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YAMAHA YZF-R6 99 Service Manual

Motorcycle yzf-r6 99 5eb-ae1.
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   Summary of Contents for YAMAHA YZF-R6 99

  • Page 2

    EB000000 YZF-R6 SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. First edition, August 1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

  • Page 3: Important Manual Information

    EB001000 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. it is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.

  • Page 4: How To Use This Manual

    EB003000 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. 1 The manual is divided into chapters.

  • Page 5

    EB004000 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor(-s) COOL CARB 7 Chassis...

  • Page 6

    INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM COOL CARBURETORS CARB CHASSIS CHAS ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...

  • Page 7: Table Of Contents

    INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .

  • Page 8: Motorcycle Identification, Vehicle Identification Number, Model Code

    MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EB100020 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 9: Important Information, Replacement Parts, Gaskets, Oil Seals And O-rings

    5. Keep all parts away from any source of fire. EB102010 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 ap- pearance, but inferior in quality.

  • Page 10: Using A Dynamometer, Lock Washers/plates And Cotter Pins, Bearings And Oil Seals, Circlips

    IMPORTANT INFORMATION INFO USING A DYNAMOMETER The YZF-R6 has a carbon muffler that may change color when exposed to high tempera- tures. Therefore, when using a dynamometer always use a fan to cool the muffler. EB102030 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins.

  • Page 11: Checking The Connections

    CHECKING THE CONNECTIONS INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.

  • Page 12: Features, Air Intake System, Thermostat

    FEATURES INFO FEATURES AIR INTAKE SYSTEM System diagram This system is designed to improve the power while riding a motorcycle at a high speed by increasing the air intake efficiency by means of pressurizing the air filter case 2 where the air is taken in via the air duct 1 from the air intake port located under the headlight.

  • Page 13: Ignition System

    FEATURES INFO Flow control operation 1) When valve is closed The lip 1 seals the coolant. 2) When valve is set as low-lift The 2nd lip 2 seals the coolant. To reduce the water temperature change, the coolant starts flowing through the notch depending on its area at a section.

  • Page 14

    FEATURES INFO 2. Ignition coil Compact and right weight design is provided since the plug top ignition coil is equipped in which the plug cap ignition coil are inte- grated. High tension cord was cut an end to use and ignition energy loss has become lower.

  • Page 15: Special Tools

    SPECIAL TOOLS INFO EB104000 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 inappropri- ate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 16

    SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench 90890-01426 This tool is needed to loosen or tighten the oil filter cartridge. Rod holder 90890-01434 This tool is used to support the damper ad- justing rod. Rod puller Rod puller 90890-01437 Rod puller attachment...

  • Page 17

    SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Engine tachometer 90793-80009 This tool is used to check engine speed. Timing light 90890-03141 This tool is used to check the ignition timing. Oil pressure Oil pressure gauge gauge Adapter 90890-03153 Adapter These tools are used to measure engine oil 90890-03139 pressure.

  • Page 18

    This tool is used to rebore the new valve guides. Ignition checker 90890-06754 This tool is used to check the ignition system components. Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). 1-11...

  • Page 19: Table Of Contents

    SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .

  • Page 20: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Dimensions Overall length 2025 mm (except for NOR, SWE, FIN, AUS NZL) 2075 mm (for NOR, SWE, FIN, AUS, NZL) Overall width 690 mm Overall height 1105 mm Seat height 820 mm Wheelbase 1380 mm Minimum ground clearance...

  • Page 21: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine tipe Liquid-cooled, 4-stroke, DOHC Displacement 600 cm Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 65.5 44.5 mm Compression ratio 12.4 : 1 1,250 X 1,350 r/min Engine idling speed Vacuum pressure at engine idling 24.0 kPa (0.24 kg/cm speed Standard compression pressure...

  • Page 22

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) 80 X 120 kPa (0.8 X 1.2 kgf/cm Bypass valve opening pressure Oil pump Oil pump type Trochoidal 0.03 X 0.09 mm Inner-rotor-to-outer-rotor-tip 0.15 mm clearance 0.03 X 0.08 mm Outer-rotor-to-oil-pump-housing 0.15 mm clearance...

  • Page 23

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 23.000 X 23.021 mm Camshaft cap inside diameter 22.967 X 22.980 mm Camshaft journal diameter 0.020 X 0.054 mm Camshaft-journal-to-camshaftcap 0.08 mm clearance Intake camshaft lobe dimensions 33.05 X 33.15 mm Measurement A 33.0 mm 25.14 X 25.24 mm...

  • Page 24

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015/120 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.11 X 0.20 mm Intake 0.21 X 0.30 mm Exhaust Valve dimensions Head Diameter Face Width Seat Width Margin Thickness 24.9 X 25.1 mm Valve head diameter A...

  • Page 25

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake (inner) 37.0 mm 35 mm (outer) 38.4 mm 36.5 mm Exhaust 41.7 mm 39.5 mm Installed length (valve closed) Intake (inner) 30.0 mm (outer) 32.5 mm Exhaust 36.1 mm Compressed spring force (installed) 69 X 79 N (7.0 X 8.0 kgf)

  • Page 26

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons 0.025 X 0.050 mm Piston-to-cylinder clearance 0.07 mm 65.460 X 65.475 mm Diameter D Height H 4 mm Piston pin bore (in the piston) 16.002 X 16.013 mm Diameter 0.35 X 0.65 mm Offset Offset direction Intake side...

  • Page 27

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.028 X 0.052 mm Crankshaft-pin-to-big-end-bearing clearance Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green Crankshaft 268.8 X 270.0 mm Width B Max. runout C 0.03 mm 0.160 X 0.262 mm Big end side clearance D 0.034 X 0.058 mm...

  • Page 28

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 86/44 (1.9545) Secondary reduction system Chain drive Secondary reduction ratio 48/16 (3.000) Operation Left-foot operation Gear ratios 1st gear 37/13 (2.846) 2nd gear 37/19 (1.947) 3rd gear...

  • Page 29

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Starter jet 1 Starter jet 2 Butterfly valve size #110 17.5 X 18.5 mm Fuel level (below the line on the float chamber) 2-10...

  • Page 30: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle Trail 81 mm Front wheel Wheel type Cast wheel Size MT3.50 Material Aluminum Wheel travel 130 mm Wheel runout Max. radial wheel runout 1 mm Max. lateral wheel runout 0.5 mm Rear wheel Wheel type...

  • Page 31

    SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 180/55 ZR17 (73 W) Model (manufacturer) BRIDGESTON BT56R DUNLOP D207 Tire pressure (cold) 0 X 90 kg 250 kPa (2.5 kg/cm , 2.5 bar) 90 X 197 kg 290 kPa (2.9 kg/cm , 2.9 bar) High-speed riding...

  • Page 32

    SPEC CHASSIS SPECIFICATION Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 130 mm Spring Free length 251.8 mm 246 mm Spacer length 125 mm Installed length 247.8 mm Spring rate (K1) 7.5 N/mm (0.75 kgf/mm) 0 X 130 mm Spring stroke (K1)

  • Page 33

    SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular ball bearings Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assemblytype Coil spring/gas-oil damper Rear shock absorber assemblytravel 60 mm Spring Free length Installed length 169.5 mm Spring rate (K1) 159 mm Spring stroke (K1)

  • Page 34: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type C.D.I. Ignition timing 10_ BTDC at 1700 r/min Advanced timing 55_ BTDC at 5250 r/min Advancer type Throttle position sensor and electrical 248 X 372 Pickup coil resistance/color /Gy-B Transistorized coil ignition unit model...

  • Page 35

    SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit License plate light 12 V 5 W Meter light 12 V 1.4 W Electric starting system System type Constant mesh Starter motor Model (manufacturer) SM-14 (MITSUBA) Power output 0.6 kW Brushes Overall length 10 mm 3.5 mm 7.16 X 9.52 N (730 X 970 gf) Spring force...

  • Page 36

    SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Temperature sender Model (manufacturer) 11H (NIPPON SEIKI) 50.6 X 64.2 Resistance at 80_C 16.1 X 17.3 at 120_C Fuses (amperage quantity) Main fuse 30 A Headlight fuse 20 A Signaling system fuse 20 A Ignition fuse 15 A Radiator fan fuse...

  • Page 37: Conversion Table, Tightening Torques, General Tightening Torques

    SPEC CONVERSION TABLE/TIGHTENING TORQUES EB202001 EB201000 CONVERSION TABLE TIGHTENING TORQUES All specification data in this manual are GENERAL TIGHTENING TORQUES listed in SI and METRIC UNITS. This chart specifies tightening torques for standard Use this table to convert METRIC unit data fasteners with a standard ISO thread pitch.

  • Page 38: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks nSkgf Spark plugs – Cylinder head Bolt Cylinder head Bolt Camshaft caps Bolt Cylinder head cover Bolt Oil passage check bolt Bolt Cylinder head (exhaust pipe) Stud bolt Connecting rod caps See NOTE...

  • Page 39

    SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size size mSkgf Clutch cover Bolt Pickup coil rotor cover Bolt Shift shaft cover Bolt Breather plate 2 – Starter clutch Bolt Clutch boss Use a lock washer. Clutch springs Bolt Drive sprocket Use a lock...

  • Page 40

    SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2-21...

  • Page 41: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks mSkgf Upper bracket pinch bolts Steering stem nut 11.5 Handlebar pinch bolts Lower ring nut See NOTE. Lower bracket pinch bolts Brake fluid reservoir cap stopper Front brake hose union bolts Front brake master cylinder Engine mounting Front mounting bolts...

  • Page 42: Lubrication Points And Lubricant Types, Engine Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Engine mounting bolts (rear) Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Clutch cover (crankcase mating surface) No.1215...

  • Page 43: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB202010 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal Sidestand pivoting point and metal-to-metal moving parts...

  • Page 44: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS OIL FLOW DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil pipe 5 Oil strainer 6 Oil pump 2-25...

  • Page 45

    SPEC OIL FLOW DIAGRAMS 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter 4 Oil cooler 2-26...

  • Page 46

    SPEC OIL FLOW DIAGRAMS 1 Cylinder head 2 Crankshaft 2-27...

  • Page 47

    SPEC OIL FLOW DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 driveaxle 2-28...

  • Page 48: Coolant Flow Diagrams

    SPEC COOLANT FLOW DIAGRAMS COOLANT FLOW DIAGRAMS 1 Radiator 2 Radiator fan 3 Oil cooler 2-29...

  • Page 49

    SPEC COOLANT FLOW DIAGRAMS 1 Thermostat housing 2 Thermostat 3 Radiator 4 Therm 2-30...

  • Page 50

    SPEC COOLANT FLOW DIAGRAMS 1 Radiator cap 2 Radiator 3 Oil cooler 4 Water jacket joint 5 Water pump 2-31...

