Yamaha XVZ13TF 1999 Service Manual

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Page 3 EAS00001 XVZ13TF (L) SERVICE MANUAL 1999 by Yamaha Motor Co., Ltd. First edition, January 1999 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd is expressly prohibited.
Page 4: Important Information
If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed- eral environmental quality objectives.
Page 5: How To Use This Manual
EAS00007 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 inspection procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Engine 5 Cooling system 6 Carburetor(-s) COOL CARB 7 Chassis...
Page 7 EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETORS CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
Page 9 INFO...
Page 10: Table Of Contents
INFO CONTENTS GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
Page 11 INFO...
Page 12: General Information
MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
Page 13: Features
FEATURES INFO EAS00019 FEATURES CRUISE CONTROL This motorcycle is equipped with cruise control which designed to maintain a set speed. CAUTION: S Giving a severe load like using as a trailer/tractor or driving on a steep slope could remove the cruise control.
Page 14 FEATURES INFO Operation chart Rear brake Mannual cancel Resume Cruise SW Opera- acceleration Clutch tion Front brake CRUISE Out of range Speed Out of range Indica- Flash (After1.4sec) Cruise control function 1) The cruise control can only be activated when riding in 4th, 5th gear and traveling between the speed of 50 and 130 km/h.
Page 15: Digital Speedometer
FEATURES INFO DIGITAL SPEEDOMETER This speedometer is equipped with: S An odometer S Two trip odometers S A fuel reserve trip meter S A clock Odometer and trip meter modes 1) Selecting a mode Push the “SELECT” button to change between the odometer mode “ODO” and the trip odometer modes “TRIP 1”...
Page 16: Audio System
FEATURES INFO Clock mode To change the display to the clock mode, push both the “SELECT” and “RESET” buttons. To change the display back to odometer mode, push the “RESET” button. 1) To set the clock a. Push both the “SELECT” and “RESET” buttons for at least two seconds. b.
Page 17 FEATURES INFO 2. CASSETTE DESK OPERATION The cassette tape deck has the following func- tions. S Song search S Change tape play direction S Dolby noise reduction S Blank tape skip a. Turn the main switch to the “ACC” or “ON” position and push the “AUDIO”button to turn on the power.
Page 18 FEATURES INFO Reserving tape play direction Push the up-down button 1 in either direction for more than one second to reverse tape play. When the tape is playing the forward direction, the “F” indicator will appear. When the tape is playing in the reverse direc- tion, the “R”...
Page 19 FEATURES INFO 3. RADIO OPERATION The radio has the following functions. S Switching the receiving band S Switching the receiving station S Automatic tuning (Seek) S Manual tuning S Programing preset stations in memory S Automatic writing of stations in memory (Auto store operation) Switching the receiving bands This radio system has 3 bands for FM and 1...
Page 20 FEATURES INFO c. Push the up-down switch 1 in either direc- tion to select the channel number to be set for the current station. (Ch1, Ch2, Ch3, Ch4, Ch5 and Ch6) d. Press the “SELECT” button to programing the channel in memory. Repeat this procedure for the remaining sta- tions desired to be preset in the memory.
Page 21 FEATURES INFO “AUX” (Auxiliary) operation Auxiliary audio equipment can be used to play through the audio system. a. Insert the output plug of the auxiliary equip- ment into the jack located at the right side of the dassette deck. b. Push the “AUDIO” button until “AUX” ap- pears and the auxiliary equipment can be used to play through the audio system.
Page 22 FEATURES INFO Selecting the output for speaker or headset (optional) To select the output for speaker or headset, push the “SELECT” button and the “SP” (speak- er) or “HS” (headset) indicator will appear. To change between speaker and headset, push the up-down switch 1 in either direction.
Page 23 FEATURES INFO Changing the level for auto volume control system a. To control the level for the auto volume con- trol system, push the “SELECT” button untill the “AV:” indicator appears. b. Push the up-down switch 1 in either direc- tion to change the volume level.
Page 24: Important Information
5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in-function and appearance, but inferior in quality.
Page 25: Lock Washers/Plates And Cotter Pins
IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS 1. After removal, replace all lock wash- ers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS 1.
Page 26: Checking The Connections
CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.
Page 27: Special Tools
SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part umbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 28 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Ring nut wrench YU-01268 90890-01268 YU-33975 This tool is needed to loosen and 90890-01403 tighten the steering stem ring nut. Pocket tester YU-03112 90890-03112 This instrument is needed for check- ing the electrical system. Compressor Valve spring compressor/adapter YM-04019...
Page 29 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Quick gasket Yamaha Bond No.1215 ACC-1100-15-01 90890-85505 This sealant (bond) is used on crankcase mating surfaces, etc. Piston pin puller YU-01304 90890-01304 This tool is used to remove the pis- ton pin.
Page 30 SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration Tester Radiator cap tester/adapter YU-24460-01 90890-01325 Adapter This tester and its adapter are need- YU-33984 ed for checking the cooling system. Fuel level gauge YM-01312-A 90890-01312 This gauge is used to measure the fuel level in the float chamber.
Page 31 INFO...
Page 32 SPEC...
Page 33 SPEC CONTENTS SPECIFICATIONS GENERAL SPECIFICATIONS ........MAINTENANCE SPECIFICATIONS .
Page 34 SPEC...
Page 35: Specifications
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: XVZ13TF: 5JC1 (for GB. N. S. SF. D. NL. B. F. G. E. P. I. A. GR) XVZ13TFL: 5JL1 (for OCE) Dimensions: Overall length 2,705 mm Overall width 900 mm Overall height 1,565 mm (except for G) 1,380 mm (for G)
Page 36 SPEC GENERAL SPECIFICATIONS Item Standard Carburetor: Type/quantity BDS32/4 Manufacturer MIKUNI Spark plug: Type DPR8EA-9/X24EPR-U9 Manufacturer NGK/DENSO 0.8 X 0.9 mm Spark plug gap Clutch type: Wet, multiple-disc Transmission: Primary reduction system Spur gear Primary reduction ratio 87/49 (1,776) Secondary reduction system Shaft drive Secondary reduction radio 21/27...
Page 37 SPEC GENERAL SPECIFICATIONS Item Standard Shock absorber: Front shock absorber Coil-air spring/Oil damper Rear shock absorber Coil-air spring/Oil damper Wheel travel: Front wheel travel 140 mm Rear wheel travel 105 mm Electrical: Ignition system T.C.I. (Digital) Generator system A.C. magneto Battery type YTX20L-BS Battery capaity...
Page 38: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.03 mm Cylinder: 78.967 X 79.016 mm Bore size Measuring point* 40 mm Out of round limit 0.05 mm Camshaft: Drive method Chain drive (Center) 25.000 X 25.021 mm Cam cap inside diameter 24.967 X 24.980 mm Camshaft outside diameter...
Page 39 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Camshaft runout limit 0.03 mm Cam chain: Cam chain type/No. of links BF05M/118 Cam chain adjustment method Automatic Valve, valve seat, valve guide: 0.11 X 0.15 mm Valve clearance (cold) 0.16 X 0.20 mm Valve dimensions: Head Dia Face Width...
Page 40 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit 0.01 mm Valve spring: Inner: Free length 37.3 mm 35.3 mm 37.3 mm 35.3 mm Set length (valve closed) 31.8 mm 31.8 mm 4.57 X 5.37 kg Compressed pressure 4.57 X 5.37 kg (installed) Tilt limit* 2.5_/1.6 mm...
Page 41 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: 0.055 X 0.069 mm Piston to cylinder clearance 0.15 mm 78.926 X 78.933 mm Piston size “D” Measuring point “H” 4 mm Piston off-set 0 mm 19.004 X 19.015 mm Piston pin bore inside diameter 19.045 mm 18.991 X 19.000 mm Piston pin outside diameter...
Page 42 SPEC MAINTENANCE SPECIFICATION Item Standard Limit Connecting rod: 0.021 X 0.039 mm Oil clearance 0.09 mm Color code (corresponding size) Blue Black Brown Green Yellow Pink Crankshaft: 83.92 X 83.97 mm Crank width “A” 242.72 X 243.17 mm Assembly width “B” Runout limit “C”...
Page 43 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Transmission: Main axle runout limit 0.08 mm Drive axle runout limit 0.08 mm Shifter: Shifter type Guide bar Guide bar bending limit 0.025 mm Carburetor: I.D.mark 5JC1 00 Main jet (M.J) #1, 2 : #122.5 #3 : #117.5 #4 : #120 Main air jet (M.A.J) #110...
Page 44 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Cooling system: Radiator core size Width 257.4 mm Height 360 mm Thickness 27 mm 95 X 125 kPa (0.95 X 1.25 kg/cm Radiator cap opening pressure 0.95 X 1.25 bar) Reservoir tank capacity 0.84 L <From low to full level>...
Page 45 SPEC MAINTENANCE SPECIFICATIONS Item Standard Crankcase tightening sequence: 2-11...
Page 46 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Part name Thread size Q’ty Remarks Nm mSkg Camshaft cap Bolt Blind plug Plug Exhaust pipe Stand bolt 1.25 Spark plug 1.25 Cylinder head 1.25 Cylinder head cover Bolt Chrome cover Bolt Connecting rod...
Page 47 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Part name Thread size Q’ty Remarks Nm mSkg Oil drain plug (crankcase) Bolt 1.25 Starter clutch Bolt 1.25 Clutch spring plate Bolt Clutch boss Clutch release cylinder Bolt Air bleed screw Screw 1.25 Clutch pipe...
Page 48: Chassis
(K1) Optional spring Oil capacity 0.553 L Oil level 117 mm Oil grade Yamaha fork oil 5WT Endosed gas/air pressure (STD) 0 kPa (0 kgf/cm , 0 bar) (Min X Max) 0 X 50 kPa (0 X 0.5 kgf/cm 0 X 0.5 bar)
Page 49 SPEC GENERAL SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual Disc outside diameter thickness 5 mm Pad thickness inner 6 mm 0.5 mm Pad thickness outer 6 mm 0.5 mm Master cylinder inside diameter 15.87 mm Caliper cylinder inside diameter 30.1 mm Caliper cylinder inside diameter 33.3 mm...
Page 50 SPEC MAINTENANCE SPECIFICATIONS Tightening torques Tightening torque Part to be tightened Thread size Remarks mSkg Upper bracket and inner tube Upper bracket and steering shaft 13.0 Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) See NOTE Brake hose joint and lower bracket Front master cylinder cap (brake and clutch) Handlebar holder (lower) Front master cylinder (brake and clutch)
Page 51 SPEC MAINTENANCE SPECIFICATIONS Tightening toque Part to be tightened Thread size Remarks mSkg Rear fender side mold and rear fender stay Main switch and frame Sidestand bolt and nut 12.2 Footrest bracket and frame Rear footrest and frame Rear master cylinder and rear brake bracket Rear master cylinder and brake hose joint Brake hose joint and brake hose Rear brake reservoir tank...
Page 52: Electrical
SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage: 12 V Ignition system: Ignition timing (B.T.D.C.) 5_ at 1,000 r/min Advanced timing (B.T.D.C.) 45_ at 5,000 r/min T.C.I.: 189 X 231 Ω at 20_C/Gray/Black Pickup coil resistance/color T.C.I. unit model/manufacturer JT112/MITSUBISHI Ignition coil: Model/manufacturer F6T541/MITSUBISHI...
Page 53 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Battery: Specific gravity 1.320 Electric starter system: Type Constant mesh type Starter motor: Model/manufacturer SM-13/MITSUBA I.D. number SM-13 Output 0.8 kW Brush overall length 10 mm 5 mm Commutator diameter 28 mm 27 mm Mica undercut 0.7 mm Starter relay:...
Page 54 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Thermo switch: Model/manufacturer 5EB/NIPPON THERMOSTAT Thermo unit: Model/manufacturer 3YX/NIPPON SEIKI Vacume actuator: 4XY/MITSUBISHI Vacume pump: 4XY/MITSUBISHI Circuit breaker: Type Fuse Amperage for individual circuit MAIN 30 A HEAD 15 A SIGNAL 15 A IGNITION 10 A 10 A Back up (odometer)
Page 55: Audio System Specifications
SPEC MAINTENANCE SPECIFICATIONS AUDIO SYSTEM SPECIFICATIONS Item Standard AM/FM Radio: 531 X 1,602 KHz Tuning Range: AM 87.5 X 108 MHz Intermediate Frequency: AM 450 KHz 10.7 MHz "10dB/100 HZ Bass "10dB/10KHz Treb Amplifier: Output Power 14W x 4 (SP)/1W x 2 (HS) Auto-Vol.
Page 56: General Tightening Torque Specifications
SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tight- ening torque specifications for special components or assemblies are provided for each chapter of this manual.
Page 57: Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication Point Symbol Oil seal lips O-ring Bearing Connecting rod bolt/nut Connecting rod small end and big end Crankshaft pin Crankshaft journal/big end Piston surface Piston pin Camshaft cam lobe/journal Timing chain tensioner Valve stem (IN, EX)
Page 58: Chassis
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication Point Symbol Steering bearing (upper/lower) Steering bearing cover Steering lock Steering head pipe lower oil seal Front wheel oil seal (right/left) Rear wheel oil seal Clutch hub fitting area Rear brake pedal shaft Shift pedal Front footrest pivot Rear footrest pivot...
Page 59: Cooling System Diagrams
SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS Radiator cap A To coolant reservoir tank. Thermostatic valve housing Radiator hose Radiator Water pump 2-25...
Page 60 SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS Camshaft (intake) Main axle Camshaft (exhaust) Drive axle Water pump impeller shaft Water pump drive gear Main gallery Oil filter Crankshaft Oil strainer Oil pump 2-26...
Page 61: Lubrication Diagrams
SPEC LUBRICATION DIAGRAMS Camshaft Main gallery Crankshaft Oil level switch 2-27...
Page 62 SPEC LUBRICATION DIAGRAMS Main axle Drive axle Middle driven pinion gear Middle drive pinion gear 2-28...
Page 63 SPEC LUBRICATION DIAGRAMS Crankshaft Oil pipe Oil filter Water pump drive gear Oil strainer Oil pump 2-29...
Page 64: Cable Routing
SPEC CABLE ROUTING EAS00035 CABLE ROUTING Under cover (right) A Fasten the wire harness with a plastic clamp. Cruise control unit B To rear brake switch Wire harness C Position the vacuum hose as shown. Radiator assembly D To regulator Cruise control cable E Fasten the wire harness with a plastic clamp.
Page 65 SPEC CABLE ROUTING I Fasten the regulator lead with a steel clamp. O Align the white mark on the rear brake switch J Route the rear brake switch lead between the lead with the metal clamp. wire harness and cover. K Fasten the side stand switch lead, fan motor lead and noise filter lead with a plastic clamp.
Page 66 SPEC CABLE ROUTING Antenna lead (with cover) Headlight harness Flasher relay Auxiliary terminal Antenna lead Ground lead CD code Front head set lead “CRUISE” switch lead Meter lead Handlebar switch lead (left) Front brake switch lead Hazard relay Handlebar switch lead (right) Handlebar switch lead (left) DC outlet lead Front brake switch lead...
Page 67 SPEC CABLE ROUTING A To the “CRUISE” switch. J Fasten the headlight harness to the pipe with B Connect the couplers with same color. plastic clamp. C Fasten the headlight harness and handlebar K To the speedometer. switch (left and right) lead with a plastic clamp. L Fasten the headlight harness to the pipe with a D Fasten the turn signal lead with a plastic clamp.
Page 68 SPEC CABLE ROUTING R Align the ground lead paint mark and main har- ness sub lead with a plastic clamp. S Clamp the head light harness (right). Route the head light harness so that DIN cable set comes upper side. T For installing the stay, do not catch the throttle cable.
Page 69 SPEC CABLE ROUTING Brake hose A Pass the clutch hose through the guide. Clutch hose B To the upper cowling. Handlebar switch lead (left) C To the engine stop switch. Remote controller lead D To the ignition coil #2. Throttle cable E To the thermo switch.
Page 70 SPEC CABLE ROUTING Wire harness A To the rear fender. Starter lead B From the radiator (breather hose). Brake hose C From the fuel tank. Battery negative lead D To the air cleaner. Wire harness E From the fuel tank (breather hose). F To the carburetor.
Page 71 SPEC CABLE ROUTING J Same rute with air cleaner drain hose. K Front the air cleaner. L From the coolant reservoir tank. M From the engine. N To the horn. O Fasten the wire harness with a plastic clamp (with the end towards the front side of the motor- cycle).
Page 72 SPEC CABLE ROUTING Plastic clamp A Route the high tension cord throgh the guide on the air induction box. Emergency stop switch B Clamp the coolant hose inside of the motorcycle with hose clamp. Bolt (ground) C Fasten the audio lead and CD lead (option) with a plastic clamp. Platic clamp D Route the audio lead tensely.
Page 73 SPEC CABLE ROUTING M Position the end of clamp to the rear side of the V To the coolant reservoir tank cap. motorcycle. W Fasten the high tension cord #1 and #3 with a N Position the end of clamp to the rear side of the plastic clamp.
Page 74 SPEC CABLE ROUTING Front remote controller A Connect the fuel sender lead on the fuel tank. TPS lead B Route the head set lead to the switch cover on the fuel tank. Carburetor heater lead C Fasten the wire harness sub lead, antenna lead and head set lead with Speed sensor lead a plastic clamp.
