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Yamaha 2014 MT-07 Service Manual

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Table of Contents
2014
SERVICE MANUAL
MT07A
1XB-28197-E0

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Table of Contents

   Summary of Contents for Yamaha 2014 MT-07

  • Page 1 2014 SERVICE MANUAL MT07A 1XB-28197-E0...
  • Page 2 EAS20002 MT07A 2014 SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. First edition, October 2014 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3 EAS20003 IMPORTANT This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man- ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
  • Page 4: How To Use This Manual

    EAS20004 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: Symbols

    EAS20005 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
  • Page 7: Table Of Contents

    EAS10003 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 THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 OUTLINE OF THE ABS................1-4 ABS COMPONENT FUNCTIONS ............. 1-8 ABS OPERATION ...................1-13 ABS WARNING LIGHT AND OPERATION..........1-16 MULTI-FUNCTION METER UNIT ............1-18 IMPORTANT INFORMATION ...............
  • Page 10: Identification

    IDENTIFICATION EAS20007 IDENTIFICATION EAS30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS30003 MODEL LABEL The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts.
  • Page 11: Features

    FEATURES EAS20008 FEATURES EAS30005 OUTLINE OF THE 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 and the atmospheric temperature. In the 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 carburetor.
  • Page 12: Fi System

    FEATURES EAS30617 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 13: Abs Layout

    EAS30683 OUTLINE OF THE ABS 1. The Yamaha ABS (anti-lock brake system) features an electronic control system, which acts on the front and rear brakes independently. 2. The ABS features a compact and lightweight design to help maintain the basic maneuverability of the vehicle.
  • Page 14 FEATURES The operation of the Yamaha ABS brakes is the same as conventional brakes on other vehicles, with a brake lever for operating the front brake and a brake pedal for operating the rear brake. When wheel lock is detected during emergency braking, hydraulic control is performed by the hydraulic system on the front and rear brakes independently.
  • Page 15 FEATURES Wheel slip and hydraulic control The ABS ECU calculates the wheel speed of each wheel according to the rotation signal received from the front and rear wheel sensors. In addition, the ABS ECU calculates the vehicle chassis speed and the rate of speed reduction based on the wheel speed values.
  • Page 16 Slip ratio b. Brake force Electronic ABS features The Yamaha ABS (anti-lock brake system) has been developed with the most advanced electronic technology. The ABS control is processed with good response under various vehicle travel conditions. The ABS also includes a highly developed self-diagnosis function. The ABS detects any problem con- dition and allows normal braking even if the ABS is not operating properly.
  • Page 17: Abs Component Functions

    FEATURES ABS block diagram 1. Rear brake master cylinder 9. Buffer chamber 2. Hydraulic unit assembly 10. Rear brake caliper 3. Front brake master cylinder 11. Rear wheel sensor 4. Inlet solenoid valve 12. ABS warning light 5. ABS motor 13.
  • Page 18 FEATURES 3. At low speed 7. Voltage 4. At high speed 8. Time 5. Wheel sensor 6. Wheel sensor rotor ABS warning light The ABS warning light “1” comes on to warn the rider if a malfunction in the ABS occurs. When the main switch is turned to “ON”, the ABS warning light comes on to check the electrical circuit and the system function (ABS self-diagnosis), and goes off when the vehicle is operated (the function check is properly completed at a speed of about 6 to 10 km/h [3.8 to 6.3 mi/h]).
  • Page 19 FEATURES Hydraulic unit assembly The hydraulic unit assembly “1” is composed of hydraulic control valves (each with a outlet solenoid valve and inlet solenoid valve), buffer chambers, hydraulic pumps, an ABS motor, and ABS ECU. The hydraulic unit adjusts the front and rear wheel brake fluid pressure to control the wheel speed according to signals transmitted from the ABS ECU.
  • Page 20 FEATURES 3. When the ABS ECU sends a signal to stop reducing the hydraulic pressure, the outlet solenoid valve “2” closes and the brake fluid is pressurized again. The inlet solenoid valve “1” controls the hydraulic pressure difference between the brake fluid in the upper brake lines (brake master cylinder side) and the brake fluid in the lower brake lines (brake caliper side).
  • Page 21 25. ECU (engine control unit) 12. Tail/brake light 26. Front wheel sensor 13. Yamaha diagnostic tool coupler 27. Rear wheel sensor 14. Hydraulic unit assembly The necessary actions are confirmed using the monitor circuit and control signals are transmitted to the hydraulic unit assembly.
  • Page 22: Abs Operation

    FEATURES • The ABS performs a self-diagnosis test for a few seconds each time the vehicle first starts off after the main switch was turned on. During this test, a “clicking” noise can be heard from under the seat, and if the brake lever or brake pedal is even slightly operated, a vibration can be felt at the lever and pedal, but these do not indicate a malfunction.
  • Page 23 FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
  • Page 24 FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
  • Page 25: Abs Warning Light And Operation

