection limit(maximum)

0.1 mm (0.004 in)

Place the motorcycle on a suitable stand so thatthe wheel is elevated.

a. Before measuring the front brake disc deflec-tion, turn the handlebar to the left or right toensure that the front wheel is stationary.

b. Remove the brake caliper.c. Hold the dial gauge at a right angle against

the brake disc surface.d. Measure the deflection 2 3 mm below the

edge of the brake disc.

3. Measure:brake disc thickness Measure the brake disc thickness at a fewdifferent locations.Out of specification Replace.

Brake disc thickness limit(minimum)

4.5 mm (0.18 in)

4-16


NOTE:

150 Nm (15 mkg, 108 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

NOTE:

4. Adjust:brake disc deflection

a. Remove the brake disc.b. Rotate the brake disc by one bolt hole.c. Install the brake disc.

Tighten the brake disc bolts in stages and in acrisscross pattern.

Brake disc bolt18 Nm (1.8 mkg, 13 ftlb)LOCTITE

d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment

steps until the brake disc deflection is withinspecification.

f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.

EAS00572

INSTALLING THE REAR WHEEL1. Lubricate:wheel axlewheel bearingsoil seal lips


2. Tighten:wheel axle nutbrake caliper bolts

EAS00575

ADJUSTING THE REAR WHEEL STATICBALANCE

After replacing the tire, wheel or both, the rearwheel static balance should be adjusted.

Adjust the rear wheel static balance with thebrake disc and rear wheel drive hub installed.

1. Adjust: rear wheel static balanceRefer to “FRONT WHEEL”.

4-17

FRONT AND REAR BRAKES CHAS


123456

Removing the front brake padsBrake pad clipBrake pad pinBrake pad springbrake padBrake pad shimBleed scrw

211221



40 Nm (4.0 m kg, 29 ft lb) 6 Nm (0.6 m kg, 4.3 ft lb)

EAS00577

FRONT AND REAR BRAKESFRONT BRAKE PADS

4-18



123456

Removing the rear brake padsBrake pad clipBrake pad pinBrake pad springBrake padBrake pad shimBleed screw

421222



6 Nm (0.6 m kg, 4.3 ft lb)

40 Nm (4.0 m kg, 29 ft lb)

4-19


CAUTION:

NOTE:

EAS00579

Disc brake components rarely require disas-sembly.Therefore, always follow these preventivemeasures:Never disassemble brake components un-less absolutely necessary.If any connection on the hydraulic brakesystem is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled after reas-sembly.Never use solvents on internal brake com-ponents.Use only clean or new brake fluid for clean-ing brake components.Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt fluid immediately.Avoid brake fluid coming into contact withthe eyes as it can cause serious injury.

First aid for brake fluid entering the eyes:Flush with water for 15 minutes and get im-mediate medical attention.

EAS00582

REPLACING THE FRONT BRAKE PADSThe following procedure applies to both brakecalipers.

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:brake hose holder 1brake caliper 2

4-20


NOTE:

2. Remove:brake pad clips 1brake pad pins 2brake pad spring 3

3. Remove:brake pads 1(along with the brake pad shims)

4. Measure:brake pad wear limitOut of specification Replace the brakepads as a set.

Brake pad wear limit0.5 mm (0.02 in)

5. Install:brake pad shims(onto the brake pads)brake padsbrake pad spring

Always install new brake pads, brake padshims, and a brake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


4-21


NOTE:

40 Nm (4.0 m kg, 29 ft lb)

NOTE:

d. Install new brake pad shims onto the newbrake pads.

e. Install new brake pads and a new brake padspring.

The arrow a on the brake pad spring must pointin the direction of disc rotation.

6. Install:brake pad pinsbrake pad clipsbrake caliper

7. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.

8. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

EAS00583

REPLACING THE REAR BRAKE PADS

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:brake caliper 1

2. Remove:brake pad clips 1brake pad pins 2brake pad spring 3brake pads(along with the brake pad shims)

4-22


NOTE:

3. Measure:brake pad wear limit Out of specification Replace the brakepads as a set.

Brake pad wear limit0.5 mm (0.02 in)

4. Install:brake pad shims(onto the brake pads)brake padsbrake pad spring

Always install new brake pads, brake padshims, brake pad pins, brake pad clips, and abrake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


d. Install a new brake pad shim 3 onto eachnew brake pad 4 .

e. Install new brake pads and a new brake padspring.

4-23


40 Nm (4.0 m kg, 29 ft lb)

5. Install:brake pad pinsbrake pad clipsbrake caliper



4-24



1234567

Removing the front brake mastercylinderBrake fluidBrake leverBrake switch leadBrake switchUnion boltBrake hose/copper washerMaster cylinder bracketMaster cylinder

1211

1/211


Drain.


Refer to “REMOVING/ASSEMBLINGAND INSTALLING THE FRONT BRAKEMASTER CYLINDER” section.

10 Nm (1.0 m kg, 7.2 ft lb)

30 Nm (3.0 m kg, 22 ft lb)

EAS00584

FRONT BRAKE MASTER CYLINDER

4-25



Disassembling the front brakemaster cylinderMaster cylinder bootCirclipMaster cylinder kitSpring

1111



1234

EAS00585

4-26


4 Nm (0.4 mkg,2.9 ftlb)


123

45678

Removing the rear brake mastercylinderSide cover (right)Brake fluidMaster cylinder boltUnion boltBrake hose/copper washer

Clip/hoseCotter pinPinWasherMaster cylinder

21

1/2

2/11111


Drain.


Refer to “REMOVING/ASSEMBLINGAND INSTALLING THE REAR BRAKEMASTER CYLINDER” section.

23 Nm (2.3 mkg, 17 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

EAS00586

REAR BRAKE MASTER CYLINDER

4-27



Disassembling the rear brake mastercylinderMaster cylinder bootCirclipMaster cylinder kitSpring

1111



1234

EAS00587

4-28


NOTE:

NOTE:

NOTE:

EAS00588

REMOVING AND DISASSEMBLING THEFRONT BRAKE MASTER CYLINDER

Before disassembling the front brake mastercylinder, drain the brake fluid from the entirebrake system.

1. Disconnect:brake switch coupler (from the brake switch)

2. Remove:union bolt 1copper washers 2brake hose 3

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

3. Remove:master cylinder bracketmaster cylinder

4. Remove:master cylinder bootcirclip

5. Remove:master cylinder kitspring

EAS00589

REMOVING AND DISASSEMBLING THEREAR BRAKE MASTER CYLINDER1. Remove:

side cover (right)


To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

4-29

A B

DC


3. Remove:cliphosecotter pinpinwasher

4. Remove:master cylinder

5. Remove:master cylinder bootcirclip

6. Remove:master cylinder kitspring

EAS00592

CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERSThe following procedure applies to the both ofthe brake master cylinders.1. Check:

brake master cylinder bodyDamage/scratches/wear Replace.brake fluid delivery passages(brake master cylinder body)Obstruction Blow out with compressed air.

A FrontB Rear2. Check:

brake master cylinder kit seals 1Damage/scratches/wear Replace.

C FrontD Rear

3. Check:rear brake fluid reservoir 1Cracks/damage Replace.rear brake fluid reservoir diaphragm 2Cracks/damage Replace.

4-30


WARNING

4. Check:front brake master cylinder reservoir 1Cracks/damage Replace.front brake master cylinder reservoir dia-phragm 2Damage/wear Replace.

5. Check:brake hoses Cracks/damage/wear Replace.

EAS00598

ASSEMBLING AND INSTALLING THEFRONT BRAKE MASTER CYLINDER

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.Never use solvents on internal brake com-ponents.


1. Install:springmaster cylinder kit

2. Install:circlipmaster cylinder boot

4-31

a


10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

30 Nm (3.0 mkg, 22 ftlb)

CAUTION:

WARNING

NOTE:

3. Install:brake master cylinder 1

Install the brake master cylinder holder withthe “UP” mark facing up.

Align the end of the brake master cylinder hold-er with the punch mark a on the handlebar.

First, tighten the upper bolt, then the lower bolt.

4. Install:copper washers 1 Newbrake hose 2union bolt 3

When installing the brake hose onto thebrake master cylinder, make sure that thebrake pipe touches the projection a on thebrake master cylinder.

Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

While holding the brake hose, tighten theunion bolt as shown.

Turn the handlebar to the left and to the right tomake sure that the brake hose does not touchother parts (e.g., wire harness, cables, leads).Correct if necessary.

5. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)


4-32


WARNING

CAUTION:



6. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.



4-33


30 Nm (3.0 m kg, 22 ft lb)

CAUTION:

WARNING

EAS00608

ASSEMBLING THE REAR BRAKE MASTERCYLINDER1. Install:

springmaster cylinder kit

2. Install:circlipmaster cylinder boot

3. Install:master cylinder

4. Install:washerpincotter pinhoseclip

5. Install:copper washers 1 Newbrake hose 2union bolt 3

When installing the brake hose onto thebrake master cylinder, make sure that thebrake pipe touches the projection a asshown.


6. Fill:brake fluid reservoir(to the maximum level mark a )


4-34


WARNING

CAUTION:





9. Adjust:brake pedal position aRefer to “ADJUSTING THE REAR BRAKE”in chapter 3.

Brake pedal position (below thetop of the rider footrest)

40 mm (1.57 in)

10. Adjust:rear brake light operation timingRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH” in chapter 3.

4-35



1234

Removing the front brake calipersBrake fluidUnion boltCopper washerBrake hoseBrake caliper

1211

Remove the parts in the order listed.Drain.


6 Nm (0.6 m kg, 4.3 ft lb)

30 Nm (3.0 m kg, 22 ft lb)

40 Nm (4.0 m kg, 29 ft lb)

EAS00613

FRONT BRAKE CALIPERS

4-36



Disassembling the front brake calipers

Brake pad clipBrake pad pinBrake pad springBrake padBrake caliper pistonBrake caliper piston sealBleed screw

2112481

Disassemble the parts in the order listed.The following procedure applies to both ofthe front brake calipers.


1234567

6 Nm (0.6 m kg, 4.3 ft lb)

EAS00615

4-37



1234

Removing the rear brake caliperBrake fluidUnion boltCopper washerBrake hoseBrake caliper

1211



30 Nm (3.0 m kg, 22 ft lb)

40 Nm (4.0 m kg, 29 ft lb)

EAS00616

REAR BRAKE CALIPER

4-38



Disassembling the rear brake caliperBrake pad clipBrake pad pinBrake pad springBrake padBrake caliper pistonBrake caliper piston sealBleed screw

4212242



1234567

6 Nm (0.6 m kg, 4.3 ft lb)

EAS00617

4-39


NOTE:

NOTE:

WARNING

EAS00625

DISASSEMBLING THE FRONT BRAKE CAL-IPERSThe following procedure applies to both of thebrake calipers.

Before disassembling either brake caliper, drainthe brake fluid from the entire brake system.


Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Secure the right side brake caliper pistonswith a piece of wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the left side pis-tons from the brake caliper.

Never try to pry out the brake caliper pis-tons.

Do not loosen the bolts 3 .

c. Remove the brake caliper piston seals.d. Repeat the previous steps to force out the

right side pistons from the brake caliper.

4-40


NOTE:

NOTE:

WARNING

EAS00628

DISASSEMBLING THE REAR BRAKE CAL-IPER

Before disassembling the brake caliper, drainthe brake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Secure the right side brake caliper pistonwith a piece of wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the left side pis-ton from the brake caliper.

Never try to pry out the brake caliper pis-tons.

Do not loosen the bolts 3 .

c. Remove the brake caliper piston seals.d. Repeat the previous steps to force out the

right side piston from the brake caliper.

4-41

A

B


WARNING

EAS00633

CHECKING THE FRONT AND REAR BRAKECALIPERS

Recommended brake componentreplacement schedule

Brake pads If necessary

Piston seals Every two years

Brake hoses Every two years

Brake fluid

Every two yearsand whenever thebrake is disas-sembled.

1. Check:brake caliper pistons 1Rust/scratches/wear Replace the brakecaliper.

brake caliper cylinders 2Scratches/wear Replace the brake cali-per.

brake calipers Cracks/damage Replace.

brake fluid delivery passages(brake caliper body)Obstruction Blow out with compressed Air.

Whenever a brake caliper Is disassembled,replace the brake caliper piston seals.

A FrontB Rear

2. Check:brake caliper brackets 1Cracks/damage Replace.

4-42


WARNING

30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:

6 Nm (0.6 mkg, 4.3 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

EAS00638

ASSEMBLING AND INSTALLING THEFRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.

Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.

Whenever a brake caliper is disassembled,replace the brake caliper piston seals.


1. Install:brake caliper (temporarily)

copper washers 1 Newbrake hose 2union bolt 3


When installing the brake hose onto thebrake caliper, make sure that the brake pipea touches the projection b on the brakecaliper.

2. Remove:brake caliper

3. Install:brake padsbrake pad pinsbrake pad clipsbrake hose holder

brake caliperRefer to “REPLACING THE BRAKE PADS”.

4-43


WARNING

CAUTION:

4. Fill:brake master cylinder reservoir(with the specified amount of the recom-mended brake fluid)


Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.





4-44


WARNING

30 Nm (3.0 mkg, 22 ftlb)

WARNING

CAUTION:

40 Nm (4.0 mkg, 29 ftlb)

EAS00644

ASSEMBLING AND INSTALLING THE REARBRAKE CALIPER

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.

Never use solevents on internal brake com-ponents as they will cause the piston sealsto swell and distort.

Whenever a brake caliper is disassembled,replace the brake caliper piston seals.


1. Install:brake caliper 1(temporarily)

copper washers Newbrake hose 2union bolt 3


When installing the brake hose onto thebrake caliper, make sure that the brake pipea touches the projection b on the brakecaliper.

2. Remove:brake caliper

3. Install:brake padsbrake pad pinbrake pad clipsbrake caliperRefer to “REPLACING THE BRAKE PADS”.

4. Fill:brake fluid reservoir(with the specified amount of the recom-mended brake fluid)


4-45


WARNING

CAUTION:

Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe brake fluid and could cause vapor lock.




7. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

4-46

FRONT FORK CHAS


12345

Removing the front forkFront wheel

Front fenderUpper bracket pinch boltCap boltLower bracket pinch boltFront fork assembly (left /right)

1224

1/1

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.

Loosen.Loosen.Loosen.


Refer to “REMOVING/INSTALLING THE FRONTFORK LEGS” section.

23 Nm (2.3 mkg, 17 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

25 Nm (2.5 mkg,18 ftlb)

EAS00647

FRONT FORK

4-47

FRONT FORK CHAS


Disassembly the front forkCap boltO-ringSpacerSpring seatFork springDamper adjusting rodDust sealOil seal clipDamper rod boltCopper washerDamper rodInner tubeOil sealWasherSlide metalOil flow stopper

1111111111111111



12345678910111213141516

25 Nm (2.5 mkg, 18 ftlb)

35 Nm (3.5 mkg, 25 ftlb)

EAS00648

4-48

FRONT FORK CHAS

WARNING

NOTE:

WARNING

NOTE:

EAS00649

REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a level surface.



2. Loosen:upper bracket pinch bolt 1cap bolt 2 lower bracket pinch bolt 3

Before loosening the upper and lowerbracket pinch bolts, support the front forkleg.

3. Remove: front fork leg

EAS00653

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Remove:cap bolt 1(from the damper adjusting rod)

nut 2

Remove the cap bolt with the piston rod holder3 .

Rod holderYM-01434

4-49

FRONT FORK CHAS

CAUTION:

NOTE:

2. Remove:spacer 1spring seat 2spring 3damper adjusting rod 4

3. Drain: fork oil

4. Remove:oil seal clip 1(with a flat-head screwdriver)

Do not scratch the inner tube.

5. Remove:damper rod boltdamper rod 1

While holding the damper rod with the damperrod holder 2 , loosen the damper rod bolt.

Damper rod holderYM-01447

6. Remove: inner tube

a. Hold the front fork leg horizontally.b. Securely clamp the brake caliper bracket in a

vise with soft jaws.c. Separate the inner tube from the outer tube

by pulling the inner tube forcefully but care-fully.

4-50

FRONT FORK CHAS

CAUTION:

WARNING

CAUTION:

Excessive force will damage the oil sealand bushing. A damaged oil seal or bush-ing must be replaced.

Avoid bottoming the inner tube into theouter tube during the above procedure, asthe oil flow stopper will be damaged.

EAS00657

CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check: inner tube 1outer tube 2Bends/damage/scratches Replace.

Do not attempt to straighten a bent innertube as this may dangerously weaken it.

2. Measure:spring free length aOver the specified limit Replace.

Spring free length limit344.0 mm (13.5 in)

3. Check:damper rod Damage/wear Replace.Obstruction Blow out all of the oil pas-sages with compressed air.

oil flow stopperDamage Replace.

The front fork leg has a built-in damper ad-justing rod and a very sophisticated inter-nal construction, which are particularlysensitive to foreign material.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

4. Check:cap bolt O-ringDamage/wear Replace.

4-51

FRONT FORK CHAS

WARNING

NOTE:

CAUTION:

NOTE:

35 Nm (3.5 mkg, 25 ftlb)

NOTE:

EAS00660

ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Make sure that the oil levels in both frontfork legs are equal.

Uneven oil levels can result in poor han-dling and a loss of stability.

When assembling the front fork leg, be sure toreplace the following parts:-inner tube bushing-outer tube bushing-oil seal-dust seal

Before assembling the front fork leg, makesure that all of the components are clean.

1. Install:damper rod 1

Allow the damper rod to slide slowly downthe inner tube 2 until it protrudes from thebottom of the inner tube. Be careful not todamage the inner tube.

Install the oil flow stopper with a flat surface parta downward.

2. Lubricate: inner tube’s outer surface

Recommended lubricantSuspension oil “01” orequivalent

3. Tighten:damper rod bolt 1

LOCTITE

While holding the damper rod with the damperrod holder 2 , tighten the damper rod bolt.

Damper rod holderYM-01447

4-52

FRONT FORK CHAS

CAUTION:

NOTE:

NOTE:

CAUTION:

NOTE:

4. Install:oil seal 1(with the driver 2 and 43 mm adapter 3 )

DriverYM-33963

43 mm AdaptersYM-8020-A

Make sure that the numbered side of the oilseal faces up.

Before installing the oil seal, apply lithium soapbase grease onto its lips.

Apply fork oil onto the outer surface of the innertube.

Before installing the oil seal, cover the top ofthe front fork leg with a plastic bag to protectthe oil seal during installation.

5. Install:oil seal clip

Adjust the oil seal clip so that it fits into the outertube’s groove.

6. Fill: front fork leg(with the specified amount of the recom-mended fork oil)

Quantity (each front fork leg)0.44 L (435 cm3)(15.3 Imp oz, 14.7 US oz)

Recommended oilYamaha suspension oil “01” orequivalent

Be sure to use the recommended fork oil.Other oils may have an adverse effect onfront fork performance.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

Be sure to bleed the front fork.

4-53

FRONT FORK CHAS

NOTE:

NOTE:

NOTE:

7. Install: rod puller 1(onto the damper rod 2 )

Rod pullerYM-01437

8. After filling the front fork leg, slowly stroke thedamper rod 1 up and down (at least tentimes) to distribute the fork oil.

Be sure to stroke the damper rod slowly be-cause the fork oil may spurt out.

9. Slowly stroke the inner tube 2 up and downto distribute the fork oil once more (1 stroke =about 150 mm (5.9 in)).

Be careful not to stroke the inner tube over 150mm (5.9 in) as this will cause air to enter. If theinner tube is stroke more than 150 mm (5.9 in),repeat steps (10) and (11).

10. Before checking the fork oil level, wait tenminutes until the oil has settled and the airbubbles have dispersed.

Be sure to bleed the front fork leg of any residualair.

11. Measure: front fork leg oil level aOut of specification Correct.

Front fork leg oil level (from thetop of the inner tube and damper rod, with the inner tube fullycompressed, and without thespring)

140 mm (5.51 in)

4-54

FRONT FORK CHAS

NOTE:

NOTE:

CAUTION:

12. Install:spring 1spring seats 2spacer 3nut 4damper adjusting rod 5cap bolt 6

a. Install the fork spring, spring seats, andspacer.

Install the fork spring with the larger pitch a fac-ing up.

b smaller pitchb. Install the rod puller onto the damper rod.

c. Pull up the rod puller and install the rod hold-er 1 between the rod puller 2 and thespacer.

Use the side of the rod holder that is marked “B”.

Rod holderYM-01434

d. Remove the rod puller.e. Install the damper adjusting rod locknut.f. Tighten the damper adjusting rod locknut.

Damper adjusting rod locknut25 Nm (2.5 mkg, 18 ftlb)

g. Install the damper adjusting rod and cap bolt,and finger tighten it.

h. Remove the rod holder.

The spring is compressed.

4-55

FRONT FORK CHAS

NOTE:

23 Nm (2.3 mkg, 17 ftlb)

25 Nm (2.5 mkg, 18 ftlb)

30 Nm (3.0 mkg, 22 ftlb)

WARNING

EAS00662

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install: front fork legTemporarily tighten the upper and lowerbracket pinch bolts.

Make sure that the inner fork tube is flush withthe top of the handlebar holder.

2. Tighten: lower bracket pinch bolt 1

cap bolt 2upper bracket pinch bolt 3

Make sure that the brake hoses are routedproperly.

