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Yamaha YZF-R1 98 Service Manual

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Table of Contents

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YZF-R1
'98
4XV1-AE1
SERVICE MANUAL

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Summary of Contents for Yamaha YZF-R1 98

  • Page 1 YZF-R1 ’98 4XV1-AE1 SERVICE MANUAL...
  • Page 2 EB000000 YZF - R1 SERVICE M ANUAL ©1997 by Yamaha M otor Co., Ltd. First edition, October 1997 All rights reserved. Any reproduction or unauthorized use w ithout the w ritten permission of Yamaha M otor Co., Ltd. is expressly prohibited.

  • Page 3: Specifications

    EB001000 NOTICE This m anual w as produced by the Yam aha M otor Com pany, Ltd. prim arily for use by Yam aha dealers and their qualified m echanics. It is not possible to include all the know ledge of a m echanic in one m anual.
  • Page 4 EB003000 HOW TO USE THIS M ANUAL This m anual is intended as a handy, easy-to-read reference book for the m echanic. Com pre- hensive explanations of all installation, rem oval, disassem bly, assem bly, repair and check procedures are laid out w ith the individual steps in sequential order. 1 The m anual is divided into chapters.

  • Page 5: Engine

    EB004000 SYM BOLS The follow ing sym bols are not relevant to SPEC every vehicle. INFO Sym bols 1 to 9 indicate the subject of each chapter. 1 General inform ation 2 Specifications 3 Periodic checks and adjustm ents 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis...

  • Page 6: Troubleshooting Trbl

    CHAPTER TITLES GENERAL INFORM ATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTM ENTS ENGINE COOLING COOL CARBURETION CARB CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO...

  • Page 8: General Information

    INFO CHAPTER 1. GENERAL 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 USING A DYNAMOMETER ..............1-3 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS ..............1-4...
  • Page 9 INFO...
  • Page 10 M OTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORM ATION M OTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUM BER The vehicle identification num ber 1 is stam ped into the right side of the steering head pipe. EB100020 M ODEL CODE The m odel code label 1 is affixed to the fram e.

  • Page 11: Gaskets, Oil Seals And O-Rings

    IM PORTANT INFORM ATION INFO EB102000 IM PORTANT INFORM ATION PREPARATION FOR REM OVAL AND DISASSEM BLY 1. Before rem oval disassem bly, rem ove all dirt, m ud, dust, and foreign m aterial. 2. Use only the proper tools and cleaning equipm ent.

  • Page 12: Bearings And Oil Seals

    IM PORTANT INFORM ATION INFO USING A DYNAM OM ETER The YZF-R1 has a carbon m uffler that m ay change color w hen exposed to high tem - peratures. Therefore, w hen using a dyna- m om eter alw ays use a fan to cool the m uffler.

  • Page 13: Checking The Connections

    CHECKING THE CONNECTIONS INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, m oisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector M oisture → Dry w ith an air blow er. Rust/stains →...

  • Page 14: Special Tools

    SPECIAL TOOLS INFO EB104000 SPECIAL TOOLS The follow ing special tools are necessary for com plete and accurate tune-up and assem bly. Use only the appropriate special tools as this w ill help prevent dam age caused by the use of inappropriate tools or im provised techniques.
  • Page 15 SPECIAL TOOLS INFO Tool No. Tool name/ Function Illustration Oil filter w rench 90890-01426 This tool is needed to loosen or tighten the oil filter cartridge. Rod holder 90890-01434 This tool is used to support the dam per adjusting rod. Rod puller Rod puller 90890-01437...
  • Page 16 SPECIAL TOOLS INFO Tool No. Tool name/ Function Illustration Engine tachom eter 90890-03113 This tool is used to check engine speed. Tim ing light 90890-03141 This tool is used to check the ignition tim - ing. Carburetor angle driver 90890-03158 This tool is used to turn the pilot screw w hen adjusting the engine idling speed.
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/ Function Illustration Ignition checker 90890-06754 This tool is used to check the ignition sys- tem com ponents. Yam aha bond No. 1215 90890-85505 This bond is used to seal tw o m ating sur- faces (e.g., crankcase m ating surfaces).
  • Page 18 SPEC...

  • Page 19: Table Of Contents

    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 LUBRICATION POINTS AND LUBRICANT TYPES .....2-23 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ...2-24 OIL FLOW DIAGRAMS ................2-25 COOLANT FLOW DIAGRAMS ..............2-29...
  • Page 20 SPEC...

  • Page 21: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Lim it Dimensions Overall length 2,035 m m (except for N, S, SF) ---- 2,095 m m (for N, S, SF) ---- Overall w idth 695 m m ---- Overall height 1,095 m m ---- Seat height 815 m m...

  • Page 22: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Lim it Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacem ent 998 cm ---- Cylinder arrangem ent Forw ard-inclined parallel 4-cylinder ---- Bore × stroke 74 × 58 m m ---- Com pression ratio 11.8:1 ---- Engine idling speed...
  • Page 23 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Oil filter Oil fi lter type Cartridge (paper) ---- Bypass valve opening pressure 180 ~ 220 kPa (1.8 ~ 2.2 kgf/cm ---- Oil pump Oil pum p type Trochoidal ---- Inner-rotor-to-outer-rotor-tip 0.09 ~ 0.15 m m ---- clearance Outer-rotor-to-oil-pum p-housing...
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Camshafts Drive system Chain drive (right) ---- Cam shaft cap inside diam eter 24.500 ~ 24.521 m m ---- Cam shaft journal diam eter 24.437 ~ 24.450 m m ---- Cam shaft-journal-to-cam shaft- 0.050 ~ 0.084 m m ---- cap clearance...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Timing chain M odel/num ber of links RH2015 / 130 ---- Tensioning system Autom atic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.11 ~ 0.20 m m ---- Exhaust 0.21 ~ 0.30 m m ---- Valve dim ensions Head Diameter...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Valve springs Free length Intake 38.9 m m ---- Exhaust 40.67 m m ---- Installed length (valve closed) Intake 34.5 m m ---- Exhaust 35 m m ---- Com pressed spring force (installed) Intake 82 ~ 96 N (8.36 ~ 9.79 kgf) ----...
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Pistons Piston-to-cylinder clearance 0.03 ~ 0.055 m m 0.12 m m Diam eter D 73.955 ~ 73.970 m m ---- Height H 5 m m ---- Piston pin bore (in the piston) Diam eter 17.002 ~ 17.013 m m ---- Offset...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Connecting rods Crankshaft-pin-to-big-end-bear- 0.016 ~ 0.040 m m ---- ing clearance Bearing color code –1 = Violet 0 = White 1 = Blue 2 = Black ---- Crankshaft Width A 52.40 ~ 57.25 m m ---- Width B 300.75 ~ 302.65 m m...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Transmission Transm ission type Constant m esh, 6-speed ---- Prim ary reduction system Spur gear ---- Prim ary reduction ratio 68/43 (1.581) ---- Secondary reduction system Chain drive ---- Secondary reduction ratio 43/16 (2.688) ---- Operation Left-foot operation...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Lim it Starter jet 1 ---- Starter jet 2 ---- Butterfl y valve size #100 ---- Fuel level (below the line on the 4.1 ~ 5.1 m m ---- fl oat cham ber) M ax. EXUP cable free play (at the 1.5 m m ---- EXUP valve pulley)

  • Page 31: Chassis

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Lim it Frame Fram e type Diam ond ---- Caster angle 24˚ ---- Trail 92 m m ---- Front w heel Wheel type Cast w heel ---- 17 × M T3.50 Size ---- M aterial Alum inum ----...
  • Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Lim it Rear tire Tire type Tubeless ---- Size 190/50 ZR17 (73W) ---- M odel (m anufacturer) M EZ3 (M ETZELER) (for GB) ---- TX25 (M ICHELIN) (for N, D, NL, B, E, P , I, GR) Tire pressure (cold) 0 ~ 90 kg...
  • Page 33 SPEC CHASSIS SPECIFICATIONS Item Standard Lim it Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil dam per ---- Front fork travel 135 m m ---- Spring Free length 255 m m ---- Spacer length 85 m m ---- Installed length 242.4 m m...
  • Page 34 SPEC CHASSIS SPECIFICATIONS Item Standard Lim it Steering Steering bearing type Angular ball bearings ---- Rear suspension Suspension type Sw ingarm (link suspension) ---- Rear shock absorber assem bly Coil spring/gas-oil dam per ---- type Rear shock absorber assem bly 65 m m ---- travel...

  • Page 35: Electrical

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Lim it System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition ---- Ignition tim ing 5˚ BTDC at 1,100 r/m in ---- Advanced tim ing 55˚ BTDC at 5,000 r/m in ---- Advancer type Throttle position sensor and electrical...

  • Page 36: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS Item Standard Lim it Electric starting system System type Constant m esh ---- Starter m otor M odel (m anufacturer) SM -13 (M ITSUBA) ---- Pow er output 0.8 kW ---- Brushes Overall length 10 m m 5 m m Spring force 7.03 ~ 10.63 N (717 ~ 1,084 gf)
  • Page 37 SPEC ELECTRICAL SPECIFICATIONS Item Standard Lim it Temperature sender M odel (m anufacturer) 2YK (NIPPON SEIKI) ---- 47.5 ~ 56.8 Ω at 80 ˚C Resistance ---- 16.5 ~ 20.5 Ω at 115 ˚C Fuses (amperage × quantity) 30 A × 1 M ain fuse ---- 20 A ×...

  • Page 38: Tightening Torques

    SPEC CONVERSION TABLE/ TIGHTENING TORQUES EB201000 EB202001 CONVERSION TABLE TIGHTENING TORQUES All specification data in this m anual are GENERAL TIGHTENING TORQUES listed in SI and M ETRIC UNITS. This chart specifies tightening torques for Use this table to convert M ETRIC unit data standard fasteners w ith a standard ISO to IM PERIAL unit data.

  • Page 39: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Rem arks Nm m ·kgf Spark plugs – M 10 Cylinder head M 10 Cylinder head Cap nut M 10 Cylinder head Bolt Cam shaft caps Bolt Cylinder head cover Bolt Oil passage check bolt...
  • Page 40 SPEC TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Rem arks Nm m ·kgf Clutch cover Bolt Pickup coil rotor cover Bolt Shift shaft cover Bolt Oil baffle plate Bolt Tim ing m ark accessing screw – Starter clutch idle gear shaft Bolt Starter clutch Bolt...
  • Page 41 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2 - 21...

  • Page 42: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Rem arks m ·kgf Upper bracket pinch bolts Steering stem nut M 28 11.5 Handlebar pinch bolts Low er ring nut M 30 See NOTE. Low er bracket pinch bolts Brake fluid reservoir cap stopper Front brake hose union bolts M 10...

  • Page 43: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB202000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Cam shaft lobes Cam shaft journals Valve stem s (intake and exhaust) Valve stem ends (intake and exhaust)

  • Page 44: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB202010 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and low er) Front w heel oil seal (right and left) Rear w heel oil seal Rear w heel drive hub oil seal Rear w heel drive hub m ating surface Rear brake pedal Sidestand pivoting point and m etal-to-m etal m oving parts...

  • Page 45: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAM S EB203000 OIL FLOW DIAGRAM S 1 Intake cam shaft 2 Exhaust cam shaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pum p 2 - 25...
  • Page 46 SPEC OIL FLOW DIAGRAM S 1 Exhaust cam shaft 2 Intake cam shaft 3 Oil filter 2 - 26...
  • Page 47 SPEC OIL FLOW DIAGRAM S 1 Cylinder head 2 Crankshaft 2 - 27...
  • Page 48 SPEC OIL FLOW DIAGRAM S 1 M ain axle 2 Oil delivery pipe 3 Drive axle 2 - 28...

  • Page 49: Coolant Flow Diagrams

    SPEC OIL FLOW DIAGRAM S EB203000 COOLANT FLOW DIAGRAM S 1 Therm ostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint 2 - 29...
  • Page 50 SPEC OIL FLOW DIAGRAM S 1 Therm ostat housing 2 Water pum p 3 Radiator 4 Radiator fan 2 - 30...
  • Page 51 SPEC OIL FLOW DIAGRAM S 1 Radiator cap 2 Therm ostat 3 Therm ostat housing 4 Water pum p 2 - 31...
  • Page 52 SPEC OIL FLOW DIAGRAM S 1 Radiator 2 Therm o sw itch 3 Tem perature sender 2 - 32...