Page 75 SPEC CABLE ROUTING L Fasten the speed sensor lead, fuel pump lead and fuse box lead with a plastic clamp. M Fasten the speed sensor lead with a plastic clamp. N Turn the lead wire to clamp on the rear arm section. O Route the wire harness behind the igniter unit.
Page 76 SPEC CABLE ROUTING W Fasten the side stand switch lead with a plastic Insert the wire harness into the air induction box G’ clamp. guide and hold it with clamp. X Fasten the side stand switch lead with a plastic Fasten the fuel hose on the carburetor with a H’...
Page 77 SPEC CABLE ROUTING Fuel tank breather hose Tail / brake light lead A Fasten the handlebar switch Bracket Head set lead lead (right) and clutch hose with Head set lead CD cord (option) a plastic clamp. CD code (option) Antenna lead B Fasten the handlebar switch Antenna lead Plastic clamp...
Page 78 SPEC CABLE ROUTING F Positon the clip end at upper. N Route the wire harness with the guide (T-bar). G Route the AIS hose through the clip. O Route the AIS hose between the carburetor joints. H Route the tail / brake light lead through the hole in P The protector section must be exposed.
Page 80 CONTENTS PERIODIC CHECKS AND ADJUSTMENTS ..... . . INTRODUCTION ......... . . PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .
Page 81 ADJUSTING THE FRONT AND REAR SHOCK ABSORBER ASSEMBLY ..........3-45 CHECKING THE TIRES .
Page 82: Periodic Checks And Adjustments
INTRODUCTION/PERIODICK MAINTENANCE AND LUBRICATION INTERVALS PERIODIC CHECKS AND ADJUSTMENTS 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 longer 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 83: Brake Fluid
PERIODIC MAINTENANCE/LUBRICATION INTERVALS EVERY 6,000 km 12,000 km INITIAL ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) 6 months 12 months (whichever (whichever comes first) comes first) S Check engine idling speed, synchronization and starter operation. Carburetors S Adjust if necessary. S Check oil level and vehicle for oil leakage.
Page 84: Front Cowling
FRONT COWLING FRONT COWLING Order Job/Part Q’ty Remarks Removing the front cowling Remove the parts in the order listed. Front cowling chrome cover Refer to “REMOVING/INSTALLING THE FRONT COWLING COVER.” Wind shield Front cowling Headlight unit MCU lead/speedometer lead/ 1/1/1 Disconnect headlight lead Front pannel...
Page 85: Removing The Front Cowling Cover
FRONT COWLING REMOVING THE FRONT COWLING COVER 1. Remove S front cowling cover a. Loosen the bolt 1 b. First, lift up each side of the cowling cover 2 . c. Then, push the center portion of the cover 3 inward and lift the entire cover upward.
Page 86: Rider And Passenger Seats
RIDER AND PASSENGER SEATS EB302001 RIDER AND PASSENGER SEATS Order Job/Part Q’ty Remarks Removing the rider and passenger Remove the parts in the order listed. seats Rider seat Passenger seat For installation, reverse the removal procedure.
Page 87: Fuel Tank
FUEL TANK EB302002 FUEL TANK 7 Nm (0.7mSkg) 16 Nm (1.6mSkg) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “RIDER AND PASSENGER SEATS”. Top cover Fuel tank breather hose Fuel sender lead coupler Disconnect Fuel hose...
Page 88: Saddlebags
SADDLEBAGS SADDLEBAGS 7.5 Nm (0.75 mSkg) 6.5 Nm (0.65 mSkg) 6.5 Nm (0.65 mSkg) 2.5 Nm (0.25 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the trunk and saddlebags Remove the parts in the order listed. Antenna Antenna/trunk/wire harness lead 1/1/1 Disconnect Trunk...
Page 89: Engine
ADJUSTING THE VALVE CLEARANCE EAS00044 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 90 ADJUSTING THE VALVE CLEARANCE a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the generator rotor with the mark b on the crankcase cover. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
Page 91 ADJUSTING THE VALVE CLEARANCE NOTE: Make sure that the tappet adjusting tool touches only the valve lifter 2 , not the valve pad 3 . c. Slowly turn the tappet adjusting tool so that the valve pad can be removed. d.
Page 92 ADJUSTING THE VALVE CLEARANCE INTAKE INSTALLED PAD NUMBER MEASURED 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 320 CLEARANCE 0.00 X 0.05 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 0.06 X 0.10 200 205 210 215 220 225 230 235 240 245 250 255 260 265 270 275 280 285 290 295 300 305 310 315 0.11 X 0.15...
Page 93 ADJUSTING THE VALVE CLEARANCE f. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 248 (thickness = 2.48 mm) Rounded value = 250 g.
Page 94: Synchronizing The Carburetors
SYNCHRONIZING THE CARBURETORS EAS00050 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand.
Page 95 SYNCHRONIZING THE CARBURETORS NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in ei- ther direction until both gauges read the same.
Page 96: Adjusting The Engine Idling Speed
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00053 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression.
Page 97 ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Check: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 4 X 6 mm 2. Remove: S rider seat S fuel tank Refer “RIDER PASSENGER...
Page 98: Checking The Spark Plugs
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS ! Throttle cable free play is Direction increased. ! Throttle cable free play is Direction decreased. c. Tighten the locknut. WARNING After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the en- gine idling speed to change.
Page 99: Checking The Ignition Timing
CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 5. Clean: S spark plug (with a spark plug cleaner or wire brush) 6. Measure: S spark plug gap a (with a wire gauge) Out of specification ! Regap. Spark plug gap 0.8 X 0.9 mm 7.
Page 100: Measuring The Compression Pressure
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 3. Check: S ignition timing a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed. Engine idling speed 950 X 1,050 r/min b.
Page 101 MEASURING THE COMPRESSION PRESSURE 4. Remove: S spark plug CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: S compression gauge 1 Compression gauge YU-33223, 90890-03081...
Page 102: Checking The Engine Oil Level
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL a. Turn the main switch to “ON”. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes. WARNING To prevent sparking, ground all spark plug leads before cranking the engine.
Page 103: Changing The Engine Oil
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CAUTION: S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives. S Do not allow foreign materials to enter the crankcase.
Page 104 CHANGING THE ENGINE OIL a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench YU-38411, 90890-01426 b. Apply a thin coat of engine oil onto the O-ring 3 of the new oil filter cartridge. CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter car-...
Page 105: Measuring The Engine Oil Pressure
CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE 10. Start the engine, warm it up for several min- utes, and then turn it off. 11. Check: S engine (for engine oil leaks) 12. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.
Page 106 MEASURING THE ENGINE OIL PRESSURE 3. Remove: S main gallery bolt 1 WARNING The engine, muffler and engine oil are ex- tremely hot. 4. Install: S oil pressure gauge 1 S adapter 2 Oil pressure gauge 90890-03153 Adapter 90890-03124 5. Measure: S engine oil pressure (at the following conditions) Engine oil pressure...
Page 107: Checking The Clutch Fluid Level
CHECKING THE CLUTCH FLUID LEVEL EAS00083 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Check: S clutch fluid level Below the minimum level mark a ! Add the recommended clutch fluid to the proper level.
Page 108: Bleeding The Hydraulic Clutch System
BLEEDING THE HYDRAULIC CLUTCH SYSTEM EAS00084 BLEEDING THE HYDRAULIC CLUTCH SYS- WARNING Bleed the hydraulic clutch system whenever: S the system was disassembled, S a clutch hose was loosened or removed, S the clutch fluid level is very low, S clutch operation is faulty. NOTE: S Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to overflow.
Page 109: Cleaning The Air Filter Element
BLEEDING THE HYDRAULIC CLUTCH SYSTEM/ CLEANING THE AIR FILTER ELEMENT WARNING After bleeding the hydraulic clutch system, check the clutch operation. EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S under cover 1 2. Remove: S air filter case 1 3.
Page 110: Checking The Carburetor Joints And Intake Manifolds
CLEANING THE AIR FILTER ELEMENT/CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS 7. Install: S air filter element S air filter case cover CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
Page 111: Checking The Fuel Hoses And Fuel Filter
CHECKING THE FUEL HOSES AND FUEL FILTER EAS090097 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1.Remove: S rider seat S fuel tank Refer “RIDER PASSENGER SEATS” and “FUEL TANK”. 2. Remove: S left side cover S right side cover 3.
Page 112: Checking The Crankcase Breather Hose
CHECKING THE FUEL HOSE AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM / CHECKING THE COOLANT LEVEL 7. Install: S fuel tank S rider seat Refer to “FUEL TANK” and “RIDER AND PASSENGER SEAT”. EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1.
Page 113: Checking The Cooling System
CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM 3. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level marks b . Below the minimum level mark ! Add the recommended coolant to the proper level. CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant.
Page 114: Changing The Coolant
CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove: S rider seat S fuel tank Refer “RIDER PASSENGER SEATS” and “FUEL TANK”. 2. Remove: S left side cover S right side cover S rear inner cover 3. Remove: S reservoir tank 1 Drain the reservoir tank of its coolant.
Page 115 CHANGING THE COOLANT 6. Remove: S coolant drain bolt (radiator) 1 (along with the copper washer) S coolant drain bolt (water pump) 2 (along with the copper washer) 7. Remove: S drain plugs (cylinders) 1 Drain the coolant. NOTE: To remove the drain plug (cylinder) screw a spark plug into the threaded hole and pull on the spark plug.
Page 116 CHANGING THE COOLANT Quantity Total amount 3.5 L Coolant reservoir capacity 0.84 L From minimum to maximum level mark 0.25 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care. WARNING S If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor.
Page 117 CHANGING THE COOLANT 13. Fill: S coolant reservoir (with the recommended coolant to the maxi- mum level mark a ) 14. Install: S coolant reservoir cap 15. Start the engine, warm it up for several min- utes, and then turn it off. 16.
Page 118: Chassis
ADJUSTING THE REAR BRAKE EAS00111 CHASSIS ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 100 mm 2.
Page 119: Checking The Brake Fluid Level
CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE BRAKE PADS EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2.
Page 120: Adjusting The Rear Brake Light Switch
CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH 2. Check: S front brake pad S rear brake pad Wear indicators 1 almost touch the brake disc. Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in CHAPTER 7.
Page 121: Checking The Brake Hoses
CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check: S brake hose Cracks/damage/wear ! Replace. 2. Check: S brake hose clamp Loose connection ! Tighten.
Page 122: Adjusting The Shift Pedal
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL 3-41 2. Bleed: S hydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2 .
Page 123: Checking The Final Drive Oil Level
ADJUSTING THE SHIFT PEDAL/CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL 2. Adjust: S shift pedal position a. Loosen both locknuts 1 . b. Turn the shift rod 2 in direction a or b to obtain the correct shift pedal position. ! Shift pedal is raised.
Page 124: Checking And Adjusting The Steering Head
CHANGING THE FINAL DRIVE OIL/ CHECKING AND ADJUSTING THE STEERING HEAD 4. Install: S final drive housing oil drain bolt 23 Nm (2.3 mSkg) 5. Fill: S final drive housing (with the specified amount of the recom- mended final drive oil) Quantity 0.2 L Refer to “CHECKING THE FINAL DRIVE...
Page 125 CHECKING AND ADJUSTING THE STEERING HEAD 7. Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 .
Page 126: Checking The Front Fork
CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK / ADJUSTING THE FRONT AND REAR SHOCK ABSORBER ASSEMBRY 9. Install: S front cowling EAS00149 CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
Page 127 CHECKING THE TIRES / CHECKING THE FRONT FORK /ADJUSTING THE FRONT AND REAR SHOCK ABSORBER ASSEMBRY EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification ! Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
Page 128 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. FRONT TIRE: Manufacturer Size...
Page 129 CHECKING THE TIRES/CHECKING THE WHEELS WARNING S After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident with pos- sible injury to the rider or damage to the motorcycle.
Page 130 CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS / LUBRICATINGTHE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its move- ment.
Page 131 CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
Page 132 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 133 CHECKING AND CHARGING THE BATTERY 5. Charge: S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. CAUTION: S Make sure that the battery breather hose and battery vent are free of obstructions. S Never remove the MF battery sealing caps.
Page 134 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger NOTE: Measure the open-circuit Voltage should be measured 30 min- voltage prior to charging. utes after the machine is stopped. NOTE: Set the charging voltage at 16 X 17 V. Connect a charger and (If the setting is lower, charging will be AMP meter to the battery...
Page 135 CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger NOTE: Measure the open-circuit Voltage should be measured 30 min- voltage prior to charging. utes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
Page 136 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Check: S battery. Damage ! Replace. 7. Install: S battery 8. Connect: S battery leads (to he battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 9.
Page 137 CHECKING THE FUSES a. Connect the pocket tester to the fuse and check it for continuity. NOTE: Set the pocket tester selector to “Ω 1”. Pocket tester YU-03112, 90890-03112 b. If the pocket tester indicates “ ”, replace the fuse. 3.
Page 138 REPLACING THE HEADLIGHT BULB 4. Install: S side cover left EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: S headlight unit 2. Disconnect: S headlight leads 1 3. Remove: S bulb cover 2 4. Remove: S headlight bulb holder 1 5. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot,...
Page 139 REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 7. Install: S headlight bulb holder 8. Install: S bulb cover 9. Connect: S headlight leads 10. Install: S headlight unit EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: S headlight beam (vertically) a.
Page 141 CONTENTS ENGINE ENGINE REMOVAL ..........LEADS, CABLES AND HOSES .
Page 142 CHECKING THE PRESSURE PLATE ......4-51 CHECKING THE CLUTCH PUSH RODS ..... . . 4-51 INSTALLING THE CLUTCH .
Page 143 TRANSMISSION ..........4-98 CHECKING THE BEARINGS AND OIL SEALS .
Page 145: Engine Removal
ENGINE REMOVAL ENGINE ENGINE REMOVAL LEADS, CABLES AND HOSES 64 Nm (6.4 mSkg) Order Job/Part Q’ty Remarks Disconnecting the leads, cables Disconnecting the parts in the order listed. and hoses Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.
Page 146 ENGINE REMOVAL 64 Nm (6.4 mSkg) Order Job/Part Q’ty Remarks Battery leads Disconnect NOTE: First, disconnect the negative lead, then the positive lead. Battery Disconnect Cylinder head stays Spark plug leads Disconnect Hoses (coolant) Side covers (left and right) Rear inner cover Disconnect Plastic shroud Under covers...
Page 147: Radiator And Ais
ENGINE REMOVAL RADIATOR AND AIS Order Job/Part Q’ty Remarks Removing the radiator and AIS Remove the parts in the order listed. Radiator Refer to “RADIATOR” in CHAPTER 5. Engine guards and horn (left and right) For EUR. Starter lead AIS pipe Reed valve Air cutoff valve Air cleaner...
Page 148: Mufflers And Exhausts
ENGINE REMOVAL MUFFLERS AND EXHAUSTS 30 Nm (3.0 mSkg) 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 25 Nm (2.5 mSkg) 30 Nm (3.0 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the mufflers and exhausts Remove the parts in the order listed. Carburetors Refer to “CARBURETORS”...
Page 149: Horn And Brake Pedal
ENGINE REMOVAL HORN AND BRAKE PEDAL 52 Nm (5.2 mSkg) Order Job/Part Q’ty Remarks Removing the Horn and brake pedal Remove the parts in the order listed. Horn leads Disconnect For OCE. Horn For OCE. Ground lead Spring (rear brake switch) Disconnect Reservoir tank (rear brake) Brake pedal assembly...
Page 150: Engine
ENGINE REMOVAL ENGINE 78 Nm (7.8 mSkg) 45 Nm (4.5 mSkg) 30 (4) 40 Nm (4.0 mSkg) 70 (6) 40 Nm (4.0 mSkg) 70 (4) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.
Page 151 ENGINE REMOVAL 78 Nm (7.8 mSkg) 45 Nm (4.5 mSkg) 30 (4) 40 Nm (4.0 mSkg) 70 (6) 40 Nm (4.0 mSkg) 70 (4) Order Job/Part Q’ty Remarks Engine bracket Refer to “INSTALLING THE ENGINE”. Bolts (rear) Engine assembly NOTE: Remove the engine assembly from the right side of the motorcycle.
