Yamaha YZF-R15 Service Manual
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Yamaha YZF-R15 Service Manual

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2008
SERVICE MANUAL
YZF-R15
20P-F8197-E0

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Summary of Contents for Yamaha YZF-R15

  • Page 1 2008 SERVICE MANUAL YZF-R15 20P-F8197-E0...
  • Page 2 YZF-R15 SERVICE MANUAL All rights reserved. Any reproduction or unauthorized use without the written permission of YAMAHA MOTOR INDIA SALES PVT. LTD. is expressly prohibited.
  • Page 3 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. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.
  • Page 4 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

    SYMBOLS 1. Serviceable with engine mounted 2. Filling fluid The following symbols are used in this manual for 3. Lubricant easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 6: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 7: General Information

    GENERAL INFORMATION IDENTIFICATION ....................1-1 VEHICLE IDENTIFICATION NUMBER............1-1 ENGINE SERIAL NUMBER ...............1-1 FEATURES ......................1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 IMPORTANT INFORMATION ................1-4 PREPARATION FOR REMOVALAND DISASSEMBLY.......1-5 REPLACEMENT PARTS................1-5 GASKETS, OIL SEALS AND O-RINGS ............1-5 LOCK WASHERS/PLATES AND COTTER PINS........1-5 BEARINGS AND OIL SEALS..............1-6 CIRCLIPS....................1-6 CHECKING THE CONNECTIONS...

  • Page 8: Identification

    IDENTIFICATION IDENTIFICATION VEHICLE IDENTIFICATION NUMBER (FRAME NO.) The vehicle identification number “1” is stamped into the frame. ENGINE SERIAL NUMBER The engine serial number “1” is stamped into the crankcase. NOTE: Designs and specifications are subject to change without notice.

  • Page 9: Features

    FEATURES FEATURES 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 10: Fi System

    FEATURES 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 only 250 kPa (2.50 kg/cm², 35.6 psi). 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 11: Multi-Function Display

    FEATURES MULTI-FUNCTION DISPLAY Tripmeter will reset itself automatically and the display will return to the prior mode after refueling and traveling 5 km (3 mi). Fuel meter 1. Multi-function display 2. “RESET/SELECT” button 1. Fuel meter The multi-function display is equipped with the following: The fuel meter indicates the amount of fuel in the •...

  • Page 12: Important Information

    5. Keep all parts away from any source of fire. REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. 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 13: Bearings And Oil Seals

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

  • Page 14: Checking The Connections

    CHECKING THE CONNECTIONS CHECKING THE CONNECTIONS NOTE: • If there is no continuity, clean the terminals. Check the leads couplers and connectors for • When checking the wire harness, perform stains rust moisture etc steps (1) to (3). Disconnect • As a quick remedy, use a contact revitalizer •...

  • Page 15: Special Tools

    SPECIAL TOOLS 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. Tool name/Tool No. Illustration T appet screw holder YSST-706...
  • Page 16 SPECIAL TOOLS Tool name/Tool No. Illustration Crank Shaft Installing Tool with Spacer (a) YSST-266 (b) YSST-267 These tools are used for installation of Crank Shaft. Crankshaft removing tool YSST-265 This tool is used to remove the Crank Shaft from the Crank Case. Clutch hub holder YSST-733 This tool is used to hold the Clutch Hub while...
  • Page 17 SPECIAL TOOLS Tool name/Tool No. Illustration Radiator cap tester This instrument is used to test the radiator cap functionality. Radiator cap tester adapter This adapter is used to connect the radiator cap tester with radiator cap for radiator cap testing. Fuel Pressure gauge This instrument is used to measure the fuel pressure.
  • Page 18 SPECIAL TOOLS Reference Tool name/Tool No. Illustration Mechanical seal/bearing Installer YSST-722 This tool is used to install the seal and bearing in water pump assy. Ignition checker This instrument is used to check the effficiency of ignition at spark plug. Multimeter This instrument is used to check the electrical circuits or components.

  • Page 19: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-9 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUES ................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-15 ENGINE TIGHTENING TORQUES............2-16 CHASSIS TIGHTENING TORQUES............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE....................2-22 CHASSIS....................2-24 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-25 ENGINE OIL LUBRICATION CHART ............2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS...

  • Page 20: General Specifications

    GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model 20 P1 Dimensions Overall length 1995 mm Overall width 670 mm Overall height 1070 mm Seat height 790 mm Wheelbase 1290 mm Ground clearance 160 mm Minimum turning radius 2500 mm Weight With oil and fuel 131 kg Maximum load 199 kg...

  • Page 21: Engine Specifications

    ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Engine Engine type Liquid cooled stroke SOHC Displacement 149.8 Cylinder arrangement Forward-inclined single cylinder Bore x stroke 57.0 x 58.7 mm Compression ratio 10.40 :1 Compression pressure 5Psi 3.866 kgf cm ) Starting system Electric starter Fuel Recommended fuel Regular unleaded gasoline only...
  • Page 22 ENGINE SPECIFICATIONS Valve opening temperature 80.5–83.5 °C Valve full open temperature 95.0 °C Valve lift (full open) 3.0 mm Radiator core Width 198.0 mm Height 128.0 mm Depth 24.0 mm Water pump Water pump type Single suction centrifugal pump Reduction ratio ½...
  • Page 23 ENGINE SPECIFICATIONS Timing chain Model/number of links SILENT CHAIN/96 Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 9.985–10.000 mm Limit 10.030 mm Rocker arm shaft outside diameter 9.966–9.976 mm Limit 9.950 mm Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm Limit 0.08 mm Valve, valve seat, valve guide Valve clearance (cold)
  • Page 24 ENGINE SPECIFICATIONS Limit 0.080 mm Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm Limit 0.100 mm Valve stem runout 0.010 mm Valve spring Free length (intake) 41.71 mm Limit 39.62 mm Free length (exhaust) 41.71 mm Limit 39.62 mm Installed length (intake) 35.30 mm Installed length (exhaust) 35.30 mm Spring rate K1 (intake)
  • Page 25 ENGINE SPECIFICATIONS Height H Offset 0.25 Offset direction Intake side Piston pin bore inside diameter 14.002 14.013 – Limit 14.043 Piston pin outside diameter 13.995 14.000 – Limit 13.975 Piston pin to piston pin bore clearance 0.002 0.018 – Limit 0.068 Piston ring Top ring...
  • Page 26 ENGINE SPECIFICATIONS Connecting rod Small end inside diameter 14.015–14.028 mm Connected Rod Length 99.90–100.10 mm Crankshaft Width A 47.95–48.00 mm Runout limit C 0.030 mm Big end side clearance D 0.110–0.410 mm Big end radial clearance E 0.004–0.014 mm Balancer Balancer drive method Gear Clutch...
  • Page 27 ENGINE SPECIFICATIONS 30/16 (1.875) 30/2 (1. 24/21 (1.143) 22/23 (0.957) 21/25 (0.840) Shifting mechanism Shift mechanism type Shift drum and guide bar Shift fork L thickness 5.76 5.89 – Decompression device Device type Auto Decompression Air filter Air filter element Dry element Fuel injector Model quantity...

  • Page 28: Chassis Specifications

    CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Chassis Frame type Delta Box Caster angle 26.00 Trail 100.0 mm Front wheel Wheel type Cast wheel Rim size x 1.60. Rim material Aluminum Wheel travel 115.0 Radial wheel runout limit Lateral wheel runout limit Rear wheel Wheel type Cast wheel Rim size...
  • Page 29 CHASSIS SPECIFICATIONS Front disc brake Disc outside diameter & thickness 267.0 x 4.0 mm Brake disc thickness limit 3.5 mm Brake disc deflection limit 0.10 mm Brake pad lining thickness (inner) 5.3 mm Limit 0.8 mm Brake pad lining thickness (outer) 5.3 mm Limit 0.8 mm...
  • Page 30 CHASSIS SPECIFICATIONS Spring free length 166.8 mm Installed length 156.5 mm Spring rate K1 90.00 N/mm Spring stroke K1 0.0–50.0 mm Optional spring available Swingarm Swingarm end free play limit (axial) 2.4 mm Drive chain Type/manufacturer 428VI3/DAIDO Link quantity Drive chain slack 20–40 mm 15-link length limit 190.5 mm...

  • Page 31: Electrical Specifications

    ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Voltage System voltage Ignition system Ignition system Transistorized coil ignition digital Advancer type Digital Ignition timing B T D C ( ..) /1400 r/min Engine control unit Model manufacturer 3 100/ MORIC Ignition coil Primary coil resistance 2.16 2.64 –...
  • Page 32 ELECTRICAL SPECIFICATIONS Indicator light Neutral indicator light Turn signal indicator light High beam indicator light Coolant temperature warning light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer 3C1/PT. MORIC Power output 0.20 kW Armature coil resistance 0.0315–0.0385 Brush overall length 7.0 mm...
  • Page 33 ELECTRICAL SPECIFICATIONS Coil resistance 54.0–66.0 Fuse Fuse 20.0 A 2-14...

  • Page 34: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.

  • Page 35: Engine Tightening Torques

    TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Thread Item Tightening torque Remarks size Cylinder head bolt 22 Nm (2.2 m·kg, 16 ft·lb) Cylinder head bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Air cut-off valve assembly bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 36 TIGHTENING TORQUES Thread Item Tightening torque Remarks size Muffler protector screw 8 Nm (0.8 m·kg, 5.8 ft·lb) Crankcase bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Magneto cover bolt 10 Nm (1.0 m ·kg, 7.2 ft·lb) Clutch cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Drive sprocket cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Starter clutch bolt...
  • Page 37 TIGHTENING TORQUES Cylinder head tightening sequence: Magneto cover tightening sequence: 3,11 2,10 Clutch cover tightening sequence: 2,12 3,13 2-18...
  • Page 38 TIGHTENING TORQUES Crankcase tightening sequence: 2,12 2,12 3,13 A. Left crankcase B. Right crankcase 2-19...

  • Page 39: Chassis Tightening Torques

    TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Thread Item Tightening torque Remarks size Ignition coil bolt 9 Nm (0.9 m·kg, 6.5 ft·lb) Engine mounting nut (front side) 49 Nm (4.9 m·kg, 35 ft·lb) Engine mounting nut (rear lower 49 Nm (4.9 m·kg, 35 ft·lb) side) Engine mounting nut (rear upper 49 Nm (4.9 m·kg, 35 ft·lb)
  • Page 40 TIGHTENING TORQUES Thread Item Tightening torque Remarks size Damper rod bolt 28 Nm (2.8 m·kg, 20 ft·lb) Front turn signal light assembly 7 Nm (0.7 m·kg, 5.1 ft·lb) and meter assembly bracket bolt Horn bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Fuel tank and frame bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Fuel tank bracket and frame bolt...

  • Page 41: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips Bearings O-rings Cylinder head bolts and washers Connecting rod big end thrust surface Piston, Piston rings, and cylinder inner surface Balancer driven gear inner surface Camshaft lobes Decompression cam Valve stem seal...
  • Page 42 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Y amaha bond No. Crankshaft position sensor/stator assembly lead grommet 1215 (Three Bond No.1215®) Y amaha bond No. Crankcase mating surface 1215 (Three Bond No.1215®) Y amaha bond No. Timing chain tensioner bolts 1215 (Three Bond No.1215®) 2-23...