  • Page 53: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Å Properly insert the m eter assem bly coupler and rubber boot 1 Throttle cables 2 Front brake hose into the m eter assem bly. ı Route the m eter assem bly lead through the left side of the 3 Clutch cable 4 Starter cable headlight housing.
  • Page 54 SPEC CABLE ROUTING Ï Fasten the auxiliary light leads w ith a plastic lock-  Route the right handlebar sw itch lead in ing tie. front of the throttle cables. Ì Fasten the w ire harness to the headlight housing Ò...
  • Page 55 SPEC CABLE ROUTING 1 Rear brake sw itch lead over the tim ing chain tensioner. Ç Insert the plastic clip through the hole in the 2 Charcoal canister (California only) 3 Rollover valve (California only) plastic frame panel and then fasten the wire har- 4 Therm ostat assem bly breather hose ness and coolant reservoir breather hose with it.
  • Page 56 SPEC CABLE ROUTING Å Route the air filter case breather hose to the inside of the 1 Air filter case breather hose 2 Water pum p breather hose w ire harness. ı Route the stator coil lead over all of the hoses and leads and 3 Sidestand sw itch lead 4 Oil level sw itch lead then fasten them w ith a plastic clip.
  • Page 57 SPEC CABLE ROUTING Ó 50 m m coolant reservoir breather hose to the inside È Fasten the sidestand sw itch lead, engine oil of the radiator outlet hose. M ake sure that level sw itch lead, and w ater pum p breather the ends of all of the hoses are below the hose w ith a plastic clip.
  • Page 58 SPEC CABLE ROUTING 1 Speed sensor lead 2 Charcoal canister (California only) 3 Neutral sw itch lead 4 EXUP cables Å Route the EXUP cables on the outside of the engine m ount. ı Fasten the EXUP cables w ith a plastic locking tie. 2 - 38...
  • Page 59 SPEC CABLE ROUTING 1 Headlight sub-w ire harness C Fuel tank overflow hose 2 Left handlebar sw itch lead D Fuel tank breather hose (except for California) 3 M ain sw itch lead E Starter m otor lead 4 Starter cable F Battery positive lead 5 Right handlebar sw itch coupler G Battery negative lead...
  • Page 60 SPEC CABLE ROUTING Å Route the horn lead over the horn bracket w ire harness w ith a plastic clam p. Ì Fasten the EXUP servom otor lead, fuel pum p and m ake sure that the lead has no slack. ı...
  • Page 61 SPEC CABLE ROUTING Ô Route the w ire harness and turn signal leads harness w ith a plastic locking tie. Ø Route the fuel tank overflow hose and fuel under the rear cow ling m ounting post on the tail/brake light bracket. tank breather hose in front of the crankcase ...
  • Page 62 SPEC CABLE ROUTING Œ Fasten the w ire harness w ith a plastic clam p Ë Fasten the w ire harness and radiator fan lead to and then insert the clam p into the fram e. the plastic frame panel with a plastic locking tie. Â...
  • Page 63 SPEC CABLE ROUTING Á Install the rubber baffle over the carburetor air funnels. Û The end of the plastic locking tie m ust face in and dow n. 2 - 43...
  • Page 64 SPEC 2 - 44...
  • Page 66 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ...................3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....3-1 SEATS ......................3-3 FUEL TANK ....................3-4 COWLINGS ....................3-5 REMOVAL .....................3-6 INSTALLATION ..................3-6 AIR FILTER CASE AND IGNITION COIL PLATE ..........3-7 REMOVAL .....................3-8 INSTALLATION ..................3-8 ENGINE ......................3-9 ADJUSTING THE VALVE CLEARANCE ..........3-9 VALVE PAD SELECTION TABLE ............3-13 SYNCHRONIZING THE CARBURETORS ...........3-14 ADJUSTING THE ENGINE IDLING SPEED ........3-16...
  • Page 67 CHECKING THE BRAKE PADS ............3-41 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-41 CHECKING THE BRAKE HOSES ............3-42 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........3-42 ADJUSTING THE SHIFT PEDAL ............3-44 ADJUSTING THE DRIVE CHAIN SLACK ...........3-44 LUBRICATING THE DRIVE CHAIN .............3-46 CHECKING AND ADJUSTING THE STEERING HEAD .....3-46 CHECKING THE FRONT FORK ............3-49 ADJUSTING THE FRONT FORK LEGS ..........3-50 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ....3-52...
  • Page 68 INTRODUCTION/ PERIODIC M AINTENANCE AND LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTM ENTS INTRODUCTION This chapter includes all inform ation necessary to perform recom m ended checks and adjust- m ents. If follow ed, these preventive m aintenance procedures w ill ensure m ore reliable vehi- cle operation, a longer service life and reduce the need for costly overhaul w ork.
  • Page 69 PERIODIC M AINTENANCE/ LUBRICATION INTERVALS EVERY 12,000 km 6,000 km or INITIAL ITEM CHECKS AND M AINTENANCE JOBS 6 months (1,000 km) 12 months (w hichever (w hichever comes first) comes first) • M ake sure that all nuts, bolts and screw s are properly √...
  • Page 70 SEATS EB302000 SEATS Order Job/Part Q’ty Rem arks Removing the seats Rem ove the parts in the order listed. Passenger seat Rider seat For installation, reverse the rem oval procedure. 3 - 3...

  • Page 71: Fuel Tank

    FUEL TANK EB302010 FUEL TANK Order Job/Part Q’ty Rem arks Removing the fuel tank Rem ove the parts in the order listed. Rider seat Refer to “ SEATS” . Bolt Bolt Fuel sender coupler Disconnect. NOTE: Fuel hose Before disconnecting the fuel hose, set the fuel cock to “...
  • Page 72 COWLINGS EB302020 COWLINGS Order Job/Part Q’ty Rem arks Removing the cow lings Rem ove the parts in the order listed. Rider and passenger seats Refer to “ SEATS” . Rear cow ling Bottom cow ling Front cow ling inner panel (left) Front cow ling inner panel (right) Left side cow ling Right side cow ling...
  • Page 73 COWLINGS REM OVAL 1. Rem ove: • rear cow ling • side cow lings NOTE: To rem ove the quick fastener, push its center in w ith a screw driver, then pull the fastener out. INSTALLATION 1. Install: • side cow lings •...

  • Page 74: Air Filter Case And Ignition Coil Plate

    AIR FILTER CASE AND IGNITION COIL PLATE EB302040 AIR FILTER CASE AND IGNITION COIL PLATE Order Job/Part Q’ty Rem arks Removing the air filter case and igni- Rem ove the parts in the order listed. tion coil plate Rider seat and fuel tank Refer to “...
  • Page 75 AIR FILTER CASE AND IGNITION COIL PLATE REM OVAL 1. Rem ove: • rubber baffle NOTE: To rem ove the quick fastener, push its center in w ith a screw driver, then pull the fastener out. INSTALLATION 1. Install: • rubber baffle NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener...
  • Page 76 ADJUSTING THE VALVE CLEARANCE EB303001 ENGINE ADJUSTING THE VALVE CLEARANCE The follow ing procedure applies to all of the valves. NOTE: • Valve clearance adjustm ent should be m ade on a cold engine, at room tem - perature. • When the valve clearance is to be m ea- sured or adjusted, the piston m ust be at top dead center (TDC) on the com - pression stroke.
  • Page 77 ADJUSTING THE VALVE CLEARANCE 4. M easure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.11 ~ 0.20 mm Exhaust valve 0.21 ~ 0.30 mm a. Turn the crankshaft clockw ise. b. When piston #1 is at TDC on the com - pression stroke, align...
  • Page 78 ADJUSTING THE VALVE CLEARANCE 5. Rem ove: • tim ing chain tensioner • tim ing chain guide (exhaust side) • intake cam shaft caps • exhaust cam shaft caps • tim ing chain (from the cam shaft sprockets) • intake cam shaft •...
  • Page 79 ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad num - ber according to the follow ing table. Last digit Rounded value 0 or 2 EXAM PLE: Original valve pad num ber = 148 (thickness = 1.48 m m ) Rounded value = 150 d.
  • Page 80 ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE ı Å ORIGINAL VALVE PAD NUM BER MEASURED VALVE CLEARANCE 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 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 ~ 0.07...
  • Page 81 ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS g. M easure the valve clearance again. h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustm ent steps until the specified clearance is obtained. 7. Install: •...
  • Page 82 SYNCHRONIZING THE CARBURETORS 3. Rem ove: • bolts 1 • copper w ashers 4. Install: • vacuum gauge attachm ents (into the bolt holes) • vacuum gauge 1 (onto the vacuum gauge attachm ents) • engine tachom eter 2 (onto the spark plug lead of cylinder #1) Vacuum gauge 90890-03094 Vacuum gauge attachment...
  • Page 83 SYNCHRONIZING THE CARBURETORS/ ADJUSTING THE ENGINE IDLING SPEED NOTE: After each step, rev the engine tw o or three tim es, each tim e for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carbure- tor #3 by turning the synchronizing screw 2 in either direction until both gauges read the sam e.
  • Page 84 ADJUSTING THE ENGINE IDLING SPEED 2. Rem ove: • air filter case • quick fasteners 1 Refer to “ AIR FILTER CASE AND IGNI- TION COIL PLATE” . 3. Install: • engine tachom eter (onto the spark plug lead of cylinder #1) Engine tachometer 90890-03113 4.
  • Page 85 ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 7. Adjust: • throttle cable free play Refer to “ ADJUSTING THE THROTTLE CABLE FREE PLAY” . Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm EB303031 ADJUSTING THE THROTTLE CABLE FREE PLAY...
  • Page 86 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: • throttle cable free play NOTE: When the throttle is opened, the acceler- ator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the deceler- ator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.
  • Page 87 CHECKING THE SPARK PLUGS EB303040 CHECKING THE SPARK PLUGS The follow ing procedure applies to all of the spark plugs. 1. Rem ove: • rider seat • fuel tank Refer to “ SEATS” and “ FUEL TANK” . • air filter case •...
  • Page 88 CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIM ING 8. Install: • spark plug 13 Nm (1.3 m · kg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. EB303050 CHECKING THE IGNITION TIM ING NOTE: Prior to checking the ignition tim ing, check the w iring connections of the entire ignition system .
  • Page 89 CHECKING THE IGNITION TIM ING/ M EASURING THE COM PRESSION PRESSURE b. Check that the m ark a is w ithin the required firing range b on the pickup coil rotor. Incorrect firing range → Check the ignition system . NOTE: The ignition tim ing is not adjustable.
  • Page 90 M EASURING THE COM PRESSION PRESSURE 5. Install: • com pression gauge 1 Compression gauge 90890-03081 Adapter 90890-04136 6. M easure: • com pression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) M inimum 1,350 kPa (13.5 kg/ cm 13.5 bar)
  • Page 91 M EASURING THE COM PRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL Refer to the follow ing table. Compression pressure (w ith oil applied into the cylinder) Reading Diagnosis Higher than w ith- Piston w ear or damage → Repair. out oil Piston ring(-s), valve(-s), cylinder Same as w ithout...
  • Page 92 CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CAUTION: ACHTUNG: • Engine oil also lubricates the clutch and the w rong oil types or additives could cause clutch slippage. There- fore, do not add any chemical addi- tives or use engine oils w ith a grade of CD c or higher and do not use oils labeled “ENERGY CONSERVING II”...
  • Page 93 CHANGING THE ENGINE OIL b. Lubricate the O-ring 3 of the new oil filter cartridge w ith a thin coat of engine oil. CAUTION: ACHTUNG: M ake sure that the O-ring 3 is posi- tioned correctly in the groove of the oil filter cartridge.
  • Page 94 CHANGING THE ENGINE OIL 15.Check: • engine oil pressure a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil com es out after one m inute, turn the engine off so that it w ill not seize.
  • Page 95 ADJUSTING THE CLUTCH CABLE FREE PLAY EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. M easure: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm 2.
  • Page 96 CLEANING THE AIR FILTER ELEM ENT/ CHECKING THE CARBURETOR JOINTS EB303130 CLEANING THE AIR FILTER ELEM ENT 1. Rem ove: • fuel tank Refer to “ FUEL TANK” . • air filter case cover 1 • air filter elem ent 2.
  • Page 97 CHECKING THE CARBURETOR JOINTS/ CHECKING THE FUEL HOSES AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE 2. Check: • carburetor joint 1 Cracks/dam age → Replace. Refer to “ CARBURETORS” in chapter 6. 3. Install: • carburetor assem bly Refer to “ CARBURETORS” in chapter 6. EB303181 CHECKING THE FUEL HOSES AND FUEL FILTER...
  • Page 98 CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 2. Check: • crankcase breather hose 1 Cracks/dam age → Replace. Loose connection → Connect properly. CAUTION: ACHTUNG: M ake sure that the crankcase breather hose is routed correctly. 3. Install: •...
  • Page 99 ADJUSTING THE EXUP CABLES EB303210 ADJUSTING THE EXUP CABLES 1. Rem ove: • fuel tank • bottom cow ling Refer to “ FUEL TANK” and “ COWL- INGS” . 2. Rem ove: • EXUP valve pulley cover 1 3. Check: •...
  • Page 100 ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 5. Adjust: • EXUP cable free play a. Loosen both locknuts 1. b. Insert a 4-m m long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover. c.
  • Page 101 CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM 3. Start the engine, w arm it up for several m inutes, and then turn it off. 4. Check: • coolant level NOTE: Before checking the coolant level, w ait a few m inutes until the coolant has set- tled.
  • Page 102 CHANGING THE COOLANT EB303240 CHANGING THE COOLANT 1. Rem ove: • bottom cow ling • right side cow ling Refer to “ COWLINGS” . 2. Disengage: • clutch cable holder 1 (from the coolant reservoir) 3. Rem ove: • coolant reservoir bolts 2 •...
  • Page 103 CHANGING THE COOLANT 8. Rem ove: • coolant drain bolt 1 (along w ith the copper w asher) 9. Drain: • coolant 10.Check: • copper w asher 1 • coolant drain bolt 2 Dam age → Replace. 11.Install: • coolant drain bolt 7 Nm (0.7 m ·...
  • Page 104 CHANGING THE COOLANT CAUTION: ACHTUNG: • Adding w ater instead of coolant low - ers the antifreeze content of the cool- ant. If w ater is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the cool- ant.
  • Page 105 ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever for- w ard, turn the adjusting dial 1 until the brake lever is in the desired posi- tion.
  • Page 106 ADJUSTING THE REAR BRAKE 2. Adjust: • brake pedal position a. Loosen the locknut 1. b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Brake pedal is raised. Direction b Brake pedal is low ered.
  • Page 107 CHECKING THE BRAKE FLUID LEVEL EB304020 CHECKING THE BRAKE FLUID LEVEL 1. Stand the m otorcycle on a level surface. NOTE: • Place the m otorcycle on a suitable stand. • M ake sure that the m otorcycle is upright. 2.