Page 152: Installing The Engine
ENGINE REMOVAL EAS00192 INSTALLING THE ENGINE 1. Install: S engine assembly (from the right side of the motorcycle) 2. Install: S bolts (rear) 1 S down tube (right) 2 S engine bracket 3 S rear brake switch S bolts (front-lower) 4 S bolts (front-upper) 5 S cylinder head stay 6 NOTE:...
Page 153: Camshafts
CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVERS 18 Nm (1.8 mSkg) 10 Nm (1.0 mSkg) 30 (4) 10 Nm (1.0 mSkg) 14 (12) 10 Nm (1.0 mSkg) 23 (16) Order Job/Part Q’ty Remarks Removing the cylinder head covers Remove the parts in the order listed. Stand the motorcycle on a level surface.
Page 154 CAMSHAFTS 18 Nm (1.8 mSkg) 10 Nm (1.0 mSkg) 30 (4) 10 Nm (1.0 mSkg) 14 (12) 10 Nm (1.0 mSkg) 23 (16) Order Job/Part Q’ty Remarks Spark plug caps Disconnect Coolant hoses (to cylinder head) Disconnect Chrome cylinder head covers Spark plugs Bolts (cylinder head covers) Cylinder head covers...
Page 155: Camshafts
CAMSHAFTS CAMSHAFTS 20 Nm (2.0 mSkg) 10 Nm (1.0 mSkg) 40 (32) 12 Nm (1.2 mSkg) 20 (4) 20 Nm (2.0 mSkg) 12 (8) 7 Nm (0.7 mSkg) 12 (2) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Cylinder head covers Refer to “CYLINDER HEAD COVERS”.
Page 156: Removing The Camshafts
CAMSHAFTS EAS00201 REMOVING THE CAMSHAFTS Rear cylinder head 1. Remove: S spark plugs S cylinder head cover S gasket (cylinder head cover) NOTE: Loosen each bolt 1/4 of a turn in a crisscross pattern. After all the bolts are loosened, remove them.
Page 157 CAMSHAFTS 7. Remove: S camshaft sprocket bolts Hold the camshaft with a 22 mm wrench. 8. Remove: S camshaft caps CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in.
Page 158: Checking The Camshafts
CAMSHAFTS Front cylinder head NOTE: When removing the front cylinder camshafts, repeat the rear cylinder camshaft removal pro- cedure. However, note the following points. 1. Turn: S crankshaft NOTE: From the “–” and “I” marks, turn the crankshaft counterclockwise 430_ (i.e., 360_ plus an addi- tional 70_).
Page 159 CAMSHAFTS 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ! Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.020 X 0.054 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of Plastigauge 1 onto the camshaft journal as shown.
Page 160: Checking The Timing Chains, Camshaft Sprockets, And Timing Chain Guides
CAMSHAFTS EAS00209 CHECKING THE TIMING CHAINS, CAM- SHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the tim- ing chains, camshaft sprockets, and timing chain guides. 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and its respective camshaft sprockets as a set.
Page 161: Installing The Camshafts
CAMSHAFTS EAS00218 INSTALLING THE CAMSHAFTS 1. Align: S “–” and “I” marks on the generator rotor (with the crankcase edge) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “–” and “I” marks 1 on the generator rotor with the crankcase edge CAUTION: Do not turn the crankshaft when installing...
Page 162 CAMSHAFTS S Be sure to keep the timing chain as tight as possible on the exhaust side. S Remove the wire from the timing chain. CAUTION: Do not turn the camshaft, as damage could occur to the pistons and valves. c.
Page 163 CAMSHAFTS CAUTION: Do not turn the crankshaft when installing the camshaft sprockets to avoid damage or improper valve. a. Place the timing chain onto the intake sprocket. b. Install the intake camshaft sprocket with the “REAR” mark facing out, and then finger tighten the camshaft sprocket bolts.
Page 164 CAMSHAFTS 3. Install: S timing chain tensioner a. Remove the cap bolt 1 , washer 2 and spring 3 . b. Release the timing chain tensioner one-way cam 4 . c. Install the timing chain tensioner 5 and gas- ket 6 onto the cylinder block. WARNING Always use a new gasket.
Page 165 CAMSHAFTS 6. Tighten: S camshaft sprocket bolts 20 Nm (2.0 mSkg) CAUTION: Be sure to tighten the camshaft sprocket bolts to the specified torque to avoid the possibility of the bolts coming loose and damaging the engine. 7. Install: S camshaft caps “I-2” 1 S camshaft caps “E-2”...
Page 166 CAMSHAFTS c. Install the camshaft sprockets onto the cam- shafts. Refer to the camshaft sprocket installation steps below. NOTE: Make sure that the “FRONT” marks 1 on the camshaft sprockets face away from the “IN” 2 and “EX” marks 3 on the camshafts. d.
Page 167: Cylinder Heads
CYLINDER HEADS CYLINDER HEADS 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 22 (2) Order Job/Part Q’ty Remarks Removing the cylinder heads Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head covers Refer to “CAMSHAFTS”.
Page 168: Checking The Cylinder Heads
CYLINDER HEADS EAS00230 CHECKING THE CYLINDER HEADS The following procedure applies to all of the cyl- inder heads. 1. Eliminate: S carbon deposits (from the combustion chambers with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: S spark plug threads S valve seats...
Page 169 CYLINDER HEADS 2. Install: S cylinder head 1 43 Nm (4.3 mSkg) S washers NOTE: S To prevent the timing chain 2 from falling into the crankcase, fasten it with a wire. S Tighten the cylinder head nuts and bolts in two stages and in a crisscross pattern.
Page 170: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Engine assembly Refer to “ENGINE REMOVAL”. Camshafts Refer to “CAMSHAFTS”. Cylinder heads Refer to “CYLINDER HEADS”. Valve pads Valve lifters Valve cotters...
Page 171: Removing The Valves
VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1.
Page 172: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 4. Remove: S upper spring seat 1 S valve springs 2 S oil seal 3 S lower spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
Page 173 VALVES AND VALVE SPRINGS a. Remove the valve guide with a valve guide remover 1 . b. Install the new valve guide with a valve guide installer 2 and valve guide remover 1 . c. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance.
Page 174: Checking The Valve Seats
VALVES AND VALVE SPRINGS 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 1.15 X 1.45 mm <Limit>: 0.7 mm 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide.
Page 175 VALVES AND VALVE SPRINGS 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. a. Apply a coarse lapping compound a to the valve face.
Page 176: Checking The Valve Springs
VALVES AND VALVE SPRING j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.
Page 177: Installing The Valves
VALVES AND VALVE SPRING EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: S valve stem end (with an oil stone) 2. Lubricate: S valve stem 1 S oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
Page 178 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6. Install: S valve lifter 1 S valve pad 2 NOTE: S Apply molybdenum disulfide oil onto the valve...
Page 179: Clutch
CLUTCH CLUTCH CLUTCH MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the clutch master cylinder Remove the parts in the order listed. NOTE: Before removing the master cylinder, drain the clutch fluid from the entire clutch system.
Page 180 CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch master Disassemble the parts in the order listed. cylinder Master cylinder cap Holder (diaphragm) Diaphragm Push rod Dust boot Circlip Washer Master cylinder kit For assembly, reverse the disassembly procedure. 4-36...
Page 181: Checking The Clutch Master Cylinder
CLUTCH EAS00307 CAUTION: Clutch components rarely require disas- sembly. Therefore, always follow these preventive measures: S Never disassemble clutch components un- less absolutely necessary. S If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
Page 182: Assemblyng The Clutch Master Cylinder
CLUTCH 2. Check: S clutch master cylinder 1 S clutch master cylinder kit 2 Rust/scratches/wear ! Replace the clutch master cylinder and clutch master cylinder kit as a set. S clutch hose Cracks/damage/wear ! Replace. EAS00309 ASSEMBLING THE CLUTCH MASTER CYL- INDER WARNING S Before installation, all internal clutch com-...
Page 183 CLUTCH 2. Install: S copper washers (New) S clutch hose 1 S union bolt 2 30 Nm (3.0 mSkg) WARNING Proper clutch hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”. NOTE: While holding the clutch hose, tighten the union bolt.
Page 184 CLUTCH CAUTION: Clutch fluid may damage painted surfaces or plastic parts. Therefore, always clean up any spilt clutch fluid immediately. NOTE: In order to ensure a correct reading of the clutch fluid level, make sure that the top of the reser- voir is horizontal.
Page 185 CLUTCH CLUTCH RELEASE CYLINDER 12 Nm (1.2 mSkg) 25 Nm (2.5 mSkg) Order Job/Part Q’ty Remarks Removing the clutch release cylinder Remove the parts in the order listed. NOTE: Before removing the clutch release cylinder or the master cylinder, drain the clutch fluid from the entire clutch system.
Page 186 CLUTCH 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the clutch rlease Disassemble the parts in the order listed. cylinder Oil seal Piston (release cylinder) Refer to “DISASSEMBLING THE Spring CLUTCH RELEASE CYLINDER”. Piston seal CAUTION: Never attempt to pry out the piston. Air bleed screw For assembly, reverse the disassembly procedure.
Page 187: Disassembling The Clutch Release Cylinder
CLUTCH EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER 1. Remove: S oil seal 1 S clutch release cylinder piston 2 S spring 3 S piston seal 4 a. Blow compressed air into the clutch hose joint opening a to force out the piston from the clutch release cylinder.
Page 188: Assembling The Clutch Release Cylinder
CLUTCH 3. Check: S spring 1 Wear/rust ! Replace the clutch release cyl- inder assembly. ASSEMBLING THE CLUTCH RELEASE CYL- INDER WARNING S All internal parts shoud be cleaned in new fluid only. S During installation internal parts should be lubricated with new fluid.
Page 189 CLUTCH 2. Fill: S clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) Recommended clutch fluid Brake fluid DOT 4 WARNING S Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance.
Page 190 CLUTCH CLUTCH COVER 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Stand the motorcycle on a level surface WARNING Securely support the motorcycle so there is no danger of it falling over. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 191: Cluch
CLUCH CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) 25 (6) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch spring plate Clutch spring Clutch spring seat Pressure plate Push rod #2 Refer to “INSTALLING THE CLUTCH”. O-ring Ball Friction plates...
Page 192 CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) 25 (6) Order Job/Part Q’ty Remarks Friction plate Spring plate Refer to “INSTALLING THE CLUTCH”. Washer Clutch housing Push rod #1 Circlip Oil pump drive gear Dowel pins For installation, reverse the removal procedure.
Page 193: Removing The Clutch
CLUTCH EAS00275 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder YM-91042, 90890-04086 EAS00280 CHECKING THE FRICTION PLATES...
Page 194: Checking The Clutch Plates
CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. 2. Measure: S clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification ! Replace the clutch plates as a set.
Page 195: Checking The Pressure Plate
CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: S pressure plate 1 Cracks/damage ! Replace. S bearing 2 Damage/wear ! Replace. EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: S short clutch push rod 1 S O-ring 2 S ball 3 S long clutch push rod 4 Cracks/damage/wear ! Replace the de- fective part(-s).
Page 196 CLUTCH 5. Install: S friction plates S clutch plates NOTE: S First, install a friction plate and then alternate between a clutch plate and a friction plate. S Align the two slots a in the friction plates with the two punch marks b in the clutch housing. 6.
Page 197 CLUTCH 9. Install: S clutch spring plate seat 1 S clutch spring plate 2 S clutch spring plate retainer 3 S clutch spring plate bolts 4 8 Nm (0.8 mSkg) NOTE: Tighten the clutch spring plate bolts in stages and in a crisscross pattern. 10.
Page 198: Shift Shaft
SHIFT SHAFT SHIFT SHAFT SHIFT ARM 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 35 (3) 45 (3) Order Job/Part Q’ty Remarks Removing the shift arm Remove the parts in the order listed. Engine oil Refer to “CHANGING THE ENGINE OIL” in CHAPTER 3.
Page 199: Shift Shaft And Stopper Lever
SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever (B) Shift shaft assembly Circlip Washer Refer to “INSTALLING THE SHIFT Torsion spring SHAFT”.
Page 200: Checking The Shift Shaft
SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 S shift lever 2 Bends/damage/wear ! Replace. S shift lever spring 3 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
Page 201: Starter Clutch And Generator
STARTER CLUTCH AND GENERATOR STARTER CLUTCH AND GENERATOR STARTOR COIL 7 Nm (0.7 mSkg) 30 (3) 10 Nm (1.0 mSkg) 52 Nm (5.2 mSkg) 45 (7) 32 (2) 60 (4) Order Job/Part Q’ty Remarks Removing the stator coil Remove the parts in the order listed. Engine oil Refer to “CHANGING THE ENGINE OIL”...
Page 202 STARTER CLUTCH AND GENERATOR 7 Nm (0.7 mSkg) 30 (3) 10 Nm (1.0 mSkg) 52 Nm (5.2 mSkg) 45 (7) 32 (2) 60 (4) Order Job/Part Q’ty Remarks Plate (stater coil) Stater coil For installation, reverse the removal procedure. 4-58...
Page 203 STARTER CLUTCH AND GENERATOR STARTER CLUTCH AND GENERATOR 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) 25 (6) 130 Nm (13.0 mSkg) Order Job/Part Q’ty Remarks Removing the stater clutch and Remove the parts in the order listed. generator rotor Shafts Starter idler gears Rotor...
Page 204: Removing The Generator
STARTER CLUTCH AND GENERATOR EAS00346 REMOVING THE GENERATOR 1. Remove: S generator rotor bolt 1 S washer NOTE: S While holding the generator rotor with the sheave holder 2 , loosen the generator rotor bolt. S Do not allow the sheave holder to touch the projection on the generator rotor.
Page 205: Installing The Generator
STARTER CLUTCH AND GENERATOR 4. Check: S starter clutch operation a. Install the starter clutch 1 onto the genera- tor rotor 2 and hold the starter clutch. b. When turning the starter clutch drive gear clockwise A , the starter clutch and the start- er clutch drive gear should engage.
Page 206: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP OIL PAN AND OIL PUMP 17 Nm (1.7 mSkg) 24 Nm (2.4 mSkg) 10 Nm (1.0 mSkg) 25 (3) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 30 (12) Order Job/Part Q’ty Remarks Removing the oil pan and oil pump...
Page 207 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. Oil strainer Oil strainer housing Gasket Circlip Driven gear (oil pump) Refer to “ASSEMBLING THE OIL Gear housing PUMP”. Spring Relief valve Inner rotor Shaft...
Page 208 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Refer to “ASSEMBLING THE OIL Dowel pins PUMP”. Oil pump housing For assembly, reverse the disassembly procedure. 4-64...
Page 209: Removing The Oil Pan
OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: S oil lever switch 1 S oil pan 2 S gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 210: Checking The Relief Valve
OIL PAN AND OIL PUMP EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body S relief valve 1 S spring 2 Damage/wear ! Replace the defective part(-s). EAS00367 CHECKING THE OIL GALLERY PIPES The following procedure applies to all of the oil gallery pipes.
Page 211: Assembling The Oil Pump
OIL PAN AND OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump shaft 1 (to the oil pump cover 2 ) S pin 3 S inner rotor 4 S outer rotor 5...
Page 212: Installing The Oil Strainer
OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: S oil strainer housing 1 2. Install: S oil strainer cover 2 S relief valve NOTE: The arrow a on the oil strainer cover must point towards the rear of the engine. EAS00380 INSTALLING THE OIL PAN 1.
Page 213: Crankcase
CRANKCASE CRANKCASE 25 Nm (2.5 mSkg) 21 (4) 30 Nm (3.0 mSkg) 30 (3) 7 Nm (0.7 mSkg) 13 (3) Order Job/Part Q’ty Remarks Crankcase separation Remove the parts in the order listed. Engine assembly Refer to “ENGINE REMOVAL”. Cylinder head Refer to “CYLINDER HEADS”.
Page 214 CRANKCASE 25 Nm (2.5 mSkg) 21 (4) 30 Nm (3.0 mSkg) 30 (3) 7 Nm (0.7 mSkg) 13 (3) Order Job/Part Q’ty Remarks Retainer (main axle bearing) Retainers (middle gear bearing) Refer to “ASSEMBLING THE Middle driven gear assembly CRANKCASE”. Shims Crankcase (upper) Refer to “DISASSEMBLING/...
Page 215 CRANKCASE 10 Nm (1.0 mSkg) 40 (6) 10 Nm (1.0 mSkg) 16 (4) 18 Nm (1.8 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks Disassembling the crankcase Disassemble the parts in the order listed. Crankcase breather cover Crankcase breather spacer Rubber gaskets Oil pipe Drain plugs (cylinders)
Page 216: Disassembling The Crankcase
CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Remove: S crankcase bolts A Upper crankcase B Lower crankcase NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).
Page 217: Checking The Crankcase
CRANKCASE EAS00399 CHECKING THE CRANKCASE 1. Throughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: S crankcase Cracks/damage ! Replace. S oil delivery passages Obstruction ! Blow out with compressed air. 4.
Page 218: Assembling The Crankcase
CRANKCASE EAS00417 ASSEMBLING THE CRANKCASE 1. Install: S shaft 1 S Idler gear (oil pump) 2 S circlip 3 2. Install: S bracket (timing chain damper) 1 24 Nm (2.4 mSkg) S oil pipe 2 18 Nm (1.8 mSkg) NOTE: Apply LOCTITE to the bracket bolt.