  • Page 43: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS Lubrication point Lubricant Front wheel oil seal lip Front wheel axle outer surface Speed sensor unit Rear wheel drive hub oil seal lip Rear wheel drive hub mating surface Rear wheel axle outer surface Rear wheel axle and nut threads Brake pedal pivoting point Brake caliper bracket boots inner surface...

  • Page 44: Lubrication System Chart And Diagrams

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART 2-25...
  • Page 45 LUBRICATION POINTS AND LUBRICANT TYPES 1. Oil pump 2. Oil filter element 3. Crankshaft 4. Camshaft 5. Main axle 6. Drive axle 2-26...

  • Page 46: Lubrication Diagrams

    LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION DIAGRAMS 2-27...
  • Page 47 LUBRICATION POINTS AND LUBRICANT TYPES 1. Clutch push lever 2. Main axle 3. Drive axle 4. Crankshaft 5. Oil filter 6. Oil pump assembly 7. Oil strainer A. T o cylinder head 2-28...
  • Page 48 LUBRICATION POINTS AND LUBRICANT TYPES 2-29...
  • Page 49 LUBRICATION POINTS AND LUBRICANT TYPES 1. Camshaft 2. Crankshaft 3. Main axle 4. Drive axle 2-30...

  • Page 50: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 2-31...
  • Page 51 COOLING SYSTEM DIAGRAMS 1. Coolant reservoir 2. Radiator inlet hose 3. Coolant reservoir hose 4. Radiator 5. Water pump 6. Radiator outlet hose 7. Water pump breather hose 2-32...

  • Page 52: Cable Routing

    CABLE ROUTING CABLE ROUTING 2-33...
  • Page 53 CABLE ROUTING 1. Head Light lead wire clamp. 2. Front flasher lead wire (left) 3. Head light lead wire 4. Meter harness 5. Auxiliary harness 6. Front flasher lead wire (right) 7. Right Handle bar switch lead wire 8. Brake switch lead wire 2-34...
  • Page 54 CABLE ROUTING 7 8 9 1 2 3 4 5 2-35...
  • Page 55 CABLE ROUTING 1. Throttle body 2. Coolant reservoir hose 3. Wire harness 4. Radiator inlet hose 5. Coolant temperature sensor lead 6. Throttle cable 7. Ignition coil 8. Spark plug lead 9. Air induction system vacuum hose 10. Right handlebar switch lead 11.
  • Page 56 CABLE ROUTING 2-37...
  • Page 57 CABLE ROUTING 1. ECU wiring harness clamp 2. Wire harness 3. Starter motor lead 4. Rear brake light switch lead 5. Rear brake hose 2-38...
  • Page 58 CABLE ROUTING 2-39...
  • Page 59 CABLE ROUTING 1. Front brake hose 2. Throttle cable 3. Left handlebar switch lead 4. Clutch cable 5. Wire harness (to horn) 6. Ignition coil 7. Air filter case silencer hose 8. Sidestand switch lead 9. Coolant reservoir hose 10. Fuel tank breather hose 11.
  • Page 60 CABLE ROUTING 2-41...
  • Page 61 CABLE ROUTING 1. Wire harness 2. Negative battery lead 3. Battery 4. Rectifier/regulator 5. Seat lock cable 6. T ail/brake light lead 7. Rear left turn signal light lead 8. Coolant reservoir breather hose 9. Neutral switch lead 10. Crankshaft position sensor/stator coil lead A.
  • Page 62 CABLE ROUTING ROUTING OF FUEL DRAIN PIPE While servicing of the vehicle, pay attention to route the fuel drain pipe. It should not have any bend during fitment, any bend may result the poor performance of an engine caused by water entry into the fuel tank.
  • Page 63 CABLE ROUTING 2-44...
  • Page 64 CABLE ROUTING 1. Coolant reservoir hose 2. Radiator inlet hose 3. Spark plug lead 4. Wire harness 5. FID (fast idle solenoid) lead 6. Fuel injector lead 7. Rear brake light switch lead 8. Throttle body sensor assembly 9. Ignition coil leads 10.
  • Page 65 CABLE ROUTING 2-46...
  • Page 66 CABLE ROUTING 1. Positive battery lead 2. Fuse box 3. Lean angle sensor 4. Condenser 5. Self-diagnosis signal lead 6. ECU (engine control unit) 7. Radiator fan motor relay 8. Starting circuit cut-off relay 9. Rear right turn signal light lead 10.

  • Page 67: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION..................3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....3-1 ENGINE ......................3-3 ADJUSTING THE VALVE CLEARANCE ..........3-3 ADJUSTING THE ENGINE IDLING SPEED........3-4 ADJUSTING THE EXHAUST GAS VOLUME ........3-5 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-6 CHECKING THE SPARK PLUG ............3-7 CHECKING THE IGNITION TIMING.............3-7 MEASURING THE COMPRESSION PRESSURE........3-8 CHECKING THE ENGINE OIL LEVEL..........3-9...
  • Page 68 TROUBLESHOOTING ELECTRICAL SYSTEM.................3-26 CHECKING AND CHARGING THE BATTERY........3-26 CHECKING THE FUSE..............3-26 REPLACING THE HEADLIGHT BULB..........3-26 ADJUSTING THE HEADLIGHT BEAM ..........3-27...

  • Page 69: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long- er service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 70 PERIODIC MAINTENANCE ODOMETER READING (x 1000 km) ITEM CHECK OR MAINTENANCE JOB • Check bearing play and steering for √ √ √ √ √ √ roughness. 15 * Steering • Lubricate with lithium-soap-based bearings Every 12000 km grease. • Make sure that all nuts, bolts and screws 16 * Chassis √...

  • Page 71: Engine

    ENGINE ENGINE Valve clearance (cold) Intake 0.10–0.14 mm ADJUSTING THE VALVE CLEARANCE Exhaust The following procedure applies to all of the 0.20–0.24 mm valves. s s s s s s s s s s s s s s s s s s s s s s s s NOTE: a.

  • Page 72: Adjusting The Engine Idling Speed

    ENGINE 8. Install: Cylinder head cover gasket Cylinder head cover Refer to “CYLINDER HEAD” on page 5-6. Reed valve plate Reed valve Air cut-off valve Refer to “AIR INDUCTION SYSTEM” on page 7-9. 9. Connect: c. Turn the adjusting screw “3” in direction “a” or Air induction system hose (3-way joint to air “b”...

  • Page 73: Adjusting The Exhaust Gas Volume

    ENGINE s s s s s s s s s s s s s s s s s s s s s s s s a. Turn the pilot screw “1” in direction “a” or “b” FI diagnostic tool until the specified engine idling speed is ob- tained.

  • Page 74: Adjusting The Throttle Cable Free Play

    ENGINE Throttle cable free play 3.0–5.0 mm FI Diagnostic Tool 2. Adjust: 1400rpm Throttle cable free play C1 : -10 s s s s s s s s s s s s s s s s s s s s s s s s Throttle body side a.

  • Page 75: Checking The Spark Plug

    ENGINE 7. Measure: Spark plug gap “a” (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.7–0.8 mm d. Tighten the locknut e. Slide the rubber cover to its original position. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to the right or left to ensure that this does not cause the engine idling speed to change.

  • Page 76: Measuring The Compression Pressure

    ENGINE 2. Remove: 6. Remove: Seat Digital tachometer Refer to “GENERAL CHASSIS” on page 4-1. Timing light 3. Lift the front of the fuel tank. (Do not discon- 7. Install: nect the fuel hose.) Fuel tank 4. Connect: Refer to “FUEL TANK ” on page 7-1. Timing light “1”...

  • Page 77: Checking The Engine Oil Level

    ENGINE Seat Refer to “GENERAL CHASSIS” on page 4-1. 12.Install: Spark plug Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) 13.Connect: Spark plug cap 14.Install: 9. Measure: Right front panel Compression pressure Refer to “GENERAL CHASSIS” on page 4-1. Out of specification → Refer to steps (c) and (d).

  • Page 78: Changing The Engine Oil

    ENGINE CAUTION: Do not allow foreign materials to enter the crankcase. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.

  • Page 79: Adjusting The Clutch Cable Free Play

    ENGINE 12.Check: 2. Adjust: Engine oil level Clutch cable free play Refer to “CHECKING THE ENGINE OIL LEVEL” on page 3-9. Handlebar side 13.Check: a. Pull back the rubber cover “1” Engine oil pressure b. Loosen the locknut “2”. s s s s s s s s s s s s s s s s s s s s s s s s c.

  • Page 80: Cleaning The Air Filter Element

    ENGINE 3. Clean: Air filter element “1” Apply compressed air to the outer surface of the air filter element. c. Tighten the locknut. Locknut 7 Nm (0.7 m·kg, 5.1 ft·lb) 4. Check: ssssssssssssssssssssssss Air filter element Damage → Replace. CLEANING THE AIR FILTER ELEMENT 5.

  • Page 81: Checking The Fuel Line

    ENGINE Loose connection → Connect properly. CAUTION: Make sure the cylinder head breather hose is routed correctly. 3. Install: Fuel tank Refer to “FUEL TANK ” on page 7-1. Seat Refer to “GENERAL CHASSIS” on page 4-1. 3. Install: CHECKING THE FUEL LINE Fuel tank Refer to “FUEL TANK ”...

  • Page 82: Checking The Cooling System

    ENGINE Make sure the vehicle is upright. CHECKING THE COOLING SYSTEM 2. Check: 1. Remove: Coolant level Front panels The coolant level should be between the Seat maximum level mark “a” and minimum level Refer to “GENERAL CHASSIS” on page 4-1. mark “b”.
  • Page 83 ENGINE 7. Drain: WARNING Coolant A hot radiator is under pressure. Therefore, (from the coolant reservoir) do not remove the radiator cap when the en- 8. Install: gine is hot. Scalding hot fluid and steam may Coolant reservoir be blown out, which could cause serious in- Coolant reservoir bolt jury.
  • Page 84 ENGINE If coolant splashes on your clothes, quickly 18.Install: wash it away with water and then with soap Seat and water. Refer to “GENERAL CHASSIS” on page 4-1. If coolant is swallowed, induce vomiting Side panels and get immediate medical attention. Refer to “GENERAL CHASSIS”...

  • Page 85: Chassis

    CHASSIS CHASSIS WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake ADJUSTING THE REAR DISC BRAKE system. Before the vehicle is operated, the 1. Check: air must be removed by bleeding the brake Brake pedal position system.

  • Page 86: Checking The Front Brake Pads

    CHASSIS 1. Operate the brake. 2. Check: Front brake pad Wear indicator grooves “a” have almost dis- appeared → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-15. A. Front brake B. Rear brake WARNING Use only the designated brake fluid.

  • Page 87: Checking The Reart Brake Hose

    CHASSIS the brake fluid level is very low. brake operation is faulty. NOTE: Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.

  • Page 88: Adjusting The Drive Chain Slack

    CHASSIS f. Fully pull the brake lever or fully press down 2. Spin the rear wheel several times and find the the brake pedal and hold it in position. tightest position of drive chain. g. Loosen the bleed screw. 3. Check: Drive chain slack “a”...