  • Page 108: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EB304032 Å CHECKING THE BRAKE PADS The follow ing procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad • rear brake pad Brake pad w ear lim it a Wear lim it reached →...
  • Page 109 CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EB304062 CHECKING THE BRAKE HOSES The follow ing procedure applies to all of the brake hoses and brake hose clam ps. 1. Check: • brake hose 1 Cracks/dam age/w ear → Replace. 2.
  • Page 110 BLEEDING THE HYDRAULIC BRAKE SYSTEM 5. Bleed: Å • hydraulic brake system a. Fill the brake fluid reservoir to the proper level w ith the recom m ended brake fluid. b. Install the brake fluid reservoir dia- phragm . c. Connect a clear plastic hose 1 tightly to the bleed screw 2.
  • Page 111 ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EB304081 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determ ined by the installed shift rod length a. 1. M easure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 305 mm 2.
  • Page 112 ADJUSTING THE DRIVE CHAIN SLACK 2. Rotate the rear w heel several tim es and check the drive chain to locate its tight- est point. 3. M easure: • drive chain slack a Out of specification → Adjust. Drive chain slack 40 ~ 50 mm 4.

  • Page 113: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of m any interact- ing parts. If the drive chain is not m ain- tained properly, it w ill w ear out rapidly. Therefore, the drive chain should be ser- viced, especially w hen the m otorcycle is used in dusty areas.
  • Page 114 CHECKING AND ADJUSTING THE STEERING HEAD 3. Rem ove: • front brake fluid reservoir 1 • plastic caps 2 4. Loosen: • upper bracket pinch bolts 1 • handlebar pinch bolts 2 5. Rem ove: • upper bracket bolts 3 •...

  • Page 115: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the low er ring nut com pletely, then tighten it to specification. WARNING WARNING Do not overtighten the low er ring nut. Low er ring nut (final tighten- ing torque) 9 Nm (0.9 m • kg) d.
  • Page 116 CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Hold the spring gauge at a 45˚ angle from the handlebar, pull the spring gauge, and record the m easurem ent w hen the handlebar starts to turn. Steering head tension 200 ~ 500 g e.
  • Page 117 ADJUSTING THE FRONT FORK LEGS EB304153 ADJUSTING THE FRONT FORK LEGS The follow ing procedure applies to both of the front fork legs. WARNING WARNING • Alw ays adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. •...
  • Page 118 ADJUSTING THE FRONT FORK LEGS Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound dam ping a. Turn the adjusting screw 1 in direc- tion a or b. Rebound damping is Direction a increased (suspension is harder).
  • Page 119 ADJUSTING THE REAR SHOCK ABSORBER ASSEM BLY EB304162 ADJUSTING THE REAR SHOCK ABSORBER ASSEM BLY WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions.
  • Page 120 ADJUSTING THE REAR SHOCK ABSORBER ASSEM BLY Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound dam ping a. Turn the adjusting screw 1 in direc- tion a or b. Rebound damping is Direction a increased (suspension is harder).
  • Page 121 CHECKING THE TIRES EB304170 CHECKING THE TIRES The follow ing procedure applies to both of the tires. 1. M easure: • tire pressure Out of specification → Regulate. WARNING WARNING • The tire pressure should only be checked and regulated w hen the tire temperature equals the ambient air temperature.
  • Page 122 • After extensive tests, the tires listed below have been approved Yamaha M otor Co., Ltd. for this model. The front and rear tires should alw ays be by the same manufacturer and of the same design. No guarantee concerning handling characteristics...
  • Page 123 CHECKING THE TIRES/ CHECKING THE WHEELS Rear tire M anufacturer Size M odel 190/ 50 ZR17 BT56R BRIDGESTONE (73W) BT57R 190/ 50 ZR17 M EZ1 M ETZELER (73W) RACING 190/ 50 ZR17 M ETZELER M EZ3 (73W) 190/ 50 ZR17 DUNLOP D207L (73W)
  • Page 124 CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EB304200 CHECKING AND LUBRICATING THE CABLES The follow ing procedure applies to all of the cable sheaths and cables. WARNING WARNING Damaged cable sheaths may cause the cable to corrode and interfere w ith its movement.

  • Page 125: Electrical System

    CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING WARNING Batteries generate explosive hydrogen gas and contain electrolyte w hich is made of poisonous and highly caustic sulfuric acid. Therefore, alw ays follow these preven- tive measures: •...
  • Page 126 CHECKING AND CHARGING THE BATTERY NOTE: Since M F batteries are sealed, it is not possible to check the charge state of the battery by m easuring the specific grav- ity of the electrolyte. Therefore, the charge of the battery has to be checked by m easuring the voltage at the battery term inals.
  • Page 127 CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer to the appropriate charging m ethod illustration) WARNING WARNING Do not quick charge a battery. CAUTION: ACHTUNG: • Never remove the M F battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage cur- rent into the battery quickly and can cause battery overheating and bat-...
  • Page 128 CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger 3 - 61...
  • Page 129 CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger 3 - 62...
  • Page 130 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery term inals) CAUTION: ACHTUNG: First, connect the positive lead 1, then the negative lead 2. 8. Check: • battery term inals Dirt →...
  • Page 131 CHECKING THE FUSES 3. Replace: • blow n fuse a. Set the m ain sw itch to “ OFF” . b. Install a new fuse of the correct am perage. c. Set the m ain sw itch to “ ON” and ver- ify if the electrical circuit is opera- tional.
  • Page 132 REPLACING THE HEADLIGHT BULBS EB305051 REPLACING THE HEADLIGHT BULBS The follow ing procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler 1 • headlight bulb holder cover 2 2. Detach: • headlight bulb holder 1 3. Rem ove: •...
  • Page 133 ADJUSTING THE HEADLIGHT BEAM S EB305061 ADJUSTING THE HEADLIGHT BEAM S The follow ing procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) a. Turn the adjusting screw 1 in direc- tion a or b. Direction a Headlight beam is raised. Headlight beam is low - Direction b ered.
  • Page 135 CHAPTER 4. OVERHAULING THE ENGINE ENGINE ......................4-1 INSTALLING THE ENGINE ..............4-7 CAMSHAFTS ....................4-8 REMOVING THE CAMSHAFTS ............4-11 CHECKING THE CAMSHAFTS ............4-12 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES ............4-13 CHECKING THE TIMING CHAIN TENSIONER ........4-14 INSTALLING THE CAMSHAFTS ............4-15 CYLINDER HEAD ..................4-18 REMOVING THE CYLINDER HEAD ............4-19 CHECKING THE CYLINDER HEAD .............4-19...
  • Page 136 SHIFT SHAFT ....................4-49 CHECKING THE SHIFT SHAFT ............4-50 CHECKING THE STOPPER LEVER .............4-50 INSTALLING THE SHIFT SHAFT ............4-50 OIL PAN AND OIL PUMP ................4-51 REMOVING THE OIL PAN ..............4-54 CHECKING THE OIL PUMP ..............4-54 CHECKING THE RELIEF VALVE ............4-55 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE ......4-55 CHECKING THE OIL STRAINER ............4-55 ASSEMBLING THE OIL PUMP ............4-55 INSTALLING THE OIL PUMP .............4-56...
  • Page 137 ENGINE EB400011 OVERHAULING THE ENGINE ENGINE Order Job/Part Q’ty Rem arks Removing the drive sprocket Rem ove the parts in the order listed. Locknut Shift rod Drive sprocket cover Lock w asher Drive sprocket Shift arm For installation, reverse the rem oval procedure.
  • Page 138 ENGINE Order Job/Part Q’ty Rem arks Removing the exhaust assembly Rem ove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS” and “ FUEL TANK” in chapter 3. Bottom cow ling and side cow lings Refer to “...
  • Page 139 ENGINE Order Job/Part Q’ty Rem arks M uffler EXUP cable holder EXUP valve cover Spacer EXUP valve Spacer For installation, reverse the rem oval procedure. 4 - 3...
  • Page 140 ENGINE Order Job/Part Q’ty Rem arks Disconnecting the leads and hoses Disconnect the parts in the order listed. Air filter case Refer to “ AIR FILTER CASE AND IGNI- TION COIL PLATE” in chapter 3. Carburetor assem bly and carburetor Refer to “...
  • Page 141 ENGINE Order Job/Part Q’ty Rem arks Clutch cable Crankcase breather hose Starter m otor lead Disconnect. Ground lead Disconnect. Starter m otor Stator coil assem bly coupler Disconnect. Pickup coil coupler Disconnect. Oil level sw itch connector Disconnect. Neutral sw itch Speed sensor For connecting, reverse the disconnec- tion procedure.
  • Page 142 ENGINE Order Job/Part Q’ty Rem arks Removing the engine Rem ove the parts in the order listed. NOTE: Place a suitable stand under the fram e and engine. Pinch bolt Loosen. Right front m ounting bolt Washer Spacer Left front m ounting bolt Washer Self-locking nut Rear m ounting bolt...
  • Page 143 ENGINE EB400700 INSTALLING THE ENGINE 1. Install: • spacer 1 • rear m ounting bolts 2 • self-locking nuts 3 • w ashers 4 • left front m ounting bolts 5 • spacer 6 • w asher 7 • right front m ounting bolt 8 NOTE: •...
  • Page 144 CAM SHAFTS EB401000 CAM SHAFTS Order Job/Part Q’ty Rem arks Removing the cylinder head cover Rem ove the parts in the order listed. Carburetor assem bly Refer to “ CARBURETORS” in chapter 6. Radiator assem bly and therm ostat Refer to “ RADIATOR” and “ THERM O- assem bly STAT ASSEM BLY”...
  • Page 145 CAM SHAFTS EB401011 Order Job/Part Q’ty Rem arks Removing the camshafts Rem ove the parts in the order listed. Pickup coil rotor cover Refer to “ PICKUP COIL” . Float cham ber air vent hose holder Tim ing chain tensioner Tim ing chain tensioner gasket Tim ing chain guide (exhaust side) Intake cam shaft cap...
  • Page 146 CAM SHAFTS Order Job/Part Q’ty Rem arks Intake cam shaft sprocket Exhaust cam shaft sprocket Tim ing chain guide (intake side) For installation, reverse the rem oval procedure. 4 - 10...
  • Page 147 CAM SHAFTS EB401101 REM OVING THE CAM SHAFTS 1. Align: • TDC m ark on the pickup coil rotor (w ith the crankcase m ating surface) a. Turn the crankshaft clockw ise. b. When piston #1 is at TDC on the com - pression stroke, align...
  • Page 148 CAM SHAFTS EB401401 CHECKING THE CAM SHAFTS 1. Check: • cam shaft lobes Blue discoloration/pitting/scratches → Replace the cam shaft. 2. M easure: • cam shaft lobe dim ensions a and b Out of specification → Replace the cam shaft. Camshaft lobe dimensions limit Intake camshaft...
  • Page 149 CAM SHAFTS NOTE: • Tighten the cam shaft cap bolts in stages and in a crisscross pattern, w orking from the inner caps out. • Do not turn the cam shaft w hen m ea- suring the cam shaft-journal-to-cam - shaft-cap clearance w ith...
  • Page 150 CAM SHAFTS 2. Check: • cam shaft sprocket M ore than 1/4 tooth w ear a → Replace the cam shaft sprockets and the tim ing chain as a set. a 1/4 tooth b Correct 1 Tim ing chain roller 2 Cam shaft sprocket 3.
  • Page 151 CAM SHAFTS EB401701 INSTALLING THE CAM SHAFTS 1. Install: • tim ing chain guide (intake side) 1 2. Install: • intake cam shaft sprocket 24 Nm (2.4 m · kg) • exhaust cam shaft sprocket 24 Nm (2.4 m · kg) 3.
  • Page 152 CAM SHAFTS 4. Install: • tim ing chain guide (exhaust side) 5. Install: • tim ing chain tensioner a. Lightly press the tim ing chain ten- sioner rod into the tim ing chain ten- sioner housing by hand. b. While pressing the tim ing chain ten- sioner rod, w ind it clockw ise w ith a thin screw driver 1 until it stops.
  • Page 153 CAM SHAFTS 7. Check: • TDC m ark a M ake sure that the TDC m ark is aligned w ith the crankcase m ating sur- face b. • cam shaft punch m ark c M ake sure that the cam shaft punch m ark is aligned w ith the arrow m ark d on the cam shaft cap.

  • Page 154: Cylinder Head

    CYLINDER HEAD EB402000 CYLINDER HEAD Order Job/Part Q’ty Rem arks Removing the cylinder head Rem ove the parts in the order listed. Engine Refer to “ ENGINE” . Intake and exhaust cam shafts Refer to “ CAM SHAFTS” . Cylinder head Cylinder head gasket Dow el pin For installation, reverse the rem oval...
  • Page 155 CYLINDER HEAD EB402102 REM OVING THE CYLINDER HEAD 1. Rem ove: • cylinder head bolts • cylinder head nuts NOTE: Loosen each bolt and nut 1/2 of a turn at a tim e, in stages and in a crisscross pat- tern.
  • Page 156 CYLINDER HEAD d. Place a 400 ~ 600 grit w et sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several tim es. EB402702 INSTALLING THE CYLINDER HEAD 1.