Page 219 (with the recommended lubricant) Recommended lubricant Engine oil 7. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 Quick Gasket ACC-11001-15-01 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.
Page 220 CRANKCASE 11. Tighten: S upper crankcase bolts S lower crankcase bolts WARNING Always use new copper washers. NOTE: S Tighten the bolts in the tightening sequence cast on the crankcase. S Install copper washers on bolts S Install the cable holder on bolts S Install the washers on bolts 2 and 4 X 8 .
Page 221: Crankshaft
CRANKSHAFT CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Balancer shaft Balancer shaft bearings Refer to “REMOVING/INSTALLING Crankshaft THE CRANKSHAFT”. Timing chains Main journal bearings For installation, reverse the removal procedure.
Page 222: Removing The Crankshaft Assembly
CRANKSHAFT EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S balancer shaft 1 S crankshaft assembly 2 S crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.
Page 223 CRANKSHAFT NOTE: Align the projections a of the crakshaft journal upper bearings with the notches b in the crank- case. d. Put a piece of Plastigauge 2 on each crankshaft journal. NOTE: Do not put the Plastigauge over the oil hole in the crankshaft journal.
Page 224 CRANKSHAFT f. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase. NOTE: S Install copper washers on bolts S Install the coble holder on bolts S Install the washers on bolts 2 and 4 X 8 . A Upper crankcase B Lower crankcase M 10 bolt...
Page 225 CRANKSHAFT 4. Select: S crankshaft journal bearings (J NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 stamped into the low- er crankcase are used to determine the re- placement crankshaft journal bearing sizes. S “J ”...
Page 226: Checking The Balancer Shaft
CRANKSHAFT CHECKING THE BALANCER SHAFT 1. Measure S balancer shaft runout out of specification ! Replace the balancer shaft Balancer shaft runout Less than 0.03 mm 2. Check: S balancer shaft journal surfaces S bearing surface S balancer shaft driven gear 1 S water pump drive gear 2 Scratches/wear ! Replace the balancer shaft...
Page 227 CRANKSHAFT a. Clean the balancer shaft journal bearings, balancer shaft journals, and bearing portions of the crankcas. b. Place the upper crankcase upside down on a bench. c. Install the balancer shaft journal upper bear- ings 1 and the balancer shaft into the upper crankcase.
Page 228 CRANKSHAFT f. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase. NOTE: S Install copper washers on bolts S Install the coble holder on bolts S Install the washers on bolts 2 and 4 X 8 . A Upper crankcase B Lower crankcase M 10 bolt...
Page 229 CRANKSHAFT 4. Select: S Balancer shaft journal bearings (P NOTE: The numgers A stamped into the balancer weight and the numbers 1 stamped into the lower creankcase are used to determine the re- placement balancer shaft journal bearing sizes. “P ”...
Page 230: Installing The Crankshaft
CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.
Page 231: Connecting Rods And Pistons
CONNECTING RODS AND PISTONS CONNECTING RODS AND PISTONS 36 Nm (3.6 mSkg) Order Job/Part Q’ty Remarks Connecting rod and piston removal Remove th parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Nuts (connecting rod caps) Refer to “INSTALLING THE PISTONS Connecting rod caps/plain bearings AND CONNECTING RODS”.
Page 232: Removing The Connecting Rods And Pistons
ONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS 1. Remove: S connecting rod bearings NOTE: Identify the position of each bearing very care- fully so that it can be reinstalled in its original place. The following procedure applies to all of the cyl- inders and pistons.
Page 233: Checking The Cylinders And Pistons
CONNECTING RODS AND PISTONS EAS00260 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Check: S piston wall S cylinder wall Vertical scratches ! Rebore or replace the cylinder, and replace the piston and piston rings as a set.
Page 234: Checking The Piston Rings
CONNECTING RODS AND PISTONS c. Measure piston skirt diameter “P” with the micrometer. b 4 mm from the bottom edge of the piston. Piston size P 78.926 X 78.933 mm Standard Oversize 2 79.25 mm Oversize 4 79.50 mm d. If out of specification, replace the piston and piston rings as a set.
Page 235 CONNECTING RODS AND PISTONS Piston ring side clearance Top ring 0.03 X 0.07 mm <Limit>: 0.12 mm 2nd ring 0.02 X 0.06 mm <Limit>: 0.12 mm 2. Install: S piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown as shown.
Page 236: Checking The Piston Pins
CONNECTING RODS AND PISTONS S Oil ring The expander spacer of the oil ring is color- coded for size identificaton. Size Color Oversize 2 Blue Oversize 4 EAS00266 CHECKING THE PISTON PINS The following procedure applies to all of the pis- ton pins.
Page 237: Checking The Crankshaft And Connecting Rods
CONNECTING RODS AND PISTONS EAS00395 CHECKING THE CRANKSHAFT AND CON- NECTING RODS 1. Measure: S crankshaft-pin-to-big-end-bearing clear- ance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end- bearing clearance 0.021 X 0.039 mm The following procedure applies to all of the connecting rods.
Page 238 CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. CAUTION: S When tightening the connecting rod nuts, be sure to use an F-type torque wrench. S Without pausing, tighten the connecting rod nuts to the specified torque. Apply con- tinuous torque between 3.0 and 3.6 mSkg.
Page 239 CONNECTING RODS AND PISTONS BIG END BEARING COLOR CODE blue black brown green EAS00267 INSTALLING THE PISTONS AND CONNECT- ING RODS 1. Install: S top ring 1 S 2nd ring 2 S lower oil ring rail 3 S upper oil ring rail 4 S oil ring expander 5 NOTE: Be sure to install the piston rings so that the...
Page 240 CONNECTING RODS AND PISTONS 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring 5. Install: S plain bearings 1 NOTE: S Align the projection a of the bearings with the notches b in the connecting rod cap.
Page 241 CONNECTING RODS AND PISTONS 8. Install: S connecting rod cap NOTE: Be sure that the characters on the side of the cap and connecting rod are aligned. 9. Tighten: S nuts (connecting rod cap) 36 Nm (3.6 mSkg) NOTE: S Apply Molybdenum disulfide grease to the rod cap bolt threads and nut surfaces.
Page 242: Transmission
TRANSMISSION TRANSMISSION 7 Nm (0.7 mSkg) 13 (3) 4 Nm (0.4 mSkg) 9 (3) Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase separation Refer to “CRANKCASE”. Drive axle assembly Refer to “INSTALLING THE Main axle assembly TRANSMISSION”.
Page 243 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the transmission Remove the parts in the order listed. Middle drive pinion gear assembly Refer to “MIDDLE GEAR”. Circlip Bearing 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle Plug 2nd wheel gear Washer Circlip...
Page 244 TRANSMISSION Order Job/Part Q’ty Remarks 5th wheel gear Bearing Circlip Bearing Main axle 4th pinion gear Washer Circlip 2nd, 3rd pinion gear 5th pinion gear Washer Circlip Bearing For installation, reverse the disassembly procedure. 4-100...
Page 245: Checking The Bearings And Oil Seals
TRANSMISSION EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: S bearings 1 Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement ! Replace. 2. Check: S oil seals 2 Damage/wear ! Replace. S circlips 3 Bends/damage/looseness ! Replace.
Page 246: Checking The Shift Drum Assembly
TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum. S shift drum bearing 1 Damage/pitting ! Replace. S shift drum segment 2 Damage/wear ! Replace. EAS00425 CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main...
Page 247: Installing The Shift Forks
TRANSMISSION EAS00426 INSTALLING THE SHIFT FORKS 1. Install: S shift forks 1 S shift fork guide bars 2 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.
Page 248: Middle Geae
MIDDLE GEAE MIDDLE GEAE 90 Nm (9.0 mSkg) 30 Nm (3.0 mSkg) 110 Nm (11.0 mSkg) Order Job/Part Q’ty Remarks Removing the middle gear Remove the parts in the ordr listed. Crankcase separation Refer to “CRANKCASE”. Drive axle assembly Refer to “TRANSMISSION”. Refer to “DISASSEMBLING/ Washer ASSEMBLING THE MIDDLE DRIVEN...
Page 249 MIDDLE GEAR 90 Nm (9.0 mSkg) 30 Nm (3.0 mSkg) 110 Nm (11.0 mSkg) Order Job/Part Q’ty Remarks Thrust washer Middle drive pinion gear Damper cam Damper spring Spring seat Bearing Refer to “DISASSEMBLING/ Bearing ASSEMBLING THE MDDLE DRIVE SHAFT ASSEMBLY”. For installation, reverse the removal procedure.
Page 250: Disassembling The Middle Drive Shaft Assembly
MIDDLE GEAR EAS00434 DISASSEMBLING MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: S spring retainers 1 NOTE: While compressing the spring with a damper spring compressor 2 , remove the spring re- tainers. Damper spring compressor YM-33286, 90890-04090 2. Straighten the stake. 3.
Page 251: Disassembling The Middle Driven Shaft Assembly
MIDDLE GEAR EAS00437 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY NOTE: The following procedure should only be per- formed if the middle drive gear or middle driven shaft bearing(-s) has to be replaced. 1. Remove: S universal joint a. Remove the circlips 1 . b.
Page 252: Checking The Middle Driven Shaft Assembly
MIDDLE GEAR EAS00439 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: S middle driven gear Galling/pitting/wear ! Replace the middle driven shaft assembly. 2. Check: S bearings Damage/pitting ! Replace the middle drive shaft bearing housing assembly. 3. Check: S O-ring S oil seal Damage ! Replace the defective part(-s).
Page 253: Assembling The Middle Driven Shaft Assembly
MIDDLE GEAR 2. Install: S spring retainers 1 NOTE: While compressing the spring with a damper spring compressor 2 , and then install the spring retainers. Damper spring compressor YM-33286, 90890-04090 EAS00443 ASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY NOTE: The following points are critical when assem- bling the middle gears: S The collapsible collar must be replaced when- ever the middle driven shaft assembly is re-...
Page 254 MIDDLE GEAR CAUTION: Tighten the middle driven shaft nut in small increments, checking the torque it takes to keep the middle driven gear turning in the middle driven shaft bearing housing – not the torque it takes to start it turning. Universal joint holder YM-04062, 90890-04062 3.
Page 255: Aligning The Middle Gear
MIDDLE GEAR 5. Install: S bearings (onto the universal joint driven yoke/cross joint) CAUTION: Then needles can easily fall out of their races, so check each bearing carefully. Slide the universal joint driven yok assembly back and forth on the bearings. If a needle is out of place, the yoke will not go all the way onto the bearings.
Page 256 MIDDLE GEAR Example Shim thickness = Distance “A” – Distance “B” A = 43 + a B = 42 + b a. If the middle drive gear is stamped “06” ( a positive number (+ 06) is implied since only the negative (–) designations are stamped alongside the numbers), then: “A”...
Page 257: Adjusting The Middle Gear Backlash
MIDDLE GEAR EAS00450 ADJUSTING THE MIDDLE GEAR BACK- LASH 1. Install: S middle gear backlash tool Middle gear backlash tool 90890-04080 2. Loosen: S middle driven shaft bearing housing bolts 3. Remove: S shim(-s) 4. Tighten: S middle driven shaft bearing housing bolts CAUTION: Do not overtighten the middle driven shaft bearing housing bolts or you may obtain too...
Page 258: Middle Gear
MIDDLE GEAR 7. Select: S shim(-s) 1 a. Shims can only be selected in 0.05 mm incre- ments, therefore round off to the hundredths digit of the calculated thickness and select the appropriate shim(-s) with the following chart. b. For example, the clearance between the crankcase and the middle driven shaft bear- ing housing is 0.42 mm.
Page 259 COOL...
Page 260 COOL CONTENTS COOLING SYSTEM RADIATOR ........... . CHECKING THE RADIATOR .
Page 261 COOL...
Page 262: Cooling System
COOL RADIATOR COOLING SYSTEM RADIATOR 2 Nm (0.2 mSkg) 12 (3) 7 Nm (0.7 mSkg) 40 (2) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat, fuel tank Refer to “RIDER AND PASSENGER SEATS”...
Page 263: Checking The Radiator
COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: S 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. 2.
Page 264: Installing The Radiator
COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in CHAPTER 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. 3.
Page 265: Thermostat
COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Rider seat, fuel tank Refer to “SEATS” and “FUEL TANK” in CHAPTER 3.
Page 266 COOL THERMOSTAT 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Radiator cap pipe For installation, reverse the removal procedure.
Page 267: Thermostat Housing
COOL THERMOSTAT THERMOSTAT HOUSING 23 Nm (2.3 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the thermostat Disassemble the parts in the order listed. Thermostat stay Thermostat housing cover O-ring (housing cover) Thermostatic valve Refer to “ASSEMBLING THE Thermo switch THERMOSTAT”.
Page 268: Checking The Thermostat
COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 80.5 X 83.5_C ! Replace. Thermostat full opening range 8 mm at 95 _C a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c.
Page 269: Installing The Thermostat
COOL THERMOSTAT 2. Install: S thermo switch 1 75Nm (0.75 mSkg) CAUTION: Use extreme care when handing the thermo switch and temperature sender. Replace any part that was dropped or subjected to a strong impact. EAS00466 INSTALLING THE THERMOSTAT 1. Fill: S cooling system (with the specified amount of the recom- mended coolant)
Page 270: Water Pump
COOL WATER PUMP WATER PUMP 10 Nm (1.0 mSkg) 25 (4) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 30 (2) 80 (3) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. Coolant Refer to “CHANGING THE COOLANT” in CHAPTER 3.
Page 271: Disassembling The Water Pump
COOL WATER PUMP Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. Circlip Driven gear Refer to “ASSEMLING THE WATER Gear stopper pin PUMP”. Circlip Impeller Bearing Oil seal Refer to “DISASSEMBLING/ Water pump seal ASSEMBLING THE WATER PUMP”.
Page 272 COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: S bearing 1 S oil seal 2 NOTE: Tap out the bearing and oil seal from the outside of the water pump housing. 2. Remove: S water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing.
Page 273 COOL WATER PUMP 3. Check: S water pump seal 1 S oil seal 2 Cracks/damage/wear ! Replace. 4. Check: S bearing Roughness ! Replace. 5. Check: S water pump driven gear Pitting/wear ! Replace. 7. Check: S water pump inlet pipe S radiator outlet hose Cracks/damage/wear ! Replace.
Page 274 NOTE: S Install the water pump seal from the special tools. S Before installing the water pump seal, apply Yamaha bond No. 1215 to the water pump housing 2 . Mechanical seal installer 3 90890-04078 Middle driven shaft bearing...
Page 275: Installing The Water Pump
COOL WATER PUMP 4. Install: S oil seal S bearing 1 NOTE: S Install the oil seal and bearing from the inside of the water pump housing. S Make sure that the side of the bearing with the number faces up. S Gently tap the bearing into place until it is flush with the water pump housing.
Page 276 COOL WATER PUMP 2. Install: S O-ring (New) S water pump housing cover 1 10 Nm (1.0 mSkg) S O-ring (New) S water pump inlet hose 2 WARNING Always use a new O-ring. NOTE: Before installing the water pump inlet pipe 2 , apply a thin coat of lithium soap base grease onto the O-rings.
Page 277 COOL...
Page 278 CARB...
Page 279: Carburetors Carb
CARB CONTENTS CARBURETORS CARBURETORS ..........CHECKING THE CARBURETORS .
Page 280 CARB...
Page 281: Carburetors
CARB CARBURETORS CARBURETORS CARBURETORS Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Rider seat, fuel tank Refer to “RIDER AND PASSENGER SEATS” and “FUEL TANK” in CHAPTER 3. Air induction box Fuel hose Disconnect Drain hose Disconnect Throttle position sensor lead...
Page 282 CARB CARBURETORS Order Job/Part Q’ty Remarks Separating the carburetors Remove the parts in the order listed. Choke knob Choke knob bracket Choke lever Throttle stop screw Bracket Connecting bolt Bracket Carburetor heater Bracket Fuel feed pipe Breather hose Synchronization rod Bracket...
Page 283 CARB CARBURETORS Order Job/Part Q’ty Remarks Bracket Carburetors For assembly, reverse the disassembly procedure.
Page 284 CARB CARBURETORS Order Job/Part Q’ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. NOTE: The remaining steps should be followed for all four of the carburetors. Starter plunger holder O-ring Starter plunger assembly Coasting enrichment cover Spring Diaphragm Refer to “ASSEMBLING THE Vacuum chamber cover...
Page 285 CARB CARBURETORS Order Job/Part Q’ty Remarks Jet needle Float chamber cover Gasket Float pin Float Needle valve Holding screw (valve seat) Valve seat Main jet Main jet holder Pilot jet Needle jet For assembly, reverse the disassembly procedure.
Page 286: Checking The Carburetors
CARB CARBURETORS EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleumbased solvent.
Page 287 CARB CARBURETORS 8. Check: S piston valve 1 Damage/scratches/wear ! Replace. S rubber diaphragm 2 Cracks/tears ! Replace. 9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder Cracks/damage ! Replace. 10. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S pilot jet 4...