  • Page 89: Lubricating The Drive Chain

    CHASSIS NOTE: Wheel axle nut Place the vehicle on a suitable stand so that the 110 Nm (11.0 m· kg, 80 ft ·lb) front wheel is elevated. ssssssssssssssssssssssss 2. Check: Steering head LUBRICATING THE DRIVE CHAIN Grasp the bottom of the front fork legs and The drive chain consists of many interacting gently rock the front fork.

  • Page 90: Checking The Front Fork

    CHASSIS NOTE: Set the torque wrench at a right angle to the steering nut wrench. 5. Install: Upper bracket Refer to “STEERING HEAD” on page 4-49. CHECKING THE FRONT FORK Steering nut socket 1. Stand the vehicle on a level surface. YSST-721 WARNING Securely support the vehicle so that there is...
  • Page 91 (including cargo, rid- tyre combination other than one approved er, passenger and accessories) and the by YAMAHA is used on this vehicle. anticipated riding speed. Operation of an overloaded vehicle could cause tyre damage, an accident or an injury.

  • Page 92: Checking The Wheels

    CHASSIS CHECKING AND LUBRICATING THE Rear tyre CABLES Size The following procedure applies to all of the in- 100/80–17 M/C 52P ner and outer cables. Manufacturer/model MRF/ZAPPER WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- WARNING place damaged outer cable and inner cables New tyres have a relatively low grip on the...

  • Page 93: Lubricating The Brake Lever

    CHASSIS LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal-to-metal moving parts of the lever. Recommended lubricant Silicone grease LUBRICATING THE PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the pedals. Recommended lubricant Lithium-soap-based grease LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.
  • Page 94 ELECTRICAL SYSTEM ELECTRICAL SYSTEM WARNING Since the headlight bulb gets extremely hot, CHECKING AND CHARGING THE BATTERY keep flammable products and your hands Refer to “ELECTRICAL COMPONENTS” on away from the bulb until it has cooled down. page 8-61 CHECKING THE FUSES 4.
  • Page 95 ELECTRICAL SYSTEM a. Turn the adjusting screw “1” in direction “a” or “b”. Direction “a” Headlight beam is lowered. Direction “b” Headlight beam is raised. 4. Remove: • Headlight bulb “1” WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
  • Page 96 CHASSIS GENERAL CHASSIS..................4-1 INSTALLING THE AIR FILTER CASE ...........4-3 FRONT WHEEL....................4-4 REMOVING THE FRONT WHEEL............4-6 DISASSEMBLING THE FRONT WHEEL..........4-6 CHECKING THE FRONT WHEEL ............4-6 ASSEMBLING THE FRONT WHEEL............4-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-7 INSTALLING THE FRONT WHEEL (DISC) ..........4-8 REAR WHEEL....................4-10 REMOVING THE REAR WHEEL (DISC)..........4-13 DISASSEMBLING THE REAR WHEEL..........4-13...
  • Page 97 CHASSIS FRONT FORK....................4-41 REMOVING THE FRONT FORK LEGS..........4-44 DISASSEMBLING THE FRONT FORK LEGS........4-44 CHECKING THE FRONT FORK LEGS ..........4-45 ASSEMBLING THE FRONT FORK LEGS..........4-45 INSTALLING THE FRONT FORK LEGS ..........4-48 STEERING HEAD..................4-49 REMOVING THE LOWER BRACKET..........4-51 CHECKING THE STEERING HEAD...........4-51 INSTALLING THE STEERING HEAD..........4-51 REAR SHOCK ABSORBER ASSEMBLY ............4-53 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY....4-54...
  • Page 98 GENERAL CHASSIS GENERAL CHASSIS Removing the seat and covers 7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 26 Nm (2.6 m kg, 19 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 7 Nm (0.7 m Order...
  • Page 99 GENERAL CHASSIS Removing the air filter case 2 Nm (0.2 m kg, 1.4 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS” on page Seat/Left and Right side cover 4-1.

  • Page 100: General Chassis

    GENERAL CHASSIS INSTALLING THE AIR FILTER CASE 1. Install: Air filter case joint clamp NOTE: Align the projection “a” on the air filter case with the slot “b” in the air filter case joint clamp.

  • Page 101: Front Wheel

    FRONT WHEEL FRONT WHEEL Removing the front wheel and brake discs 23 Nm (2.3 m kg, 17 ft Ib) 7 Nm (0.7 m kg, 5.1 ft Ib) 60 Nm (6.0 m kg, 43 ft Ib) Order Job/Parts to remove Remarks Speed sensor lead holder Front wheel axle nut Front wheel axle...
  • Page 102 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Remarks Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly pro- cedure.

  • Page 103: Removing The Front Wheel

    FRONT WHEEL REMOVING THE FRONT WHEEL sssssssssssssssssssssssssssssssssssss 1. Stand the vehicle on a level surface. CHECKING THE FRONT WHEEL WARNING 1. Check: Wheel axle Securely support the vehicle so that there is Roll the wheel axle on a flat surface. no danger of it falling over.

  • Page 104: Assembling The Front Wheel

    FRONT WHEEL 4. Check: Wheel bearings Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings. BALANCE Oil seal NOTE: Damage/wear → Replace. After replacing the tyre, wheel or both, the front wheel static balance should be adjusted.

  • Page 105: Installing The Front Wheel (Disc)

    FRONT WHEEL s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s a.
  • Page 106 FRONT WHEEL NOTE: WARNING Install the tyre and wheel with the mark“1” point- Make sure the brake hose is routed properly. ing in the direction of wheel rotation. CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- 5.

  • Page 107: Rear Wheel

    REAR WHEEL REAR WHEEL Removing the rear wheel assembly 110 Nm (11.0 m kg, 80 ft Ib) Order Job/Parts to remove Remarks Rear wheel axle nut Rear wheel axle Drive chain puller Collar Collar Rear wheel For installation, reverse the removal proce- dure.
  • Page 108 REAR WHEEL Removing the brake disc and rear wheel sprocket 18 Nm (1.8 m kg, 13 ft Ib) 43 Nm (4.3 m kg, 31 ft Ib) Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Oil seal Bearing Rear wheel drive hub Collar...
  • Page 109 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Remarks Bearing Spacer Oil seal Bearing For assembly, reverse the disassembly pro- cedure. 4-12...

  • Page 110: Removing The Rear Wheel (Disc)

    REAR WHEEL Refer to “CHECKING THE TYRES” on page REMOVING THE REAR WHEEL (DISC) 3-23 and “CHECKING THE WHEELS” on 1. Stand the vehicle on a level surface. page 3-25. 3. Measure: WARNING • Radial wheel runout Securely support the vehicle so that there is •...

  • Page 111: Assembling The Rear Wheel

    REAR WHEEL s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s Rear brake disc bolt a.

  • Page 112: Front Brake

    FRONT BRAKE FRONT BRAKE Removing the front brake pads 7 Nm (0.7 m kg, 5.1 ft Ib) 6 Nm (0.6 m kg, 4.3 ft Ib) 35 Nm (3.5 m kg, 25 ft Ib) Order Job/Parts to remove Remarks The following procedure applies to both of the front brake calipers.
  • Page 113 FRONT BRAKE Removing the front brake master cylinder 26 Nm (2.6 m kg, 19 ft Ib) • • 7 Nm (0.7 m kg, 5 ft Ib) • • Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 114 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Remarks Dust boot Circlip Washer Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-17...

  • Page 115: Introduction

    FRONT BRAKE s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s INTRODUCTION a.

  • Page 116: Replacing The Front Brake Pads

    FRONT BRAKE 2. Install: Brake pads Brake pad spring NOTE: Always install new brake pads and a new brake pad spring as a set. s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s a.

  • Page 117: Removing The Front Brake Caliper

    FRONT BRAKE b. Remove the brake caliper piston seals and REMOVING THE FRONT BRAKE CALIPER dust seals. NOTE: Before disassembling the brake caliper, drain sssssssssssssssssssssssssssssssssssssss the brake fluid from the entire brake system. CHECKING THE FRONT BRAKE CALIPER 1. Remove: Recommended brake component replace- Brake hose union bolt ment schedule...

  • Page 118: Assembling The Front Brake Caliper

    FRONT BRAKE 3. Install: ASSEMBLING THE FRONT BRAKE CALIPER Brake pad spring Brake pads WARNING Brake caliper Before installation, all internal brake com- Brake hose holder ponents should be cleaned and lubricated with clean or new brake fluid. Brake caliper bolt Never use solvents on internal brake com- 35 Nm (3.5 m·kg, 25 ft·lb) ponents as they will cause the piston seals...

  • Page 119: Removing The Front Brake Master Cylinder

    FRONT BRAKE CHECKING THE FRONT BRAKE MASTER CYLINDER 1. Check: Brake master cylinder“1” Damage/scratches/wear → Replace. Brake fluid delivery passages“2” (brake master cylinder body) Obstruction → Blow out with compressed air. 7. Check: Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem.
  • Page 120 FRONT BRAKE 3. Fill: NOTE: Brake master cylinder reservoir Install the brake master cylinder holder with the (with the specified amount of the recom- “UP” mark facing up. mended brake fluid) Align the end of the brake master cylinder hold- er with the punch mark “a”...
  • Page 121 FRONT BRAKE Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-18. 4-24...

  • Page 122: Rear Brake

    REAR BRAKE REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kg, 4.3 ft Ib) • • 18 Nm (1.8 m kg, 13 ft Ib) • • Order Job/Parts to remove Remarks Rear wheel Refer to “REAR WHEEL” on page 4-10. Rear brake caliper Brake pad retaining bolt Rear brake pad...
  • Page 123 REAR BRAKE Removing the rear brake master cylinder 26 Nm (2.6 m kg, 19 ft Ib) • • 13 Nm (1.3 m kg, 9.4 ft Ib) • • Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS” on page Right side panel 4-1.
  • Page 124 REAR BRAKE Disassembling the rear brake master cylinder 17 Nm (1.7 m kg, 12 ft Ib) • • Order Job/Parts to remove Remarks Brake hose joint Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
  • Page 125 REAR BRAKE Removing the rear brake caliper 7 Nm (0.7 m kg, 5.1 ft Ib) • • 26 Nm (2.6 m kg, 19 ft Ib) • • Order Job/Parts to remove Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
  • Page 126 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.2 ft Ib) • • 18 Nm (1.8 m kg, 13 ft Ib) • • Order Job/Parts to remove Remarks Brake pad retaining bolt Rear brake pad Brake pad spring Brake caliper bracket Brake caliper piston Brake caliper piston dust seal...

  • Page 127: Checking The Rear Brake Disc

    REAR BRAKE INTRODUCTION Brake disc thickness limit 4.0 mm 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 Never disassemble brake components un- DISC”...

  • Page 128: Removing The Rear Brake Caliper

    REAR BRAKE NOTE: Brake pad lining thickness (in- Install the brake pad spring as shown. ner) 7.0 mm Limit 1.5 mm Brake pad lining thickness (out- 7.0 mm Limit 1.5 mm sssssssssssssssssssssssssssssssssssssss sssssssssssssssssssssssssssssssssssssss 4. Install: • Brake pad retaining bolts •...