  • Page 157: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EB403000 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Rem arks Removing the valves and valve Rem ove the parts in the order listed. springs Cylinder head Refer to “ CYLINDER HEAD” . Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring...
  • Page 158 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Rem arks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve low er spring seat Exhaust valve Exhaust valve guide For installation, reverse the rem oval procedure.
  • Page 159 VALVES AND VALVE SPRINGS EB403100 REM OVING THE VALVES The follow ing procedure applies to all of the valves and related com ponents. NOTE: Before rem oving the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), m ake sure that the valves properly seal.
  • Page 160 VALVES AND VALVE SPRINGS 3. Rem ove: • valve cotters 1 NOTE: Rem ove the valve cotters by com press- ing the valve spring w ith the valve spring com pressor 2 and attachm ent 3. Valve spring compressor 90890-04019 Attachment (for the intake valve) 90890-04114...
  • Page 161 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide rem oval and instal- lation, and to m aintain the correct fit, heat the cylinder head to 100 ˚C in an oven. a. Rem ove the valve guide w ith a valve guide rem over 1.
  • Page 162 VALVES AND VALVE SPRINGS 5. M easure: • valve m argin thickness a Out of specification → Replace the valve. Valve margin thickness 0.5 ~ 0.9 mm 6. M easure: • valve stem runout Out of specification → Replace the valve.
  • Page 163 VALVES AND VALVE SPRINGS a. Apply M echanic’s blueing (Dykem ) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to m ake a clear im pression.
  • Page 164 VALVES AND VALVE SPRINGS e. Apply a fine lapping com pound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping com pound from the valve face and valve seat.
  • Page 165 VALVES AND VALVE SPRINGS 2. M easure: • com pressed spring force a Out of specification → Replace the valve spring. b Installed length Compressed spring force (installed) Intake valve spring 8.36 ~ 9.79 kg at 34.5 mm Exhaust valve spring 11.22 ~ 12.85 kg at 35.0 mm 3.
  • Page 166 VALVES AND VALVE SPRINGS 3. Install: • low er spring seat 1 • oil seal 2 • valve 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) NOTE: • M ake sure that each valve is installed in its original place.
  • Page 167 VALVES AND VALVE SPRINGS 6. Lubricate: • valve pad (w ith the recom m ended lubricant) Recommended lubricant M olybdenum disulfide oil 7. Install: • valve pad • valve lifter NOTE: • The valve lifter m ust m ove sm oothly w hen rotated w ith a finger.
  • Page 168 GENERATOR EB410000 GENERATOR Order Job/Part Q’ty Rem arks Removing the stator coil assembly Rem ove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS” and “ FUEL TANK” in chapter 3. Bottom cow ling Refer to “...
  • Page 169 Flyw heel puller 90890-01080 EB410700 INSTALLING THE GENERATOR 1. Apply: • sealant (onto the stator coil assem bly lead grom m et) Yamaha bond No. 1215 90890-85505 2. Install: • generator rotor • w asher • generator rotor bolt WARNING WARNING Alw ays use a new generator rotor bolt.
  • Page 170 GENERATOR 3. Tighten: • generator rotor bolt 1 95 Nm (9.5 m · kg) NOTE: While holding the generator rotor 2 w ith the rotor holding tool 3, tighten the generator rotor bolt. Rotor holding tool 90890-01235 4. Install: • generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern.

  • Page 171: Pickup Coil

    PICKUP COIL PICKUP COIL Order Job/Part Q’ty Rem arks Removing the pickup coil and Rem ove the parts in the order listed. pickup coil rotor Rider seat and fuel tank Refer to “ SEATS” and “ FUEL TANK” in chapter 3. Bottom cow ling and right side cow l- Refer to “...
  • Page 172 PICKUP COIL Order Job/Part Q’ty Rem arks Pickup coil coupler Disconnect. Pickup coil Pickup coil rotor For installation, reverse the rem oval procedure. 4 - 36...
  • Page 173 PICKUP COIL REM OVING THE PICKUP COIL ROTOR 1. Rem ove: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 NOTE: Loosen each bolt 1/4 of a turn at a tim e, in stages and in a crisscross pattern.
  • Page 174 Rotor holding tool 90890-01235 3. Apply: • sealant (onto the pickup coil lead grom m et) Yamaha bond No. 1215 90890-85505 4. Install: • pickup coil rotor cover • pickup coil lead holder • clutch cable holder NOTE: •...
  • Page 175 CLUTCH EB405000 CLUTCH Order Job/Part Q’ty Rem arks Removing the clutch cover Rem ove the parts in the order listed. Bottom cow ling and right side cow l- Refer to “ COWLINGS” in chapter 3. Engine oil Drain. Refer to “ CHANGING THE ENGINE OIL”...
  • Page 176 CLUTCH EB405010 Order Job/Part Q’ty Rem arks Removing the pull lever shaft Rem ove the parts in the order listed. Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the rem oval procedure. 4 - 40...
  • Page 177 CLUTCH Order Job/Part Q’ty Rem arks Removing the clutch Rem ove the parts in the order listed. Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Inside diam eter =124 m m Clutch plate Lock w asher Wire circlip...
  • Page 178 CLUTCH Order Job/Part Q’ty Rem arks Thrust w asher Clutch housing Bearing Starter clutch gear Bearing Starter clutch assem bly Circlip Starter clutch idle gear For installation, reverse the rem oval procedure. 4 - 42...
  • Page 179 CLUTCH EB405102 REM OVING THE CLUTCH 1. Rem ove: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a tim e, in stages and in a crisscross pattern. After all of the bolts are fully loosened, rem ove them .
  • Page 180 CLUTCH EB405410 CHECKING THE CLUTCH PLATES The follow ing procedure applies to all of the clutch plates. 1. Check: • clutch plate Dam age → Replace the clutch plates as a set. 2. M easure: • clutch plate w arpage (w ith a surface plate and thickness gauge 1) Out of specification →...
  • Page 181 CLUTCH EB405450 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Dam age/pitting/w ear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines w ill cause erratic clutch operation. EB405460 CHECKING THE PRESSURE PLATE 1. Check: •...
  • Page 182 CLUTCH 2. Check: • starter clutch operation a. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch gear clockw ise Å, the starter clutch and the starter clutch gear should engage, otherw ise the starter clutch is faulty and m ust be replaced.
  • Page 183 CLUTCH 3. Install: • lock w asher • clutch boss nut 1 70 Nm (7.0 m · kg) NOTE: While holding the clutch boss 2 w ith the clutch holding tool 3, tighten the clutch boss nut. Clutch holding tool 90890-04086 4.
  • Page 184 CLUTCH 9. Install: • clutch cover 12 Nm (1.2 m · kg) NOTE: • When installing the clutch cover, push the pull lever and check that the punch m ark a on the pull lever aligns w ith the m ark b on the clutch cover. M ake sure that the pull rod teeth and pull lever shaft pinion gear are engaged.

  • Page 185: Shift Shaft

    SHIFT SHAFT EB408000 SHIFT SHAFT Order Job/Part Q’ty Rem arks Removing the shift shaft and stop- Rem ove the parts in the order listed. per lever Drive sprocket cover Refer to “ ENGINE” . Throttle stop screw holder Shift shaft cover Shift shaft cover gasket Dow el pin Shift shaft...
  • Page 186 SHIFT SHAFT EB408401 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/dam age/w ear → Replace. • shift shaft spring 2 Dam age/w ear → Replace. EB408410 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/dam age → Replace. Roller turns roughly →...
  • Page 187 OIL PAN AND OIL PUM P EB411000 OIL PAN AND OIL PUM P Order Job/Part Q’ty Rem arks Removing the oil pan and oil pump Rem ove the parts in the order listed. Engine oil Drain. Refer to “ CHANGING THE ENGINE OIL”...
  • Page 188 OIL PAN AND OIL PUM P EB411001 Order Job/Part Q’ty Rem arks Drain pipe Oil strainer Oil pipe Oil delivery pipe Oil/w ater pum p assem bly drive sprocket cover Dow el pin Oil/w ater pum p assem bly Relief valve assem bly For installation, reverse the rem oval procedure.
  • Page 189 OIL PAN AND OIL PUM P EB411003 Order Job/Part Q’ty Rem arks Removing the oil pump Rem ove the parts in the order listed. Oil/w ater pum p assem bly driven sprocket Washer Oil pum p housing Bearing Oil pum p outer rotor Oil pum p inner rotor For installation, reverse the rem oval procedure.
  • Page 190 OIL PAN AND OIL PUM P EB411100 REM OVING THE OIL PAN 1. Rem ove: • oil level sw itch 1 • oil pan 2 • oil pan gasket • dow el pins NOTE: Loosen each bolt 1/4 of a turn at a tim e, in stages and in a crisscross pattern.
  • Page 191 OIL PAN AND OIL PUM P 3. Check: • oil pum p operation Unsm ooth → Repair or replace the defective part(-s). Refer to “ WATER PUM P” in chapter 5. EB411410 CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 •...
  • Page 192 OIL PAN AND OIL PUM P 2. Check: • oil pum p operation Refer to “ CHECKING THE OIL PUM P” . EB411710 INSTALLING THE OIL PUM P 1. Install: • oil pum p 1 10 Nm (1.0 m · kg) NOTE: Install the oil/w ater pum p assem bly drive chain onto the oil/w ater pum p...
  • Page 193 CRANKCASE CRANKCASE Order Job/Part Q’ty Rem arks Separating the crankcase Rem ove the parts in the order listed. Engine Refer to “ ENGINE” . Cylinder head Refer to “ CYLINDER HEAD” . Pickup coil and pickup coil rotor Refer to “ PICKUP COIL” . Stator coil assem bly Refer to “...
  • Page 194 CRANKCASE Order Job/Part Q’ty Rem arks Oil/w ater pum p assem bly drive sprocket Washer Plate Low er crankcase Dow el pin For installation, reverse the rem oval procedure. 4 - 58...
  • Page 195 CRANKCASE Order Job/Part Q’ty Rem arks Removing the oil baffle plates and Rem ove the parts in the order listed. oil filter bolt Connecting rod assem blies Refer to “ CONNECTING RODS AND PISTONS” . Crankshaft Refer to “ CRANKSHAFT” . Transm ission Refer to “...
  • Page 196 CRANKCASE EB412100 DISASSEM BLING THE CRANKCASE 1. Rem ove: • crankcase bolts NOTE: • Loosen each bolt 1/4 of a turn at a tim e, in stages and in a crisscross pat- tern. After all of the bolts are fully loos- ened, rem ove them .
  • Page 197 CRANKCASE EB412420 CHECKING THE CRANKCASE 1. Thoroughly w ash the crankcase halves in a m ild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase m ating surfaces. 3. Check: • upper crankcase • low er crankcase Cracks/dam age → Replace. •...
  • Page 198 Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase m ating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to com e into contact w ith the oil gallery or crankshaft journal bearings. Do not apply sealant to w ithin 2 ~ 3 m m of the crankshaft jour- nal bearings.
  • Page 199 CRANKCASE 6. Install: • low er crankcase 1 (onto the upper crankcase 2) CAUTION: ACHTUNG: Before tightening the crankcase bolts, make sure that the transmission gears shift correctly w hen the shift drum assembly is turned by hand. 7. Install: •...
  • Page 200 CONNECTING RODS AND PISTONS EB404001 CONNECTING RODS AND PISTONS Order Job/Part Q’ty Rem arks Removing the connecting rods and Rem ove the parts in the order listed. pistons Crankcase Separate. Refer to “ CRANKCASE” . Connecting rod cap Big end low er bearing Piston pin clip Piston pin Piston...
  • Page 201 CONNECTING RODS AND PISTONS EB412131 REM OVING THE CONNECTING RODS AND PISTONS The follow ing procedure applies to all of the connecting rods and pistons. 1. Rem ove: • connecting rod cap 1 • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 202 CONNECTING RODS AND PISTONS EB404403 CHECKING THE CYLINDERS AND PISTONS The follow ing procedure applies to all of the cylinders and pistons. 1. Check: • piston w all • cylinder w all scratches → Replace the Vertical crankcases, and the piston and piston rings as a set.
  • Page 203 CONNECTING RODS AND PISTONS e. Calculate the piston-to-cylinder clear- ance w ith the follow ing form ula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.030 ~ 0.055 mm <Limit>: 0.12 mm f. If out of specification, replace the crankcases, and the pistons and pis- ton rings as a set.
  • Page 204 CONNECTING RODS AND PISTONS 3. M easure: • piston ring end gap Out of specification → Replace the pis- ton ring. NOTE: The oil ring expander spacer’s end gap cannot be m easured. If the oil ring rail’s gap is excessive, replace all three piston rings.
  • Page 205 CONNECTING RODS AND PISTONS 4. Calculate: • piston-pin-to-piston-pin-bore clear- ance Out of specification → Replace the pis- ton pin. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter Piston-pin-to-piston-pin-bore clearance 0.002 ~ 0.022 mm <Limit>: 0.072 mm CHECKING THE BIG END BEARINGS 1.
  • Page 206 CONNECTING RODS AND PISTONS ® c. Put a piece of Plastigauge 1 on the crankshaft pin. d. Assem ble the connecting rod halves. NOTE: • Do not m ove the connecting rod or crankshaft until the clearance m ea- surem ent has been com pleted. •...
  • Page 207 CONNECTING RODS AND PISTONS 2. Select: • big end bearings (“ P ” ~ “ P ” ) NOTE: • The num bers stam ped into the crank- shaft w eb and the num bers on the connecting rods are used to determ ine the replacem ent big end bearing sizes.
  • Page 208 CONNECTING RODS AND PISTONS 2. Install: • piston 1 (onto the respective connecting rod 2) • piston pin 3 • piston pin clip 4 NOTE: • Apply engine oil onto the piston pin. • M ake sure that the “ Y” m ark a on the connecting rod faces left w hen the arrow m ark b on the piston is pointing up.
  • Page 209 CONNECTING RODS AND PISTONS 6. Lubricate: • crankshaft pins • big end bearings • connecting rod big end inner surface (w ith the recom m ended lubricant) Recommended lubricant Engine oil 7. Install: • big end bearings • connecting rod assem bly (into the cylinder and onto the crank- shaft pin) •...
  • Page 210 CRANKSHAFT EB412000 CRANKSHAFT Order Job/Part Q’ty Rem arks Removing the crankshaft assembly Rem ove the parts in the order listed. Crankcase Separate. Refer to “ CRANKCASE” . Connecting rod caps Refer to “ CONNECTING RODS AND PISTONS” . Crankshaft Crankshaft journal low er bearing Crankshaft journal upper bearing For installation, reverse the rem oval procedure.
  • Page 211 CRANKSHAFT EB412110 REM OVING THE CRANKSHAFT 1. Rem ove: • crankshaft 1 • crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EB412403 CHECKING THE CRANKSHAFT 1.
  • Page 212 CRANKSHAFT a. Clean the crankshaft journal bearings, crankshaft journals, and bearing por- tions of the crankcase. b. Place the upper crankcase upside dow n on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a on the crank- shaft journal upper bearings w ith the...
  • Page 213 CRANKSHAFT g. Rem ove the low er crankcase and the crankshaft journal low er bearings. h. M easure com pressed Plasti- ® w idth c on each crankshaft gauge journal. If the clearance is out of specification, select replacem ent crankshaft jour- nal bearings.
  • Page 214 CRANKSHAFT EB412720 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearings (into the upper crankcase) NOTE: • Align the projections a on the crank- shaft journal upper bearings w ith the notches b in the upper crankcase. • Be sure to install each crankshaft jour- nal upper bearing in its original place.
  • Page 215 TRANSM ISSION EB413000 TRANSM ISSION Order Job/Part Q’ty Rem arks Removing the transmission, shift Rem ove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “ CRANKCASE” . Stopper lever Refer to “ SHIFT SHAFT” . Drive axle assem bly Circlip Oil seal...
  • Page 216 TRANSM ISSION Order Job/Part Q’ty Rem arks Shift drum assem bly Shift fork “ C” M ain axle assem bly For installation, reverse the rem oval procedure. 4 - 80...
  • Page 217 TRANSM ISSION Order Job/Part Q’ty Rem arks Disassembling the main axle assem- Rem ove the parts in the order listed. 2nd pinion gear Toothed lock w asher Toothed lock w asher retainer 6th pinion gear Toothed spacer Toothed w asher Circlip 3rd/4th pinion gears 5th pinion gear...
  • Page 218 TRANSM ISSION Order Job/Part Q’ty Rem arks M ain axle/1st pinion gear Bearing M ain axle bearing housing For installation, reverse the rem oval procedure. 4 - 82...
  • Page 219 TRANSM ISSION Order Job/Part Q’ty Rem arks Disassembling the drive axle assem- Rem ove the parts in the order listed. Washer 1st w heel gear Spacer 5th w heel gear Circlip Washer 3rd w heel gear Toothed spacer Toothed lock w asher Toothed lock w asher retainer 4 - 83...
  • Page 220 TRANSM ISSION Order Job/Part Q’ty Rem arks 4th w heel gear 6th w heel gear 2nd w heel gear Spacer Drive axle Bearing Spacer For installation, reverse the rem oval procedure. 4 - 84...
  • Page 221 TRANSM ISSION EB413100 REM OVING THE TRANSM ISSION 1. Rem ove: • m ain axle assem bly 1 ® (w ith the Torx w rench T30) a. Insert tw o bolts 2 of the proper size, as show n in the illustration, into the m ain axle assem bly bearing housing.
  • Page 222 TRANSM ISSION 3. Check: • shift fork m ovem ent (along the shift fork guide bar) Rough m ovem ent → Replace the shift fork(-s) and shift fork guide bar as a set. EB413410 CHECKING THE SHIFT DRUM ASSEM BLY 1.
  • Page 223 TRANSM ISSION 4. Check: • transm ission gear engagem ent (each pinion gear to its respective w heel gear) Incorrect → Reassem ble the transm is- sion axle assem blies. 5. Check: • transm ission gear m ovem ent Rough m ovem ent → Replace the defective part(-s).
  • Page 224 4 - 88...
  • Page 225 COOL...
  • Page 226 COOL CHAPTER 5. COOLING SYSTEM RADIATOR .....................5-1 CHECKING THE RADIATOR ..............5-3 INSTALLING THE RADIATOR ..............5-4 OIL COOLER ....................5-5 CHECKING THE OIL COOLER ..............5-6 INSTALLING THE OIL COOLER ............5-6 THERMOSTAT ASSEMBLY .................5-8 CHECKING THE THERMOSTAT ............5-11 ASSEMBLING THE THERMOSTAT ASSEMBLY ......5-11 INSTALLING THE THERMOSTAT ASSEMBLY .........5-12 WATER PUMP .....................5-13 DISASSEMBLING THE WATER PUMP ..........5-15...
  • Page 227 COOL...
  • Page 228 COOL RADIATOR EB500000 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Rem arks Removing the radiator Rem ove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS” and “ FUEL TANK” in chapter 3. Air filter case and rubber cover Refer to “...
  • Page 229 COOL RADIATOR Order Job/Part Q’ty Rem arks Therm o sw itch Tem perature sender Therm ostat assem bly breather hose Disconnect. Radiator inlet hose Oil cooler outlet hose Disconnect. Water pum p breather hose Radiator outlet hose Water pum p inlet pipe Radiator fan m otor coupler Disconnect.
  • Page 230 COOL RADIATOR EB500010 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply com pressed air to the rear of the radiator. Dam age → Repair or replace. NOTE: Straighten any flattened fins w ith a thin, flat-head screw driver. 2.
  • Page 231 COOL RADIATOR EB500020 INSTALLING THE RADIATOR 1. Fill: • cooling system (w ith the specified am ount of the rec- om m ended coolant) Refer to “ CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part.