  • Page 51

    SPEC COOLANT FLOW DIAGRAMS 1 Radiator 2 Radiator fan switch 3 Radiator fan 2-32...

  • Page 52: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Throttle cables A Install the headlight relays onto the headlight housing bridge. 2 Front brake hose B Route the headlight lead through the plastic guide. 3 Clutch cable C Route the right handlebar switch lead in front of the front fork inner 4 Starter cable tube.

  • Page 53

    SPEC CABLE ROUTING G Fasten the throttle cables and starter cable with a band. Locate the end of band to forward. H Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie.

  • Page 54

    SPEC CABLE ROUTING 1 Fuel pump lead E Route the clutch cable through the guide on the ra- 2 Pickup coil lead diator. 3 Clutch cable F Fasten the clutch cable to the coolant hose protec- 4 Rear brake switch lead tor with a plastic band.

  • Page 55

    SPEC CABLE ROUTING 1 AC magneto lead C Do not touch the wireharness with the throttle cable 2 Sidestand switch lead pully. 3 Oil lever switch lead Route the wireharness under the radiator hose. 4 Reservoir tank breather hose D Route the wireharness through the slit of rear fender. 5 Fuel tank breather hose E Route the rear turn signal light leads (left and right) 6 Fuel tank drain hose...

  • Page 56

    SPEC CABLE ROUTING 1 Throttle cable Battery negative (–) cable 2 Handlebar switch lead (right) Fuel sender connector 3 Coolant reservoir breather hose Coolant reservoir tank cap 4 Carburetor idle adjusting cable Crankcase breather hose 5 Pickup coil connector Therm unit lead 6 Neutral switch connector Fan motor lead connector 7 Rear brake switch connector...

  • Page 57

    SPEC CABLE ROUTING C Fasten the handlebar switch leads (left and right) H Route the starter motor lead under the wirehar- and main switch lead with a band. ness. D Route the ignition coil lead and handlebar switch I Fasten the starter motor to the rear fender with a leads (left and right) over the heat protection plate.

  • Page 58

    SPEC CABLE ROUTING P Insert the projection of the band (wireharness) into U Route the starter cable and wireharness through the hole of the frame. the guide of the heat protection plate. Q 1: Speed sensor connector V Route the fan motor lead under the throttle cable 2: AC magneto connector and then, fasten the fan motor lead and throttle 3: Sidestand switch connector...

  • Page 59

    CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .

  • Page 60

    ADJUSTING THE REAR BRAKE LIGHT SWITCH ....3-42 CHECKING THE BRAKE HOSES ......3-43 BLEEDING THE HYDRAULIC BRAKE SYSTEM .

  • Page 61: Periodic Checks And Adjustments, Periodic Maintenance And Lubrication Intervals

    INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.

  • Page 62

    * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. NOTE: S The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 63

    RIDER AND PASSENGER SEATS EB302000 RIDER AND PASSENGER SEATS 7Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the rider and passenger Remove the parts in the order listed. seats Passenger seat Rider seat For installation, reverse the removal procedure.

  • Page 64: Fuel Tank

    FUEL TANK FUEL TANK 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed Rider seat Refer to “SEATS”. Bolt Bolts Fuel sender coupler...

  • Page 65

    COWLINGS COWLINGS 5 Nm (0.5 mSkg) 5 Nm (0.5 mSkg) Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed Rider and passenger seats Refer to “SEATS”. Rear cowling Bottom cowling (left) Bottom cowling (right) Front cowling inner panel (left) Front cowling inner panel (right) Side cowling inner panel (left) Side cowling inner panel (right)

  • Page 66

    COWLINGS COWLINGS 5 Nm (0.5 mSkg) 5 Nm (0.5 mSkg) Order Job/Part Q’ty Remarks Left side cowling Right side cowling Windshield Rear view mirror Front cowling For installation, reverse the removal procedure.

  • Page 67

    COWLINGS REMOVAL 1. Remove: S rear cowling S side cowlings NOTE: To remove the quick fastener, turn its center to 90_ with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S side cowlings S rear cowling NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver.

  • Page 68

    AIR FILTER CASE AND IGNITION COILS AIR FILTER CASE AND IGNITION COILS Order Job/Part Q’ty Remarks Removing the air filter case and Remove the parts in the order listed. ignition coils Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK”. Front cowling inner panel (left) Refer to “COWLINGS”.

  • Page 69

    AIR FILTER CASE AND IGNITION COILS Order Job/Part Q’ty Remarks Heat protector plate Ignition coil coupler Ignition coil For installation, reverse the removal procedure.

  • Page 70

    AIR FILTER CASE AND IGNITION COIL PLATE REMOVAL 1. Remove: S heat protector plate NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: S heat protector plate NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the rubber baffle and push the...

  • Page 71: Adjusting The Valve Clearance

    ADJUSTING THE VALVE CLEARANCE EB303001 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

  • Page 72

    ADJUSTING THE VALVE CLEARANCE 4. Measure: S valve clearance Out of specification ! Adjust Valve clearance (cold) Intake valve 0.11 0.20 mm Exhaust valve 0.21 0.30 mm a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the pickup coil rotor with the crankcase mating surface b .

  • Page 73: Adjusting The Valve Clearance

    ADJUSTING THE VALVE CLEARANCE 5. Remove: S timing chain tensioner S timing chain guide (exhaust side) S camshaft cap S timing chain (from the camshaft sprockets) S intake camshaft S exhaust camshaft NOTE: S Refer to “CAMSHAFTS” in chapter 4. S When removing the timing chain from cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase.

  • Page 74

    ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm) Rounded value = 150 d.

  • Page 75

    ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE ORIGINAL VALVE PAD NUMBER MEASURED 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 VALVE CLEARANCE 0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225...

  • Page 76

    ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS g. Measure the valve clearance again. h. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained. 7. Install: S all removed parts NOTE: For installation, reverse the removal procedure.

  • Page 77

    SYNCHRONIZING THE CARBURETORS 3. Remove: S hose 1 4. Install: S vacuum gauge attachments (into the bolt holes) S vacuum gauge 1 (onto the vacuum gauge attachments) S engine tachometer 2 (onto the ignition coil of cylinder #1) Vacuum gauge 90890-03094 Vacuum gauge attachment 90890-03060...

  • Page 78

    SYNCHRONIZING THE CARBURETORS/ ADJUSTING THE ENGINE IDLING SPEED NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in ei- ther direction until both gauges read the same.

  • Page 79

    ADJUSTING THE ENGINE IDLING SPEED 2. Remove: S air filter case S quick fasteners 1 S band 2 Refer to “AIR FILTER CASE AND IGNITION COILS”. 3. Install: S engine tachometer (onto the ignition coil of cylinder #1) Engine tachometer 90793-80009 4.

  • Page 80

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 7. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 8 mm EB303031 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE:...

  • Page 81

    ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: S throttle cable free play NOTE: When the throttle is opened, the accelerator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.

  • Page 82

    CHECKING THE SPARK PLUGS EB303040 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S rider seat S fuel tank Refer to “SEATS” and “FUEL TANK”. S air filter case S heat protector plate Refer to “AIR FILTER CASE AND IGNITION COILS”.

  • Page 83

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 5. Check: S electrodes 1 Damage/wear ! Replace the spark plug. S insulator 2 Abnormal color ! Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: S spark plug (with a spark plug cleaner or wire brush) 7.

  • Page 84

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 2. Install: S timing light 1 S engine tachometer (onto the ignition coil of cylinder #1) Timing light 90890-03141 Engine tachometer 90793-80009 3. Check: S ignition timing a. Start the engine, warm it up for several min- utes, and then let it run at the specified en- gine idling speed.

  • Page 85

    MEASURING THE COMPRESSION PRESSURE 4. Remove: S spark plug CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: S compression gauge 1 Compression gauge 90890-03081...

  • Page 86

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. Carbon deposits ! Eliminate. d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again.

  • Page 87

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL Recommended oil Refer to the chart for the engine oil grade which is best suited for cer- tain atmospheric temperatures. API standard SE or higher grade (Non-Friction modified) ACEA standard G4 or G5 CAUTION: S Engine oil also lubricates the clutch and the wrong oil types or additives could...

  • Page 88

    CHANGING THE ENGINE OIL 6. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01426 b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil.

  • Page 89

    CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE 13. Check: S engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”. 14. Install: S bottom cowling Refer to “COWLINGS”. EB303090 MEASURING THE ENGINE OIL PRESSURE 1. Check: S engine oil level Below the minimum level mark ! Add the recommended engine oil to the proper level.

  • Page 90

    MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH CABLE FREE PLAY NOTE: Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity, the oil pressure may fluctuate when measuring. The following data should be used only as a reference when measuring the engine oil pressure.

  • Page 91

    CLEANING THE AIR FILTER ELEMENT/ ADJUSTING THE CLUTCH CABLE FREE PLAY EB303130 CLEANING THE AIR FILTER ELEMENT 1. Remove: S fuel tank Refer to “FUEL TANK”. S air filter case cover 1 S air filter element 2. Clean: S air filter element Use solvent to clean the air filter element.

  • Page 92

    CHECKING THE CARBURETOR JOINTS/ CHECKING THE FUEL HOSES AND FUEL FILTER/ EB303171 CHECKING THE CARBURETOR JOINTS The following procedure applies to all of the car- buretor joints and intake manifolds. 1. Remove: S carburetor assembly Refer to “CARBURETORS” in chapter 6. 2.

  • Page 93

    CHECKING THE EXHAUST SYSTEM/ CLEANING THE AIR INTAKE SYSTEM EB303190 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: S fuel tank Refer to “FUEL TANK”. 2. Check: S crankcase breather hose 1 Cranks/damage ! Replace. Loose connection ! Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly.

  • Page 94

    CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 2. Check: S crankcase breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly. 3. Install: S fuel tank Refer to “FUEL TANK”.

  • Page 95

    CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM EB303220 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level...

  • Page 96

    CHANGING THE COOLANT EB303240 CHANGING THE COOLANT 1. Remove: S bottom cowling S left side cowling Refer to “COWLINGS”. S reservoir hose clamps 1 2. Remove: S coolant reservoir bolts 2 S coolant reservoir cap 3 NOTE: When draining the coolant from the coolant res- ervoir, be sure to tilt the reservoir so that coolant cannot flow through the coolant reservoir breather hose 4 .

  • Page 97

    CHANGING THE COOLANT 6. Remove: S coolant drain bolt 1 (along with the copper washer) 7. Drain: S coolant 8. Check: S coper washer 1 S coolant drain bolt 2 Damage ! Replace 9. Install: S coolant drain bolt 7 Nm (0.7 mSkg) 10.

  • Page 98

    CHANGING THE COOLANT CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. S Use only distilled water. However, soft wa- ter may be used if distilled water is not available.

