Page 1 2014 SERVICE MANUAL XVS95CE(C) LIT-11616-27-30 1TP-28197-11...
Page 2 EAS20050 XVS95CE(C) SERVICE MANUAL ©2013 by Yamaha Motor Corporation, U.S.A. First edition, June 2013 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-27-30...
Page 3 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
Page 4: How To Use This Manual
EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 5: Symbols
EAS20101 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES...................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ................. 1-6 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-6 REPLACEMENT PARTS................1-6 GASKETS, OIL SEALS AND O-RINGS ............ 1-6 LOCK WASHERS/PLATES AND COTTER PINS ........
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame under the rider seat. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES EAS5S71022 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.
Page 12: Fi System
FEATURES EAS5S71020 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 220–300 kPa (2.20–3.00 kg/cm², 31.3–42.7 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 13: Instrument Functions
FEATURES EAS5S71021 2. “RESET” switch INSTRUMENT FUNCTIONS Odometer, tripmeters, fuel reserve tripmeter Multi-function meter unit and clock 1. Speedometer 1. Odometer/tripmeter/fuel reserve tripmeter 2. Odometer/tripmeter/fuel reserve tripmeter/clock Push the “SELECT” switch to switch the display between the odometer mode “ODO”, the tripme- EWA12422 WARNING ter modes “TRIP 1”...
Page 14 FEATURES To set the clock 1. Clock 1. Push the “SELECT” and “RESET” switches together for at least three seconds. 2. When the hour digits start flashing, push the “SELECT” switch to set the hours. 3. Push the “RESET” switch, and the minute digits will start flashing.
Page 15: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
Page 16: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 EAS1TP1072 BEARINGS AND OIL SEALS RUBBER PARTS Install bearings and oil seals so that the manu- Check rubber parts for deterioration during in- facturer’s marks or numbers are visible. When spection. Some of the rubber parts are sensitive installing oil seals “1”, lubricate the oil seal lips to gasoline, flammable oil, grease, etc.
Page 17: Basic Service Information
BASIC SERVICE INFORMATION EAS30380 BASIC SERVICE INFORMATION EAS30390 QUICK FASTENERS Rivet type 1. Remove: • Quick fastener To remove the quick fastener, push its pin with a screwdriver, then pull the fastener out. Screw type 1. Remove: • Quick fastener To remove the quick fastener, loosen the screw with a screwdriver, then pull the fastener out.
Page 18: Electrical System
BASIC SERVICE INFORMATION ECA16760 EAS30402 NOTICE ELECTRICAL SYSTEM Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- Electrical parts handling tery lead connections could damage the ECA16600 NOTICE electrical components. Never disconnect a battery lead while the en- gine is running;...
Page 19 BASIC SERVICE INFORMATION ECA16620 Checking the electrical system NOTICE Handle electrical components with special Before checking the electrical system, make care, and do not subject them to strong sure that the battery voltage is at least 12 V. shocks. ECA14371 ECA16630 NOTICE NOTICE...
Page 20 BASIC SERVICE INFORMATION 2. Check: Checking the connections • Lead Check the leads, couplers, and connectors for • Coupler stains, rust, moisture, etc. • Connector 1. Disconnect: Moisture → Dry with an air blower. • Lead Rust/stains → Connect and disconnect sev- •...
Page 21 BASIC SERVICE INFORMATION The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). If the measuring temperature is not 20 °C (68 °F), the specified measuring conditions will be shown. Intake air temperature sensor re- sistance 5.40–6.60 kΩ...
Page 22: Special Tools
SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil filter wrench 3-22 90890-01426 YU-38411 Damper rod holder (22 mm) 4-56, 4-58 90890-01365 T-handle 4-56, 4-58 90890-01326 T-handle 3/8" drive 60 cm long YM-01326 Fork seal driver weight 4-58, 4-59 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø41)
Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor holding tool 5-19, 5-23, 90890-01235 5-24 Universal magneto & rotor holder YU-01235 Slide hammer bolt 5-20 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-20 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-30, 5-35 90890-04019 YM-04019...
Page 25 5-45, 5-46, 90890-01701 5-53, 5-58 Primary clutch holder YS-01880-A Flywheel puller 5-45 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-46, 5-70 90890-85505 (Three Bond No.1215®) Universal clutch holder 5-53, 5-56 90890-04086 YM-91042 Digital circuit tester 5-63, 6-11, 90890-03174...
Page 26 6-11 90890-03153 YU-03153 Fuel pressure adapter 6-11 90890-03176 YM-03176 Test harness- TPS (3P) 6-11 90890-03204 YU-03204 Yamaha diagnostic tool (US) 7-31 90890-03216 Ignition checker 7-85 90890-06754 Oppama pet-4000 spark checker YM-34487 Test harness- lean angle sensor (6P) 7-87 90890-03209 YU-03209...
Page 27: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ................2-9 ELECTRICAL SPECIFICATIONS ..............2-12 TIGHTENING TORQUES ................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-15 CHASSIS TIGHTENING TORQUES............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-25 ENGINE....................2-25 CHASSIS....................2-27 LUBRICATION SYSTEM CHART AND DIAGRAMS........
Page 28: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XVS95CE 1TP1 (USA) (for models with rear suspensions not equipped with gas cylinders) XVS95CE 2DX1 (USA) (for models with rear suspensions equipped with gas cylinders) XVS95CEC 1TP2 (California) (for models with rear suspensions not equipped with gas cylinders) XVS95CEC 2DX2 (California) (for models with rear suspensions equipped with gas cylinders)
Page 29: Engine Specifications
ENGINE SPECIFICATIONS EAS20291 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, SOHC Displacement 942 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 85.0 × 83.0 mm (3.35 × 3.27 in) Compression ratio 9.00 : 1 Standard compression pressure (at sea level) 1400 kPa/400 r/min (14.0 kgf/cm²/400 r/min, 199.1 psi/400 r/min) Minimum-maximum...
Page 30 ENGINE SPECIFICATIONS Warpage limit 0.03 mm (0.0012 in) Camshaft Drive system Chain drive (left and right) Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720–1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583–1.4622 in) Limit 36.941 mm (1.4544 in) Exhaust A 42.138–42.238 mm (1.6590–1.6629 in) Limit...
Page 31 ENGINE SPECIFICATIONS Valve face width B (exhaust) 2.300 mm (0.0906 in) Valve seat width C (intake) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in) Valve seat width C (exhaust) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in) Valve margin thickness D (intake) 1.00 mm (0.0394 in) Valve margin thickness D (exhaust) 1.00 mm (0.0394 in)
Page 32 ENGINE SPECIFICATIONS Installed compression spring force (exhaust) 171.00–197.00 N (17.44–20.09 kgf, 38.44– 44.29 lbf) Spring tilt (intake) 2.5 °/1.9 mm (0.07 in) Spring tilt (exhaust) 2.5 °/1.9 mm (0.07 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 85.000–85.010 mm (3.3465–3.3468 in) Wear limit 85.100 mm (3.3504 in)
Page 33 ENGINE SPECIFICATIONS Dimensions (B × T) 1.20 × 3.30 mm (0.05 × 0.13 in) End gap (installed) 0.30–0.45 mm (0.0118–0.0177 in) Limit 0.80 mm (0.0315 in) Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.100 mm (0.0039 in) Oil ring Dimensions (B ×...
Page 34 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 5-speed Primary reduction ratio 1.674 (72/43) Final drive Belt Secondary reduction ratio 2.333 (70/30) Operation Left foot operation Gear ratio 3.067 (46/15) 2.063 (33/16) 1.579 (30/19) 1.259 (34/27) 1.042 (25/24) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in)
Page 35 ENGINE SPECIFICATIONS Intake vacuum 34.7–40.0 kPa (260–300 mmHg,10.2–11.8 inHg) Oil temperature 60.0–70.0 °C (140.00–158.00 °F) Throttle grip free play 4.0–6.0 mm (0.16–0.24 in)
Page 36: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 29.00 ° Trail 130 mm (5.1 in) Front wheel Wheel type Cast wheel 19M/C × MT2.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 37 Spring stroke K1 0.0–120.0 mm (0.00–4.72 in) Inner tube outer diameter 41.0 mm (1.61 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 547.0 cm³ (18.49 US oz, 19.29 Imp.oz) Level 116.0 mm (4.57 in) Rear suspension Type...
Page 38 CHASSIS SPECIFICATIONS Spring free length 167.7 mm (6.60 in) (for models not equipped with gas cylinders) 128.5 mm (5.06 in) (for models equipped with gas cylinders) Spring installed length 159.7 mm (6.29 in) (for models not equipped with gas cylinders) 120.5 mm (4.74 in) (for models equipped with gas cylinders) Spring rate K1...
Page 39: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Advancer type Throttle position sensor and electrical Ignition timing (B.T.D.C.) 5.0 °/1000 r/min Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω Primary coil resistance Secondary coil resistance 8.64–12.96 kΩ...
Page 40 ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Power output 0.80 kW 0.0050–0.0150 Ω Armature coil resistance Brush overall length 12.0 mm (0.47 in) Limit 6.50 mm (0.26 in) Brush spring force 6.025–6.515 N (614–664 gf, 21.69–23.45 oz) Mica undercut (depth) 0.70 mm (0.03 in) Starter relay...
Page 41: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
Page 42: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kgf, 11 ft·lbf) pipe) Oil check bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) Cylinder head nut 65 Nm (6.5 m·kgf, 47 ft·lbf) See TIP Cylinder head bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Page 43 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil pump housing screw 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Oil filter cartridge 17 Nm (1.7 m·kgf, 12 ft·lbf) Oil filter cartridge union bolt 70 Nm (7.0 m·kgf, 51 ft·lbf) Oil level switch bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Engine oil drain bolt 43 Nm (4.3 m·kgf, 31 ft·lbf)
Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size l = 40 mm (1.57 in) Clutch cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) See TIP l = 40 m (1.57 in) Clutch cover bolt (with washer) 10 Nm (1.0 m·kgf, 7.2 ft·lbf) See TIP l = 65 mm (2.56 in)
Page 45 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Throttle position sensor screw 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Inlet pipe assembly bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Pressure regulator 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) Cylinder head nut 1.
Page 46 TIGHTENING TORQUES Generator cover bolt Temporally tighten “a” and “b” and then tighten the generator cover bolts in the order shown in the illus- tration. Clutch cover bolt Temporally tighten the bolts “a” and “b”, and then tighten the clutch cover bolts in the order shown in the illustration.
Page 47: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (front upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (front lower 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear lower...
Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front wheel axle 59 Nm (5.9 m·kgf, 43 ft·lbf) Front wheel axle pinch bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) See TIP Front brake caliper bracket bolt 40 Nm (4.0 m·kgf, 29 ft·lbf) Front brake caliper retaining bolt 27 Nm (2.7 m·kgf, 20 ft·lbf) Front brake disc bolt...
Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake hose holder and low- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) er bracket bolt Front brake hose holder and re- 10 Nm (1.0 m·kgf, 7.2 ft·lbf) flector bracket bolt Front reflector nut 1.5 Nm (0.15 m·kgf, 1.1 ft·lbf) Front fender bolt 23 Nm (2.3 m·kgf, 17 ft·lbf)
Page 50 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Battery box bracket bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Owner’s tool kit guide bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Lean angle sensor screw 2 Nm (0.20 m·kgf, 1.4 ft·lbf) Fuel pump bolt 4 Nm (0.40 m·kgf, 2.9 ft·lbf) See TIP...
Page 51 TIGHTENING TORQUES Fuel pump bolt Tighten the fuel pump bolts in the proper tightening sequence as shown in the illustration. Front wheel axle pinch bolt 1. Insert the front wheel axle from the right side and tighten it to 59 Nm (5.9 m·kgf, 43 ft·lbf). 2.
Page 52: Lubrication Points And Lubricant Types
Oil pump drive sprocket (inner surface) Clutch thrust washers Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift Yamaha bond No.1215 Crankcase (mating surface) (Three Bond No.1215®) 2-25...
Page 53 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Yamaha bond No.1215 Crankshaft position sensor lead grommet (Three Bond No.1215®) Yamaha bond No.1215 Crankcase breather pipe (Three Bond No.1215®) 2-26...
Page 54: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing race cover (lip) Lower bearing steering seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub (mating surface) Brake pedal shaft (pivoting point) Shift pedal (pivoting point) Sidestand (pivoting point) and metal-to-metal moving parts Footrest assembly (pivoting point)
Page 55 LUBRICATION POINTS AND LUBRICANT TYPES 2-28...
Page 56: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-29...
Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Oil delivery pipe 2 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7. Main axle 8. Main gallery 9. Crankshaft 10. Clutch cover 11. Valve stem end (intake side) 12.
Page 58: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-31...
Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil delivery pipe 2 3. Relief valve assembly 2-32...
Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 2-34...
Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil drain bolt 2. Crankshaft 2-36...
Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Oil delivery pipe 1 3. Main axle 4. Oil delivery pipe 2 5. Oil pump assembly 6. Oil strainer 2-38...
Page 66: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING Handlebar (top and front view) 2-39...
Page 67 CABLE ROUTING 1. Clutch cable 2. Throttle cable (accelerator cable) 3. Throttle cable (decelerator cable) 4. Front brake hose 5. Right handlebar switch lead 6. Left handlebar switch lead 7. Intake air temperature sensor 8. Intake air temperature sensor sub-wire harness 9.
Page 68 CABLE ROUTING Headlight 2-41...
Page 69 CABLE ROUTING 1. Intake air temperature sensor sub-wire harness 2. Headlight lead 3. Headlight coupler 4. Accessory light lead (OPTION) 5. Accessory light coupler (OPTION) 6. Intake air temperature sensor coupler 7. Front brake hose 8. Throttle cables 9. Clutch cable 10.
Page 70 CABLE ROUTING Steering head cable (right side view) 2-43...
Page 71 CABLE ROUTING 1. Clutch cable V. Route the front left turn signal light lead over the guide on the meter bracket. 2. Joint coupler W. Route the right handlebar switch lead through the 3. Throttle cable (accelerator cable) guide on the meter bracket. Make sure that there is 4.
Page 72 CABLE ROUTING Clutch cable (right side view) 2-45...
Page 73 CABLE ROUTING 1. Lean angle sensor 2. Tail sub-wire harness 3. Wire harness 4. Clutch cable 5. Starter motor lead 6. Rear brake light switch 7. O sensor 8. Brake fluid reservoir hose 9. Positive battery lead 10. Frame 11. Rear brake light switch lead A.
Page 74 CABLE ROUTING Frame (inner side view) 2-47...
Page 75 CABLE ROUTING 1. Clutch cable 2. Wire harness 3. Crankshaft position sensor lead 4. Oil level switch lead 5. Neutral switch lead 6. Starter motor lead 7. Rear brake hose 8. O sensor 9. Rear brake light switch lead 10. O sensor lead 11.
Page 76 CABLE ROUTING Rear brake hose (right side view) 2-49...
Page 77 CABLE ROUTING 1. Brake fluid reservoir hose 2. Rear brake light switch 3. Rear brake hose A. Install the brake fluid reservoir hose with its white paint mark facing inward. B. Do not install the hose clamp on the flange at the end of the hose fitting.
Page 78 CABLE ROUTING Front brake hose (front and left side view) 2-51...
Page 79 CABLE ROUTING 1. Front brake hose 2. Cable guide 3. Brake hose holder A. Route the front brake hose through the cable guide. – ° B. 20 C. Fasten the front brake hose with the holder, making sure that the paint mark on the hose is visible through the hole in the holder.
Page 80 CABLE ROUTING Steering head (left side view) 2-53...
Page 81 CABLE ROUTING 1. Right handlebar switch lead 2. Left handlebar switch lead 3. Main switch lead 4. Fuel pump lead 5. Main switch coupler (white) 6. Main switch coupler (red) 7. Rear cylinder injector lead 8. Front cylinder injector coupler 9.
Page 82 CABLE ROUTING Spark plug lead 2-55...
Page 83 CABLE ROUTING 1. Front cylinder spark plug lead 2. Fuel hose (hose joint to pressure regulator) 3. Fuel tank breather hose 4. Fuel tank bracket 5. Frame 6. Clutch cable 7. Rear right cylinder head cover 8. Wire harness 9. Canister purge hose (for California) 10.
Page 84 CABLE ROUTING Electrical components tray (left side view) 2-57...
Page 85 14. Relay unit 15. Lean angle sensor lead 16. Starter motor lead 17. Main fuse 18. Yamaha diagnostic tool coupler 19. Speed sensor lead 20. Ground lead A. After connecting the couplers, cover the couplers with the coupler cover, and then place the couplers in the air duct.
Page 86 CABLE ROUTING Rectifier/regulator (rear view) 2-59...
Page 87 CABLE ROUTING 1. Starter motor lead 2. Clutch cable 3. Brake fluid reservoir hose 4. O sensor lead 5. Rear brake hose 6. Rear brake light switch lead 7. Lean angle sensor 8. Rear turn signal light and license plate light sub- wire harness coupler 9.
Page 88 CABLE ROUTING Rear fender (top and left view) 2-61...
Page 89 CABLE ROUTING 1. Tail sub-wire harness 2. Tail/brake light 3. License plate light 4. Rear left turn signal light lead 5. Rear left turn signal light 6. Tail/brake light lead 7. Rear left turn signal light coupler 8. Tail/brake light coupler 9.
Page 90 CABLE ROUTING Fuel tank 2-63...
Page 91 CABLE ROUTING 1. Fuel tank breather/overflow hose (fuel tank to hose joint) 2. Fuel tank breather/overflow hose (hose joint to rollover valve) 3. Hose joint 4. Fuel filter 5. Fuel hose (fuel pump to fuel filter) 6. Fuel pump 7. Fuel hose (hose joint to pressure regulator) 8.
Page 92 CABLE ROUTING Fuel tank breather hose (except for California) (left and rear view) 2-65...
Page 93 CABLE ROUTING 1. Fuel tank breather/overflow hose (hose joint to rollover valve) 2. Rollover valve 3. Fuel tank breather/overflow hose (from rollover valve) A. Route the fuel tank breather hose (hose joint to rollover valve) to the left of the battery box. –...
Page 94 CABLE ROUTING Canister (for California) (left and rear view) 2-67...
Page 95 CABLE ROUTING 1. Fuel tank breather hose (hose joint to rollover valve) 2. Canister purge hose 3. Rollover valve 4. Fuel tank breather hose (rollover valve to canister) 5. Canister A. Route the fuel tank breather hose (hose joint to rollover valve) and canister purge hose between the engine mudguard and the battery box.
Page 96 CABLE ROUTING Fuel tank breather hose (top and right view) 2-69...
Page 97 CABLE ROUTING 1. Canister purge hose (for California) 2. Intake air pressure hose 3. Intake air pressure sensor 4. Fuel tank breather hose (hose joint to rollover valve) 5. Canister (for California) A. Route the canister purge hose along the fuel tank breather hose (hose joint to rollover valve).
Page 98 CABLE ROUTING Canister (top and right view) 2-71...
Page 99 CABLE ROUTING 1. Intake air pressure sensor hose 2. Hose fitting 3. Canister purge hose (for California) A. Point the ends of the hose clamp to the right. B. Install the intake air pressure sensor hose completely onto the hose fitting, making sure that the yellow paint mark on the hose is facing upward.
Page 100 CABLE ROUTING Crankcase breather hose (left side view) 2-73...
Page 101 CABLE ROUTING 1. Crankcase breather hose 2. Crankcase 3. Air filter case A. Install the crankcase breather hose with its white paint mark facing upward. B. Point the ends of the hose clamp rearward, angled upward. C. Route the crankcase breather hose over the timing chain tensioner.
Page 102 CABLE ROUTING 2-75...
Page 103: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE ................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .......3-1 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS ............. 3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 CHECKING THE CRANKCASE BREATHER HOSE ........3-7 SYNCHRONIZING THE THROTTLE BODIES..........
Page 104 LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE ...3-25 CHECKING THE SWITCHES, LIGHTS AND SIGNALS ......3-26 ADJUSTING THE HEADLIGHT BEAM ...........3-26 REPLACING THE HEADLIGHT BULB............3-26...
Page 106: Periodic Maintenance
• From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months. • Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 107 PERIODIC MAINTENANCE INITIAL ODOMETER READINGS 8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi ITEM ROUTINE (13000 (19000 (25000 (31000 (1000 km) (7000 km) 1 month 6 months 12 months 18 months 24 months 30 months Air filter element •...
Page 108 Front and rear √ √ √ √ √ √ 24 * • Check operation. brake switches • Apply Yamaha chain and ca- √ √ √ √ √ √ 25 * Control cables ble lube or engine oil thor- oughly. • Check operation.
Page 109: Checking The Fuel Line
PERIODIC MAINTENANCE 5. Check: EAS21030 CHECKING THE FUEL LINE • Electrode The following procedure applies to all of the fuel Damage/wear → Replace the spark plug. and breather hoses. • Insulator 1. Remove: Abnormal color → Replace the spark plug. •...
Page 110 PERIODIC MAINTENANCE 1. Remove: • Fuel tank Refer to “FUEL TANK” on page 6-1. • Front cylinder left cover • Front cylinder right cover • Rear cylinder left cover • Rear cylinder right cover Refer to “ENGINE REMOVAL” on page 5-3. 2.
Page 111 PERIODIC MAINTENANCE 12.Adjust: • Valve clearance ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Loosen the locknuts “1”. c. Measure the valve clearance with a thickness gauge. Thickness gauge 90890-03180 b.
Page 112: Checking The Crankcase Breather Hose
PERIODIC MAINTENANCE 13.Install: • Rear cylinder tappet covers • Fuel filter bracket • Front cylinder tappet covers Rear cylinder tappet cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Front cylinder tappet cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 14.Install: 3.
Page 113 PERIODIC MAINTENANCE 5. Install: • Hose “1” (Parts No.: 5JW-24311-00) • 3-way joint “2” (Parts No.: 90413-05014) • Vacuum gauge hose #1 “3” • Vacuum gauge hose #2 “4” • Intake air pressure sensor hose “5” • Vacuum gauge “6” •...
Page 114: Checking The Exhaust System
PERIODIC MAINTENANCE Exhaust pipe joint nut The difference in vacuum pressure between two 15 Nm (1.5 m·kgf, 11 ft·lbf) throttle bodies should not exceed 1.33 kPa (10 Exhaust pipe nut mmHg). 20 Nm (2.0 m·kgf, 14 ft·lbf) Exhaust pipe bolt ▲...
Page 115: Checking The Clutch Operation