  • Page 232: Oil Cooler

    COOL OIL COOLER EB501000 OIL COOLER Order Job/Part Q’ty Rem arks Removing the oil cooler Rem ove the parts in the order listed. Radiator assem bly Refer to “ RADIATOR” . Exhaust pipe assem bly Refer to “ ENGINE” in chapter 4. Engine oil Drain.
  • Page 233 COOL OIL COOLER EB501010 CHECKING THE OIL COOLER 1. Check: • oil cooler Cracks/dam age → Replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose Cracks/dam age/w ear → Replace. 3. Check: • w ater jacket joint •...
  • Page 234 COOL OIL COOLER 4. Fill: • cooling system (w ith the specified am ount of the rec- om m ended coolant) Refer to “ CHANGING THE COOLANT” in chapter 3. • crankcase (w ith the specified am ount of the rec- om m ended engine oil) Refer to “...
  • Page 235 COOL THERM OSTAT ASSEM BLY EB502000 THERM OSTAT ASSEM BLY Order Job/Part Q’ty Rem arks Removing the thermostat assembly Rem ove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS” and “ FUEL TANK” in chapter 3.
  • Page 236 COOL THERM OSTAT ASSEM BLY Order Job/Part Q’ty Rem arks Therm ostat assem bly Therm ostat assem bly inlet pipe (left) Therm ostat assem bly inlet pipe (right) For installation, reverse the rem oval procedure. 5 - 9...
  • Page 237 COOL THERM OSTAT ASSEM BLY EB502010 Order Job/Part Q’ty Rem arks Disassembling the thermostat Rem ove the parts in the order listed. assembly Therm ostat housing cover Therm ostat Therm ostat housing For assem bly, reverse the disassem bly procedure. 5 - 10...
  • Page 238 COOL THERM OSTAT ASSEM BLY EB502020 CHECKING THE THERM OSTAT 1. Check: • therm ostat 1 Does not open at 71 ~ 85 ˚C → Replace. a. Suspend the therm ostat in a con- tainer filled w ith w ater. b.
  • Page 239 COOL THERM OSTAT ASSEM BLY EB502040 INSTALLING THE THERM OSTAT ASSEM BLY 1. Fill: • cooling system (w ith the specified am ount of the rec- om m ended coolant) Refer to “ CHANGING THE COOLANT” in chapter 3. 2. Check: •...
  • Page 240 COOL WATER PUM P EB503000 WATER PUM P Order Job/Part Q’ty Rem arks Removing the impeller shaft Rem ove the parts in the order listed. NOTE: • The w ater pum p and oil pum p are com bined into one unit (oil/w ater pum p assem bly).
  • Page 241 COOL WATER PUM P Order Job/Part Q’ty Rem arks Water pum p seal Oil seal Bearing For installation, reverse the rem oval procedure. 5 - 14...
  • Page 242 COOL WATER PUM P EB503020 DISASSEM BLING THE WATER PUM P 1. Rem ove: • w ater pum p seal 1 NOTE: Tap out the w ater pum p seal from the inside of the w ater pum p housing. 2 Water pum p housing 2.
  • Page 243 3. M echanical seal installer 4 90890-04078 M iddle driven shaft bearing driver 5 90890-04058 Yamaha bond No. 1215 90890-85505 Å Push dow n. 3. Install: • rubber dam per 1 • rubber dam per holder 2...
  • Page 244 COOL WATER PUM P 4. M easure: • im peller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: ACHTUNG: M ake sure that the rubber damper and rubber damper holder are flush w ith the impeller. M ax.
  • Page 245 COOL 5 - 18...
  • Page 246 CARB...
  • Page 247 CARB CHAPTER 6. CARBURETORS CARBURETORS ....................6-1 CHECKING THE CARBURETORS ............6-6 ASSEMBLING THE CARBURETORS ...........6-8 INSTALLING THE CARBURETORS ............6-10 MEASURING AND ADJUSTING THE FUEL LEVEL ......6-11 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ..................6-12 CHECKING THE FUEL PUMP .............6-15...
  • Page 248 CARB...
  • Page 249 CARB CARBURETORS EB600001 CARBURETORS CARBURETORS Order Job/Part Q’ty Rem arks Removing the carburetors Rem ove the parts in the order listed. Rider seat and fuel tank Refer to “ SEATS” and “ FUEL TANK” in chapter 3. Air filter case and rubber baffle Refer to “...
  • Page 250 CARB CARBURETORS EB600010 Order Job/Part Q’ty Rem arks Separating the carburetors Rem ove the parts in the order listed. Starter plunger link Connecting bolt R = 245 m m Copper w asher Connecting bolt R = 270 m m Spacer R = 43 m m Spacer R = 38 m m...
  • Page 251 CARB CARBURETORS Order Job/Part Q’ty Rem arks Fuel feed pipe R = 37 m m Fuel feed pipe R = 32 m m Fuel feed pipe R = 29 m m Pipe R = 73 m m Pipe R = 68 m m Pipe R = 66 m m Throttle stop screw...
  • Page 252 CARB CARBURETORS EB600021 Order Job/Part Q’ty Rem arks Disassembling the carburetor Rem ove the parts in the order listed. NOTE: The follow ing procedure applies to all of the carburetors. Starter plunger Air funnel Air funnel joint Pilot air jet Vacuum cham ber cover Piston valve spring Jet needle holder...
  • Page 253 CARB CARBURETORS Order Job/Part Q’ty Rem arks Float cham ber Float pivot pin Float Needle valve Needle valve seat M ain jet M ain jet holder Pilot jet For assem bly, reverse the disassem bly procedure. 6 - 5...
  • Page 254 CARB CARBURETORS EB600031 CHECKING THE CARBURETORS The follow ing procedure applies to all of the carburetors. 1. Check: • carburetor body • float cham ber Cracks/dam age → Replace. 2. Check: • fuel passages Obstruction → Clean. a. Wash the carburetor in a petroleum - based solvent.
  • Page 255 CARB CARBURETORS 8. Check: • piston valve 1 Dam age/scratches/w ear → Replace. • piston valve diaphragm 2 Cracks/tears → Replace. 9. Check: • vacuum cham ber cover 1 • piston valve spring 2 • jet needle holder 3 • jet needle spring 4 Cracks/dam age →...
  • Page 256 CARB CARBURETORS 13.Check: • fuel hoses Cracks/dam age/w ear → Replace. Obstruction → Clean. Blow out the hoses w ith com pressed air. EB600043 ASSEM BLING THE CARBURETORS The follow ing procedure applies to all of the carburetors. CAUTION: ACHTUNG: •...
  • Page 257 CARB CARBURETORS 3. Install: • pipes • fuel feed pipes • vacuum cham ber pipe • vacuum cham ber air vent hose • springs • float cham ber air vent hoses • hose joints • spacers • copper w asher •...
  • Page 258 CARB CARBURETORS EB600051 INSTALLING THE CARBURETORS 1. Adjust: • carburetor synchronization Refer to “ SYNCHRONIZING THE CAR- BURETORS” in chapter 3. 2. Adjust: • engine idling speed Engine idling speed 1,050 ~ 1,150 r/ min Refer to “ ADJUSTING THE ENGINE IDLING SPEED”...
  • Page 259 CARB CARBURETORS EB600063 M EASURING AND ADJUSTING THE FUEL LEVEL 1. M easure: • fuel level a Out of specification → Adjust. Fuel level (below the line on the float chamber) 4.1 ~ 5.1 mm a. Stand the m otorcycle on a level sur- face.
  • Page 260 CARB CARBURETORS EB600072 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor (installed on the carburetor) a. Disconnect the throttle position sen- sor coupler.
  • Page 261 CARB CARBURETORS 2. Check: • throttle position sensor (rem oved from the carburetor) a. Disconnect the throttle position sen- sor coupler. b. Rem ove the throttle position sensor from the carburetor. c. Connect the pocket tester (Ω × 1k) to the throttle position sensor.
  • Page 262 CARB CARBURETORS 3. Adjust: • throttle position sensor angle a. Set the m ain sw itch to “ ON” . b. Disconnect the throttle position sen- sor coupler. c. Reconnect the throttle position sen- sor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachom eter sw itches to the throttle position sensor adjust- m ent m ode.
  • Page 263 CARB CARBURETORS EB600090 CHECKING THE FUEL PUM P 1. Check: • fuel pum p 1 a. Rem ove the fuel tank. Refer to “ FUEL TANK” in chapter 3. b. Disconnect the fuel-pum p-to-carbure- tor fuel hose 2 from the carburetor. c.
  • Page 264 CARB 6 - 16...
  • Page 265 CHAS...
  • Page 266 CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS ............7-1 REMOVING THE FRONT WHEEL ............7-3 DISASSEMBLING THE FRONT WHEEL ..........7-3 CHECKING THE FRONT WHEEL ............7-4 CHECKING THE BRAKE DISCS ............7-5 ASSEMBLING THE FRONT WHEEL ............7-6 INSTALLING THE FRONT WHEEL ............7-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......7-7 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET ....7-10 REMOVING THE REAR WHEEL ............7-13...
  • Page 267 CHAS HANDLEBARS .....................7-56 REMOVING THE HANDLEBARS ............7-58 CHECKING THE HANDLEBARS ............7-58 INSTALLING THE HANDLEBARS ............7-59 STEERING HEAD ..................7-61 REMOVING THE LOWER BRACKET ..........7-63 CHECKING THE STEERING HEAD .............7-63 INSTALLING THE STEERING HEAD ..........7-64 REAR SHOCK ABSORBER ASSEMBLY .............7-66 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER ..............7-67 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER ..............7-67...
  • Page 268 CHAS FRONT WHEEL AND BRAKE DISCS EB700002 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Rem arks Removing the front w heel and brake Rem ove the parts in the order listed. discs NOTE: Place the m otorcycle on a suitable stand so that the front w heel is ele- vated.
  • Page 269 CHAS FRONT WHEEL AND BRAKE DISCS EB700010 Order Job/Part Q’ty Rem arks Disassembling the front w heel Rem ove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assem bly, reverse the disassem bly procedure.
  • Page 270 CHAS FRONT WHEEL AND BRAKE DISCS EB700102 REM OVING THE FRONT WHEEL 1. Stand the m otorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the m otorcycle on a suitable stand so that the front w heel is elevated.
  • Page 271 CHAS FRONT WHEEL AND BRAKE DISCS EB700400 CHECKING THE FRONT WHEEL 1. Check: • w heel axle Roll the w heel axle on a flat surface. Bends → Replace. WARNING WARNING Do not attempt to straighten a bent w heel axle. 2.
  • Page 272 CHAS FRONT WHEEL AND BRAKE DISCS c. Rem ove the w heel bearings 3 w ith a general bearing puller. d. Install the new w heel bearings and oil seals in the reverse order of disas- sem bly. CAUTION: ACHTUNG: Do not contact the w heel bearing center race 4 or balls 5.
  • Page 273 CHAS FRONT WHEEL AND BRAKE DISCS 3. M easure: • brake disc thickness M easure the brake disc thickness at a few different locations. Out of specification → Replace. M in. brake disc thickness Front: 4.5 mm Rear: 4.5 mm 4.
  • Page 274 CHAS FRONT WHEEL AND BRAKE DISCS EB700725 INSTALLING THE FRONT WHEEL 1. Lubricate: • w heel axle • oil seal lips Recommended lubricant Lithium soap base grease 2. Install: • brake discs 18 Nm (1.8 m · kg) NOTE: ® •...
  • Page 275 CHAS FRONT WHEEL AND BRAKE DISCS 1. Rem ove: • balancing w eight(-s) 2. Find: • front w heel’s heavy spot a. Place the front w heel on a suitable balancing stand. b. Spin the front w heel. c. When the front w heel stops, put an “...
  • Page 276 CHAS FRONT WHEEL AND BRAKE DISCS 4. Check: • front w heel static balance a. Turn the front w heel and m ake sure that it stays at each position show n. b. If the front w heel does not rem ain stationary at all of the positions, rebalance it.
  • Page 277 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701000 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET Order Job/Part Q’ty Rem arks Removing the rear w heel Rem ove the parts in the order listed. NOTE: Place the m otorcycle on a suitable stand so that the rear w heel is ele- vated.
  • Page 278 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701010 Order Job/Part Q’ty Rem arks Removing the brake disc and rear Rem ove the parts in the order listed. w heel sprocket Brake disc Rear w heel sprocket Oil seal cover (left and right) Spacer (left and right) Oil seal Bearing...
  • Page 279 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET Order Job/Part Q’ty Rem arks Disassembling the rear w heel Rem ove the parts in the order listed. Spacer Bearing Spacer Oil seal Circlip Bearing For assem bly, reverse the disassem bly procedure.
  • Page 280 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701100 REM OVING THE REAR WHEEL 1. Stand the m otorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the m otorcycle on a suitable stand so that the rear w heel is elevated.