3. Adjust:spring preload rebound dampingcompression dampingRefer to “ADJUSTING THE FRONT FORK”in chapter 3.

4-56

HANDLEBAR CHAS


123456789

10111213

Removing the handlebarFront brake master cylinderRight handlebar switchThrootle cableGrip end (right)Throttle gripGrip end (left)Left gripLeft handlebar switchStarter cableClutch cableClutch leverHandlebar holderHandlebar

1111111111121



23 Nm (2.3 mkg, 17 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

26 Nm (2.6 mkg, 19 ftlb)

EAS00664

HANDLEBAR

4-57

HANDLEBAR CHAS

WARNING

NOTE:

WARNING

WARNING

EAS00666

REMOVING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Remove: throttle cable housing 1 throttle grip 2

3. Remove:handlebar grip 1

Blow compressed air between the handlebarand the handlebar grip, and gradually push thegrip off the handlebar.

EAS00668

CHECKING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Check:handlebarBends/cracks/damage Replace.

Do not attempt to straighten a bent handle-bar as this may dangerously weaken it.

4-58

HANDLEBAR CHAS

WARNING

WARNING

23 Nm (2.3 mkg, 17 ftlb)

CAUTION:

NOTE:

NOTE:

3.Install:handlebar grip

a. Apply a light coat of rubber adhesive onto theleft end of the handlebar.

b. Slide the handlebar grip over the left end ofthe handlebar.

c. Wipe off any excess rubber adhesive with aclean rag.

Do not touch the handlebar grip until therubber adhesive has fully dried.

EAS00672

INSTALLING THE HANDLEBAR1. Stand the motorcycle on a level surface.


2. Install:handlebar 1upper handlebar holders 2

First, tighten the bolts on the front side ofthe handlebar holder, then on the rear side.

Turn the handlebar all the way to the leftand right. If there is any contact with thefuel tank, adjust the handlebar position.

Align the match marks a in the handlebar withthe upper surface of the lower handlebar hold-ers.

3. Install: throttle grip 1 throttle cables

Align the pins a on the right handlebar switchwith the holes b in the handlebar.

4-59

HANDLEBAR CHAS

NOTE:

NOTE:

5. Install: left handlebar switch

Align the pins a on the right handlebar switchwith the holes b in the handlebar.

6. Install:clutch lever holder

Align the slit in the clutch lever holder with thepunch mark a in the left handlebar.

7. Install:brake master cylinderRefer to “ASSEMBLING AND INSTALLINGTHE FRONT BRAKE MASTER CYL-INDER”.

8. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.

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

3 5 mm (0.12 0.20 in)

4-60

STEERING HEAD CHAS


123456789

10111213

Removing the steering headFront wheelFront forkHandlebarFront brake hose bracketHorn/bracketBrake hose jointUpper bracket cap nutUpper bracketLock washerUpper ring nutRubber washerLower ring nutDust coverSteering bearing (upper)Lower bracketSteering bearing (lower)

11/111111111111

Remove the parts in the order listed.Refer to “FRONT WHEEL”Refer to “FRONT FORK”Refer to “HANDLEBAR”


1st2nd

52 Nm (5.2 mkg, 38 ftlb)18 Nm (1.8 mkg, 13 ftlb)

110 Nm (11.0 mkg, 80 ftlb)

EAS00676

STEERING HEAD

4-61

STEERING HEAD CHAS

WARNING

WARNING

EAS00677

REMOVING THE LOWER BRACKET1. Stand the motorcycle on a level surface.


2. Remove: lower ring nut 1(with the special tool 2 )

Steering nut wrenchYU-1268

Securely support the lower bracket so thatthere is no danger of it falling.

EAS00681

CHECKING THE STEERING HEAD1. Wash:bearingsbearing races

Recommended cleaning solventKerosine

2. Check:bearings 1bearing races 2Damage/pitting Replace.

3. Replace:bearingsbearing races

a. Remove the bearing races 1 from the steer-ing head pipe with a long rod 2 and hammer.

4-62

STEERING HEAD CHAS

CAUTION:

NOTE:

NOTE:

NOTE:

b. Remove the bearing race 3 from the lowerbracket with a floor chisel 4 and hammer.

c. Install a new rubber seal and new bearingraces.

If the bearing race is not installed properly,the steering head pipe could be damaged.

Always replace the bearings and bearingraces as a set.

Whenever the steering head is disassembled,replace the rubber seal.

4. Check:upper bracket lower bracket(along with the steering stem)Bends/cracks/damage Replace.

EAS00683

INSTALLING THE STEERING HEAD1. Lubricate:upper bearing lower bearingbearing races


2. Install: lower ring nut 1 rubber washer 2upper ring nut 3 lock washer 4Refer to “CHECKING AND ADJUSTINGTHE STEERING HEAD” in chapter 3.

3. Install:upper bracketsteering stem nut

Temporarily tighten the steering stem nut.

4. Install: front fork legsRefer to “FRONT FORK”.

Temporarily tighten the upper and lower bracketpinch bolts.

4-63

REAR SHOCK ABSORBER ASSEMBLY CHAS


1234

Removing the rear shock absorberassemblyRear wheelSide cover (left /right)Connecting armRelay armRear shock absorber

1/1111


Refer to “REAR WHEEL”


40 Nm (4.0 mkg, 29 ftlb)

48 Nm (4.8 mkg, 35 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

40 Nm (4.0 mkg, 29 ftlb)

48 Nm (4.8 mkg, 35 ftlb)

EAS00685

REAR SHOCK ABSORBER ASSEMBLY

4-64


WARNING

WARNING

EAS00687

HANDLING THE REAR SHOCK ABSORBERAND GAS CYLINDER

This rear shock absorber and gas cylindercontain highly compressed nitrogen gas.Before handling the rear shock absorber orgas cylinder, read and make sure you under-stand the following information. Themanufacturer cannot be held responsiblefor property damage or personal injury thatmay result from improper handling of therear shock absorber and gas cylinder.Do not tamper or attempt to open the rearshock absorber or gas cylinder.

Do not subject the rear shock absorber orgas cylinder to an open flame or any othersource of high heat. High heat can cause anexplosion due to excessive gas pressure.

Do not deform or damage the rear shockabsorber or gas cylinder in any way. If therear shock absorber, gas cylinder or bothare damaged, damping performance willsuffer.

EAS00689

DISPOSING OF A REAR SHOCK ABSORB-ER AND GAS CYLINDER

a. Gas pressure must be released before dis-posing of a rear shock absorber and gas cyl-inder. To release the gas pressure, drill a 2 3 mm (0.08 0.12 in) hole through the gascylinder at a point 15 20 mm (0.59 0.79in) from its end as shown.

Wear eye protection to prevent eye damagefrom released gas or metal chips.

4-65


WARNING

NOTE:

NOTE:

NOTE:

EAS00694

REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the motorcycle on a level surface.



2. Remove:connecting arm bolt 1 relay arm bolt 2 rear shock absorber assembly lower bolt 3

While removing the rear shock absorber as-sembly lower bolt, hold the swingarm so that itdoes not drop down.

3. Remove: rear shock absorber assembly upper bolt 1 rear shock absorber assembly

Raise the swingarm and then remove the rearshock absorber assembly from between theswingarm and relay arm.

4-66


NOTE:

EAS00696

CHECKING THE REAR SHOCK ABSORBERASSEMBLY1. Check: rear shock absorber rodBends/damage Replace the rear shockabsorber assembly.

rear shock absorberGas leaks/oil leaks Replace the rearshock absorber assembly.

springDamage/wear Replace the rear shock ab-sorber assembly.

bushingsDamage/wear Replace.

dust sealsDamage/wear Replace.

boltsBends/damage/wear Replace.

EAS00698

INSTALLING THE REAR SHOCK ABSORB-ER ASSEMBLY1. Lubricate:spacersbearings

Recommended lubricantMolybdenum disulfide grease

2. Install: rear shock absorber assembly

Rear shock absorber assemblyupper nut

40 Nm (4.0 mkg, 29 ftlb)Rear shock absorber assemblylower nut

40 Nm (4.0 mkg, 29 ftlb)Relay-arm-to-frame-nut

40 Nm (4.0 mkg, 29 ftlb)

When installing the rear shock absorber as-sembly, lift up the swingarm.

Install the connecting arm front bolt from theright.

4-67

SWINGARM AND DRIVE CHAIN CHAS


123

456789

Removing the swing arm and drivechainRear wheelRear shock absorber assembly

Rear brake caliperBrake hose holderSide protector (left /right)

Pivot shaftSwing armDrive chain caseDrive chain guardDust coverOil seal

12

1/1

111122


Refer to “REAR WHEEL”Refer to “REAR SHOCK ABSORBERASSEMBLY”

Remove the side protector assembly.Do not remove the center cap.

NOTE:

85 Nm (8.5 mkg, 61 ftlb)

125 Nm (12.5 mkg, 90 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

EAS00700

SWINGARM AND DRIVE CHAIN

4-68



10111213141516

BearingSpacerShoft pedal assemblyDrive sprocket coverDrive chain guideDrive sprocketDrive chain

2111111


85 Nm (8.5 mkg, 61 ftlb)

125 Nm (12.5 mkg, 90 ftlb)

23 Nm (2.3 mkg, 17 ftlb)

4-69


WARNING

NOTE:

NOTE:

EAS00703

REMOVING THE SWINGARM1. Stand the motorcycle on a level surface.



2. Remove:connecting arm bolt 1 relay arm bolt 2 rear shock absorber assembly lower bolt 3

When removing the rear shock absorber as-sembly lower bolt, hold the swingarm so that itdoes not drop down.

3. Check:swingarm side play Aswingarm vertical movement B

a. Check the tightening torque of the pivot shaftnut.

Pivot shaft nut125 Nm (12.5 mkg, 90 ftlb)

b. Check the swingarm side play A by movingthe swingarm from side to side.

c. If the swingarm side play is out of specifica-tion, check the spacers, bearings, washers,and dust covers.

Swingarm side play (at the endof the swingarm)

1.0 mm (0.04 in)

d. Check the swingarm vertical movement Bby moving the swingarm up and down.If swingarm vertical movement is not smoothor if there is binding, check the spacers,bearings, washers, and dust covers.

4-70


WARNING

NOTE:

WARNING

EAS00704

REMOVING THE DRIVE CHAIN1. Stand the motorcycle on a level surface.



2. Remove: foot rest (left)drive sprocket coverdrive chain guide 1drive sprocket 2

EAS00707

CHECKING THE SWINGARM1. Check:swingarmBends/cracks/damage Replace.

2. Check:pivot shaftRoll the pivot shaft on a flat surface.Bends Replace.

Do not attempt to straighten a bent pivotshaft.

3. Wash:pivot shaftdust coversspacerwashersbearings

Recommended cleaning solventKerosine

4-71


NOTE:

4. Check:dust covers 1spacer 2oil seals 3Damage/wear Replace.

bearings 4Damage/pitting Replace.

5. Check:connecting arms 1 relay arm 2Damage/wear Replace.

bearings 3oil seals 4Damage/pitting Replace.

spacers 5Damage/scratches Replace.

EAS00709

CHECKING THE DRIVE CHAIN1. Measure: ten-link section a of the drive chainOut of specification Replace the drivechain, the drive sprocket and the rear wheelsprocket as a set.

Ten-link drive chain section limit(maximum)

150.1 mm (5.91 in)

While measuring the ten-link section, pushdown on the drive chain to increase its tension.

Measure the length between drive chain roller1 and 11 as shown.

Perform this measurement at two or three dif-ferent places.

2. Check:drive chainStiffness Clean and lubricate or replace.

4-72


CAUTION:

3. Clean:drive chain

a. Wipe the drive chain with a clean cloth.b. Put the drive chain in kerosine and remove

any remaining dirt.c. Remove the drive chain from the kerosine

and completely dry it.

This motorcycle has a drive chain with smallrubber O-rings 1 between the drive chainside plates. Never use high-pressure wateror air, steam, gasoline, certain solvents(e.g., benzine), or a coarse brush to clean thedrive chain. High-pressure methods couldforce dirt or water into the drive chain’s in-ternals, and solvents will deteriorate the O-rings. A coarse brush can also damage theO-rings. Therefore, use only kerosine toclean the drive chain.

4. Check:O-rings 1Damage Replace the drive chain.

drive chain rollers 2Damage/wear Replace the drive chain.

drive chain side plates 3Damage/wear Replace the drive chain.Cracks Replace the drive chain and makesure that the battery breather hose is proper-ly routed away from the drive chain and be-low the swingarm.

5. Lubricate:drive chain

Recommended lubricantEngine oil or chain lubricantsuitable for O-ring chains

6. Check:drive sprocket rear wheel sprocketMore than 1/4 tooth a wear Replace thedrive chain, the drive sprocket and the rearwheel sprocket as a set.Bent teeth Replace the drive chain, thedrive sprocket and the rear wheel sprocketas a set.

b Correct1 Drive chain roller2 Drive chain sprocket

4-73


85 Nm (8.5 mkg, 61 ftlb)

NOTE:

48 Nm (4.8 mkg, 35 ftlb)

48 Nm (4.8 mkg, 35 ftlb)

EAS00713

INSTALLING THE DRIVE CHAIN1. Lubricate:drive chain

Recommended lubricantEngine oil or chain lubricantsuitable for O-ring chains

2. Install:drive chain 1drive sprocket 2 lock washer 3 Newdrive sprocket nut 4

drive chain guide 5

While applying the rear brake, tighten the drivesprocket nut.

3. Bend the lock washer tab a along a flat sideof the nut.

EAS00711

INSTALLING THE SWINGARM1. Lubricate:bearingsspacersdust coverspivot shaft

Recommended lubricantMolybdenum disulfide grease

2. Install: relay arm left connecting arm right connecting arm

4-74


NOTE:

CAUTION:

Install the connecting arm front bolt 1 from theright.

3. Install: rear shock absorber assembly rear wheelRefer to “INSTALLING THE REAR SHOCKABSORBER ASSEMBLY” and ”REARWHEEL”.

4. Adjust:drive chain slackRefer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.

Drive chain slack40 50 mm (1.57 1.97 in)

A drive chain that is too tight will overload theengine and other vital parts, and one that istoo loose can skip and damage the swingarmor cause an accident. Therefore, keep thedrive chain slack within the specified limits.

ENG

CHAPTER 5OVERHAULING THE ENGINE

ENGINE 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET AND EXHAUST PIPE 5-1. . . . . . . . . . . . . . . . . . . . . LEADS AND HOSES 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAMSHAFT 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CYLINDER HEAD COVERS 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAMSHAFTS 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CAMSHAFTS 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CAMSHAFTS 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS,

AND TIMING CHAIN GUIDES 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE TIMING CHAIN TENSIONER 5-11. . . . . . . . . . . . . . . . . INSTALLING THE CAMSHAFTS 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CYLINDER HEAD 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CYLINDER HEADS 5-17. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CYLINDER HEADS 5-17. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CYLINDER HEAD 5-18. . . . . . . . . . . . . . . . . . . . . . . . . .

VALVES AND VALVE SPRINGS 5-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE VALVES 5-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVES AND VALVE GUIDES 5-22. . . . . . . . . . . . . . . . CHECKING THE VALVE SEATS 5-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE SPRINGS 5-26. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE VALVE LIFTERS 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE VALVES 5-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR 5-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE GENERATOR 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTATLLING THE GENERATOR 5-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PICKUP COIL 5-32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE PLCKUP COIL ROTOR 5-34. . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PICKUP COIL ROTOR 5-34. . . . . . . . . . . . . . . . . . . . . .

ENG

CLUTCH 5-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH COVER 5-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH 5-38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 5-40. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 5-42. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS 5-42. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 5-43. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 5-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE 5-43. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PULL LEVER AND PULL ROD 5-43. . . . . . . . . . . . . . . . CHECKING THE STARTER CLUTCH 5-44. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CLUTCH 5-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SHIFT SHAFT 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERATOR ROTOR COVER 5-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STOPPER LEVER 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SHIFT SHAFT 5-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN AND OIL PUMP 5-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN 5-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 5-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE 5-54. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL STRAINER 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP 5-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP 5-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER 5-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN 5-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE 5-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CRANKCASE 5-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONNECTING RODS AND PISTONS 5-59. . . . . . . . . . . . . . . . . . . . . . . . . CRANKSHAFT 5-60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 5-61. . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS 5-62. . . . . . . . . REMOVING THE CRANKSHAFT ASSEMBLY 5-63. . . . . . . . . . . . . . . . . . CHECKING THE CYLINDERS AND PISTONS 5-64. . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 5-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS 5-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT AND CONNECTING RODS 5-67. . . . CHECKING THE CRANKCASE 5-72. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BEARINGS AND OIL SEALS 5-72. . . . . . . . . . . . . . . . . CHECKING THE SPROCKETS AND CHAINS 5-73. . . . . . . . . . . . . . . . . . INSTALLING THE CRANKSHAFT 5-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CONNECTING ROD AND PISTON 5-74. . . . . . . . . . . ASSEMBLING THE CRANKCASE 5-76. . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENG

TRANSMISSION 5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMISSION, SHIFT DRUM ASSEMBLY AND

SHIFT FORKS 5-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION 5-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS 5-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 5-84. . . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 5-84. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION 5-85. . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

85 Nm (8.5 m kg, 61 ft lb)20 Nm (2.0 m kg, 14 ft lb)

20 Nm (2.0 m kg, 14 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)


1234567

Removing the drive sprocket and exhaust pipeCarburetorPlug codeIgnition coilRadiatorWater hoseAir iduction system

Side cover (left)Stator coil coupler/oil level switchShit rodDrive sprocket coverDrive sprocketWater outlet hoseExhaust pipe

11/111111


Refer to “CARBURETORS” in chapter 7.

Refer to “AIR INDUCTION SYSTEM” inchapter 7.

For installation, reverse the removal procedure.

Refer to “RADIATOR” in chapter 6.

ENGINE ENG

EAS00188

OVERHAULING THE ENGINEENGINEDRIVE SPROCKET AND EXHAUST PIPE

5-2


123

45

Removing the leads and hosesCoverClutch cableNuetral switch/speed sensor/pickupcoil leadWater head pipeCoolant outlet hose

11

1/1/1

11


Disconnect.

For installation, reverse the removal pro-cedure.

ENGINE ENG

EAS00189

LEADS AND HOSES

5-3

24 Nm (2.4 m kg, 17 ft lb)33 Nm (3.3 m kg, 24 ft lb)

55 Nm (5.5 m kg, 40 ft lb)

24 Nm (2.4 m kg,17 ft lb)

55 Nm (5.5 m kg,40 ft lb)


123456

Removing the engineDown tubeEngine mounting bolt (front)Engine bracketEngine mounting bolt (rear upper)Engine mounting bolt (rear lower)Engine

121111



ENGINE ENG

EAS00191

ENGINE

5-4

ENGINE ENG

NOTE:

10 Nm (10 m kg, 7.2 ft lb)

NOTE:

EAS00192

INSTALLING THE ENGINE1. Install:

engine mount bolt 1engine mount bolt 2engine mount bolts 3engine bracket 4engine mount bolt 5down tube 6

Do not fully tighten the bolts.

2. Tighten the bolts in the following order.

Engine mount bolt 155 Nm (5.5 m kg, 40 ft lb)




Down tube 624 Nm (2.4 m kg, 17 ft lb)

3. Install:shift arm 1

Align the punch mark a in the shift shaft withthe slot in the shift arm.Align the bottom edge of the shift pedal with themark on the frame-to-swingarm bracket.

5-5

CAMSHAFT ENG

13 Nm (1.3 m kg, 9.4 ft lb)

12 Nm (1.2 m kg, 8.7 ft lb)


1234

Removing the cylinder head coverCarburetor assemblyRadiator assembly and thermostat assemblySpark plugCylinder head coverCylinder head cover gasketTiming chain guide (top side)

4111

Remove the parts in the order listed.Refer to “CARBURETORS” in chapter 7.Refer to “RADIATOR” and “THERMOSTAT ASSEMBLY” in chapter 6.


EAS00194

CAMSHAFTCYLINDER HEAD COVER

5-6


123456789

Removing the camshaftsPickup coil rotor coverTiming chain tensionerTiming chain tensioner gasketTiming chain guide (exhaust side)Intake camshaft capDowel pinExhaust camshaft capDowel pinIntake camshaftExhaust camshaft

111363611

Remove the parts in the order listed.Refer to “PICKUP COIL”.

During removal, the dowel pins may stillbe connected to the camshaft caps.

NOTE:

10 Nm (1.0 m kg, 7.2 ft lb)

24 Nm (2.4 m kg, 17 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

CAMSHAFT ENG

EAS00196

CAMSHAFTS

5-7

CAMSHAFT ENG


10111213

Intake camshaft sprocketExhaust camshaft sprocketPinTiming chain guide (intake side)

1111


10 Nm (1.0 m kg, 7.2 ft lb)

24 Nm (2.4 m kg, 17 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

5-8

CAMSHAFT ENG

NOTE:

NOTE:

EAS00198

REMOVING THE CAMSHAFTS1. Remove:

pickup rotor coil cover2. Align:

“T” mark on the pickup coil rotor a(with the crankcase mating surface b )


sion stroke, align the “T” mark a with thecrankcase mating surface b .

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

3. Loosen:camshaft sprocket bolts 1

4. Loosen:cap bolt 1

5. Remove:timing chain tensioner 2gasket

6. Remove:camshaft sprocket 1

To prevent the timing chain from falling into thecrankcase, fasten it with a wire 2 .