    FEATURES 1. Brake master cylinder 8. Brake caliper 2. Brake light switch 9. Wheel sensor 3. ABS motor 10. ABS ECU 4. Hydraulic pump 11. ABS warning light 5. Buffer chamber 12. Brake fluid pressure 6. Outlet solenoid valve 13. Time 7.
  • Page 26 FEATURES ABS function EWA16520 WARNING • When hydraulic control is performed by the ABS, the brake system alerts the rider that the wheels have a tendency to lock by generating a reaction-force pulsating action in the brake lever or brake pedal. When the ABS is activated, the grip between the road surface and tires is close to the limit.
  • Page 27: Multi-function Meter Unit

    FEATURES EAS30982 MULTI-FUNCTION METER UNIT • Be sure to turn the key to “ON” before using the left and right set buttons except for setting the brightness control mode. • For the U.K. only: To switch the speedometer and multi-function display between kilometers and miles, set the multi-function display to the odometer mode or a tripmeter mode, and then press the left set button for at least three sec-...
  • Page 28 FEATURES The clock displays when the key is turned to Eco indicator “ON”. In addition, the clock can be displayed for 10 seconds by pushing the left set button when the main switch is in the “OFF”, “LOCK” or “ ”...
  • Page 29 FEATURES Multi-function display If the fuel level warning indicator “ ” and left segment of the fuel meter start flashing, the dis- play automatically changes to the fuel reserve tripmeter mode “TRIP F” and starts counting the distance traveled from that point. In that case, push the left set button to switch the display be- tween the various tripmeter, odometer, instanta- neous fuel consumption and average fuel...
  • Page 30 FEATURES To switch between the instantaneous fuel con- Coolant temperature display sumption displays, push the left set button for one second when one of the displays is shown. If traveling at speeds under 20 km/h (12 mi/h), “_ _._” is displayed. Average fuel consumption mode 1.
  • Page 31 FEATURES Self-diagnosis device 2. If the engine starts, turn it off and try starting the engine with the standard keys. 3. If one or both of the standard keys do not start the engine, take the vehicle, the code re-reg- istering key and both standard keys.
  • Page 32: Important Information

    5. Keep all parts away from any source of fire. EAS30007 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 inferior in quality.
  • Page 33: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS30010 EAS30012 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in- manufacturer marks or numbers are visible. spection. Some of the rubber parts are sensitive When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc.
  • Page 34: Basic Service Information

    BASIC SERVICE INFORMATION EAS20010 BASIC SERVICE INFORMATION EAS30013 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
  • Page 35: Electrical System

    BASIC SERVICE INFORMATION ECA16760 EAS30014 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
  • Page 36 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA16630 ECA14371 NOTICE NOTICE...
  • Page 37 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
  • Page 38 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...
  • Page 39: Special Tools

    8-134, 8-135, 8-135, 8-137, 8-137, 8-138, 8-139, 8-140, 8-140, 8-141, 8-141 Thickness gauge 3-6, 4-25, 4-34, 90890-03180 5-55 Feeler gauge set YU-26900-9 Valve lapper 90890-04101 Valve lapping tool YM-A8998 Yamaha diagnostic tool 3-8, 4-67, 4-68, 90890-03231 5-2, 8-36, 8-95, 8-116 1-30...
  • Page 40 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Vacuum gauge 90890-03094 Vacuummate YU-44456 YU-44456 Carburetor angle driver 2 90890-03173 Steering nut wrench 3-19, 4-89 90890-01403 Exhaust flange nut wrench YU-A9472 Oil filter wrench 3-22 90890-01426 Oil filter wrench YU-38411 Pressure gauge 3-23, 7-16, 7-17 90890-03153 Pressure gauge...
  • Page 41 90890-03081 Engine compression tester YU-33223 YU-33223 Rotor holding tool 5-17, 5-21 90890-01235 Universal magneto and rotor holder YU-01235 Yamaha bond No. 1215 5-24, 5-44, 5-71, 90890-85505 5-73 (Three bond No.1215®) Valve spring compressor 5-32, 5-37 90890-04019 Valve spring compressor YM-04019...
  • Page 42 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve spring compressor attachment 5-32, 5-37 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (ø4.5) 5-34 90890-04116 Valve guide remover (4.5 mm) YM-04116 Valve guide installer (ø4.5) 5-34 90890-04117 Valve guide installer (4.5 mm) YM-04117 Valve guide reamer (ø4.5)
  • Page 43 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Piston pin puller set 5-77 90890-01304 Piston pin puller YU-01304 YU-01304 Piston ring compressor 5-84 90890-05158 Piston ring compressor YM-08037 Radiator cap tester 90890-01325 Mityvac cooling system tester kit YU-24460-A YU-24460-A Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984...
  • Page 44 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Middle driven shaft bearing driver 6-12 90890-04058 Middle drive bearing installer 40 & 50 mm YM-04058 Vacuum/pressure pump gauge set 90890-06756 Mityvac brake bleeding tool YS-42423 Fuel injector pressure adapter 7-16 90890-03210 Fuel injector pressure adapter YU-03210 Fuel pressure adapter...
  • Page 45: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-8 ELECTRICAL SPECIFICATIONS ..............2-11 TIGHTENING TORQUES ................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS........2-25 ENGINE OIL LUBRICATION CHART .............2-25 LUBRICATION DIAGRAMS ..............
  • Page 46: General Specifications

