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Table of Contents
2009

SERVICE MANUAL

XP500Y
LIT-11616-22-08
4B5-28197-10

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Table of Contents

   Summary of Contents for Yamaha 2009 XP500Y TMAX

  • Page 1: Service Manual

    2009 SERVICE MANUAL XP500Y LIT-11616-22-08 4B5-28197-10...
  • Page 2 EAS20050 XP500Y SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, March 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-22-08...
  • Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4 EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
  • Page 5 EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.
  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF FI SYSTEM ................. 1-2 FI SYSTEM....................1-3 MULTI-FUNCTION DISPLAY..............1-4 IMPORTANT INFORMATION ................. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-7 REPLACEMENT PARTS................1-7 GASKETS, OIL SEALS AND O-RINGS ............ 1-7 LOCK WASHERS/PLATES AND COTTER PINS ........
  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.
  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS4B51038 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.
  • Page 12: Fi System

    FEATURES EAS4B51039 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 240–260 kPa (2.40–2.60 kg/cm², 34.1– 37.0 psi) higher than the intake manifold pressure.
  • Page 13: Multi-function Display

    FEATURES • an odometer (which shows the total distance EAS4B51037 MULTI-FUNCTION DISPLAY traveled) EWA4B54001 • two tripmeters (which show the distance trav- WARNING eled since they were last set to zero) Be sure to stop the vehicle before making • a fuel reserve tripmeter (which shows the dis- any setting changes to the multi-function tance traveled when the remaining fuel in the display.
  • Page 14 FEATURES Odometer and tripmeter modes 1. Fuel reserve tripmeter 1. Odometer/tripmeters To reset a tripmeter, select it by pushing the “SE- LECT” button until “F Trip”, “Trip-A” or “Trip-B” is displayed. While “F Trip”, “Trip-A” or “Trip-B” is displayed, push the “RESET” button for at least one second.
  • Page 15 FEATURES “OIL” must be reset after the oil change for the Self-diagnosis device next periodic oil change to be indicated at the correct time. The electrical circuit of the indicator can be checked according to the following procedure. 1. Set the engine stop switch to “ ”...
  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
  • Page 18: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •...
  • Page 19: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-12, 6-6 90890-01469 YM-01469 66.8 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter B 3-13 90890-03124 Pressure gauge 3-13, 7-4 90890-03153 YU-03153 Steering nut wrench...
  • Page 21 Fork seal driver weight 4-54, 4-55 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 4-54 90890-01374 Replacement 43 mm YM-A5142-3 Yamaha bond No. 1215 5-14, 5-44, 90890-85505 5-52, 5-69, (Three Bond No.1215®) 6-12 Valve spring compressor 5-19, 5-24 90890-04019 YM-04019...
  • Page 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø4) 5-21 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-21 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Piston pin puller set 5-27 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave spring compressor 5-41, 5-44 90890-04134 YM-04134 Sheave fixed block 5-41, 5-44 90890-04135 Sheave fixed bracket YM-04135 Oil seal guide (ø41) 5-43 90890-01396 Sheave holder 5-50, 5-51, 90890-01701 5-52 Primary clutch holder YS-01880-A Flywheel puller 5-50...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Clutch spring compressor 5-57, 5-60 90890-01482 Universal clutch holder 5-57, 5-60 90890-04086 YM-91042 Plane bearing installer 5-73, 5-76 90890-04139 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984...
  • Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Mechanical seal installer 6-12 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Bearing driver 40 mm YM-04058 Fuel pressure adapter 90890-03181 Ignition checker 8-72 90890-06754 Opama pet-4000 spark checker YM-34487 1-16...
  • Page 26 SPECIAL TOOLS 1-17...
  • Page 27: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-10 ELECTRICAL SPECIFICATIONS ..............2-13 TIGHTENING TORQUES ................2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-16 ENGINE TIGHTENING TORQUES............2-17 CHASSIS TIGHTENING TORQUES............2-21 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE....................2-24 CHASSIS....................2-26 LUBRICATION SYSTEM DIAGRAMS ............
  • Page 28: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 4B54 (USA) Dimensions Overall length 2195 mm (86.4 in) Overall width 775 mm (30.5 in) Overall height 1445 mm (56.9 in) Seat height 800 mm (31.5 in) Wheelbase 1580 mm (62.2 in) Ground clearance 125 mm (4.92 in) Minimum turning radius 2800 mm (110.2 in)
  • Page 29: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 499.0 cm³ Cylinder arrangement Forward-inclined parallel 2-cylinder Bore × stroke 66.0 × 73.0 mm (2.60 × 2.87 in) Compression ratio 11.00 :1 Standard compression pressure (at sea level) 1400 kPa/360 r/min (199.1 psi/360 r/min) (14.0 kgf/cm²/360 r/min) Minimum–maximum...
  • Page 30 ENGINE SPECIFICATIONS Pressure check location MAIN GALLERY Cooling system Radiator capacity (including all routes) 1.48 L (1.56 US qt) (1.30 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 107.9–137.3 kPa (15.6–19.9 psi) (1.08–1.37 kgf/cm²) Thermostat...
  • Page 31 ENGINE SPECIFICATIONS Limit 24.856 mm (0.9786 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links SCR-0409 SV/132 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.20 mm (0.0059–0.0079 in) Exhaust 0.25–0.30 mm (0.0098–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
  • Page 32 ENGINE SPECIFICATIONS Valve margin thickness D (exhaust) 0.60–0.80 mm (0.0236–0.0315 in) Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in) Limit 3.945 mm (0.1553 in) Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in) Limit 3.930 mm (0.1547 in) Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.050 mm (0.1594 in)
  • Page 33 ENGINE SPECIFICATIONS Winding direction (exhaust) Clockwise Valve lifter Valve lifter outside diameter (intake) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Valve lifter outside diameter (exhaust) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Cylinder Bore 66.000–66.010 mm (2.5984–2.5988 in) Wear limit 66.100 mm (2.6024 in) Taper limit...
  • Page 34 ENGINE SPECIFICATIONS Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.40–0.50 mm (0.0157–0.0197 in) Limit 0.75 mm (0.0295 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.100 mm (0.0039 in) Oil ring Dimensions (B ×...
  • Page 35 ENGINE SPECIFICATIONS Plate quantity 4 pcs Warpage limit 0.10 mm (0.0039 in) Clutch plate 2 thickness 1.80–2.00 mm (0.071–0.079 in) Plate quantity 2 pcs Warpage limit 0.20 mm (0.0079 in) Clutch spring free length 25.80 mm (1.02 in) Minimum length 20.40 mm (0.80 in) Spring quantity 6 pcs...
  • Page 36 ENGINE SPECIFICATIONS Intake air pressure sensor output voltage 3.15–4.15 V Intake air temperature sensor resistance 2.21–2.69 kΩ at 20 °C (68 °F) Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F) 310–326 Ω at 80 °C (176 °F) Idling condition Engine idling speed 1100–1300 r/min...
  • Page 37: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00° Trail 92.0 mm (3.62 in) Front wheel Wheel type Cast wheel 15M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 38 Inner tube outer diameter 43.0 mm (1.69 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) Level 87.0 mm (3.43 in) Rear suspension...
  • Page 39 CHASSIS SPECIFICATIONS Installed length 180.0 mm (7.09 in) Spring rate K1 225.60 N/mm (1288.18 lb/in) (23.00 kgf/mm) Spring rate K2 294.00 N/mm (1678.74 lb/in) (29.98 kgf/mm) Spring stroke K1 0.0–28.8 mm (0.00–1.13 in) Spring stroke K2 28.8–43.0 mm (1.13–1.69 in) Optional spring available Enclosed gas/air pressure (STD) 4900 kPa (696.9 psi) (49.0 kgf/cm²)
  • Page 40: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Digital Ignition timing (B.T.D.C.) 10.0°/1200 r/min Engine control unit Model/manufacturer TBDF81/DENSO Ignition coil Model/manufacturer JO313/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) 1.87–2.53 Ω...
  • Page 41 ELECTRICAL SPECIFICATIONS Meter lighting Indicator light LED × 2 Turn signal indicator light High beam indicator light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM-18/MITSUBA Power output 0.70 kW 0.0100–0.0200 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 12.0 mm (0.47 in)
  • Page 42 ELECTRICAL SPECIFICATIONS Fuel injection system relay Model/manufacturer 5JJ/MATSUSHITA Fuses Main fuse 30.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 15.0 A Ignition fuse 10.0 A Radiator fan fuse 15.0 A Fuel injection system fuse 10.0 A Backup fuse 10.0 A Spare fuse...
  • Page 43: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
  • Page 44: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft cap 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil check bolt 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe stud bolt 15 Nm (1.5 m·kg, 11 ft·lb) Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) Cylinder head nut...
  • Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Muffler nut 31 Nm (3.1 m·kg, 22 ft·lb) Muffler end protector bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Exhaust pipe protector bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler end protector cover bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler protector (side) bolt 8 Nm (0.8 m·kg, 5.8 ft·lb)
  • Page 46 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size BEL-RAY Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) assem- bly lube® Crankshaft right end bearing re- 11 Nm (1.1 m·kg, 8.0 ft·lb) tainer screw Secondary shaft bearing retainer 12 Nm (1.2 m·kg, 8.7 ft·lb) bolt Stator coil bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 47 TIGHTENING TORQUES Cylinder head tightening sequence: 2-20...
  • Page 48: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front upper 88 Nm (8.8 m·kg, 64 ft·lb) side) Engine mounting bolt (front right 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting bolt (front left 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting nut (rear side)
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Pivot shaft 7 Nm (0.7 m·kg, 5.1 ft·lb) Pivot shaft nut 100 Nm (10.0 m·kg, 72 ft·lb) Swingarm bolt 40 Nm (4.0 m·kg, 29 ft·lb) Swingarm damper nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear shock absorber assembly 53 Nm (5.3 m·kg, 38 ft·lb) rear nut...
  • Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) Rear wheel drive hub bolt 69 Nm (6.9 m·kg, 50 ft·lb) Front brake hose joint bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front brake hose holder bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake hose holder bolt...
  • Page 51: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nut seats and washers Camshaft cap bolt seats Big end bearings and crank pins Connecting rod big end contact surfaces (to crank) Balancer big end bearings and crank pin Balancer connecting rod big end contact surface (to crank) Pistons, ring grooves, and piston rings...
  • Page 52 BEL-RAY assembly Secondary sheave nut seats lube® Outer V-belt case crankshaft right end point Pivot shaft taper roller bearing Yamaha bond Cylinder head cover inner gaskets mating surface No.1215 (Three bond No.1215®) Yamaha bond Timing chain guide (upper side) mating surface No.1215 (Three bond...
  • Page 53: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings (upper and lower) Upper bearing cover seal lip and lower bearing dust seal lip Steering bearing races (inner and outer) Tube guide (throttle grip) inner surface and throttle cables Rear brake lock cable end (lever end) Brake lever pivoting point and metal-to-metal moving parts Drive axle spline...
  • Page 54: Lubrication System Diagrams