  • Page 129: Disassembling The Rear Brake Caliper

    REAR BRAKE 1. Remove: • Union bolt “1” • Copper washers “2” • Brake hose “3” b. Remove the brake caliper piston seal and dust seal. sssssssssssssssssssssssssssssssssssssss CHECKING THE REAR BRAKE CALIPER NOTE: Put the end of the brake hose into a container Recommended brake component and pump out the brake fluid carefully.

  • Page 130: Assembling The Rear Brake Caliper

    REAR BRAKE WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and piston seals. 2. Check: • Brake caliper bracket Cracks/damage → Replace. ASSEMBLING THE REAR BRAKE CALIPER 2. Install: • Brake pad spring WARNING •...

  • Page 131: Removing The Rear Brake Master Cylinder

    REAR BRAKE 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-19. 6. 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 132: Installing The Rear Brake Master Cylinder

    REAR BRAKE INSTALLING THE REAR BRAKE MASTER CAUTION: CYLINDER Brake fluid may damage painted surfaces 1. Install: and plastic parts. Therefore, always clean up • Copper washers “1” any spilt brake fluid immediately. • Brake hose “2” 3. Bleed: • Rear brake light switch “3” •...
  • Page 133 HANDLEBARS HANDLEBARS Removing the handlebars 9 Nm (0.9 m kg, 6.5 ft Ib) • • 7 Nm (0.7 m kg, 5.0 ft Ib) 7 Nm (0.7 m kg, 5.0 ft Ib) • • • • 9 Nm (0.9 m kg, 6.5 ft Ib) •...
  • Page 134 HANDLEBARS Removing the handlebars 9 Nm (0.9 m kg, 6.5 ft Ib) • • 7 Nm (0.7 m kg, 5.0 ft Ib) 7 Nm (0.7 m kg, 5.0 ft Ib) • • • • 9 Nm (0.9 m kg, 6.5 ft Ib) •...

  • Page 135: Handlebar

    HANDLEBARS • Align the mating surfaces of the brake master REMOVING THE HANDLEBARS cylinder holder with the punch mark “b” on the 1. Stand the vehicle on a level surface. handlebar. • First, tighten the front bolt, then the rear bolt. WARNING Securely support the vehicle so that there is no danger of it falling over.
  • Page 136 HANDLEBARS NOTE: Align the projection “a” on the clutch switch with the slit “b” in the clutch lever holder. 5. Install: • Right grip end “1” NOTE: There should be 1–3 mm (0.04–0.12 in) of clear- 8. Connect: ance “a” between the throttle grip and the right •...
  • Page 137 HANDLEBARS NOTE: There should be 3 mm of clearance“a” between the handlebar grip and the grip end. s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s 12.Check: •...

  • Page 138: Front Fork

    FRONT FORK FRONT FORK Removing the front fork legs 9 Nm (0.9 m kg, 6.5 ft Ib) • • 23 Nm (2.3 m kg, 17 ft Ib) • • 28 Nm (2.8 m kg, 20 ft Ib) • • 7 Nm (0.7 m kg, 5.1 ft Ib) •...
  • Page 139 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft Ib) • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Parts to remove Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer...
  • Page 140 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft Ib) • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Remarks Outer tube For assembly, reverse the disassembly pro- cedure. 4-43...

  • Page 141: Removing The Front Fork Legs

    FRONT FORK REMOVING THE FRONT FORK LEGS 2. Drain: The following procedure applies to both of the • Fork oil front fork legs. NOTE: 1. Stand the vehicle on a level surface. Stroke the inner tube several times while drain- ing the fork oil.

  • Page 142: Checking The Front Fork Legs

    FRONT FORK 3. Check: NOTE: • Damper rod While holding the damper rod with the damper Damage/wear → Replace. rod holder “2” and T-handle “3”, loosen the Obstruction → Blow out all of the oil passag- damper rod bolt. es with compressed air. •...
  • Page 143 FRONT FORK Recommended oil Fork oil 10W or equivalent 3. Tighten: • Damper rod bolt “1” Damper rod bolt 28 Nm (2.8 m·kg, 20 ft·lb) NOTE: 5. Install: While holding the damper rod with the damper • Oil seal “1” rod holder “2”...
  • Page 144 FRONT FORK Recommended oil Fork oil 10W or equivalent Quantity Total-240± 3cm ³ CAUTION: Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance. When disassembling and assembling the 6. Install: front fork leg, do not allow any foreign ma- •...

  • Page 145: Installing The Front Fork Legs

    FRONT FORK 12.Install: 2. Tighten: • Fork spring “1” • Lower bracket pinch bolt “1” NOTE: Lower bracket pinch bolt Install the spring with the smaller pitch “a” facing 28 Nm (2.8 m·kg, 20 ft·lb) • Upper bracket pinch bolt “2” Upper bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) •...

  • Page 146: Steering Head

    STEERING HEAD STEERING HEAD Removing the lower bracket 22 Nm (2.2 m kg, 16 ft lb) • • 35 Nm (3.5 m kg, 25 ft lb) • • 7 Nm (0.7 m kg, 5.0 ft Ib) • • 1st 48 Nm (4.8 m kg, 35 ft lb) •...
  • Page 147 STEERING HEAD Removing the lower bracket 35 Nm (3.5 m kg, 25 ft lb) • • 7 Nm (0.7 m kg, 5.0 ft Ib) • • 1st 48 Nm (4.8 m kg, 35 ft lb) • • 7 Nm (0.7 m kg, 5.1 ft Ib) •...

  • Page 148: Removing The Lower Bracket

    STEERING HEAD b. Remove the bearing race from the lower REMOVING THE LOWER BRACKET bracket with a floor chisel “2” and hammer. 1. Stand the vehicle on a level surface. c. Install a new dust seal and new bearing rac- WARNING Securely support the vehicle so that there is CAUTION:...
  • Page 149 STEERING HEAD • Upper ring nut • Lock washer Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-21. 3. Install: • Upper bracket • Steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • Front fork legs Refer to “FRONT FORK”...
  • Page 150 REAR SHOCK ABSORBER ASSEMBLY REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 44 Nm (4.4 m kg, 32 ft Ib) 44 Nm (4.4 m kg, 32 ft Ib) 44 Nm (4.4 m kg, 32 ft Ib) Order Job/Parts to remove Remarks Connecting arm nut/bolt Connecting arm...

  • Page 151: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY 2. Install: REMOVING THE REAR SHOCK ABSORBER • Bearing “1” ASSEMBLY (to the relay arm) 1. Stand the vehicle on a level surface. • Oil seal “2” (to the relay arm) WARNING Securely support the vehicle so that there is Installed depth “a”...
  • Page 152 REAR SHOCK ABSORBER ASSEMBLY 2. Connecting arm 3. Rear shock absorber assembly 4. Swingarm 5. Frame 2. Tighten: • Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 44 Nm (4.4 m·kg, 32 ft·lb) • Relay arm nut Relay arm nut 44 Nm (4.4 m·kg, 32 ft·lb) •...

  • Page 153: Swingarm

    SWINGARM SWINGARM Removing the swingarm 10 Nm (1.0 m kg, 7.2 ft Ib) • • 70 Nm (7.0 m kg, 50 ft lb) • • Order Job/Parts to remove Remarks Muffler Refer to “ENGINE REMOVAL” on page 5-1. Rear wheel Refer to “REAR WHEEL”...
  • Page 154 SWINGARM Removing the swingarm 10 Nm (1.0 m kg, 7.2 ft Ib) • • 70 Nm (7.0 m kg, 50 ft lb) • • Order Job/Parts to remove Remarks Bearing For installation, reverse the removal proce- dure. 4-57...

  • Page 155: Removing The Swingarm

    SWINGARM REMOVING THE SWINGARM WARNING 1. Stand the vehicle on a level surface. Do not attempt to straighten a bent pivot shaft. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 156 SWINGARM 2. Swingarm A. Left side B. Right side 4. Install: • Rear shock absorber assembly • Relay arm • Rear wheel Refer to “REAR SHOCK ABSORBER AS- SEMBLY” on page 4-48 and “REAR WHEEL” on page 4-10. 5. Adjust: •...

  • Page 157: Chain Drive

    CHAIN DRIVE CHAIN DRIVE Removing the drive chain 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) Order Job/Parts to remove Remarks Rear wheel Refer to “REAR WHEEL” on page 4-10. Swingarm Refer to “SWINGARM” on page 4-56. Drive sprocket cover Drive sprocket retainer Drive sprocket...

  • Page 158: Checking The Drive Chain

    CHAIN DRIVE CHECKING THE DRIVE CHAIN 1. Measure: • 15-link section “a” of the drive chain Out of specification → Replace the drive chain. 15-link length limit 190.5 mm s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s a.

  • Page 159: Installing The Drive Chain

    CHAIN DRIVE 6. Check: • Drive sprocket Refer to “REAR WHEEL” on page 4-10. INSTALLING THE DRIVE CHAIN 1. Lubricate: • Drive chain Recommended lubricant chain lubricant suitable for O-ring chains 2. Install: • Drive chain • Drive sprocket • Drive sprocket retainer Drive sprocket retainer bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 3.

  • Page 160: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE............5-5 INSTALLING THE SHIFT ARM .............5-5 CYLINDER HEAD ....................5-6 REMOVING THE CYLINDER HEAD............5-8 CHECKING THE CYLINDER HEAD .............5-8 CHECKING THE CAMSHAFT SPROCKET AND TIMING CHAIN GUIDE ................5-9 CHECKING THE TIMING CHAIN TENSIONER........5-9 CHECKING THE DECOMPRESSION SYSTEM.........5-10 INSTALLING THE CYLINDER HEAD ..........5-10 CAMSHAFT ....................5-13...
  • Page 161 CLUTCH ......................5-36 REMOVING THE CLUTCH ..............5-40 CHECKING THE FRICTION PLATES..........5-40 CHECKING THE CLUTCH PLATES...........5-40 CHECKING THE CLUTCH SPRINGS..........5-41 CHECKING THE CLUTCH HOUSING..........5-41 CHECKING THE CLUTCH BOSS............5-41 CHECKING THE PRESSURE PLATE ..........5-41 CHECKING THE CLUTCH PUSH LEVER AND SHORT CLUTCH PUSH ROD............5-41 CHECKING THE PRIMARY DRIVE GEAR.........5-41 CHECKING THE PRIMARY DRIVEN GEAR ........5-42 INSTALLING THE CLUTCH..............5-42...
  • Page 162 CRANKSHAFT ....................5-60 REMOVING THE CRANKSHAFT ............5-61 CHECKING THE CRANKSHAFT............5-61 INSTALLING THE CRANKSHAFT............5-61 TRANSMISSION ....................5-63 CHECKING THE SHIFT FORKS............5-66 CHECKING THE SHIFT DRUM ASSEMBLY........5-66 CHECKING THE TRANSMISSION.............5-66 CHECKING THE CLUTCH PUSH RODS ...........5-67 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-67 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ..5-67...