5-9

CAMSHAFT ENG

CAUTION:

7. Removetiming chain guide (exhaust side) 1camshaft capsdowel pins

To prevent damage to the cylinder head,camshafts or camshaft caps, loosen thecamshaft cap bolts in stages and in a criss-cross pattern, working from the outside in.

8. Remove:intake camshaft 1exhaust camshaft 2

EAS00204

CHECKING THE CAMSHAFTS1. Check:

camshaft lobesBlue discoloration/pitting/scratches Re-place the camshaft.

2. Measure:camshaft lobe dimensions a and bOut of specification Replace the cam-shaft.

Camshaft lobe dimension limitIntake

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

Exhausta 32.85 mm (1.2933 in)b 24.85 mm (0.9783 in)

5-10

CAMSHAFT ENG

NOTE:

3. Measure:camshaft runoutOut of specification Replace.

Camshaft runoutLess than 0.03 mm (0.0012 in)

4. Measure:camshaft-journal-to-camshaft-cap clear-anceOut of specification Measure the camshaftjournal diameter.

Camshaft-journal-to-camshaft-cap clearance

0.028 0.062 mm(0.0011 0.0024 in)

a. Install the camshaft into the cylinder head(without the dowel pins and camshaft caps).

b. Position a strip of Plastigauge 1 onto thecamshaft journal as shown.

c. Install the dowel pins and camshaft caps.

Tighten the camshaft cap bolts in stages and ina crisscross pattern, working from the innercaps out.

Do not turn the camshaft when measuring thecamshaft journal-to-camshaft cap clearancewith the Plastigauge.

Camshaft cap bolt10 Nm (1.0 mkg, 7.2 ftlb)

d. Remove the camshaft caps and then mea-sure the width of the Plastigauge 1 .

5. Measure:camshaft journal diameter aOut of specification Replace the cam-shaft.Within specification Replace the cylinderhead and the camshaft caps as a set.

Camshaft journal diameter24.459 24.472 mm(0.9630 0.9635 in)

5-11

CAMSHAFT ENG

EAS00208

CHECKING THE TIMING CHAIN, CAMSHAFTSPROCKETS, AND TIMING CHAIN GUIDESThe following procedure applies to all of thecamshaft sprockets and timing chain guides.1. Check:timing chain 1Damage/stiffness Replace the timingchain and camshaft sprockets as a set.

2. Check:camshaft sprocketMore than 1/4 tooth a wear Replace thecamshaft sprockets and the timing chain as aset.

a 1/4 toothb Correct

1 Timing chain roller2 Camshaft sprocket

3. Check:timing chain guide (exhaust side) 1timing chain guide (intake side) 2timing chain guide (top side) 3Damage/wear Replace the defectivepart(-s).

EAS00210

CHECKING THE TIMING CHAIN TENSIONER1. Check:timing chain tensionerCracks/damage Replace.

5-12

CAMSHAFT ENG

NOTE:

NOTE:

NOTE:

2. Check:one-way cam operationRough movement Replace the timingchain tensioner housing.

a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.

While pressing the timing chain tensioner rod,wind it clockwise with a thin screwdriver 1 untilit stops.

b. Remove the screwdriver and slowly releasethe timing chain tensioner rod.

c. Make sure that the timing chain tensioner rodcomes out of the timing chain tensionerhousing smoothly. If there is rough move-ment, replace the timing chain tensioner.

3. Check:cap boltcopper washerspringgaskettiming chain tensioner rodDamage/wear Replace the defectivepart(-s).

EAS00217

INSTALLING THE CAMSHAFTS1. Install:exhaust camshaft 1intake camshaft 2

Install the camshafts with the punch mark afacing up.

2. Install:dowel pinsintake camshaft capsexhaust camshaft caps

Make sure that the punch marks a on the cam-shafts are aligned with the arrow marks b onthe camshaft caps.Out of alignment Reinstall.

5-13

CAMSHAFT ENG

10 Nm (1.0 mkg, 7.2 ftlb)

NOTE:

CAUTION:

NOTE:

CAUTION:

3. Install:camshaft cap bolts

Tighten the camshaft cap bolts in stages and ina crisscross pattern, working from the innercaps out.

The camshaft cap bolts must be tightenedevenly or damage to the cylinder head, cam-shaft caps, and camshafts will result.

4. Install:intake camshaft sprocketexhaust camshaft sprocket


sion stroke, align the “T” mark a on the pick-up coil rotor with the crankcase mating sur-face b .

c. Place the timing chain onto both camshaftsprockets and then install the camshaftsprockets onto the camshafts.

When installing the camshaft sprockets, startwith the exhaust camshaft and be sure to keepthe timing chain as tight as possible on the ex-haust side.

Do not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.

5-14

CAMSHAFT ENG

WARNING

d. Turn both camshafts opposite each other sothat the punch marks c in the camshaft arealigned with the arrow marks d in the cam-shaft caps as shown.

e. While holding the camshafts, temporarilytighten the camshaft sprocket bolts.

5. Install:timing chain tensioner

a. While lightly pressing the timing chain ten-sioner rod by hand, turn the tensioner rod ful-ly clockwise with a thin screwdriver 1 .

b. With the timing chain tensioner rod turned allthe way into the timing chain tensioner hous-ing (with the thin screwdriver still installed),install the gasket and the timing chain ten-sioner 2 onto the cylinder block.

Always use a new gasket.

c. Tighten the timing chain tensioner bolts 3 tothe specified torque.

Timing chain tensioner bolt10 Nm (1.0 mkg, 7.2 ftlb)

d. Remove the screwdriver, make sure that thetiming chain tensioner rod releases, and thentighten the cap bolt to the specified torque.

Timing chain cap bolt12 Nm (1.2 mkg, 8.7 ftlb)

6. Turn:crankshaft(several turns clockwise)

5-15

CAMSHAFT ENG

15 Nm (15 mkg, 11 ftlb)

7. Check:“T” mark aMake sure that the “T” mark a on the pickupcoil rotor is aligned with the crankcase mat-ing surface b .

camshaft punch marks cMake sure that the marks c on the camshaftare aligned with the arrow marks d in thecomshaft caps.Out of alignment Adjust.Refer to the installation steps above.

8. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE” in chapter 3.

9. Install:timing mark accessing screw

crankshaft end cover

5-16

CYLINDER HEAD ENG

12 Nm (1.2 mkg, 8.7 ftlb)


123

Removing the cylinder headEngineIntake and exhaust camshaftsCylinder headCylinder head gasketDowel pin

112

Remove the parts in the order listed.Refer to “ENGINE”.Refer to “CAMSHAFTS”.


20 Nm (2.0 mkg, 14 ftlb)1st50 Nm (5.0 mkg, 36 ftlb)2nd 20 Nm (2.0 mkg, 14 ftlb)1st

50 Nm (5.0 mkg, 36 ftlb)2nd

EAS00221

CYLINDER HEAD

5-17

CYLINDER HEAD ENG

NOTE:

NOTE:

NOTE:

EAS00223

REMOVING THE CYLINDER HEADS1. Remove:cylinder head nutscylinder head cap nutscylinder head bolts

Loosen the nuts in the proper sequence asshown.

Loosen each nut 1/2 of a turn at a time. After allof the nuts are fully loosened, remove them.

EAS00230

CHECKING THE CYLINDER HEADSThe following procedure applies to all of the cyl-inder heads.1. Eliminate:carbon deposits(from the combustion chambers with arounded scraper)

Do not use a sharp instrument to avoid damag-ing or scratching:spark plug threadsvalve seats

2. Check:cylinder headDamage/scratches Replace.

cylinder head water jacketMineral deposits/rust Eliminate.

3. Measure:cylinder head warpageOut of specification Resurface the cylin-der head.

Cylinder head warpageLess than 0.1 mm (0.004 in)

a. Place a straightedge 1 and a thicknessgauge 2 across the cylinder head.

b. Measure the warpage.c. If the limited is exceeded, resurface the cylin-

der head as follows.d. Place a 400 600 grit wet sandpaper on the

surface plate and resurface the cylinderhead using a figure-eight sanding pattern.

To ensure an even surface, rotate the cylinderhead several times.

5-18

CYLINDER HEAD ENG

NOTE:

20 Nm (2.0 mkg, 14 ftlb)

50 Nm (5.0 mkg, 36 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

NOTE:

NOTE:

EAS00233

INSTALLING THE CYLINDER HEAD1. Install:gasket New 1dowel pins 2

2. Install:cylinder head

Pass the timing chain through the timing chaincavity.

3. Tighten:cylinder head nuts 1 10

1st2nd

cylinder head bolt 11 12

First, tighten the nuts 1 10 to approximate-ly 20 Nm (2.0 mkg, 14 ftlb) with a torquewrench.

Retighten the nuts to 50 Nm (5.0 mkg, 36ftlb).

Apply engine oil onto the threads of the cylin-der head nuts.

Tighten the cylinder head nuts in the propertightening sequence as shown and torquethem in two stages.

4. Install:exhaust camshaftintake camshaftRefer to “INSTALLING THE CAMSHAFTS”.

5-19

VALVES AND VALVE SPRINGS ENG


123456789

Removing the valves and valvespringsCylinder headIntake valve lifterIntake valve padIntake valve cotterIntake valve upper spring seatIntake valve springIntake valve oil sealIntake valve lower spring seatIntake valveIntake valve guide

121224121212121212


Refer to “CYLINDER HEAD”.

EAS00236

VALVES AND VALVE SPRINGS

5-20


101112131415161718

Exhaust valve lifterExhaust valve padExhaust valve cotterExhaust valve upper spring seatExhaust valve springExhaust valve oil sealExhaust valve lower spring seatExhaust valveExhaust valve guide

88

16888888



5-21


NOTE:

NOTE:

NOTE:

NOTE:

EAS00237

REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.

Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure that the valves properly seal.

1. Remove:valve lifter 1valve pad 2

Make a note of the position of each valve lifterand valve pad so that they can be reinstalled intheir original place.

2. Check:valve sealingLeakage at the valve seat Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent a into the intake andexhaust ports.

b. Check that the valves properly seal.

There should be no leakage at the valve seat 1 .

3. Remove:valve cotters 1

Remove the valve cotters by compressing thevalve spring with the valve spring compressor2 and adapter 3 .

Valve spring compressor set, Quick release

YM-04019Adapter

Intake valveYM-4114

Exhaust valveYM-4108

5-22

NOTE:


4. Remove:upper spring seat 1valve spring 2oil seal 3lower spring seat 4valve 5

Identify the position of each part very carefullyso that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALVEGUIDESThe following procedure applies to all of thevalves and valve guides.1. Measure:valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =Valve guide inside diameter A –Valve stem diameter B

Out of specification Replace the valveguide.

Valve-stem-to-valve-guideclearance

Intake0.010 0.037 mm(0.0004 0.0015 in)

<Limit>: 0.08 mm (0.0031 in)Exhaust

0.020 0.047 mm(0.0008 0.0019 in)<Limit>: 0.1 mm (0.0039 in)

5-23


NOTE:

NOTE:

2. Replace:valve guide

To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100C in an oven.

a. Remove the valve guide with a valve guideremover 1 .

b. Install the new valve guide with a valve guideinstaller 2 and valve guide remover 1 .

c. After installing the valve guide, bore thevalve guide with a valve guide reamer 3 toobtain the proper valve-stem-to-valve-guideclearance.

After replacing the valve guide, reface the valveseat .

Valve guide removerIntake (4.0 mm)

YM-04111Exhaust (4.5 mm)

YM-4116Valve guide installer

Intake (4.0 mm)YM-04112

Exhaust (4.5 mm)YM-4117

Valve guide reamerIntake

YM-04113Exhaust

YM4118

5-24


NOTE:

3. Eliminate:carbon deposits(from the valve face and valve seat)

4. Check:valve facePitting/wear Grind the valve face.

valve stem endMushroom shape or diameter larger than thebody of the valve stem Replace the valve.

5. Measure:valve margin thickness aOut of specification Replace the valve.

Valve margin thickness0.5 0.9 mm (0.020 0.035 in)

6. Measure:valve stem runoutOut of specification Replace the valve.

When installing a new valve, always replacethe valve guide.

If the valve is removed or replaced, always re-place the oil seal.

Valve stem runout0.01 mm (0.0004 in)

EAS00240

CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:carbon deposits(from the valve face and valve seat)

2. Check:valve seatPitting/wear Replace the cylinder head.

3. Measure:valve seat width aOut of specification Replace the cylinderhead.

Valve seat widthIntake: 0.9 1.1 mm(0.035 0.043 in)Exhaust: 0.9 1.1 mm(0.035 0.043 in)

5-25


NOTE:

NOTE:

CAUTION:

NOTE:

a. Apply Mechanic’s blueing dye (Dykem) 1onto the valve face.

b. Install the valve into the cylinder head.c. Press the valve through the valve guide and

onto the valve seat to make a clear pattern.d. Measure the valve seat width.

Where the valve seat and valve face contactedone another, the blueing will have been re-moved.

4. Lap:valve facevalve seat

After replacing the cylinder head or replacingthe valve and valve guide, the valve seat andvalve face should be lapped.

a. Apply a coarse lapping compound a to thevalve face.

Do not let the lapping compound enter thegap between the valve stem and the valveguide.

b. Apply molybdenum disulfide oil onto thevalve stem.

c. Install the valve into the cylinder head.d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all ofthe lapping compound.

For the best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hand.

e. Apply a fine lapping compound to the valveface and repeat the above steps.

f. After every lapping procedure, be sure toclean off all of the lapping compound fromthe valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) ontothe valve face.

h. Install the valve into the cylinder head.i. Press the valve through the valve guide and

onto the valve seat to make a clear impression.j. Measure the valve seat width a again. If the

valve seat width is out of specification, refaceand lap the valve seat.

5-26


EAS00241

CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:valve spring free length aOut of specification Replace the valvespring.

Valve spring free lengthIntake spring

38.9 mm (1.53 in)Exhaust spring

40.67 mm (1.60 in)

2. Measure:compressed spring force aOut of specification Replace the valvespring.

b Installed length

Compressed spring forceIntake

8.2 9.6 kg at 34.5 mm(18.4 25.4 lb at 1.36 in)

Exhaust11.0 12.6 kg at 35.0 mm(24.7 28.3 lb at 1.38 in)

3. Measure:valve spring tilt aOut of specification Replace the valvespring.

Spring tilt limitIntake

1.7 mm (0.067 in)Exhaust

1.8 mm (0.071 in)

5-27


NOTE:

NOTE:

EAS00242

CHECKING THE VALVE LIFTERSThe following procedure applies to all of thevalve lifters.1. Check:valve lifterDamage/scratches Replace the valve lift-ers and cylinder head.

EAS00245

INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:valve stem end(with an oil stone)

2. Lubricate:valve stem 1oil seal 2(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide oil

3. Install:valve 1lower spring seat 2oil seal 3valve spring 4upper spring seat 5(into the cylinder head)

Install the valve spring with the larger pitch afacing up.

b Smaller pitch

Make sure that each valve is installed in its origi-nal place. Refer to the following embossedmarks.Right and left intake valve(-s): “4XV:”Middle intake valve(-s): “4XV.”Exhaust valve(-s): “5LV”

5-28


NOTE:

CAUTION:

NOTE:

4. Install:valve cotters 1

Install the valve cotters by compressing thevalve spring with the valve spring compressor2 and adapter 3 .

Valve spring compressor set, Quick release

YM-04019Adapter

Intake valveYM-4114

Exhaust valveYM-4108

5. To secure the valve cotters onto the valvestem, lightly tap the valve tip with a soft-facehammer.

Hitting the valve tip with excessive forcecould damage the valve.

6. Install:valve pad 1valve lifter 2

Apply molybdenum disulfide oil onto the valvelifter and valve pad.

The valve lifter must move smoothly when ro-tated with a finger.

Each valve lifter and valve pad must be rein-stalled in its original position.

5-29

14 Nm (1.4 mkg, 10 ftlb)

65 Nm (6.5 mkg, 47 ftlb) + 60

12 Nm (1.2 mkg, 8.7 ftlb)


12345678

Removing the stator coil assemblyRider seat and fuel tank

Bottom cowlingEngine oil

Generator rotor coverGenerator rotor cover gasketDowel pinGenerator rotor boltGenerator rotorStator coil assembly couplerStator coil assembly lead holderStator coil assembly

11211111

Remove the parts in the order listed.Refer to “SEATS” and “FUEL TANK” inchapter 3.Refer to “COWLINGS” in chapter 3.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.

Disconnect.


GENERATOR ENG

EB410000

GENERATOR

5-30

GENERATOR ENG

NOTE:

NOTE:

WARNING

CAUTION:

REMOVING THE GENERATOR1. Remove:generator rotor cover 1

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern.After all of the bolts are fully loosened, removethem.

2. Remove:generator rotor bolt 1washer

While holding the generator rotor 2 with theuniversal magneto & rotor holder 3 , loosen thegenerator rotor bolt.

Universal magneto & rotor holderYU-01235

3. Remove:generator rotor 1(with the alternator roter puller 2 and rotorholding tool 3 )

Alternator roter pullerYM-01080-A

INSTALLING THE GENERATOR1. Apply:sealant(onto the stator coil assembly lead grommet)

Yamaha bond No. 1215ACC-11001-05-01

2. Install:generator rotorwashergenerator rotor bolt

Always use a new generator rotor bolt.

Clean the tapered portion of the crankshaftand the generator rotor hub with lacquerthinner.

Lubricate the generator rotor bolt threadswith engine oil.

5-31

GENERATOR ENG

65 Nm (6.5 mkg, 47 ftlb) + 60

NOTE:

NOTE:

3. Tighten:generator rotor bolt 1 New

While holding the generator rotor 2 with theuniversal magneto & rotor holder 3 , tightenthe generator rotor bolt.

After tightening to 65 Nm (6.5 mkg, 47 ftlb),tighten another 60.


4. Install:generator rotor cover

Tighten the generator rotor cover bolts in stagesand in a crisscross pattern.

5-32

12 Nm (1.2 mkg, 8.7 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

60 Nm (6.0 mkg, 43 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)


1234

Removing the pickup coil andpickup coil rotorRider seat and fuel tank

Bottom cowling and right side cowlingEngine oil

Generator rotor coverPickup coil lead holderPickup coil rotor coverPickup coil rotor cover gasketDowel pin

1112


Refer to “SEATS” and “FUEL TANK” inchapter 3.Refer to “COWLINGS” in chapter 3.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “GENERATOR”.

PICKUP COIL ENG

PICKUP COIL

5-33

PICKUP COIL ENG


567

Pickup coil couplerPickup coilPickup coil rotor

111

Disconnect.


12 Nm (1.2 mkg, 8.7 ftlb)

15 Nm (1.5 mkg, 11 ftlb)

60 Nm (6.0 mkg, 43 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)

5-34

PICKUP COIL ENG

NOTE:

NOTE:

NOTE:

REMOVING THE PICKUP COIL ROTOR1. Remove:pickup coil lead holder 1pickup coil rotor cover 2

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern.After all of the bolts are fully loosened, removethem.

2. Remove:pickup coil rotor bolt 1washerpickup coil rotor 2

While holding the generator rotor 3 with theuniversal magneto & rotor holder 4 , loosen thepickup coil rotor bolt.


INSTALLING THE PICKUP COIL ROTOR1. Install:pickup coil rotor 1washerpickup coil rotor bolt

When installing the pickup coil rotor, align thepin 2 in the crankshaft sprocket with the groovea in the pickup coil rotor.

5-35

PICKUP COIL ENG

60 Nm (6.0 mkg, 43 ftlb)

NOTE:

NOTE:

2. Tighten:pickup coil rotor bolt 1

While holding the generator rotor 2 with theuniversal magneto & rotor holder 3 , tighten thepickup coil rotor bolt.


3. Apply:sealant(onto the pickup coil lead grommet)


4. Install:pickup coil rotor coverpickup coil lead holder

When installing the pickup coil rotor cover,align the timing chain guide (intake side) pin 1with the hole 2 in the pickup coil rotor cover.

Tighten the pickup coil rotor cover bolts instages and in a crisscross pattern.

5-36

CLUTCH ENG

12 Nm (1.2 mkg,8.7 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)


1234

Removing the clutch coverEngine oil

Clutch cableClutch coverClutch cover gasketDowel pin

1112

Remove the parts in the order listed.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.


EAS00273

CLUTCHCLUTCH COVER

5-37


123456

Removing the pull lever shaftCirclipPull leverPull lever springPull lever shaftOil sealBearing

211112



CLUTCH ENG

EB405010

5-38

CLUTCH ENG

8 Nm (0.8 mkg, 5.8 ftlb)


123456789

10

Removing the clutchClutch coverPull rodFriction plateClutch plateFriction plateClutch plateFriction plateFriction plateClutch damper springClutch damper spring seat

1112463111


Refer to “INSTALLING THE CLUTCH”.

Select.Color code: Black

Color code: Blue

12 Nm (1.2 mkg, 8.7 ftlb)

70 Nm (7.0 mkg, 51 ftlb)

EAS00274

CLUTCH

5-39

CLUTCH ENG


1112131415161718192021

Clutch boss nutLock washerClutch bossThrust washerClutch housingBearingStarter clutch gearBearingStarter clutch assemblyCirclipStarter clutch idle gear

11111111111


8 Nm (0.8 mkg, 5.8 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)

70 Nm (7.0 mkg, 51 ftlb)

5-40

CLUTCH ENG

NOTE:

EAS00277

REMOVING THE CLUTCH1. Straighten the lock washer tab.2. Loosen:clutch boss nut 1

While holding the clutch boss 2 with the univer-sal clutch holder 3 , loosen the clutch boss nut.