    LUBRICATION SYSTEM DIAGRAMS EAS4B51021 LUBRICATION SYSTEM DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
  • Page 55 LUBRICATION SYSTEM DIAGRAMS 1. Oil delivery pipe 2. Oil pump 3. Oil cooler 4. Oil filter cartridge 5. Oil pipe 6. Oil strainer 2-28...
  • Page 56 LUBRICATION SYSTEM DIAGRAMS 2-29...
  • Page 57 LUBRICATION SYSTEM DIAGRAMS 1. Secondary shaft 2. Drive axle 3. Clutch 4. Crankshaft 2-30...
  • Page 58: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-31...
  • Page 59 COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator filler hose 3. Radiator inlet hose 4. Coolant reservoir 5. Coolant pipe 6. Thermostat outlet hose 7. Oil cooler outlet hose 8. Thermostat 9. Oil cooler 10. Coolant hose 11. Water pump inlet pipe 12.
  • Page 60 COOLING SYSTEM DIAGRAMS 2-33...
  • Page 61 COOLING SYSTEM DIAGRAMS 1. Thermostat outlet hose 2. Cooling system air bleed hose 3. Radiator cap 4. Radiator filler pipe 5. Radiator filler hose 6. Coolant reservoir hose 7. Radiator 8. Radiator inlet hose 9. Coolant reservoir 10. Coolant reservoir breather hose 11.
  • Page 62: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING A B C 2-35...
  • Page 63 CABLE ROUTING 1. Rear brake hose 2. Left handlebar switch lead 3. Right handlebar switch lead 4. Front brake hose 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Rear brake lock cable 8. Front brake light switch connectors A.
  • Page 64 CABLE ROUTING 2-37...
  • Page 65 CABLE ROUTING 1. Front brake pipe 2. Wire harness (to horn) 3. Front brake hose (to left front brake caliper) 4. Front brake hose (to right front brake caliper) 5. Horn 6. Speed sensor lead 7. Speed sensor A. Fasten the wire harness (to horn) and front brake pipe with plastic locking ties, making sure to –...
  • Page 66 CABLE ROUTING 26 27 2-39...
  • Page 67 CABLE ROUTING 1. Left handlebar switch lead P. Route the starter motor lead and generator lead to the outside of the wire harness. 2. Right handlebar switch lead Q. To meter assembly 3. Rectifier/regulator R. Route the wire harness (to starter relay) behind 4.
  • Page 68 CABLE ROUTING 22 23 2-41...
  • Page 69 CABLE ROUTING 1. Positive battery lead L. Fasten the main switch lead with the holder, making sure that the plastic locking tie is 2. Fuse box positioned to the inside of the holder. Face the 3. Negative battery lead catch of the holder forward. 4.
  • Page 70 CABLE ROUTING 2-43...
  • Page 71 CABLE ROUTING 1. Intake air temperature sensor coupler P. Pass the wire harness (to storage box light switch) between the rear frame and the tail/brake light 2. Cylinder head breather hose assembly. 3. Fast idle plunger intake hose Q. Pass the plastic band through the holes in the 4.
  • Page 72 CABLE ROUTING 2-45...
  • Page 73 CABLE ROUTING 1. Rear brake hose 2. Rear brake pipe 3. Rear brake lock cable 4. Ribs (bottom of storage box) A. Install the rear brake hose holder to the front cowling stay, making sure to fit the projection on the holder into the hole in the stay.
  • Page 74 CABLE ROUTING H I J 2-47...
  • Page 75 CABLE ROUTING 1. Fast idle plunger intake hose 2. Cylinder head breather hose 3. Intake air pressure sensor hose 4. Fuel hose 5. Fast idle plunger inlet coolant hose 6. Fast idle plunger outlet coolant hose 7. Fuel injector #2 8.
  • Page 76 CABLE ROUTING 2-49...
  • Page 77 CABLE ROUTING 1. Rollover valve U. Route the canister purge hose (3-way joint to canister) over the frame cross member. 2. Fuel tank breather hose (fuel tank to rollover valve) 3. Fuel tank breather hose (rollover valve to canister) 4. Canister purge hose (throttle body #2 to 3-way joint) 5.
  • Page 78 CABLE ROUTING 2-51...
  • Page 79: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODY ..........3-7 ADJUSTING THE ENGINE IDLING SPEED ..........3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY ........3-9 CHECKING THE SPARK PLUGS .............
  • Page 80 ELECTRICAL SYSTEM................. 3-30 CHECKING AND CHARGING THE BATTERY........3-30 CHECKING THE FUSES ................3-30 REPLACING THE HEADLIGHT BULBS ..........3-30 ADJUSTING THE HEADLIGHT BEAMS..........3-30...
  • Page 82: Periodic Maintenance