    GENERAL SPECIFICATIONS EAS20013 GENERAL SPECIFICATIONS Model Model 1XB1 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB2 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB5 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB6 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB7 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) 1XB8 (BEL)(CHE)(CZE)(DNK)(FIN)(GBR)(GRC)(HU N)(IRL)(NLD)(NOR)(POL)(PRT)(SVK)(SVN)(S WE)(TUR)(ZAF) Dimensions Overall length 2085 mm (82.1 in) Overall width 745 mm (29.3 in) Overall height 1090 mm (42.9 in)
  • Page 47: Engine Specifications

    ENGINE SPECIFICATIONS EAS20014 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 689 cm³ Cylinder arrangement Inline 2-cylinder Bore × stroke 80.0 × 68.6 mm (3.15 × 2.70 in) Compression ratio 11.5 : 1 Standard compression pressure (at sea level) #1 880 kPa/355 r/min (8.8 kgf/cm²/355 r/min, 125.2 psi/355 r/min) #2 790 kPa/355 r/min (7.9 kgf/cm²/355 r/min,...
  • Page 48 ENGINE SPECIFICATIONS Relief valve operating pressure 630.0–810.0 kPa (6.30–8.10 kgf/cm², 91.4– 117.5 psi) Cooling system Radiator capacity (including all routes) 1.60 L (1.69 US qt, 1.41 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 108.0–137.4 kPa (1.08–1.37 kgf/cm², 15.7–19.9 psi)
  • Page 49 ENGINE SPECIFICATIONS Valve dimensions Valve head diameter (intake) 31.40–31.60 mm (1.2362–1.2441 in) Valve head diameter (exhaust) 26.40–26.60 mm (1.0394–1.0472 in) Valve seat contact width (intake) 0.90–1.10 mm (0.0354–0.0433 in) Valve seat contact width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in) Limit 4.445 mm (0.1750 in)
  • Page 50 ENGINE SPECIFICATIONS Piston-pin-to-piston-pin-bore clearance 0.009–0.025 mm (0.0004–0.0010 in) Limit 0.075 mm (0.0030 in) Piston ring Top ring Ring type Barrel End gap (installed) 0.15–0.25 mm (0.0059–0.0098 in) Limit 0.50 mm (0.0197 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) Limit 0.115 mm (0.0045 in) 2nd ring Ring type...
  • Page 51 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 6-speed Primary reduction ratio 1.925 (77/40) Final drive Chain Secondary reduction ratio 2.688 (43/16) Operation Left foot operation Gear ratio 2.846 (37/13) 2.125 (34/16) 1.632 (31/19) 1.300 (26/20) 1.091 (24/22) 0.964 (27/28) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in)
  • Page 52 ENGINE SPECIFICATIONS Intake vacuum 29.8–32.4 kPa (224–243 mmHg, 8.8–9.6 inHg) Water temperature 85.0–105.0 °C (185.00–221.00 °F) Oil temperature 60.0–80.0 °C (140.00–176.00 °F) Throttle grip free play 3.0–5.0 mm (0.12–0.20 in)
  • Page 53: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20015 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 24.80 ° Trail 90 mm (3.5 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 130 mm (5.1 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 54 CHASSIS SPECIFICATIONS Brake pad lining thickness (inner) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Brake pad lining thickness (outer) 4.5 mm (0.18 in) Limit 0.5 mm (0.02 in) Master cylinder inside diameter 15.00 mm (0.59 in) Caliper cylinder inside diameter 30.23 mm (1.19 in) Caliper cylinder inside diameter 27.00 mm (1.06 in)
  • Page 55 CHASSIS SPECIFICATIONS Enclosed gas/air pressure (STD) 980 kPa (9.8 kgf/cm², 139.4 psi) Spring preload adjusting positions Minimum Standard Maximum Drive chain Type/manufacturer 525VAZ/DAIDO Number of links 15-link length limit 239.3 mm (9.42 in) Drive chain slack 51.0–56.0 mm (2.01–2.20 in) Limit 58.0 mm (2.28 in) 2-10...
  • Page 56: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20016 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Ignition timing (B.T.D.C.) 10.0 °/1200 r/min Engine control unit Model/manufacturer TBDFH8/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 1.19–1.61 Ω Primary coil resistance Secondary coil resistance 8.50–11.50 kΩ...
  • Page 57 ELECTRICAL SPECIFICATIONS Oil pressure warning light High beam indicator light Coolant temperature warning light Engine trouble warning light ABS warning light Immobilizer system indicator light Electric starting system System type Constant mesh Starter motor Power output 0.50 kW 0.0150–0.0250 Ω Armature coil resistance Brush overall length 12.0 mm (0.47 in)
  • Page 58 ELECTRICAL SPECIFICATIONS Spare fuse 2.0 A 2-13...
  • Page 59: Tightening Torques