Universal clutch holderYM-91042

3. Remove:clutch boss nut 1lock washer 2clutch boss 3

EAS00280

CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check:friction plateDamage/wear Replace the friction platesas a set.

5-41

CLUTCH ENG

NOTE:

NOTE:

2. Measure: friction plate thicknessOut of specification Replace the frictionplates as a set.

Measure the friction plate at four places.

Friction plate thicknessFriction plate a

3.42 3.58 mm(0.135 0.141 in)<Limit>: 3.32 mm (0.131 in)

Friction plate b2.92 3.08 mm(0.115 0.121 in)<Limit>: 2.82 mm (0.111 in)

3. Measure:assembly width aOut of specification Adjust.

Assembly width43.1 43.9 mm (1.70 1.73 in)

a. Assembly width adjusted by clutch plate 1and 2 .

b. Select the clutch plate from the followingtable.

Clutch plate 1

Part No. Thickness

168-16325-00 1.6 mm(0.06 in)

31A-16325-00 2.0 mm(0.08 in)

STD

168-16324-00 2.3 mm(0.09 in)

Clutch plate 2

Part No. Thickness

31A-16325-00 2.0 mm(0.08 in)

STD

168-16324-00 2.3 mm(0.09 in)

When adjusting the clutch assembly width [byreplacing the clutch plate(s)], be sure to replacethe clutch plate 1 first. After replacing thecltuch plate 1 , if specifications cannot be met,replace the clutch plate 2 .

5-42

CLUTCH ENG

EAS00281

CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:clutch plateDamage Replace the clutch plates as aset.

2. Measure:clutch plate warpage(with a surface plate and thickness gauge 1 )Out of specification Replace the clutchplates as a set.

Clutch plate warpage limitLess than 0.1 mm (0.004 in)

EAS00282

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:clutch springDamage Replace the clutch springs as aset.

2. Measure:clutch spring free lengthOut of specification Replace the clutchsprings as a set.

Clutch spring free length50 mm (1.97 in)<Limit>: 47.5 mm (1.87 in)

5-43

CLUTCH ENG

NOTE:

NOTE:

EAS00284

CHECKING THE CLUTCH HOUSING1. Check:clutch housing dogsDamage/pitting/wear Deburr the clutchhousing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause er-ratic clutch operation.

2. Check:bearingDamage/wear Replace the clutch hous-ing.

EAS00285

CHECKING THE CLUTCH BOSS1. Check:clutch boss splinesDamage/pitting/wear Replace the clutchboss.

Pitting on the clutch boss splines will cause er-ratic clutch operation.

EAS00286

CHECKING THE PRESSURE PLATE1. Check:pressure plate 1Cracks/damage Replace.

bearing 2Damage/wear Replace.

EAS00287

CHECKING THE PULL LEVER AND PULLROD1. Check:pull lever 1pull rod 2Damage/wear Replace the pull rod andpull lever pinion gear as a set.

5-44

CLUTCH ENG

2. Check:pull rod bearingDamage/wear Replace.

EAS00351

CHECKING THE STARTER CLUTCH1. Check:starter clutch rollersDamage/wear Replace.

2. Check:starter clutch idle gearstarter clutch drive gearstarter clutch gear Burrs/chips/roughness/wear Replacethe defective part(-s).

3. Check:starter clutch gear’s contacting surfaces Damage/pitting/wear Replace the starterclutch gear.

5-45

CLUTCH ENG

NOTE:

90 Nm (9.0 m kg, 65 ft lb)

NOTE:

4. Check:starter clutch operation

a. Install the starter clutch drive gear 1 ontothe starter clutch 2 and hold the starterclutch.

b. When turning the starter clutch drive gearclockwise A , the starter clutch and the start-er clutch drive gear should engage.If the starter clutch drive gear and starterclutch do not engage, the starter clutch isfaulty and must be replaced.

c. When turning the starter clutch drive gearcounterclockwise B , it should turn freely.If the starter clutch drive gear does not turnfreely, the starter clutch is faulty and must bereplaced.

EAS00299

INSTALLING THE CLUTCH1. Install:

clutch housing

Make sure that the slots a in the clutch hous-ing align with the tabs b on the oil /water pumpassembly drive sprocket.Make sure that the primary driven gear teethand primary drive gear teeth mesh correctly.Make sure that the starter clutch gear teeth andstarter clutch idle gear teeth mesh correctly.

2. Install:lock washer Newclutch boss nut 1

While holding the clutch boss 2 with the univer-sal clutch holder 3 , tighten the clutch boss nut.

Universal clutch holderYM-91042

5-46

CLUTCH ENG

NOTE:

3. Bend the lock washer tab along a flat side ofthe nut.

4. Lubricate: friction platesclutch plates(with the recommended lubricant)

Recommended lubricantEngine oil

5. Install: friction platesclutch plates

First, install a friction plate and then alternatebetween a clutch plate and a friction plate.

a. Install the clutch damper spring seat 1 ,clutch damper spring 2 and friction plate(smaller size) 3 .

b. Install the clutch plate and friction plate at fol-lowing the illustrated.Friction plate 4 : Color code/BlueFriction plate 5 : Color code/BlackClutch plate 6 : 2.0 mmClutch plate 7 : Select. Refer to “CHECKING

THE FRICTION PLATE”

6. Measure:assembly width aOut of specification Adjust.Refer to “CHECKING THE FRICTIONPLATE”.

Assembly width43.1 43.9 mm (1.70 1.73 in)

5-47

CLUTCH ENG

NOTE:

8 Nm (0.8 m kg, 5.8 ft lb)

NOTE:

NOTE:

12 Nm (1.2 m kg, 8.7 ft lb)

NOTE:

7. Install:pressure plate 1

Align the punch mark b in the pressure platewith the punch mark a in the clutch boss.

8. Install:clutch springsclutch spring bolts

Tighten the clutch spring bolts in stages and in acrisscross pattern.

9. Install:pull lever

Align the punch mark a in the pull lever shaftwith the mark b on the clutch cover.

10. Install:dowel pinsgasket Newclutch cover

When installing the clutch cover, push the pulllever and check that the punch mark a on thepull lever aligns with the mark b on the clutchcover. Make sure that the pull rod groove cand pull lever shaft groove d are engaged.Tighten the clutch cover bolts in stages and ina crisscross pattern.

5-48

SHIFT SHAFT ENG

12 Nm (1.2 m kg, 8.7 ft lb)


123456789

10

Removing the shift shaft and stopperleverDrive sprocket coverShift shaft coverShift shaft cover gasketDowel pinShift shaftShift shaft springSpacerStopper lever springStopper leverCollarShift shaft spring stopper

1121111111


Refer to “ENGINE”.


EAS00326

SHIFT SHAFTGENERATOR ROTOR COVER

5-49

SHIFT SHAFT ENG

22 Nm (2.2 m kg, 16 ft lb)

NOTE:

NOTE:

EAS00328

CHECKING THE SHIFT SHAFT1. Check:

shift shaft 1Bends/damage/wear Replace.shift shaft spring 3Damage/wear Replace.

EAS00330

CHECKING THE STOPPER LEVER1. Check:

stopper lever 1Bends/damage Replace.Roller turns roughly Replace the stopperlever.

EAS00331

INSTALLING THE SHIFT SHAFT1. Install:

shift shaft spring stopper 1

stopper lever spring 2stopper lever 3

Apply LOCTITE to the threads of the shiftshaft spring stopper.Hook the ends of the stopper lever spring ontothe stopper lever and the crankcase boss.Mesh the stopper lever with the shift drum seg-ment assembly.

2. Install:shift shaft 1spacer

Lubricate the oil seal lips with lithium soapbase grease.Install the end of the shift shaft spring onto theshift shaft spring stopper 2 .

5-50

OIL PAN AND OIL PUMP ENG


123456

Removing the oil pan and oil pumpEngine oil

Coolant

Radiator assembly and water pump outlet pipeExhaust pipe assemblyOil level switch connectorOil level switchOil level switch lead holderOil panOil pan gasketDowel pin

111112

Remove the parts in the order listed.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Refer to “RADIATOR” in chapter 6.

Refer to “ENGINE”.Disconnect.

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg,7.2 ft lb)

43 Nm (4.3 m kg,31 ft lb)

EAS00356

OIL PAN AND OIL PUMP

5-51


789

1011

121314

Drain pipeOil strainerOil pipeOil delivery pipeOil /water pump assembly drivesprocket coverDowel pinOil /water pump assemblyRelief valve assembly

11111

111

For installation, reverse the removal pro-cedure.

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg,7.2 ft lb)

43 Nm (4.3 m kg,31 ft lb)


EB411001

5-52


10 Nm (1.0 m kg, 7.2 ft lb)

15 Nm (1.5 m kg, 11 ft lb)


Disassembling the oil pumpOil/water pump assembly drivensprocketWasherOil pump housingBearingPinOil pump outer rotorOil pump inner rotorPin

1

1112111



1

2345678

EAS00360

5-53


NOTE:

EAS00362

REMOVING THE OIL PAN1. Remove:

oil level switch 1oil pan 2engine oil drain bolt 3gasketdowel pins

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

EAS00364

CHECKING THE OIL PUMP1. Check:

oil pump drive gear 1oil pump driven gear 2oil pump housingoil pump housing coverCracks/damage/wear Replace the de-fective part(-s).

2. Measure:inner-rotor-to-outer-rotor-tip clearance aouter-rotor-to-oil-pump-housing clearanceboil-pump-housing-to-inner-rotor-and-outer-rotor clearance cOut of specification Replace the oil pump.

1 Inner rotor2 Outer rotor3 Oil pump housing

Inner-rotor-to-outer-rotor-tipclearance

0.09 0.15 mm(0.004 0.006 in)<Limit>: 0.23 mm (0.009 in)

Outer-rotor-to-oil-pump-housingclearance

0.03 0.08 mm(0.001 0.003 in)<Limit>: 0.15 mm (0.006 in)

Oil-pump-housing-to-inner-rotor-and-outer-rotor clearance

0.06 0.11 mm(0.002 0.004 in)<Limit>: 0.18 mm (0.007 in)

3. Check:oil pump operationUnsmooth Repeat steps (1) and (2) or re-place the defective part(-s).

5-54


EAS00365

CHECKING THE RELIEF VALVE1. Check:

relief valve body 1relief valve 2spring 3O-ring 4Damage/wear Replace the defectivepart(-s).

EAS00366

CHECKING THE OIL DELIVERY PIPE1. Check:

oil delivery pipe 1oil pipe 2Damage Replace.Obstruction Wash and blow out with com-pressed air.

EAS00368

CHECKING THE OIL STRAINER1. Check:

oil strainer 1Damage Replace.Contaminants Clean with engine oil.

EAS00374

ASSEMBLING THE OIL PUMP1. Lubricate:

inner rotorouter rotoroil pump shaft(with the recommended lubricant)


5-55


NOTE:

12 Nm (1.2 m kg, 8,7 ft lb)

NOTE:

10 Nm (1.0 m kg, 7.2 ft lb)

NOTE:

2. Install:pin 1inner rotor 2outer rotor 3oil pump housing 4

Oil pump housing screw10 Nm (1.0 m kg, 7.2 ft lb)

When installing the inner rotor, align the pin 1 inthe oil pump shaft with the groove a on the in-ner rotor 2 .

3. Check:oil pump operationRefer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP1. Install:

oil pump

Install the oil /water pump drive chain 1 ontothe oil /water pump driven sprocket 2 .

EAS00378

INSTALLING THE OIL STRAINER1. Install:

oil strainer housing 1

LOCTITE

The arrow a on the oil strainer housing mustpoint towards the front of the engine.

5-56


10 Nm (10 m kg, 7.2 ft lb)

10 Nm (10 m kg, 7.2 ft lb)

43 Nm (4.3 m kg, 31 ft lb)

WARNING

NOTE:

EAS00380

INSTALLING THE OIL PAN1. Install:

dowel pinsgasket Newoil pan 1oil level switch 2

engine oil drain bolt 3

Always use new copper washers.

Tighten the oil pan bolts in stages and in acrisscross pattern.Lubricate the oil level switch’s O-ring with en-gine oil.

5-57

CRANKCASE ENG


1234

5

Removing the crankcaseEngineCylinder headPickup coil and pickup coil rotorStator coil assemblyClutch housing and starter clutch idlegearOil /water pump assemblyTiming chainCrankshaft sprocketPinOil /water pump assembly drive chainguideOil /water pump assembly drive chain

1111

1

Remove the parts in the order listed.Refer to “ENGINE”.Refer to “CYLINDER HEAD”.Refer to “PICKUP COIL”.Refer to “GENERATOR”.Refer to “CLUTCH”.

Refer to “OIL PAN AND OIL PUMP”.

10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

EAS00381

CRANKCASECRANKCASE

5-58


6

789

10

Oil /water pump assembly drivesprocketWasherPlateLower crankcaseDowel pin

1

1113


10 Nm (1.0 m kg, 7.2 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

CRANKCASE ENG

5-59

CRANKCASE ENG


123456789

10

Removing the connecting rods andpistonsConnecting rod capBig end lower bearingPiston pin clipPiston pinPistonConnecting rodBig end upper bearingTop ring2nd ringOil ring

4484444444



36 Nm (3.6 m kg, 25 ft lb)

EAS00382

CONNECTING RODS AND PISTONS

5-60

CRANKCASE ENG


123

Removing the crankshaft assemblyCrankcase

Connecting rod caps

CrankshaftCrankshaft journal lower bearingCrankshaft journal upper bearing

155

Remove the parts in the order listed.Separate.Refer to “CRANKCASE”.Refer to “CONNECTING RODS ANDPISTONS”.


CRANKSHAFT

5-61

CRANKCASE ENG

NOTE:

CAUTION:

NOTE:

EAS00384

DISASSEMBLING THE CRANKCASE1. Place the engine upside down.2. Remove:

crankcase bolts

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.Loosen the bolts in decreasing numerical or-der (refer to the numbers in the illustration).The numbers embossed on the crankcase in-dicate the crankcase tightening sequence.

3. Remove:lower crankcase

Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced por-tions of the crankcase, not on the crankcasemating surfaces. Work slowly and carefullyand make sure that the crankcase halvesseparate evenly.

M9 125 mm bolts: 1 10

M8 125 mm bolts: 21 22

M6 100 mm bolts: 11 20 , 23 28

4. Remove:dowel pinsO-ring

5. Remove:crankshaft journal lower bearing(from the lower crankcase)

Identify the position of each crankshaft journallower bearing so that it can be reinstalled in itsoriginal place.

5-62

CRANKCASE ENG

NOTE:

CAUTION:

NOTE:

EAS00393

REMOVING THE CONNECTING RODS ANDPISTONSThe following procedure applies to all of theconnecting rods and pistons.1. Remove:

connecting rod cap 1big end bearings

Identify the position of each big end bearing sothat it can be reinstalled in its original place.

2. Remove:piston pin clips 1piston pin 2piston 3

Do not use a hammer to drive the piston pinout.

For reference during installation, put identifica-tion marks on the piston crown.Before removing the piston pin, deburr the pis-ton pin clip’s groove and the piston’s pin borearea. If both areas are deburred and the pistonpin is still difficult to remove, remove it with thepiston pin puller 1 .

Piston pin pullerYU-01304

5-63

CRANKCASE ENG

NOTE:

NOTE:

3. Remove:top ring2nd ringoil ring

When removing a piston ring, open the end gapwith your fingers and lift the other side of the ringover the piston crown.

EAS00387

REMOVING THE CRANKSHAFT ASSEMBLY1. Remove:

crankshaft assembly 1crankshaft journal upper bearings(from the upper crankcase)

Identify the position of each crankshaft journalupper bearing so that it can be reinstalled in itsoriginal place.

5-64

CRANKCASE ENG

NOTE:

EAS00256

CHECKING THE CYLINDERS AND PISTONSThe following procedure applies to all of the cyl-inders and pistons.1. Check:

piston wallcylinder wallVertical scratches Rebore or replace thecylinder, and replace the piston and pistonrings as a set.

2. Measure:piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinderbore gauge.

Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cyl-inder. Then, find the average of the measure-ments.

Cylinder bore “C” 74.00 74.01 mm(2.9134 2.9138 in)

Wear limit 74.06 mm(2.9157 in)

Taper limit “T” 0.05 mm(0.0016 in)

Out of round “R” 0.05 mm(0.0016 in)

“C” = maximum of D1 D6

“T” = maximum of D1 or D2 – maximum ofD5 or D6

“R” = maximum of D1 D3 or D5 – minimum ofD2 D4 or D6

b. If out of specification, replace the cylinder,and the piston and piston rings as a set.

5-65

CRANKCASE ENG

NOTE:

c. Measure piston skirt diameter “P” with themicrometer.

a 5 mm (0.20 in) from the bottom edge of the piston.

Piston size “P”73.955 73.970 mm(2.9118 2.9122 in)

d. If out of specification, replace the piston andpiston rings as a set.

e. Calculate the piston-to-cylinder clearancewith the following formula.

Piston-to-cylinder clearance =Cylinder bore “C” –Piston skirt diameter “P”

Piston-to-cylinder clearance0.030 0.055 mm(0.001 0.002 in)<Limit>: 0.12 mm (0.005 in)

f. If out of specification, replace the cylinder,and the piston and piston rings as a set.

EAS00263

CHECKING THE PISTON RINGS1. Measure:

piston ring side clearanceOut of specification Replace the pistonand piston rings as a set.

Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.

Piston ring side clearanceTop ring0.030 0.065 mm(0.0012 0.0026 in)2nd ring0.020 0.055 mm(0.0008 0.0022 in)

5-66

CRANKCASE ENG

NOTE:

NOTE:

2. Install:piston ring(into the cylinder)

Level the piston ring in the cylinder with the pis-ton crown as shown.

a 5 mm (0.20 in)3. Measure:

piston ring end gapOut of specification Replace the pistonring.

The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

Piston ring end gapTop ring

0.32 0.44 mm(0.010 0.020 in)

2nd ring0.43 0.58 mm(0.017 0.023 in)

Oil ring0.10 0.35 mm(0.004 0.014 in)

EAS00266

CHECKING THE PISTON PINSThe following procedure applies to all of the pis-ton pins.1. Check:

piston pinBlue discoloration/grooves Replace thepiston pin and then check the lubrication sys-tem.

2. Measure:piston pin outside diameterOut of specification Replace the pistonpin.

Piston pin outside diameter16.991 17.000 mm(0.6689 0.6693 in)

5-67

CRANKCASE ENG

3. Measure:piston pin bore inside diameterOut of specification → Replace the piston.

Piston pin bore inside diameter17.002 17.013 mm(0.6694 0.6698 in)

4. Calculate:piston-pin-to-piston clearanceOut of specification Replace the piston pinand piston as a set.

Piston-pin-to-piston clearance =Piston pin bore size –Piston pin outside diameter

Piston-pin-to-piston clearance0.002 0.022 mm(0.00008 0.00087 in)<Limit>: 0.072 mm (0.0028 in)

EAS00395

CHECKING THE CRANKSHAFT AND CON-NECTING RODS1. Measure:

crankshaft runoutOut of specification Replace the crank-shaft.

Crankshaft runoutLess than 0.03 mm (0.0012 in)

2. Check:crankshaft journal surfacescrankshaft pin surfacesbearing surfacesScratches/wear Replace the crankshaft.

3. Measure:crankshaft-journal-to-crankshaft-journal-bearing clearanceOut of specification Replace the crank-shaft journal bearings.

Crankshaft-journal-to-crankshaft-journal-bearing clearance

0.029 0.053 mm(0.0011 0.0021 in)

5-68

CRANKCASE ENG

CAUTION:

NOTE:

NOTE:

NOTE:

Do not interchange the crankshaft journalbearings. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearing clear-ance and prevent engine damage, the crank-shaft journal bearings must be installed intheir original positions.

a. Clean the crankshaft journal bearings,crankshaft journals, and bearing portions ofthe crankcase.

b. Place the upper crankcase upside down on abench.

c. Install the crankshaft journal upper bearings1 and the crankshaft into the upper crank-case.

Align the projections a of the crankshaft journalupper bearings with the notches b in the crank-case.

d. Put a piece of Plastigauge 2 on eachcrankshaft journal.

Do not put the Plastigauge over the oil hole inthe crankshaft journal.

e. Install the crankshaft journal lower bearings1 into the lower crankcase and assemblethe crankcase halves.

Align the projections a of the crankshaft jour-nal lower bearings with the notches b in thecrankcase.Do not move the crankshaft until the clearancemeasurement has been completed.

5-69

CRANKCASE ENG

NOTE:

NOTE:

f. Tighten the bolts to specification in the tight-ening sequence cast on the crankcase.

Crankcase boltBolt 1 10

1st: 15 Nm (1.5 mkg, 11 ftlb)2nd: 15 Nm (1.5 mkg, 11 ftlb) +45 50

Bolt 11 15 , 17 20 , 23 ,25 28

12 Nm (1.2 mkg, 8.7 ftlb)Bolt 16 , 24

14 Nm (1.4 mkg, 10 ftlb)Bolt 21 22

24 Nm (24 mkg, 17 ftlb)

Lubricate the crankcase bolt threads with en-gine oil.

g. Remove the lower crankcase and the crank-shaft journal lower bearings.

h. Measure the compressed Plastigauge

width c on each crankshaft journal.If the clearance is out of specification, selectreplacement crankshaft journal bearings.