  • Page 99

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.

  • Page 100

    ADJUSTING THE REAR BRAKE 2. Adjust: S brake pedal position a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is ob- tained. Direction Brake pedal is raised. Direction Brake pedal is lowered.

  • Page 101

    CHECKING THE BRAKE FLUID LEVEL EB304020 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

  • Page 102

    CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EB304032 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S front brake pad S rear brake pad Brake pad wear limit a Wear limit reached ! Replace the brake pads as a set.

  • Page 103

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EB304062 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: S brake hose 1 Cracks/damage/wear ! Replace. 2. Check: S brake hose clamp Loose ! Tighten the clamp bolt.

  • Page 104

    BLEEDING THE HYDRAULIC BRAKE SYSTEM 5. Bleed: S hydraulic brake system a. Fill the brake fluid reservoir to the proper lev- el with the recommended brake fluid. b. Install the brake fluid reservoir diaphragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2 .

  • Page 105

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EB304081 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed. 1. Measure: S incorrect ! Adjust. The top of sift pedal should be aligned with the lower part of the bracket.

  • Page 106

    ADJUSTING THE DRIVE CHAIN SLACK 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Measure: S drive chain slack a Out of specification ! Adjust. Drive chain slack 50 mm 4. Adjust: S drive chain slack a.

  • Page 107

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.

  • Page 108

    CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: S upper bracket bolts 1 S front brake fluid reservoir bolt 2 4. Loosen: S upper bracket pinch bolts 1 S handlebar pinch bolts 2 S washer 3 5. Remove: S handlebars (from the upper bracket) 6.

  • Page 109: Checking And Adjusting The Steering Head

    CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 9 Nm (0.9 mSkg) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.

  • Page 110

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Hold the spring gauge at a 90_ angle from the handlebar, pull the spring gauge, and re- cord the measurement when the handlebar starts to turn. Steering head tension 500 g e.

  • Page 111

    ADJUSTING THE FRONT FORK LEGS EB304153 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over.

  • Page 112

    ADJUSTING THE FRONT FORK LEGS Rebound damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or Rebound damping is Direction increased (suspension is harder). Rebound damping is Direction decreased (suspension is...

  • Page 113

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EB304162 ADJUSTING THE REAR SHOCK ABSORB- ER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.

  • Page 114

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or Rebound damping is Direction increased (suspension is harder).

  • Page 115

    CHECKING THE TIRES EB304170 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification ! Regulate. WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.

  • Page 116

    Tubeless wheel tire S After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee con-...

  • Page 117

    CHECKING THE TIRES/CHECKING THE WHEELS Rear tire Manufacturer Size Model 180/55 ZR17 BRIDGESTONE BT56RSE (73W) 180/55 ZR17 DUNLOP D207SN (73W) WARNING After mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim.

  • Page 118

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION EB304200 CHECKING LUBRICATING CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its move- ment.

  • Page 119: Electrical System

    CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.

  • Page 120

    CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.

  • Page 121

    CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20_C S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger Ambient temperature...

  • Page 122

    CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger Charger Measure the open-circuit NOTE: Ammeter voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- NOTE: meter to the battery and Set the charging voltage to 16...

  • Page 123

    CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger Measure the open-circuit NOTE: voltage prior to charging. Leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Connect a charger and am- meter to the battery and start charging.

  • Page 124

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 8. Check: S battery terminals Dirt ! Clean with a wire brush.

  • Page 125

    CHECKING THE FUSES 3. Replace: S blown fuse a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage. c. Set the main switch to “ON” and verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit.

  • Page 126

    REPLACING THE HEADLIGHT BULBS EB305051 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: S headlight coupler 1 S headlight bulb holder cover 2 2. Detach: S headlight bulb holder 1 3. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot,...

  • Page 127

    ADJUSTING THE HEADLIGHT BEAMS EB305061 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or Direction Headlight beams is raised. Headlight beams is low- Direction ered.

  • Page 128

    CLUTCH ........... 4-46 REMOVING THE CLUTCH .

  • Page 129

    ENGINE EAS00190 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg) 70 Nm (7.0 mSkg) Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. Reserve tank Refer to “CHANGING THE COOLANT” Locknut Shift rod Shift arm Drive sprocket cover Lock washer...

  • Page 130

    ENGINE EXHAUST ASSEMBLY 38 Nm (3.8 mSkg) 20 Nm (2.0 mSkg) 20 Nm (2.0 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the exhaust assembly Remove the parts in the order listed. Bottom cowling and side cowlings Refer to “COWLINGS” in chapter 3 Coolant Drain.

  • Page 131

    ENGINE LEADS AND HOSES Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Fuel tank Refer to “FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE AND IGNITION COILS” in chapter 3. Carburetor assembly and joints Refer to “CARBURETORS”...

  • Page 132

    ENGINE Order Job/Part Q’ty Remarks Battery negative lead CAUTION: Battery positive lead First, disconect the negative lead, then the positive lead. Startor coil assembly coupler Pickup coil coupler Engine earth Clutch wire and holder Crankcase breather hose Separator For connecting reverse the discomecting procedure.

  • Page 133

    ENGINE ENGINE 24 Nm (2.4 mSkg) 55 Nm (5.5 mSkg) 45 Nm (4.5 mSkg) 38 Nm (3.8 mSkg) 13 Nm (1.3 mSkg) 55 Nm (5.5 mSkg) 24 Nm (2.4 mSkg) 7 Nm (0.7 mSkg) Order Job/Part Q’ty Remarks Removing the engine Remove The Parts In The Order Listed.

  • Page 134

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: S engine mounting adjust bolts 1 S rear mounting bolts 2 S self-locking nuts 3 S collars 4 S front mounting bolts 5 S collars 6 S button head bolts 7 S pinch bolts 8 NOTE: S Lubricate the rear mounting bolt threads with lithium soap base grease.

  • Page 135

    CAMSHAFTS EAS00194 CAMSHAFTS CYLINDER HEAD COVER 13 Nm (1.3 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Carburetor assembly Refer to “CARBURETORS” in chapter 6. Radiator assembly Refer to “RADIATOR”...

  • Page 136

    CAMSHAFTS EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Pickup coil rotor cover Refer to “PICKUP COIL AND PICK UP COIL COVER”.

  • Page 137

    CAMSHAFTS 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) 24 Nm (2.4 mSkg) Order Job/Part Q’ty Remarks Intake camshaft sproket Refer to “INSTALLING THE Exhaust camshaft sproket CAMSHAFTS”. Timing chain guide (intake side) For installation reverse the removal procedure.

  • Page 138

    CAMSHAFTS EAS00198 REMOVING THE CAMSHAFTS 1. Align: S TDC mark on the pickup coil rotor (with the crankcase mating surface) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the mark a on the pickup coil rotor with the crankcase mating surface NOTE: TDC on the compression stroke can be found...

  • Page 139

    CAMSHAFTS EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft. 2. Measure: S camshaft lobe dimensions a and b Out of specification ! Replace the cam- shaft. Camshaft lobe dimensions limit Intake camshaft a 33.0 mm b 25.09 mm Exhaust camshaft...

  • Page 140

    CAMSHAFTS NOTE: S Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. S Do not turn the camshaft when measuring the camshaft-journal-to-camshaft-cap clearance with the Plastigauge . Camshaft cap bolt 10 Nm (1.0 mSkg) d.

  • Page 141

    CAMSHAFTS 1. Check: S camshaft sprocket More than 1/4 tooth wear a ! Replace the camshaft sprockets and the timing chain as a set. a 1 / 4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 2. Check: S timing chain guide (exhaust side) 1 S timing chain guide (intake side) 2 S timing chain guide (top side) 3...

  • Page 142

    CAMSHAFTS INSTALLING THE CAMSHAFTS 1. Install: S timing chain guide (intake side) S timing chain guide (exhaust side) 2. Install: S intake camshaft sprocket 24 Nm (2.4 mSkg) S exhaust camshaft sprocket 24 Nm (2.4 mSkg) NOTE: Cam sprocket timing mark is outside and align the cam sprocket hole to camshaft hole.

  • Page 143

    CAMSHAFTS NOTE: Make sure that the camshaft sprocket timing marks c are aligned with the cylinder head edge d Out of alignment ! Reinstall. e. Remove the wire from the timing chain. 4. Install: S timing chain tensioner a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand.

  • Page 144

    CAMSHAFTS 6. Check: S TDC mark a Make sure that the TDC mark is aligned with the crankcase mating surface b . S camshaft sprocket timing mark c Make sure that the camshaft sprocket timing mark is aligned with the cylinder head edge Out of alignment ! Adjust.

  • Page 145: Cylinder Head

    CYLINDER HEAD EAS00220 CYLINDER HEAD 51 Nm (5.1 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Intake and exhaust camshafts Refer to “CAMSHAFTS”. Water hose Disconnect Temp senser lead Disconnect Front mounting bolt Refer to “ENGINE”.

  • Page 146

    CYLINDER HEAD EAS00223 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts S cylinder head NOTE: Loosen each bolt and nut 1/2 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts and nuts are fully loosened, remove them.

  • Page 147

    CYLINDER HEAD d. Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. EAS00223 INSTALLING THE CYLINDER HEAD 1.

  • Page 148: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Refer to “REMOVING/INSTALLING Intake valve spring outer...

  • Page 149

    VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Refer to “REMOVING/INSTALLING THE Exhaust valve upper spring seat VALVES”. Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure.

  • Page 150

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1.

  • Page 151

    VALVES AND VALVE SPRINGS 3. Remove: S valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor 90890-04019 Attachment 90890-04114 4. Remove: S upper spring seat 1 S valve spring outer 2 S valve spring inner (intake only) 3 S valve 4...

  • Page 152

    VALVES AND VALVE SPRINGS 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_C) in an oven. a. Remove the valve guide with a valve guide remover 1 .

  • Page 153

    VALVES AND VALVE SPRINGS 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 0.6 mm 0.8 mm <LIMIT>: 0.5mm 6. Measure: S valve stem runout Out of specification ! Replace the valve. NOTE: S When installing a new valve, always replace the valve guide.

  • Page 154

    VALVES AND VALVE SPRINGS a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impres- sion.

  • Page 155

    VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g.

  • Page 156

    VALVES AND VALVE SPRINGS 2. Measure: S compressed spring force a Out of specification ! Replace the valve spring. b Installed length Compressed spring force (installed) Intake valve spring inner 8.0 kg at 30.0 mm Intake valve spring outer 11.6 13.4 kg at 32.5 mm Exhaust valve spring 16.3...

  • Page 157

    VALVES AND VALVE SPRINGS 3. Install: S lower spring seat 6 S oil seal 5 S valve 4 S valve spring inner (intake only) 3 S valve spring outer 2 S upper spring seat 1 (into the cylinder head) NOTE: S Make sure that each valve is installed in its original place.