PERIODIC MAINTENANCE EAS1TP1017 CHECKING THE CLUTCH OPERATION 1. Check: • Clutch operation Dysfunctional → Check the clutch system. Refer to “CLUTCH” on page 5-48. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 116: Checking The Brake Operation
PERIODIC MAINTENANCE Drive on the dry road, operate the front and rear brakes separately and check to see if the brakes are operating fully. EAS21240 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. • Place the vehicle on a suitable stand. c.
Page 117: Checking The Front Brake Pads
PERIODIC MAINTENANCE • When refilling, be careful that water does not enter the brake master cylinder reser- voir and brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.
Page 118: Checking The Front Brake Hose
PERIODIC MAINTENANCE 2. Bleed: k. Fill the brake master cylinder reservoir or • Hydraulic brake system brake fluid reservoir to the proper level with the specified brake fluid. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 119: Checking The Wheels
PERIODIC MAINTENANCE EWA13180 WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed.
Page 120: Checking The Wheel Bearings
No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. 1. Tire tread depth Front tire 2. Side wall Size 3.
Page 121: Checking The Swingarm Pivot Shaft Bearings
PERIODIC MAINTENANCE 1. Check: • Wheel bearings Refer to “CHECKING THE FRONT WHEEL” on page 4-12 and “CHECKING THE REAR WHEEL” on page 4-20. EAS1TP1021 CHECKING THE SWINGARM PIVOT SHAFT BEARINGS 1. Check: • Swingarm pivot shaft bearings Refer to “SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES”...
Page 122 PERIODIC MAINTENANCE 2. Rotate the rear wheel several times and check the drive belt to locate its tightest point. 3. Check: • Drive belt slack “a” Out of specification → Adjust. b. Loosen both drive belt adjusting bolt locknuts “2”. c.
Page 123: Checking And Adjusting The Steering Head
PERIODIC MAINTENANCE EAS21510 CHECKING AND ADJUSTING THE Lower ring nut (initial tightening STEERING HEAD torque) 1. Stand the vehicle on a level surface. 52 Nm (5.2 m·kgf, 38 ft·lbf) EWA13120 WARNING Securely support the vehicle so that there is Set the torque wrench at a right angle to the no danger of it falling over.
Page 124: Lubricating The Steering Bearings
PERIODIC MAINTENANCE Recommended lubricant Lithium-soap-based grease EAS1TP1027 CHECKING THE SIDESTAND 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 125: Checking The Sidestand Switch
PERIODIC MAINTENANCE Refer to “SWINGARM AND REAR SHOCK EAS1TP1028 CHECKING THE SIDESTAND SWITCH ABSORBER ASSEMBLIES” on page 4-65. Refer to “ELECTRICAL COMPONENTS” on page 7-71. EAS1TP1073 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLIES (for models not equipped with EAS21530 CHECKING THE FRONT FORK gas cylinders) 1.
Page 126: Adjusting The Rear Shock Absorber Assemblies (For Models Equipped With Gas Cylinders)
PERIODIC MAINTENANCE Adjusting positions Standard 1 notch out* Minimum (soft) 0 notches out* Maximum (hard) 4 notches out* * : from the fully turned-in position ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲...
Page 127: Changing The Engine Oil
PERIODIC MAINTENANCE EAS20780 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • Dipstick “1” (along with the O-ring) •...
Page 128 PERIODIC MAINTENANCE b. Lubricate the O-ring “3” of the new oil filter 10.Start the engine, warm it up for several min- cartridge with a thin coat of engine oil. utes, and then turn it off. 11.Check: ECA13390 NOTICE • Engine Make sure the O-ring “3”...
Page 129: Checking The Brake Light Switch
PERIODIC MAINTENANCE 15.Install: • Rear cylinder right cover bracket • Rear cylinder right cover Rear cylinder right cover bracket bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Rear cylinder right cover bolt 8 Nm (0.8 m·kgf, 5.8 ft·lbf) Refer to “ENGINE REMOVAL” on page 5-3. ▲...
Page 130 PERIODIC MAINTENANCE With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle grip turns smoothly and returns properly when released. Repeat this check with the handlebar turned all the way to the left and right. 3.
Page 131 PERIODIC MAINTENANCE EAS1TP1034 CHECKING THE SWITCHES, LIGHTS AND SIGNALS 1. Check that all switches operate and that all lights come on. Refer to “INSTRUMENT AND CONTROL FUNCTIONS” in Owner’s manual. Faulty → Refer to “CHECKING THE SWITCHES” on page 7-75 and “CHECKING THE BULBS AND BULB SOCKETS”...
Page 132 PERIODIC MAINTENANCE EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 6. Install: • Headlight bulb Secure the new headlight bulb with the head- light bulb holder. ECA13690 NOTICE Avoid touching the glass part of the head-...
Page 133: Chassis
CHASSIS GENERAL CHASSIS..................4-1 INSTALLING THE RIDER SEAT............... 4-2 INSTALLING THE TOOL BOX ..............4-5 FRONT WHEEL..................... 4-10 REMOVING THE FRONT WHEEL............4-12 DISASSEMBLING THE FRONT WHEEL..........4-12 CHECKING THE FRONT WHEEL ............4-12 ASSEMBLING THE FRONT WHEEL............4-13 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-13 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC)....
Page 134 REAR BRAKE ....................4-35 INTRODUCTION ..................4-41 CHECKING THE REAR BRAKE DISC............4-41 REPLACING THE REAR BRAKE PADS..........4-41 REMOVING THE REAR BRAKE CALIPER ..........4-42 DISASSEMBLING THE REAR BRAKE CALIPER ........4-42 CHECKING THE REAR BRAKE CALIPER..........4-43 ASSEMBLING THE REAR BRAKE CALIPER ........4-43 INSTALLING THE REAR BRAKE CALIPER...........4-43 REMOVING THE REAR BRAKE MASTER CYLINDER ......
Page 136: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and side cover 2.3 Nm (0.23 m kgf, 1.7 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) 16 Nm (1.6 m kgf, 12 ft Ibf) • • • • • •...
Page 137: Installing The Rider Seat
GENERAL CHASSIS EAS1TP1013 INSTALLING THE RIDER SEAT 1. Install: • Rider seat “1” Rider seat bolt 16 Nm (1.6 m·kgf, 12 ft·lbf) • Insert the projection “a” on the rear of the seat into the seat holder “b” as shown. •...
Page 138 GENERAL CHASSIS Removing the battery and relays 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Side cover 4-1.
Page 139 GENERAL CHASSIS Removing the battery and relays 3.6 Nm (0.36 m kgf, 2.6 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Starter relay cover Starter motor lead Disconnect. Positive battery lead (starter relay) Disconnect.
Page 140: Installing The Tool Box
GENERAL CHASSIS EAS1TP1065 INSTALLING THE TOOL BOX 1. Install: • Tool box “1” Install the tool box with the “INSIDE” mark “a” facing inward.
Page 141 GENERAL CHASSIS Removing the air filter case 4.2 Nm (0.42 m kgf, 3.0 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Air filter case cover...
Page 142 GENERAL CHASSIS Removing the rear fender 28 Nm (2.8 m kgf, 20 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
Page 143 GENERAL CHASSIS Removing the rear fender 28 Nm (2.8 m kgf, 20 ft Ibf) • • 65 Nm (6.5 m kgf, 47 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.0 Nm (0.20 m kgf, 1.4 ft Ibf) •...
Page 144 GENERAL CHASSIS Removing the headlight 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) •...
Page 145: Front Wheel
FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc 40 Nm (4.0 m kgf, 29 ft Ibf) • • 59 Nm (5.9 m kgf, 43 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 146 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-11...
Page 147: Removing The Front Wheel
FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake caliper Do not apply the brake lever when removing the ▲...
Page 148: Assembling The Front Wheel
FRONT WHEEL 4. Check: ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ • Wheel bearings EAS21970 Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings.
Page 149: Installing The Front Wheel (Front Brake Disc)
FRONT WHEEL ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
Page 150 FRONT WHEEL 4. Tighten: • Front wheel axle • Front wheel axle pinch bolt Front wheel axle 59 Nm (5.9 m·kgf, 43 ft·lbf) Front wheel axle pinch bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) ECA1TP1008 NOTICE Before tightening the wheel axle, push down hard on the handlebar several times and check if the front fork rebounds smoothly.
Page 151: Rear Wheel
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel 150 Nm (15 m kgf, 108 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 152 REAR WHEEL Removing the rear wheel 150 Nm (15 m kgf, 108 ft lbf) • • 16 Nm (1.6 m kgf, 12 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 153 REAR WHEEL Removing the rear brake disc and rear wheel drive hub 95 Nm (9.5 m kgf, 69 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel pulley Oil seal Circlip...
Page 154 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Bearing Oil seal Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-19...
Page 155: Removing The Rear Wheel (Disc)
REAR WHEEL • Oil seals EAS28760 REMOVING THE REAR WHEEL (DISC) Refer to “CHECKING THE FRONT WHEEL” 1. Stand the vehicle on a level surface. on page 4-12. EWA13120 2. Check: WARNING • Tire Securely support the vehicle so that there is •...
Page 156: Assembling The Rear Wheel
REAR WHEEL Rear wheel pulley self-locking Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) 95 Nm (9.5 m·kgf, 69 ft·lbf) LOCTITE® Tighten the self-locking nuts in stages and in a • Apply locking agent (LOCTITE®) to the crisscross pattern. threads of the brake disc bolts.
Page 157 REAR WHEEL 6. Tighten: • Rear wheel axle nut Rear wheel axle nut 150 Nm (15 m·kgf, 108 ft·lbf) 7. Install: • Rear brake caliper Rear brake caliper retaining bolt 27 Nm (2.7 m·kgf, 20 ft·lbf) EWA13500 WARNING Make sure the brake hose is routed properly. 4-22...
Page 158: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 159 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 1 Nm (0.1 m kgf, 0.7 ft Ibf) • • 1 Nm (0.1 m kgf, 0.7 ft Ibf) •...
Page 160 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-25...
Page 161 FRONT BRAKE Removing the front brake caliper 30 Nm (3.0 m kgf, 22 ft Ibf) • • 40 Nm (4.0 m kgf, 29 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 162 FRONT BRAKE Disassembling the front brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front brake caliper retaining bolt Brake pad Brake pad shim Brake pad spring Brake pad support...
Page 163: Introduction
FRONT BRAKE EAS22220 INTRODUCTION Brake disc runout limit (as mea- EWA1TP1022 sured on wheel) WARNING 0.15 mm (0.0059 in) Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 164: Replacing The Front Brake Pads
FRONT BRAKE 2. Install: • Brake pad supports • Brake pad spring • Brake pad shims (onto the brake pads) • Brake pads Always install new brake pads brake pad shims, brake pad supports and a brake pad spring as a set.
Page 165: Removing The Front Brake Caliper
FRONT BRAKE 5. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-11. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 166: Assembling The Front Brake Caliper
FRONT BRAKE • Brake caliper cylinders “2” Front brake hose union bolt Scratches/wear → Replace the brake caliper 30 Nm (3.0 m·kgf, 22 ft·lbf) assembly. • Brake caliper body “3” EWA13530 Cracks/damage → Replace the brake caliper WARNING assembly. Proper brake hose routing is essential to in- •...
Page 167: Removing The Front Brake Master Cylinder
FRONT BRAKE EWA1TP1005 EAS22490 REMOVING THE FRONT BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to Before removing the front brake master cylinder, deteriorate, causing leakage and poor drain the brake fluid from the entire brake sys- brake performance.
Page 168: Assembling The Front Brake Master Cylinder