  • Page 281 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 3. M easure: • radial w heel runout • lateral w heel runout Refer to “ FRONT WHEEL” . Over the specified lim its → Replace. M ax. radial w heel runout 1.0 mm M ax.
  • Page 282 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701710 INSTALLING THE REAR WHEEL 1. Lubricate: • w heel axle • w heel bearings • oil seal lips Recommended lubricant Lithium soap base grease 2. Adjust: • drive chain slack a Drive chain slack 40 ~ 50 mm Refer to “...
  • Page 283 CHAS FRONT AND REAR BRAKES EB702001 FRONT AND REAR BRAKES Order Job/Part Q’ty Rem arks Removing the front brake pads Rem ove the parts in the order listed. The follow ing procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...
  • Page 284 CHAS FRONT AND REAR BRAKES EB702002 Order Job/Part Q’ty Rem arks Removing the rear brake pads Rem ove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw For installation, reverse the rem oval procedure.
  • Page 285 CHAS FRONT AND REAR BRAKES EB702100 CAUTION: ACHTUNG: Disc brake components rarely require disassembly. Therefore, alw ays follow these preven- tive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disas- sembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 286 CHAS FRONT AND REAR BRAKES 2. Rem ove: • brake pad clips 1 • brake pad pin 2 • brake pad spring 3 • brake pads (along w ith the brake pad shim s) 3. M easure: • brake pad w ear lim it a Out of specification →...
  • Page 287 CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pin • brake pad clips • brake caliper 40 Nm (4.0 m · kg) 6. Check: • brake fluid level Below the m inim um level m ark a → Add the recom m ended brake fluid to the proper level.
  • Page 288 CHAS FRONT AND REAR BRAKES 3. M easure: • brake pad w ear lim it a Out of specification → Replace the brake pads as a set. Brake pad w ear limit 0.5 mm 4. Install: • brake pad shim s (onto the brake pads) •...
  • Page 289 CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pins • brake pad clips • brake pad cover • brake caliper 40 Nm (4.0 m · kg) 6. Check: • brake fluid level Below the m inim um level m ark a → Add the recom m ended brake fluid to the proper level.
  • Page 290 CHAS FRONT AND REAR BRAKES EB702200 Order Job/Part Q’ty Rem arks Removing the front brake master Rem ove the parts in the order listed. cylinder and brake fluid reservoir Brake fluid Drain. Brake fluid reservoir cap stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 291 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Rem arks Brake hose Brake m aster cylinder holder Brake m aster cylinder Front brake sw itch For installation, reverse the rem oval procedure. 7 - 24...
  • Page 292 CHAS FRONT AND REAR BRAKES EB702201 Order Job/Part Q’ty Rem arks Disassembling the front brake mas- Rem ove the parts in the order listed. ter cylinder Dust boot Circlip Brake m aster cylinder kit Brake m aster cylinder For assem bly, reverse the disassem bly procedure.
  • Page 293 CHAS FRONT AND REAR BRAKES EB702202 Order Job/Part Q’ty Rem arks Removing the rear brake master cyl- Rem ove the parts in the order listed. inder and brake fluid reservoir Brake fluid Drain. Brake fluid reservoir cap stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 294 CHAS FRONT AND REAR BRAKES EB702203 Order Job/Part Q’ty Rem arks Disassembling the rear brake mas- Rem ove the parts in the order listed. ter cylinder Brake m aster cylinder kit Brake m aster cylinder For assem bly, reverse the disassem bly procedure.
  • Page 295 CHAS FRONT AND REAR BRAKES EB702210 DISASSEM BLING THE FRONT BRAKE M ASTER CYLINDER NOTE: Before disassem bling the front brake m aster cylinder, drain the brake fluid from the entire brake system . 1. Rem ove: • union bolt 1 •...
  • Page 296 CHAS FRONT AND REAR BRAKES 2. Check: Å • brake m aster cylinder kit Dam age/scratches/w ear → Replace. Å Front ı Rear ı 3. Check: Å ı • brake fluid reservoir 1 Cracks/dam age → Replace. • brake fluid reservoir diaphragm 2 Cracks/dam age →...
  • Page 297 CHAS FRONT AND REAR BRAKES 1. Install: • brake m aster cylinder 1 13 Nm (1.3 m · kg) NOTE: • Install the brake m aster cylinder holder w ith the “ UP” m ark facing up. • Align the end of the brake m aster cyl- inder holder w ith the punch m ark a in the right handlebar.
  • Page 298 CHAS FRONT AND REAR BRAKES CAUTION: ACHTUNG: Brake fluid may damage painted sur- faces and plastic parts. Therefore, alw ays clean up any spilt brake fluid immediately. 4. Bleed: • brake system Refer to “ BLEEDING THE HYDRAULIC BRAKE SYSTEM ” in chapter 3. 5.
  • Page 299 CHAS FRONT AND REAR BRAKES 2. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance. •...
  • Page 300 CHAS FRONT AND REAR BRAKES EB702301 Order Job/Part Q’ty Rem arks Removing the front brake calipers Rem ove the parts in the order listed. The follow ing procedure applies to both of the front brake calipers. Brake fluid Drain. Union bolt Copper w asher Brake hose Brake caliper...
  • Page 301 CHAS FRONT AND REAR BRAKES EB702303 Order Job/Part Q’ty Rem arks Disassembling the front brake cali- Rem ove the parts in the order listed. pers The follow ing procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad...
  • Page 302 CHAS FRONT AND REAR BRAKES EB702304 Order Job/Part Q’ty Rem arks Removing the rear brake caliper Rem ove the parts in the order listed. Brake fluid Drain. Union bolt Copper w asher Brake hose Brake caliper For installation, reverse the rem oval procedure.
  • Page 303 CHAS FRONT AND REAR BRAKES EB702305 Order Job/Part Q’ty Rem arks Disassembling the rear brake caliper Rem ove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assem bly, reverse the disassem bly procedure.
  • Page 304 CHAS FRONT AND REAR BRAKES EB702317 DISASSEM BLING THE FRONT BRAKE CALIPERS The follow ing procedure applies to both of the brake calipers. NOTE: Before disassem bling either brake cali- per, drain the brake fluid from the entire brake system . 1.
  • Page 305 CHAS FRONT AND REAR BRAKES EB702322 DISASSEM BLING THE REAR BRAKE CALIPER NOTE: Before disassem bling the brake caliper, drain the brake fluid from the entire brake system . 1. Rem ove: • union bolt 1 • copper w ashers 2 •...
  • Page 306 CHAS FRONT AND REAR BRAKES EB702343 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every tw o years Brake hoses Every tw o years Every tw o years and w henever the Brake fluid brake is disassem- bled...
  • Page 307 CHAS FRONT AND REAR BRAKES EB702376 ASSEM BLING AND INSTALLING THE FRONT BRAKE CALIPERS The follow ing procedure applies to both of the brake calipers. WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated w ith clean or new brake fluid.
  • Page 308 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (w ith the specified am ount of the rec- om m ended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance.
  • Page 309 CHAS FRONT AND REAR BRAKES EB702378 ASSEM BLING AND INSTALLING THE REAR BRAKE CALIPER WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated w ith clean or new brake fluid. • Never use solvents on internal brake components as they w ill cause the pis- ton seals to sw ell and distort.
  • Page 310 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (w ith the specified am ount of the rec- om m ended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance.

  • Page 311: Front Fork

    CHAS FRONT FORK EB703001 FRONT FORK Order Job/Part Q’ty Rem arks Removing the front fork legs Rem ove the parts in the order listed. The follow ing procedure applies to both of the front fork legs. Front w heel Refer to “ FRONT WHEEL AND BRAKE DISCS”...
  • Page 312 CHAS FRONT FORK EB703002 Order Job/Part Q’ty Rem arks Disassembling the front fork legs Rem ove the parts in the order listed. The follow ing procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Spring seat Fork spring Dam per adjusting rod Outer tube...
  • Page 313 CHAS FRONT FORK Order Job/Part Q’ty Rem arks Dam per rod assem bly bolt Copper w asher Dam per rod assem bly Inner tube For assem bly, reverse the disassem bly procedure. 7 - 46...
  • Page 314 CHAS FRONT FORK EB703100 REM OVING THE FRONT FORK LEGS The follow ing procedure applies to both of the front fork legs. 1. Stand the m otorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the m otorcycle on a suitable stand so that the front w heel is elevated.
  • Page 315 CHAS FRONT FORK NOTE: Use the side of the rod holder that is m arked “ B” . c. Loosen the nut. d. Rem ove the cap bolt. e. Rem ove the rod holder and fork spring com pressor WARNING WARNING The fork spring is compressed.
  • Page 316 CHAS FRONT FORK EB703401 CHECKING THE FRONT FORK LEGS The follow ing procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/dam age/scratches → Replace. WARNING WARNING Do not attempt to straighten a bent inner tube as this may dangerously w eaken it.
  • Page 317 2 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 01 or equivalent 7 - 50...
  • Page 318 CHAS FRONT FORK 3. Tighten: • dam per rod assem bly bolt 1 40 Nm (4.0 m · kg) NOTE: While holding the dam per rod w ith the dam per rod holder 2, tighten the dam per rod assem bly bolt. Damper rod holder 90890-01423 4.
  • Page 319 (w ith the specified am ount of the rec- om m ended fork oil) Quantity (each front fork leg) 477 cm Recommended oil Yamaha fork and shock oil 01 or equivalent CAUTION: ACHTUNG: • Be sure to use the recommended fork oil.
  • Page 320 CHAS FRONT FORK 13.Slow ly stroke the outer tube 1 up and dow n to distribute the fork oil once m ore (1 stroke = about 100 m m ). NOTE: Be careful not to stroke the inner tube over 100 m m as this w ill cause air to enter.
  • Page 321 CHAS FRONT FORK c. Install the rod puller and adapter onto the dam per rod. Rod puller 90890-01437 Adapter 90890-01436 d. Install the fork spring, spring seat, and spacer. NOTE: Install the spring w ith the sm aller pitch a facing up Å . e.
  • Page 322 CHAS FRONT FORK 17.Install: • outer tube (onto the inner tube) NOTE: Tem porarily tighten the cap bolt. EB703710 INSTALLING THE FRONT FORK LEGS The follow ing procedure applies to both of the front fork legs. 1. Install: • front fork leg Tem porarily tighten the upper and low er bracket pinch bolts.
  • Page 323 CHAS HANDLEBARS EB704001 HANDLEBARS Order Job/Part Q’ty Rem arks Removing the handlebars Rem ove the parts in the order listed. Left grip end Handlebar grip Clutch sw itch connector Disconnect. Left handlebar sw itch Starter cable Disconnect. Starter lever Clutch cable Disconnect.
  • Page 324 CHAS HANDLEBARS Order Job/Part Q’ty Rem arks Front brake sw itch connector Disconnect. Right handlebar sw itch Brake m aster cylinder holder Brake m aster cylinder Handlebar pinch bolt Upper bracket bolt Upper bracket pinch bolt Steering stem nut Upper bracket Left handlebar Right handlebar For installation, reverse the rem oval...
  • Page 325 CHAS HANDLEBARS EB704101 REM OVING THE HANDLEBARS 1. Stand the m otorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Rem ove: • handlebar grip NOTE: Blow com pressed air betw een the left handlebar and the handlebar grip, and gradually push the grip off the handle- bar.
  • Page 326 CHAS HANDLEBARS EB704704 INSTALLING THE HANDLEBARS 1. Install: • right handlebar sw itch 1 NOTE: Align the projection a on the right han- dlebar sw itch w ith the hole b in the right handlebar. 2. Install: • brake m aster cylinder holder 1 CAUTION: ACHTUNG: •...
  • Page 327 CHAS HANDLEBARS 5. Install: • left handlebar sw itch 1 NOTE: Align the projection a on the left han- dlebar sw itch w ith the hole b in the left handlebar. 6. Install: • handlebar grip a. Apply a thin coat of rubber adhesive onto the end of the left handlebar.