    TIGHTENING TORQUES EAS20017 TIGHTENING TORQUES EAS30015 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 60: Engine Tightening Torques

    TIGHTENING TORQUES EAS30016 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Exhaust pipe nut 20 Nm (2.0 m·kgf, 14 ft·lbf) Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kgf, 11 ft·lbf) pipe) Muffler bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Muffler bracket bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Muffler cover bolt...
  • Page 61 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Stake. Clutch boss nut 95 Nm (9.5 m·kgf, 69 ft·lbf) Clutch spring bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cable holder bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Oil pump drive chain guide bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 62 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Shift drum retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Radiator cap bolt 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf) Coolant reservoir bolt 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Radiator side cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Radiator fan motor bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
  • Page 63 TIGHTENING TORQUES 4. Loosen and retighten the cylinder head bolts “1”–“6” to 20 Nm (2.0 m·kgf, 14 ft·lbf) in the proper tight- ening sequence, and then tighten them further to reach the specified angle 90° in the proper tight- ening sequence. 5.
  • Page 64 TIGHTENING TORQUES ×8 ×2 ×3 ×2 ×6 ×6 26 27 Connecting rod bolt Tighten the connecting rod bolts to 20 Nm (2.0 m·kgf, 14 ft·lbf), and then tighten them further to reach the specified angle 175–185°. 2-19...
  • Page 65: Chassis Tightening Torques

    TIGHTENING TORQUES EAS30017 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (rear upper 55 Nm (5.5 m·kgf, 40 ft·lbf) side) Engine mounting nut (rear lower 55 Nm (5.5 m·kgf, 40 ft·lbf) side) Engine mounting bolt (left front side) 75 Nm (7.5 m·kgf, 54 ft·lbf) Engine mounting bolt (left upper 55 Nm (5.5 m·kgf, 40 ft·lbf)
  • Page 66 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rectifier/regulator bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Electrical components tray 2 nut 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Electrical components tray 2 bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Hydraulic unit assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front brake hose guide bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
  • Page 67 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rearview mirror 17 Nm (1.7 m·kgf, 12 ft·lbf) Handlebar switch screw (right) 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Throttle cable housing bolt 3.8 Nm (0.38 m·kgf, 2.8 ft·lbf) Handlebar switch screw (left) 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf) Grip end 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
  • Page 68 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Connecting arm nut (frame side) 52 Nm (5.2 m·kgf, 38 ft·lbf) Drive sprocket cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Stake Drive sprocket nut 95 Nm (9.5 m·kgf, 69 ft·lbf) Shift rod locknut (shift arm side) 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Left-hand...
  • Page 69: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20018 LUBRICATION POINTS AND LUBRICANT TYPES EAS30018 ENGINE Lubrication point Lubricant Oil seal lips O-rings Coolant hose insertion part Water or Bearings Camshaft lobes and journals (intake and exhaust) Valve stem seal (installed on valve guide) Valve lifter outer surface (intake and exhaust) Valve stems and stem ends (intake and exhaust) Decompression camshaft moving point...
  • Page 70: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20019 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30020 ENGINE OIL LUBRICATION CHART 2-25...
  • Page 71 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil cooler 5. Oil filter cartridge 6. Main gallery 7. Oil pressure switch 8. Crankshaft 9. Oil nozzle 10. Balancer shaft assembly 11. Timing chain tensioner 12.
  • Page 72: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS30021 LUBRICATION DIAGRAMS Crankcase, cylinder, and cylinder head (right side view) 2-27...
  • Page 73 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Timing chain tensioner 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil filter cartridge 6. Oil cooler 7. Oil drain bolt 8. Oil strainer 9. Oil pump 2-28...
  • Page 74 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (left side view) 2-29...
  • Page 75 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Crankshaft 2. Balancer shaft assembly 3. Connecting rod 4. Oil cooler 5. Oil filter cartridge 2-30...
  • Page 76 LUBRICATION SYSTEM CHART AND DIAGRAMS Oil pump (bottom view) 2-31...
  • Page 77 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Oil pressure switch 3. Oil filter cartridge 4. Oil cooler 5. Oil strainer 2-32...
  • Page 78 LUBRICATION SYSTEM CHART AND DIAGRAMS Camshaft (top view) 2-33...
  • Page 79 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshaft 2. Cylinder head 3. Exhaust camshaft 2-34...
  • Page 80 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (front view) 2-35...
  • Page 81 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil nozzle 2. Piston 3. Crankshaft 4. Main gallery 2-36...
  • Page 82 LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view) 2-37...
  • Page 83 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Balancer shaft assembly 2. Crankshaft 3. Main axle 4. Drive axle 2-38...
  • Page 84: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20020 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 85 COOLING SYSTEM DIAGRAMS 1. Thermostat 2. Oil cooler inlet hose 3. Oil cooler 4. Oil cooler outlet hose 5. Water jacket joint inlet hose 6. Water pump outlet pipe 7. Water pump inlet pipe 8. Radiator outlet hose 9. Water jacket joint 10.
  • Page 86: Cable Routing