    • Check control system for √ sion control sys- damage. • Replace if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32185 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS...
  • Page 83 • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi...
  • Page 84 PERIODIC MAINTENANCE EAU38260 • The air filter and V-belt filter need more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.
  • Page 85: Engine

    ENGINE 6. Measure: EAS20471 ENGINE • Valve clearance Out of specification → Adjust. EAS20490 ADJUSTING THE VALVE CLEARANCE Valve clearance (cold) The following procedure applies to all of the Intake valves. 0.15–0.20 mm (0.0059–0.0079 in) Exhaust • Valve clearance adjustment should be made 0.25–0.30 mm (0.0098–0.0118 in) on a cold engine, at room temperature.
  • Page 86 ENGINE 0˚ 360˚ 720˚ A. Degrees that the crankshaft is turned c. Measure the valve clearance with a thickness clockwise gauge “1”. B. Cylinder C. Combustion cycle Cylinder #2 360° L LLL L LLL L LLL L LLL L LLL 7.
  • Page 87 ENGINE Last digit Rounded value 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available valve pads. Valve pad range Nos. 120–240 1.20–2.40 mm b. Calculate the difference between the speci- Valve pad thickness (0.0472–0.0945 in) fied valve clearance and the measured valve clearance.
  • Page 88: Synchronizing The Throttle Body

    ENGINE • Turn the crankshaft clockwise several full turns Vacuum gauge to seat the parts. 90890-03094 h. Measure the valve clearance again. Carburetor synchronizer i. If the valve clearance is still out of specifica- YU-44456 Digital tachometer tion, repeat all of the valve clearance adjust- 90890-06760 ment steps until the specified clearance is YU-39951-B...
  • Page 89: Adjusting The Engine Idling Speed

    ENGINE 3. Install: ECA14900 NOTICE • Digital tachometer Do not use the throttle valve adjusting (onto the spark plug lead of cylinder #1) screws to adjust the throttle body syncroni- Digital tachometer zation. 90890-06760 YU-39951-B Carburetor angle driver 90890-03158 4. Check: •...
  • Page 90: Adjusting The Throttle Cable Free Play

    ENGINE EAS20630 EAS20680 ADJUSTING THE THROTTLE CABLE FREE CHECKING THE SPARK PLUGS PLAY The following procedure applies to all of the spark plugs. 1. Remove: Prior to adjusting the throttle cable free play, the • Bottom cowling engine idling speed and throttle body synchroni- Refer to “GENERAL CHASSIS”...
  • Page 91: Measuring The Compression Pressure

    ENGINE Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • Spark plug 10.Remove: • Bottom cowling 7. Measure: Refer to “GENERAL CHASSIS” on page 4-1. • Compression pressure Out of specification →...
  • Page 92: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into Type the cylinder) YAMALUBE 4 (10W-40) or SAE Reading Diagnosis 10W-40, YAMALUBE 4 (20W-50) or SAE 20W-50 Higher than without Piston ring(s) wear or Recommended engine oil grade damage → Repair. API service SG type or higher, Piston, valves, cylin- JASO standard MA der head gasket or...
  • Page 93: Changing The Engine Oil

    ENGINE b. Lubricate the O-ring “3” of the new oil filter EAS20780 CHANGING THE ENGINE OIL cartridge with a thin coat of engine oil. 1. Start the engine, warm it up for several min- ECA13390 utes, and then turn it off. NOTICE 2.
  • Page 94: Measuring The Engine Oil Pressure

    ENGINE 10.Start the engine, warm it up for several min- 2. Start the engine, warm it up for several min- utes, and then turn it off. utes, and then turn it off. 11.Check: ECA13410 NOTICE • Engine When the engine is cold, the engine oil will (for engine oil leaks) have a higher viscosity, causing the engine 12.Check:...
  • Page 95: Replacing The Air Filter Element

    ENGINE Oil pressure (hot) 150.0 kPa/1200 r/min (21.8 psi/1200 r/min) (1.50 kgf/cm²/1200 r/min) Oil temperature 70.0 °C (158.00 °F) Out of specification → Adjust. Engine oil pressure Possible causes 4. Install: • Faulty oil pump • Clogged oil filter • Air filter case cover Below specification •...
  • Page 96: Cleaning The V-belt Case Air Filter Element

    ENGINE EAS20980 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: • Footrest boards Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • V-belt case air filter element (left) “1” 3. Remove: • V-belt case air filter case cover “1” •...
  • Page 97: Checking The Fuel Line

    ENGINE 2. Check: 2. Check: • Throttle body joints “1” • Cylinder head breather hose “1” Cracks/damage → Replace the intake mani- Cracks/damage → Replace. Loose connection → Connect properly. folds. ECA14920 NOTICE Make sure the cylinder head breather hose is routed correctly.
  • Page 98: Checking The Canister

    ENGINE Below the minimum level mark → Add the 4. Install: • Bottom cowling recommended coolant to the proper level. Refer to “GENERAL CHASSIS” on page 4-1. EAS21090 CHECKING THE CANISTER 1. Remove: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. •...
  • Page 99: Changing The Coolant

    ENGINE 3. Install: • Footrest boards • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. EAS21130 CHANGING THE COOLANT 1. Remove: • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: • Coolant reservoir hose “1” 3. Drain: •...
  • Page 100 ENGINE be blown out, which could cause serious in- Recommended antifreeze jury. When the engine has cooled, open the High-quality ethylene glycol an- radiator cap as follows: tifreeze containing corrosion in- Place a thick rag or a towel over the radiator hibitors for aluminum engines cap and slowly turn the radiator cap counter- Mixing ratio...
  • Page 101 ENGINE 12.Install: • Coolant reservoir cap 13.Start the engine, warm it up for several min- utes, and then stop it. 14.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-17. Before checking the coolant level, wait a few minutes until the coolant has settled.
  • Page 102: Chassis

    CHASSIS EAS21140 M MMM M MMM M MMM M MMM M MMM CHASSIS a. While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in EAS21160 the desired position. ADJUSTING THE FRONT DISC BRAKE 1.
  • Page 103: Checking The Front Brake Pads

    CHASSIS 1. Operate the brake. 2. Check: • Front brake pad Wear indicator groove “a” has almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-18. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads.
  • Page 104: Checking The Rear Brake Hose

    CHASSIS 2. Check: Rear brake lock cable length • Brake hose holders 45–47 mm (1.77–1.85 in) Loose → Tighten the holder bolt. 3. Hold the vehicle upright and apply the brake 2. Adjust: several times. • Rear brake lock cable length “a” 4.
  • Page 105: Checking The Chain Drive Oil Level