FRONT BRAKE EAS22520 EWA13530 ASSEMBLING THE FRONT BRAKE MASTER WARNING CYLINDER Proper brake hose routing is essential to in- EWA13520 sure safe vehicle operation. Refer to “CABLE WARNING ROUTING” on page 2-39. • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
Page 169 FRONT BRAKE ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 5. Check: • Brake fluid level Below the minimum level mark “a”...
Page 170: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 27 Nm (2.7 m kgf, 20 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper Rear brake pad Rear brake pad shim...
Page 171 REAR BRAKE Removing the rear brake master cylinder 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
Page 172 REAR BRAKE Removing the rear brake master cylinder 2.8 Nm (0.28 m kgf, 2.0 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 23 Nm (2.3 m kgf, 17 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) •...
Page 173 REAR BRAKE Disassembling the rear brake master cylinder 18 Nm (1.8 m kgf, 13 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake master cylinder joint Brake master cylinder kit Brake hose joint Bush Brake master cylinder body For assembly, reverse the disassembly pro- cedure.
Page 174 REAR BRAKE Removing the rear brake caliper 27 Nm (2.7 m kgf, 20 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM”...
Page 175 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper bracket Brake pad Brake pad shim Brake pad spring...
Page 176: Introduction
REAR BRAKE Refer to “CHECKING THE FRONT BRAKE EAS22560 INTRODUCTION DISC” on page 4-28. EWA1TP1022 WARNING Brake disc thickness limit Disc brake components rarely require disas- 5.5 mm (0.22 in) sembly. Therefore, always follow these pre- ventive measures: 5. Adjust: •...
Page 177: Removing The Rear Brake Caliper
REAR BRAKE • Brake pad shims Refer to “CHECKING THE BRAKE FLUID (onto the brake pads) LEVEL” on page 3-11. • Brake pad springs Always install new brake pads, brake pad shims and brake pad springs as a set. ▼ ▼▼▼...
Page 178: Checking The Rear Brake Caliper
REAR BRAKE EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • Never try to pry out the brake caliper pis- ton. EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA1TP1007...
Page 179: Removing The Rear Brake Master Cylinder
REAR BRAKE 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-12. 6. Check: • Brake fluid level Below the minimum level mark “a” → Add the specified brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
Page 180: Checking The Rear Brake Master Cylinder
REAR BRAKE EAS22720 EAS22750 CHECKING THE REAR BRAKE MASTER INSTALLING THE REAR BRAKE MASTER CYLINDER CYLINDER 1. Check: 1. Install: • Brake master cylinder • Rear brake light switch “1” Damage/scratches/wear → Replace. • Brake fluid delivery passages • The rear brake light switch installation length (brake master cylinder body) “a”...
Page 181 REAR BRAKE Refer to “CHECKING THE BRAKE FLUID Rear brake hose holder bolt LEVEL” on page 3-11. 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Make sure that the projection “a” on the rear brake hose holder contacts the engine bracket (rear lower side) “2” as shown in the illustration. 7.
Page 182: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 183 HANDLEBAR Removing the handlebar 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 28 Nm (2.8 m kgf, 20 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 184: Removing The Handlebar
HANDLEBAR • Turn the handlebar all the way to the left EAS22860 REMOVING THE HANDLEBAR and right. If there is any contact with the 1. Stand the vehicle on a level surface. fuel tank, adjust the handlebar position. EWA13120 WARNING Securely support the vehicle so that there is Align the end of the upper handlebar holder with no danger of it falling over.
Page 185 HANDLEBAR b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. EWA13700 WARNING Do not touch the handlebar grip until the rub- ber adhesive has fully dried. There should be less than 3 mm (0.12 in) of 5.
Page 186 HANDLEBAR 10.Install: • Front brake master cylinder “1” • Front brake master cylinder holder “2” Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Install the front brake master cylinder holder with the “UP” mark facing up. •...
Page 187: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kgf, 17 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
Page 188 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kgf, 17 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) • • 3.8 Nm (0.38 m kgf, 2.8 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 189 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Protector Front fork cap bolt O-ring Spacer Spring seat Fork spring...
Page 190 FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Outer tube bushing Inner tube bushing Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure.
Page 191: Removing The Front Fork Legs
FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 3.
Page 192: Checking The Front Fork Legs
FRONT FORK ECA14200 NOTICE • 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. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
Page 193 2. Lubricate: Fork seal driver weight • Inner tube’s outer surface 90890-01367 Replacement hammer Recommended oil YM-A9409-7 Yamaha fork oil 10WT Fork seal driver attachment (ø41) 90890-01381 3. Install: Replacement 41 mm • Inner tube YM-A5142-2 (in the outer tube) 4.
Page 194 Quantity 547.0 cm³ (18.49 US oz, 19.29 Imp.oz) Recommended oil Yamaha fork oil 10WT 8. Install: 11.Measure: • Front fork leg oil level “a” • Oil seal clip “1” (from the top of the inner tube, with the outer...
Page 195: Installing The Front Fork Legs
FRONT FORK 2. Install: • Front fork leg “1” • Before installing the front fork cap bolt, lubri- Temporarily tighten the lower bracket pinch cate its O-ring with grease. bolts. • Temporarily tighten the front fork cap bolt. • Tighten the front fork cap bolt specified torque, when installing the front fork with upper brack- Make sure the inner tube end is flush with the top of the upper bracket.
Page 196: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the upper bracket and lower bracket 1st 52 Nm (5.2 m kgf, 38 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) •...
Page 197 STEERING HEAD Removing the upper bracket and lower bracket 1st 52 Nm (5.2 m kgf, 38 ft lbf) • • 2nd 18 Nm (1.8 m kgf, 13 ft lbf) • • 110 Nm (11 m kgf, 80 ft lbf) • •...
Page 198: Removing The Lower Bracket
STEERING HEAD b. Remove the bearing race from the lower EAS23110 REMOVING THE LOWER BRACKET bracket with a floor chisel “2” and hammer. 1. Stand the vehicle on a level surface. c. Install a new dust seal and new bearing rac- EWA13120 WARNING ECA14270...
Page 199 STEERING HEAD Face the hole “a” in the lower bracket cap rear- Align the projection “a” on the front brake hose ward. holder with the hole “b” in the lower bracket. 3. Install: • Lower ring nut “1” • Rubber washer “2” •...
Page 200: Swingarm And Rear Shock Absorber Assemblies
SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES EAS1TP1016 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES Removing the swingarm and rear shock absorber assemblies 23 Nm (2.3 m kgf, 17 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • •...
Page 201 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES Removing the swingarm and rear shock absorber assemblies 23 Nm (2.3 m kgf, 17 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • 85 Nm (8.5 m kgf, 61 ft Ibf) •...
Page 202: Removing The Swingarm And Rear Shock Absorber Assemblies
SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES EAS1TP1066 EAS23360 REMOVING THE SWINGARM AND REAR CHECKING THE SWINGARM SHOCK ABSORBER ASSEMBLIES 1. Check: 1. Stand the vehicle on a level surface. • Swingarm Bends/cracks/damage → Replace. EWA13120 WARNING 2. Check: Securely support the vehicle so that there is •...
Page 203: Disposing Of A Rear Shock Absorber (For Models Equipped With Gas Cylinders)
SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES property damage or personal injury that may • Spring Damage/wear → Replace the rear shock ab- result from improper handling of the rear shock absorber and gas cylinder. sorber assembly. • Do not tamper or attempt to open the rear •...
Page 204 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLIES Pivot shaft nut 85 Nm (8.5 m·kgf, 61 ft·lbf) 4. Install: • Rear shock absorber assembly “1” Make sure that the slot “a” in the rear shock ab- sorber assembly faces inward. (for models not equipped with gas cylinders) 5.
Page 205: Belt Drive
BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 140 Nm (14 m kgf, 100 ft lbf) •...
Page 206: Removing The Drive Belt And Drive Pulley
BELT DRIVE EAS23520 ECA1TP1030 REMOVING THE DRIVE BELT AND DRIVE NOTICE PULLEY • To protect the drive belt from damage, han- 1. Straighten the drive pulley nut ribs “a”. dle it with care. • The drive belt can not be bent smaller than 125 mm (4.92 in) “a”.
Page 207 BELT DRIVE Drive pulley nut 140 Nm (14 m·kgf, 100 ft·lbf) LOCTITE® • Stake the drive pulley nut at the cutouts “a” in the drive axle. • When tightening the drive pulley nut, press down on the brake pedal so the drive pulley does not move.
Page 208 BELT DRIVE 4-73...
Page 209: Engine
ENGINE ENGINE INSPECTION ..................5-1 MEASURING THE COMPRESSION PRESSURE........5-1 ENGINE REMOVAL ..................5-3 INSTALLING THE EXHAUST PIPE ............5-5 INSTALLING THE MUFFLER ..............5-6 INSTALLING THE SHIFT ARM ..............5-9 ADJUSTING THE SHIFT PEDAL.............. 5-9 INSTALLING THE HORN................5-11 REMOVING THE ENGINE ..............5-14 INSTALLING THE ENGINE..............
Page 210 CLUTCH ......................5-48 REMOVING THE PRIMARY DRIVE GEAR ..........5-53 REMOVING THE CLUTCH ..............5-53 CHECKING THE FRICTION PLATES.............5-53 CHECKING THE CLUTCH PLATES ............5-54 CHECKING THE CLUTCH SPRING PLATE...........5-54 CHECKING THE CLUTCH HOUSING ............5-54 CHECKING THE CLUTCH BOSS............5-55 CHECKING THE PRESSURE PLATE ............5-55 CHECKING THE PRIMARY DRIVE GEAR..........
Page 211 TRANSMISSION.................... 5-80 CHECKING THE SHIFT FORKS............. 5-83 CHECKING THE SHIFT DRUM ASSEMBLY..........5-83 CHECKING THE TRANSMISSION ............5-83 ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ......5-84 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY ..............5-84...
Page 212: Engine Inspection
ENGINE INSPECTION 7. Measure: EAS1TP1047 ENGINE INSPECTION • Compression pressure Out of specification → Refer to steps (c) and EAS20710 (d). MEASURING THE COMPRESSION PRESSURE Standard compression pressure The following procedure applies to all of the cyl- (at sea level) inders.
Page 213 ENGINE INSPECTION 10.Install: • Rear cylinder right cover Refer to “ENGINE REMOVAL” on page 5-3.
Page 214: Engine Removal
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipe 15 Nm (1.5 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • •...
Page 215 ENGINE REMOVAL Removing the muffler and exhaust pipe 15 Nm (1.5 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 45 Nm (4.5 m kgf, 33 ft Ibf) •...
Page 216: Installing The Exhaust Pipe
ENGINE REMOVAL EAS1TP1068 INSTALLING THE EXHAUST PIPE 1. Install: • Exhaust pipe joint • Exhaust pipe joint cover Exhaust pipe joint nut 15 Nm (1.5 m·kgf, 11 ft·lbf) Exhaust pipe joint cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Tighten the exhaust pipe joint nuts, and then in- stall the exhaust pipe joint cover and bolts.
Page 217: Installing The Muffler