    CABLE ROUTING EAS20021 CABLE ROUTING Handlebar (front view) 2-41...
  • Page 87 CABLE ROUTING 1. Throttle cable (decelerator cable) L. Face the damper on the holder toward the front brake master cylinder and face the catch 2. Throttle cable (accelerator cable) of the holder downward. 3. Clutch cable M. Connect the auxiliary light coupler. 4.
  • Page 88 CABLE ROUTING Clutch cable (right side view) 2-43...
  • Page 89 CABLE ROUTING 1. Fuel tank breather hose K. Make sure that there is no slack in the fuel tank breather hose or fuel tank overflow hose. 2. Fuel tank overflow hose 3. Intake solenoid coupler 4. Brake hose (hydraulic unit to left front brake caliper) 5.
  • Page 90 CABLE ROUTING Rectifier/regulator (left side view) J 14 2-45...
  • Page 91 CABLE ROUTING 1. Wire harness I. Make sure that the throttle cables do not twist between the throttle body assembly and the 2. Intake air temperature sensor coupler steering head pipe. 3. Fuel pump coupler J. Route the headlight lead to the rear of the 4.
  • Page 92 CABLE ROUTING Engine (left side view) I 10 2-47...
  • Page 93 2. Tail/brake light assembly coupler M. Insert the projection on the coupler into the 3. Yamaha diagnostic tool coupler hole in the bracket. 4. License plate light coupler N. Fit the starter motor lead between the bottom 5.
  • Page 94 CABLE ROUTING Frame (top view) 35 N 33 L 2-49...
  • Page 95 36. Rectifier/regulator bracket 37. Battery 38. Battery box 39. Lean angle sensor lead 40. Yamaha diagnostic tool coupler lead 41. Rear left turn signal light lead 42. Rear right turn signal light lead 43. Seat lock cable 44. License plate light lead 45.
  • Page 96 CABLE ROUTING Rear fender (top view) 2-51...
  • Page 97 CABLE ROUTING 1. Battery band 2. Wire harness 3. Positive battery lead 4. Negative battery lead 5. Fuse box 1 6. Fuse box 2 7. Lean angle sensor 8. Rear turn signal light lead (left turn signal light) 9. Rear turn signal light lead (right turn signal light) 10.
  • Page 98 CABLE ROUTING Rear fender (left side view) 2-53...
  • Page 99 CABLE ROUTING 1. Seat lock cable 2. License plate light lead 3. Rear turn signal light lead (right turn signal light) 4. Tail/brake light assembly lead 5. Tail/brake light assembly 6. Rear turn signal light lead (left turn signal light) 7.
  • Page 100 CABLE ROUTING Rear brake hose (right side view) 2-55...
  • Page 101 CABLE ROUTING 1. Rear wheel sensor lead 2. Rear brake fluid reservoir hose 3. Brake hose (rear brake master cylinder to hydraulic unit) 4. Brake hose (hydraulic unit to rear brake caliper) 5. O sensor lead 6. Rear brake light switch lead A.
  • Page 102 CABLE ROUTING Front brake hose (left and right side view) 2-57...
  • Page 103 CABLE ROUTING 1. Brake hose (hydraulic unit to left front brake caliper) 2. Front wheel sensor lead 3. Brake hose (left front brake caliper to right front brake caliper) 4. Brake hose (front brake master cylinder to hydraulic unit) A. Make sure that there is no slack in the front wheel sensor lead and that the lead is not pinched between the headlight unit side cover (right) and the brake hose (hydraulic unit to...
  • Page 104 CABLE ROUTING Hydraulic unit assembly (top and right side view) 2-59...
  • Page 105 CABLE ROUTING 1. Brake hose (rear brake master cylinder to hydraulic unit) 2. Brake hose (front brake master cylinder to hydraulic unit) 3. Brake hose (hydraulic unit to left front brake caliper) 4. Brake hose (hydraulic unit to rear brake caliper) A.
  • Page 106 CABLE ROUTING Fuel tank (left side view) 2-61...
  • Page 107 CABLE ROUTING 1. Fuel tank 2. Fuel hose 3. Fuel tank breather hose 4. Fuel tank overflow hose A. Face the blue paint mark on the fuel tank breather hose to the right. Install the hose up to the wide portion of the pipe. B.
  • Page 108 CABLE ROUTING Throttle bodies (top view) 2-63...
  • Page 109 CABLE ROUTING 1. Air filter case 2. Fuel hose 3. Surge tank hose 4. Surge tank 5. Intake solenoid 6. Intake solenoid vacuum hose (one-way valve to intake solenoid) 7. One-way valve 8. Intake solenoid vacuum hose (throttle body to one-way valve) 9.
  • Page 110 CABLE ROUTING Air filter case (left and right side view) 2-65...
  • Page 111 CABLE ROUTING 1. Throttle cable (accelerator cable) N. Face the blue paint mark on the surge tank hose downward. 2. Throttle cable (decelerator cable) O. Install the hose up to the bend in the hose 3. Intake air pressure sensor fitting.
  • Page 112 CABLE ROUTING Radiator (front view) 2-67...
  • Page 113 CABLE ROUTING 1. Radiator 2. Radiator cap 3. Coolant reservoir hose 4. Radiator inlet hose 5. Coolant reservoir 6. Radiator outlet hose A. Connect the end of the coolant reservoir hose that is identified by the white paint mark to the radiator.
  • Page 114 CABLE ROUTING Radiator (left side view) 2-69...
  • Page 115 CABLE ROUTING 1. Coolant reservoir hose 2. Radiator inlet hose 3. Thermostat housing 4. Oil cooler inlet hose 5. Coolant reservoir breather hose 6. Coolant reservoir 7. Coolant reservoir cap 8. Radiator 9. Radiator cap 10. AC magneto lead 11. Horn lead A.
  • Page 116 CABLE ROUTING Radiator (right side view) 2-71...
  • Page 117 CABLE ROUTING 1. Radiator inlet hose 2. Coolant reservoir hose 3. Radiator cap 4. Radiator 5. Coolant reservoir 6. Coolant reservoir breather hose 7. Radiator outlet hose 8. Oil cooler inlet hose A. Align the plastic locking tie with the white paint marks on the radiator inlet hose and coolant reservoir hose.
  • Page 118 CABLE ROUTING 2-73...
  • Page 119: 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 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE ENGINE IDLING SPEED ..........3-8 SYNCHRONIZING THE THROTTLE BODIES..........
  • Page 120 CHECKING AND LUBRICATING THE CABLES ........3-27 CHECKING THE THROTTLE GRIP OPERATION .........3-27 CHECKING AND CHARGING THE BATTERY........3-28 CHECKING THE FUSES ................3-28 REPLACING THE HEADLIGHT BULB............3-28 ADJUSTING THE HEADLIGHT BEAM ...........3-29...
  • Page 122: Periodic Maintenance