Page 288: Assembling The Carburetors
CARB CARBURETORS Check: S fuel feed hoses S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air. EAS00489 ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent.
Page 289 CARB CARBURETORS a. Hold the carburetor upside down. b. Measure the distance from the mating sur- face of the float chamber (with the gasket re- moved) to the top of the float. NOTE: The float arm should rest on the needle valve without depressing it.
Page 290: Installing The Carburetors
CARB CARBURETORS EAS00493 INSTALLING THE CARBURETORS 1. Adjust: S carburetor synchronization Refer to “SYNCHRONIZING THE CARBU- RETORS” in CHAPTER 3. 2. Adjust: S engine idling speed Engine idling speed 950 X 1,050 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in CHAPTER 3. 3.
Page 291: Checking And Adjusting The Throttle Position Sensor
CARB CARBURETORS e. Hold the fuel level gauge vertically next to the edge of body 4 . f. Measure the fuel level on both sides of the carburetor assembly. NOTE: The fuel level readings should be equal on both sides. 2.
Page 292 CARB CARBURETORS d. Connect the pocket tester (Ω 1 k) to the throttle position sensor. Tester positive lead ! Yellow 3 Tester negative lead ! Black 2 e. While slowly opening the throttle, check that the throttle position sensor resistance is with- in the specified range.
Page 293 CARB CARBURETORS NOTE: Check mainly that the resistance changes grad- ually when turning the throttle, since the read- ings (from closed to wide -open throttle) may dif- fer slightly from those specified. Throttle position sensor resistance 0.6 X 5.7 kΩ at 20_C (Yellow X Blue) 3.
Page 294: Checking The Fuel Pump
CARB CARBURETORS EAS00504 CHECKING THE FUEL PUMP 1. Check: S fuel pump a. Place a container under the end of the fuel hose. b. Start the engine and check if fuel flows from the fuel hose 1 . Fuel flows ! Fuel pump is OK Fuel does not flow ! Replace the fuel pump c.
Page 295: Checking The Fuel Cock
CARB CARBURETORS EAS00505 CHECKING THE FUEL COCK 1. Check: S fuel lock Cracks/damage/wear ! Replace. EAS00506 CHECKING THE FUEL COCK OPERATION NOTE: After installing the fuel cock, check its operation. 1. Check that the fuel cock lever is positioned to “ON”...
Page 296: Air Induction System
CARB AIR INDUCTION SYSTEM EB601000 AIR INDUCTION SYSTEM(AIS) AIR INJECTION This system burns the unburned exhaust gases by injecting fresh air (secondary air) at the ex- haust port. This is to reduce the output of the hy- drocarbons. When there is negative pressure around the ex- haust port, the reed valve opens and the sec- ondary air flows into the exhaust port.
Page 297: Air Induction System Diagrams
CARB AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS Reed valve A To cylinder #1 Air cleaner B To cylinder #2 Air cutoff valve C To cylinder #3 Carburetor joint (cylinder #2) D To cylinder #4 Carburetor joint (cylinder #4) E To carburetor joint (#2) F To carburetor joint (#4) 6-17...
Page 298: Checking The Air Induction System
CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S air cutoff valve Cracks/damage ! Replace. 6-18...
Page 299 CHAS...
Page 300: Chassis Chas
CHAS CONTENTS CHASSIS FRONT WHEEL AND BRAKE DISCS ......FRONT WHEEL ..........REMOVING THE FRONT WHEEL .
Page 301 CHAS INSTALLING THE FRONT FORK LEGS ..... . . 7-55 HANDLEBAR ..........7-56 HANDLEBAR .
Page 302 CHAS CHECKING THE DRIVE SHAFT ......7-91 INSTALLING THE DRIVE SHAFT .
Page 303 CHAS...
Page 304: Front Wheel And Brake Discs
CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 25 Nm (2.5 mSkg) 78 Nm (7.8 mSkg) 23 Nm (2.3 mSkg) 25 (6) 19 Nm (1.9 mSkg) 40 Nm (4.0 mSkg) 23 Nm (2.3 mSkg) 25 (6) Order Job/Part Q’ty...
Page 305 CHAS FRONT WHEEL AND BRAKE DISCS “ 25 Nm (2.5 mSkg) 78 Nm (7.8 mSkg) 23 Nm (2.3 mSkg) 25 (6) 19 Nm (1.9 mSkg) 40 Nm (4.0 mSkg) 23 Nm (2.3 mSkg) 25 (6) Order Job/Part Q’ty Remarks Collars Brake disc cover (left) Refer to “INSTALLING THE FRONT Brake discs...
Page 306: Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seals Bearings Spacer For assembly, reverse the disassembly procedure.
Page 307: Removing The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Page 308 CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits ! Replace. Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 4.
Page 309: Checking The Brake Discs
CHAS FRONT WHEEL AND BRAKE DISCS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc.
Page 310: Installing The Front Wheel
CHAS FRONT WHEEL AND BRAKE DISCS Brake disc bolt 23 Nm (2.3 mSkg) LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.
Page 311: Adjusting The Front Wheel Static Balance
CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake discs installed. 1.
Page 312 CHAS FRONT WHEEL AND BRAKE DISCS b. Turn the front wheel 90_ so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that posi- tion, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced.
Page 313: Rear Wheel And Brake Disc
CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC REAR FENDER 48 Nm (4.8 mSkg) 48 Nm (4.8 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear fender Remove the parts in the order listed. Stand the motorcycle on a level surface.
Page 314 CHAS REAR WHEEL AND BRAKE DISC EAS00560 REAR WHEEL AND BRAKE DISC 40 Nm (4.0 mSkg) 150 Nm (1.5 mSkg) 40 Nm (4.0 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed. disc Muffler (right) Saddlebag guide bar (left and right)
Page 315: Rear Wheel And Brake Disc
CHAS REAR WHEEL AND BRAKE DISC 40Nm (4.0mSkg) 150 Nm (1.5 mSkg) 40Nm (4.0mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Rear wheel axle NOTE: S Elevate the rear wheel. Place a suitable stand under the engine. S Move the wheel to the right to separate it from the final gear case.
Page 316 CHAS REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Oil seal Bearing Collar Oil seal Bearing Circlip Clutch hub Hub dust seal Damper O-ring For assembly, reverse the disassembly procedure.
Page 317: Removing The Rear Wheel
CHAS REAR WHEEL AND BRAKE DISC EAS00562 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 318: Checking The Rear Wheel Drive Hub
CHAS REAR WHEEL AND BRAKE DISC EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: S rear wheel drive hub Cracks/damage ! Replace. S rear wheel drive hub dampers Damage/wear ! Replace. EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant...
Page 319: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 25 Nm (2.5 mSkg) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed Brake caliper retaining bolts Refer to “REPLACING THE FRONT Brake caliper BRAKE PADS”.
Page 320: Rear Brake Pads
CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake pad Remove the parts in the order listed. Brake pad cover Retaining clips Refer to “REPLACING THE REAR Retaining pins BRAKE PADS”.
Page 321: Replacing The Front Brake Pads
CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
Page 322 CHAS FRONT AND REAR BRAKES 2. Remove: S brake pads 1 (along with the brake pad shims) 3. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.6 mm 4.
Page 323: Replacing The Rear Brake Pads
CHAS FRONT AND REAR BRAKES 5. Install: S brake caliper retaining bolt 25 Nm (2.5 mSkg) 6. Check: S 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 324 CHAS FRONT AND REAR BRAKES 3. Remove: S brake pads 1 4. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install: S brake pad shims (onto the brake pads) S brake pads S brake pad spring...
Page 325 CHAS FRONT AND REAR BRAKES 6. Install: S brake pad pins S brake pad clips S brake pad cover S brake caliper Brake caliper bolt 40 Nm (4.0 mSkg) 7. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
Page 326: Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order below. cylinder NOTE: Before removing the master cylinder, drain the brake fluid from the entire brake system.
Page 327 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Master cylinder cap Holder (diaphragm) Master cylinder diaphragm Dust boot Circlip Master cylinder kit For assembly, reverse the disassembly procedure.
Page 328: Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg) 52 Nm (5.2 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder NOTE: Before removing the master cylinder, drain the brake fluid from the entire brake system.
Page 329 CHAS FRONT AND REAR BRAKES 30 Nm (3.0 mSkg) 52 Nm (5.2 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Clevis pin Reservoir hose Unhook from the clamps. Reservoir tank cover Reservoir tank For installation, reverse the removal procedure. 7-26...
Page 330 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake master Disassemble the parts in the order listed. cylinder Dust boot Circlip Brake pedal push rod Master cylinder kit Cap (reservoir tank) Diaphragm Reservoir tank For assembly, reverse the disassembly procedure.
Page 331: Removing The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00588 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: S brake switch 1 2. Remove: S union bolt 1 S copper washers 2 S brake hoses 3 NOTE:...
Page 332: Checking The Front And Rear Brake Master Cylinders
CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder 1 Damage/scratches/wear ! Replace. S brake fluid delivery passages 2 (brake master cylinder body) Obstruction ! Blow out with compressed air.
Page 333: Installing The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES 5. Check: S brake reservoir hose 1 Cracks/damage/wear ! Replace. EAS00598 INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
Page 334 CHAS FRONT AND REAR BRAKES 3. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 335: Installing The Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00610 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: S copper washers 1 (New) S brake hose 2 30 Nm (3.0 mSkg) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation. Refer to “CABLE ROUTING”.
Page 336 CHAS FRONT AND REAR BRAKES 5. Adjust: S brake pedal position a Refer to “ADJUSTING THE REAR BRAKE” in CHAPTER 3. Brake pedal position (below the top of the rider footrest) 100 mm 6. Adjust: S rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”...
Page 337: Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) 25 Nm (2.5 mSkg) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system.
Page 338 CHAS FRONT AND REAR BRAKES 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. caliper Air bleed screw Caliper pistons Refer to “DISASSEMBLING THE FRONT Caliper piston seals BRAKE CALIPERS For assembly, reverse the disassembly procedure.
Page 339: Rear Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. NOTE: Before removing the master cylinder, drain the brake fluid from the entire brake system.
Page 340 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Brake pads cover Refer to “REAR BRAKE PADS”. Brake pads Air bleed screw Caliper pistons Refer to “DISASSEMBLING THE REAR Caliper piston seals BRAKE CALIPER”.
Page 341: Disassembling The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CAL- IPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE:...
Page 342 CHAS FRONT AND REAR BRAKES 1. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: S brake caliper pistons 1 S brake caliper piston seals 2 a.
Page 343: Checking The Front And Rear Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00632 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Every two years and Brake fluid whenever the brake is disassembled 1.
Page 344: Installing The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00638 INSTALLING THE FRONT BRAKE CAL- IPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
Page 345 CHAS FRONT AND REAR BRAKES 3. Install: S brake pads S brake pad shim S brake caliper 25 Nm (2.5 mSkg) Refer to “REPLACING THE BRAKE PADS”. 4. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4...
Page 346: Installing The Rear Brake Caliper
CHAS FRONT AND REAR BRAKES 7. Check: S brake lever operation Soft or spongy feeling ! Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake-com- ponents should be cleaned and lubricated with clean or new brake fluid.
Page 347 CHAS FRONT AND REAR BRAKES 3. Install: S brake pads S brake pad springs S brake pins S retaining clips S brake caliper 40 Nm (4.0 mSkg) Refer to “REPLACING THE BRAKE PADS”. 4. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4...
Page 348 CHAS FRONT AND REAR BRAKES 7. Check: S brake pedal operation Soft or spongy feeling ! Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in CHAPTER 3. 7-45...
Page 349: Front Fork
CHAS FRONT FORK EAS00647 FRONT FORK 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.
Page 350 CHAS FRONT FORK 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Upper bracket Refer to “CHECKING THE STEERING HEAD” in CHAPTER 3. Upper fork covers Upper fork cover spacers Refer to “REMOVING/INSTALLING THE Upper fork cover washers FRONT FORK LEGS”.
Page 351 CHAS FRONT FORK EAS00648 23 Nm (2.3 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the front fork Disassemble the parts in the order listed. Cap bolt O-ring Fork spring Drain the fork oil. Pump the fork tube several times to remove the fork oil.
Page 352 CHAS FRONT FORK 23 Nm (2.3 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Outer tube bushing Refer to “DISASSEMBLING/ Inner tube bushing ASSEMBLING THE FRONT FORK Oil flow stopper LEGS”. Outer tube For assembly, reverse the disassembly procedure. 7-49...
Page 353: Removing The Front Fork Legs
CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motocycle on a suitable stand so that the front wheel is elevated.
Page 354: Checking The Front Fork Legs
CHAS FRONT FORK 3. Remove: S inner tube a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but care- fully.
Page 355: Assembling The Front Fork Legs
CHAS FRONT FORK CAUTION: S The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. S When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
Page 356 CHAS FRONT FORK 2. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 5W or equivalent 3. Tighten: S damper rod bolt 20 Nm (2.0 mSkg) LOCTITE 204 NOTE: While holding the damper rod with the damper rod holder and T-handle, tighten the damper rod bolt.
Page 357 117 mm Recommended oil Yamaha fork and shock oil 5W or equivalent NOTE: S While filling the front fork leg, keep it upright. S After filling, slowly pump the front fork leg up and down to distribute the fork oil.
Page 358: Installing The Front Fork Legs
CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder.
Page 359: Handlebar
CHAS HANDLEBAR EAS00664 HANDLEBAR 28 Nm (2.8 mSkg) 25 (4) 10 Nm (1.0 mSkg) 32 Nm (3.2 mSkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed . Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
Page 360: Handlebar
CHAS HANDLEBAR 23 Nm (2.3 mSkg) 25 (4) 10 Nm (1.0 mSkg) 35 Nm (3.5 mSkg) Order Job/Part Q’ty Remarks Clutch master cylinder Refer to “CLUTCH” in CHAPTER 4. Clutch switch coupler Disconnect Handlebar switches (left) Grip (left) Refer to “INSTALLING THE HANDLEBAR”. Handlebar bracket (upper) Handlebar Handlebar bracket (lower)
Page 361: Removing The Handlebar
CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is not danger of it falling over. 2. Remove: S throttle cable housing 1 S throttle grip 2 3.
Page 362: Installing The Handlebar
CHAS HANDLEBAR c. Wipe off any excess rubber adhesive with a clean rag. WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried. EAS00672 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
Page 363 CHAS HANDLEBAR a. Installing the throttle cable 1 on cruise con- trol rotor No.4 b. Installing the throttle cable 2 on cruise con- trol rotor No.3 c. Installing the throttle 3 on cruise control ro- tor No.2 d. Installing the throttle cable 4 on cruise con- trol rotor No.1 WARNING Pay attention to the mark on throttle cable 1...
Page 364: Steering Head
CHAS STEERING HEAD EAS00676 STEERING HEAD 130 Nm (13.0 mSkg) 1st. 52 Nm (5.2 mSkg) 2nd. 3 Nm (0.3 mSkg) Order Job/Part Q’ty Remarks Removing the steering head Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over.
Page 365 CHAS STEERING HEAD 130 Nm (13.0 mSkg) 1st. 52 Nm (5.2 mSkg) 2nd. 3 Nm (0.3 mSkg) Order Job/Part Q’ty Remarks Flasher light bracket assembly Brake hose joint Brake hose guide Steering stem nut Upper bracket Lock washer Upper ring nut Refer to “REMOVING THE LOWER Rubber washer BRAKET/INSTALLING THE STEERING...
Page 366: Removing The Lower Bracket
CHAS STEERING HEAD EAS00679 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S upper ring nut 1 S lower ring nut 2 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench, then remove the upper ring...
Page 367: Installing The Steering Head
CHAS STEERING HEAD 3. Replace: S bearing balls S bearing races a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c.
Page 368 CHAS STEERING HEAD 3. Install: S upper bracket S steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: S front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the upper and lower bracket pinch bolts. 7-65...
Page 369: Rear Shock Absorber
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 59 Nm (5.9 mSkg) 48 Nm (4.8 mSkg) 50 Nm (5.0 mSkg) 50 Nm (5.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Stand the motorcycle on a level surface.
Page 370 CHAS REAR SHOCK ABSORBER ASSEMBLY 59 Nm (5.9 mSkg) 48 Nm (4.8 mSkg) 50 Nm (5.0 mSkg) 50 Nm (5.0 mSkg) Order Job/Part Q’ty Remarks Connecting arms Bolt (relay arm -frame) Relay arm For installation, reverse the removal procedure. 7-67...