4. Select:crankshaft journal bearings (J1 J5)

The numbers A stamped into the crankshaftweb and the numbers 1 stamped into the low-er crankcase are used to determine the re-placement crankshaft journal bearing sizes.

“J1 J5” refer to the bearings shown in thecrankshaft illustration.

If “J1 J5” are the same, use the same sizefor all of the bearings.

For example, if the crankcase “J1” and crank-shaft web “J1” numbers are “6” and “2” respec-tively, then the bearing size for “J1” is:

Bearing size for J1:J1 (crankcase) – J1 (crankshaft web) –2 =6 – 2 – 2 = 2 (Pink/black)

5-70

CRANKCASE ENG

CAUTION:

NOTE:

CRANKSHAFT JOURNAL BEARINGCOLOR CODE

–1 Pink/violet

0 Pink/white

1 Pink/blue

2 Pink/black

3 Pink/brown

5. Measure:crankshaft-pin-to-big-end-bearing clear-anceOut of specification Replace the big endbearings.

Crankshaft-pin-to-big-end-bearingclearance

0.031 0.055 mm(0.0012 0.0022 in)

The following procedure applies to all of theconnecting rods.

Do not interchange the big end bearings andconnecting rods. To obtain the correctcrankshaft-pin-to-big-end-bearing clear-ance and prevent engine damage, the bigend bearings must be installed in their origi-nal positions.

a. Clean the big end bearings, crankshaft pins,and bearing portions of the connecting rods.

b. Install the big end upper bearing into the con-necting rod and the big end lower bearinginto the connecting rod cap.

Align the projections a on the big end bearingswith the notches b in the connecting rod andconnecting rod cap.

5-71

CRANKCASE ENG

NOTE:

CAUTION:

c. Put a piece of Plastigauge 1 on the crank-shaft pin.

d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaftuntil the clearance measurement has beencompleted.Apply molybdenum disulfide grease onto thebolts, threads, and nut seats.

Make sure that the “Y” mark c on the connect-ing rod faces towards the left side of the crank-shaft.Make sure that the characters d on both theconnecting rod and connecting rod cap arealigned.

e. Tighten the connecting rod nuts.

When tightening the connecting rod nuts,be sure to use an F-type torque wrench.Without pausing, tighten the connectingrod nuts to the specified torque. Apply con-tinuous torque between 2.0 and 3.6 m kg.Once you reach 2.0 m kg, DO NOT STOPTIGHTENING until the specified torque isreached. If the tightening is interrupted be-tween 2.0 and 3.6 m kg, loosen the con-necting rod nut to less than 2.0 m kg andstart again.

Refer to “INSTALLING THE CONNECTINGRODS”.

Connecting rod nut36 Nm (3.6 m kg, 25 ft lb)

f. Remove the connecting rod and big endbearings.Refer to “REMOVING THE CONNECTINGRODS”.

g. Measure the compressed Plastigauge

width on the crankshaft pin.If the clearance is out of specification, selectreplacement big end bearings.

5-72

CRANKCASE ENG

NOTE:

6. Select:big end bearings (P1 P4)

The numbers A stamped into the crankshaftweb and the numbers 1 on the connectingrods are used to determine the replacementbig end bearing sizes.“P1” “P5” refer to the bearings shown in thecrankshaft illustration.

For example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “4” and “1” re-spectively, then the bearing size for “P1” is:

Bearing size for “P1”:“P1” (connecting rod) – “P1”(crankshaft) –2 =4 – 1 – 2 = 1 (Blue)

BIG END BEARING COLOR CODE

–1 Violet

0 White

1 Blue

2 Black

EAS00399

CHECKING THE CRANKCASE1. Thoroughly wash the crankcase halves in a

mild solvent.2. Thoroughly clean all the gasket surfaces and

crankcase mating surfaces.3. Check:

crankcaseCracks/damage Replace.oil delivery passagesObstruction Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OILSEALS1. Check:

bearingsClean and lubricate the bearings, then rotatethe inner race with your finger.Rough movement Replace.

2. Check:oil sealsDamage/wear Replace.

5-73

CRANKCASE ENG

NOTE:

CHECKING THE SPROCKETS AND CHAINS1. Check:

crankshaft sprocket 1oil /water pump assembly drive sprocket 2Cracks/damage/wear Replace the de-fective part(-s).

2. Check:timing chain 1Damage/stiffness Replace the timingchain and crankshaft sprocket as a set.oil /water pump assembly drive chain 2Damage/stiffness Replace the oil /waterpump assembly drive chain and oil /waterpump assembly drive sprocket as a set.

EAS00407

INSTALLING THE CRANKSHAFT1. Install:

crankshaft journal upper bearings 1(into the upper crankcase)

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in thecrankcase.Be sure to install each crankshaft journal up-per bearing in its original place.

2. Install:crankshaft

5-74

CRANKCASE ENG

NOTE:

NOTE:

EAS00268

INSTALLING THE CONNECTING ROD ANDPISTONThe following procedure applies to all of theconnecting rods and pistons.1. Install:

top ring 12nd ring 2upper oil ring rail 3oil ring expander 4lower oil ring rail 5

Be sure to install the piston rings so that themanufacturer’s marks or numbers a face up.

2. Install:piston 1(onto the respective connecting rod 2 )piston pin 3piston pin clip New 4

Apply engine oil onto the piston pin.Make sure that the “Y” mark a on the connect-ing rod faces left when the arrow mark b onthe piston is pointing up. Refer to the illustra-tion.Reinstall each piston into its original cylinder(numbering order starting from the left: #1 to#4).

3. Lubricate:pistonpiston ringscylinder(with the recommended lubricant)


4. Offset:piston ring end gaps

a Top ringb Lower oil ring railc Upper oil ring raild 2nd ringe Oil ring expander

5-75

CRANKCASE ENG

NOTE:

36 Nm (3.6 m kg, 25 ft lb)

CAUTION:

5. Lubricate:crankshaft pinsbig end bearingsconnecting rod big end inner surface(with the recommended lubricant)


6. Install:big end bearingsconnecting rod assembly(into the cylinder and onto the crankshaftpin).connecting rod cap(onto the connecting rod)

Align the projections on the big end bearingswith the notches in the connecting rods andconnecting rod caps.Be sure to reinstall each big end bearing in itsoriginal place.While compressing the piston rings with onehand, install the connecting rod assembly intothe cylinder with the other hand.Make sure that the “Y” marks a on the con-necting rods face towards the left side of thecrankshaft.Make sure that the characters b on both theconnecting rod and connecting rod cap arealigned.

7. Align:bolt heads(with the connecting rod caps)

8. Tighten:connecting rod nuts

When tightening the connecting rod nuts,be sure to use an F-type torque wrench.Without pausing, tighten the connectingrod nuts to the specified torque. Apply con-tinuous torque between 2.0 and 3.6 m kg.Once you reach 2.0 m kg DO NOT STOPTIGHTENING until the specified torque isreached. If the tightening is interrupted be-tween 2.0 and 3.6 m kg, loosen the con-necting rod nut to less than 2.0 m kg andstart again.

5-76

CRANKCASE ENG

NOTE:

NOTE:

EAS00414

ASSEMBLING THE CRANKCASE1. Lubricate:

crankshaft journal bearings(with the recommended lubricant)


2. Apply:sealant(onto the crankcase mating surfaces)


Do not allow any sealant to come into contactwith the oil gallery or crankshaft journal bear-ings. Do not apply sealant to within 2 3 mm ofthe crankshaft journal bearings.

3. Install:dowel pin

4. Install:crankshaft journal lower bearings 1(into the lower crankcase)

Align the projections a on the crankshaft jour-nal lower bearings with the notches b in thecrankcase.Install each crankshaft journal lower bearing inits original place.

5. Set the shift drum assembly and transmis-sion gears in the neutral position.

5-77

CRANKCASE ENG

CAUTION:

NOTE:

6. Install:upper crankcase 1(onto the lower crankcase 2 )

Before tightening the crankcase bolts, makesure that the transmission gears shift cor-rectly when the shift drum assembly isturned by hand.

7. Install:crankcase bolts

Lubricate the bolt threads with engine oil.Tighten the bolts in increasing numerical order. Install washers on bolts 1 10 .

M9 125 mm bolts: 1 10

M8 125 mm bolts: 21 22

M6 100 mm bolts: 11 20 , 23 28

Crankcase boltBolt 1 10

1st: 15 Nm(1.5 mkg, 11 ftlb)2nd: 15 Nm(1.5 mkg, 11 ftlb) +45 50

Bolt 11 15 , 17 20 , 23 ,25 28

12 Nm (1.2 mkg, 8.7 ftlb)Bolt 16 , 24

14 Nm (1.4 mkg, 10 ftlb)Bolt 21 22

24 Nm (24 mkg, 17 ftlb)

5-78

TRANSMISSION ENG


123456789

Removing the transmission, shiftdrum assembly, and shift forksCrankcase

Stopper leverDrive axle assemblyCirclipOil sealBearingShift drum retainerShift fork guide barSpringShift fork “L”Shift fork “R”

111112411


Separate.Refer to “CRANKCASE”.Refer to “SHIFT SHAFT”.


12 Nm (1.2 m kg, 8.7 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)

EAS00419

TRANSMISSIONTRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS

5-79


Disassembling the main axleassembly2nd pinion gearToothed lock washerToothed lock washer retainer6th pinion gearToothed spacerToothed washerCirclip3rd/4th pinion gears5th pinion gearCollar

1111122111

Disassembly the parts in the order listed.

1

10

23456789

TRANSMISSION ENG

5-80


Main axle/1st pinion gearBearingMain axle bearing housing

111


11

1312

TRANSMISSION ENG

5-81


Disassembling the drive axleassemblyWasher1st wheel gearSpacer5th wheel gearCirclipWasher3rd wheel gearToothed spacerToothed lock washerToothed lock washer retainer

1111331211

Disassembly the parts in the order listed.

1

10

23456789

TRANSMISSION ENG

5-82


4th wheel gear6th wheel gear2nd wheel gearSpacerDrive axleBearingSpacer

1111111


11

1312

14151617

TRANSMISSION ENG

5-83

TRANSMISSION ENG

WARNING

EAS00420

REMOVING THE TRANSMISSION1. Remove:

main axle assembly 1(with the Torx wrench T30)

a. Insert two bolts 2 of the proper size, asshown in the illustration, into the main axleassembly bearing housing.

b. Tighten the bolts until they contact the crank-case surface.

c. Continue tightening the bolts until the mainaxle assembly comes free from the uppercrankcase.

EAS00421

CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks and related components.1. Check:

shift fork cam follower 1shift fork pawl 2Bends/damage/scoring/wear Replacethe shift fork.

2. Check:shift fork guide barRoll the shift fork guide bar on a flat surface.Bends Replace.

Do not attempt to straighten a bent shift forkguide bar.

3. Check:shift fork movement(on the shift fork guide bar)Rough movement Replace the shift forksand shift fork guide bar as a set.

5-84

TRANSMISSION ENG

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY1. Check:

shift drum groovesDamage/scratches/wear Replace theshift drum.shift drum segment 1Damage/wear Replace.shift drum bearing 2Damage/pitting Replace.

EAS00425

CHECKING THE TRANSMISSION1. Measure:

main axle runout(with a centering device and dial gauge 1 )Out of specification Replace the mainaxle.

Main axle runout limit0.08 mm (0.003 in)

2. Measure:drive axle runout(with a centering device and dial gauge 1 )Out of specification Replace the driveaxle.

Drive axle runout limit0.08 mm (0.003 in)

3. Check:transmission gearsBlue discoloration/pitting/wear Replacethe defective gear(-s).transmission gear dogsCracks/damage/rounded edges Replacethe defective gear(-s).

4. Check:transmission gear engagement(each pinion gear to its respective wheelgear)Incorrect Reassemble the transmissionaxle assemblies.

5. Check:transmission gear movementRough movement Replace the defectivepart(-s).

6. Check:circlipsDamage/bends/looseness Replace.

5-85

TRANSMISSION ENG

NOTE:

NOTE:

EAS00428

INSTALLING THE TRANSMISSIONmain axle assemblyshift fork “C”shift drum assemblyshift fork “R”shift fork “L”springsshift fork guide barsdrive axle assembly

Carefully position the shift forks so that theyare installed correctly into the transmissiongears.Install shift fork “C” into the groove in the 3rdand 4th pinion gear on the main axle.Install shift fork “L” into the groove in the 6thwheel gear and shift fork “R” into the groove inthe 5th wheel gear on the drive axle.Make sure that the drive axle bearing circlip isinserted into the grooves in the upper crank-case.

2. Check:transmissionRough movement Repair.

Oil each gear, shaft, and bearing thoroughly.

COOL

CHAPTER 6COOLING SYSTEM

RADIATOR 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIATOR 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE RADIATOR 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE THERMOSTAT 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 6-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP 6-10. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP 6-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

RADIATOR COOL


123456

Removing the radiatorCoolantWater inlet hoseCarburetor hoseOil cooler hoseWater outlet hoseRadiatorFan motor

111111



EAS00454

COOLING SYSTEMRADIATOR

6-2

RADIATOR COOL

NOTE:

EAS00455

CHECKING THE RADIATOR1. Check: radiator finsObstruction Clean.Apply compressed air to the rear of the radia-tor.Damage Repair or replace.

Straighten any flattened fins with a thin, flat-head screwdriver.

2. Check: radiator hoses radiator pipesCracks/damage Replace.

3. Measure: radiator cap opening pressureBelow the specified pressure Replace theradiator cap.

Radiator cap opening pressure95 125 kPa(0.95 1.25 kg/cm2,13.1 17.8 psi)

a. Install the radiator pressure tester 1 and ra-diator pressure adapter 2 to the radiator cap3 .

Radiator pressure testerYU-24460-01

Radiator pressure tester adapterYU-33984

b. Apply the specified pressure for ten secondsand make sure that there is no drop in pres-sure.

4. Check: radiator fanDamage Replace.Malfunction Check and repair.Refer to “COOLING SYSTEM” in chapter 8.

6-3

RADIATOR COOL

EAS00456

INSTALLING THE RADIATOR1. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.

2. Check:cooling systemLeaks Repair or replace any faulty part.

a. Attach the radiator pressure tester 1 to theradiator.

Radiator pressure testerYU-24460-01

b. Apply 100 kPa (1.0 kg/cm2, 14.2 psi) of pres-sure.

c. Measure the indicated pressure with thegauge.

6-4

THERMOSTAT COOL


1234

Removing the thermostatFront cowlingCoolant reservoir hoseWater inlet hoseWater outlet hoseThermostat housing

1111

Remove the parts in the order listed.Refer to “FRONT COWLING” in chapter 3.


EAS00460

THERMOSTAT

6-5

THERMOSTAT COOL


Disassembling the thermostat housingThermostat housing coverThermostat /O-ringThermostat housingThermo unit

11/111



1234

15 Nm (1.5 mkg, 11 ftlb)

EAS00461

6-6

THERMOSTAT COOL

NOTE:

NOTE:

EAS00462

CHECKING THE THERMOSTAT1. Check: thermostatDoes not open at 71 85C (160 185F) Replace.

a. Suspend the thermostat in a container filledwith water.

b. Slowly heat the water.c. Place a thermometer in the water.d. While stirring the water, observe the ther-

mometer’s indicated temperature.

1 Thermometer2 Water3 Thermostat4 ContainerA ClosesB Opens

If the accuracy of the thermostat is in doubt, re-place it. A faulty thermostat could cause seriousoverheating or overcooling.

2. Check: thermostat housing cover 1 thermostat housing 2Cracks/damage Replace.

EAS00464

ASSEMBLING THE THERMOSTAT1. Install: thermostat housing 1 thermostat 2O-ring New thermostat housing cover

Install the thermostat with its breather hole afacing up.

6-7

THERMOSTAT COOL

15 Nm (1.5 m kg, 11 ft lb)

CAUTION:

2. Install:thermo unit 1

Use extreme care when handling the thermounit. Replace any part that was dropped orsubjected to a strong impact.

EAS00466

INSTALLING THE THERMOSTAT1. Fill:

cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.

2. Check:cooling systemLeaks Repair or replace any faulty part.

6-8

WATER PUMP COOL


Disassembling the water pump

Oil/water pump assembly and oilpump rotorWater pump coverO-ringPinImpeller shaft (along with the impeller)

1121


The water pump and oil pump arecombined into one unit (oil /water pumpassembly).It is not necessary to remove theimpeller shaft unless the coolant levelis extremely low or coolant leaks fromthe oil pan.

Refer to “OIL PAN AND OIL PUMP” inchapter 5.

NOTE:

1234

10 Nm (1.0 m kg, 7.2 ft lb)

EAS00469

WATER PUMP

6-9

WATER PUMP COOL


Water pump sealOil sealBearing

111


567

10 Nm (1.0 m kg, 7.2 ft lb)

6-10

WATER PUMP COOL

NOTE:

NOTE:

NOTE:

EAS00470

DISASSEMBLING THE WATER PUMP1. Remove:

water pump seal 1

Tap out the water pump seal from the inside ofthe water pump housing.

2 Water pump housing

2. Remove:oil sesal 1bearing 2

Tap out the bearing and oil seal from the outsideof the water pump housing.

3 Water pump housing

3. Remove:rubber damper holder 1rubber damper 2(from the impeller, with a thin, flat-headscrewdriver)

Do not scratch the impeller shaft.

EAS00473

CHECKING THE WATER PUMP1. Check:

water pump housing cover 1water pump housing 2impeller 3rubber damper 4rubber damper holder 5

2. Check:water pump sealoil sealwater pump inlet pipeCrack/damage/wear ReplacebearingRoughness Replace.

6-11

WATER PUMP COOL

NOTE:

CAUTION:

NOTE:

EAS00475

ASSEMBLING THE WATER PUMP1. Install:

oil seal New 1

(to the water pump housing 2 )

Install the oil seal with a socket that matches itsoutside diameter.Before installing the oil seal, apply tap water orcoolant onto its outer surface.

2. Install:water pump seal New 1

Never apply oil or grease onto the waterpump seal surface.

Install the water pump seal with the waterpump seal installers.Before installing the water pump seal, applyYamaha bond No.1215 2 to the water pumphousing 3 .

Water pump seal installer 4YM-33221

40 and 50 mm Bearing driver 5YM-4058

Yamaha bond No.1215ACC-11001-05-01

A Push down

6-12

WATER PUMP COOL

NOTE:

CAUTION:

3. Install:rubber damper New 1rubber damper holder New 2

Before installing the rubber damper, apply tapwater or coolant onto its outer surface.

4. Measure:tiltOut of specification Repeat steps (3) and(4).

Make sure that the rubber damper and rub-ber damper holder are flush with the impel-ler.

Tilt limit0.15 mm (0.006 in)

1 Straightedge2 Impeller

CARB

CHAPTER 7CARBURETORS

CARBURETORS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FILTER CASE 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETORS 7-8. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETORS 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL 7-10. . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR INDUCTION SYSTEM 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INJECTION 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR CUTOFF VALVE 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INDUCTION SYSTEM DIAGRAMS 7-15. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE AIR INDUCTION SYSTEM 7-16. . . . . . . . . . . . . . . . . . .

7-1

CARBURETORS CARB


12345

Removing the air filter caseSeat, fueltank and sidecovers

Drain the coolant

Air filter case panel (left /right)Battery negative leadBattery positive leadBatteryStay

1/11111

Remove the parts in the order listed.Refer to “FRONT COWLING/SEAT/SIDE COVER/FUEL TANK” section in chapter 3.Refer to “CHANGING THE COOLANT” section.


CARBURETORSCARBURETORSAIR FILTER CASE

7-2

CARBURETORS CARB


123456

Removing the carburetorsThrottle position sensor leadAir filter joint screwCarburetors joint screwCarburetor inlet/outlet hoseCarburetors assemblyStarter cableThrottle cable

44

1/1112

Remove the parts in the order listed.Disconnect.


EAS00481

7-3

CARBURETORS CARB


123456789

101112131415

Separating the carburetorThrottle stop screwCoolant hoseStarter plunger linkConnecting boltSpacerConnecting boltSpacerFuel inlet pipeFuel feed pipeSpringVacuum chamber air vent hoseFloat chamber air vent hoseThrottle position sensorThrottle position sensor bracketCarburetor

111111312222114



EAS00482

7-4

CARBURETORS CARB


Disassembling the carburetor

Starter plungerPilot air jetVacuum chamber coverPiston valve springPiston valveJet needle holderJet needle kitFuel drain boltFloat pin

111111111


The following procedure applies to all ofthe carburetors.

NOTE:

123456789

EAS00484

7-5

CARBURETORS CARB


FloatNeedle valveNeedle valve seatMain jetMain jet holderPilot jetNeedle jet

1111111


10111213141516

7-6

CARBURETORS CARB

EAS00486

CHECKING THE CARBURETORSThe following procedure applies to all of the car-buretors.1. Check:carburetor body float chamber jet housingCracks/damage Replace.

2. Check: fuel passagesObstruction Clean.

a. Wash the carburetor in a petroleum-basedsolvent. Do not use any caustic-carburetor-cleaning solution.

b. Blow out all of the passages and jets withcompressed air.

3. Check: float chamber body 1Dirt Clean.

4. Check: float chamber rubber gasket 2Cracks/damage/wear Replace.

5. Check: float 1Damage Replace.

6. Check:needle valve 1needle valve seat 2Damage/obstruction/wear Replace theneedle valve, needle valve seat and O-ringas a set.