  • Page 158

    VALVES AND VALVE SPRINGS 6. Lubricate: S valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 7. Install: S valve pad S valve lifter NOTE: S The valve lifter must move smoothly when ro- tated with a finger. S Each valve lifter and valve pad must be rein- stalled in its original position.

  • Page 159

    PICKUP COIL AND PICKUP COIL ROTOR PICKUP COIL AND PICKUP COIL ROTOR 10 Nm (1.0 mSkg) 15 Nm (1.5 mSkg) 35 Nm (3.5 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the pickup coil and Remove the parts in the order listed. pickup coil rotor Riders seat and fuel tank Refer to “SEATS”...

  • Page 160

    PICKUP COIL AND PICKUP COIL ROTOR 10 Nm (1.0 mSkg) 15 Nm (1.5 mSkg) 35 Nm (3.5 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Clutch cable Clutch cable holder Pickup coil coupler Disconnect Pickup coil cover Pickup coil cover gasket Refer to “REMOVING/INSTALLING Dowel pin THE PICKUP COIL ROTOR”.

  • Page 161

    PICKUP COIL AND PICKUP ROTOR REMOVING THE PICKUP COIL ROTOR 1. Remove: S clutch cable holder 1 S pickup coil cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 162

    3 , tighten the pickup coil rotor bolt. Sheave holder 90890-01701 3. Apply: S sealant (onto the pickup coil lead grommet) Yamaha bond No.1215 90890-85505 4. Install: S pickup coil cover S clutch cable holder NOTE: S When installing the pickup coil cover, align the timing chain guide (intake side) pin 1 of the with the hole 2 in the pickup coil cover.

  • Page 163: Starter Clutch And Generator

    STARTER CLUTCH AND GENERATOR EAS00341 STARTER CLUTCH AND GENERATOR 65 Nm (6.5 mSkg) 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the starter clutch and gener- Remove the parts in the order listed. ator Riders seat and fuel tank Refer to “SEATS”...

  • Page 164

    STARTER CLUTCH AND GENERATOR 65 Nm (6.5 mSkg) 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Generator rotor bolt Refer to “REMOVING/INSTALLING Plain washer THE GENERATOR”. Generator rotor Starter one-way assy Idler gear shaft Idler hear Starter clutch gear For installation reverse the removal proceduer.

  • Page 165

    STARTER CLUTCH AND GENERATOR EAS00346 REMOVING THE GENERATOR 1. Remove: S generator rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

  • Page 166

    STARTER CLUTCH AND GENERATOR EAS00345 REMOVING THE STARTER CLUTCH 1. Remove: S Generator S Starter one-way assy 1 S Idler gear shaft 2 S Idler gear 3 S Starter clutch gear 4 EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S Starter one-way assy Damage/wear ! Replace.

  • Page 167

    Do not allow the sheave holder to touch the pro- jection on the generator rotor. Sheave holder 90890-01701 3. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No.1215 90890-85505 4. Install: S stator coil 5. Install: S generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern.

  • Page 168: Shift Shaft

    SHIFT SHAFT EAS00327 SHIFT SHAFT 22 Nm (2.2 mSkg) Order Job/Part Q’ty Remarks Removing the shift shaft Remove the parts in the order listed. Coolant reserver Drain. Refer to “CHNGING THE COOLANT” in chapter 3. Drive sprocket cover, sift rod and sift Refer to “ENGINE”.

  • Page 169

    SHIFT SHAFT 22 Nm (2.2 mSkg) Order Job/Part Q’ty Remarks Shift shaft spring Collar Stopper lever spring Circrip Washer Stopper lever Collar Refer to “INSTALLING THE SHIFT Washer SHAFT”. Shift shaft spring stopper For installation reverse the removal procedure. 4-41...

  • Page 170

    SHIFT SHAFT EAS00329 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift shaft spring 2 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.

  • Page 171

    CLUTCH EB405000 CLUTCH CLUTCH COVER 12 Nm (1.2 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Bottom cowing and right side cowling Refer to “COWLINGS” in chapter 3. Engine oil Drain.

  • Page 172

    CLUTCH 12 Nm (1.2 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Clutch cover Refer to “REMOVING/INSTALLING THE CLUTCH”. Clutch cover gasket Dowel pin For installation reverse the removal procedure. 4-44...

  • Page 173

    CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch cover Disassemble the parts in the order listed. assembly Circlip Plain washer Pull lever Refer to “INSTALLING THE CLUTCH”. Pull lever spring Oil seal Bearing For assembly, reverse the disassembly procedure. 4-45...

  • Page 174

    CLUTCH CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spling Pressure plate Pull rod Refer to “INSTALLING THE CLUTCH”. Bearing Friction plate Clutch plate Clutch plate Refer to“REMOVING/INSTALLING Clutch boss nut...

  • Page 175

    CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Thrust plate For installation, reverse the removal procedure. 4-47...

  • Page 176

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Remove: S clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Pressure plate S Fricttion and clutch plates 2.

  • Page 177

    CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. 2. Measure: S clutch plate warpage (with a surface plate and thickness gauge Out of specification ! Replace the clutch plates as a set.

  • Page 178

    CLUTCH EAS00285 CHECKING THE CLUTCH BOSS 1. Check: S clutch boss splines Damage/pitting/wear ! Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause er- ratic clutch operation. EAS00286 CHECKING THE PRESSURE PLATE 1. Check: S pressure plate 1 Cracks/damage ! Replace.

  • Page 179

    CLUTCH EAS00296 INSTALLING THE CLUTCH 1. Install: S thrust plate 1 S clutch boss 2 2. Install: S lock washer 3 S clutch boss nut 4 70 Nm (7.0 mSkg) NOTE: While holding the clutch boss 2 with the clutch holding tool 5 , tighten the clutch boss nut.

  • Page 180

    CLUTCH 7. Install: S pressure plate S clutch springs S clutch spring bolts 8 Nm (0.8 mSkg) NOTE: Tighten the clutch spring bolts in stages and in a criss cross pattern. 8. Install: S clutch cover 12 Nm (1.2 mSkg) NOTE: S When installing the clutch cover, push the pull lever and check that the punch mark a on the...

  • Page 181: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 10 Nm (1.0 mSkg) 43 Nm 12 Nm (1.2 mSkg) (4.3 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed. Engine oil Drain.

  • Page 182

    OIL PAN AND OIL PUMP 10 Nm (1.0 mSkg) 43 Nm 12 Nm (1.2 mSkg) (4.3 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Oil level switch lead holder Oil pan Refer to “REMOVEING/INSTALLING Oil pan gasket THE OIL PAN. Dowel pin Oil strainer Refer to “INSTALLING THE OIL...

  • Page 183

    OIL PAN AND OIL PUMP EB411010 OIL PUMP 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Disassemblying the oil pump Disassemble the parts in the order listed. assembly Oil pump rotor housing Dowel pin Oil pump inner rotor Oil pump outer rotor Dowel pin Washer Oil pump cover...

  • Page 184

    OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S oil pan gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

  • Page 185

    OIL PAN AND OIL PUMP 3. Check: S oil pump operation Unsmooth ! Repair or replace the defective part(-s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 S O-ring 4 Damage/wear ! Replace the defective part(-s).

  • Page 186

    OIL PAN AND OIL PUMP EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S impeller shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Check: S oil pump operation Refer to “CHECKING THE OIL PUMP”. EAS00376 INSTALLING THE OIL PUMP 1.

  • Page 187

    CRANKCASE CRANKCASE 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Starter clutch and generator Refer to “STARTER CLUTCH AND GENERATOR”. Shift shaft Refer to “SHIFT SHAFT”.

  • Page 188

    CRANKCASE 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Timing chain Oil pump drive chain guide Oil pump drive chain Lower crankcase Refer to “DISASSEMBLY/ASSEMBLY THE CRANKCASE”. Dowel pin For installation, reverse the removal procedure. 4-60...

  • Page 189

    CRANKCASE OIL BAFFLE PLATES AND OIL FILTER BOLT 80 Nm (8.0 mSkg) 12 Nm (1.2 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the oil baffle plates and Remove the parts in the order listed. oil filter bolt Transmission Refer to “TRANSMISSION”.

  • Page 190

    CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).

  • Page 191

    CRANKCASE EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: S upper crankcase S lower crankcase Cracks/damage ! Replace. S oil delivery passages Obstruction ! Blow out with compressed air.

  • Page 192

    2. Apply: S sealant (onto the crankcase mating surfaces and the groove a of the oil baffle plate) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings.

  • Page 193

    CRANKCASE 6. Install: S crankcase bolts NOTE: S Lubricate the bolt threads with engine oil. S Install a washer on bolts 1 X S Install a gasket on bolt S Not lubricate seal botts 18 12 S Tighten the bolts in the tightening sequence cast on the crankcase.

  • Page 194: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EAS00252 CONNECTING RODS AND PISTONS 15 Nm (1.5 mSkg)+90_ Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Lower crankcase Separate. Refer to “CRANKCASE”. Connecting rod cap Big end lower bearing Big end upper bearing Refer to “REMOVING/INSTALLING THE Piston pin clip...

  • Page 195

    CONNECTING RODS AND PISTONS 15 Nm (1.5 mSkg)+90_ Order Job/Part Q’ty Remarks Top ring Refer to “REMOVING/INSTALLING THE 2nd ring CONNECTING RODS AND PISTONS”. Oil ring For installation, reverse the removal procedure. 4-67...

  • Page 196

    CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: S connecting rod cap 1 S big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 197

    CONNECTING RODS AND PISTONS EAS00262 CHECKING THE CYLINDER AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Check: S piston wall S cylinder wall Vertical scratches ! Replace the crank- cases, and the piston and piston rings as a set.

  • Page 198

    CONNECTING RODS AND PISTONS e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.025 0.045 mm <Limit>: 0.07 mm f. If out of specification, replace the crank- cases, and the pistons and piston rings as a set.

  • Page 199

    CONNECTING RODS AND PISTONS 3. Measure: S piston ring end gap Out of specification ! Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring end gap Top ring 0.15...

  • Page 200

    CONNECTING RODS AND PISTONS 4. Calculate: S piston-pin-to-piston-pin-bore clearance Out of specification ! Replace the piston pin. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter Piston-pin-to-piston-pin-bore clearance 0.002 0.022 mm <Limit>: 0.072 mm CHECKING THE BIG END BEARINGS 1.

  • Page 201

    CONNECTING RODS AND PISTONS 1 on the crank- c. Put a piece of Plastigauge shaft pin. d. Assemble the connecting rod halves. NOTE: S Do not move the connecting rod or crankshaft until the clearance measurement has been completed. S Lubricate the bolt threads and nut seats with molybdenum disulfide grease.