  • Page 163: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL Removing the muffler 20 Nm (2.0 m kg, 14 ft Ib) • • 8 Nm (0.8 m kg, 5.8 ft Ib) • • 15 Nm (1.5 m kg, 11 ft Ib) • • Order Job/Parts to remove Remarks Muffler end cap Muffler protector...
  • Page 164 ENGINE REMOVAL Disconnecting the leads and couplers 9 Nm (0.9 m kg, 6.5 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Remarks CAUTION: First, disconnect the negative battery...
  • Page 165 ENGINE REMOVAL Disconnecting the leads and couplers 9 Nm (0.9 m kg, 6.5 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Remarks Coolant temperature sensor coupler Disconnect.
  • Page 166 ENGINE REMOVAL Removing the engine 49 Nm (4.9 m kg, 35 ft Ib) • • 49 Nm (4.9 m kg, 35 ft Ib) • • Order Job/Parts to remove Remarks NOTE: Place a suitable stand under the engine. Engine mounting bolt/nut (front side) Engine mounting bolt/nut (rear lower side) Engine mounting bolt/nut (rear upper side) Engine...

  • Page 167: Installing The Engine

    ENGINE REMOVAL INSTALLING THE ENGINE INSTALLING THE SHIFT ARM 1. Install: 1. Install: • Engine “1” • Shift arm “1” • Engine mounting bolt (rear upper side) “2” • Engine mounting nut (rear upper side) “3” Shift arm bolt • Engine mounting bolt (rear lower side) “4” 10 Nm (1.0 m·kg, 7.2 ft·lb) •...

  • Page 168: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD Removing the cylinder head 22 Nm (2.2 m kg, 16 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • 13 Nm (1.3 m kg, 9.4 ft Ib) ∗ • • 10 Nm (1.0 m kg, 7.2 ft Ib) •...
  • Page 169 Dowel pin Timing chain tensioner Timing chain tensioner gasket Camshaft sprocket Decompression cam Cylinder head Cylinder head gasket Dowel pin Timing chain guide (exhaust side) For installation, reverse the removal proce- dure. * Yamaha bond No. 1215 (Three Bond No. 1215)

  • Page 170: Removing The Cylinder Head

    CYLINDER HEAD NOTE: REMOVING THE CYLINDER HEAD To prevent the timing chain from falling into the 1. Align: crankcase, fasten it with a wire “1”. • “I” mark “a” on the magneto rotor (with the stationary pointer “b” on the magneto cover) s s s s s s s s s s s s s s s s s s s s s s s s s s a.

  • Page 171: Checking The Camshaft Sprocket And Timing Chain Guide

    CYLINDER HEAD 2. Check: • Cylinder head Damage/scratches → Replace. • Cylinder head water jacket Mineral deposits/rust → Eliminate. 3. Measure: • Cylinder head warpage Out of specification → Resurface the cylinder head. Warpage limit a. 1/4 tooth 0.03 mm b.

  • Page 172: Checking The Decompression System

    CYLINDER HEAD CHECKING THE DECOMPRESSION SYSTEM INSTALLING THE CYLINDER HEAD 1. Check: 1. Install: • Decompression system • Cylinder head NOTE: a. Check the decompression system with the Pass the timing chain through the timing chain camshaft sprocket and the decompression cavity.
  • Page 173 CYLINDER HEAD c. Align the “I” mark “c” on the camshaft sprock- c. Tighten the timing chain tensioner bolts “3” to et with the stationary pointer “d” on the cylin- the specified torque. der head. Timing chain tensioner bolt d. Install the timing chain onto the camshaft 10 Nm (1.0 m·kg, 7.2 ft·lb) sprocket, and then install the camshaft sprocket onto the camshaft.
  • Page 174 CYLINDER HEAD 7. Tighten: • Camshaft sprocket bolt Camshaft sprocket bolt 30 Nm (3.0 m·kg, 22 ft·lb) CAUTION: Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibil- ity of the bolt coming loose and damaging the engine.

  • Page 175: Camshaft

    CAMSHAFT CAMSHAFT Removing the rocker arms and camshaft 7 Nm (0.7 m kg, 5.1 ft Ib) • • 7 Nm (0.7 m kg, 5.1 ft Ib) • • Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-6. Locknut Adjusting screw Camshaft retainer...

  • Page 176: Removing The Rocker Arms And Camshaft

    CAMSHAFT REMOVING THE ROCKER ARMS AND Camshaft lobe dimensions CAMSHAFT Intake a 1. Loosen: 25.177 ± 0.05 mm • Locknut “1” Limit • Valve clearance adjusting screw “2” 25.027 mm Intake b 30.275 ± 0.05 mm Limit 30.125 mm Exhaust a 25.115 ±...

  • Page 177: Installing The Camshaft And Rocker Arms

    CAMSHAFT 2. Check: Rocker-arm-to-rocker-arm-shaft • Rocker arm shaft clearance Blue discoloration/excessive wear/pit- 0.009–0.034 mm ting/scratches → Replace or check the lubri- cation system. Limit 3. Measure: 0.08 mm • Rocker arm inside diameter “a” Out of specification → Replace. INSTALLING THE CAMSHAFT AND ROCKER Rocker arm inside diameter ARMS 9.985–10.000 mm...

  • Page 178: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-6. Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-13. Valve cotter Upper spring seat Valve spring Intake valve Exhaust valve...

  • Page 179: Removing The Valves

    VALVES AND VALVE SPRINGS REMOVING THE VALVES NOTE: The following procedure applies to all of the Identify the position of each part very carefully so valves and related components. that it can be reinstalled in its original place. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure the valves properly seal.

  • Page 180: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 2. Eliminate: CHECKING THE VALVE SEATS • Carbon deposits The following procedure applies to all of the (from the valve face and valve seat) valves and valve seats. 3. Check: 1. Eliminate: • Valve face • Carbon deposits Pitting/wear →...

  • Page 181: Checking The Valve Springs

    VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. s s s s s s s s s s s s s s s s s s s s s s s s s s a.

  • Page 182: Installing The Valves

    VALVES AND VALVE SPRINGS Free length (intake) Spring tilt (intake) 41.71 mm 2.5°/1.8 mm Limit Spring tilt (exhaust) 39.62 mm 2.5°/1.8 mm Free length (exhaust) 41.71 mm Limit 39.62 mm INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
  • Page 183 VALVES AND VALVE SPRINGS • Valve stem seal “2” • Valve “3” • Valve spring “4” • Upper spring seat “5” (into the cylinder head) NOTE: • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up.

  • Page 184: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON Removing the cylinder and piston 7 Nm (0.7 m kg, 5.1 ft Ib) • • Order Job/Parts to remove Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-6. Cylinder Cylinder gasket Dowel pin Piston pin circlip Piston pin Piston...

  • Page 185: Removing The Piston

    CYLINDER AND PISTON REMOVING THE PISTON 1. Remove: • Piston pin clips “1” • Piston pin “2” • Piston “3” CAUTION: Do not use a hammer to drive the piston pin out. NOTE: • Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent CHECKING THE CYLINDER AND PISTON the piston pin clip from falling into the crank-...

  • Page 186: Checking The Piston Rings

    CYLINDER AND PISTON “C” = maximum of D – D CHECKING THE PISTON RINGS 1. Measure: “T” = maximum of D or D - maximum of D • Piston ring side clearance or D Out of specification → Replace the piston “R”...

  • Page 187: Checking The Piston Pin

    CYLINDER AND PISTON 3. Measure: 3. Measure: • Piston ring end gap • Piston pin bore diameter “b” Out of specification → Replace the piston Out of specification → Replace the piston. ring. Piston pin bore inside diameter NOTE: 14.002–14.013 mm The oil ring expander spacer end gap cannot be measured.
  • Page 188 CYLINDER AND PISTON 120º 120º 120º 90º 45º 45º 2. Install: a. T op ring • Piston “1” b. Oil ring expander • Piston pin “2” c. Upper oil ring rail d. Lower oil ring rail • Piston pin clips “3” e.

  • Page 189: Magneto And Starter Clutch

    MAGNETO AND STARTER CLUTCH MAGNETO AND STARTER CLUTCH Removing the magneto and starter clutch 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 14 Nm (1.4 m kg, 10 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 70 Nm (7.0 m kg, 50 ft lb)
  • Page 190 MAGNETO AND STARTER CLUTCH Removing the magneto and starter clutch 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 14 Nm (1.4 m kg, 10 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 70 Nm (7.0 m kg, 50 ft lb) Order...

  • Page 191: Removing The Starter Clutch

    MAGNETO AND STARTER CLUTCH REMOVING THE MAGNETO 1. Remove: • Magneto rotor nut • Washer NOTE: • While holding the magneto rotor using magneto holder “1”, loosen the magneto rotor nut. REMOVING THE STARTER CLUTCH 1. Remove: • Starter clutch bolts “1” NOTE: •...

  • Page 192: Installing The Starter Clutch

    MAGNETO AND STARTER CLUTCH NOTE: • While holding the magneto rotor, tighten the starter clutch bolts “1” • Stake the end “a” of each starter clutch bolt. 2. Check: • Starter clutch idle gear • Starter clutch gear Burrs/chips/roughness/wear → Replace the defective part(s).
  • Page 193 “1”. 3,11 2,10 3. Apply: • Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 TG-1215 4. Install: • Magneto cover Magneto cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Tighten the magneto cover bolts in the proper tightening sequence as shown.

  • Page 194: Electric Starter

    ELECTRIC STARTER ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft Ib) Order Job/Parts to remove Remarks Starter motor Starter motor lead Disconnect. For installation, reverse the removal proce- dure. 5-32...
  • Page 195 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Remarks O-ring Starter motor yoke O-ring Commutator Starter motor front cover/brush holder set Brush Brush spring For assembly, reverse the disassembly pro- cedure. 5-33...

  • Page 196: Disassembling The Starter Motor

    ELECTRIC STARTER NOTE: DISASSEMBLING THE STARTER MOTOR The mica of the commutator must be undercut to 1. Remove: ensure proper operation of the commutator. • Starter motor yoke “1” • Starter motor front cover/brush holder set “2” NOTE: Before disassembling the starter motor, make alignment marks “a”...

  • Page 197: Assembling The Starter Motor

    ELECTRIC STARTER 6. Measure: • Brush spring force Out of specification → Replace the brush spring as a set. Brush spring force 3.92–5.88 N 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing • Oil seal Damage/wear →...

  • Page 198: Clutch

    CLUTCH CLUTCH Removing the clutch cover 9 Nm (0.9 m kg, 6.5 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) • • • • Order Job/Parts to remove Remarks Drain.
  • Page 199 CLUTCH Removing the clutch 70 Nm (7.0 m kg, 50 ft lb) 12 Nm (1.2 m kg, 8.7 ft Ib) 8 Nm (0.8 m kg, 5.8 ft Ib) Order Job/Parts to remove Remarks Locknut Clutch spring Pressure plate Short clutch push rod Clutch push rod holder Ball Friction plate 1...
  • Page 200 CLUTCH Removing the clutch 70 Nm (7.0 m kg, 50 ft lb) 12 Nm (1.2 m kg, 8.7 ft Ib) 8 Nm (0.8 m kg, 5.8 ft Ib) Order Job/Parts to remove Remarks Conical spring washer For installation, reverse the removal proce- dure.
  • Page 201 CLUTCH Removing the push lever Order Job/Parts to remove Remarks Clutch housing Refer to “CLUTCH” on page 5-36. Clutch push lever Clutch push lever spring Circlip Oil seal Bearing For installation, reverse the removal proce- dure. 5-39...