Page 371: Removing The Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00690 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
Page 372: Installing The Rear Shock Absorber Assembly
CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00698 INSTALLING THE REAR SHOCK ABSORB- ER ASSEMBLY 1. Lubricate: S spacers S bearings Recommended lubricant Molybdenum disulfide grease 2. Install: S rear shock absorber assembly Rear shock absorber assembly upper nut 1 59 Nm (5.9 mSkg) Rear shock absorber assembly lower nut 2 50 Nm (5.0 mSkg)
Page 373: Swingarm
CHAS SWINGARM EAS00701 SWINGARM SWINGARM 100 Nm (10.0 mSkg) 42 Nm (4.2 mSkg) 16 Nm (1.6 mSkg) Order Job/Part Q’ty Remarks Removing the swingarm Remove the parts in the order listed. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.
Page 374 CHAS SWINGARM 100 Nm (10.0 mSkg) 42 Nm (4.2 mSkg) 16 Nm (1.6 mSkg) Order Job/Part Q’ty Remarks Pivot shafts (right and left) Swingarm Refer to “REMOVING THE SWINGARM”. For installation, reverse the removal procedure. 7-71...
Page 375: Removing The Swingarm
CHAS SWINGARM EAS00702 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2.
Page 376: Installing The Swingarm
CHAS SWINGARM 2. Check: S left pivot bolt S right pivot bolt Damage/wear ! Replace. 3. Check: S spacers 1 S oil seals 2 S bearings 3 S universal joint boot 4 Damage/wear ! Replace. EAS00712 INSTALLING THE SWINGARM 1. Lubricate: S drive shaft splines Recommended lubricant Lithium soap base grease...
Page 377: Shaft Drive
CHAS SHAFT DRIVE SHAFT DRIVE TROUBLESHOOTING The following conditions may indicate damaged shaft drive components: Symptoms Possible Causes 1.A Pronounced hesitation of jerky movement A. Bearing damage during acceleration, deceleration, or sustained B. Improper gear lash speeds (This must not be confused with C.Damaged gear teeth engine surging or transmission-related D.Broken drive shaft...
Page 378 CHAS SHAFT DRIVE Inspection notes 1. Investigate any unusual noises. The following noises may indicate a me- chanical defect: a. A rolling “rumble” during coasting, accelera- tion, or deceleration. The noise increases with rear wheel speed, but does not increase with higher engine or transmission speeds.
Page 379 CHAS SHAFT DRIVE EAS00716 Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section exist, check following points. Place the motorcycle on a suitable stand so that the front wheel is elevated and then spin the front wheel.
Page 380: Checking The Final Drive Oil For Contamination And Inspecting The Shaft Drive For Leaks
CHAS SHAFT DRIVE EAS00717 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND INSPECTING THE SHAFT DRIVE FOR LEAKS 1. Drain: S final drive oil (from the final drive housing) Refer to “CHANGING THE FINAL DRIVE OIL” in CHAPTER 3. 2. Check: S final drive oil Large amount of metal particles ! Check for bearing seizure.
Page 381: Final Drive Assembly And Drive Shaft
CHAS FINAL DRIVE ASSEMBLY AND DRIVE SHAFT EAS00718 FINAL DRIVE ASSEMBLY AND DRIVE SHAFT 42 Nm (4.2 mSkg) Order Job/Part Q’ty Remarks Removing the final drive assembly Remove the parts in the order listed. and drive shaft Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so there is no danger of it falling over.
Page 382: Measuring The Ring Gear Backlash
CHAS FINAL DRIVE ASSEMBLY AND DRIVE SHAFT EAS00719 MEASURING THE RING GEAR BACKLASH 1. Secure the final drive assembly in a vise. 2. Remove: S final drive oil drain bolt 3. Drain: S final drive oil (from the final drive assembly) 4.
Page 383: Adjusting The Ring Gear Backlash
CHAS FINAL DRIVE ASSEMBLY AND DRIVE SHAFT g. Rotate the final drive pinion gear 90_. h. Reinstall the bolt, special tool, and dial gauge. i. Repeat steps (d) to (h) three more times (for a total of four measurements). j. If any of the readings are over specification, adjust the ring gear backlash.
Page 384: Measuring The Ring-Gear-To-Stopper-Bolt Clearance
CHAS FINAL DRIVE ASSEMBLY AND DRIVE SHAFT b. If it is necessary to increase the ring gear backlash by more than 0.2 mm, reduce the thrust washer thickness by 0.2 mm for every 0.2 mm increase of ring gear shim thickness. c.
Page 385: Final Drive
CHAS FINAL DRIVE ASSEMBLY AND DRIVE SHAFT Select: stopper bolt shim(-s) Stopper bolt shims thickness (mm) 0.10, 0.15, 0.20, 0.30, 0.40, 0.50 2. Install: S stopper bolt shim(-s) 1 S stopper bolt 2 9 Nm ( 0.9 mSkg) S ring gear 3 4 Ring gear bearing housing CAUTION: Apply LOCTITE onto the stopper bolt.
Page 386: Final Drive Assembly
CHAS FINAL DRIVE EAS00723 FINAL DRIVE ASSEMBLY 23 Nm (2.3 mSkg) 9 Nm (0.9 mSkg) 40 Nm (4.0 mSkg) 23 Nm (2.3 mSkg) 110 Nm (11.0 mSkg) 110 Nm (11.0 mSkg) 42 Nm (4.2 mSkg) Order Job/Part Q’ty Remarks Disassembling the final drive Disassemble the parts in the order listed assembly Nuts (bearing housing)
Page 387 CHAS FINAL DRIVE 23 Nm (2.3 mSkg) 9 Nm (0.9 mSkg) 40 Nm (4.0 mSkg) 23 Nm (2.3 mSkg) 110 Nm (11.0 mSkg) 110 Nm (11.0 mSkg) 42 Nm (4.2 mSkg) Order Job/Part Q’ty Remarks Shim(s) Final drive shaft assembly Final drive shaft roller bearing Refer to “REMOVING AND INSTALLING THE RING GEAR BEARINGS”.
Page 388: Disassembling The Final Drive Assembly
CHAS FINAL DRIVE EAS00724 DISASSEMBLING THE FINAL DRIVE AS- SEMBLY 1. Remove: S ring gear bearing housing nuts S ring gear bearing housing bolts NOTE: Working in a crisscross pattern, loosen each nut 1/4 of a turn. After all of the nuts are fully loos- ened, remove them and the bolts.
Page 389: Removing And Installing The Ring Gear Bearings
CHAS FINAL DRIVE EAS00725 REMOVING AND INSTALLING THE RING GEAR BEARINGS 1. Remove: S collar 1 S oil seal 2 S bearing 3 (With an appropriate press tool 4 and an ap- propriate support for the final drive housing) 2. Check: S bearing Damage ! Replace.
Page 390: Aligning The Final Drive Pinion Gear And Ring Gear
S oil seal 2 (New) S bearing 3 (with an appropriate press tool 4 and press) NOTE: The bearing can be reused, but Yamaha recom- mends installing a new one. EAS00726 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR...
Page 391 CHAS FINAL DRIVE Where: a = a numeral (positive or negative) on the ring gear, to be divided by 100 and added to “87” b = a numeral on the final drive housing, to be divided by 100 and added to “86” Example: If the final drive pinion gear is marked “+01”...
Page 392 CHAS FINAL DRIVE Ring gear bearing thickness “f” 13 mm Example: If the final drive housing is marked “51” the ring gear bearing housing is marked “35”, the ring gear is marked “-05”, and “f” is 13.00: B = (45 + 51/100) + (3 + 35/100) - [35.40 - 5/ 100) + 13] = (45 + 0.51) + (3 + 0.35) - [(35.40 - 0.05) + 13] = 45.51 + 3.35 -[(35.40 - 0.05) + 13]...
Page 393 CHAS FINAL DRIVE 3. Install: S gear coupling S self-locking nut 110 Nm (11.0 mSkg) (with the special tool 1 ) Coupling gear/middle shaft tool YM-01229, 90890-01229 CAUTION: Apply LOCTITE to the self-locking nut. 4. Install: S ring gear bearing housing (along with the ring gear, but without the thrust washer) 5.
Page 394 1. Lubricate: S drive shaft splines Recommended lubricant Molybdenum disulfide grease 2. Apply: S sealant (onto both final drive housing mating sur- faces) Quickgasket ACC-11001-15-01 Yamaha bond No.1215 90890-85505 3. Install: S drive shaft (to the final drive pinion gear) 7-91...
Page 395 CHAS FINAL DRIVE 4. Install: S drive shaft NOTE: Align the drive shaft splines with the driven yoke to the universal joint. 5. Tighten: S final bearing housing nuts 42 Nm (4.2 mSkg) 6. Install: S rear wheel Refer to “REAR WHEEL AND BRAKE DISC”.
Page 396 – ELEC...
Page 397 ELEC CONTENTS ELECTRICAL ELECTRICAL COMPONENTS ........SWITCHES .
Page 398 ELEC CARBURETOR HEATING SYSTEM ......8-48 CIRCUIT DIAGRAM ......... 8-48 TROUBLESHOOTING .
Page 399: Electrical Components
ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Front brake switch Battery Rear brake switch Clutch switch Fuse (main) Flasher relay Thermo unit Starter relay Starting circuit cut-off relay Fuel sender Speed sensor Rectifier/ regulator TPS (throttle position sensor) Neutral switch Horn Ignition coil Oil level switch...
Page 400: Switches
ELEC SWITCHES EAS00730 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1 .
Page 401: Switch Continuity Inspection
ELEC SWITCH INSPECTION EAS00731 SWITCH CONTINUITY INSPECTION Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
Page 402 ELEC SWITCH INSPECTION for OCE Dimmer switch Front brake switch Side stand switch Horn switch Gruise control switch Neutral switch Turn signal switch “CANCEL” switch Rear brake switch Pass switch Engine stop switch Oil level switch Clutch switch Start switch Main switch Emargency stop switch...
Page 403: Checking The Bulbs And Bulb Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING BULBS BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect.
Page 404 ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: S Be sure to hold the socket firmly when re- moving the bulb.
Page 405: Checking The Condition Of The Bulb Sockets
ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...
Page 406: Ignition System
ELEC IGNITION SYSTEM DAS00734 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Ignitor Ignition coil Spark plug Engine stop switch Fuse (ignition) Pick up coil Neutral switch...
Page 407: Troubleshooting
ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING THE BATTERY” in spark or intermittent spark). CHAPTER 3. Check: Open-circuit voltage 1. Main and ignition fuses 12.8 V or more at 20_C 2.
Page 408 ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 kΩ at 20_C S The following procedure applies to all of the S Is the spark plug cap OK? spark plugs. S Disconnect the spark plug cap from the spark plug.
Page 409 ELEC IGNITION SYSTEM EAS00750 Secondary coil resistance 9. Engine stop switch 10.71 X 14.49 kΩ at 20_C S Check the engine stop switch for continuity. S Is the ignition coil OK? Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? Replace the ignition coil.
Page 410 ELEC IGNITION SYSTEM EAS00754 13. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly con- nected and without defects? Properly connect or Replace the ignitor repair the ignition unit. system’s wiring. 8-12...
Page 411: Electric Starting System Circuit Diagram
ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starter relay Starter motor Starting circuit cutoff relay Diode Engine stop switch Start switch Fuse (ignition) Side stand switch Clutch switch Neutral switch 8-13...
Page 412: Starting Circuit Cutoff System Operation
ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUTOFF SYSTEM OP- ERATION 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: S The transmission is in neutral (the neutral switch is closed).
Page 413: Troubleshooting
ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING THE BATTERY” in Check: CHAPTER 3. 1. Main and ignition fuses Open-circuit voltage 2. Battery 12.8 V or more at 20_C 3.
Page 414 ELEC ELECTRIC STARTING SYSTEM EAS00759 S Does the starter relay have continuity be- 4. Starting circuit cut-off relay tween red and black? S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay Replace the starter...
Page 415 ELEC ELECTRIC STARTING SYSTEM EAS00752 9. Sidestand switch S Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK? Replace the side- stand switch. EAS00763 10. Clutch switch S Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”.
Page 416: Starter Motor
ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 7 Nm (0.7 mSkg) 110 (2) 10 Nm (1.0 mSkg) 25 (1) 55 (1) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Exhaust pipe assembly Refer to “REMOVING THE ENGINE” in CHAPTER 4.
Page 417 ELEC ELECTRIC STARTING SYSTEM 7 Nm (0.7 mSkg) 110 (2) 10 Nm (1.0 mSkg) 25 (1) 55 (1) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassemble the parts in the order listed. Front bracket Washer kit Refer to “ASSEMBLING THE STARTER Rear bracket MOTOR”.
Page 418: Checking The Starter Motor
ELEC ELECTRIC STARTING SYSTEM EAS00770 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm 3. Measure: S mica (insulation) undercut a Out of specification ! Scrape the mica (in- sulation) to the proper measurement with a...
Page 419: Assembling The Starter Motor
ELEC ELECTRIC STARTING SYSTEM 5. Measure: S brush length a Out of specification ! Replace the brushes as a set. Brush length wear limit 5 mm 6. Measure: S brush spring force Fatigue/out of specification ! Replace the brush springs as a set. Brush spring force 570 X 920 N 7.
Page 420: Installation
ELEC ELECTRIC STARTING SYSTEM 3. Install: S o-ring 1 S washers 2 S front bracket 3 S o-ring 4 NOTE: Align the match marks a on the yoke with the match marks b on the brackets. 4. Install: S bolts 1 7 Nm (0.7 mSkg) INSTALLATION 1.
Page 421: Charging System
ELEC CHARGING SYSTEM YP804000 CHARGING SYSTEM CIRCUIT DIAGRAM AC magneto Rectifire/ reguretor Battery Fuse (main) 8-23...
Page 422: Troubleshooting
ELEC CHARGING SYSTEM EAS00774 EAS00775 TROUBLESHOOTING 3. Charging voltage S Connect the engine tachometer to the spark The battery is not being charged. plug lead of cylinder #1. Check: S Connect the pocket tester (20 V DC) to the 1. Main fuse battery as shown.
Page 423 ELEC CHARGING SYSTEM S Measure the stator coil resistances. Stator coil resistance 0.279 X 0.341 Ω at 20_C S Is the stator coil OK? Replace the stator coil assembly. EAS00779 5. Wiring S Check the wiring connections of the entire charging system.
Page 424: Lighting System
ELEC LIGHTING SYSTEM EB804000 LIGHTING SYSTEM CIRCUIT DIAGRAM Main switch High beam indicator light Ilumination light Battery Tail / brake light Fuse (main) Light switch Headlight Fuse (headlight) Front turn signallight (left) Front turn signallight (right) Dimmer switch 8-26...
Page 425: Troubleshooting
ELEC LIGHTING SYSTEM EAS00782 EAS00739 TROUBLESHOOTING 3. Main switch Any of the following fail to come on: head- S Check the main switch for continuity. light, high beam indicator light, taillight, Refer to “CHECKING THE SWITCHES”. and meter light. S Is the main switch OK? Check: 1.
Page 426: Checking The Lighting System
ELEC LIGHTING SYSTEM EAS00788 S Set the main switch to “ON”. CHECKING THE LIGHTING SYSTEM S Set the dimmer switch to “ ” or “ ”. 1. The headlight and the high beam indicator S Measure the voltage (12 V) of green (yel- light fail to come on.
Page 427 ELEC LIGHTING SYSTEM S Set the main switch to “ON”. S Set the main switch to “ON”. S Measure the voltage (12 V) of blue S Measure the voltage (12 V) of blue/red on the meter light coupler (wire harness side). yellow on the tail/brake light coupler S Is the voltage within specification?
Page 428: Signal System
ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 8-30...
Page 429 ELEC SIGNAL SYSTEM 4 Main switch 5 Battery 6 Fuse (main) 9 Oil level switch Starting circuit cutoff relay Front brake switch Engine stop switch Fuse (ignition) Fuse (signal) Brake light relay Rear brake switch Horn 2 Horn 1 Flasher relay Horn switch Turn signal switch Oil level indicator light...
Page 430: Troubleshooting
ELEC SIGNAL SYSTEM EAS00794 EAS00749 TROUBLESHOOTING 3. Main switch S Any of the following fail to come on: turn S Check the main switch for continuity. signal light, brake light or indicator light. Refer to “CHECKING THE SWITCHES”. S The horn fails to sound. S Is the main switch OK? Check: 1.
Page 431 ELEC SIGNAL SYSTEM Tester positive probe ! black/white Tester positive probe ! pink Tester negative probe ! ground Tester negative probe ! ground S Set the main switch to “ON”. S Set the main switch to “ON”. S Measure the voltage (12 V) of the black/ S Measure the voltage (12 V) of pink at the white connector at the horn terminal.
Page 432 ELEC SIGNAL SYSTEM Tester positive probe ! yellow 3. Voltage Tester negative probe ! black S Connect the pocket tester (20 V DC) to the flasher relay coupler (flasher relay side) as shown. Tester positive probe ! brown Tester negative probe ! ground S Set the main switch to “ON”.
Page 433 ELEC SIGNAL SYSTEM EAS00800 S Set the main switch to “ON”. 4. The neutral indicator light fails to come on. S Measure the voltage (12 V) on brown/white at the flasher relay coupler (wire harness 1. Neutral indicator light bulb and socket side).
Page 434 ELEC SIGNAL SYSTEM 4. Voltage 2. Starting circuit cut-off relay S Connect the pocket tester (20 V DC) to the S Disconnect the starting circuit cut-off relay coupler from the wire harness. neutral switch coupler (wire harness side) as S Connect the pocket tester (Ω 1) to the shown.
Page 435 ELEC SIGNAL SYSTEM Tester positive probe ! green/red 5. Voltage Tester negative probe ! black S Connect the pocket tester (20 V DC) to the meter light coupler (wire harness side) as shown. Tester positive probe ! red/brack Tester negative probe ! ground S Check: Does the fuel sender have continu- ity? S Set the main switch to “ON”.
Page 436 ELEC SIGNAL SYSTEM 7. The over drive indicator light fails to come on. S Set the main switch to “ON”. S Set the transmission 5th gear. 1. Over drive indicator light bulb and socket S Measure the voltage (12 V). S Check the over drive indicator light bulb and socket for continuity.
Page 437: Cooling System
ELEC COOLING SYSTEM COOLING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Thermo switch Noise filter Fan motor Fues (fan motor) Fuse (signal) Engine overheat indica tor light Thermo unit 8-39...