ENGINE REMOVAL EAS1TP1048 INSTALLING THE MUFFLER Clamp bolt 1. Install: 12 Nm (1.2 m·kgf, 8.7 ft·lbf) • Gasket “1” (to muffler) Install the gasket with the chamfer “a”, located on an inner rim of the gasket, and the chamfer “b”, located on an outer rim of the gasket, as shown.
Page 218 ENGINE REMOVAL Removing the sidestand and drive pulley housing 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 219 ENGINE REMOVAL Removing the sidestand and drive pulley housing 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 15 Nm (1.5 m kgf, 11 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 220: Installing The Shift Arm
ENGINE REMOVAL EAS1TP1050 INSTALLING THE SHIFT ARM Make sure that the engaged thread length on 1. Install: both ends of the shift rod is 4 ridges or more. • Shift arm “1” Shift arm bolt Direction “a” 16 Nm (1.6 m·kgf, 12 ft·lbf) Installed shift rod length is increased.
Page 221 ENGINE REMOVAL Disconnecting the leads and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 30 Nm (3.0 m kgf, 22 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 222: Installing The Horn
ENGINE REMOVAL EAS1TP1070 INSTALLING THE HORN 1. Install: • Horn “1” Horn bracket bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) Make sure that the horn bracket “2” contacts the portion “a” of the stay on the frame. 5-11...
Page 223 ENGINE REMOVAL Removing the engine 48 Nm (4.8 m kgf, 35 ft Ibf) • • 88 Nm (8.8 m kgf, 64 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) •...
Page 224 ENGINE REMOVAL Removing the engine 48 Nm (4.8 m kgf, 35 ft Ibf) • • 88 Nm (8.8 m kgf, 64 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) • • 48 Nm (4.8 m kgf, 35 ft Ibf) •...
Page 225: Removing The Engine
ENGINE REMOVAL EAS1TP1051 REMOVING THE ENGINE 1. Remove: • Engine bracket (front upper side) “1” Before removing the engine, remove the engine bracket (front upper side) so that the cylinder head does not strike the bracket. EAS23720 INSTALLING THE ENGINE 1.
Page 226 ENGINE REMOVAL 3. Tighten: • Engine mounting nut (rear upper side) “16” • Engine mounting nut (front upper side) “17” • Engine mounting nut (rear lower side) “18” • Engine mounting nut (front lower side) “19” Engine mounting nut (rear upper side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (front upper...
Page 227: Camshafts
CAMSHAFTS EAS23740 CAMSHAFTS Removing the cylinder head covers 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 228 CAMSHAFTS Removing the camshafts and rocker arms 27 Nm (2.7 m kgf, 20 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 55 Nm (5.5 m kgf, 40 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) •...
Page 229 CAMSHAFTS Removing the camshafts and rocker arms 27 Nm (2.7 m kgf, 20 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 55 Nm (5.5 m kgf, 40 ft Ibf) • • 13 Nm (1.3 m kgf, 9.4 ft Ibf) •...
Page 230: Removing The Camshafts And Rocker Arms
CAMSHAFTS EAS1TP1052 REMOVING THE CAMSHAFTS AND ROCKER ARMS 1. Align: • “I” mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder head) ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 231: Checking The Camshafts
CAMSHAFTS Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 90890-01084 YU-01083-3 ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7. Remove: • Rear cylinder timing chain tensioner •...
Page 232: Checking The Camshaft Sprockets
CAMSHAFTS Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720– 1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583– 1.4622 in) Limit 36.941 mm (1.4544 in) a. 1/4 tooth Exhaust A b. Correct 42.138–42.238 mm (1.6590– 1. Timing chain roller 1.6629 in) 2.
Page 233: Checking The Timing Chain Tensioners
CAMSHAFTS • Timing chain tensioner rod “6” Rocker arm shaft outside diame- Damage/wear → Replace the defective part(s). 11.981–11.991 mm (0.4717– 0.4721 in) Limit 11.941 mm (0.4701 in) EAS24040 INSTALLING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts.
Page 234 CAMSHAFTS 5. Install: d. Remove the wire from the timing chain. • Front cylinder camshaft sprocket ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 6. Tighten: ▼ ▼▼▼ ▼ ▼▼▼ ▼...
Page 235 CAMSHAFTS ECA13740 • Copper washer “4” NOTICE • Timing chain tensioner cap bolt “3” Do not turn the crankshaft when installing the camshaft(s) to avoid damage or improper Timing chain tensioner cap bolt valve timing. 24 Nm (2.4 m·kgf, 17 ft·lbf) •...
Page 236: Installing The Cylinder Head Covers
CAMSHAFTS 11.Install: • Tappet covers • Rear cylinder timing chain tensioner gasket Rear cylinder side cover bolt “1” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) • Rear cylinder timing chain tensioner “2” LOCTITE® Tappet cover 10 Nm (1.0 m·kgf, 7.2 ft·lbf) To push in the timing chain tensioner rod, re- lease the lock by pushing in the one-way cam 2.
Page 237: Cylinder Heads
CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 15 Nm (1.5 m kgf, 11 ft Ibf) 15 Nm (1.5 m kgf, 11 ft Ibf) • • • • 25 Nm (2.5 m kgf, 18 ft Ibf) 25 Nm (2.5 m kgf, 18 ft Ibf) •...
Page 238: Removing The Cylinder Heads
CYLINDER HEADS EAS24150 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Cylinder head nuts • Loosen the cylinder head nuts in the proper se- quence as shown. • Loosen each cylinder head nut 1/2 of a turn at a time.
Page 239 CYLINDER HEADS Cylinder head nut 1st: 15 Nm (1.5 m·kgf, 11 ft·lbf) 2nd: 25 Nm (2.5 m·kgf, 18 ft·lbf) Final: 65 Nm (6.5 m·kgf, 47 ft·lbf) Cylinder head bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf) • Lubricate the cylinder head nuts and washers with engine oil.
Page 240 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-26. Valve cotter Upper spring seat Valve spring Intake valve...
Page 241: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal. 1.
Page 242 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 12.7–13.1 mm (0.500–0.515 in) 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020...
Page 243: Checking The Valve Seats
VALVES AND VALVE SPRINGS 4. Check: 1. Eliminate: • Valve face • Carbon deposits Pitting/wear → Grind the valve face. (from the valve face and valve seat) • Valve stem end 2. Check: Mushroom shape or diameter larger than the •...
Page 244: Checking The Valve Springs
VALVES AND VALVE SPRINGS 4. Lap: • Valve face • Valve seat After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 245: Installing The Valves
VALVES AND VALVE SPRINGS Free length (intake) Spring tilt (intake) 42.43 mm (1.67 in) 2.5 °/1.9 mm (0.07 in) Limit Spring tilt (exhaust) 40.31 mm (1.59 in) 2.5 °/1.9 mm (0.07 in) Free length (exhaust) 42.43 mm (1.67 in) Limit 40.31 mm (1.59 in) EAS24340 INSTALLING THE VALVES...
Page 246 VALVES AND VALVE SPRINGS Install the valve cotters by compressing the valve spring with the valve spring compressor “1” and the valve spring compressor attachment “2”. Valve spring compressor 90890-04019 YM-04019 Valve spring compressor attach- 4. Install: ment • Lower spring seat “1” 90890-01243 Valve spring compressor adapt- •...
Page 247 CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-26. Front cylinder Rear cylinder Front cylinder gasket Rear cylinder gasket Dowel pin Circlip Piston pin Piston Top ring...
Page 248: Cylinders And Pistons
CYLINDERS AND PISTONS EAS24380 REMOVING THE PISTONS When removing a piston ring, open the end gap The following procedure applies to all of the pis- with your fingers and lift the other side of the ring tons. over the piston crown. 1.
Page 249: Checking The Piston Rings
CYLINDERS AND PISTONS f. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲...
Page 250: Checking The Piston Pins
CYLINDERS AND PISTONS Piston pin outside diameter 20.991–21.000 mm (0.8264– 0.8268 in) Limit 20.971 mm (0.8256 in) a. 10 mm (0.39 in) 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. 3. Measure: The oil ring expander spacer end gap cannot be •...
Page 251: Installing The Pistons And Cylinders
CYLINDERS AND PISTONS EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis- tons and cylinders. 1. Install: • Top ring “1” • 2nd ring “2” • Oil ring expander “3” • Lower oil ring rail “4” •...
Page 252 CYLINDERS AND PISTONS 6. Install: • Cylinder “1” • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide through the timing chain cavity. 5-41...
Page 253: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (12) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) •...
Page 254 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • (12) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 255 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 24 Nm (2.4 m kgf, 17 ft Ibf) • • 90 Nm (9.0 m kgf, 65 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Generator rotor Starter clutch Woodruff key Starter clutch gear Starter clutch idle gear 2 shaft...
Page 256: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer • While holding the generator rotor “2” with the sheave holder “3”, loosen the generator rotor bolt. • Do not allow the sheave holder to touch the projection on the generator rotor.
Page 257: Installing The Starter Clutch
While holding the generator rotor “2” with the sheave holder “3”, tighten the starter clutch bolts. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 3. Apply: • Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-46...
Page 258: Installing The Generator Cover
GENERATOR AND STARTER CLUTCH EAS1TP1054 INSTALLING THE GENERATOR COVER 1. Install: Generator cover bolt 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Temporally tighten “a” and “b” and then tighten the generator cover bolts in the order shown in the illustration. 5-47...
Page 259: Clutch
CLUTCH EAS25060 CLUTCH Removing the primary drive gear 100 Nm (10 m kgf, 72 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
Page 260 CLUTCH Removing the primary drive gear 100 Nm (10 m kgf, 72 ft lbf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
Page 261 CLUTCH Removing the pull lever shaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing Oil seal retainer Oil seal For installation, reverse the removal proce- dure.
Page 262 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Bearing...
Page 263 CLUTCH Removing the clutch 125 Nm (12.5 m kgf, 90 ft lbf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump drive sprocket Thrust washer 2 For installation, reverse the removal proce- dure.
Page 264: Removing The Primary Drive Gear
CLUTCH EAS25090 REMOVING THE PRIMARY DRIVE GEAR While holding the clutch boss “2” with the univer- 1. Straighten the lock washer tab. sal clutch holder “3”, loosen the clutch boss nut. 2. Remove: • Primary drive gear nut “1” • Lock washer “2” Universal clutch holder 90890-04086 YM-91042...
Page 265: Checking The Clutch Plates
CLUTCH Friction plate 1 thickness 2.90–3.10 mm (0.114–0.122 in) Wear limit 2.80 mm (0.110 in) Friction plate 2 thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.82 mm (0.111 in) EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage →...
Page 266: Checking The Clutch Boss
CLUTCH EAS25210 CHECKING THE PRIMARY DRIVEN GEAR 1. Check: • Primary driven gear Damage/wear → Replace the primary drive and primary driven gears as a set. Excessive noise during operation → Replace the primary drive and primary driven gears as a set.
Page 267 CLUTCH • Lubricate the clutch boss nut threads and con- ical spring washer mating surfaces with engine oil. • Install the conical spring washer with the “OUT” mark “a” facing out. • While holding the clutch boss with the univer- sal clutch holder “4”, tighten the clutch boss nut.
Page 268 CLUTCH • Starter motor lead and rear brake light switch lead holder Clutch cover bolt “1”–“13”, “15” 12 Nm (1.2 m·kgf, 8.7 ft·lbf) Clutch cover bolt (with washer) “14” 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Temporally tighten the bolts “a” and “b”, and then 6.