    CHASSIS caution could allow air to enter the hydraulic i. Repeat steps (e) to (h) until all of the air bub- brake system, considerably lengthening the bles have disappeared from the brake fluid in bleeding procedure. the plastic hose. • If bleeding is difficult, it may be necessary to let j.
  • Page 106: Changing The Chain Drive Oil

    CHASSIS 3. Check: • Chain drive oil level Wipe the dipstick clean, insert it into the oil fill- er hole (without screw it in), and then remove it to check the oil level. The chain drive oil level should be between the minimum level mark “a”...
  • Page 107 CHASSIS 2. Check: EWA13140 WARNING • Steering head Do not overtighten the lower ring nut. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering Lower ring nut (final tightening torque) head.
  • Page 108: Checking The Front Fork

    CHASSIS 2. Check: • Inner tube Damage/scratches → Replace. • Oil seal Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds d.
  • Page 109 No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. 1. Tire tread depth Front tire 2. Side wall Size 3.
  • Page 110: Checking The Wheels

    CHASSIS 1. Check: EWA13210 WARNING • Outer cable Damage → Replace. New tires have a relatively low grip on the road surface until they have been slightly 2. Check: worn. Therefore, approximately 100 km • Cable operation Rough movement → Lubricate. should be traveled at normal speed before any high-speed riding is done.
  • Page 111 ELECTRICAL SYSTEM 6. Install: EAS21750 ELECTRICAL SYSTEM • Headlight bulb Secure the new headlight bulb with the head- EAS21760 CHECKING AND CHARGING THE BATTERY light bulb holder. Refer to “ELECTRICAL COMPONENTS” on ECA13690 NOTICE page 8-57. Avoid touching the glass part of the head- EAS21770 light bulb to keep it free from oil, otherwise CHECKING THE FUSES...
  • Page 112 ELECTRICAL SYSTEM Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. L LLL L LLL L LLL L LLL L LLL...
  • Page 113 CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE FUEL HOSE ..............4-7 INSTALLING THE FUEL HOSE ..............4-7 FRONT WHEEL....................4-8 REMOVING THE FRONT WHEEL............4-11 DISASSEMBLING THE FRONT WHEEL..........4-11 CHECKING THE FRONT WHEEL ............4-11 ASSEMBLING THE FRONT WHEEL............4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-12 INSTALLING THE FRONT WHEEL (DISC) ..........4-13 REAR WHEEL ....................4-15 REMOVING THE REAR WHEEL (DISC) ..........
  • Page 114 HANDLEBAR ....................4-44 REMOVING THE HANDLEBAR..............4-46 CHECKING THE HANDLEBAR ..............4-46 INSTALLING THE HANDLEBAR ............4-46 FRONT FORK....................4-49 REMOVING THE FRONT FORK LEGS..........4-52 DISASSEMBLING THE FRONT FORK LEGS ........4-52 CHECKING THE FRONT FORK LEGS ..........4-53 ASSEMBLING THE FRONT FORK LEGS ..........4-53 INSTALLING THE FRONT FORK LEGS ..........
  • Page 116 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the battery and windshield 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rear view mirror...
  • Page 117 GENERAL CHASSIS Removing the bottom cowling 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Footrest board mat Footrest board cover Side panel Left side cowling Bottom panel Right side cowling Wire harness (to ignition coil) Unhook.
  • Page 118 GENERAL CHASSIS Removing the footrest boards 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Front lower outer panel Front lower inner panel Center panel Fuel tank overflow hose Unhook. Rear brake pipe Unhook. Left footrest board Fuel tank breather hose Unhook.
  • Page 119 GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Windshield bracket lower cover Meter ring Meter assembly cover Meter assembly coupler Disconnect. Meter assembly Storage compartment Headlight sub-wire harness coupler Disconnect.
  • Page 120 GENERAL CHASSIS Removing the rear cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 121: General Chassis

    GENERAL CHASSIS Removing the storage box 10 Nm (1.0 m kg, 7.2 ft 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 122: Removing The Fuel Hose

    GENERAL CHASSIS EAS4B51010 ECA4B51021 REMOVING THE FUEL HOSE NOTICE 1. Remove: When installing the fuel hose, make sure that • Fuel hose connector cover “1” it is securely connected, and that the fuel 2. Disconnect: hose connector cover is in the correct posi- •...
  • Page 123: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •...
  • Page 124 FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •...
  • Page 125 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Collar For assembly, reverse the disassembly pro- cedure. 4-10...
  • Page 126: Removing The Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake calipers Do not apply the brake lever when removing the L LLL L LLL L LLL...
  • Page 127: Assembling The Front Wheel

    FRONT WHEEL 4. Check: L LLL L LLL L LLL L LLL L LLL • Wheel bearings EAS21970 Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings. BALANCE • Oil seal Damage/wear →...
  • Page 128: Installing The Front Wheel (disc)

    FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
  • Page 129 FRONT WHEEL Be sure to fit the two projections on the speed sensor in between the projections on the wheel hub. 5. Install: • Front wheel Make sure the slot “a” in the speed sensor fits over the stopper “b” on the outer tube. 6.
  • Page 130: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel and brake disc 40 Nm (4.0 m kg, 29 ft • • 17 Nm (1.7 m kg, 12 ft • • 105 Nm (10.5 m kg, 75 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 131 REAR WHEEL Disassembling the rear wheel 69 Nm (6.9 m • kg, 50 ft • Ib) Order Job/Parts to remove Q’ty Remarks Rear wheel drive hub O-ring Oil seal Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-16...
  • Page 132: Removing The Rear Wheel (disc)

    REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on the centerstand so that the rear wheel is elevated.
  • Page 133: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 134 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 135 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-20...
  • Page 136 FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 137 FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston Brake caliper piston dust seal...
  • Page 138: Introduction

    FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA4B51008 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.
  • Page 139: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Front brake pads steps until the brake disc deflection is within • Brake pad spring specification. f. If the brake disc deflection cannot be brought Always install new brake pads and a new brake within specification, replace the brake disc.
  • Page 140: Removing The Front Brake Calipers

    FRONT BRAKE Put the end of the brake hose into a container and pump out the brake fluid carefully. e. Install the brake pad pin and brake pad clips. L LLL L LLL L LLL L LLL L LLL 3. Install: •...
  • Page 141: Checking The Front Brake Calipers

    FRONT BRAKE EWA4B51006 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and piston seals. EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA4B51007 WARNING • Before installation, all internal brake com- b. Remove the brake caliper piston dust seals ponents should be cleaned and lubricated and piston seals.
  • Page 142: Removing The Front Brake Master Cylinder

    FRONT BRAKE • When refilling, be careful that water does ECA14170 NOTICE not enter the brake fluid reservoir. Water When installing the brake hose onto the will significantly lower the boiling point of brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.
  • Page 143: Checking The Front Brake Master Cylinder

    FRONT BRAKE • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the end of the brake master cylinder hold- er with the punch mark “b” on the handlebar. • First, tighten the upper bolt, then the lower bolt. EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER...
  • Page 144 FRONT BRAKE 3. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 145: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt (rear) Rear brake caliper bolt Rear brake caliper Rear brake pad...
  • Page 146 REAR BRAKE Removing the rear brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 147 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32...
  • Page 148 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •...
  • Page 149 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •...
  • Page 150 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper body For assembly, reverse the disassembly pro- cedure.
  • Page 151: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA4B51008 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •...
  • Page 152 REAR BRAKE 3. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake pad lining thickness (in- ner) 8.0 mm (0.31 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (out- M MMM M MMM M MMM...
  • Page 153: Removing The Rear Brake Caliper