  • Page 328: Steering Head

    CHAS STEERING HEAD EB705001 STEERING HEAD Order Job/Part Q’ty Rem arks Removing the low er bracket Rem ove the parts in the order listed. Front w heel Refer to “ FRONT WHEEL AND BRAKE DISCS” . Front fork legs Refer to “ FRONT FORK” . M ain sw itch coupler Disconnect.
  • Page 329 CHAS STEERING HEAD Order Job/Part Q’ty Rem arks Low er ring nut Low er bracket Bearing cover Bearing inner race Upper bearing Low er bearing Dust seal Bearing outer race For installation, reverse the rem oval procedure. 7 - 62...
  • Page 330 CHAS STEERING HEAD EB705100 REM OVING THE LOWER BRACKET 1. Stand the m otorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Rem ove: • low er ring nut 1 (w ith the special tool 2) Ring nut w rench 90890-01403...
  • Page 331 CHAS STEERING HEAD b. Rem ove the bearing race from the low er bracket w ith a floor chisel 2 and ham m er. c. Install a new dust seal and new bear- ing races. CAUTION: ACHTUNG: If the bearing race is not installed prop- erly, the steering head pipe could be damaged.
  • Page 332 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Tem porarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “ FRONT FORK” . NOTE: Tem porarily tighten the upper and low er bracket pinch bolts, and handlebar pinch bolts.
  • Page 333 CHAS REAR SHOCK ABSORBER ASSEM BLY EB706000 REAR SHOCK ABSORBER ASSEM BLY Order Job/Part Q’ty Rem arks Removing the rear shock absorber Rem ove the parts in the order listed. assembly Self-locking nut/bolt Bolt R= 54 m m Self-locking nut/bolt Bolt R = 80 m m Self-locking nut/bolt/spacer 1/1/1 Bolt R = 65 m m...
  • Page 334 CHAS REAR SHOCK ABSORBER ASSEM BLY EB706101 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING WARNING This rear shock absorber and gas cylin- der contain highly compressed nitro- gen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the follow ing information.
  • Page 335 CHAS REAR SHOCK ABSORBER ASSEM BLY EB706204 REM OVING THE REAR SHOCK ABSORBER ASSEM BLY 1. Stand the m otorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the m otorcycle on a suitable stand so that the rear w heel is elevated.
  • Page 336 CHAS REAR SHOCK ABSORBER ASSEM BLY CHECKING THE RELAY ARM AND CONNECTING ARM 1. Check: • relay arm 1 • connecting arm 2 Dam age/w ear → Replace. • bearings • oil seals Dam age/pitting → Replace. • spacers Dam age/scratches → Replace. EB706701 INSTALLING THE REAR SHOCK ABSORBER ASSEM BLY...

  • Page 337: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EB707000 SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Rem arks Removing the sw ingarm and drive Rem ove the parts in the order listed. chain Drive sprocket Refer to “ ENGINE” in chapter 4. Rear w heel Refer to “...
  • Page 338 CHAS SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Rem arks Drive chain Dust cover Drive chain guide Spacer Left bearing Right bearing For installation, reverse the rem oval procedure. 7 - 71...
  • Page 339 CHAS SWINGARM AND DRIVE CHAIN EB707100 NOTE: Before rem oving the drive sprocket, drive chain, and rear w heel, m easure the drive chain slack and the length of a ten- link section of the drive chain. EB707111 REM OVING THE SWINGARM 1.
  • Page 340 CHAS SWINGARM AND DRIVE CHAIN EB707120 REM OVING THE DRIVE CHAIN 1. Rem ove: • drive chain (w ith the drive chain cutter) Drive chain cutter 90890-01286 NOTE: Only cut the drive chain if it or the sw in- garm is to be replaced. EB707400 CHECKING THE SWINGARM 1.
  • Page 341 CHAS SWINGARM AND DRIVE CHAIN 4. Check: • dust covers • spacer • oil seals Dam age/w ear → Replace. • bearings Dam age/pitting → Replace. EB707410 CHECKING THE DRIVE CHAIN 1. M easure: • ten-link section a of the drive chain Out of specification →...
  • Page 342 CHAS SWINGARM AND DRIVE CHAIN c. Rem ove the drive chain from the ker- osine and com pletely dry it. CAUTION: ACHTUNG: This motorcycle has a drive chain w ith small rubber O-rings 1 betw een the drive chain side plates. Never use high- pressure w ater or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.
  • Page 343 CHAS SWINGARM AND DRIVE CHAIN EB707700 INSTALLING THE SWINGARM 1. Lubricate: • bearings • spacers • dust covers • pivot shaft Recommended lubricant Lithium soap base grease 2. Install: • sw ingarm • pivot shaft • w asher • pivot shaft nut 125 Nm (12.5 m ·...
  • Page 344 – ELEC...
  • Page 345 – ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS ...............8-1 INSTRUMENT FUNCTIONS .................8-2 INDICATOR LIGHTS ................8-2 OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT ....8-2 COMBINATION METER ................8-3 SWITCHES ....................8-5 CHECKING SWITCH CONTINUITY ............8-5 CHECKING THE SWITCHES .................8-6 CHECKING THE BULBS AND BULB SOCKETS ..........8-8 TYPES OF BULBS .................8-8 CHECKING THE CONDITION OF THE BULBS ........8-8 CHECKING THE CONDITION OF THE BULB SOCKETS ....8-10...
  • Page 346 – ELEC SIGNALING SYSTEM .................8-35 CIRCUIT DIAGRAM ................8-35 TROUBLESHOOTING .................8-37 CHECKING THE SIGNALING SYSTEM ..........8-38 COOLING SYSTEM ..................8-44 CIRCUIT DIAGRAM ................8-44 TROUBLESHOOTING .................8-45 FUEL PUMP SYSTEM .................8-48 CIRCUIT DIAGRAM ................8-48 FUEL PUMP CIRCUIT OPERATION ...........8-49 TROUBLESHOOTING .................8-50 CHECKING THE FUEL PUMP .............8-52 EXUP SYSTEM ...................8-53 CIRCUIT DIAGRAM ................8-53 TROUBLESHOOTING .................8-54...
  • Page 347 ELEC – ELECTRICAL COM PONENTS EB800000 ELECTRICAL ELECTRICAL COM PONENTS A Starter relay K Oil level sw itch 1 Wire harness B M ain fuse L Pickup coil 2 M ain sw itch C Oil level relay M Radiator fan 3 Front brake light sw itch D Battery N Horn...
  • Page 348 ELEC – INSTRUM ENT FUNCTIONS INSTRUM ENT FUNCTIONS INDICATOR LIGHTS Turn indicator light “ ” This indicator flashes w hen the turn sw itch is m oved to the left or right. Neutral indicator light “ ” This indicator com es on w hen the trans- m ission is in neutral.
  • Page 349 ELEC – INSTRUM ENT FUNCTIONS Coolant Display Conditions What to do temperature Sym bol is on and 0 ˚C ~ 40 ˚C Go ahead w ith riding. “ LO” is displayed. Sym bol is on and 41 ˚C ~ 117 ˚C tem perature is dis- Go ahead w ith riding.
  • Page 350 ELEC – INSTRUM ENT FUNCTIONS When the fuel level indicator light com es on the odom eter display w ill autom atically change to the fuel reserve trip m eter m ode “ TRIP F” and start counting the distance traveled from that...
  • Page 351 ELEC – SWITCHES EB801000 SWITCHES CHECKING SWITCH CONTINUITY Check each sw itch for continuity w ith the pocket tester. If the continuity reading is incorrect, check the w iring connections and if necessary, replace the sw itch. CAUTION: ACHTUNG: Never insert the tester probes into the coupler terminal slots 1.

  • Page 352: Checking The Switches

    ELEC – CHECKING THE SWITCHES EB801010 CHECKING THE SWITCHES Check each sw itch for dam age or w ear, proper connections, and also for continuity betw een the term inals. Refer to “ CHECKING SWITCH CONTINUITY” . Dam age/w ear → Repair or replace the sw itch. Im properly connected →...
  • Page 353 ELEC – CHECKING THE SWITCHES 1 M ain sw itch 9 Start sw itch 2 Pass sw itch 0 Front brake light sw itch 3 Dim m er sw itch A Fuse 4 Turn signal sw itch B Sidestand sw itch 5 Horn sw itch C Rear brake light sw itch 6 Clutch sw itch...
  • Page 354 ELEC – CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for dam - age or w ear, proper connections, and also for continuity betw een the term inals. Dam age/w ear → Repair or replace the bulb, bulb socket or both.
  • Page 355 ELEC – CHECKING THE BULBS AND BULB SOCKETS WARNING WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands aw ay from the bulb until it has cooled dow n. CAUTION: ACHTUNG: • Be sure to hold the socket firmly w hen removing the bulb.
  • Page 356 ELEC – CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The follow ing procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (w ith the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE:...

  • Page 357: Ignition System

    ELEC – IGNITION SYSTEM EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 11...
  • Page 358 ELEC – IGNITION SYSTEM EB802011 EB802401 TROUBLESHOOTING 2.Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “ CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: M in. open-circuit voltage 1.
  • Page 359 ELEC – IGNITION SYSTEM EB802405 Spark plug cap resistance 4.Ignition spark gap 10 kΩ at 20 ˚C The follow ing procedure applies to all of • Is the spark plug cap OK? the spark plugs. • Disconnect the spark plug cap from the spark plug.
  • Page 360 ELEC – IGNITION SYSTEM EB802411 8.M ain sw itch • Check the m ain sw itch for continuity. Refer to “ CHECKING THE SWITCHES” . • Is the m ain sw itch OK? Replace the m ain sw itch. Secondary coil resistance 12 ~ 18 kΩ...
  • Page 361 ELEC – IGNITION SYSTEM EB802415 EB802416 12.Relay unit 13.Wiring • Rem ove the relay unit from the w ire har- • Check the entire ignition system ’s w ir- ness. ing. • Connect the pocket tester (Ω × 1) to the Refer to “...
  • Page 362 ELEC – ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 16...
  • Page 363 ELEC – ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop sw itch is set to “ ” and the m ain sw itch is set to “ ON” (both sw itches are closed), the starter m otor can only operate if at least one of the follow ing conditions is m et: •...