  • Page 202

    CONNECTING RODS AND PISTONS 2. Select: S big end bearings (“P ” “P ”) NOTE: S The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. S “P ”...

  • Page 203

    CONNECTING RODS AND PISTONS 2. Install: S piston 1 (onto the respective connecting rod 2 ) S piston pin 3 S piston pi clip 4 NOTE: S Apply engine oil onto the piston pin. S Make sure that the “Y” mark a on the connect- ing rod faces left when the arrow mark b on the piston is pointing up.

  • Page 204

    CONNECTING RODS AND PISTONS 6. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: S big end bearings S connecting rod assembly (into the cylinder and onto the crankshaft pin).

  • Page 205

    CONNECTING RODS AND PISTONS b. Clean the connecting rod bolts and nuts. c. Tighten the connecting rod nuts. d. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 . e. Tighten the nut further to reach the specified angle (90_).

  • Page 206

    CRANKSHAFT EAS00381 CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase lower Separate. Refer to “CRANKCASE”. Connecting rods and pistons Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Refer to “REMOVING/INSTALLING Crankshaft journal lower bearing THE CRANKSHAFT”.

  • Page 207

    CRANKSHAFT EAS00387 REMOVING THE CRANKSHAFT 1. Remove: S crankshaft 1 S crankshaft journal upper bearings (from the upper / lower crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EAS00397 CHECKING THE CRANKSHAFT 1.

  • Page 208

    CRANKSHAFT a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case.

  • Page 209

    CRANKSHAFT g. Remove the lower crankcase and the crank- shaft journal lower bearings. h. Measure the compressed Plastigauge width c each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings. 2. Select: S crankshaft journal bearings (J NOTE: S The numbers stamped into the crankshaft web and the numbers stamped into the lower...

  • Page 210

    CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings (into the upper / lower crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.

  • Page 211

    TRANSMISSION EAS00419 TRANSMISSION 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the transmission Remove the parts in the order listed. Crankcase lower Separate. Refer to “CRANKCASE”. Shift shaft and stopper lever Refer to “SHIFT SHAFT”. Drive axle assembly Circlip Oil seal...

  • Page 212

    TRANSMISSION 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Spring Refer to “INSTALLING THE Shift fork “L” TRANSMISSION”. Shift fork “R” Refer to “REMOVING THE Shift drum assembly TRANSMISSION”. Shift fork “C” Main axle assembly For installation, reverse the removal procedure.

  • Page 213

    TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. assembly Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip 4-85...

  • Page 214

    TRANSMISSION Order Job/Part Q’ty Remarks Washer 5th pinion gear Collar Main axle Bearing housing Bearing For installation, reverse the removal procedure. 4-86...

  • Page 215

    TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear 4-87...

  • Page 216

    TRANSMISSION Order Job/Part Q’ty Remarks Collar Washer Circrip 6th wheel gear Circrip washer 2nd wheel gear Collar Collar Oil seal Bearing Circrip Drive axle For installation, reverse the removal procedure. 4-88...

  • Page 217

    TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: S drive axle assembly 2. Remove: S main axle assembly 1 (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing.

  • Page 218

    TRANSMISSION 3. Check: S shift fork movement (along the shift fork guide bar) Rough movement ! Replace the shift fork(-s) and shift fork guide bar as a set. EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum assembly.

  • Page 219

    TRANSMISSION 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(-s). 6. Check: S circlips Bends/damage/looseness ! Replace. INSTALLING THE TRANSMISSION 1.

  • Page 220

    COOL CHAPTER 5. COOLING SYSTEM RADIATOR ........... . CHECKING THE RADIATOR .

  • Page 221: Cooling System

    COOL RADIATOR COOLING SYSTEM RADIATOR 9 Nm (0.9 mSkg) 7 Nm (0.7 mSkg) 28 Nm (2.8 mSkg) Order Job/Part Q’ty Remarks Removeing the radiator Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3.

  • Page 222

    COOL RADIATOR 9 Nm (0.9 mSkg) 7 Nm (0.7 mSkg) 28 Nm (2.8 mSkg) Order Job/Part Q’ty Remarks Radiator inlet hose Disconnect. Oil cooler outlet hose Thermo switch coupler Disconnect. Radiator fan motor coupler Disconnect. Radiator Radiator fan For installation reverse the removal procedure.

  • Page 223

    COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.

  • Page 224

    COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. 3.

  • Page 225: Oil Cooler

    COOL OIL COOLER EAS00457 OIL COOLER 63 Nm (6.3 mSkg) Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Radiator assembly Refer to “RADIATOR”. Exaust pipe assembly Refer to “ENGINE” in chapter 4. Engine oil Drain.

  • Page 226

    COOL OIL COOLER 63 Nm (6.3 mSkg) Order Job/Part Q’ty Remarks Oil cooler inlet hose Water jacket joint Water jacket joint hose Water pump outlet pipe Water pump outlet hose Water pump inlet hose For installation, reverse the removal procedure.

  • Page 227

    COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: S oil cooler Cracks/damage ! Replace. 2. Check: S oil cooler inlet hose S oil cooler outlet hose Cracks/damage/wear ! Replace. 3. Check: S water jacket joint S water jacket joint inlet hose S water pump outlet hose Cracks/damage ! Replace.

  • Page 228

    COOL OIL COOLER 4. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. S crankcase (with the specified amount of the recom- mended engine oil) Refer to “CHANGING THE ENGINE OIL” in chapter 3.

  • Page 229

    COOL THERMOSTAT THERMOSTAT Order Job/Part Q’ty Remarks Removing the termostat Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEAT” and “FUEL TANK” in chapter 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Air filter case Refer to “AIRFILTER CASE AND IGNITION COILS”...

  • Page 230

    COOL THERMOSTAT Order Job/Part Q’ty Remarks Radiator inlet hose Carburator outlet hose Thermostat cover Refer to “INSTALLING THE Thermostat THERMOSTAT For installation, revers the removal procedure. 5-10...

  • Page 231

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 84_C ! Replace. Does not open at 71 a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.

  • Page 232

    COOL THERMOSTAT 3. Fill: S coolling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 4. Check: S cooling system Leaks ! Repair or replace any faulty part. 5. Measure: S radiator cap opening pressure Below the specified pressure ! Replace the radiator cap.

  • Page 233: Water Pump

    COOL WATER PUMP WATER PUMP 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the water pump assembly Remove the parts in the order listed. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Water pump inlet hose Water pump outlet hose Water pump hose Clutch wire and holder Water pump...

  • Page 234

    COOL WATER PUMP 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. assembly Water pump cover O-ring Impeller shaft (along with the impeller) Refer to “DISASSEMBLING/ Water pump seal ASSEMBLING THE WATER PUMP”. Oil seal Bearing Circlip...

  • Page 235

    COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: S water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: S oil seal 1 S circlip S bearing 2 NOTE:...

  • Page 236

    NOTE: S Install the water pump seal with the special tools. S Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Mechanical seal installer 90890-04078 4 Middle driven shaft bearing...

  • Page 237

    COOL WATER PUMP 4. Measure: S impeller shaft tilt Out of specification ! Repeat steps (3) and (4). CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. Max. impeller shaft tilt 0.15 mm 1 Straightedge 2 Impeller...

  • Page 238

    CARB CHAPTER 6. CARBURETORS CARBURETORS ..........CHECKING THE CARBURETORS .

  • Page 239

    CARB CARBURETORS EAS00481 CARBURETORS CARBURETORS Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Rider seat and fuel tank Refer to “Seats” and “FUEL TANK” in chapter 3. Air filter case and heat protector plate Refer to “AIR FILTER CASE AND IGNITION COILS”...

  • Page 240

    CARB CARBURETORS Order Job/Part Q’ty Remarks Therm bypass hose Carburetor joint clamp screw Throttle cable Carburetor assembly Carburetor joint Side cover For installation, reverse the removal procedure.

  • Page 241

    CARB CARBURETORS Order Job/Part Q’ty Remarks Separating the carburetors Remove the parts in the order listed. Starter plunger link Refer to “ASSEMBLING THE Connecting bolt CARBURETORS” Connecting bolt Hose joint Spring Refer to “ASSEMBLING THE CARBURETORS” Fuel feed pipe Fuel feed pipe Pipe Throttle stop screw Throttle position sensor...

  • Page 242

    CARB CARBURETORS Order Job/Part Q’ty Remarks Balance pipe Balance pipe bracket Throttle cable bracket Carburetor For installation, reverse the removal procedure...

  • Page 243

    CARB CARBURETORS Order Job/Part Q’ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. NOTE: The following procedure applies to all of the carburetors. Starter plunger Air funnel Vacuum chamber cover Piston valve spring Jet needle holder Jet needle kit Piston valve Refer to “ASSEMBLING THE Pilot screw...

  • Page 244

    CARB CARBURETORS Order Job/Part Q’ty Remarks Float Needle valve Main jet Main jet holder Pilot jet For assembly, reverse the disassembly procedure.

  • Page 245

    CARB CARBURETORS EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: S carburetor body S float chamber Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleum-based solvent.

  • Page 246

    CARB CARBURETORS 7. Check: S piston valve 1 Damage/scratches/wear! Replace. S piston valve diaphragm 2 Cracks/tears ! Replace. 8. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 Cracks/damage ! Replace. 9. Check: S jet needle kit 1 S main jet 2 S main jet holder 3...

  • Page 247

    CARB CARBURETORS 12. Check: S fuel hoses Cracks/damage/wear ! Replace. Obstruction ! Clean. Blow out the hoses with compressed air. EAS00490 ASSEMBLING THE CARBURETORS The following procedure applies to all of the car- buretors. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleumbased sol- vent.

  • Page 248

    CARB CARBURETORS 3. Install: S pipes S fuel feed pipes S vacuum chamber pipe S vacuum chamber air vent hose S springs S float chamber air vent hoses S hose joint S spacers S copper washer S connecting bolts NOTE: S Do not tighten the connecting bolts yet.

  • Page 249

    CARB CARBURETORS EAS00493 INSTALLING THE CARBURETORS 1. Adjust: S carburetor synchronization Refer to “SYNCHRONIZING THE CARBU- RETORS” in chapter 3. 2. Adjust: S engine idling speed Engine idling speed 1250 1350 r/min Refer to “ADJUSTING THE ENGINE ID- LING SPEED” in chapter 3. 3.

  • Page 250

    CARB CARBURETORS EAS00497 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust. Fuel level (below the mark on the body) 17.5 18.5 mm a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up.

  • Page 251

    CARB CARBURETORS EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: S throttle position sensor (installed on the carburetor) a. Disconnect the throttle position sensor cou- pler.

  • Page 252

    CARB CARBURETORS 2. Check: S throttle position sensor (removed from the carburetor) a. Disconnect the throttle position sensor cou- pler. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester ( 1k) to the throttle position sensor. Tester positive probe ! blue 1 Tester negative probe ! black/blue 2 d.