Page 438: Troubleshooting
ELEC COOLING SYSTEM EAS00808 S Is the battery OK? TROUBLESHOOTING S The radiator fan motor fails to turn. S The engine overheat indicator light fails to come on when the engine is hot. S Clean the battery terminals. Check: S Recharge 1.
Page 439 ELEC COOLING SYSTEM EAS00811 WARNING 5. Thermo switch S Handle the thermo switch with special care. S Remove the thermo switch from the thermo- S Never subject the thermo switch to strong stat housing. S Connect the pocket tester (Ω shocks.
Page 440 ELEC COOLING SYSTEM EAS00812 EAS00813 7. Thermo unit 8. Wiring S Remove the thermo unit sender from the ra- S Check the entire cooling system’s wiring. diator. Refer to “CIRCUIT DIAGRAM”. S Connect the pocket tester (Ω S Is the cooling system’s wiring properly con- 10) to the thermo unit as shown.
Page 441: Fuel Pump System
ELEC FUEL PUMP SYSTEM FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starting circuit cutoff relay Fuel pump Ignitor Engine stop switch Fuse (ignition) 8-43...
Page 442: Fuel Pump Circuit Operation
ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION Battery The fuel pump circuit consists of the fuel pump Main fuse relay, fuel pump, engine stop switch and ignitor Main switch unit. Ignition fuse The ignitor unit includes the control unit for the Engine stop switch fuel pump.
Page 443: Troubleshooting
ELEC FUEL PUMP SYSTEM EAS00816 EAS00749 TROUBLESHOOTING 3. Main switch If the fuel pump fails to operate: S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Check: S Is the main switch OK? 1. Main and ignition fuses 2.
Page 444 ELEC FUEL PUMP SYSTEM EAS00817 6. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel pump coupler as shown. Tester positive probe ! blue/black Tester negative probe ! black S Measure the fuel pump resistance.
Page 445: Checking The Fuel Pump
ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refuelling. S Do not smoke, and keep away from open flames, sparks, or any other source of fire.
Page 446 ELEC CARBURETOR HEATING SYSTEM CABURETOR HEATING SYSTEM Main switch Thermo switch Battery Neutral switch Fuse (main) Carburetor heater #1 Carburetor heater #2 Fuse (carburetor heater) Carburetor heater relay Carburetor heater #3 Carburetor heater #4 8-48...
Page 447: Carburetor Heating System
ELEC CARBURETOR HEATING SYSTEM EAS00821 EAS00749 TROUBLESHOOTING 3. Main switch The carburetor heating system fails to S Check the main switch for continuity. operate. Refer to “CHECKING THE SWITCHES”. Check: S Is the main switch OK? 1. Main and carburetor heater fuses 2.
Page 448: Circuit Diagram
ELEC CARBURETOR HEATING SYSTEM EAS00825 6. Thermo switch The following procedure applies to all of the carburetor heating elements. S Remove the thermo switch from the thermo 7. Carburetor heater switch plate. S Connect the pocket tester to the (Ω 1) to S Remove the carburetor heating element the thermo switch as shown.
Page 449 ELEC AUDIO SYSTEM AUDIO SYSTEM Main switch Battery Fuse (main) Fuse (back up) 8-51...
Page 450 ELEC AUDIO SYSTEM Fuse (audio) Speaker (front) Speaker (front) Speaker (rear) Rear remoto controller Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) 8-52...
Page 451 ELEC AUDIO SYSTEM AUDIO SYSTEM CIRCUIT OPERATION The audio system circuit con- Battery FM / AM antenna Fuse (main) Tape deck sists of the front/rear remote Main switch Fuse (front DC outlet) controllers, front/rear speakers, Fuse (back up) Fuse (rear DC outlet) tape deck, and main control unit Fuse (audio) DC outlet (front)
Page 452 ELEC AUDIO SYSTEM REMOVAL 1. Disconnect: S Front remote control coupler (from the main control unit) S Tape deck coupler (from the main control unit) CAUTION: When disconnect a coupler, be sure to push on the coupler as shown, and pull it out straight.
Page 453 ELEC AUDIO SYSTEM 3. MCU coupler AUDIO SYSTEM does not operation S Check the connection of MCU 18P connec- Check: tor. 1. Fuses Refer to “checking the connection”. 2. Ground 3. MCU S Is the MCU connector OK? 4. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting, remove the following...
Page 454 ELEC AUDIO SYSTEM S Is the MCU X front remote controller wiring S Is the MCU X cassette deck 13P wiring properly connected and without defects? properly connected and without defected? Correct the MCU X Correct the MCU X Replace the MCU. Replace the MCU.
Page 455 ELEC AUDIO SYSTEM 3. Does not sound of the speaker. Speaker does not sound 1. Speaker Check: S Remove the speaker. 1. Out put mode S Connect the pocket tester (Ω 1) to the 2. Speaker speaker as shown. 3. Wiring connections (of the entire audio system) Front left Tester positive prove ! red/white...
Page 456 ELEC AUDIO SYSTEM Headset does not sound 2. Wiring connections S Check the wiring of MCU X wire harness X Check: speaker wiring. 1. Out put mode 2. Front head set 3. Rear head set 4. Wiring connections (of the entire audio system) NOTE: S Before troubleshooting, remove the following part(-s).
Page 457 ELEC AUDIO SYSTEM S Check the head set wiring for continuity. S Is the rear remote controller volume out put S Is the head set wiring OK? level OK? Correct the head set Adjust the rear re- wiring. mote controller vol- ume out put level.
Page 458 ELEC AUDIO SYSTEM 2. Wiring connections Mike Tester positive prove ! 1 S Check the wiring of MCU X 5P DIN cable X Tester negative prove ! 4 head set (white). S Check the head set wiring for continuity. S Is the MCU X 5P DIN cable X head set wir- S Is the head set wiring OK? ing properly connected and without de- fected?
Page 459 ELEC AUDIO SYSTEM Front remote controller does not opera- Rear remote controller does not operation tion Check: Check: 1. Wiring connections 1. Wiring connections (of the entire audio system) (of the entire audio system) NOTE: NOTE: S Before troubleshooting, remove the follow- S Before troubleshooting, remove the following ing part(-s): part(-s):...
Page 460: Cruise Control System
ELEC CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM CIRCUIT DIAGRAM 8-62...
Page 461 ELEC CRUISE CONTROL SYSTEM 4 Main switch 5 Battery 6 Fuse (main) Ignition coil Front brake switch Cruise control switch “CANCEL” switch Fuse (signal) Brake light relay Rear brake switch Clutch switch Speedometer/ Fuel meter Cruise control light (MAIN) Cruise control light (SET) Cruise control light (RES) Speed sensor Tail/ brake light...
Page 462: Cruise Control Circuit Operation
ELEC CRUISE CONTROL SYSTEM CRUISE CONTROL CIRCUIT OPERATION Battery Cruise contrl unit Brake light Main fuse Vacuum pump To ignition coil Main switch Cruise contrl switch Speed sensor Signal fuse Rear brake switch Speedometer Cruise control fuse Cancel switch “CRUISE” switch Clutch switch Cruise contrl relay Front brake switch...
Page 463: Cruise Control System Components
ELEC CRUISE CONTROL SYSTEM CRUISE CONTROL SYSTEM COMPONENTS Speed sensor Front brake switch Battery Cruise control switch /cancel Carburetor (s) Fuse switch Throttle valve Main switch Clutch switch Air/ Fuel mixture Fuse Cruise control unit “CRUISE” switch Indicators Rear brake switch Ignition coil Vacuum pump Vacuum autuator...
Page 464: Troubleshooting
ELEC CRUISE CONTROL SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery Check: S Check the condition of the battery. 1. main, signal and cruise control 2. battery Refer to “CHECKING AND CHARGING 3. main switch THE BATTERY” in CHAPTER 3. 4. “CRUISE” switch Open-circuit voltage 5.
Page 465 ELEC CRUISE CONTROL SYSTEM CHECKING THE CRUISE CONTROL SYSTEM 5. Cruise control relay. Detecting an abnormality with the motor- S Disconnect the relay from the coupler. cycle stopped S Connect the pocket tester (Ω 1) and bat- 1. The cruise control indicator light fail to come tery (12 V) to the relay unit terminal as shown.
Page 466 ELEC CRUISE CONTROL SYSTEM 2. The “SET”/“RES” indicator light will show any 3. Check an abnormality of the cruise control system. S Set the main switch to “ON” and the 1. “SET”/“RES” indicator light bulb and socket “CRUISE” switch to “ON”. S The cruise control, “SET”...
Page 467 ELEC CRUISE CONTROL SYSTEM 2. Speed sensor 3. Cruise control unit S Check the following items. S Disconnect the coupler from the cruise 1) Speedometer is faulty operation control unit. S Connect the pocket tester (DC20V) to the a. Engine warning light is flashing (Fault code 4) Refer to “SELF-DIAGNOSIS”.
Page 468 ELEC CRUISE CONTROL SYSTEM 5. Throttle cables 2. Throttle cable joint S Checke the throttle cables and throttle S Check the throttle cable joint operation by housing condition. operating the actuator manualy, and check if the throttle valve opens. S Is the throttle cables OK? S Is the throttle cable joint OK? Replace the cruise Repair or replace the...
Page 469 ELEC CRUISE CONTROL SYSTEM 4. Vehicle speed fluctuate during the cruising 4. Vacuum pump 1 1. Speed sensor S Reconnect the vacuum hose and discon- S Check the following items. nect the vacuum pump connector. S Connect the battery (12 V) as shown. 1) Speedometer is faulty operation.
Page 470: Self Diagnosis Function Of The Cruise Control System
ELEC CRUISE CONTROL SYSTEM SELF DIAGNOSIS FUNCTION OF THE CRUISE CONTROL SYSTEM The cruise control system has a self diagno- sis function. Use of the function allows the self diagnosis about the following: 1. Trouble diagnosis of the cancel switch sig- nal.
Page 471 ELEC CRUISE CONTROL SYSTEM Rear brake switch 1. Trouble diagnosis of the cancel switch Concel switch signal Clutch switch 1) The “SET” indicator light is lit. Front brake light switch 2) Operate the cancel, front brake, rear brake, Rear brake light switch and clutch switches.
Page 472 ELEC CRUISE CONTROL SYSTEM 2. Trouble diagnosis of the brake light sig- 1) The “RES” indicator light is lit. 2) Operate the following front brake and rear switches. If the RES indicator light is not extinguished after either of these switches is operated, it means that the relevant switch is in failure.
Page 473: Self-Diagnosis
ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The XVZ13TF features a self-diagnosing system for following displays. 1. Engine warning light 2. Fuel meter 3. “SET”/“RES” indicator light 1. ENGINE TROUBLE INDICATOR LIGHT When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the engine trouble indicator light (irrespective of whether the engine is running or not).
Page 474 ELEC SELF-DIAGNOSIS Display order on the engine warning light When one item being monitored Light on (seconds) ..0.5 seconds Light off (seconds) ..0.5 seconds Number of blinks .
Page 475: Troubleshooting
ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING S Check the wire harness for continuity. The tachometer starts to display the self- Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? diagnosis sequence. Check: 1. throttle position sensor 2. speed sensor Repair or replace the 3.
Page 476 ELEC SELF-DIAGNOSIS EB812401 2. Speed sensor 2. Speedometer CIRCUIT DIAGRAM S Check the speedometer operation. S Is the speedometer OK? Replace the ignitor Replace the speed unit. sensor. 3. Emergency stop switch CIRCUIT DIAGRAM Ignitor unit Emergency stop switch 1. Wire harness S Check the wire harness for continuity.
Page 477 ELEC SELF-DIAGNOSIS EB812401 2. Emergency stop switch S Remove the emergency stop switch. S Connect the pocket tester (Ω 1) to the emergency stop switch coupler as shown. Tester positive prove ! black/white Tester negative prove ! black S When turn the emergency stop switch approx. 50_, the resistance reading is 0 Ω...
Page 478: Fuel Meter
ELEC SELF-DIAGNOSIS 2. FUEL METER The fuel meter is indicated the fault displays as follows S Fuel sender S Fuel thermistor Fuel meter display sequence Fuel sender Light on ... 0.5 seconds Light off .
Page 479 ELEC SELF-DIAGNOSIS Fuel thermistor Light on ... 0.5 seconds Light off ... 0.5 seconds Number of blinks . . . 8 times Light off .
Page 480: Troubleshooting
ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING S Check the wire harness for continuity. The tuel meter starts to display the self- Refer to “CIRCUIT DIAGRAM”. diagnosis sequence. S Is the wire harness OK? Check: 1. fuel sender 2. fuel thermistor Repair or replace the NOTE: wire harness.
Page 481 ELEC SELF-DIAGNOSIS 1. Wire harness S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Repair or replace the wire harness. EB812401 2. Fuel thermistor S Check the fuel thermistor operation. S When set the main switch to on, the fuel level indicator light comes on.
Page 482: Set"/"Res" Indicator Light
ELEC SELF-DIAGNOSIS 3. “SET”/“RES” INDICATOR LIGHT When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the “SET”/“RES” indicator light at same time (irrespective of whether the engine is run- ning or not).
Page 483 ELEC Fault code 1 0.5 seconds Light on 2 0.5 seconds Light off 3 Number of blinks ..Fault code 4 3 seconds 8-85...
Page 484: Troubleshooting
ELEC SELF-DIAGNOSIS EAS00835 1. Wire harness TROUBLESHOOTING S Check the wire harness for continuity. The “SET”/“RES” indicator light starts to Refer to “CIRCUIT DIAGRAM”. display the self-diagnosis sequence. S Is the wire harness OK? Check: 1. cruise control unit 2. vacuum pump 3.
Page 485 ELEC SELF-DIAGNOSIS CIRCUIT DIAGRAM Front brake switch “CANCEL” switch Rear brake switch Clutch switch Cruise control unit 8-87...
Page 486 ELEC SELF-DIAGNOSIS 4. Speed sensor 5. Ignition coil CIRCUIT DIAGRAM CIRCUIT DIAGRAM Speed sensor Cruise control unit 1. Wire harness S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Repair or replace the wire harness.
Page 487 ELEC SELF-DIAGNOSIS 6. Cruise control switch 1. Wire harness 1. Wire harness S Check the wire harness for continuity. S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Repair or replace the wire harness.
Page 488 ELEC SELF-DIAGNOSIS CIRCUIT DIAGRAM 8-90...
Page 489 TRBL SHTG...
Page 490 TRBL SHTG CONTENTS TROUBLESHOOTING STARTING PROBLEMS ........ENGINE .
Page 491 TRBL SHTG FAULTY SIGNALING SYSTEM ........HEADLIGHT DOES NOT LIGHT .
Page 492: Troubleshooting
TRBL TROUBLESHOOTING SHTG EAS00844 TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however,as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts. STARTING PROBLEMS ENGINE Cylinder(-s) and cylinder head (-s)
Page 493: Electrical Systems
TRBL TROUBLESHOOTING SHTG ELECTRICAL SYSTEMS Battery Ignition system S Improperly charged battery S Faulty ignitor unit S Faulty battery S Faulty pickup coil S Broken generator rotor woodruff key Fuse(-s) S Blown, damaged or incorrect fuse S Switches and wiring S Improperly installed fuse S Faulty main switch S Faulty engine stop switch...
Page 494: Poor Medium-And-High-Speed Performance
TRBL TROUBLESHOOTING SHTG EAS00849 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE Air filter FUEL SYSTEM S Clogged air filter element Carburetor(-s) S Air intake system S Faulty diaphragm S Bent, clogged or disconnected carburetor air S Incorrect fuel level S Loose or clogged main jet vent hose S Clogged or leaking air duct...
Page 495: Overheating
TRBL TROUBLESHOOTING SHTG EAS00855 OVERHEATING ENGINE COOLING SYSTEM S Clogged coolant passages Cylinder head(-s) Coolant S Low coolant level and piston(-s) S Heavy carbon buildup Radiator S Damaged or leaking radiator Engine oil S Incorrect oil level S Faulty radiator cap S Incorrect oil viscosity S Bent or damaged radiator fins S Inferior oil quality...
Page 496: Faulty Front Fork Legs
TRBL TROUBLESHOOTING SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL MALFUNCTION S Bent, damaged or rusty inner tube S Bent, deformed or damaged inner tube S Cracked or damaged outer tube S Bent, deformed or damaged outer tube S Improperly installed oil seal S Damaged fork spring S Damaged oil seal lip S Worn or damaged outer tube bushing...
Page 497 TRBL TROUBLESHOOTING SHTG EAS00866 FAULTY SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT HEADLIGHT BULB BURNT OUT S Wrong headlight bulb S Wrong headlight bulb S Too many electrical accessories S Faulty battery S Hard charging S Faulty rectifier/regulator S Incorrect connection S Incorrect ground S Incorrect ground S Faulty main switch...
Page 498 XVZ13TF (for EUR) WIRING DIAGRAM AC magneto Horn 2 Condenser Horn 1 Rectifire/ regurator Flasher relay Main switch Handlebar switch (left) Battery Dimmer switch Fuse (main) Horn switch Starter relay Turn signal switch Starter motor “PASS” switch Oil level switch Clutch switch Starting circuit cutoff relay Meter assembly...
Page 499 CUISE CONTROL UNIT “CRUISE” SWITCH Fuse (audio) Speaker (front) Speaker (front) Speaker (rear) Rear remote controller Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) Cruise control unit Vacuum pump Fuse (cruise control) “CRUISE” switch Cruise control relay D.C OUTLET COLOR CODE...
Page 500 XVZ13TFL (for OCE) WIRING DIAGRAM AC magneto Horn 2 Condenser Horn 1 Rectifire/ regurator Flasher relay Fuse (back up) Handlebar switch (left) Main switch Dimmer switch Fuse (main) Horn switch Battery Turn signal switch Starter relay “PASS” switch Starter motor Clutch switch Oil level switch Meter assembly...
Page 501 CUISE CONTROL UNIT “CRUISE” SWITCH Fuse (audio) Speaker (front) Speaker (front) Speaker (rear) Rear remote controller Fuse (front DC outlet) Fuse (rear DC outlet) DC outlet (front) DC outlet (rear) Cruise control unit Vacuum pump Fuse (cruise control) “CRUISE” switch Cruise control relay D.C OUTLET COLOR CODE...