  • Page 364: Electric Starting System

    ELEC – ELECTRIC STARTING SYSTEM EB803020 EB802401 TROUBLESHOOTING 2.Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “ CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. m ain and ignition fuses Open-circuit voltage 2.
  • Page 365 ELEC – ELECTRIC STARTING SYSTEM EB803402 EB803403 4.Starting circuit cutoff relay 5.Relay unit • Disconnect the relay unit from the cou- • Disconnect the relay unit from the cou- pler. pler. • Connect the pocket tester (Ω × 1) and •...
  • Page 366 ELEC – ELECTRIC STARTING SYSTEM EB803404 EB802412 6.Starter relay 8.Engine stop sw itch • Disconnect the starter relay from the • Check the engine stop sw itch for conti- coupler. nuity. • Connect the pocket tester (Ω × 1) and Refer to “...
  • Page 367 ELEC – ELECTRIC STARTING SYSTEM EB803406 12.Start sw itch • Check the start sw itch for continuity. Refer to “ CHECKING THE SWITCHES” . • Is the start sw itch OK? Replace right handlebar sw itch. EB803408 13.Wiring • Check the entire starting system ’s w ir- ing.
  • Page 368 ELEC – STARTER M OTOR EB803500 STARTER M OTOR Order Job/Part Q’ty Rem arks Removing the starter motor Rem ove the parts in the order listed. Rider seat Refer to “ SEATS” in chapter 3. Fuel tank Refer to “ FUEL TANK” in chapter 3. Left side cow ling Refer to “...
  • Page 369 ELEC – STARTER M OTOR EB803501 Order Job/Part Q’ty Rem arks Disassembling the starter motor Rem ove the parts in the order listed. Starter m otor front cover Lock w asher Oil seal Bearing Washer set Starter m otor rear cover Washer set Arm ature assem bly Brush seat (along w ith the brushes)
  • Page 370 ELEC – STARTER M OTOR EB803511 CHECKING THE STARTER M OTOR 1. Check: • com m utator Dirt → Clean w ith 600 grit sandpaper. 2. M easure: • com m utator diam eter a Out of specification → Replace the starter m otor.
  • Page 371 ELEC – STARTER M OTOR 5. M easure: • brush length a Out of specification → Replace the brushes as a set. M in. brush length 5 mm 6. M easure: • brush spring force Out of specification → Replace the brush springs as a set.
  • Page 372 ELEC – CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM R/ G R/ G L/ W R/ W R/ W L/ W L/ Y L/ B B L/ Y L L/ R L/ R L Br/ L Br/ L L/ R Br/ L L/ Y Br/ L...
  • Page 373 ELEC – CHARGING SYSTEM EB804010 EB802401 TROUBLESHOOTING 2.Battery The battery is not being charged. • Check the condition of the battery. Refer to “ CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. m ain fuse Open-circuit voltage 2. battery 12.8 V or more at 20 ˚C 3.
  • Page 374 ELEC – CHARGING SYSTEM EB804404 5.Wiring NOTE: M ake sure that the battery is fully • Check the w iring connections of the charged. entire charging system . Refer to “ CIRCUIT DIAGRAM ” . • Is the charging voltage w ithin specifica- tion? •...
  • Page 375 ELEC – LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 29...
  • Page 376 ELEC – LIGHTING SYSTEM EB805010 EB802401 TROUBLESHOOTING 2.Battery Any of the follow ing fail to light: head- • Check the condition of the battery. light, high beam indicator light, taillight, Refer to “ CHECKING AND CHARGING THE BATTERY” in chapter 3. auxiliary light or meter light.
  • Page 377 ELEC – LIGHTING SYSTEM EB805401 EB805410 CHECKING THE LIGHTING SYSTEM 5.Dim m er sw itch 1. The headlight and the high beam indi- • Check the dim m er sw itch for continuity. cator light fail to com e on. Refer to “...
  • Page 378 ELEC – LIGHTING SYSTEM Headlight Tester positive probe → black/ yellow 1 or black/ blue 2 Tester negative probe → black 3 High beam indicator light Tester positive probe → yellow 4 Tester negative probe → black 5 M eter assem bly coupler (w ire harness side) •...
  • Page 379 ELEC – LIGHTING SYSTEM • Set the m ain sw itch to “ ON” . • Set the m ain sw itch to “ ON” . • Set the light sw itch to “ ” or “ ” . • Set the light sw itch to “ ”...
  • Page 380 ELEC – LIGHTING SYSTEM • Set the m ain sw itch to “ ON” . • Set the light sw itch to “ ” or “ ” . • M easure the voltage (12 V) of blue/red 1 on the auxiliary light couplers (w ire har- ness side).
  • Page 381 ELEC – SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 35...
  • Page 382 ELEC – SIGNALING SYSTEM 1 M ain sw itch 5 Battery 6 M ain fuse D Fuel sender K Neutral sw itch O Fuel level indicator light P Oil level/coolant tem perature w arning light Q Neutral indicator light R Tachom eter S Com bination m eter V Turn signal indicator light [ Horn sw itch...
  • Page 383 ELEC – SIGNALING SYSTEM EB806010 EB802401 TROUBLESHOOTING 2.Battery • Any of the follow ing fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “ CHECKING THE BATTERY” in light. chapter 3.
  • Page 384 ELEC – SIGNALING SYSTEM EB806410 3.Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the black connector at the horn term inal. 1.Horn sw itch • Connect a jum per lead 1 to the horn ter- m inal and ground the jum per lead.
  • Page 385 ELEC – SIGNALING SYSTEM EB806411 • Set the m ain sw itch to “ ON” . 2. A tail/brake light fails to com e on. • Pull in the brake lever or push dow n on 1.Tail/brake light bulb and socket the brake pedal.
  • Page 386 ELEC – SIGNALING SYSTEM Tester positive probe → brow n/ w hite 1 3.Turn signal sw itch Tester negative probe → ground • Check the turn signal sw itch for continu- ity. Refer to “ CHECKING THE SWITCHES” . • Is the turn signal sw itch OK? Replace the left han- dlebar sw itch.
  • Page 387 ELEC – SIGNALING SYSTEM • Set the m ain sw itch to “ ON” . 3.Voltage • Set the turn signal sw itch to “ ” or • Connect the pocket tester (DC 20V) to “ ” . the m eter assem bly coupler (w ire har- •...
  • Page 388 ELEC – SIGNALING SYSTEM 2.Oil level sw itch 4.Voltage • Connect the pocket tester (DC 20V) to • Drain the engine oil and rem ove the oil level sw itch from the oil pan. the m eter assem bly coupler (w ire har- •...
  • Page 389 ELEC – SIGNALING SYSTEM 2.Fuel sender • Set the m ain sw itch to “ ON” . • M easure the voltage (12V). • Disconnect the fuel sender coupler from • Is the voltage w ithin specification? the w ire harness. •...
  • Page 390 ELEC – COOLING SYSTEM EB807000 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 44...
  • Page 391 ELEC – COOLING SYSTEM EB807010 • Is the battery OK? TROUBLESHOOTING • The radiator fan motor fails to turn. • The coolant temperature meter needle fails to move w hen the engine is w arm. • Clean the battery term inals. Check: •...
  • Page 392 ELEC – COOLING SYSTEM EB807400 Coolant temperature Test 5.Radiator fan m otor (test 2) Continuity step Thermo sw itch • Disconnect the therm o sw itch coupler. 0 ~ 98 ˚C • Set the m ain sw itch to “ ON” . •...
  • Page 393 ELEC – COOLING SYSTEM • Does the therm o sw itch operate prop- erly as described above? Replace the therm o sw itch. 7.Tem perature sender WARNING WARNING • Rem ove the tem perature sender from Handle the temperature sender w ith spe- the radiator.
  • Page 394 ELEC – FUEL PUM P SYSTEM EB808000 FUEL PUM P SYSTEM CIRCUIT DIAGRAM 8 - 48...
  • Page 395 ELEC – FUEL PUM P SYSTEM EB808010 FUEL PUM P CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pum p. 1 Battery 2 M ain fuse 3 M ain sw itch 4 Ignition fuse 5 Engine stop sw itch 6 Ignitor unit 7 Fuel pum p relay 8 Fuel pum p...
  • Page 396 ELEC – FUEL PUM P SYSTEM EB808020 EB802401 TROUBLESHOOTING 2.Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to “ CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. m ain and ignition fuses Open-circuit voltage 2.
  • Page 397 ELEC – FUEL PUM P SYSTEM • M easure the fuel pum p resistance. 5.Fuel pum p relay Fuel pump resistance • Disconnect the relay unit from the cou- 4 ~ 30 Ω at 20 ˚C pler. • Connect the pocket tester (Ω × 1) and •...
  • Page 398 ELEC – FUEL PUM P SYSTEM EB808410 CHECKING THE FUEL PUM P WARNING WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the follow - ing points: •...

  • Page 399: Exup System

    ELEC – EXUP SYSTEM EB811000 EXUP SYSTEM CIRCUIT DIAGRAM 8 - 53...
  • Page 400 ELEC – EXUP SYSTEM EB811010 TROUBLESHOOTING When the engine speed changes, the EXUP servomotor does not operate. Procedure 1 Check: 1. Exup servom otor operation (w ith the EXUP servom otor coupler connected to the w ire harness) 2. voltage •...
  • Page 401 ELEC – EXUP SYSTEM EB811402 3.EXUP servom otor operation (w ith the servom otor coupler disconnected from the w ire harness) • Disconnect the EXUP cables from the EXUP servom otor pulley. • Disconnect the EXUP servom otor cou- pler from the w ire harness. •...
  • Page 402 ELEC – EXUP SYSTEM EB811404 EB802411 5.Wiring 3.M ain sw itch • Check the entire EXUP system ’s w iring. • Check the m ain sw itch for continuity. Refer to “ CIRCUIT DIAGRAM ” . Refer to “ CHECKING THE SWITCHES” . •...
  • Page 403 ELEC – SELF-DIAGNOSIS EB812000 SELF-DIAGNOSIS The YZF-R1 features a self-diagnosing system for the follow ing circuit(-s): • throttle position sensor • EXUP • fuel level indicator light If any of these circuits are defective, their respective condition codes w ill be displayed on the tachom eter w hen the m ain sw itch is set to “...
  • Page 404 ELEC – SELF-DIAGNOSIS EB812010 1.Wire harness TROUBLESHOOTING • Check the w ire harness for continuity. The tachometer starts to display the self- Refer to “ CIRCUIT DIAGRAM ” . diagnosis sequence. • Is the w ire harness OK? Check: 1. throttle position sensor 2.
  • Page 405 ELEC – SELF-DIAGNOSIS EB812030 EB812402 2. EXUP 2.EXUP servom otor CIRCUIT DIAGRAM • Check the EXUP servom otor for continu- ity. R/ B R/ B Refer to “ EXUP SYSTEM ” . B/ L B/ R Y/ B R/ W •...

  • Page 406: Fuel Sender

    ELEC – SELF-DIAGNOSIS EB812040 EB812403 3. Fuel level indicator light 1.Fuel level indicator light LED CIRCUIT DIAGRAM • Check the LED of the fuel level indicator light. Refer to “ CHECKING THE LEDs” . • Is the fuel level indicator light LED OK? R/ Y Br G/W R/ G...
  • Page 407 ELEC – SELF-DIAGNOSIS EB812405 3.Wire harness • Check the w ire harness for continuity. Refer to “ CIRCUIT DIAGRAM ” . • Is the w ire harness OK? Replace the ignitor Replace or replace unit. the w ire harness. 8 - 61...
  • Page 408 ELEC – 8 - 62...
  • Page 409 TRBL SHTG...
  • Page 410 TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING PROBLEMS ................9-1 ENGINE ....................9-1 FUEL SYSTEM ..................9-1 ELECTRICAL SYSTEMS ...............9-1 INCORRECT ENGINE IDLING SPEED ............9-2 ENGINE ....................9-2 FUEL SYSTEM ..................9-2 ELECTRICAL SYSTEMS ...............9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........9-2 ENGINE ....................9-2 FUEL SYSTEM ..................9-2 FAULTY GEAR SHIFTING ................9-2 SHIFTING IS DIFFICULT ...............9-2 SHIFT PEDAL DOES NOT MOVE ............9-2 JUMPS OUT OF GEAR .................9-2...
  • Page 411 TRBL SHTG UNSTABLE HANDLING ................9-4 FAULTY LIGHTING AND SIGNALING SYSTEMS ........9-5 HEADLIGHT DOES NOT LIGHT ............9-5 HEADLIGHT BULB BURNT OUT ............9-5 TAIL/BRAKE LIGHT DOES NOT LIGHT ..........9-5 TAIL/BRAKE LIGHT BULB BURNT OUT ..........9-5 TURN SIGNAL DOES NOT LIGHT ............9-5 TURN SIGNAL BLINKS SLOWLY ............9-5 TURN SIGNAL REMAINS LIT ..............9-5 TURN SIGNAL BLINKS QUICKLY ............9-5 HORN DOES NOT SOUND ..............9-5...

  • Page 412: Troubleshooting

    TRBL STARTING PROBLEM S SHTG EB900000 TROUBLESHOOTING NOTE: The follow ing guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, how ever, as a guide to basic troubleshooting. Refer to the relative proce- dure in this m anual for checks, adjustm ents, and replacem ent of parts.

  • Page 413: Faulty Gear Shifting

    TRBL INCORRECT ENGINE IDLING SPEED/ POOR MEDIUM-AND- HIGH-SPEED PERFORMANCE/ FAULTY GEAR SHIFTING SHTG EB901000 INCORRECT ENGINE IDLING SPEED ENGINE ELECTRICAL SYSTEM S Cylinders and cylinder head Battery • Incorrect valve clearance • Faulty battery • Dam aged valve train com ponents •...
  • Page 414 TRBL FAULTY CLUTCH/ OVERHEATING/ OVERCOOLING SHTG EB904000 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch • Incorrectly assem bled clutch • Unevenly tensioned clutch spring plate • Incorrectly adjusted clutch cable • Warped pressure plate • Loose or fatigued clutch spring •...

  • Page 415: Unstable Handling

    TRBL POOR BRAKING PERFORM ANCE/ FAULTY FRONT FORK LEGS/ UNSTABLE HANDLING SHTG EB907000 POOR BRAKING PERFORM ANCE • Worn brake pad • Loose union bolt • Worn brake disc • Dam aged brake hose • Air in hydraulic brake system •...
  • Page 416 TRBL FAULTY LIGHTING AND SIGNALING SYSTEM S SHTG EB910000 FAULTY LIGHTING AND SIGNALING SYSTEM S TURN SIGNAL BLINKS SLOWLY HEADLIGHT DOES NOT LIGHT • Faulty turn signal relay • Wrong headlight bulb • Faulty m ain sw itch • Too m any electrical accessories •...
  • Page 417 TRBL SHTG 9 - 6...
  • Page 418 YZF-R1 WIRING DIAGRAM 1 M ain sw itch 2 Backup fuse (odom eter) 3 Rectifier/regulator 4 Generator R/ B R/ B R/ Y Br G/W R/ G G/ R G/ R R/ G R/ Y R/ G R/ G 5 Battery R/ Y L/ Y G/ Y...

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