    REAR BRAKE 7. Install: • Rear brake caliper bolts Rear brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) 8. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 154: Disassembling The Rear Brake Caliper

    REAR BRAKE Recommended brake component replace- ment schedule Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1. Check: • Brake caliper piston “1” Rust/scratches/wear → Replace the brake caliper piston. EAS22630 DISASSEMBLING THE REAR BRAKE •...
  • Page 155: Assembling The Rear Brake Caliper

    REAR BRAKE • Rear brake caliper “1” EAS22660 ASSEMBLING THE REAR BRAKE CALIPER (temporarily) EWA4B51010 WARNING • Brake hose gaskets • Rear brake hose “2” • Before installation, all internal brake com- • Brake hose union bolt “3” ponents should be cleaned and lubricated with clean or new brake fluid.
  • Page 156: Removing The Rear Brake Master Cylinder

    REAR BRAKE 4. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- 8. Install: mended brake fluid) • Rear brake lock cable holder • Spring Recommended fluid •...
  • Page 157: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 2. Check: • Rear brake hose “2” • Brake master cylinder kit • Brake hose union bolt “3” Damage/scratches/wear → Replace. Brake hose union bolt 3. Check: 30 Nm (3.0 m·kg, 22 ft·lb) • Brake master cylinder reservoir •...
  • Page 158 REAR BRAKE • When refilling, be careful that water does not enter the brake master cylinder reser- voir. Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.
  • Page 159: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft •...
  • Page 160 HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft • • 40 Nm (4.0 m kg, 29 ft •...
  • Page 161: Removing The Handlebar

    HANDLEBAR EAS4B51014 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” 3. Install: Blow compressed air between the left end of the •...
  • Page 162 HANDLEBAR 6. Connect: 9. Install: • Rear brake lock cable • Throttle grip “1” (to rear brake lock lever) • Throttle cables “2” Lubricate the inside of the rear brake lock cable Lubricate the inside of the throttle grip with a thin and rear brake lock lever with a thin coat of lithi- coat of lithium-soap-based grease and install it um-soap-based grease.
  • Page 163 HANDLEBAR Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 12.Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-23. 4-48...
  • Page 164: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 165 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring seat Fork spring Dust seal Oil seal clip...
  • Page 166 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure. 4-51...
  • Page 167: Removing The Front Fork Legs

    FRONT FORK EAS22960 EAS22980 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. 1.
  • Page 168: Checking The Front Fork Legs

    FRONT FORK • Outer tube Damper rod holder Bends/damage/scratches → Replace. 90890-01460 EWA13650 T-handle WARNING 90890-01326 Do not attempt to straighten a bent inner T-handle 3/8" drive 60 cm long tube as this may dangerously weaken it. YM-01326 2. Measure: •...
  • Page 169 3. Lubricate: (with the fork seal driver weight “3” and fork • Inner tube’s outer surface “2” seal driver attachment “4”) Recommended oil Fork seal driver weight Yamaha fork oil 10WT 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 90890-01374...
  • Page 170 10.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil.
  • Page 171: Installing The Front Fork Legs

    FRONT FORK 11.After filling the front fork leg, slowly stroke the • Temporarily tighten the cap bolt. inner tube “1” up and down (at least ten times) to distribute the fork oil. EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the Be sure to stroke the inner tube slowly because front fork legs.
  • Page 172 FRONT FORK 4-57...
  • Page 173: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 174 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Dust seal Lower bearing inner race...
  • Page 175: Removing The Lower Bracket

    STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut • Rubber washer •...
  • Page 176: Installing The Steering Head

    STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: •...
  • Page 177: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 53 Nm (5.3 m kg, 38 ft • • 68 Nm (6.8 m kg, 49 ft • • Order Job/Parts to remove Q’ty Remarks Exhaust assembly Refer to “ENGINE REMOVAL”...
  • Page 178: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly bolts “1” the rear shock absorber, read and make sure you understand the following information.
  • Page 179 REAR SHOCK ABSORBER ASSEMBLY • Lubricate the rear shock absorber assembly front bolt seats with lithium-soap-based grease. 3. Tighten: • Rear shock absorber assembly rear nut Rear shock absorber assembly rear nut 53 Nm (5.3 m·kg, 38 ft·lb) 4. Tighten: •...
  • Page 180: Swingarm And Transmission Chain Drive

    SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51015 SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 181 SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 182 SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Outer chain drive case Secondary drive gear Secondary drive chain Secondary driven gear Chain drive case gasket Dowel pin Middle shaft...
  • Page 183 SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Bearing retainer For assembly, reverse the disassembly pro- cedure. * Apply chain drive oil. 4-68...
  • Page 184: Checking The Swingarm

    SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51017 CHECKING THE SWINGARM 1. Check: • Swingarm “1” Damage/wear → Replace. EAS4B51018 ASSEMBLING THE TRANSMISSION CHAIN DRIVE ASSEMBLY 1. Install: • Outer chain drive case 2. Check: • Pivot shaft Chain drive case bolt •...
  • Page 185 SWINGARM AND TRANSMISSION CHAIN DRIVE 5. Fill: • Transmission chain drive case Refer to “CHANGING THE CHAIN DRIVE OIL” on page 3-25. 6. Check: • Chain drive oil level Refer to “CHECKING THE CHAIN DRIVE OIL LEVEL” on page 3-24. 2.
  • Page 186 SWINGARM AND TRANSMISSION CHAIN DRIVE 4-71...
  • Page 187: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE............... 5-5 CAMSHAFTS....................5-6 REMOVING THE CAMSHAFTS..............5-9 CHECKING THE CAMSHAFTS ..............5-10 CHECKING THE CAMSHAFT SPROCKETS .........5-11 CHECKING THE TIMING CHAIN GUIDES..........5-11 CHECKING THE TIMING CHAIN TENSIONER........5-12 INSTALLING THE CAMSHAFTS ............5-12 CYLINDER HEAD..................5-15 REMOVING THE CYLINDER HEAD............5-16 CHECKING THE CYLINDER HEAD ............5-16 INSTALLING THE CYLINDER HEAD .............5-16...
  • Page 188 V-BELT AUTOMATIC TRANSMISSION ............5-35 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE..5-41 DISASSEMBLING THE SECONDARY SHEAVE........5-41 CHECKING THE V-BELT................5-42 CHECKING THE PRIMARY SHEAVE ............5-42 CHECKING THE V-BELT CASE AIR DUCT ...........5-42 CHECKING THE PRIMARY SHEAVE WEIGHTS........5-42 CHECKING THE SLIDERS ..............5-42 CHECKING THE SECONDARY SHEAVE ..........
  • Page 189 CRANKSHAFT ....................5-71 REMOVING THE CONNECTING RODS ..........5-73 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ......5-73 CHECKING THE CRANKSHAFT AND CONNECTING RODS....5-73 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS.....5-76 INSTALLING THE CONNECTING RODS..........5-77 INSTALLING THE CRANKSHAFT ASSEMBLY........5-78 TRANSMISSION.................... 5-79 CHECKING THE TRANSMISSION ............5-80...
  • Page 190: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust assembly 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 45 Nm (4.5 m kg, 32 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 191 ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front cowling/Storage box 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”...
  • Page 192 ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “SWINGARM AND TRANSMIS- Transmission chain drive holder assembly SION CHAIN DRIVE” on page 4-65. Refer to “ELECTRIC STARTER”...
  • Page 193 ENGINE REMOVAL Removing the engine 83 Nm (8.3 m kg, 60 ft • • 105 Nm (10.5 m kg, 75 ft • • 45 Nm (4.5 m kg, 32 ft • • 88 Nm (8.8 m kg, 64 ft • •...
  • Page 194: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolts (front right lower side) “1”, en- gine mounting bolts (front left lower side) “2”, and rear frame bolts “3”. •...
  • Page 195: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 196 CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 197 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Timing chain tensioner rod accessing plug Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap...
  • Page 198: Removing The Camshafts

    CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. L LLL L LLL L LLL...
  • Page 199: Checking The Camshafts

    CAMSHAFTS 3. Measure: • Camshaft runout EAS23850 Out of specification → Replace. CHECKING THE CAMSHAFTS 1. Check: Camshaft runout limit • Camshaft lobes 0.030 mm (0.0012 in) Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →...
  • Page 200: Checking The Camshaft Sprockets

    CAMSHAFTS EAS4B51035 c. Install the dowel pins and camshaft caps. CHECKING THE CAMSHAFT SPROCKETS The following procedure applies to both of the • Tighten the camshaft cap bolts in stages and in camshaft sprockets. a crisscross pattern, working from the inner 1.
  • Page 201: Checking The Timing Chain Tensioner

    CAMSHAFTS EAS23960 EAS24000 CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS 1. Check: 1. Install: • Timing chain tensioner • Exhaust camshaft “1” Cracks/damage → Replace. • Intake camshaft “2” M MMM M MMM M MMM M MMM M MMM a.
  • Page 202 CAMSHAFTS hole “d” on the exhaust camshaft sprocket ECA13730 NOTICE align with the cylinder head mating surface, as The camshaft cap bolts must be tightened shown in the illustration. evenly or damage to the cylinder head, cam- ECA4B51015 shaft caps, and camshafts will result. NOTICE 4.
  • Page 203 • Timing chain guide (upper side) • Gaskets (to the cylinder head cover) ECA4B51014 • Apply Yamaha bond No.1215 “1” onto the mat- NOTICE ing surface of the cylinder head cover and tim- Do not push up the timing chain. Push up “c”...
  • Page 204: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kg, 7.2 ft • • 46 Nm (4.6 m kg, 33 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks Camshafts...
  • Page 205: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.03 mm (0.0012 in) • Cylinder head bolts • Cylinder head nuts • Loosen the bolts and nuts in the proper se- quence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
  • Page 206 CYLINDER HEAD Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) • Cylinder head nuts “2” Cylinder head nut 46 Nm (4.6 m·kg, 33 ft·lb) • Cylinder head bolts “3” Cylinder head bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Lubricate the cylinder head nuts and washers with engine oil.
  • Page 207 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Valve lifter Valve pad Valve cotter Valve retainer Valve spring Intake valve Exhaust valve Valve stem seal...
  • Page 208: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “2” and the valve spring compressor attachment “3”.
  • Page 209 VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”...
  • Page 210: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve guide remover (ø4) Valve stem runout 90890-04111 0.040 mm (0.0016 in) Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 L LLL L LLL...
  • Page 211 VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. c. Install the valve into the cylinder head. c. Press the valve through the valve guide and d. Turn the valve until the valve face and valve onto the valve seat to make a clear impres- seat are evenly polished, then clean off all of sion.
  • Page 212: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. L LLL L LLL L LLL L LLL L LLL EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
  • Page 213 VALVES AND VALVE SPRINGS 1. Deburr: • Valve stem end (with an oil stone) 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil b. Smaller pitch 4. Install: • Valve cotters “1” Install the valve cotters by compressing the valve spring with the valve spring compressor “2”...
  • Page 214 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
  • Page 215 CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin...
  • Page 216: Cylinder And Pistons

    CYLINDER AND PISTONS • 2nd ring EAS24380 REMOVING THE PISTONS • Oil ring The following procedure applies to all of the pis- ton. When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring •...
  • Page 217: Checking The Piston Rings

    CYLINDER AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.
  • Page 218: Checking The Piston Pins

    CYLINDER AND PISTONS 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. The oil ring expander spacer end gap cannot be measured. If the oil ring rail gap is excessive, re- place all three piston rings. Piston ring 3.
  • Page 219 CYLINDER AND PISTONS 3. Install: • Dowel pins Be sure to install the top and 2nd rings so that the manufacturer marks or numbers face up. • Cylinder gasket 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5.
  • Page 220: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Negative battery lead Starter motor lead Starter motor...
  • Page 221 ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover Bearing Oil seal Circlip Armature assembly Starter motor yoke O-ring Insulator Brush Brush spring Brush holder Starter motor rear cover For assembly, reverse the disassembly pro- cedure.
  • Page 222: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. L LLL L LLL L LLL...
  • Page 223: Installing The Starter Motor

    ELECTRIC STARTER 2. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers.
  • Page 224 V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 225: V-belt Automatic Transmission

    V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 226 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •...
  • Page 227 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •...
  • Page 228 V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave Order Job/Parts to remove Q’ty Remarks Slider Primary sheave weight Primary sliding sheave Collar Oil seal For assembly, reverse the disassembly pro- cedure. * Apply BEL-RAY assembly lube®. 5-39...
  • Page 229 V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 90 Nm (9.0 m kg, 65 ft • • Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat Secondary sheave compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave...
  • Page 230: Removing The Primary Sheave And Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS4B51022 EAS24640 REMOVING THE PRIMARY SHEAVE AND DISASSEMBLING THE SECONDARY SECONDARY SHEAVE SHEAVE 1. Remove: 1. Loosen: • Primary sheave nut “1” • Secondary sheave spring seat nut “1” • Secondary sheave nut “2” • While holding the secondary fixed sheave “2” While holding the primary and secondary with the sheave holder “3”, loosen the second- sheave with the sheave holder “3”, loosen the...
  • Page 231: Checking The V-belt

    V-BELT AUTOMATIC TRANSMISSION EAS24690 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear → Replace. 2. Measure: • Primary sheave weight outside diameter Out of specification → Replace. EAS24670 CHECKING THE V-BELT Primary sheave weight outside...
  • Page 232: Assembling The Primary Sheave

    V-BELT AUTOMATIC TRANSMISSION 2. Install: EAS24720 • Secondary sliding sheave “1” ASSEMBLING THE PRIMARY SHEAVE 1. Clean: Install the secondary sliding sheave onto the • Primary fixed sheave secondary fixed sheave “2” with the oil seal • Primary sliding sheave guide “3”.
  • Page 233: Installing The Primary Sheave Assembly, Secondary Sheave Assembly And V-belt

    INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1. Apply: • Sealant (onto the inner V-belt case seal) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 2. Install: • V-belt case air duct joint clamp “1” 6. Tighten: •...
  • Page 234 V-BELT AUTOMATIC TRANSMISSION While holding the secondary sheave with the sheave holder “2”, tighten the secondary sheave nut. Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) Sheave holder 90890-01481 3. Install: • Primary fixed sheave “1” • V-belt “2” •...
  • Page 235: Installing The V-belt Case

    V-BELT AUTOMATIC TRANSMISSION EAS4B51025 INSTALLING THE V-BELT CASE 1. Install: • Oil seal “1” (into outer V-belt case) Installed depth of oil seal “a” 4.0–4.3 mm (0.16–0.17 in) 2. Fill the space “b” shown in the illustration with 10 g or more of lithium-soap-based grease. 3.
  • Page 236 GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft •...
  • Page 237: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft • • 30 Nm (3.0 m kg, 22 ft 10 Nm (1.0 m...
  • Page 238 GENERATOR AND STARTER CLUTCH Removing the stator coil and oil tank 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil tank...
  • Page 239: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator cover Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 240: Checking The Starter Clutch