  • Page 253

    CARB CARBURETORS 3. Adjust: S throttle position sensor angle a. Set the main switch to “ON”. b. Disconnect the throttle position sensor cou- pler. c. Reconnect the throttle position sensor cou- pler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode.

  • Page 254

    CARB CARBURETORS EAS00504 CHECKING THE FUEL PUMP 1. Check: S fuel pump 1 a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Disconnect the fuel-pump-to-carburetor fuel hose 2 from the carburetor. c. Connect the fuel-tank-to-fuel-pump fuel hose to the fuel tank and then set the fuel cock to “ON”.

  • Page 255

    CARB CARBURETORS EAS00505 CHECKING THE FUEL COCK 1. Remove S fuel tank S fuel filter 1 S fuel cock 2 2. Check: S fuel cock Cracks/damage/wear ! Replace. 3. Check: S fuel cock strainer 1 (with compressed air) Dirt/obstruction ! Clean. Damage ! Replace.

  • Page 256

    CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS ......REMOVING THE FRONT WHEEL .

  • Page 257

    CHAS FRONT FORK ..........7-42 REMOVING THE FRONT FORK LEGS .

  • Page 258

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 mSkg) 72 Nm (7.2 mSkg) 20 Nm (2.0 mSkg) 40 Nm (4.0 mSkg) 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed.

  • Page 259

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seals (left and right) Wheel bearings (left and right) Spacer For assembly, reverse the disassembly procedure.

  • Page 260

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

  • Page 261

    CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: S radial wheel runout 1 S lateral wheel runout 2 Over the specified limits ! Replace. Front radial wheel runout 1.0 mm Front lateral wheel runout 0.5 mm 4. Check: S wheel bearings Front wheel turns roughly or is loose ! Re- place the wheel bearings.

  • Page 262

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00533 CHECKING THE BRAKE DISCS The following procedure applies to both of the brake discs. 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc.

  • Page 263: Front Wheel And Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS Brake disc bolt 18 Nm (1,8 mSkg) LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc.

  • Page 264

    CHAS FRONT WHEEL AND BRAKE DISCS 1. Remove: S balancing weight(-s) 2. Find: S front wheel’s heavy spot a. Place the front wheel on a suitable balancing stand. b. Spin the front wheel. c. When the front wheel stops, put an “X ”...

  • Page 265

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00550 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET REAR WHEEL 40 Nm (4.0 mSkg) 150 Nm (15 mSkg) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 266

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00556 BRAKE DISC AND REAR WHEEL SPROCKET 18 Nm (1.8 mSkg) 69 Nm (6.9 mSkg) Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel sprocket Brake disc Rear wheel sprocket...

  • Page 267

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Spacer Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 7-10...

  • Page 268

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 269

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 3. Measure: S radial wheel runout S lateral wheel runout Refer to “FRONT WHEEL”. Over the specified limits ! Replace. Max. radial wheel runout 1.0 mm Max. lateral wheel runout 0.5 mm EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1.

  • Page 270

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EAS00571 INSTALLING THE REAR WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2. Install: S rear wheel S brake caliper bracket S adjusting blocks S wheel axle S washer...

  • Page 271

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.

  • Page 272: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 6 Nm (0.6 mSkg) 27 Nm (2.7 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper bolts Brake pads Refer to “REPLACING THE REAR Brake pad shims...

  • Page 273

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.

  • Page 274

    CHAS FRONT AND REAR BRAKES 2. Remove: S brake pad clips 1 S brake pad pins 2 S brake pad spring 3 S brake pads (along with the brake pad shims) 3. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set.

  • Page 275

    CHAS FRONT AND REAR BRAKES 5. Install: S brake pad pins S brake pad clips S brake caliper bolts 40 Nm (4.0 mSkg) S brake hose holder bolt 6 Nm (0.6 mSkg) 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

  • Page 276

    CHAS FRONT AND REAR BRAKES 3. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.8 mm 4. Install: S brake pad shims (onto the brake pads) S brake pads NOTE: Always install new brake pads, brake pad...

  • Page 277

    CHAS FRONT AND REAR BRAKES 5. Install: S brake caliper bolts 40 Nm (4.0 mSkg) 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 278

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 30 Nm (3.0 mSkg) 13 Nm (1.3 mSkg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder and brake fluid reservoir Brake fluidBrake fluid reservoir Drain.

  • Page 279

    CHAS FRONT AND REAR BRAKES 30 Nm (3.0 mSkg) 13 Nm (1.3 mSkg) Order Job/Part Q’ty Remarks Brake hose Refer to “INSTALLING THE FRONT Brake master cylinder holder BRAKE MASTER SYLINDER”. Brake master cylinder Front brake switch For installation, reverse the removal procedure.

  • Page 280

    CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 7-23...

  • Page 281

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR 5 Nm (0.5 mSkg) 30 Nm (3.0mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder and brake fluid reservoir Brake fluid Drain.

  • Page 282

    CHAS FRONT AND REAR BRAKES EAS00587 16 Nm (1.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 7-25...

  • Page 283

    CHAS FRONT AND REAR BRAKES EAS00588 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hoses 3 S master cylinder holder 4 NOTE: To collect any remaining brake fluid, place a...

  • Page 284

    CHAS FRONT AND REAR BRAKES 2. Check: S brake master cylinder kit Damage/scratches/wear ! Replace. A Front B Rear 3. Check: S brake fluid reservoir 1 Cracks/damage ! Replace. S brake fluid reservoir diaphragm 2 Cracks/damage ! Replace. 4. Check: S brake hoses Cracks/damage/wear ! Replace.

  • Page 285

    CHAS FRONT AND REAR BRAKES 1. Install: S brake master cylinder 1 13 Nm (1.3 mSkg) S brake master cylinder holder NOTE: S Install the brake master cylinder holder with the “UP” mark facing up. S Align the end of the brake master cylinder holder with the punch mark a in the right han- dlebar.

  • Page 286

    CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

  • Page 287

    CHAS FRONT AND REAR BRAKES 2. Fill: S brake fluid reservoir Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system.

  • Page 288

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.

  • Page 289

    CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad...

  • Page 290

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 27 Nm (2.7 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Refer to “INSTALLING THE REAR Copper washer BRAKE CALIPERS”.

  • Page 291

    CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Brake pad Brake caliper piston Refer to “REMOVING THE REAR Brake caliper piston seal BRAKE CALIPERS”.

  • Page 292

    CHAS FRONT AND REAR BRAKES EAS00625 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before removing either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 S brake caliper 4...

  • Page 293

    CHAS FRONT AND REAR BRAKES EAS00628 REMOVING THE REAR BRAKE CALIPER NOTE: Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 294

    CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Every two years and Brake fluid whenever the brake is disassembled 1.

  • Page 295

    CHAS FRONT AND REAR BRAKES EAS00640 INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 296

    CHAS FRONT AND REAR BRAKES 4. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 297

    CHAS FRONT AND REAR BRAKES EAS00642 INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.

  • Page 298

    CHAS FRONT AND REAR BRAKES 2. Fill: S brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 299: Front Fork

    CHAS FRONT FORK FRONT FORK EAS00647 13 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 6 Nm (0.6mSkg) 6 Nm (0.6mSkg) Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. Front brake calipers The following procedure applies to both of the front fork legs.

  • Page 300

    CHAS FRONT FORK EB703002 23 Nm (2.3 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Washer Refer to “DISASSEMBLING/...

  • Page 301

    CHAS FRONT FORK 23 Nm (2.3 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Dust seal Oil seal clip Refer to “DISASSEMBLING/ Oil seal ASSEMBLING THE FRONT FORK Washer LEGS”. Outer tube bushing Inner tube Oil lock piece For assembly, reverse the disassembly procedure.

  • Page 302

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

  • Page 303

    CHAS FRONT FORK NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring com- pressor. WARNING The fork spring is compressed. f.

  • Page 304

    CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

  • Page 305

    2 until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: S inner tube’s outer surface Recommended lubricant Yamaha fork and suspension oil 01 or equivalent 7-48...

  • Page 306

    CHAS FRONT FORK 3. Tighten: S damper rod assembly bolt 40 Nm (4.0 mSkg) NOTE: While holding the damper rod with the damper rod holder 2 , tighten the damper rod assembly bolt. Damper rod holder 90890-01425 4. Install: S outer tube bushing 1 S washer 2 S oil seal 3 S oil seal clip 4...

  • Page 307

    (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 476 cm Recommended oil Yamaha fork and suspension oil 01 or equivalent CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.

  • Page 308

    CHAS FRONT FORK 12. Slowly stroke the inner tube 1 up and down to distribute the fork oil once more (1 stroke = about 100 mm). NOTE: Be careful not to stroke the inner tube over 100 mm as this will cause air to enter. If the inner tube is stroked more than 100 mm, repeat steps (12) and (13).

  • Page 309

    CHAS FRONT FORK c. Install the rod puller and adapter onto the damper rod. Rod puller 90890-01437 Adapter 90890-01436 d. Install the fork spring, washers and spacer. e. Press down on the spacer with the fork spring compressor 8 . f.

  • Page 310

    CHAS FRONT FORK 16. Install: S cap bolt (onto the inner tube) NOTE: Temporarily tighten the cap bolt. EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts.

  • Page 311

    CHAS HANDLEBARS EAS00665 HANDLEBARS 115 Nm (11.5 mSkg) 13 Nm (1.3 mSkg) 13 Nm (1.3 mSkg) 13 Nm (1.3 mSkg) 13 Nm (1.3 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the handlebars Remove the parts in the order listed. Left grip end Refer to “REMOVING/INSTALLING THE Handlebar grip...

  • Page 312

    CHAS HANDLEBARS 115 Nm (11.5 mSkg) 13 Nm (1.3 mSkg) 13 Nm (1.3 mSkg) 13 Nm (1.3 mSkg) 13 Nm (1.3 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Front brake switch connector Disconnect. Right handlebar switch Refer tp “INSTALLING THE Brake master cylinder holder HANDLEBARS”.

  • Page 313

    CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S grip end S handlebar grip S left handlebar switch S clutch lever holder NOTE: Blow compressed air between the left handle-...

  • Page 314

    CHAS HANDLEBARS EAS00674 INSTALLING THE HANDLEBARS 1. Install: S brake master cylinder holder 1 CAUTION: S Install the brake master cylinder holder with the “UP” mark facing up. S First, tighten the upper bolt, then the lower bolt. NOTE: S Align the mating surfaces of the brake master cylinder holder with the punch mark a in the right handlebar.

  • Page 315

    CHAS HANDLEBARS 4. Install: S left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the left handlebar. 5. Install: S handlebar grip S grip end a. Apply a thin coat of rubber adhesive onto the end of the left handlebar.