7. Check:O-ring 3Damage/wear Replace the needle valve,needle valve seat and O-ring as a set.

7-7

CARBURETORS CARB

8. Check:piston valve 1Damage/scratches/wear Replace.

rubber diaphragm 2Cracks/tears Replace.

9. Check:vacuum chamber cover 1piston valve spring 2 jet needle holder 3Cracks/damage Replace.

10. Check: jet needle kit 1needle jet 2main jet 3main jet holder 4pilot jet 5Bends/damage/wear Replace.Obstruction Clean.Blow out the jets with compressed air.

11. Check:piston valve movementInsert the piston valve into the carburetorbody and move it up and down.Tightness Replace the piston valve.

12. Check: fuel feed pipeshose jointCracks/damage Replace.Obstruction Clean.Blow out the pipes with compressed air.

13. Check: fuel feed hoses fuel hosesCracks/damage/wear Replace.Obstruction Clean.Blow out the hoses with compressed air.

7-8

CARBURETORS CARB

CAUTION:

NOTE:

EAS00489

ASSEMBLING THE CARBURETORSThe following procedure applies to both of thecarburetors.

Before assembling the carburetors, washall of the parts in a petroleum-based sol-vent.

Always use a new gasket.

1. Install: jet needle kit

2. Install:needle jet 1pilot jet 2main jet 3

3. Measure: float height aOut of specification Adjust.

Float height12.5 13.5 mm (0.49 0.53 in)

a. Hold the carburetor upside down.b. Measure the distance from the mating sur-

face of the float chamber (with the gasket re-moved) to the top of the float.

The float arm should rest on the needle valvewithout depressing it.

c. If the float height is not within specification,check the needle valve seat and needlevalve.

7-9

CARBURETORS CARB

NOTE:

NOTE:

d. If either the needle valve seat or needle valveis worn, replace them both.

e. If both the needle valve seat and needlevalve are fine, adjust the float height by bend-ing the float tang 1 .

f. Check the float height again.

4. Install:piston valvepiston valve springvacuum chamber cover

Align the tab a on the piston valve diaphragmwith the recess b in the carburetor body.

5. Install:connecting bracket

After installing the connecting bracket, checkthat the throttle cable lever and starter plungerlink operate smoothly.

EAS00493

INSTALLING THE CARBURETORS1. Adjust:carburetor synchronizationRefer to “SYNCHRONIZING THE CARBU-RETORS” in chapter 3.

2. Adjust:engine idling speed


Refer to “ADJUSTING THE ENGINE IDLINGSPEED” in chapter 3.

3. Adjust: throttle cable free play


3 5 mm (0.12 0.20 in)

Refer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.

7-10

CARBURETORS CARB

NOTE:

EAS00495

MEASURING AND ADJUSTING THE FUELLEVEL1. Measure: fuel level aOut of specification Adjust.

Fuel level (below the line on the float chamber)

3.0 4.0 mm (0.118 0.157 in)

a. Stand the motorcycle on a level surface.b. Place the motorcycle on a suitable stand to

ensure that the motorcycle is standingstraight up.

c. Install the fuel level gauge 1 to the fuel drainpipe 2 .

Fuel level gaugeYU-01312-A

d. Loosen the fuel drain screw.e. Hold the fuel level gauge vertically next to the

line on the float chamber 3 .f. Measure the fuel level a on both sides of the

carburetor assembly.

The fuel level readings should be equal on bothsides.

2. Adjust: fuel level

a. Remove the carburetor assembly.b. Check the needle valve seat and needle

valve.c. If either is worn, replace them as a set.d. If both are fine, adjust the float level by slight-

ly bending the float tang 1 .e. Install the carburetor assembly.f. Measure the fuel level again.g. Repeat steps (a) to (f) until the fuel level is

within specification.

7-11

CARBURETORS CARB

NOTE:

EAS00500

CHECKING AND ADJUSTING THETHROTTLE POSITION SENSOR

Before adjusting the throttle position sensor,the engine idling speed should be properly ad-justed.

When installing the throttle position sensor,adjust its angle according to the RPM which isdisplayed on the tachometer. Refer to the ad-justment procedure below.

1. Check: throttle position sensor

a. Disconnect the throttle position sensor cou-pler.

b. Remove the throttle position sensor from thecarburetor.

c. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Tester positive lead Black/blue 1Tester negative lead Blue 2

d. Check the throttle position sensor maximumresistance.Out of specification Replace the throttleposition sensor.

Throttle position sensor maximum resistance

4 6 kΩ at 20C (68F)

e. Install the throttle position sensor onto thecarburetor.

f. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Tester positive lead Yellow 3Tester negative lead Blue 2

g. While slowly opening the throttle, check thatthe throttle position sensor resistance is with-in the specified range.Out of specification Replace the throttleposition sensor.

Throttle position sensor resistance

0.4 5.4 kΩ at 20C (68F)

7-12

CARBURETORS CARB

NOTE:

NOTE:

1

2

3

NOTE:

2. Adjust:throttle position sensor angle

a. Turn the main switch to “ON”.b. Disconnect the throttle position sensor cou-

pler.c. Reconnect the throttle position sensor cou-

pler.

After reconnecting the throttle position sensorcoupler, the tachometer switches to the throttleposition sensor adjustment mode.

d. Loosen the throttle position sensor screws1 .

e. Adjust the throttle position sensor angle ac-cording to the following table:

The angle of the throttle position sensor is indi-cated by the RPM which are displayed on thetachometer.

Tachometer reading Throttle positionTachometer readingsensor angle

0 r/min Too small

5,000 r/min Correct

10,000 r/min Too large

f. After adjusting the throttle position sensorangle, tighten the throttle position sensorscrews.

To exit the throttle position sensor adjustmentmode, start the engine or turn the main switch to“OFF”.

7-13

CARBURETORS CARB

EAS00504

CHECKING THE FUEL PUMP1. Check:

fuel pump 1

a. Place a container under the end of the fuelhose.

b. Start the engine and check if fuel flows fromthe fuel hose 2 .

Fuel flows. Fuel pump is OK.

Fuel does not flow. Replace the fuelpump.

c. Stop the engine and check if the fuel stopsflowing from the fuel hose 2 .

Fuel stops flowing. Fuel pump is OK.

Fuel flows. Replace the fuelpump.

7-14

VIEW 1. (NO FLOW)

VIEW 2. (FLOW)

AIR INDUCTION SYSTEM CARB

EAS00507

AIR INDUCTION SYSTEMAIR INJECTIONThe air induction system burns unburned ex-haust gases by injecting fresh air (secondaryair) into the exhaust port, reducing the emissionof hydrocarbons.When there is negative pressure at the exhaustport, the reed valve opens, allowing secondaryair to flow into the exhaust port. The requiredtemperature for burning the unburned exhaustgases is approximately 600 to 700C (1112 to1292F).

EAS00508

AIR CUTOFF VALVEThe air cutoff valve is operated by the intake gaspressure through the piston valve diaphragm.Normally, the air cutoff valve is open to allowfresh air to flow into the exhaust port. Duringsudden deceleration (the throttle valve sudden-ly closes), negative pressure is generated andthe air cutoff valve is closed in order to preventafter-burning.Additionally, at high engine speeds and whenthe pressure decreases, the air cutoff valve au-tomatically closes to guard against a loss of per-formance due to self-EGR.

VIEW 1. (NO FLOW)When decelerating (the throttle closes), the valve willclose.VIEW 2. (FLOW)During normal operation the valve is open.A From the air cleanerB To the reed valveC To the carburetor joint

7-15


EAS00509

AIR INDUCTION SYSTEM DIAGRAMS

1 Reed valve2 Air cleaner3 Air cutoff valve4 Carburetor joint (cylinder #4)A To the air cutoff valveB To cylinder #1C To cylinder #2D To cylinder #3E To cylinder #4

7-16


EAS00510

CHECKING THE AIR INDUCTION SYSTEM1. Check:hosesLoose connection Connect properly.Cracks/damage Replace.

pipesCracks/damage Replace.

2. Check:fibre reed 1fibre reed stopperreed valve seatCracks/damage Replace the reed valve.

3. Measure:fibre reed bending limit aOut of specification Replace the reedvalve.

Fibre reed bending limit0.2 mm (0.008 in)

1 Surface plate

4. Check:air cutoff valveCracks/damage Replace.

ELEC

CHAPTER 8ELECTRICAL

ELECTRICAL COMPONENTS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND

COUPLERS 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT FUENCTIONS 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING SWITCH CONTINUITY 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWITCHES 8-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BULBS AND BULB SOCKETS 8-10. . . . . . . . . . . . . . . . . . TYPES OF BULBS 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS 8-11. . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS 8-12. . . . . . . .

IGNITION SYSTEM 8-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 8-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUTOFF SYSTEM OPERATION 8-18. . . . . . . . . . . TROUBLESHOOTING 8-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTER MOTOR 8-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE STARTER MOTOR 8-25. . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 8-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SIGNAL SYSTEM 8-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP SYSTEM 8-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP CIRCUIT OPERATION 8-47. . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELEC

EXUP SYSTEM 8-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUT DIAGRAM 8-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 8-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

ELECTRICAL COMPONENTS ELEC

1 Main switch2 Fuel sender3 Rear brake switch4 Battery5 Ignitor unit6 Starter relay

7 Starting circuit cutoff relay8 Flasher relay9 Speed sensor10 Sidestand switch11 Neutral switch

12 Oil level gauge13 Ignition coil14 Rectifier /Regulator15 Thermo unit16 Horn17 Emargency stop switch18 Fan motor relay

EAS00729

ELECTRICALELECTRICAL COMPONENTS

8-2

1 Thermo unit2 T.P.S.3 Starter motor4 Pickup rotor5 Pickup coil

ARRANGEMENT OF THE ELECTRICALCOMPONENTS AND COUPLERS ELEC

ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS

8-3


1 Ignitor unit2 Fuse box3 Battery4 Fuel pump5 Fuel pump coupler6 Brake light switch coupler7 Newtral switch coupler8 Pickup coil coupler9 Speed sensor coupler

8-4


1 Ignition coil #2.32 Ignition coil #1.43 Rectifier / regulator4 Stator coil

8-5


1 Emargency stop switch2 Flasher relay3 Starter relay4 Fan motor relay5 Starting circuit cutoff relay6 Stator coil coupler7 Sidestand switch coupler8 Fuel sender coupler9 Oil level switch coupler

8-6

INSTRUMENT FUNCTIONS ELEC

Oil level warning light “ ”Coolant temperature warning light “ ”Fuel level warning light “ ”

Turn indicator light (left) “ ”Turn indicator light (right) “ ”Neutral indicator light “ ”High beam indicator light “ ”

1

2

3

4

1

2

3

CAUTION:

NOTE:

INSTRUMENT FUNCTIONSINDICATOR LIGHTS

Turn indicator light “ ” “ ”This indicator flashes when the turn switch ismoved to the left or right.

Neutral indicator light “ ”This indicator comes on when the transmis-sion is in neutral.

High beam indicator light “ ”This indicator comes on when the headlighthigh beam is used.

WARNING LIGHT

Oil evel warning light “ ”This warning light comes on when the engineoil level is low. If this symbol flashes, stop theengine immediately and fill it with oil to thespecified level.

Coolant temperature warning light “ ”This warning light comes on when the cool-ant temperature is too high.

Fuel level warning light “ ”When the fuel level drops below approxi-mately 5.5 L, this light will come on.When thislight comes on, fill the fuel tank at the first op-portunity.

Do not run the motorcycle until you know ithas sufficient engine oil.Do not run the motorcycle if the engine isoverheated.

Even if the oil is filled to the specified level, thewarning light may flicker when riding on a slopeor during sudden acceleration or deceleration,but this is normal.

8-7

INSTRUMENT FUNCTIONS ELEC

“SELECT” button“RESET” button

1

2NOTE:

DIGITAL CLOCK

ClockTo set the clock:1. Push both the “SELECT” 1 and “RESET” 2

buttons for at least two seconds.2. When the hour digits start flashing, push the

“RESET” button 2 to set the hours.3. Push the “SELECT” button 1 to change the

minutes.4. When the minute digits start flashing, push

the “RESET” button 2 to set the minutes.5. Push the “SELECT” button 1 to start the

clock.

After setting the clock, be sure to push the “SE-LECT” button 1 before turning the main switchto “OFF”, otherwise the clock will not be set.

8-8

CHECKING SWITCH CONTINUITY ELEC

CAUTION:

NOTE:

NOTE:

EAS00730

CHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch.

Never insert the tester probes into the cou-pler terminal slots 1 . Always insert theprobes from the opposite end of the coupler,taking care not to loosen or damage theleads.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.When checking for continuity, switch back andforth between the switch positions a few times.

The terminal connections for switches (e.g.,main switch, engine stop switch) are shown inan illustration similar to the one on the left.The switch positions a are shown in the far leftcolumn and the switch lead colors b are shownin the top row in the switch illustration.

“ ” indicates a continuity of electricitybetween switch terminals (i.e., a closed circuitat the respective switch position).

The example illustration on the left showsthat:There is continuity between blue/red and redwhen the switch is set to “P”.There is continuity between blue/red and bluewhen the switch is set to “ON”.

8-9

1 Main switch2 Dimmer switch3 Horn switch4 Clutch switch5 Hazard switch6 Turn signal switch

7 Front brake switch8 Engine stop switch9 Start switch10 Rear brake switch11 Fuse12 Side stand switch

13 Neutral switch14 Oil level switch

CHECKING THE SWITCHES ELEC

EAS00731

CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between the termi-nals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear Repair or replace the switch.Improperly connected Properly connect.Incorrect continuity reading Replace the switch.

8-10

CHECKING THE BULBS AND BULB SOCKETS ELEC

EAS00732

CHECKING THE BULBS ANDBULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity between the terminals.Damage/wear Repair or replace the bulb,bulb socket or both.Improperly connected Properly connect.Incorrect continuity reading Repair or replacethe bulb, bulb socket or both.

TYPES OF BULBSThe bulbs used on this motorcycle are shown inthe illustration on the left.Bulbs A are used for headlights and usuallyuse a bulb holder which must be detached be-fore removing the bulb. The majority of thesebulbs can be removed from their respectivesocket by turning them counterclockwise.Bulb B is used for turn signal and tail /brakelights and can be removed from the socket bypushing and turning the bulb counterclock-wise.Bulbs C are used for meter and indicator lightsand can be removed from their respectivesocket by carefully pulling them out.

8-11


WARNING

CAUTION:

NOTE:

CHECKING THE CONDITION OF THEBULBSThe following procedure applies to all of thebulbs.1. Remove:

bulb

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

Be sure to hold the socket firmly when re-moving the bulb. Never pull the lead, other-wise it may be pulled out of the terminal inthe coupler.Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverse-ly affected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

2. Check:bult (for continuity)(with the pocket tester)No continuity Replace.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

a. Connect the tester positive probe to terminal1 and the tester negative probe to terminal2 , and check the continuity.

b. Connect the tester positive probe to terminal1 and the tester negative probe to terminal3 , and check the continuity.

c. If either of the readings indicate no continuity,replace the bulb.

8-12


NOTE:

WARNING

CHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of the bulbsockets.1. Check:

bulb socket (for continuity)(with the pocket tester)No continuity Replace.


Check each bulb socket for continuity in thesame manner as described in the bulb section;however, note the following.

a. Install a good bulb into the bulb socket.b. Connect the pocket tester probes to the re-

spective leads of the bulb socket.c. Check the bulb socket for continuity.

If any of the readings indicate no continuity,replace the bulb socket.

CHECKING THE LEDsThe following procedures applies to all of theLEDs.1. Check:

LED (for proper operation)Improper operation Replace.

a. Disconnect the meter assembly coupler (me-ter assembly side).

b. Connect two jumper leads 1 from the bat-tery terminals to the respective coupler ter-minal as shown.

A wire that is used as a jumper lead musthave at least the same capacity of the bat-tery lead, otherwise the jumper lead mayburn.This check is likely to produce sparks,therefore, make sure no flammable gas orfluid is in the vicinity.

c. When the jumper leads are connected to theterminals the respective LED should illumi-nate.Does not light Replace the meter assem-bly.

8-13

1 Main switch5 Battery7 Fuse (main)15 Ignitor16 Ignition coil17 Spark plug18 Pickup coil40 Engine stop switch54 Fuse (ignition)

IGNITION SYSTEM ELEC

EAS00735

IGNITION SYSTEMCIRCUIT DIAGRAM

8-14

YES NO

YES NO

EAS00739

EAS00741

2. Battery

Check the condition of the battery.Refer to “CHECKING THE BATTERY” inCHAPTER 3.

Minimum open-circuit voltage12.8 V or more at 20C (68F)

Is the battery OK?

Clean the batteryterminals.

Recharge or replacethe battery.

3. Spark plugs

The following procedure applies to all of thespark plugs.Check the condition of the spark plug.Check the spark plug type.Measure the spark plug gap.Refer to “CHECKING THE SPARK PLUGS”in CHAPTER 3.

Standard spark plugCR9E (NGK)U27ESR-N (DENSO)

Spark plug gap0.7 0.8 mm (0.028 0.031 in)

Is the spark plug in good condition, it is of thecorrect type, and is its gap within specifica-tion?

Re-gap or replacethe spark plug.


NOTE:

YES NO

1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” inCHAPTER 3.

Replace the fuse(s).

Are the main and ignition fuses OK?

EAS00737

TROUBLESHOOTING

The ignition system fails to operate (nospark or intermittent spark).

Check:1. Main and ignition fuses2. Battery3. Spark plugs4. Ignition spark gap5. Spark plug cap resistance6. Ignition coil resistance7. Main switch8. Engine stop switch9. Pickup coil resistance

10. Wiring connections(of the entire ignition system)

Before troubleshooting, remove the followingpart(-s):1) Seat2) Fuel tank3) Side coverTroubleshoot with the following specialtool(-s).

Dynamic spark testerYM-34487


EAS00738

8-15


NO YES

EAS00745

YES NO

EAS00747

1

a

4. Ignition spark gap

The following procedure applies to all of thespark plugs.Disconnect the spark plug cap from thespark plug.

Connect the dynamic spark tester asshown.

Set the main switch to “ON”.Measure the ignition spark gap .Crank the engine by pushing the starterswitch and gradually increase the spark gapuntil a misfire occurs.

Minimum ignition spark gap6.0 mm (0.24 in)

Is there a spark and is the spark gap withinspecification?

The ignition systemis OK.

5. Spark plug cap resistance

The following procedure applies to all of thespark plug caps.Remove the spark plug cap from the sparkplug lead.

Connect the pocket tester (“Ω 1k”) to thespark plug cap as shown.

Measure the spark plug cap resistance.

Spark plug cap resistance10 kΩ at 20C (68F)

Is the spark plug cap OK?

Replace the sparkplug cap.

6. Ignition coil resistance

The following procedure applies to all of theignition coils.Disconnect the ignition coil leads from thewire harness.

Connect the pocket tester (Ω 1) to theignition coil as shown.

Positive tester probe red/blackNegative tester probe orange (gray)

Measure the primary coil resistance.

Primary coil resistance1.87 2.53 Ω at 20C (68F)

Connect the pocket tester (Ω 1k) to theignition coil as shown.

Posltlve tester probe spark plug leadNegative tester probe spark plug lead

Measure the secondary coil resistance.

EAS00743

8-16

12

9. Pickup coil resistance

Disconnect the pickup coil coupler from thewire harness.

Connect the pocket tester (Ω 100) to thepickup coil terminal as shown.

Positive tester probe gray Negative tester probe black

YES NO

NO

EAS00749

YESMeasure the pickup coil resistance.

Pickup coil resistance248 372 Ω at 20C (68F)(between gray and black)

Is the pickup coil OK?

Replace the pickupcoil.

7. Main switch

Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.

Replace the mainswitch.

NO

EAS00750

YES

Replace the righthandlebar switch.

8. Engine stop switch

Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.

Secondary coil resistance12 18 kΩ at 20C (68F)

Is the ignition coil OK?

YES NO

Replace the ignitioncoil.

EAS00748

Is the main switch OK?

Is the engine stop switch OK?

NO YES

10. Wiring

Check the entire ignition system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the ignition system’s wiring properly con-nected and without defects?

Properly connect orrepair the ignitionsystem’s wiring.

Replace the ignitorunit.

EAS00754


8-17

1 Main switch5 Battery6 Starter relay7 Fuse (main)8 Starter motor9 Starting circuit cutoff relay10 Side stand switch19 Neutral switch40 Engine stop switch41 Start switch46 Clutch switch54 Fuse (ignition)

ELECTRIC STARTING SYSTEM ELEC

EAS00755

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

8-18


EAS00756

STARTING CIRCUIT CUTOFF SYSTEM OP-ERATIONIf the engine stop switch is set to “ ” and themain switch is set to “ON” (both switches areclosed), the starter motor can only operate if atleast one of the following conditions is met:

The transmission is in neutral (the neutralswitch is closed).The clutch lever is pulled to the handlebar(the clutch switch is closed) and the side-stand is up (the sidestand switch is closed).

The starting circuit cutoff relay prevents thestarter motor from operating when neither ofthese conditions has been met. In this instance,the starting circuit cutoff relay is open so currentcannot reach the starter motor. When at leastone of the above conditions has been met thestarting circuit cutoff relay is closed and the en-gine can be started by pressing the start switch.