Page 269: Installing The Primary Drive Gear
CLUTCH EAS25230 INSTALLING THE PRIMARY DRIVE GEAR 1. Install: • Primary drive gear “1” • Spacer “2” • Lock washer “3” • Primary drive gear nut Primary drive gear nut 100 Nm (10 m·kgf, 72 ft·lbf) • Make sure that the shorter side of the primary drive gear is facing outward.
Page 270 SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drive pulley cover Refer to “BELT DRIVE” on page 4-70. Shift arm Refer to “ENGINE REMOVAL”...
Page 271: Shift Shaft
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
Page 272: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 273 ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kgf, 8.0 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Armature assembly Starter motor yoke Gasket Starter motor rear cover Brush set assembly...
Page 274: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. ▲...
Page 275: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: • Bearing Damage/wear → Replace the starter motor. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush set assembly 2. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a”...
Page 276: Crankcase
CRANKCASE EAS25540 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • •...
Page 277 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 278 CRANKCASE Separating the crankcase 15 Nm (1.5 m kgf, 11 ft Ibf) • • (19) 15 Nm (1.5 m kgf, 11 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil baffle plate 1 Left crankcase Dowel pin Joint pipe O-ring Oil baffle plate 2 Gasket...
Page 279 CRANKCASE Removing the oil seal and bearings Order Job/Parts to remove Q’ty Remarks Oil pump assembly Refer to “OIL PUMP” on page 5-72. Crankshaft Refer to “CRANKSHAFT” on page 5-75. Transmission Refer to “TRANSMISSION” on page 5-80. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.
Page 280: Disassembling The Crankcase
CRANKCASE EAS25560 EAS25580 DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE 1. Remove: 1. Thoroughly wash the crankcase halves in a • Crankcase bolts mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. Loosen each bolt 1/4 of a turn at a time, in stag- 3.
Page 281: Assembling The Crankcase
1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 • M6 × 120 mm bolts: “a” 90890-85505 • Oil baffle plate 1 bolts: “b” (Three Bond No.1215®) Do not allow any sealant to come into contact with the oil gallery.
Page 282 CRANKCASE 5. Apply: • Engine oil (onto the crankshaft pin bearings and oil de- livery holes) 6. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-71...
Page 283 OIL PUMP EAS24910 OIL PUMP Removing the oil pump assembly 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • Order Job/Parts to remove Q’ty...
Page 284: Oil Pump
OIL PUMP EAS24960 EAS24970 CHECKING THE OIL PUMP CHECKING THE RELIEF VALVE 1. Check: 1. Check: • Oil pump housing • Relief valve body “1” Cracks/damage/wear → Replace the oil • Relief valve “2” pump assembly. • Spring “3” 2. Measure: •...
Page 285: Installing The Oil Pump Assembly
OIL PUMP When installing the inner rotor, align the pin in the impeller shaft with the grooves “a” in the in- ner rotor. Oil pump housing screw 8 Nm (0.8 m·kgf, 5.8 ft·lbf) 3. Check: • Oil pump operation Refer to “CHECKING THE OIL PUMP” on page 5-73.
Page 286: Crankshaft
CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Crankshaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.
Page 287: Removing The Connecting Rods
CRANKSHAFT The following procedure applies to all of the EAS26010 REMOVING THE CONNECTING RODS connecting rods. 1. Remove: ECA13930 • Connecting rod caps “1” NOTICE • Connecting rods Do not interchange the big end bearings and • Big end bearings connecting rods.
Page 288 CRANKSHAFT • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. e. Tighten the connecting rod bolts. Refer to “INSTALLING THE CONNECTING RODS” on page 5-78. f. Remove the connecting rod and big end bearings.
Page 289: Installing The Connecting Rods
CRANKSHAFT 6. Measure: Recommended lubricant • Crankshaft journal bearing inside diameter Engine oil “a” Out of specification → Replace the crank- 3. Install: case assembly. • Big end bearings • Connecting rods Measure the inside diameter of each crankshaft • Connecting rod caps journal bearing at two places.
Page 290: Installing The Crankshaft Assembly
CRANKSHAFT EAS26210 INSTALLING THE CRANKSHAFT Tighten the connecting rod bolts using the fol- ASSEMBLY lowing procedure. 1. Install: • Crankshaft assembly a. Tighten the connecting rod bolts to specifica- ECA1TP1023 tion with a torque wrench. NOTICE To avoid scratching the crankshaft and to Connecting rod bolt (1st) ease the installation procedure, lubricate 15 Nm (1.5 m·kgf, 11 ft·lbf)
Page 291 TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-65. Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Main axle assembly Drive axle assembly...
Page 292 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed lock washer retainer 4th pinion gear Collar Toothed washer Circlip 3rd pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
Page 293 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Circlip Toothed washer 2nd wheel gear Collar Drive axle...
Page 294: Transmission
TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks and shift fork guide bars. • Shift drum grooves Damage/scratches/wear → Replace the shift 1. Check: •...
Page 295: Assembling The Main Axle And Drive Axle
TRANSMISSION 3. Check: 2. Install: • Transmission gears • Toothed lock washer retainer “1” Blue discoloration/pitting/wear → Replace • Toothed lock washer “2” the defective gear(s). • Transmission gear dogs • With the toothed lock washer retainer in the Cracks/damage/rounded edges → Replace groove “a”...
Page 296 TRANSMISSION 2. Check: • Transmission Rough movement → Repair. • Apply molybdenum disulfide grease to each gear and bearing thoroughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-85...
Page 297: Fuel System
FUEL SYSTEM FUEL TANK..................... 6-1 REMOVING THE FUEL TANK ..............6-4 REMOVING THE FUEL PUMP ..............6-4 CHECKING THE FUEL PUMP BODY............6-4 CHECKING THE ROLLOVER VALVE ............6-4 INSTALLING THE FUEL PUMP..............6-5 INSTALLING THE FUEL SENDER ............6-6 THROTTLE BODIES ..................6-7 CHECKING THE INJECTORS ..............6-10 INSTALLING THE INJECTORS ..............6-10 CHECKING THE THROTTLE BODIES...........6-10 CHECKING THE INTAKE MANIFOLD JOINTS ........
Page 298 FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 23 Nm (2.3 m kgf, 17 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 4.0 Nm (0.40 m kgf, 2.9 ft Ibf) •...
Page 299: Fuel Tank
FUEL TANK Removing the rollover valve and canister 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Fuel tank...
Page 300 FUEL TANK Removing the rollover valve and canister 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Canister purge hose...
Page 301: Removing The Fuel Tank
FUEL TANK EAS1TP1036 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • Fuel tank ECA1TP1024 NOTICE Make sure that the fuel tank does not strike the meter assembly when removing it. EAS1TP1037 REMOVING THE FUEL PUMP 1.
Page 302: Installing The Fuel Pump
FUEL TANK • The rollover valve must be in an upright posi- tion when checking the airflow. EAS1TP1039 INSTALLING THE FUEL PUMP 1. Install: • Fuel pump • Gasket Fuel pump bolt 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf) ECA1TP1027 2. Install: NOTICE •...
Page 303: Installing The Fuel Sender
FUEL TANK A. Connection to fuel pump and fuel filter B. Connection between fuel hoses EAS1TP1040 INSTALLING THE FUEL SENDER 1. Install: • Fuel sender • O-ring Fuel sender bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Position the fuel sender coupler “1” between the guides “a”...
Page 304 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 305 THROTTLE BODIES Removing the intake manifold assembly 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Air filter case 4-1.
Page 306: Throttle Bodies
THROTTLE BODIES Disassembling the intake manifold 10 Nm (1.0 m kgf, 7.2 ft Ibf) 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Pressure regulator...
Page 307: Checking The Injectors
THROTTLE BODIES EAS26980 EAS26990 CHECKING THE INJECTORS CHECKING THE THROTTLE BODIES EWA1TP1015 1. Check: WARNING • Throttle bodies Cracks/damage → Replace the throttle bod- • Check the injectors in a well-ventilated area free of combustible materials. Make sure ies as a set. that there is no smoking or use of electric 2.
Page 308: Adjusting The Throttle Position Sensor
THROTTLE BODIES Vacuum/pressure pump gauge The vacuum pressure should not exceed 100 kPa (760 mmHg). 90890-06756 Mityvac brake bleeding tool • Increase the vacuum pressure → YS-42423 Fuel pressure is decreased Pressure gauge • Decrease the vacuum pressure → 90890-03153 Fuel pressure is increased YU-03153 Fuel pressure adapter...
Page 309: Removing The Intake Manifold Assembly
THROTTLE BODIES Throttle position sensor screw Be sure to fit the projection “b” on the intake 3.5 Nm (0.35 m·kgf, 2.5 ft·lbf) manifold assembly between the projections “c” on the rear cylinder intake manifold joint. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲...
Page 310 THROTTLE BODIES 6-13...
Page 311: Electrical System
TROUBLESHOOTING ................7-19 SIGNALING SYSTEM ...................7-21 CIRCUIT DIAGRAM ................7-21 TROUBLESHOOTING ................7-23 FUEL INJECTION SYSTEM................7-27 CIRCUIT DIAGRAM ................7-27 ECU SELF-DIAGNOSTIC FUNCTION............7-29 TROUBLESHOOTING METHOD............7-30 YAMAHA DIAGNOSTIC TOOL ...............7-31 TROUBLESHOOTING DETAILS ............7-32 FUEL PUMP SYSTEM...................7-67 CIRCUIT DIAGRAM ................7-67 TROUBLESHOOTING ................7-69...
Page 312 ELECTRICAL COMPONENTS..............7-71 CHECKING THE SWITCHES ..............7-75 CHECKING THE BULBS AND BULB SOCKETS ........7-78 CHECKING THE FUSES ................7-79 CHECKING AND CHARGING THE BATTERY........7-80 CHECKING THE RELAYS ..............7-83 CHECKING THE TURN SIGNAL RELAY ..........7-84 CHECKING THE RELAY UNIT (DIODE) ..........7-84 CHECKING THE IGNITION SPARK GAP..........
Page 314: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 315 IGNITION SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 7. Fuel injection system fuse 10.Joint connector 13.Ignition fuse 16.Joint coupler 17.Relay unit 20.Sidestand switch 21.Neutral switch 26.Crankshaft position sensor 27.Lean angle sensor 32.ECU (engine control unit) 33.Front cylinder ignition coil 34.Spark plug 35.Rear cylinder ignition coil...
Page 316: Engine Stopping Due To Sidestand Operation
IGNITION SYSTEM EAS3D81009 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 317: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Fuel tank 4. Rear cylinder right cover 5. Air duct 6.
Page 318 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-75. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...
Page 319 IGNITION SYSTEM...
Page 320: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 321 ELECTRIC STARTING SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 8. Starter relay 9. Starter motor 13.Ignition fuse 16.Joint coupler 17.Relay unit 18.Starting circuit cut-off relay 20.Sidestand switch 21.Neutral switch 56.Clutch switch 67.Right handlebar switch 69.Engine stop switch 70.Start switch A.