    GENERATOR AND STARTER CLUTCH c. When turning the starter clutch gear clock- wise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced. EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” L LLL L LLL L LLL...
  • Page 241: Installing The Generator

    • While holding the generator rotor “2” with the (onto the crankshaft position sensor lead sheave holder “3”, tighten the generator rotor grommet) nut. Yamaha bond No. 1215 • Do not allow the sheave holder to touch the 90890-85505 projection on the generator rotor. (Three Bond No.1215®)
  • Page 242 GENERATOR AND STARTER CLUTCH Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Tighten the generator cover bolts in stages and in a crisscross pattern. 5-53...
  • Page 243: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch 65 Nm (6.5 m kg, 47 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator cover CLUTCH” on page 5-47. Clutch assembly nut Clutch assembly Washer For installation, reverse the removal proce- dure.
  • Page 244 CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Circlip Spring stopper plate Clutch spring plate Pressure plate Clutch plate 2 Clutch damper spring Friction plate Clutch plate 1 Clutch spring Clutch boss nut Primary drive gear...
  • Page 245 CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Clutch housing For assembly, reverse the disassembly pro- cedure. 5-56...
  • Page 246: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch assembly nut “1” • Clutch assembly “2” • Before removal, put alignment marks “a” and “b” as shown. • While holding the clutch assembly with the ro- tor holding tool “3”, loosen the clutch assembly nut.
  • Page 247: Checking The Friction Plates

    CLUTCH EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: • Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: • Friction plate thickness Out of specification → Replace the friction EAS4B51027 plates as a set.
  • Page 248: Checking The Clutch Springs

    CLUTCH EAS25140 EAS25160 CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH BOSS The following procedure applies to all of the 1. Check: clutch springs. • Clutch boss splines 1. Check: Damage/pitting/wear → Replace the clutch • Clutch spring boss. Damage → Replace the clutch springs as a set.
  • Page 249: Installing The Clutch

    CLUTCH • Friction plates “4” Recommended lubricant • Clutch plates 1 “5” Engine oil • Pressure plate “6” • Clutch spring plate “7” 2. Install: • Clutch boss • Primary drive gear • Clutch boss nut 3. Tighten: • Clutch boss nut “1” Clutch boss nut 130 Nm (13.0 m·kg, 94 ft·lb) While holding the clutch boss “2”...
  • Page 250 CLUTCH Clutch assembly nut 65 Nm (6.5 m·kg, 47 ft·lb) • Align the “a” and “b” during reassembly. • While holding the clutch assembly with the ro- tor holding tool “3”, tighten the clutch assembly nut. Rotor holding tool 90890-01235 Universal magneto &...
  • Page 251: Oil Pump

    OIL PUMP EAS24901 OIL PUMP Removing the oil pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Starter clutch gear CLUTCH”...
  • Page 252 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing 1 Dowel pin Oil pump outer rotor 1 Oil pump inner rotor 1 Washer Oil pump housing center Oil pump outer rotor 2 Oil pump inner rotor 2 Oil pump driven gear Oil pump housing 2 For assembly, reverse the disassembly pro-...
  • Page 253: Checking The Oil Pump

    OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven gear “1” 0.040–0.120 mm (0.0016–0.0047 • Oil pump housing 2 “2” Limit • Oil pump housing 1 “3” Cracks/damage/wear → Replace the defec- 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing tive part(s).
  • Page 254: Assembling The Oil Pump

    OIL PUMP ECA13890 NOTICE After tightening the bolts, make sure the oil pump turns smoothly. EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.
  • Page 255: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft •...
  • Page 256 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 257 CRANKCASE Removing the oil seals and bearings 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-71. Transmission Refer to “TRANSMISSION” on page 5-79. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.
  • Page 258: Disassembling The Crankcase

    (onto the crankcase mating surfaces) es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Yamaha bond No. 1215 • M8 × 110 mm bolts “1” 90890-85505 • M6 × 50 mm bolts “2”...
  • Page 259 CRANKCASE • M6 × 35 mm bolts “3” 5. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-70...
  • Page 260: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft assembly 58 Nm (5.8 m kg, 42 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Dowel pin Crankshaft assembly Balancer cylinder Oil seal Crankshaft journal bearing For installation, reverse the removal proce- dure.
  • Page 261 CRANKSHAFT Removing the connecting rods 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ 60 Nm (6.0 m kg, 43 ft • • 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ Order Job/Parts to remove Q’ty...
  • Page 262: Removing The Connecting Rods

    CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod cap • Connecting rod “1” • Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 263 CRANKSHAFT 3. Measure: • Crankshaft-pin-to-big-end-bearing clearance • Do not move the connecting rod or crankshaft Out of specification → Replace the big end until the clearance measurement has been bearings. completed. • Lubricate the bolts threads and nut seats with Oil clearance (using plasti- molybdenum disulfide grease.
  • Page 264 CRANKSHAFT • P –P refer to the bearings shown in the crank- Journal oil clearance (using plas- shaft illustration. tigauge®) 0.040–0.082 mm (0.0016–0.0032 The following procedure applies to all of the crankshaft journal bearings. ECA13920 NOTICE Do not interchange the crankshaft journal bearings.
  • Page 265: Installing The Crankshaft Journal Bearings

    CRANKSHAFT d. Measure the crankshaft journal bearing in- side diameter “b” of each crankshaft journal bearing at two places. e. If crankshaft journal bearing inside diameter is “45.03” and crankshaft journal diameter is “44.98”, then the journal oil clearance is: Journal oil clearance: Crankshaft journal bearing inside diameter - Crankshaft journal diameter...
  • Page 266: Installing The Connecting Rods

    CRANKSHAFT • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. EAS26150 INSTALLING THE CONNECTING RODS 1. Lubricate: • Bolt threads • Nut seats 4. Tighten: (with the recommended lubricant) • Connecting rod nuts M MMM M MMM M MMM...
  • Page 267: Installing The Crankshaft Assembly

    CRANKSHAFT c. Tighten the connecting rod nuts further to (6.0 m·kg, 43 ft·lb), loosen the nut to less reach the specified angle 90°. than 30 Nm (3.0 m·kg, 22 ft·lb) and start again. Connecting rod nut (final) Specified angle 90° EAS4B51033 INSTALLING THE CRANKSHAFT ASSEMBLY...
  • Page 268: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Secondary shaft Collar Primary driven gear Main axle 1st pinion gear Drive axle 1st wheel gear Circlip For installation, reverse the removal proce- dure.
  • Page 269: Checking The Transmission

    TRANSMISSION EAS26300 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 4. Check: • Transmission gear movement Rough movement →...
  • Page 270 TRANSMISSION 5-81...
  • Page 271: Cooling System

    COOLING SYSTEM RADIATOR ...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER....................6-4 CHECKING THE OIL COOLER ..............6-6 INSTALLING THE OIL COOLER .............. 6-6 THERMOSTAT ....................6-7 CHECKING THE THERMOSTAT.............. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ........6-8 WATER PUMP....................6-9 DISASSEMBLING THE WATER PUMP..........6-11 CHECKING THE WATER PUMP ............
  • Page 272 RADIATOR EAS26380 RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Footrest boards 4-1.
  • Page 273 RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Radiator fan Radiator bracket For installation, reverse the removal proce- dure.
  • Page 274: Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
  • Page 275: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 276 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Oil cooler For installation, reverse the removal proce- dure.
  • Page 277: Checking The Oil Cooler