    UK, a mileage-based maintenance, is performed instead. • From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi). • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 123 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) • Check for cracks or damage. √ √ √ √ √...
  • Page 124 PERIODIC MAINTENANCE ODOMETER READING CHECK OR MAINTENANCE ANNUAL ITEM CHECK 1000 km 10000 km 20000 km 30000 km 40000 km (600 mi) (6000 mi) (12000 mi) (18000 mi) (24000 mi) Moving parts and √ √ √ √ √ • Lubricate. cables •...
  • Page 125: Checking The Fuel Line

    PERIODIC MAINTENANCE EAS30619 CHECKING THE FUEL LINE The following procedure applies to all of the fuel, vacuum and breather hoses. 1. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank top cover • Fuel tank cover (left) •...
  • Page 126: Adjusting The Valve Clearance

    PERIODIC MAINTENANCE 3. Check: • Fuel tank top cover • Spark plug type Refer to “GENERAL CHASSIS (4)” on page Incorrect → Change. 4-11. • Rider seat Manufacturer/model Refer to “GENERAL CHASSIS (1)” on page NGK/LMAR8A-9 4-1. 4. Check: EAS30622 ADJUSTING THE VALVE CLEARANCE •...
  • Page 127 PERIODIC MAINTENANCE 5. Measure: • Valve clearance Out of specification → Adjust. Valve clearance (cold) Intake 0.11–0.20 mm (0.0043–0.0079 in) Exhaust 0.24–0.30 mm (0.0094–0.0118 in) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 128 PERIODIC MAINTENANCE d. Calculate the sum of the values obtained in Valve lapper steps (b) and (c) to determine the required 90890-04101 valve pad thickness and the valve pad num- Valve lapping tool ber. YM-A8998 Example: 1.58 mm (0.0622 in) + 0.05 mm (0.0020 in) = 1.63 mm (0.0641 in) •...
  • Page 129: Checking The Engine Idling Speed

    ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Connect the Yamaha diagnostic tool. ing chain and camshaft caps. Use the diagnostic code number “67”. Exhaust camshaft cap bolt Refer to “SELF-DIAGNOSTIC FUNCTION 10 Nm (1.0 m·kgf, 7.2 ft·lbf) AND DIAGNOSTIC CODE TABLE” on page Intake camshaft cap bolt 9-5.
  • Page 130 PERIODIC MAINTENANCE • Fuel tank Engine idling speed Refer to “FUEL TANK” on page 7-1. 1100–1300 r/min 3. Disconnect: • Intake solenoid vacuum hose (throttle body to b. Check the vacuum pressure. one way valve) • Intake air pressure sensor hose The difference in vacuum pres- Refer to “THROTTLE BODIES”...
  • Page 131: Checking The Throttle Body Joints

    PERIODIC MAINTENANCE EAS30798 CHECKING THE THROTTLE BODY JOINTS 1. Remove: • Rider seat Refer to “GENERAL CHASSIS (1)” on page 4-1. • Fuel tank top cover • Fuel tank cover (left) • Fuel tank cover (right) • Fuel tank center cover •...
  • Page 132: Replacing The Air Filter Element And