Page 322: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 323: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Fuel tank 4. Air duct 5. Drive pulley NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
Page 324 ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-75. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...
Page 325 ELECTRIC STARTING SYSTEM 7-12...
Page 326: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-13...
Page 327 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 4. Main fuse 5. Battery A. Wire harness B. Negative battery sub-wire harness 7-14...
Page 328: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Air duct NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
Page 329 CHARGING SYSTEM 7-16...
Page 330: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-17...
Page 331 LIGHTING SYSTEM 3. Main switch 4. Main fuse 5. Battery 7. Fuel injection system fuse 11.Signaling system fuse 12.Tail/brake light fuse 13.Ignition fuse 15.Headlight fuse 16.Joint coupler 32.ECU (engine control unit) 40.Meter assembly 42.Multi-function meter 46.Meter light 47.High beam indicator light 51.Headlight relay 52.Left handlebar switch 53.Dimmer switch...
Page 332: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position light, meter light or auxiliary light (OPTION). 1. Left side cover 2. Rider seat 3. Fuel tank 4. Tail/brake light assembly NG →...
Page 333 LIGHTING SYSTEM NG → 7. Check the entire lighting system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 7-17. OK ↓ Replace the ECU, meter assembly or tail/brake light assembly. 7-20...
Page 334: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-21...
Page 335 SIGNALING SYSTEM 3. Main switch 4. Main fuse 5. Battery 6. Engine ground 7. Fuel injection system fuse 11.Signaling system fuse 13.Ignition fuse 14.Backup fuse 16.Joint coupler 17.Relay unit 21.Neutral switch 22.Speed sensor 32.ECU (engine control unit) 39.Oil level switch 40.Meter assembly 41.Neutral indicator light 42.Multi-function meter...
Page 336: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to come on. • The speedometer fails to operate. •...
Page 337 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 7-21. OK ↓ Replace the hone. The tail/brake light fails to come on. NG → 1.
Page 338 SIGNALING SYSTEM NG → 4. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 7-21. OK ↓ Replace the meter assembly. The neutral indicator light fails to come on. NG →...
Page 339 SIGNALING SYSTEM NG → 2. Check the entire signaling system wiring. Properly connect or replace the wire har- Refer to “CIRCUIT DIAGRAM” on ness. page 7-21. OK ↓ Replace the meter assembly. The speedometer fails to operate. NG → 1. Check the speed sensor. Refer to “CHECKING THE SPEED Replace the speed sensor.
Page 340: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-27...
Page 341 25.Intake air temperature sensor 26.Crankshaft position sensor 27.Lean angle sensor 28.Throttle position sensor 29.Intake air pressure sensor 30.ISC (idle speed control) unit 31.Yamaha diagnostic tool coupler 32.ECU (engine control unit) 33.Front cylinder ignition coil 34.Spark plug 35.Rear cylinder ignition coil 36.Front cylinder injector 37.Rear cylinder injector...
Page 342: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 343: Troubleshooting Method
FUEL INJECTION SYSTEM The engine operation is not normal, but the EAS30580 TROUBLESHOOTING METHOD engine trouble warning light does not come The engine operation is not normal and the 1. Check the operation of the following sensors engine trouble warning light comes on. and actuators in the diagnostic mode.
Page 344: Yamaha Diagnostic Tool
Remove the protective cap, and then connect the Yamaha diagnostic tool to the coupler “1”. When the Yamaha diagnostic tool is connected to the vehicle, the operation of the multi-function meter and indicators will be different from the normal operation.
Page 345: Troubleshooting Details
FUEL INJECTION SYSTEM EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the multi-function meter dis- play. Check and service the items or components that are the probable cause of the malfunction fol- lowing the order given. After the check and service of the malfunctioning part has been completed, reset the multi-function meter display according to the reinstatement method.
Page 346 FUEL INJECTION SYSTEM Fault code No. Crankshaft position sensor: no normal signals are received Item from the crankshaft position sensor. Installed condition of crank- Improperly installed sensor Crank the engine. → Reinstall or replace the shaft position sensor. Fault code number is not dis- played →...
Page 347 FUEL INJECTION SYSTEM Fault code No. Item Intake air pressure sensor: open or short circuit detected. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness. Fault code number is not dis- played →...
Page 348 FUEL INJECTION SYSTEM If fault code numbers “13” and “14” are both indicated, take the actions specified for fault code number “13” first. Fault code No. Intake air pressure sensor: hose system malfunction (clogged Item or detached hose). Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 349 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. Throttle position sensor signal Indicated • 14–20 (fully closed position) • 92–102 (fully open position) •...
Page 350 FUEL INJECTION SYSTEM Fault code No. Item Throttle position sensor: open or short circuit detected. Defective throttle position Check throttle position sen- Turn the main switch to “ON”. sensor. sor signal. Fault code number is not dis- played → Service is finished. Execute the diagnostic mode.
Page 351 FUEL INJECTION SYSTEM Fault code No. Sidestand switch: a break or disconnection of the blue/black Item lead of the ECU (engine control unit) is detected. Improperly connected → Connection of main switch Turn the main switch to “ON”, coupler. Connect the coupler secure- and then extend and retract Check the locking condition ly or replace the wire har-...
Page 352 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Improperly connected → Connection of intake air tem- Turn the main switch to “ON”. perature sensor coupler. Connect the coupler secure- Fault code number is not dis- played →...
Page 353 FUEL INJECTION SYSTEM Fault code No. Item Intake air temperature sensor: open or short circuit detected. Defective intake air tempera- Execute the diagnostic Turn the main switch to “ON”. ture sensor. mode. (Code No. 05) Fault code number is not dis- played →...
Page 354 FUEL INJECTION SYSTEM Fault code No. sensor: no normal signals are received from the O sensor. Item Improperly connected → Connection of ECU coupler. Start the engine, warm it up, Check the locking condition Connect the coupler secure- and then race it, or execute of the coupler.
Page 355 FUEL INJECTION SYSTEM Fault code No. Item Engine temperature sensor: open or short circuit detected. Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Improperly connected → Connection of engine tem- Turn the main switch to “ON”. perature sensor coupler.
Page 356 FUEL INJECTION SYSTEM If fault code numbers “28” and “37” are both indicated, take the actions specified for fault code number “28” first. Fault code No. Item Latch up detected. Unable to start engine Fail-safe system Unable to drive vehicle Diagnostic code No.
Page 357 FUEL INJECTION SYSTEM Fault code No. Front cylinder ignition coil: open or short circuit detected in Item the primary lead of the front cylinder ignition coil. Check that a spark is generated five times. Procedure • Connect an ignition checker. Probable cause of mal- Confirmation of service Item...
Page 358 FUEL INJECTION SYSTEM Fault code No. Rear cylinder ignition coil: open or short circuit detected in Item the primary lead of the rear cylinder ignition coil. Able to start engine (depending on the number of faulty cylinders) Fail-safe system Able to drive vehicle (depending on the number of faulty cylinders) Diagnostic code No.
Page 359 FUEL INJECTION SYSTEM Fault code No. Rear cylinder ignition coil: open or short circuit detected in Item the primary lead of the rear cylinder ignition coil. Malfunction in ECU. Execute the diagnostic mode. (Code No. 31) No spark → Replace the ECU.
Page 360 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is de- fective (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). ISC valve is not moving cor- Replace the throttle body as- Start the engine and let it idle rectly.
Page 361 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is defective (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). Improperly connected → Connection of ISC (idle Execute the diagnostic speed control) coupler.
Page 362 FUEL INJECTION SYSTEM Fault code No. Component other than ISC (idle speed control) unit is defective (ISC operating sound is heard). Item Defective ISC (idle speed control) unit (ISC operating sound is not heard). Delete the fault code. Start the engine and let it idle for approximately 10 sec- onds.
Page 363 FUEL INJECTION SYSTEM Fault code No. Item Injector: open or short circuit detected. Improperly connected → Connection of front cylinder Execute the diagnostic injector and/or rear cylinder Connect the coupler secure- mode. (Code Nos. 36, 37) No operating sound → Go to injector coupler.
Page 364 FUEL INJECTION SYSTEM Fault code No. Item Lean angle sensor: open or short circuit detected. Lean angle sensor output voltage Indicated • 0.4–1.4 (upright) • 3.7–4.4 (overturned) Remove the lean angle sensor and incline it more than 45 de- Procedure grees.
Page 365 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Fail-safe system Able to start engine Able to drive vehicle Diagnostic code No.
Page 366 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected → Connection of ECU coupler. Execute the diagnostic Check the locking condition Connect the coupler secure-...
Page 367 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No.
Page 368 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected → Connection of ECU coupler. Execute the diagnostic Check the locking condition Connect the coupler secure-...
Page 369 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction → Replace the Faulty shift drum (neutral de- Execute the diagnostic tection area).
Page 370 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Value does not increase → Locate the malfunction.
Page 371 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Improperly connected → Connection of ECU coupler. Execute the diagnostic Check the locking condition Connect the coupler secure-...
Page 372 FUEL INJECTION SYSTEM Fault code No. Speed sensor: no normal signals are received from the speed sensor. Item B Neutral switch: open or short circuit is detected. C Clutch switch: open or short circuit is detected. Malfunction in ECU. Replace the ECU. Delete the fault code.
Page 373 FUEL INJECTION SYSTEM Fault code No. Fuel system voltage: incorrect voltage supplied to the fuel in- Item jector and fuel pump. Open or short circuit → Re- Wire harness continuity. Start the engine and let it idle place the wire harness. for approximately 5 seconds.
Page 374 FUEL INJECTION SYSTEM Fault code No. Item Charging voltage is abnormal. Able to start engine Fail-safe system Able to drive vehicle Diagnostic code No. — Indicated — Procedure — Probable cause of mal- Confirmation of service Item Maintenance job function and check completion Malfunction in charging sys- Check the charging system.
Page 375 FUEL INJECTION SYSTEM Fault code No. Er-1 ECU (engine control unit) internal malfunction (output signal Item error): signals cannot be transmitted between the ECU and the multi-function meter. Improperly connected → Connection of meter assem- Turn the main switch to “ON”. bly coupler.