This manual is also suitable for:

Xvz13tfl 1999

Yamaha XVZ13TF 1999 Service Manual

Gen Info

General Information

Motorcycle Identification

Features

Important Information

Checking the Connections

Special Tools

2 Spec

General Specifications

Specifications

Maintenance Specifications

General Tightening Torque Specifications

Lubrication Points and Lubricant Types

Cooling System Diagrams

Lubrication Diagrams

Cable Routing

Table of Contents

Periodic Checks and Adjustments

Front Cowling

Rider and Passenger Seats

Fuel Tank

Engine

Chassis

Table of Contents

Engine Removal

Camshafts

Cylinder Heads

Valves and Valve Springs

Clutch

Shift Shaft

Starter Clutch and Generator

Oil Pan and Oil Pump

Crankcase

Crankshaft

Connecting Rods and Pistons

Transmission

Middle Geae

5 Cool

Radiator

Cooling System

Thermostat

Water Pump

6 Carb

Carburetors

Air Induction System

7 Chas

Front Wheel and Brake Discs

Rear Wheel and Brake Disc

Front and Rear Brakes

Front Fork

Handlebar

Steering Head

Rear Shock Absorber

Swingarm

Shaft Drive

Final Drive Assembly and Drive Shaft

Final Drive

8 Elec

Electrical Components

Switches

Switch Continuity Inspection

Checking the Bulbs and Bulb Sockets

Ignition System

Electric Starting System Circuit Diagram

Charging System

Lighting System

Signal System

Cooling System

Fuel Pump System

Carburetor Heating System

Cruise Control System

Self-Diagnosis

Quick Links

Chapters

Troubleshooting

Related Manuals for Yamaha XVZ13TF 1999

Summary of Contents for Yamaha XVZ13TF 1999