  • Page 202: Removing The Clutch

    CLUTCH REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: • Clutch boss nut “1” NOTE: While holding the clutch boss “2” with the clutch hub holder “3”, loosen the clutch boss nut. Clutch hub holder YSST-733 A. Friction plate 1 CHECKING THE FRICTION PLATES B.

  • Page 203: Checking The Clutch Springs

    CLUTCH Clutch plate thickness 1.45–1.75 mm Warpage limit 0.20 mm 2. Check: • Bearing Damage/wear → Replace the bearing and clutch housing. CHECKING THE CLUTCH BOSS CHECKING THE CLUTCH SPRINGS 1. Check: The following procedure applies to all of the •...

  • Page 204: Checking The Primary Driven Gear

    CLUTCH 2. Check: NOTE: • Primary drive gear Be sure the thrust washer sharp-edged conner Damage/wear → Replace the primary drive “a” is positioned opposite side to the clutch boss. gear and clutch housing as a set. Excessive noise during operation → Replace the primary drive gear and clutch housing as a set.
  • Page 205 CLUTCH 5. Bend the lock washer tab along a flat side of 9. Adjust: the nut. • Clutch mechanism free play 6. Lubricate: s s s s s s s s s s s s s s s s s s s s s s s s s a.
  • Page 206 CLUTCH 10.Install: • Oil seal “1” • Oil seal “2” 11.Install: • Clutch cover Clutch cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) NOTE: Tighten the clutch cover bolts in the proper tight- ening sequence as shown. 2,12 3,13 13.Adjust: •...

  • Page 207: Oil Pump

    OIL PUMP OIL PUMP Removing the oil pump 4 Nm (0.4 m kg, 2.9 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Remarks Clutch housing Refer to “CLUTCH” on page 5-36. Primary drive gear/Balancer drive gear Refer to “BALANCER GEAR”...
  • Page 208 OIL PUMP Disassembling the oil pump Order Job/Parts to remove Remarks Oil pump housing cover Oil pump driven gear Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly pro- cedure. 5-46...

  • Page 209: Checking The Oil Pump

    OIL PUMP CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump drive gear Less than 0.15 mm • Oil pump driven gear Limit 0.23 mm • Oil pump housing Outer-rotor-to-oil-pump-housing • Oil pump housing cover clearance Cracks/damage/wear → Replace the defec- 0.13–0.18 mm tive part(s).

  • Page 210: Installing The Oil Pump

    OIL PUMP 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-45. INSTALLING THE OIL PUMP 1. Install: • Oil pump assembly Oil pump assembly screw 4 Nm (0.4 m·kg, 2.4 ft·lb) CAUTION: After tightening the screws, make sure the oil pump turns smoothly.

  • Page 211: Shift Shaft

    SHIFT SHAFT SHIFT SHAFT Removing the shift shaft and stopper lever 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Remarks Clutch housing Refer to “CLUTCH” on page 5-36. Shift arm Shift shaft Circlip Shift shaft spring Stopper lever Stopper lever spring Oil seal...

  • Page 212: Checking The Shift Shaft

    SHIFT SHAFT CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 213: Balancer Gear

    BALANCER GEAR BALANCER GEAR Removing the primary drive gear and balancer gears 60 Nm (6.0 m kg, 43 ft Ib) • • 50 Nm (5.0 m kg, 36 ft Ib) • • Order Job/Parts to remove Remarks Clutch housing Refer to “CLUTCH” on page 5-36. Primary drive gear nut Balancer driven gear nut Washer...
  • Page 214 BALANCER GEAR Removing the primary drive gear and balancer gears 60 Nm (6.0 m kg, 43 ft Ib) • • 50 Nm (5.0 m kg, 36 ft Ib) • • Order Job/Parts to remove Remarks Spacer For installation, reverse the removal proce- dure.

  • Page 215: Removing The Primary Drive Gear And Balancer Gears

    BALANCER GEAR REMOVING THE PRIMARY DRIVE GEAR ASSEMBLING THE BALANCER DRIVEN AND BALANCER GEARS GEAR 1. Loosen: 1. Assemble: • Primary drive gear nut “1” • Dowel pins “1” • Springs “2” NOTE: (to the buffer boss) Place the aluminum plate “a” between balancer NOTE: drive gear “2”...
  • Page 216 BALANCER GEAR • Be sure the washer sharp-edged conner “c” is positioned opposite side to the primary drive gear. 3. Bend the lock washer tab along a flat side of the nut. 2. Tighten: • Balancer driven gear nut “1” •...

  • Page 217: Crankcase

    CRANKCASE CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • 32 Nm (3.2 m kg, 23 ft Ib) • • 20 Nm (2.0 m kg, 14 ft Ib) •...
  • Page 218 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • 32 Nm (3.2 m kg, 23 ft Ib) • • 20 Nm (2.0 m kg, 14 ft Ib) •...
  • Page 219 CRANKCASE Removing the oil seal and bearings 7 Nm (0.7 m kg, 5.1 ft Ib) • • Order Job/Parts to remove Remarks Crankshaft/Balancer Refer to “CRANKSHAFT” on page 5-60. Transmission Refer to “TRANSMISSION” on page 5-64. Oil seal Bearing retainer Bearing For installation, reverse the removal proce- dure.

  • Page 220: Separating The Crankcase

    CRANKCASE SEPARATING THE CRANKCASE CAUTION: 1. Remove: Tap on one side of the crankcase with a soft- • Crankcase bolts face hammer. Tap only on reinforced por- NOTE: tions of the crankcase, not on the crankcase Loosen each bolt 1/4 of a turn at a time, in stag- mating surfaces.

  • Page 221: Installing The Bearing Retainer

    • M6 × 45 mm : “1–5”, “10” 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 2,12 2,12 3,13 NOTE: Do not allow any sealant to come into contact with the oil gallery.

  • Page 222: Crankshaft

    CRANKSHAFT CRANKSHAFT Removing the crankshaft and balancer Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-55. Balancer Crankshaft For installation, reverse the removal proce- dure. 5-60...

  • Page 223: Removing The Crankshaft

    CRANKSHAFT REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft “1” NOTE: • Remove the crankshaft with the crankcase separating tool “2”. • Make sure the crankcase separating tool is centered over the crankshaft. CAUTION: 2. Measure: • Big end side clearance •...
  • Page 224 CRANKSHAFT CAUTION: To avoid scratching the crankshaft and to ease the installation procedure, lubricate the oil seal lips with lithium-soap-based grease and each bearing with engine oil. NOTE: Hold the connecting rod at top dead center (TDC) with one hand while turning the nut of the crankshaft installer bolt with the other.

  • Page 225: Transmission

    TRANSMISSION TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-56. Shift fork guide bar Spring Shift drum assembly Shift fork-R Shift fork-C Shift fork-L Drive axle assembly Main axle assembly Long clutch push rod For installation, reverse the removal proce-...
  • Page 226 TRANSMISSION Disassembling the main axle Order Job/Parts to remove Remarks 2nd pinion gear 6th pinion gear 3rd/4th pinion gear Circlip T oothed washer 5th pinion gear Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure. 5-64...
  • Page 227 TRANSMISSION Disassembling the drive axle Order Job/Parts to remove Remarks Washer 2nd wheel gear 6th wheel gear Washer 1st wheel gear Spacer 5th wheel gear Circlip T oothed washer 4th wheel gear 3rd wheel gear Drive axle For assembly, reverse the disassembly pro- cedure.

  • Page 228: Checking The Shift Forks

    TRANSMISSION CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks. Shift drum groove 1. Check: Damage/scratches/wear → Replace the shift Shift fork cam follower “1” drum assembly. Shift fork pawl “2” Shift drum segment “1”...

  • Page 229: Checking The Clutch Push Rods

    TRANSMISSION ASSEMBLING THE MAIN AXLE AND DRIVE AXLE 1. Install: Toothed washer “1” Circlip “2” NOTE: Be sure to install the circlip so that its sharp edge “a” is facing away from the toothed wash- er and gear. 3. Check: Be sure the circlip ends “b”...
  • Page 230 TRANSMISSION NOTE: The embossed marks on the shift forks should face towards the right side of the engine and be in the following sequence:“R”, “C”, “L”. 2. Check: Transmission Rough movement → Repair. NOTE: Apply engine oil to each gear and bearing thor- oughly.

  • Page 231: Cooling System

    COOLING SYSTEM RADIATOR...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 THERMOSTAT ....................6-4 CHECKING THE THERMOSTAT............. 6-5 INSTALLING THE THERMOSTAT............6-5 WATER PUMP....................6-6 DISASSEMBLING THE WATER PUMP............6-8 CHECKING THE WATER PUMP.............. 6-8 ASSEMBLING THE WATER PUMP............6-8 INSTALLING THE WATER PUMP............

  • Page 232: Radiator

    RADIATOR RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft Ib) • • 8 Nm (0.8 m kg, 5.8 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Remarks Drain.
  • Page 233 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft Ib) • • 8 Nm (0.8 m kg, 5.8 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Remarks Radiator Radiator fan Radiator cover For installation, reverse the removal proce-...

  • Page 234: Checking The Radiator

    RADIATOR CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. NOTE: 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 235: Thermostat

    THERMOSTAT THERMOSTAT Removing the thermostat 18 Nm (1.8 m kg, 13 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Remarks Drain. Coolant Refer to “CHANGING THE COOLANT” on page 3-14. Refer to “GENERAL CHASSIS”...

  • Page 236: Checking The Thermostat

    THERMOSTAT 2. Check: CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat 3. Check: Does not open at 80.5–83.5 °C (176.9–182.3 • Radiator inlet hose °F) → Replace. Cracks/damage → Replace. INSTALLING THE THERMOSTAT 1. Install: •...

  • Page 237: Water Pump

    WATER PUMP WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) • • • • Order Job/Parts to remove Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.
  • Page 238 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) Order Job/Parts to remove Q ty Remarks Radiator bracket Water pump housing cover Water pump housing cover gasket Impeller shaft retainer Impeller shaft...

  • Page 239: Disassembling The Water Pump

    WATER PUMP DISASSEMBLING THE WATER PUMP Mechanical seal/bearing installer 1. Remove: YSST-722 • Water pump seal “1” NOTE: Remove the water pump seal from the inside of the water pump housing. 2. Remove: • Bearing “2” NOTE: Remove the bearing from the outside of the wa- ter pump housing “3”.

  • Page 240: Installing The Water Pump

    WATER PUMP • Be sure to align the bolt holes in the water pump housing gasket, water pump housing plate and impeller shaft retainer. Make sure that the water pump housing plate does not block the hole “a” in the gasket. INSTALLING THE WATER PUMP 1.