    PERIODIC MAINTENANCE EAS31130 REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE There is an air filter check hose “1” at the bottom of the air filter case. If dust and/or water collects in this hose, clean the air filter check hose and replace the air filter element.
  • Page 133: Adjusting The Clutch Lever Free Play

    PERIODIC MAINTENANCE b. Turn the adjusting nut “2” in direction “a” or “b” EAS30629 ADJUSTING THE CLUTCH LEVER FREE until the specified clutch lever free play is ob- PLAY tained. 1. Check: • Clutch lever free play “a” Direction “a” Out of specification →...
  • Page 134: Checking The Front Brake Pads

    PERIODIC MAINTENANCE Position #1 Distance “a” is the largest. Position #5 Distance “a” is the smallest. EAS30631 ADJUSTING THE REAR DISC BRAKE 1. Adjust: • Brake pedal position ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
  • Page 135: Checking The Rear Brake Pads

    PERIODIC MAINTENANCE Refer to “FRONT BRAKE” on page 4-35, “REAR BRAKE” on page 4-49 and “ABS (AN- TI-LOCK BRAKE SYSTEM )” on page 4-62. EAS30893 BLEEDING THE HYDRAULIC BRAKE SYSTEM (ABS) EWA14000 WARNING Always bleed the brake system when the brake related parts are removed.
  • Page 136: Checking The Brake Fluid Level

    PERIODIC MAINTENANCE Brake caliper bleed screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) m. Fill the brake master cylinder reservoir or brake fluid reservoir to the proper level with the specified brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-15. EWA13110 WARNING After bleeding the hydraulic brake system,...
  • Page 137: Checking The Wheels

    PERIODIC MAINTENANCE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
  • Page 138: Checking The Wheel Bearings

    1. Check: en if a tire combination other than one • Swingarm operation Swingarm not working properly → Check the approved by Yamaha is used on this vehicle. swingarm. Front tire Refer to “SWINGARM” on page 4-95. Size 2.
  • Page 139 PERIODIC MAINTENANCE arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its. 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 a suitable stand so that the 5.
  • Page 140: Lubricating The Drive Chain

    PERIODIC MAINTENANCE EAS30803 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate.
  • Page 141: Checking The Fasteners

    PERIODIC MAINTENANCE EAS30647 EAS30653 CHECKING THE FASTENERS CHECKING THE FRONT FORK 1. Check: 1. Stand the vehicle on a level surface. • Fasteners EWA13120 WARNING Damage/pitting → Replace. Securely support the vehicle so that there is Refer to “GENERAL CHASSIS (1)” on page no danger of it falling over.
  • Page 142: Checking The Connecting Arm And Relay Arm

    PERIODIC MAINTENANCE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ 2. Start the engine, warm it up for several min- a. Adjust the spring preload with the special utes, and then turn it off. wrench “1”...
  • Page 143: Changing The Engine Oil

    PERIODIC MAINTENANCE 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. Before checking the engine oil level, wait a few minutes until the oil has settled. EAS30657 CHANGING THE ENGINE OIL 1.
  • Page 144: Measuring The Engine Oil Pressure

    PERIODIC MAINTENANCE 8. Install: • Engine oil filler cap (along with the O-ring 9. Start the engine, warm it up for several min- utes, and then turn it off. 10.Check: • Engine (for engine oil leaks) 11.Check: • Engine oil level 5.
  • Page 145: Checking The Coolant Level

    PERIODIC MAINTENANCE EAS30812 CHECKING THE COOLING SYSTEM Main gallery bolt 1. Check: 8 Nm (0.8 m·kgf, 5.8 ft·lbf) • Radiator “1” • Radiator inlet hose “2” • Radiator outlet hose “3” Lubricate the O-ring with a thin coat of lithium- •...
  • Page 146 PERIODIC MAINTENANCE Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re- sidual pressure to escape. When the hissing sound has stopped, press down on the radi- ator cap and turn it counterclockwise to re- move.
  • Page 147: Checking The Front Brake Light Switch

    PERIODIC MAINTENANCE EWA13040 WARNING • If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. • If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. •...
  • Page 148: Checking And Lubricating The Cables

    PERIODIC MAINTENANCE Recommended lubricant Suitable cable lubricant With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when released. Repeat this check with the handlebar turned all the way to the left and right.
  • Page 149: Checking And Charging The Battery

    PERIODIC MAINTENANCE EAS30816 CHECKING AND CHARGING THE BATTERY Refer to “CHECKING AND CHARGING THE BATTERY” on page 8-128. EAS30662 CHECKING THE FUSES Refer to “CHECKING THE FUSES” on page 8-127. EAS30665 REPLACING THE HEADLIGHT BULB 1. Remove: • Headlight assembly bolts “1” If the specified throttle grip free play cannot be obtained on the throttle body side of the cable, use the adjusting nut on the handlebar side.
  • Page 150: Adjusting The Headlight Beam