Page 376 FUEL INJECTION SYSTEM Fault code No. Er-2 ECU (engine control unit) internal malfunction (output signal Item error): no signals are received from the ECU within the speci- fied duration. Improperly connected → Connection of ECU coupler. Turn the main switch to “ON”. Check the locking condition Connect the coupler secure- Fault code number is not dis-...
Page 377 FUEL INJECTION SYSTEM Fault code No. Er-3 ECU (engine control unit) internal malfunction (output signal Item error): data from the ECU cannot be received correctly. Open or short circuit → Re- Wire harness continuity. Turn the main switch to “ON”. place the wire harness.
Page 378 FUEL INJECTION SYSTEM Fault code No. Er-4 ECU (engine control unit) internal malfunction (input signal er- Item ror): non-registered data has been received from the meter. Defective meter assembly. Replace the meter assembly. Turn the main switch to “ON”. Fault code number is not dis- played →...
Page 379 FUEL INJECTION SYSTEM 7-66...
Page 380 FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-67...
Page 381 FUEL PUMP SYSTEM 3. Main switch 4. Main fuse 5. Battery 7. Fuel injection system fuse 13.Ignition fuse 16.Joint coupler 17.Relay unit 19.Fuel pump relay 32.ECU (engine control unit) 38.Fuel pump 67.Right handlebar switch 69.Engine stop switch A. Wire harness B.
Page 382 FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING The fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Left side cover 2. Rider seat 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
Page 383 FUEL PUMP SYSTEM 7-70...
Page 384: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-71...
Page 385 ELECTRICAL COMPONENTS 1. Intake air temperature sensor 2. Intake air pressure sensor 3. Front cylinder ignition coil 4. Rear cylinder ignition coil 5. Turn signal relay 6. ECU (engine control unit) 7. Speed sensor 8. Neutral switch 9. O sensor 10.
Page 386 ELECTRICAL COMPONENTS 11 12 13 14 7-73...
Page 387 ELECTRICAL COMPONENTS 1. Main switch 2. Throttle position sensor 3. Relay unit 4. Battery 5. Lean angle sensor 6. Headlight relay 7. Starter relay 8. Fuel injection system fuse 9. Main fuse 10. Fuse box 11. Ignition fuse 12. Signaling system fuse 13.
Page 388: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES L L/Y G Y/R P Br Br/W Br B/W L/W R/W Y/G B/Y Br Y 7-75...
Page 389 ELECTRICAL COMPONENTS 1. Main switch 2. Front brake light switch 3. Reset switch 4. Select switch 5. Engine stop switch 6. Start switch 7. Rear brake light switch 8. Neutral switch 9. Sidestand switch 10. Dimmer switch 11. Turn signal switch 12.
Page 390 ELECTRICAL COMPONENTS 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. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 391 ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB • Bulb SOCKETS EWA13320 WARNING Do not check any of the lights that use LEDs. Since the headlight bulb gets extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from the bulb until it has cooled down.
Page 392 ELECTRICAL COMPONENTS Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace the The following procedure applies to all of the bulb fuse. sockets. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 393 ELECTRICAL COMPONENTS specific gravity of the electrolyte. Therefore, the EAS28030 CHECKING AND CHARGING THE BATTERY charge of the battery has to be checked by mea- EWA13290 suring the voltage at the battery terminals. WARNING Batteries generate explosive hydrogen gas 1. Remove: and contain electrolyte which is made of poi- •...
Page 394 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehi- cle, disconnect the negative battery lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
Page 395 ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is stopped. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.
Page 396 ELECTRICAL COMPONENTS Relay unit (starting circuit cut-off relay) Recommended lubricant Dielectric grease 10.Install: • Battery cover • ECU bracket • Rider seat L/W.L B/R L/W R/L Sb/W • Left side cover Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS 1.
Page 397 ELECTRICAL COMPONENTS Headlight relay b. Turn the main switch to “ON”. c. Measure the turn signal relay input voltage. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 2. Check: • Turn signal relay output voltage Out of specification →...
Page 398 ELECTRICAL COMPONENTS c. Check the relay unit (diode) for continuity. Continuity d. Check the relay unit (diode) for no continuity. Positive tester probe → sky blue ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲...
Page 399 ELECTRICAL COMPONENTS Resistance 7.5–12.5 kΩ ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼▼▼ a. Remove the spark plug cap from the spark plug lead. b. Connect the pocket tester (Ω × 1k) to the spark plug cap as shown.
Page 400 ELECTRICAL COMPONENTS 2. Check: Pocket tester • Crankshaft position sensor resistance 90890-03112 Out of specification → Replace the crank- Analog pocket tester shaft position sensor/stator assembly. YU-03112-C Test harness- lean angle sensor Crankshaft position sensor resis- (6P) tance 90890-03209 248–372 Ω YU-03209 ▼...
Page 401 ELECTRICAL COMPONENTS B B B b. Check the starter motor operation. b. Measure the stator coil resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲...
Page 402 ELECTRICAL COMPONENTS EAS1TP1008 EAS1TP1009 CHECKING THE OIL LEVEL SWITCH CHECKING THE FUEL SENDER 1. Drain: 1. Disconnect: • Engine oil • Fuel sender coupler 2. Remove: (from the wire harness) • Oil level switch 2. Remove: (from the crankcase) • Fuel sender 3.
Page 403 ELECTRICAL COMPONENTS Warning light flashes eight times, then goes b. Connect the pocket tester (DC 20 V) to the off for three seconds in a repeated cycle (mal- speed sensor coupler (wire harness side) as function detected in fuel sender or thermistor) shown.
Page 404 ELECTRICAL COMPONENTS Engine temperature sensor resis- Pocket tester tance 90890-03112 2.63–2.78 kΩ at 20 °C (68 °F) Analog pocket tester 210–221 Ω at 100 °C (212 °F) YU-03112-C ▼ ▼▼▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼ ▼ ▼▼▼ ▼...
Page 405 ELECTRICAL COMPONENTS Pocket tester Pocket tester 90890-03112 90890-03112 Analog pocket tester Analog pocket tester YU-03112-C YU-03112-C Test harness S- pressure sensor 5S7 (3P) b. Immerse the intake air temperature sensor 90890-03211 “1” in a container filled with water “2”. YU-03211 Make sure that the intake air temperature sensor •...
Page 406 ELECTRICAL COMPONENTS c. Measure the fuel injector resistance. ▲ ▲▲▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲ ▲▲▲ ▲ ▲▲▲ 7-93...
Page 407: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING..................8-1 GENERAL INFORMATION ............... 8-1 STARTING FAILURES................8-1 INCORRECT ENGINE IDLING SPEED ............ 8-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING................ 8-2 SHIFT PEDAL DOES NOT MOVE ............8-2 JUMPS OUT OF GEAR................8-2 FAULTY CLUTCH ..................8-2 OVERHEATING ..................8-2 POOR BRAKING PERFORMANCE............8-3 FAULTY FRONT FORK LEGS..............8-3 UNSTABLE HANDLING ................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........
Page 408: Troubleshooting
TROUBLESHOOTING Electrical system EAS28450 TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does not • Improperly installed fuse cover all the possible causes of trouble. It should 3.
Page 409: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2. Spark plug(s) • Improperly returned stopper lever • Incorrect spark plug gap • Incorrect spark plug heat range Shift forks •...
Page 410: Poor Braking Performance
TROUBLESHOOTING • Incorrect oil viscosity • Incorrect oil level • Inferior oil quality EAS28670 UNSTABLE HANDLING Fuel system 1. Handlebar 1. Throttle body(-ies) • Bent or improperly installed handlebar • Damaged or loose throttle body joint 2. Steering head components 2.
Page 411 TROUBLESHOOTING • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Headlight bulb life expired Tail/brake light does not come on • Faulty brake light switch • Too many electrical accessories • Incorrect connection • Faulty tail/brake light assembly Turn signal does not come on •...
Page 412 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE EAS1TP1035 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Self-diagnostic function table Fault Reference Item code No. pages Crankshaft position sensor: no normal signals are received from the 7-32 crankshaft position sensor. Intake air pressure sensor: open or short circuit detected. 7-33 Intake air pressure sensor: hose system malfunction (clogged or de- 7-35...
Page 413: Self-Diagnostic Function And Diagnostic Code Table
7-64 non-registered data has been received from the meter. Diagnostic code: sensor operation table The diagnostic code numbers cannot be displayed on the multi-function meter. To display the diagnos- tic code numbers, use the Yamaha diagnostic tool. Diagnostic Item Display Procedure code No.
Page 414 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE Diagnostic Item Display Procedure code No. Fuel system voltage (bat- Approximately 12.0 Set the start/engine stop tery voltage) switch to “ ”, and then compare the actually mea- sured battery voltage with the meter display value. (If the actually measured bat- tery voltage is low, re- charge the battery.)
Page 415 Front cylinder ignition coil Actuates the front cylinder Check that a spark is gen- ignition coil five times at erated five times. one-second intervals. • Connect an ignition Illuminates the engine checker. trouble warning light and Yamaha diagnostic tool warning light.
Page 416 Yamaha diagnostic tool warning light. (The engine trouble warn- ing light and Yamaha diag- nostic tool warning light are OFF when the relay is ON, and the engine trou- ble warning light and Yamaha diagnostic tool warning light are ON when the relay is OFF.)
Page 417 SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE 8-10...
Page 418: Wiring Diagram
Blue/Red 28. Throttle position sensor Blue/White 29. Intake air pressure sensor Blue/Yellow 30. ISC (idle speed control) unit Pink/Blue 31. Yamaha diagnostic tool coupler Pink/White 32. ECU (engine control unit) Red/Black 33. Front cylinder ignition coil Red/Green 34. Spark plug Red/Blue 35.
Page 421 XVS95CE(C) 2014 WIRING DIAGRAM B B B (Gy) R/W L Gy/W R/W Sb/W Gy/G B/L L/W.L B/R L/W R/L Sb/W Gy/W Gy/W Gy/G Gy/G Gy/R B/L Br/W Br/W Br B/L B L/G Gy/R Br/W L/Y L/B Ch Dg Br/W Br/W Br/W Br/W Br/L...
Page 422 XVS95CE(C) 2014 WIRING DIAGRAM (Gy) (Gy) (Gy) (Db) (Db) (Gy) SELECT RESET (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy) (Gy)

This manual is also suitable for:

Star xvs95ce 1tp1 2014 Star xvs95cec 1tp2 2014 Star xvs95ce 2dx3 2014 Star xvs95cec 2dx2 2014 Star xvs95ce 1tp3 2014

Yamaha STAR XVS95CE 2DX1 2014 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Swingarm and Rear Shock Absorber Assemblies

Belt Drive

Engine

Engine Inspection

Engine Removal

Camshafts

Cylinder Heads

Valves and Valve Springs

Cylinders and Pistons

Generator and Starter Clutch

Clutch

Shift Shaft

Electric Starter

Crankcase

Oil Pump

Crankshaft

Transmission

Fuel System

Fuel Tank

Throttle Bodies

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Fuel Injection System

Troubleshooting

Troubleshooting

Self-Diagnostic Function and Diagnostic Code Table

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha STAR XVS95CE 2DX1 2014