WHEN THE TRANSMISSION IS INNEUTRAL

WHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED TOTHE HANDLEBAR

1 Battery

2 Fuse (main)

3 Main switch

4 Fuse (ignition)

5 Engine stop switch

6 Starting circuit cutoff relay

7 Diode

8 Clutch switch

9 Sidestand switch

10 Neutral switch

11 Start switch

12 Starter relay

13 Starter motor

8-19

A wire that is used as a jumper lead musthave at least the same capacity or more asthat of the battery lead, otherwise thejumper lead may burn.

This check is likely to produce sparks,therefore make sure nothing flammable isin the vicinity.

Does the starter motor turn?

WARNING

NOYES

Repair or replace thestarter motor.

3. Starter motor

Connect the positive battery terminal andstarter motor lead with a jumper lead .

12 3

EAS00758

EAS00739

2. Battery



Is the battery OK?

NOYES


Recharge or re-place the battery.


NOTE:




NOYES

Replace the fuse (s).

EAS00757

TROUBLESHOOTING

The starter motor fails to turn.

Check:1. Main and ignition fuses2. Battery3. Starter motor4. Starting circuit cutoff relay5. Starter relay6. Main switch7. Engine stop switch8. Neutral switch9. Sidestand switch

10. Clutch switch11. Start switch12. Wiring connections

(of the entire starting system)

Before troubleshooting, remove the followingpart(-s):

1) Seat2) Fuel tank3) Side cover

Troubleshoot with the following special tool(-s).


EAS00738

8-20

Positive tester probe red Negative tester probe red

12

Positive battery lead blue/white Negative battery lead red/white

5. Starter relay

Disconnect the starter relay coupler from thewireharness.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starter relay coupler asshown.

34

NOYES

Does the starting circuit cutoff relay havecontinuity between blue/white and black?

Replace the startingcircuit cutoff relay.

EAS00761EAS00750

NOYES





Disconnect the starting circuit cutoff relaycoupler from the wire harness.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starting circuit cutoff relaycoupler as shown.

4. Starting circuit cutoff relay

EAS00759

Positive battery lead red/black Negative battery lead black/yellow

12

Positive tester probe blue/white Negative tester probe black

34

NOYES

Replace the starterrelay.

Does the starter relay have continuity be-tween red and red?

EAS00749

NOYES

6. Main switch



Replace the main switch.


8-21

NO

EAS00764

YES

11. Start switch

Check the start switch for continuity.Refer to “CHECKING THE SWITCHES”.


EAS00766

NOYES

12. Wiring

Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

The starting systemcircuit is OK?

Properly connect orrepair the startingsystem’s wiring.

NO

EAS00763

YES

Replace the clutchswitch.

10. Clutch switch

Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.

EAS00752

NOYES

Replace the side-stand switch.

9. Sidestand switch

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

EAS00751

NOYES

Replace the neutralswitch.

8. Neutral switch

Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?

Is the clutch switch OK?

Is the start switch OK?

Is the starting system’s wiring properly con-nected and without defects?


8-22


12

Removing the starter motorCarburetorStarter motor leadStarter motor/O-ring

11/1

Remove the parts in the order listed.Refer to “CARBURETOR” in chapter 7.



EAS00767

STARTER MOTOR

8-23



Disassembling the starter motorStarter motor front coverLock washerOil sealBearingWasher setStarter motor rear coverWasher setBrush seat (along with the brushes)Armature assemblyBrush holder (along with the brushes)O-ringStarter motor yoke

111111111121


Be sure to remove the installation nut onbrush #1 first.

For assembly reverse the disassemblyprocedure.

NOTE:

12345

Refer to “ASSEMBLING THE STARTERMOTOR”.

6789101112

10 Nm (1.0 m kg, 7.2 ft lb)5 Nm (0.5 m kg, 3.6 ft lb)

EAS00768

8-24


NOTE:

EAS00769

CHECKING THE STARTER MOTOR1. Check:commutatorDirt Clean with 600-grit sandpaper.

2. Measure:commutator diameter aOut of specification Replace the startermotor.

Commutator wear limit27 mm (1.06 in)

3. Measure:mica undercut aOut of specification Scrape the mica to theproper measurement with a hacksaw bladethat has been grounded to fit the commuta-tor.

Mica undercut0.7 mm (0.03 in)

The mica must be undercut to ensure proper op-eration of the commutator.

4. Measure:armature assembly resistances (commuta-tor and insulation)Out of specification Replace the startermotor.

a. Measure the armature assembly resistanceswith the pocket tester.


Armature coilCommutator resistance 1

0.025 0.035 Ω at 20C (68F)Insulation resistance 2

Above 1M Ω at 20C (68F)

8-25


NOTE:

b. If any resistance is out of specification, re-place the starter motor.

5. Measure:brush length aOut of specification Replace the brushesas a set.

Brush length wear limit4 mm (0.16 in)

6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.

Brush spring force7.65 10.01 N(780 1,021 gf, 27.5 36.0 oz)

7. Check:gear teethDamage/wear Replace the gear.

EAS00772

ASSEMBLING THE STARTER MOTOR1. Install:

armaturebrush seat 1

Align the tab a on the brush seat with the slot bin the starter motor rear cover.

8-26


NOTE:

2. Install:starter motor front cover 1starter motor rear cover 2O-ring 3 New

Align the match marks a on the starter motoryoke with the match marks b on the front andstarter motor rear covers.

8-27

2 Rectifire/reguretor3 AC magneto5 Battery7 Fuse (main)

CHARGING SYSTEM ELEC

EAS00773

CHARGING SYSTEMCIRCUIT DIAGRAM

8-28


3. Charging voltage

Connect the inductive self-poweredtachometer to the spark plug lead of cylinder#1.

Connect the pocket tester (DC 20 V) to thebattery as shown.

Positive tester probe positive battery terminal

Negative tester probe negative battery terminal

Start the engine and let it run at approxi-mately 5,000 r/min.

Measure the charging voltage.

Charging voltage14 V at 5,000 r/min

YES

Make sure the battery is fully charged.

Is the charging voltage within specification?

NO

NOTE:

The charging circuitis OK.

EAS00775

EAS00738

1. Main fuses

Check the fuses for continuity.Refer to “CHECKING THE FUSES” inCHAPTER 3.

Are the fuses OK?

NOYES


EAS00739

NOYES



2. Battery


Is the battery OK?


NOTE:

EAS00774

TROUBLESHOOTING

The battery is not being charged.

Check:1. Main fuse2. Battery3. Charging voltage4. Stator coil resistance5. Wiring connections

(of the entire charging system)


1) Seat2) Fuel tank3) Side coverTroubleshoot with the following specialtool(-s).

Inductive self-powered tachometer

YU-8036-BPocket tester measurement

YU-03112-C

8-29

Measure the stator coil resistances.

Stator coil resistance0.27 0.33 Ω at 20C (68F)

Is the stator coil OK?

NOYES

Replace the statorcoil assembly.

Positive tester probe white Negative tester probe white

12

31

EAS00776

4. Stator coil resistance

Remove the generator cover.Connect the pocket tester (Ω 1) to the sta-tor coils as shown.

Positive tester probe white Negative tester probe white

NOYES

Replace the rectifi-er/regulator.

Properly connect orrepair the chargingsystem’s wiring.

EAS00779

5. Wiring

Check the wiring connections of the entirecharging system.Refer to “CIRCUIT DIAGRAM”.

Is the charging system’s wiring properlyconnected and without defects?


8-30

49 Front turn signal light (right)52 Headlight53 Tail /brake light54 Fuse (ignition)56 Fuse (headlight)61 Headlight relay (dimmer)

1 Main switch5 Battery7 Fuse (main)31 Hi-beam indicator light34 Meter light44 Dimmer switch48 Front turn signal light (left)

LIGHTING SYSTEM ELEC

EAS00780

LIGHTING SYSTEMCIRCUIT DIAGRAM

8-31

EAS00749

YES NO

3. Main switch




YES NO

4. Dimmer switch

Check the dimmer switch for continuity.Refer to “CHECKING THE SWITCHES”.

The dimmer switch isfaulty. Replace theleft handlebar switch.

EAS00784

YES NO



Is the dimmer switch OK?


NOTE:

Check the main, ignition and headlight fusesfor continuity.Refer to “CHECKING THE FUSES” inCHAPTER 3.

EAS00738

YES NO

EAS00739

1. Main, ignition and headlight fuses

Are the main, ignition and headlight fusesOK?


2. Battery



Is the battery OK?

EAS00781

TROUBLESHOOTING

Any of the following fail to light: headlight,high beam indicator light, taillight, auxilia-ry light or meter light.

Check:1. Main, ignition and headlight fuses2. Battery3. Main switch4. Dimmer switch5. Headlight relay (dimmer)6. Wiring connections

(of the entire charging system)


1) Seat2) Fuel tank3) Side coverTroubleshoot with the following specialtool(-s).


8-32

Does the headlight rrelay (dimmer) havecontinuity?

NOYES

Replace the head-light relay (dimmer).

12

Hi-beamPositive battery lead yellow Negative battery lead black

Positive tester probe red/yellowNegative tester probe black/yellow

34

5. Headlight relay (dimmer)

Disconnect the headlight relay (dimmer)from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the headlight relay (dimmer)coupler as shown.

12

Low-beamPositive tester probe red/yellowNegative tester probe black/green

YES NO

EAS00787

6. Wiring

Check entire lighting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Check the conditionof each of the lightingsystem’s circuits.Refer to “CHECK-ING THE LIGHTINGSYSTEM”.

Properly connect orrepair the lightingsystem’s wiring.

Is the lighting system’s wiring properly con-nected and without defects?


8-33


HeadlightPositive tester probe

black/yellow or black/green Negative tester probe black

High beam indicator lightPositive tester probe

black/yellow Negative tester probe black 2. Vollage

Connect the pocket tester (DC 20 V) to themeter light coupler (wire harness side) asshown.

Positive tester probe blue Negative tester probe black

12

YES NO

Replace the headlightbulb, socket or both

EAS00789

2. The meter light fails to come on.

YES NO

1. Meter light bulb and socket

Check the meter light bulb and socket forcontinuity.

Replace the meterlight bulb, socket ofboth.

EAS00788

CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicator

light fail to come on.

1. Headlight buld and scocket

Check the headlight bulb and socket forcontinuity.

1 23

45

2. Voltage

Connect the pocket tester (DC 20 V) to theheadlight and high beam indicator light cou-plers as shown.

AB

When the dimmer switch is set to “ ”.When the dimmer switch is seto to “ ”.

Set the main switch to “ON”.Set the dimmer switch to “ ” or “ ”.Measure the voltage (12 V) (wire harnessside).

YES NO

This circuit is OK. The wiring circuitfrom the main switchto the headlight cou-pler is faulty andmust be repaired.

Headlight coupler (wire harness side)

Meter light coupler (wire harness side)

Are the headlight bulb and socket OK?

Is the voltage within specification?

Are the meter light bulb and socket OK?

8-34

12

2. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side)as shown.

Positive tester probe blue/redNegative tester probe black

EAS00790

3. The tail /brake light fails to come on.

Chek the tail /brake light bulb and socket forcontinuity.

YES NO

Replace the tail/brakelight bulb, socket orboth.

YES NO

Set the main switch to “ON”.Measure the voltage (12 V) of blue/red onthe tail /brake light coupler (tail /brake lightside).

The wiring circuit fromthe main switch to thetail/brake light coupleris faulty and must berepaired.

1

This circuit is OK.

Set the main switch to “ON”.Measure the voltage (12 V) of blue on themeter light coupler (wire harness side).

YES NO

This circuit is OK. The wiring circuit fromthe main switch to themeter light coupler isfaulty and must be re-paired.

1

1. Tail /brake light bulb and socket


Are the tail /brake light bulb and socket OK?



8-35

SIGNAL SYSTEM ELEC

EAS00793

SIGNAL SYSTEMCIRCUIT DIAGRAM

8-36

SIGNAL SYSTEM ELEC

1 Main switch5 Battery7 Fuse (main)9 Starting circuit cutoff relay19 Neutral switch23 Fuel level warning light24 Oil level warning light25 Neutral indicator light27 Combination meter29 Fuel gauge32 Turn signal indicator light (left)33 Turn signal indicator light (right)35 Oil level gauge36 Fuel sender37 Turn signal relay39 Front brake light switch42 Horn45 Horn switch47 Turn signal switch48 Front turn signal light (left)49 Front turn signal light (right)50 Rear turn signal light (left)51 Rear turn signal light (right)53 Tail /brake light54 Fuse (ignition)55 Fuse (turn signal)60 Rear brake light switch

8-37

EAS00749

3. Main switch



YES NO


YES NO

YES NO

4. Wiring

Check the entire signal system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Properly connect orrepair the signalingsystem’s wiring.

EAS00796

CHECKING THE SIGNAL SYSTEM1. The horn fails to sound.

1. Horn switch

Check the horn switch for continuity.Refer to “CHECKING THE SWITCHES”.

Replace the left han-dlebar switch.

Check the conditionof each of the signal-ing system’s circuits.Refer to “CHECK-ING THE SIGNAL-ING SYSTEM”.

EAS00795

2. Voltage

Connect the pocket tester (DC 20 V) to thehorn connector at the horn terminal asshown.

Is the signaling system’s wiring properlyconnected and without defects?

Is the horn switch OK?

SIGNAL SYSTEM ELEC

NOTE:

EAS00738

1. Main, signal and ignition fuses

Check the main, signal and ignition fuses forcontinuity.Refer to “CHECKING THE FUSES” inCHAPTER 3.

Are the main, signal and ignition fuses OK?

YES NO


EAS00739

2. Battery



Is the battery OK?

YES NO



EAS00794

TROUBLESHOOTING

Any of the following fail to come on: turnsignal light, brake light or indicator light.

The horn fails to sound.

Check:1. Main, signal and ignition fuses2. Battery3. Main switch4. Wiring connections

(of the entire signal system)

Before troubleshooting, remove the followingpart(s):

1) Seat2) Fuel tank3) Front cowling4) Side coverTroubleshoot with the following special tool(s).


8-38

YES NO

The wiring circuitfrom the main switchto the horn connectoris faulty and must berepaired.

Set the main switch to “ON”.Push the horn switch.Measure the voltage (12 V) of pink at thehorn terminal.

3. Horn

Disconnect the black connector at the hornterminal.Connect a jumper lead to the horn termi-nal and ground the jumper lead.Set the main switch to “ON”.Push the horn switch.

NO YES

The horn is OK.

1

4. Voltage

Connect the pocket tester (DC 20 V) to thehorn connector at the black terminal asshown.

Positive tester probe brown Negative tester probe black

1


Does the horn sound?

YES NO

Set the main switch to “ON”.Measure the voltage (12 V) of black at thehorn terminal.

Replace the horn.Repair or replace thehorn.

1

1Positive tester probe black Negative tester probe ground


NO

EAS00797

2. The tail /brake light fails to come on.

YES

1. Tail /brake light bulb and socket.

Check the tail /brake light bulb and socket forcontinuity.

Replace the tail/brakelight bulb, socket orboth.

Are the tail /brake light bulb and socket OK?

2. Brake switches

Check the brake light switches for continuity.Refer to “CHECKING THE SWITCHES”.

NOYES

Replace the brakelight switch.

Is the brake light switch OK?

SIGNAL SYSTEM ELEC

8-39

Positive tester probe yellow Negative tester probe black

NOYES

Set the main switch to “ON”.Pull in the brake lever or push down on thebrake pedal.Measure the voltage (12 V) of yellow on thetail/brake light coupler (wire harness side).

The wiring circuit fromthe main switch to thetail/brake light coupleris faulty and must berepaired.

EAS00799

3. The turn signal light, turn signal indicatorlight or both fail to blink.

Check the turn signal light bulb and socketfor continuity.

NOYES

Replace the turn sig-nal light bulb, socketor both.

This circuit is OK.

12

1

2. Turn signal switch

Check the turn signal switch for continuity.Refer to “CHECKING THE SWITCHES”.

NOYES

Replace the left han-dlebar switch.

1Positive tester probe brown Negative tester probe ground

YES NO

Set the main switch to “ON”.Measure the voltage (12 V) on brown atthe turn signal relay coupler (wire harnessside).

The wiring circuitfrom the main switchto the turn signalrelay coupler is faultyand must be re-paired.

3. Voltage

Connect the pocket tester (DC 20 V) to theturn signal relay coupler (wire harness side)as shown.

1

1. Turn signal indicator light bulb and socket

3. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side)as shown.


Are the turn signal light bulbs and socket OK?

Is the turn signal switch OK?


SIGNAL SYSTEM ELEC

8-40

Left turn signal lightPositive tester probe chocolate Negative tester probe ground

Right turn signal lightPositive tester probe dark green Negative tester probe ground

1. Neutral indicator light bulb and socket

Check the neutral indicator light bulb andsocket for continuity.

NOYES

Replace the neutralindicator light bulb,socket or both.

2. Neutral switch

Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.

NOYES

Replace the neutralswitch.

EAS00800

4. The neutral indicator light fails to come on.

NOYES

The turn signal relayis faulty and must bereplaced.

5. Voltage

Connect the pocket tester (DC 20 V) to theturn signal light connector (wire harnessside) as shown.

NOYES

The wiring circuitfrom the turn signalswitch to the turn sig-nal light connector isfaulty and must berepaired.

This circuit is OK.

Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) of the chocolate

or dark green at the turn signal lightconnector (wire harness side).

Rear turn signal lightTurn signal indicator light

1

2

1 2

AB

1

4. Voltage

Connect the pocket tester (DC 20 V) to theflasher relay coupler (wire harness side) asshown.

Positive tester probe brown/white Negative tester probe ground

1


Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) on brown/white

at the turn signal relay coupler (wire har-ness side).


Are the neutral indicator light bulb and sock-et OK?

Is the neutral switch OK?

A B

SIGNAL SYSTEM ELEC

8-41

EAS00802

5. The oil level warning light fails to come on.

1. Oil level warning light bulb and socket

Check the oil level warning light bulb andsocket for continuity.

NOYES

Replace the oil levelwarning light bulb,socket or both.

YES NO

Drain the engine oil and remove the engineoil level switch from the oil pan.Check the engine oil level switch for conti-nuity.Refer to “CHECKING THE SWITCHES”.

Replace the engineoil level switch.

2. Engine oil level switch

1Positive tester probe brown Negative tester probe ground

YES NO

Set the main switch to “ON”.Measure the voltage (12 V).

The wiring circuitfrom the main switchto the meter light bulbcoupler is faulty andmust be repaired.

3. Voltage

Connect the pocket tester (DC 20 V) to themeter light bulb coupler (wire harness side)as shown.


This circuit is OK.

Are the oil level warning light bulb and sock-et OK?

Is the engine oil level switch OK?

YES NO

Check the entire signal system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Properly connect orrepair the signalingsystem’s wiring.

3. Wiring

Is the signaling system’s wiring properlyconnected and without defects?

Replace the meterunit.

EAS00795

SIGNAL SYSTEM ELEC

8-42

1. Fuel sender

Remove the fuel sender from the fuel tank.Connect the pocket tester to the fuel sendercoupler (wire harness side) as shown.

EAS00804

5. The fuel level gauge fails to operate.

Positive tester probe green Negative tester probe black

12

Measure the fuel sender resistances.

NOYES

Replace the fuelsender.

Fuel sender resistance (up position ) (Ω 1)4 10 Ω at 20C (68F)

Fuel sender resistance (down posi-tion ) (Ω 10)

90 100 Ω at 20C (68F)

Is the fuel sender OK?

3

4

NOYES

Check the wiringconnections of theentire signaling sys-tem.

Set the main switch to “ON”.Measure the voltage (12 V) of brown onthe meter light coupler (wire harness side).


1

Positive tester probe brown Negative tester probe black

1

2. Voltage

Connect the pocket tester (DC 20 V) to themeter light coupler (wire harness side) asshown.

2

Before reading the fuel level gauge, leavethe float in one position (either up or down)for at least three minutes.

NOTE:

3. Fuel level gauge

Set the main switch to “ON”.Move the float up or down .Check that the fuel level gauge needlemoves to “F” or “E”.

NOYES

Replace the fuel lev-el gauge.

Does the fuel level gauge needle move ap-propriately?

1 2

4. Wiring

Check the entire signaling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

SIGNAL SYSTEM ELEC

8-43

COOLING SYSTEM ELEC

1 Main switch5 Battery7 Fuse (main)21 Thermo unit27 Combination meter28 Water temp warning light57 Fues (fan)58 Fan motor relay59 Fan motor

EAS00807

COOLING SYSTEMCIRCUIT DIAGRAM

8-44


3. Main switch

YES NO


YES NO



EAS00749


EAS00809

YES NO

4. Radiator fan motor

Disconnect the rediator fan motor couplerfrom the wire harness.

Connect the battery (12 V) as shown.

Positive battery lead blue Negative battery lead black

The radiator fan mo-tor is faulty and mustbe replaced.

Does the rediator fan motor turn?

12

Is the battery OK?

COOLING SYSTEM ELEC

NOTE:


Check the main and radiator fan motor fusesfor continuity.Refert to “CHECKING THE FUSES” inCHAPTER 3.

1. Main and radiator fan motor fuses

Are the main and radiator fan motor fusesOK?

YES NO


EAS00739

2. Battery

Minimum open-circuit voltage12.8 V or more at 20C

EAS00808

TROUBLESHOOTING

The radiator fan motor fails to turn.The water temperature gauge needlefails to move when the engine is warm.