    PERIODIC MAINTENANCE 4. Unhook: 10.Install: • Headlight bulb holder “1” • Headlight assembly “1” 5. Remove: • Headlight bulb “2” Fit the projections “a” on the headlight bracket into the holes “b” in the headlight assembly. EWA13320 WARNING 11.Install: Since the headlight bulb gets extremely hot, •...
  • Page 151 PERIODIC MAINTENANCE ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the adjusting screw “1” in direction “b” or “c”. To adjust the headlight beam (vertically), insert Direction “b” a crosshead screwdriver into the hole “a”...
  • Page 152 PERIODIC MAINTENANCE 3-31...
  • Page 153: Chassis

    CHASSIS GENERAL CHASSIS (1) ................. 4-1 INSTALLING THE RIDER SEAT............... 4-2 INSTALLING THE PASSENGER SEAT............ 4-2 GENERAL CHASSIS (2) ................. 4-3 REMOVING THE CENTER COVER ............4-5 INSTALLING THE CENTER COVER............4-5 REMOVING THE UPPER TAIL COVER ........... 4-5 INSTALLING THE UPPER TAIL COVER..........4-5 REMOVING THE REAR SIDE COVERS ..........
  • Page 154 REAR WHEEL ....................4-26 REMOVING THE REAR WHEEL (DISC BRAKE)........4-30 DISASSEMBLING THE REAR WHEEL ..........4-30 CHECKING THE REAR WHEEL............. 4-30 CHECKING THE REAR WHEEL DRIVE HUB ........4-30 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-31 MAINTENANCE OF THE REAR WHEEL SENSOR AND SENSOR ROTOR ..................
  • Page 155 FRONT FORK....................4-75 REMOVING THE FRONT FENDER SIDE COVERS AND FRONT FORK LEGS................4-80 DISASSEMBLING THE FRONT FORK LEGS ........4-80 CHECKING THE FRONT FORK LEGS ..........4-81 ASSEMBLING THE FRONT FORK LEGS ..........4-81 INSTALLING THE FRONT FORK LEGS AND FRONT FENDER SIDE COVERS ............
  • Page 156: General Chassis (1)

    GENERAL CHASSIS (1) EAS20026 GENERAL CHASSIS (1) Removing the seats and battery 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.2 Nm (0.22 m kgf, 1.6 ft Ibf) •...
  • Page 157: Installing The Rider Seat

    GENERAL CHASSIS (1) EAS31125 INSTALLING THE RIDER SEAT 1. Install: • Rider seat “1” Rider seat bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Fit the slot “a” in the rider seat onto the projection “b” on the rider seat bracket as shown, and then place the seat in the original position.
  • Page 158: General Chassis (2)

    GENERAL CHASSIS (2) EAS20155 GENERAL CHASSIS (2) Removing the covers, tail/brake light assembly, and mudguard 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 3.3 Nm (0.33 m kgf, 2.4 ft Ibf) •...
  • Page 159 GENERAL CHASSIS (2) Removing the covers, tail/brake light assembly, and mudguard 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • 3.3 Nm (0.33 m kgf, 2.4 ft Ibf) • •...
  • Page 160: Removing The Center Cover

    GENERAL CHASSIS (2) EAS31094 REMOVING THE CENTER COVER 1. Remove: • Center cover “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the center cover screws “2”. b. Unhook the projections “a” on the center cov- er from the rear side covers.
  • Page 161: Installing The Rear Side Covers

    GENERAL CHASSIS (2) ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ EAS31099 EAS31127 INSTALLING THE REAR SIDE COVERS INSTALLING THE LOWER TAIL COVER...
  • Page 162: General Chassis (3)

    GENERAL CHASSIS (2) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Fit the projections “a” on the lower fender cover into the holes “b” in the battery box. b. Install the quick fastener. ▲...
  • Page 163 GENERAL CHASSIS (3) EAS20156 GENERAL CHASSIS (3) Removing the headlight and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) •...
  • Page 164 GENERAL CHASSIS (3) Removing the headlight and meter assembly 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 1.3 Nm (0.13 m kgf, 0.94 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) • • 0.8 Nm (0.08 m kgf, 0.58 ft Ibf) •...
  • Page 165: Installing The Headlight Assembly

    GENERAL CHASSIS (3) EAS31128 INSTALLING THE HEADLIGHT ASSEMBLY 1. Install: • Headlight assembly “1” • Headlight assembly bolts “2” Headlight assembly bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) • Fit the projections “a” on the headlight bracket into the holes “b” in the headlight assembly. •...
  • Page 166 GENERAL CHASSIS (4) EAS20157 GENERAL CHASSIS (4) Removing the fuel tank covers and air scoops 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) •...
  • Page 167: Removing The Fuel Tank Top Cover

    GENERAL CHASSIS (4) EAS31102 REMOVING THE FUEL TANK TOP COVER 1. Remove: • Fuel tank top cover “1” ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the fuel tank top cover bolt “2”. b.
  • Page 168: Removing The Fuel Tank Center Cover

    GENERAL CHASSIS (4) b. Fit the projections “e” on the fuel tank cover ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ into the holes “f” in the fuel tank center cover. EAS31107 INSTALLING THE FUEL TANK CENTER COVER...