  • Page 241: Fuel System

    FUEL SYSTEM FUEL TANK .....................7-1 REMOVING THE FUEL TANK..............7-2 REMOVING THE FUEL PUMP ............7-2 CHECKING THE FUEL PUMP BODY...........7-2 INSTALLING THE FUEL PUMP.............7-2 INSTALLING THE FUEL TANK.............7-2 THROTTLE BODY ..................7-4 REMOVING THE THROTTLE BODY............7-6 CHECKING THE FUEL INJECTOR .............7-6 CHECKING THE THROTTLE BODY ...........7-6 CHECKING THE FUEL PRESSURE ............7-6 INSTALLING THE THROTTLE BODY ..........7-6 AIR INDUCTION SYSTEM...

  • Page 242: Fuel Tank

    FUEL TANK FUEL TANK Removing the fuel tank 10 Nm (1.0 m kg, 7.2 ft Ib) • • 4 Nm (0.4 m kg, 2.9 ft Ib) • • 10 Nm (1.0 m kg, 7.2 ft Ib) • • Order Job/Parts to remove Q ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 243: Removing The Fuel Tank

    FUEL TANK CHECKING THE FUEL PUMP BODY REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Fuel pump body 2. Disconnect: Obstruction → Clean. • Fuel hose Cracks/damage →...
  • Page 244 FUEL TANK • To install the fuel hose onto the fuel pump, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown.
  • Page 245 THROTTLE BODY THROTTLE BODY Removing the throttle body 12 Nm (1.2 m kg, 8.7 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 2 Nm (0.2 m kg, 1.4 ft Ib) Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS” on page Seat/Left and Right side panel 4-1.
  • Page 246 FUEL TANK Removing the throttle body 12 Nm (1.2 m kg, 8.7 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) 2 Nm (0.2 m kg, 1.4 ft Ib) Order Job/Parts to remove Remarks Throttle body joint Air induction system vacuum hose Disconnect.

  • Page 247: Throttle Body

    THROTTLE BODY THROTTLE BODY REMOVING THE THROTTLE BODY WARNING 1. Remove: Cover fuel hose connections with a cloth • Throttle body when disconnecting them. Residual pres- sure in the fuel lines could cause fuel to CAUTION: spurt out when removing the hoses. Do not remove the throttle body sensor as- sembly “1”, from the throttle body.
  • Page 248 THROTTLE BODY 2. Install: • Throttle body joint NOTE: Align the projection “a” on the throttle body joint with the slot “b” in the intake manifold. 3. Install: • Throttle body NOTE: Align the projection “a” on the throttle body with the slot “b”...
  • Page 249 THROTTLE BODY...

  • Page 250: Air Induction System

    AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM...
  • Page 251 AIR INDUCTION SYSTEM 1. Resonator 2. Air induction system hose (3-way joint to resonator) Air induction system hose (3-way joint to air cut-off valve) 4. Air induction system hose (air filter case to 3- way joint) 5. Air induction system vacuum hose 6.
  • Page 252 AIR INDUCTION SYSTEM Removing the air cut-off valve and reed valve 10 Nm (1.0 m kg, 7.2 ft Ib) 10 Nm (1.0 m kg, 7.2 ft Ib) Order Job/Parts to remove Remarks Refer to “GENERAL CHASSIS” on page Seat/Right side panel 4-1.

  • Page 253: Checking The Air Induction System

    AIR INDUCTION SYSTEM Cracks/damage → Replace. CHECKING THE AIR INDUCTION SYSTEM • 3-way joint Cracks/damage → Replace. Air injection 2. Check: The air induction system burns unburned ex- • Reed valve haust gases by injecting fresh air (secondary air) • Reed valve stopper into the exhaust port, reducing the emission of •...
  • Page 254 AIR INDUCTION SYSTEM Air cut-off valve opens Replace the air cut-off valve. Air cut-off valve closes Air cut-off valve is OK. sssssssssssssssssssssssssssss 7.13...

  • Page 255: 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 ................8-15 TROUBLESHOOTING ..............8-17 SIGNALING SYSTEM ...................8-19 CIRCUIT DIAGRAM ................8-19...
  • Page 256 ELECTRICAL COMPONENTS..............8-55 CHECKING THE SWITCHES ............8-57 CHECKING THE BULBS AND BULB SOCKETS ........8-60 CHECKING THE FUSE..............8-61 CHECKING AND CHARGING THE BATTERY........8-61 CHECKING THE RELAYS ..............8-64 CHECKING THE TURN SIGNAL RELAY ..........8-65 CHECKING THE DIODE..............8-66 CHECKING THE SPARK PLUG CAP..........8-66 CHECKING THE IGNITION COIL ............8-67 CHECKING THE IGNITION SPARK GAP..........8-67 CHECKING THE CRANKSHAFT POSITION SENSOR.....8-68 CHECKING THE LEAN ANGLE SENSOR..........8-68...

  • Page 258: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) START STOP LIGHT - - - LR YG BL START GB OrW Br RW...
  • Page 259 IGNITION SYSTEM 3. Battery 4. Crankshaft position sensor 10. Main switch 11. ECU (engine control unit) 15. Lean angle sensor 18. Ignition coil 41. Spark plug 42. Fuse 43. Engine stop switch...

  • Page 260: Troubleshooting

    IGNITION SYSTEM TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 3. Right front panel 1. Check the fuse. NG → Refer to “CHECKING THE FUSE” Replace the fuse.
  • Page 261 IGNITION SYSTEM 9. Check the engine stop switch. NG → The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-57. OK ↓ 10.Check the lean angle sensor. NG → Refer to “CHECKING THE LEAN Replace the lean angle sensor.

  • Page 262: Electric Starting System

    ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) LIGHT START STOP - - - LR YG BL START GB OrW...
  • Page 263 ELECTRIC STARTING SYSTEM 3. Battery 7. Starter motor 8. Starter relay 9. Starting system cut off relay. 10. Main switch 29. Start switch 33. Neutral switch 34. Clutch switch 37. Diode 42. Fuse 43. Engine stop switch...

  • Page 264: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM 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 265 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN CLUTCH LEVER IS PULLED TO THE HANDLEBAR 3. Battery 7. Starter motor 8. Starter relay 9. Starting system cut off relay. 10. Main switch 29. Start switch 33. Neutral switch 34.

  • Page 266: Troubleshooting

    ELECTRIC STARTING SYSTEM TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Right side panel 1. Check the fuse. NG → Refer to “CHECKING THE FUSE” Replace the fuse. on page 8-61. OK ↓...
  • Page 267 ELECTRIC STARTING SYSTEM 9. Check the engine stop switch. NG → The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-57. OK ↓ 10.Check the neutral switch. NG → Refer to “CHECKING THE Replace the neutral switch.

  • Page 268: Charging System

    CHARGING SYSTEM CHARGING SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) START STOP LIGHT - - - LR YG BL START GB OrW RW Y...
  • Page 269 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Battery 42. Fuse 8-12...

  • Page 270: Troubleshooting

    CHARGING SYSTEM TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Left side panel/Side Cover. 1. Check the fuse. NG → Refer to “CHECKING THE FUSE” Replace the fuse. on page 8-61. OK ↓...
  • Page 271 CHARGING SYSTEM 8-14...

  • Page 272: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) LIGHT START STOP - - - LR YG BL START GB OrW RW Y...
  • Page 273 LIGHTING SYSTEM 3. Battery 10. Main switch 20. Head light (L) 21. Tail / brake light 28. Pass switch 31. Front brake light switch 32. Rear brake light switch 38. Head light (R) 42. Fuse 44. Light switch 46. Dimmer switch 8-16...

  • Page 274: Troubleshooting

    LIGHTING SYSTEM TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Side Cover & Cowling 3. Headlight 1. Check the each bulbs and bulb NG →...
  • Page 275 LIGHTING SYSTEM 8-18...

  • Page 276: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) START STOP LIGHT - - - LR YG BL START GB OrW RW Y...
  • Page 277 SIGNALING SYSTEM 3. Battery 10. Main switch 11. ECU (engine control unit) 21. Tail light 22. Front Flasher light (L) 23. Front Flasher light (R) 24. Rear Flasher light (L) 25. Rear Flasher light ® 30. Horn 33. Neutral switch 39.

  • Page 278: Troubleshooting

    SIGNALING SYSTEM TROUBLESHOOTING • Any of the following fail to light: turn signal lights, brake light or indicator lights. • The horn fails to sound. • The fuel gauge fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1.
  • Page 279 SIGNALING SYSTEM 3. Check the entire signaling system NG → 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. 1. Check the tail/brake light bulb and NG →...
  • Page 280 SIGNALING SYSTEM 3. Check the turn signal switch. NG → The turn signal switch is faulty. Replace Refer to “CHECKING THE the left handlebar switch. SWITCHES” on page 8-57. OK ↓ 4. Check the turn signal relay. NG → Refer to “CHECKING THE TURN Replace the turn signal relay.
  • Page 281 SIGNALING SYSTEM 2. Check the entire signaling system NG → wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. OK ↓ Replace the meter assembly. 8-24...

  • Page 282: Cooling System

    COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) LIGHT START STOP - - - LR YG BL START GB OrW RW Y...
  • Page 283 COOLING SYSTEM 3. Battery 10. Main switch 11. ECU (engine control unit) 16. Coolant temperature sensor 35. Radiator fan motor 36. Radiator fan motor relay 42. Fuse 8-26...

  • Page 284: Troubleshooting

    COOLING SYSTEM TROUBLESHOOTING NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Left and right front panel 3. Headlight lens unit 1. Check the fuse. NG → Refer to “CHECKING THE FUSE” Replace the fuse. on page 8-61. OK ↓...
  • Page 285 COOLING SYSTEM 8-28...

  • Page 286: Fuel Injection System

    FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) START STOP LIGHT - - - LR YG BL START GB OrW...
  • Page 287 FUEL INJECTION SYSTEM 3. Battery 4. Crankshaft position sensor 10. Main switch 11. ECU (engine control unit) 12. Fuel injector 13. FID (fast idle solenoid) device 14. Sensor Module 15. Lean Angle Sensor 16. Coolant temperature sensor 17. Self-diagnosis signal connector 18.

  • Page 288: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM ECU SELF-DIAGNOSTIC FUNCTION The ECU 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 en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 289: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM Engine trouble warning light indication and fuel injection system operation Engine trouble warning light indication and fuel injection system operation Warning light indica- Warning light indica- Fuel injection opera- Fuel injection opera- ECU operation ECU operation Vehicle operation Vehicle operation tion tion...
  • Page 290 FUEL INJECTION SYSTEM Self-Diagnostic Function table Able / un- Fault Able / un- Item Symptom able to code No. able to start drive No normal signals are received Crankshaft position from the crankshaft position sen- Unable Unable sensor sor. Intake air pressure Intake air pressure sensor: open sensor Able...

  • Page 291: Troubleshooting Method

    FUEL INJECTION SYSTEM TROUBLESHOOTING METHOD The engine operation is not normal but the engine trouble warning light does not come The engine operation is not normal and the engine trouble warning light comes on. 1. Check the operation of following sensors and 1.