Check:1. Main and radiator fan motor fuses2. Battery3. Main switch4. Radiator fan motor5. Thermo unit6. Wiring connections

(the entire cooling system)

Before troubleshooting, remove the followingpart(-s).

1) Seat2) Fuel tankTroubleshoot with the following special tool(s).


EAS00738

8-45

COOLING SYSTEM ELEC

Thermo unit15 Nm (1.5 mkg, 11 ftlb)Three bond sealock 10 YES NO

7. Wiring

Check the entire cooling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Properly connect orrepair the coolingsystem’s wiring.

YES NO

Replace the thermounit.

Does the thetmo unit operate properly?

EAS00813

This circuit is OK.

Termo unit resistance80C (176F): 3.41 4.00 Ω105C (221F): 1.65 1.86 Ω

Handle the termo unit with special care.Never subject the thermo unit to strongshocks. If the thermo unit is dropped, re-place it.

WARNING

5. Thermo unit

Remove the thermo unit from the thermostathousing.

Connect the pocket tester (Ω 1) to the ter-mo unit as shown.

Immerse the termo unit in a container filledwith coolant .

1

EAS00812

2

3

Make sure the termo unit terminals do notget wet.

NOTE:

Place a thermometer in the coolant.Slowly heat the coolant, and then let it coolto the specified temperature indicated in thetable.

Check the thermo unit for continuity at thetemperatures indicated in the table.

Is the cooling system’s wiring properly con-nected and without defects?

NOYES

Does the fan motor relay have continuity be-tween brown and blue?

Replace the fan mo-tor relay.

Disconnect the fan motor relay coupler fromthe wire harness.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the fan mtor relay coupler asshown.

6. Fan motor relay

EAS00759

Positive battery terminal brown Negative battery terminal

green/black

1

2

Positive tester probe brown Negative tester probe blue

34

8-46

1 Main switch5 Battery7 Fuse (main)9 Starting circuit cutoff relay11 Fuel pump15 Ignitor40 Engine stop switch54 Fuse (ignition)

FUEL PUMP SYSTEM ELEC

EAS00814

FUEL PUMP SYSTEMCIRCUIT DIAGRAM

8-47


EAS00815

FUEL PUMP CIRCUIT OPERATIONThe ignitor unit includes the control unit for thefuel pump.

1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 Ignitor unit7 Fuel pump relay8 Fuel pump

8-48

EAS00749

3. Main switch



YES NO


EAS00750




YES NO


EAS00759

5. Starting circuit cutoff relay

Disconnect the starting circuit cutoff relaycoupler from the wire harness.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starting circuit cutoff relaycoupler as shown.

YES NO

Does the starting circuit cutoff relay have con-tinuity between red/black and black/blue?

Positive battery lead red/black Negative battery lead blue/red

Positive tester probe red/black Negative tester probe black/blue

12

34

Replace the startingcircuit cutoff relay.


If the fuel pump fails to operate.

NOTE:

EAS00738

1. Main, and ignition fuses



Is the battery OK?


EAS00739

2. Battery


YES NO


YES NO



EAS00816

TROUBLESHOOTING

Check:1. Main and ignition fuses2. Battery3. Main switch4. Engine stop switch5. Starting circuit cutoff relay

(the fuel pump relay)6. Fuel pump7. Wiring connections

(the entire fuel system)


1) Seat2) Fuel tank3) Side coverTroubleshoot with the following special tool(s).


8-49


YES NO

6. Fuel pump resistance

Disconnect the fuel pump coupler from thewire harness.

Connect the pocket tester (Ω 1) to the fuelpump coupler as shown.

Positive tester probe black/blue Negative tester probe black

Replace the fuelpump.

Measure the fuel pump resistance.

12

Is the fuel pump OK?

Fuel pump resistance4 30 Ω at 20C (68F)

EAS00817

7. Wiring

Check the entire fuel pump system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the fuel system’s wiring properly con-nected and without defects?

YES NO

Properly connect orrepair the fuel sys-tem’s wiring.


EAS00818

8-50


B/L

WARNING

Positive battery lead black/blue Negative battery lead black

12

EAS00819

CHECKING THE FUEL PUMP

Gasoline is extremely flammable and undercertain circumstances there can be a dangerof an explosion or fire. Be extremely carefuland note the following points:Stop the engine before refuelling.Do not smoke, and keep away from openflames, sparks, or any other source of fire.If you do accidentally spill gasoline, wipe itup immediately with dry rags.If gasoline touches the engine when it isnot, a fire may occur. Therefore, make surethat the engine is completely cool beforeperforming the following test.

1. Check:fuel pump operation

a. Fill the fuel tank.b. Put the end of the fuel hose into an open con-

tainer.c. Turn the fuel cock to “ON”.d. Connect the battery (12 V) to the fuel pump

coupler as shown.

e. If fuel flows out of the fuel hose, the fuel pumpis OK.If fuel does not flow, replace the fuel pump.

8-51

1 Main switch5 Battery7 Fuse (main)12 EXUP servomotor15 Ignitor54 Fuse (ignition)

EXUP SYSTEM ELEC

EAS00827

EXUP SYSTEMCIRCUIT DIAGRAM

8-52

EXUP SYSTEM ELEC

YES NO

Check that the EXUPcables are properlyinstalled.If the connections arecorrect, check theEXUP valve andcables. Refer to “EX-HAUST SYSTEM” inchapter 5.

EAS00830

Connect the pocket tester (DC 20 V) to theEXUP servomotor coupler as shown.

2. Voltage

Positive tester probe black/red Negative tester probe black/yellow

12

Set the main switch to “ON”.Measure the voltage (12 V) betweenblack/red and black/yellow .

YES NO

Go to Procedure 2.


1 2

Disconnect the EXUP cables at the EXUPservomotor pulley side.Start the engine and rev it to 5,000 r/min.

1. EXUP servomotor operation (with the EXUP servomotor coupler connected to the wire harness)

Does the EXUP servomotor pulley turn?

Procedure 1EAS00829

NOTE:

EAS00828

TROUBLESHOOTING

When the engine speed changes, theEXUP servomotor does not operate.

Procedure 1Check:1. EXUP servomotor operation

(with the EXUP servomotor coupler con-nected to the wire harness)

2. Voltage3. EXUP servomotor operation

(with the EXUP servomotor coupler discon-nected from the wire harness)

4. EXUP servomotor resistance(potentiometer resistance)

5. Wiring connections(the entire EXUP system)

Procedure 2Check:1. Main and turn signal fuses2. Battery3. Main switch4. Neutral switch5. Engine stop switch6. Wiring connections

(the entire EXUP system)

Before troubleshooting, remove the followingpart(s):

1) Seat2) Fuel tankTroubleshoot with the following special tool(s).


8-53

EXUP SYSTEM ELEC

YES NO

Replace the EXUPservomotor.

EAS00832

Disconnect the EXUP servomotor couplerfrom the wire harness.Connect the pocket tester (Ω 1 k) to theEXUP servomotor coupler.

4. EXUP servomotor resistance (potentiometer resistance)

Positive tester probe blue Negative tester probe white/red

12

While slowly turning the EXUP servomotorpulley, measure the EXUP servomotor re-sistance.

EXUP servomotor resistance (when the pulley is turned once)

0 approximately 7.5 k Ω(blue – white/red)

Is the EXUP servomotor OK?

EAS00831

Disconnect the EXUP cables from the EXUPservomotor pulley.Disconnect the EXUP servomotor couplerfrom the wire harness.Connect the battery leads to the EXUP ser-vomotor coupler as shown.

3. EXUP servomotor operation (with the servomotor coupler disconnected to the wire harness)

Positive battery lead black/yellow Negative battery lead black/red

12

Check that the EXUP servomotor pulley ro-tates several times.

CAUTION:

To prevent damaging the EXUP servomo-tor, perform this test within a few secondsof connecting the battery.

Does the EXUP servomotor pulley turn?

YES NO

The EXUP servomo-tor is faulty and mustbe replaced.

EAS00833

Check the entire EXUP system’s wiring.Refer to “CIRCUIT DIAGRAM”.

5. Wiring

Is the EXUP system’s wiring properly con-nected and without defects?

YES NO

Properly connect orrepair the EXUP sys-tem’s wiring.


8-54

EXUP SYSTEM ELEC

Procedure 2EAS00738

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.



YES NO

Replace the fuse(s). EAS00833

Check the entire EXUP system’s wiring.Refer to “CIRCUIT DIAGRAM”.

5. Wiring

Is the EXUP system’s wiring properly con-nected and without defects?

YES NO

Properly connect orrepair the EXUP sys-tem’s wiring.


EAS00750




YES NO



EAS00739

Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.

2. Battery

Is the battery OK?

YES NO



EAS00749


3. Main switch


YES NO


8-55

SELF-DIAGNOSIS ELEC

SELF-DIAGNOSISThe FZS1000 features a self-diagnosing system for the following circuit(-s):

Throttle position sensorEXUPSpeed sensorEmargency stop switch

If any of these circuits are defective, their respective condition codes will be displayed on the tachome-ter when the main switch is set to “ON” (irrespective of whether the engine is running or not)

Circuit Defect(-s) System response Condition code

Throttle posi-tion sensor

DisconnectedShort-circuitLocked

The ignitor unit stays set to thewide-open throttle ignition timing.The motorcycle can be ridden.The tachometer displays thecondition code.

3,000 r/min

EXUP ImproperconnectionShort-circuit

The EXUP valve stays in the openposition for three seconds andthen the servomotor shuts off. Themotorcycle can be ridden.The tachometer displays thecondition code.

7,000 r/min

Servomotor islocked.

The servomotor’s power supply isconstantly inteerupted so that itwill not burn out. The motorcyclecan be ridden.The tachometer displays thecondition code.

Speed sensor Improperconnection

The tachometer displays thecondition code.

4,000 r/min

Emargencystop switch

DisconnectedShort-circuitFail angle

The tachometer displays thecondition code.Ignition system cutoff.

9,000 r/min

8-56

SELF-DIAGNOSIS ELEC

Revolution( 103 r /min)

Tachometer display

Time (seconds)

Engine speed

0 r /min ... 3 secondsCondition code ... 2.5 secondsEngine speed ... 3 seconds

123

Tachometer display sequence

When more than one item is being monitored, the tachometer needle displays the condition codes inascending order, cycling through the sequence repeatedly.If the engine is stopped, the engine speed 3 is 0 r/min.

8-57

SELF-DIAGNOSIS ELEC

Repair or replace thewire harness.

NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.Is the wire harness OK?

YES

NO

2. Throttle position sensor

Check the throttle position sensor for conti-nuity.Refer to “CHECKING AND ADJUSTINGTHE THROTTLE POSITION SENSOR” inchapter 6.Is the throttle position sensor OK?

YES

Replace the throttleposition sensor.


NOTE:

13 Throttle position sensor15 Ignitor unit

TROUBLESHOOTING

The tachometer starts to display the self-diagnosis sequence.

Check:1. Throttle position sensor2. EXUP3. Speed sensor4. Emargency stop switch


1) Rider seat2) Fuel tank3) Air filter caseTroubleshoot with the following specialtool(-s).


1. Throttle position sensorCIRCUIT DIAGRAM

8-58

SELF-DIAGNOSIS ELEC

Replace the EXUPservomotor.

NO

2. EXUP servomotor

Check the EXUP servomotor for continuity.Refer to “EXUP SYSTEM”.Is the EXUP servomotor OK?

YES


NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.Is the wire harness OK?

YES


12 EXUP servomotor15 Ignitor unit

2. EXUPCIRCUIT DIAGRAM

8-59

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

1. Wire harness

Is the wire harness OK?

YES NO

Replace the speedsensor.

BAD



SELF-DIAGNOSIS ELEC

15 lgnitor unit20 Speed sensor

3. Speed sensorCIRCUIT DIAGRAM

8-60

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

1. Wire harness

Is the wire harness OK?

YES NO

Replace the emar-gency stop switch.

BAD



SELF-DIAGNOSIS ELEC

14 Emargency stop switch15 lgnitor unit

4. Emargency stop switchCIRCUIT DIAGRAM

TRBLSHTG

CHAPTER 9TROUBLESHOOTING

STARTING PROBLEMSENGINE 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INCORRECT ENGINE IDLING SPEEDENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCEENGINE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY GEAR SHIFTINGSHIFTING IS DIFFICULT 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS OUT OF GEAR 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY CLUTCHCLUTCH SLIPS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHEATINGENGINE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERCOOLINGCOOLING SYSTEM 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR BRAKING PERFORMANCE 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY FRONT FORK LEGSLEAKING OIL 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNSTABLE HANDLING 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRBLSHTG

FAULTY LIGHTING OR SIGNALING SYSTEMHEADLIGHT DOES NOT LIGHT 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB BURNT OUT 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT DOES NOT LIGHT 9-7. . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT BULB BURNT OUT 9-7. . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT LIGHT 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS SLOWLY 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL REMAINS LIT 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS QUICKLY 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

TROUBLESHOOTINGTRBLSHTG

NOTE:

Piston(s) and piston ring(s) Improperly installed piston ringDamaged, worn or fatigued piston ringSeized piston ringSeized or damaged piston

Air filter Improperly installed air filterClogged air filter element

Crankcase and crankshaft Improperly assembled crankcaseSeized crankshaft

Carburetor(s)Deteriorated or contaminated fuelClogged pilot jetClogged pilot air passageSucked-in airDamaged floatWorn needle valve Improperly installed needle valve seat Incorrect fuel level Improperly installed pilot jetClogged starter jetFaulty starter plunger Improperly adjusted starter cable

EAS00844

TROUBLESHOOTING

The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual forchecks, adjustments, and replacement of parts.

STARTING PROBLEMSENGINECylinder(s) and cylinder head(s)Loose spark plugLoose cylinder head or cylinderDamaged cylinder head gasketDamaged cylinder gasketWorn or damaged cylinder Incorrect valve clearance Improperly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timingFaulty valve springSeized valve

FUEL SYSTEMFuel tankEmpty fuel tankClogged fuel filterClogged fuel strainerClogged fuel tank drain hoseClogged rollover valveClogged rollover valve hoseDeteriorated or contaminated fuel

Fuel pumpFaulty fuel pumpFaulty fuel pump relay

Fuel cockClogged or damaged fuel hose

9-2


Ignition systemFaulty ignitor unitFaulty pickup coilBroken generator rotor woodruff key

Switches and wiringFaulty main switchFaulty engine stop switchBroken or shorted wiringFaulty neutral switchFaulty start switchFaulty sidestand switchFaulty clutch switch Improperly grounded circuitLoose connections

Starting systemFaulty starter motorFaulty starter relayFaulty starting circuit cutoff relayFaulty starter clutch

ELECTRICAL SYSTEMSBatteryDischarged batteryFaulty battery

Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug cap

Ignition coil(s)Broken or shorted primary or secondary coils

Faulty spark plug leadCracked or broken ignition coil

Ignition systemFaulty ignitor unitFaulty pickup coilBroken generator rotor woodruff key

ELECTRICAL SYSTEMSBatteryDischarged batteryFaulty battery

Fuse(s)Blown, damaged or incorrect fuse Improperly installed fuse

Spark plug(s) Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug cap

Ignition coil(s)Cracked or broken ignition coilBroken or shorted primary or secondary coils

Faulty spark plug lead

EAS00846

INCORRECT ENGINE IDLING SPEEDENGINECylinder(s) and cylinder head(s) Incorrect valve clearanceDamaged valve train components

Air filterClogged air filter element

FUEL SYSTEMCarburetor(s)Faulty starter plungerLoose or clogged pilot jetLoose or clogged pilot air jetDamaged or loose carburetor joint Improperly synchronized carburetors Improperly adjusted engine idling speed (throttle stop screw)

Improper throttle cable free playFlooded carburetorFaulty air induction system

9-3


FUEL SYSTEMCarburetor(s)Faulty diaphragm Incorrect fuel levelLoose or clogged main jet

Fuel pumpFaulty fuel pump

JUMPS OUT OF GEARShift shaft Incorrect shift pedal position Improperly returned stopper lever

Shift forksWorn shift fork

Shift drum Incorrect axial playWorn shift drum groove

TransmissionWorn gear dog

EAS00848

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING PROBLEMS”.

ENGINEAir filterClogged air filter element

EAS00850

FAULTY GEAR SHIFTINGSHIFTING IS DIFFICULTRefer to “CLUTCH DRAGS”.

SHIFT PEDAL DOES NOT MOVEShift shaft Improperly adjusted shift rodBent shift shaft.

Shift drum and shift forksForeign object in a shift drum grooveSeized shift forkBent shift fork guide bar

TransmissionSeized transmission gearForeign object between transmission gears

Improperly assembled transmission

9-4


CLUTCH DRAGSClutchUnevenly tensioned clutch springsWarped pressure plateBent clutch plateSwollen friction plateBent clutch push rodBroken clutch bossBurnt primary driven gear bushingMatch marks not aligned

Engine oil Incorrect oil level Incorrect oil viscosity (high)Deteriorated oil

FUEL SYSTEMCarburetor(s) Incorrect main jet setting Incorrect fuel levelDamaged or loose carburetor joint

Air filterClogged air filter element

CHASSISBrake(s)Dragging brake

ELECTRICAL SYSTEMSSpark plug(s) Incorrect spark plug gap Incorrect spark plug heat range

Ignition systemFaulty ignitor unit

EAS00851

FAULTY CLUTCHCLUTCH SLIPSClutch Improperly assembled clutch Improperly adjusted clutch cableLoose or fatigued clutch springWorn friction plateWorn clutch plate

Engine oil Incorrect oil level Incorrect oil viscosity (low)Deteriorated oil

EAS00855

OVERHEATINGENGINEClogged coolant passagesCylinder head(s) and piston(s)Heavy carbon buildup

Engine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality

COOLING SYSTEMCoolantLow coolant level

RadiatorDamaged or leaking radiatorFaulty radiator capBent or damaged radiator fin

Water pumpDamaged or faulty water pumpThermostatThermostat stays closedOil coolerClogged or damaged oil coolerHose(s) and pipe(s)Damaged hose Improperly connected hoseDamaged pipe Improperly connected pipe

9-5


MALFUNCTIONBent or damaged inner tubeBent or damaged outer tubeDamaged fork springWorn or damaged outer tube bushingBent or damaged damper rod Incorrect oil viscosity Incorrect oil level

EAS00856

OVERCOOLINGCOOLING SYSTEMThermostatThermostat stays open

EAS00857

POOR BRAKING PERFORMANCEWorn brake padWorn brake discAir in hydraulic brake systemLeaking brake fluidFaulty brake caliper sealLoose union boltDamaged brake hoseOil or grease on the brake discOil or grease on the brake pad Incorrect brake fluid level

EAS00861

FAULTY FRONT FORK LEGSLEAKING OILBent, damaged or rusty inner tubeCracked or damaged outer tube Improperly installed oil sealDamaged oil seal lip Incorrect oil level (high)Loose damper rod boltDamaged damper rod bolt copper washerCracked or damaged cap bolt O-ring

9-6


Rear shock absorber assembly(-ies)Faulty rear shock absorber springLeaking oil or gas

Tire(s)Uneven tire pressures (front and rear) Incorrect tire pressureUneven tire wear

Wheel(s) Incorrect wheel balanceDeformed cast wheelDamaged wheel bearingBent or loose wheel axleExcessive wheel runout

FrameBent frameDamaged steering head pipe Improperly installed bearing race

EAS00862

UNSTABLE HANDLINGHandlebarBent or improperly installed handlebar

Steering head components Improperly installed upper bracket Improperly installed lower bracket(improperly tightened ring nut)

Bent steering stemDamaged ball bearing or bearing race

Front fork leg(s)Uneven oil levels (both front fork legs)Unevenly tensioned fork spring (both front fork legs)

Broken fork springBent or damaged inner tubeBent or damaged outer tube

SwingarmWorn bearing or bushingBent or damaged swingarm

9-7


TURN SIGNAL DOES NOT LIGHTFaulty turn signal switchFaulty turn signal relayBurnt-out turn signal bulb Incorrect connectionDamaged or faulty wire harness Improperly grounded circuitFaulty batteryBlown, damaged or incorrect fuse

TURN SIGNAL BLINKS SLOWLYFaulty turn signal relayFaulty main switchFaulty turn signal switch Incorrect turn signal bulb

TURN SIGNAL REMAINS LITFaulty turn signal relayBurnt-out turn signal bulb

TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulbFaulty turn signal relayBurnt-out turn signal bulb

HORN DOES NOT SOUND Improperly adjusted hornDamaged or faulty hornFaulty main switchFaulty horn switchFaulty batteryBlown, damaged or incorrect fuseFaulty wire harness

EAS00866

FAULTY LIGHTING OR SIGNALING SYSTEMHEADLIGHT DOES NOT LIGHTWrong headlight bulbToo many electrical accessoriesHard charging Incorrect connection Improperly grounded circuitPoor contacts (main or light switch)Burnt-out headlight bulb

HEADLIGHT BULB BURNT OUTWrong headlight bulbFaulty batteryFaulty rectifier/regulator Improperly grounded circuitFaulty main switchHeadlight bulb life expired

TAIL/BRAKE LIGHT DOES NOT LIGHTWrong tail /brake light bulbToo many electrical accessories Incorrect connectionBurnt-out tail /brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUTWrong tail /brake light bulbFaulty battery Incorrectly adjusted rear brake light switchTail /brake light bulb life expired

YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.

US Fazer 1000 Service Manual

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Transcript of US Fazer 1000 Service Manual