  • Page 316: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD LOWER BRACKET 13 Nm (1.3 mSkg) 115 Nm (11.5 mSkg) 13 Nm (1.3 mSkg) 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 1st. 17 Nm (1.7 mSkg) 2nd. 9 Nm (0.9 mSkg) Order Job/Part Q’ty Remarks Removing the lower bracket...

  • Page 317

    CHAS STEERING HEAD 13 Nm (1.3 mSkg) 115 Nm (11.5 mSkg) 13 Nm (1.3 mSkg) 23 Nm (2.3 mSkg) 23 Nm (2.3 mSkg) 1st. 17 Nm (1.7 mSkg) 2nd. 9 Nm (0.9 mSkg) Order Job/Part Q’ty Remarks Lower ring nut Refer to “CHECK AND ADJUSTING THE STEERING HEAD”...

  • Page 318

    CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S front fork legs S steering stem nut S upper bracket S ring nuts 1 (with the special tool 2 )

  • Page 319

    CHAS STEERING HEAD b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new dust seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearing balls and bearing races as a set.

  • Page 320

    CHAS STEERING HEAD 3. Install: S upper bracket S steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: S front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the upper and lower bracket pinch bolts, and handlebar pinch bolts. 5.

  • Page 321: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Rear wheel Refer to “REMOVING THE REAR WHEEL”.

  • Page 322

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.

  • Page 323

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 324

    CHAS REAR SHOCK ABSORBER ASSEMBLY CHECKING THE RELAY ARM AND CON- NECTING ARM 1. Check: S relay arm 1 S connecting arm 2 Damage/wear ! Replace. S bearings S oil seals Damage/pitting ! Replace. S spacers Damage/scratches ! Replace. EAS00698 INSTALLING THE REAR SHOCK ABSORB- ER ASSEMBLY 1.

  • Page 325: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 95 Nm (9.5 mSkg) 6 Nm (0.6 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order listed. chain Drive sprocket Refer to “ENGINE”...

  • Page 326

    CHAS SWINGARM AND DRIVE CHAIN 95 Nm (9.5 mSkg) 6 Nm (0.6 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Pivot shaft adjust bolt Refer to “REMOVING/INSTALLING THE SWINGARM”. Drive chain Dust cover Oil seal Bush Shim Drive chain guide Bush Left bearing Right bearing...

  • Page 327

    CHAS SWINGARM AND DRIVE CHAIN NOTE: Before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a tenlink section of the drive chain. EC573000 REMOVING THE SWINGARM 1. Remove: S Bolt (connecting rod) 1 S Connecting rod 2 NOTE: Remove the bolt while holding the swingarm.

  • Page 328

    CHAS SWINGARM AND DRIVE CHAIN EAS00703 CHECKING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 329

    CHAS SWINGARM AND DRIVE CHAIN 4. Check: S pivot shaft Roll the pivot shaft on a flat surface. Bends ! Replace. WARNING Do not attempt to straighten a bent pivot shaft. 5. Wash: S pivot shaft S pivot shaft adjust bolt S dust covers S spacer S bearings...

  • Page 330

    CHAS SWINGARM AND DRIVE CHAIN EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Max. ten-link drive chain section 149 mm NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension.

  • Page 331

    CHAS SWINGARM AND DRIVE CHAIN c. Remove the drive chain from the kerosine and completely dry it. CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 332

    CHAS SWINGARM AND DRIVE CHAIN EAS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacers S dust covers S pivot shaft Recommended lubricant Lithium soap base grease 2. Install: S swingarm S pivot shaft S washer S pivot shaft adjust bolt 1 S pivot shaft nut 95 Nm (9.5 mSkg) NOTE:...

  • Page 333

    ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS ........INSTRUMENT FUNCTIONS .

  • Page 334

    ELEC SIGNALING SYSTEM ......... . 8-35 CIRCUIT DIAGRAM .

  • Page 335

    ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS Wire harness Starter relay Oil level switch Main switch Main fuse Pickup coil Front brake light switch Oil level relay Radiator fan Plug top ignition coils Battery Horn Clutch switch Rectifier/ regulator Thermo unit Starting circuit cutoff relay Rear brake light switch Thermo switch...

  • Page 336: Instrument Functions

    ELEC INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS INDICATOR LIGHTS Turn indicator light “ ” This indicator flashes when the turn switch is moved to the left or right. Neutral indicator light “ ” This indicator comes on when the transmis- sion is in neutral. High beam indicator light “...

  • Page 337

    ELEC INSTRUMENT FUNCTIONS Coolant Display Conditions What to do temperature Symbol is on and 40_C Go ahead with riding. “LO” is displayed. Symbol is on and 41_C 117_C temperature is dis- Go ahead with riding. played. Stop the motorcycle and allow it to idle until the Symbol and tem- coolant temperature goes...

  • Page 338

    ELEC INSTRUMENT FUNCTIONS When the fuel level indicator light comes on the odometer display will automatically change to the fuel reserve trip meter mode “TRIP F” and start counting the distance traveled from that point. Push the “SELECT” button to change be- tween the fuel odometer, trip odometer and odometer modes in the following order: “TRIP F”...

  • Page 339

    ELEC SWITCHES EB801000 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1 .

  • Page 340: Checking The Switches

    ELEC CHECKING THE SWITCHES EB801010 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.

  • Page 341

    ELEC CHECKING THE SWITCHES Main switch Start switch Pass switch Front brake light switch Dimmer switch Rear brake light switch Turn signal switch Neutral switch Horn switch Fuse Clutch switch Sidestand switch Light switch (for Europe) Oil level switch Engine stop switch *: for AUS...

  • Page 342: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both.

  • Page 343

    ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: S Be sure to hold the socket firmly when re- moving the bulb.

  • Page 344

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...

  • Page 345

    ELEC IGNITION SYSTEM EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Battery Main fuse Starting circuit cutoff relay Sidestand switch CDI unit Ignition coil #1 Ignition coil #2 Ignition coil #3 Ignition coil #4 Spark plugs Pick up coil Neutral switch Ignition fuse Engine stop switch Diode 2...

  • Page 346: Troubleshooting

    ELEC IGNITION SYSTEM EB802011 EB802401 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING THE spark or intermittent spark). BATTERY” in chapter 3. Check: Min. open-circuit voltage 1.

  • Page 347

    ELEC IGNITION SYSTEM EB802405 EB802409 4. Ignition spark gap 6. Ignition coil resistance The following procedure applies to all of the The following procedure applies to all of the spark plugs. ignition coils. S Disconnect the spark plug cap from the spark S Disconnect the ignition coil connectors from plug.

  • Page 348

    ELEC IGNITION SYSTEM EB802410 EB802411 7. Pickup coil resistance 8. Main switch S Disconnect the pickup coil coupler from the S Check the main switch for continuity. wire harness. Refer to “CHECKING THE SWITCHES”. S Connect the pocket tester ( S Is the main switch OK? 100) to the pickup coil terminal.

  • Page 349

    ELEC IGNITION SYSTEM EB802415 EB802416 13. Wiring 12. Starting circuit cutoff relay S Check the entire ignition system’s wiring. S Remove the relay unit from the wire harness. S Connect the pocket tester ( Refer to “CIRCUIT DIAGRAM”. 1) to the relay S Is the ignition system’s wiring properly con- terminals as shown.

  • Page 350: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Main fuse Starter relay Starter motor Starting circuit cutoff relay Sidestand switch Neutral switch Clutch switch Ignition fuse Engine stop switch Start switch Diode 1 8-16...

  • Page 351

    ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT CUTOFF SYSTEM OP- ERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: S The transmission is in neutral (the neutral switch is closed).

  • Page 352

    ELEC ELECTRIC STARTING SYSTEM EB803020 EB802401 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. main and ignition fuses Open-circuit voltage 2.

  • Page 353

    ELEC ELECTRIC STARTING SYSTEM EB803402 EB803403 4. Starting circuit cutoff relay 5. DIODE S Disconnect the relay from the coupler. S Disconnect the relay from the coupler. S Connect the pocket tester ( S Connect the pocket tester ( 1) and bat- 1) to the relay tery (12 V) to the relay terminals as shown.

  • Page 354

    ELEC ELECTRIC STARTING SYSTEM EB803404 EB802412 6. Starter relay 8. Engine stop switch S Disconnect the starter relay from the coupler. S Check the engine stop switch for continuity. S Connect the pocket tester ( 1) and bat- Refer to “CHECKING THE SWITCHES”. S Is the engine stop switch OK? tery (12 V) to the starter relay coupler as shown.

  • Page 355

    ELEC ELECTRIC STARTING SYSTEM EB8022414 11. Sidestand switch S Check the sidestand switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the sidestand switch OK? Replace the sidestand switch. EB803405 12. Clutch switch S Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”.

  • Page 356: Starter Motor

    ELEC STARTER MOTOR EAS00767 STARTER MOTOR 5Nm (0.5mSkg) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Rider seat Refer to “SEATS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Carburetors Refer to “CARBURETORS”...

  • Page 357

    ELEC STARTER MOTOR 5Nm (0.5mSkg) 10 Nm (1.0mSkg) Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set O-ring Brush holder set O-ring...

  • Page 358

    ELEC STARTER MOTOR EB803511 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Min. commutator diameter 27 mm 3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade...

  • Page 359

    ELEC STARTER MOTOR 5. Measure: S brush length a Out of specification ! Replace the brushes as a set. Min. brush length 3.5 mm 6. Measure: S brush spring force Out of specification ! Replace the brush springs as a set. Brush spring force 7.16 9.52 N (7.16...

  • Page 360: Charging System

    ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM Rectifier/ regulator AC magneto Battery Main fuse 8-26...

  • Page 361

    ELEC CHARGING SYSTEM EB804010 EB802401 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The battery is not being charged. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse Open-circuit voltage 2. battery 12.8 V or more at 20_C 3.

  • Page 362

    ELEC CHARGING SYSTEM EB804404 5. Wiring NOTE: S Check the wiring connections of the entire Make sure that the battery is fully charged. charging system. S Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. S Is the charging system’s wiring properly con- nected and without defects? The charging circuit is OK.

  • Page 363: Lighting System

    ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM Main switch Auxiliary light Battery Headlight relay (Hi) Main fuse Headlight relay (LO) High beam indicator light Tail / brake light Illumination light Headlight fuse Pass switch Signaling system fuse Dimmer switch Light switch Headlight 8-29...

  • Page 364

    ELEC LIGHTING SYSTEM EB805010 EB802401 TROUBLESHOOTING 2. Battery S Check the condition of the battery. Any of the following fail to light: head- Refer to “CHECKING AND CHARGING THE light, high beam indicator light, taillight, BATTERY” in chapter 3. auxiliary light or meter light. Open-circuit voltage Check: 12.8 V or more at 20_C...