    OIL COOLER 4. Fill: EAS26420 CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-18. • Oil cooler inlet hose •...
  • Page 278: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK”...
  • Page 279: Checking The Thermostat

    THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 71–85 °C (159.8–185.0 °F) EAS26480 INSTALLING THE THERMOSTAT → Replace. ASSEMBLY 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing forward.
  • Page 280: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Left footrest board 4-1.
  • Page 281 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil.
  • Page 282: Disassembling The Water Pump

    WATER PUMP EAS26510 EAS26550 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Rubber damper holder “1” • Water pump housing cover • Rubber damper “2” • Water pump housing (from the impeller, with a thin, flat-head •...
  • Page 283: Installing The Water Pump

    WATER PUMP • Before installing the water pump seal, apply ECA14090 NOTICE Yamaha bond No.1215 “2” to the water pump Make sure the rubber damper and rubber housing “3”. damper holder are flush with the impeller. Mechanical seal installer Impeller shaft tilt limit 90890-04078 0.15 mm (0.0059 in)
  • Page 284 WATER PUMP 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3. 6-13...
  • Page 285: Fuel System

    FUEL SYSTEM FUEL TANK..................... 7-1 REMOVING THE FUEL TANK ..............7-3 REMOVING THE FUEL PUMP ..............7-3 CHECKING THE FUEL PUMP BODY............7-3 CHECKING THE ROLLOVER VALVE ............7-3 INSTALLING THE FUEL PUMP..............7-3 CHECKING THE FUEL PRESSURE ............7-3 THROTTLE BODY................... 7-5 CHECKING THE INJECTORS ..............7-8 CHECKING THE THROTTLE BODY ............7-8 ADJUSTING THE THROTTLE POSITION SENSOR........7-8...
  • Page 286 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1.
  • Page 287 FUEL TANK Removing the canister 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel tank breather hose Canister purge hose (3-way joint to canister) Canister purge hose (throttle body to 3-way joint)
  • Page 288: Fuel Tank

    FUEL TANK EAS26630 REMOVING THE FUEL TANK • Do not damage the installation surfaces of the 1. Extract the fuel in the fuel tank through the fuel tank when installing the fuel pump. fuel tank cap with a pump. • Always use a new fuel pump gasket. 2.
  • Page 289 FUEL TANK b. Connect the pressure gauge “1” and fuel pressure adapter “2” to the fuel pump and the fuel hose “3”. Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03181 c. Start the engine. d. Measure the fuel pressure. Faulty → Replace the fuel pump. Output pressure 246.0–254.0 kPa (35.7–36.8 psi) (2.46–2.54 kgf/cm²)
  • Page 290: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 291 THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Throttle body assembly Plastic band Coupler cover...
  • Page 292 THROTTLE BODY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Before disassembling the throttle body as- sembly, make sure to note the number of times the air screw is turned out from the seated position to its set position. Throttle position sensor Fast idle plunger Idling speed adjusting screw...
  • Page 293 THROTTLE BODY EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. EAS26990 CHECKING THE THROTTLE BODY 1. Check: B/L Y • Throttle body Cracks/damage → Replace the throttle body. 2. Check: d. Measure the throttle position sensor output •...
  • Page 294 THROTTLE BODY...
  • Page 295: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM ..............8-5 CIRCUIT DIAGRAM .................. 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-7 TROUBLESHOOTING ................8-9 CHARGING SYSTEM..................8-11 CIRCUIT DIAGRAM ................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM ..................8-15 CIRCUIT DIAGRAM ................
  • Page 296 ELECTRICAL COMPONENTS..............8-57 CHECKING THE SWITCHES ..............8-61 CHECKING THE BULBS AND BULB SOCKETS ........8-64 CHECKING THE FUSES ................8-65 CHECKING AND CHARGING THE BATTERY........8-66 CHECKING THE RELAYS ..............8-69 CHECKING THE TURN SIGNAL RELAY ..........8-70 CHECKING THE DIODE .................8-71 CHECKING THE SPARK PLUG CAPS...........8-71 CHECKING THE IGNITION COIL ............
  • Page 298: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 299 IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug 39.Lean angle sensor...
  • Page 300: Troubleshooting

    IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Footrest boards 2. Front cowling assembly NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 301 IGNITION SYSTEM NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-61. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch.
  • Page 302: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
  • Page 303 ELECTRIC STARTING SYSTEM 4. Main switch 9. Signaling system fuse 11.Ignition fuse 14.Battery 15.Main fuse 16.Starter relay 17.Starter motor 18.Diode 1 20.Engine stop switch 21.Start switch 22.Front brake light switch 23.Diode 2 24.Starting circuit cut-off relay 28.Sidestand switch 57.Rear brake light switch...
  • Page 304: Starting Circuit Cut-off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 305 ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Diode 2 7. Starting circuit cut-off relay 8. Sidestand switch 9. Signaling system fuse 10. Front brake light switch 11. Rear brake light switch 12.
  • Page 306: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).
  • Page 307 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-61. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch.
  • Page 308: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
  • Page 309 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 14.Battery 15.Main fuse 8-12...
  • Page 310: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-65. OK ↓...
  • Page 311 CHARGING SYSTEM 8-14...
  • Page 312: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
  • Page 313 LIGHTING SYSTEM 4. Main switch 5. Storage box light switch 6. Storage box light 8. Backup fuse (odometer and clock) 10.Headlight fuse 13.Taillight fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 47.License plate light 51.Tail/brake light 54.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 61.Headlight relay 62.Headlight (high beam)
  • Page 314: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position lights, or meter light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Mudguard NG → 1.
  • Page 315 LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-15. OK ↓ Replace the ECU (engine control unit) or meter assembly. 8-18...
  • Page 316: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
  • Page 317 SIGNALING SYSTEM 4. Main switch 8. Backup fuse (odometer and clock) 9. Signaling system fuse 11.Ignition fuse 13.Taillight fuse 14.Battery 15.Main fuse 22.Front brake light switch 27.Fuel sender 29.ECU (engine control unit) 40.Speed sensor 49.Rear left turn signal light 50.Rear right turn signal light 51.Tail/brake light 52.Turn signal relay 55.Horn switch...
  • Page 318: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •...
  • Page 319 SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. OK ↓ This circuit is OK. The tail/brake light fails to come on. NG → 1.
  • Page 320 SIGNALING SYSTEM NG → 3. Check the turn signal relay. Refer to “CHECKING THE TURN Replace the turn signal relay. SIGNAL RELAY” on page 8-70. OK ↓ NG → 4. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”...
  • Page 321 SIGNALING SYSTEM 8-24...
  • Page 322: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25...
  • Page 323 COOLING SYSTEM 4. Main switch 11.Ignition fuse 12.Radiator fan fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 34.Coolant temperature sensor 45.Radiator fan motor relay 46.Radiator fan motor 65.Multi-function meter 66.Coolant temperature meter 8-26...
  • Page 324: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and radiator fan) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”...
  • Page 325 COOLING SYSTEM 8-28...
  • Page 326: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29...
  • Page 327 FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 7. Fuel injection system fuse 9. Signaling system fuse 10.Headlight fuse 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 23.Diode 2 24.Starting circuit cut-off relay 25.Fuel injection system relay 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug...
  • Page 328: Ecu Self-diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU (engine control unit) is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.