  • Page 292: Diagnostic Mode

    FUEL INJECTION SYSTEM DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators with the FI diagnostic tool connected to the vehicle and set to the normal mode or the diagnostic monitoring mode. FI diagnostic tool Setting the normal mode NOTE:...
  • Page 293 FUEL INJECTION SYSTEM 5. Turn the main switch to “OFF” to cancel the normal mode. 6. Disconnect the FI diagnostic tool and connect the self-diagnosis signal connector. Setting the diagnostic mode 1. Turn the main switch to “OFF”. 2. Disconnect the self-diagnosis signal connector “1”, and then connect the FI diagnostic tool “2” as shown.
  • Page 294 FUEL INJECTION SYSTEM 8. Turn the main switch to “OFF” to cancel the diagnostic mode. 9. Disconnect the FI diagnostic tool and connect the self-diagnosis signal connector. Fault code table Fault Diagnostic code Symptom Probable cause of malfunction code No. •...
  • Page 295 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Malfunction in ECU. (The CO adjustment Error is detected while value and throttle valve fully closed notifica- reading or writing on tion valve are not properly written on or EEPROM.
  • Page 296 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code When the “MODE” button is pressed, the ignition coil is Check the spark five times. actuated five times at one- Ignition coil • Connect an ignition second intervals. checker. Illuminates the “WARNING” on the FI diagnostic tool.
  • Page 297 FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Malfunction history code erasure • No history — • History exists Up to 14 fault codes T o erase the history, press the “MODE” button of the FI diagnostic tool. Control number 0–254 —...

  • Page 298: Troubleshooting Details

    FUEL INJECTION SYSTEM TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the FI diagnostic tool. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the FI diagnostic tool display according to the reinstatement method.
  • Page 299 FUEL INJECTION SYSTEM CAUTION: Do not remove the sensor module (throttle body sensor assembly) from the throttle body. Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 300 FUEL INJECTION SYSTEM CAUTION: Do not remove the sensor module (throttle body sensor assembly) from the throttle body. Fault code No. Symptom Intake air pressure sensor: malfunction clogged pressure detect hole Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 301 FUEL INJECTION SYSTEM CAUTION: Do not remove the sensor module (throttle body sensor assembly) from the throttle body. Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 302 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor is stuck. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the main sensor.
  • Page 303 FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Turning the •...
  • Page 304 FUEL INJECTION SYSTEM Fault code No. Symptom Rollover signal is received from the lean angle sensor. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method The vehicle has overturned. Raise the vehicle upright. Turning the main switch to Installed condition of the lean angle...
  • Page 305 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected in injector. Diagnostic code No. Fuel injector Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the couplers for any pins Starting the •...
  • Page 306 FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading from or writing on EEPROM (CO adjustment value, code re-registering key code, and throttle valve fully closed notification value). Diagnostic code No. EEPROM fault code display Order Item/components and probable Check or maintenance job Reinstatement cause...
  • Page 307 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the speed sensor. Diagnostic code No. Speed sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed state of speed sensor. Check for looseness or pinching. Starting the engine, and Connections...

  • Page 308: Fuel Pump System

    FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) START STOP LIGHT - - - LR YG BL START GB OrW...
  • Page 309 FUEL PUMP SYSTEM 3. Battery 10. Main switch 11. ECU (engine control unit) 19. Fuel pump 42. Fuse 43. Stop switch 8-52...

  • Page 310: Troubleshooting

    FUEL PUMP SYSTEM TROUBLESHOOTING If the fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 1. Check the fuse. NG → Refer to “CHECKING THE FUSE” Replace the fuse. on page 8-61. OK ↓...
  • Page 311 FUEL PUMP SYSTEM 8-54...

  • Page 312: Electrical Components

    ELECTRICAL COMPONENTS ELECTRICAL COMPONENTS 8-55...
  • Page 313 ELECTRICAL COMPONENTS 1. Main switch 2. Clutch switch 3. Front brake light switch 4. Ignition coil 5. Throttle body sensor assembly (intake air pressure sensor, intake air temperature sensor, throttle position sensor) 6. FID (fast idle solenoid) device 7. Rectifier/regulator 8.

  • Page 314: Checking The Switches

    ELECTRICAL COMPONENTS CHECKING THE SWITCHES R B / B R / (BLACK) (RED) Br R/W W B / Ch Br W / W B / Br/W Y PASS 8-57...
  • Page 315 ELECTRICAL COMPONENTS 1. Clutch switch 2. Main switch 3. Front brake light switch 4. Rear brake light switch 5. Neutral switch 6. Turn signal switch 7. Horn switch 8. Dimmer switch 9. Pass switch 10. Engine stop switch 11. Start switch 8-58...
  • Page 316 ELECTRICAL COMPONENTS Check each switch for continuity with the multimeter. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 317: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS CHECKING THE BULBS AND BULB WARNING SOCKETS Since headlight bulb get extremely hot, keep Check each bulb and bulb socket for damage or flammable products and your hands away wear, proper connections, and also for continuity from them until they have cooled down. between the terminals.

  • Page 318: Checking The Fuse

    ELECTRICAL COMPONENTS s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s s Checking the condition of the bulb sockets a.
  • Page 319 ELECTRICAL COMPONENTS s s s s s s s s s s s s s s s s s s s s s s s s s s s s INTERNAL a. Connect a multimeter to the battery termi- • Drink large quantities of water or milk fol- nals.
  • Page 320 ELECTRICAL COMPONENTS • If the battery becomes hot to the touch at any time during the charging process, dis- connect the battery charger and let the bat- tery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery stabi- lizes about 30 minutes after charging has been completed.

  • Page 321: Checking The Relays

    ELECTRICAL COMPONENTS • Standard charging current is reached 12.8 V or more --- Charging is complete. Battery is good. 12.7 V or less --- Recharging is required. • Standard charging current is not reached Under 12.0 V --- Replace the battery. Replace the battery.

  • Page 322: Checking The Turn Signal Relay

    ELECTRICAL COMPONENTS Starter relay Radiator fan motor relay L B / 1. Positive battery terminal 1. Positive battery terminal 2. Negative battery terminal 2. Negative battery terminal 3. Positive tester probe 3. Positive tester probe 4. Negative tester probe 4. Negative tester probe Result Result Continuity...

  • Page 323: Checking The Diode

    ELECTRICAL COMPONENTS b. Turn the main switch to “ON”. Continuity c. Measure the turn signal relay input voltage. Positive tester probe → sky blue “1” 2. Check: Negative tester probe → • Turn signal relay output voltage red/black “2” Out of specification → Replace. No continuity Positive tester probe →...

  • Page 324: Checking The Ignition Coil

    ELECTRICAL COMPONENTS Secondary coil resistance 8.64–12.96 kΩ at 20 °C (68 °F) s s s s s s s s s s s s s s s s s s s s s s s s s s s s a.

  • Page 325: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS Ignition checker b. Measure the crankshaft position sensor re- sistance. ssssssssssssssssssssssssssss CHECKING THE LEAN ANGLE SENSOR 2. Spark plug cap 1. Remove: c. Turn the main switch to “ON” and engine stop • Lean angle sensor switch to “ ”.

  • Page 326: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS e. Measure the lean angle sensor output volt- Multimeter age. ssssssssssssssssssssssssssss • Positive tester probe → CHECKING THE STARTER MOTOR white “1” OPERATION • Negative tester probe → 1. Check: white “2” • Starter motor operation Does not operate → Perform the electric •...

  • Page 327: Checking The Horn

    ELECTRICAL COMPONENTS c. Measure the horn resistance. • Positive tester probe → red “1” 2. Check: • Negative tester probe → • Horn sound black “2” Faulty sound → Adjust or replace. s s s s s s s s s s s s s s s s s s s s s s s s s s s s a.

  • Page 328: Checking The Radiator Fan Motor

    ELECTRICAL COMPONENTS CHECKING THE COOLANT TEMPERATURE SENSOR 1. Remove: • Coolant temperature sensor WARNING • Handle the coolant temperature sensor with special care. • Never subject the coolant temperature sen- sor to strong shocks. If the coolant temper- b. Move the fuel sender float to minimum ature sensor is dropped, replace it.

  • Page 329: Checking The Throttle Body Sensor Assembly

    ELECTRICAL COMPONENTS d. While slowly opening the throttle, check that Coolant temperature sensor the throttle position sensor output voltage is 18 Nm (1.8 m·kg, 13 ft·lb) increased. Voltage does not change or it changes abruptly → Replace the throttle body. CHECKING THE THROTTLE BODY SENSOR Out of specification (closed position) →...
  • Page 330 ELECTRICAL COMPONENTS CHECKING THE FID (FAST IDLE SOLENOID) 1. Disconnect: • FID (fast idle solenoid) device coupler 2. Check: • FID (fast idle solenoid) device resistance s s s s s s s s s s s s s s s s s s s s s s s s s s s s a.

  • Page 331: Checking The Speed Sensor

    ELECTRICAL COMPONENTS CHECKING THE SPEED SENSOR 1. Check: • Speed sensor output voltage Out of specification → Replace. Output voltage reading cycle 0 V to 5.0 V to 0 V to 5.0 V speed sensor a. Connect the multimeter to the coupler (wire harness end) as shown.

  • Page 332: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING..................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES.................9-1 INCORRECT ENGINE IDLING SPEED ..........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......9-2 FAULTY GEAR SHIFTING..............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR..............9-2 FAULTY CLUTCH ................9-2 OVERHEATING ................9-2 OVERCOOLING................9-3 POOR BRAKING PERFORMANCE..........9-3 FAULTY FRONT FORK LEGS............9-3 UNSTABLE HANDLING..............9-3 FAULTY LIGHTING OR SIGNALING SYSTEM .......9-4 WIRING DIAGRAM ..............9-5...

  • Page 333: Starting Failures

    TROUBLESHOOTING Electrical system TROUBLESHOOTING 1. Battery • Discharged battery • Faulty battery GENERAL INFORMATION 2. Fuse NOTE: • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.

  • Page 334: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Electrical system JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...

  • Page 335: Overcooling

    TROUBLESHOOTING • Incorrect oil viscosity • Oil or grease on the brake disc • Inferior oil quality • Oil or grease on the brake pad • Incorrect brake fluid level Cooling system 1. Coolant FAULTY FRONT FORK LEGS • Low coolant level Leaking oil 2.

  • Page 336: Faulty Lighting Or Signaling System

    TROUBLESHOOTING 5. Rear shock absorber assembly • Burnt-out turn signal bulb • Faulty rear shock absorber spring • Incorrect connection • Leaking oil • Damaged or faulty wire harness • Improperly grounded circuit 6. Tyre(s) • Uneven tyre pressures (front and rear) •...

  • Page 337: Wiring Diagram

    WIRING DIAGRAM (BLACK) B - R LB Br W W W SGND BrWPW BL YL LR Br YR MAIN (RED) (RED) GR BL RL OrB OrBRW (BLACK) (BLACK) LIGHT START STOP - - - LR YG BL START GB OrW RW Y Br RW (BLACK)
  • Page 338 WIRING DIAGRAM WIRING DIAGRAM COLOR CODE Black YZF-R15 Brown AC magneto Chocolate Dark green Rectifier / Regulator Green Battery Gray Crank shaft position sensor Blue Wire plus lead Light green Wire minus lead Orange Starter motor Pink Starter relay Sky blue...

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Yzf-r15 2008

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