  • Page 365

    ELEC LIGHTING SYSTEM EB805401 EB805410 CHECKING THE LIGHTING SYSTEM 5. Dimmer switch 1. The headlight and the high beam indicator S Check the dimmer switch for continuity. light fail to come on. Refer to “CHECKING THE SWITCHES”. S Is the dimmer switch OK? 1.

  • Page 366

    ELEC LIGHTING SYSTEM Headlight Tester positive probe ! yellow or green Tester negative probe ! black High beam indicator light Tester positive probe !yellow Tester negative probe ! black/blue Meter assembly coupler (wire harness side) S Does the headlight relay have continuity be- tween yellow (green) and red/yellow? This circuit is OK.

  • Page 367

    ELEC LIGHTING SYSTEM S Set the main switch to “ON”. S Set the main switch to “ON”. S Set the light switch to “ S Set the light switch to “ ” or “ ”. ” or “ ”. S Measure the voltage (12 V) of blue S Measure the voltage (12 V) of blue/red on the meter assembly coupler (wire harness side).

  • Page 368

    ELEC LIGHTING SYSTEM S Set the main switch to “ON”. S Set the light switch to “ ” or “ ”. S Measure the voltage (12 V) of blue/red the auxiliary light couplers (wire harness side). S Is the voltage within specification? This circuit is OK.

  • Page 369

    ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 8-35...

  • Page 370

    ELEC SIGNALING SYSTEM Main switch Battery Main fuse Starting circuit cutoff relay Fuel sender Neutral switch Speed sensor Fuel level indicator light Oil level / coolant temperature warning light Neutral indicator light Tachometer Combination meter Turn signal indicator light Horn switch Horn Turn signal switch Flasher relay...

  • Page 371

    ELEC SIGNALING SYSTEM EB806010 EB802401 TROUBLESHOOTING 2. Battery S Check the condition of the battery. S Any of the following fail to light: turn sig- Refer to “CHECKING THE BATTERY” in nal light, brake light or an indicator light. S The horn fails to sound. chapter 3.

  • Page 372: Signaling System

    ELEC SIGNALING SYSTEM EB806410 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. S Disconnect the black connector at the horn terminal. 1. Horn switch S Connect a jumper lead to the horn terminal S Check the horn switch for continuity. and ground the jumper lead.

  • Page 373

    ELEC SIGNALING SYSTEM EB806411 S Set the main switch to “ON”. 2. A tail/brake light fails to come on. S Pull in the brake lever or push down on the 1. Tail/brake light bulb and socket brake pedal. S Measure the voltage (12 V) of yellow at the S Check the tail/brake light bulb and socket for tail/brake light coupler (wire harness side).

  • Page 374

    ELEC SIGNALING SYSTEM Tester positive probe ! brown/white 3. Turn signal switch Tester negative probe ! ground S Check the turn signal switch for continuity. Refer to “CHECKING THE SWITCHES”. S Is the turn signal switch OK? Replace the left han- dlebar switch.

  • Page 375

    ELEC SIGNALING SYSTEM S Set the main switch to “ON”. 3. Voltage S Set the turn signal switch to “ ” or “ ”. S Connect the pocket tester (DC 20 V) to the S Measure the voltage (12 V) of chocolate meter assembly coupler (wire harness side) dark green at the turn signal light connec-...

  • Page 376

    ELEC SIGNALING SYSTEM 2. Oil level switch 4. Voltage S Drain the engine oil and remove the oil level S Connect the pocket tester (DC 20 V) to the switch from the oil pan. meter assembly coupler (wire harness side) S Check the oil level switch for continuity.

  • Page 377

    ELEC SIGNALING SYSTEM S Set the main switch to “ON”. 2. Fuel sender S Measure the voltage (12 V). S Disconnect the fuel sender coupler from the S Is the voltage within specification? wire harness. S Drain the fuel from the fuel tank and remove the fuel sender from the fuel tank.

  • Page 378

    ELEC SIGNALING SYSTEM EAS00806 The speedometer fails to come on. 1. Speedometer bulb socket S Check the speedometer bulb socket for con- tinuity. S Is the speedometer bulb socket OK? Replace the speedometer bulb S Set the main switch to “ON”. socket.

  • Page 379

    ELEC COOLING SYSTEM EB807000 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Battery Main fuse Thermo unit Oil level / coolant temperature warning light Combination meter Radiator fan motor Thermo switch Radiator fan motor fuse Signaling system fuse 8-45...

  • Page 380

    ELEC COOLING SYSTEM EB807010 Open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C S The radiator fan motor fails to turn. S Is the battery OK? S The coolant temperature display and/or warning light fails to indicate when the engine is warm. S Clean the battery Check: 1.

  • Page 381

    ELEC COOLING SYSTEM EB807400 Coolant temperature Test 5. Radiator fan motor (test 2) Continuity step Thermo switch S Disconnect the thermo switch coupler. 0 X 105 S Set the main switch to “ON”. S Connect the brown and blue terminals More than 105 with a jumper lead as shown.

  • Page 382

    ELEC COOLING SYSTEM 3 _C 3 _C S Does the thermo switch operate properly as described above? Replace the thermo switch. 7. Thermo unit S Remove the temperature sender from the WARNING cylinder head. S Connect the pocket tester ( Handle the temperature sender with spe- 10) to the cial care.

  • Page 383: Fuel Pump System

    ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Battery Main fuse Starting circuit cutoff relay Fuel pump CDI unit Signaling system fuse Ignition fuse Engine stop switch 8-49...

  • Page 384

    ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The CDI unit includes the control unit for the fuel pump. Battery Main fuse Main switch Ignition fuse Engine stop switch CDI unit Starting circuit cutoff relay Fuel pump 8-50...

  • Page 385

    ELEC FUEL PUMP SYSTEM EB808020 EB802401 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The fuel pump fails to operate. Refer to “CHECKING AND CHARGING THE Check: BATTERY” in chapter 3. 1. main and ignition fuses Open-circuit voltage 2.

  • Page 386

    ELEC FUEL PUMP SYSTEM S Measure the fuel pump resistance. 5. Starting circuit cutoff relay S Disconnect the relay from the coupler. Fuel pump resistance S Connect the pocket tester ( 4 X 30 1) and bat- at 20_C tery (12 V) to the relay terminals as shown. S Is the fuel pump OK? Battery positive terminal ! red Battery negative terminal ! blue/red...

  • Page 387

    ELEC FUEL PUMP SYSTEM EB808410 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refuelling. S Do not smoke and keep away from open flames, sparks or any other source of fire.

  • Page 388

    ELEC SELF-DIAGNOSIS EB812000 SELF-DIAGNOSIS The YZF-R6 features a self-diagnosing system for the following circuit(-s): S throttle position sensor S fuel level indicator light If any of these circuits are defective, their respective condition codes will be displayed on the tachome- ter when the main switch is set to “ON”...

  • Page 389

    ELEC SELF-DIAGNOSIS EB812010 1. Wire harness TROUBLESHOOTING S Check the wire harness for continuity. The tachometer starts to display the self- Refer to “CIRCUIT DIAGRAM”. diagnosis sequence. S Is the wire harness OK? Check: 1. throttle position sensor 2. fuel level indicator light Repair or replace the NOTE: wire harness.

  • Page 390

    ELEC SELF-DIAGNOSIS EB812040 EB812403 2. Fuel level indicator light 1. Fuel level indicator light LED CIRCUIT DIAGRAM S Check the LED of the fuel level indicator light. Refer to “CHECKING THE LEDs”. S Is the fuel level indicator light LED OK? Repair the fuel level indicator light LED.

  • Page 391

    ELEC SELF-DIAGNOSIS EB812405 3. Wire harness S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Replace the CDI unit. Replace or replace the wire harness. 8-57...

  • Page 392

    TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING PROBLEMS ........ENGINE .

  • Page 393

    TRBL SHTG UNSTABLE HANDLING ........FAULTY LIGHTING AND SIGNALING SYSTEMS .

  • Page 394: Troubleshooting

    TRBL STARTING PROBLEMS SHTG EB900000 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure is this manual for checks, adjustments, and replacement of parts.

  • Page 395: Faulty Gear Shifting

    INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND- TRBL HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING SHTG EB901000 INCORRECT ENGINE IDLING SPEED ELECTRICAL SYSTEMS ENGINE Battery Cylinders and cylinder head S Faulty battery S Incorrect valve clearance S Discharged battery S Damaged valve train components Spark plugs Air filter S Incorrect spark plug gap S Clogged air filter element...

  • Page 396

    TRBL FAULTY CLUTCH/OVERHEATING/OVERCOOLING SHTG EB904000 FAULTY CLUTCH CLUTCH DRAGS CLUTCH SLIPS Clutch Clutch S Unevenly tensioned clutch spring plate S Incorrectly assembled clutch S Warped pressure plate S Incorrectly adjusted clutch cable S Bent clutch plate S Loose or fatigued clutch spring S Swollen friction plate S Worn friction plate S Bent clutch pull rod...

  • Page 397: Poor Braking Performance, Unstable Handling

    POOR BRAKING PERFORMANCE/FAULTY FRONT FORK TRBL LEGS/UNSTABLE HANDLING SHTG EB907000 POOR BRAKING PERFORMANCE S Loose union bolt S Worn brake pad S Damaged brake hose S Worn brake disc S Oil or grease on the brake disc S Air in hydraulic brake system S Oil or grease on the brake pad S Leaking brake fluid S Incorrect brake fluid level...

  • Page 398

    TRBL FAULTY LIGHTING AND SIGNALING SYSTEMS SHTG EB910000 FAULTY LIGHTING AND SIGNALING SYSTEMS TURN SIGNAL DOES NOT LIGHT HEADLIGHT DOES NOT LIGHT S Faulty turn signal switch S Wrong headlight bulb S Faulty turn signal relay S Too many electrical accessories S Burnt-out turn signal bulb S Hard charging S Incorrect connection...

  • Page 399

    YZF-R6 ’99 WIRING DIAGRAM (for Europe) Main switch Fuse (backup) Rectifier / regulator AC magneto Battery Fuse (main) Starter relay Starter motor Starting circuit cutoff relay Fuel pump Sidestand switch Fuel sender Throttle position sensor CDI unit lgnition coil #1 lgnition coil #2 lgnition coil #3 lgnition coil #4...

  • Page 400

    YZF-R6 ’99 WIRING DIAGRAM (for AUS) Main switch Fuse (backup) Rectifier / regulator AC magneto Battery Fuse (main) Starter relay Starter motor Starting circuit cutoff relay Fuel pump Sidestand switch Fuel sender Throttle position sensor CDI unit lgnition coil #1 lgnition coil #2 lgnition coil #3 lgnition coil #4...

This manual also for:

1999 yzf-r6

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