Yamaha XVS13AWC Service Manual
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Yamaha XVS13AWC Service Manual

Yamaha XVS13AWC Service Manual

Yamaha motorcycle service manual
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Summary of Contents for Yamaha XVS13AWC

  • Page 1 The best Service Manuals have been CycleHippied! Over 30 Years of Powersports Industy Experience goes into the arrangement of the official Yamaha Factory Service Data. If you obtained this manual from a source other than CycleHippie, It may not have been properly CycleHippied!
  • Page 2 XVS13AW(C) XVS13CTW(C) SERVICE MANUAL LIT-11616-20-42 3D8-28197-10...
  • Page 3 EAS20050 XVS13AW(C)/XVS13CTW(C) SERVICE MANUAL ©2006 by Yamaha Motor Corporation, U.S.A. First edition, August 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-20-42...
  • Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.

  • Page 5: How To Use This Manual

    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...

  • Page 6: Symbols

    EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool NOTE: 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 8: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...

  • Page 10: General Information

    GENERAL INFORMATION IDENTIFICATION .................... 1-1 VEHICLE IDENTIFICATION NUMBER............. 1-1 MODEL LABEL ..................1-1 FEATURES ..................... 1-2 OUTLINE OF THE FI SYSTEM..............1-2 FI SYSTEM ....................1-3 INSTRUMENT FUNCTIONS..............1-4 IMPORTANT INFORMATION ................. 1-6 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-6 REPLACEMENT PARTS ................

  • Page 11: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.

  • Page 12: Features

    FEATURES EAS20170 FEATURES EAS3D81037 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor.

  • Page 13: Fi System

    FEATURES EAS3D81038 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm², 46.1 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

  • Page 14: Instrument Functions

    FEATURES EAS3D81033 Speedometer INSTRUMENT FUNCTIONS Multi-function meter unit EWA3D81011 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. Speedometer The speedometer shows the riding speed. When the key is turned to “ON”, the speedome- ter needle will sweep once across the speed range and then return to zero in order to test the electrical circuit.
  • Page 15 FEATURES If the odometer/tripmeter/clock display indicates NOTE: any error codes, note the code number, and Push the “ ” side of the “SELECT” switch to then check the vehicle. Refer to “FUEL INJEC- switch the display in the reverse order. TION SYSTEM”...

  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...

  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropri- ate.

  • Page 18: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead NOTE: • Coupler • If there is no continuity, clean the terminals. •...

  • Page 19: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-11 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-12 90890-01469 YM-01469 66.8 Belt tension gauge 3-25 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-26, 4-61 90890-01403 Spanner wrench YU-33975 Damper rod holder...
  • Page 21 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Weight 5-16 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-28, 5-33 90890-04019 YM-04019 Valve spring compressor attachment 5-28, 5-33 90890-01243 Valve spring compressor adapter (26 mm) YM-01253-1 Valve guide remover (ø6) 5-29 90890-04064 Valve guide remover (6.0 mm) YM-04064-A Valve guide installer (ø6)
  • Page 22 YU-01304 YU-01304 Sheave holder 5-43, 5-44, 90890-01701 5-51, 5-54 Primary clutch holder YS-01880-A Flywheel puller 5-43 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-45, 5-71, 90890-85505 6-10 (Three Bond No.1215®) Universal clutch holder 5-51, 5-55 90890-04086 YM-91042 1-12...
  • Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-10 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-10 90890-04058 Bearing driver 40 mm...
  • Page 24 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Digital circuit tester 7-11 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 8-83 90890-06754 Opama pet-4000 spark checker YM-34487 1-14...
  • Page 25 SPECIAL TOOLS 1-15...

  • Page 26: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ................ 2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-9 ELECTRICAL SPECIFICATIONS..............2-12 TIGHTENING TORQUES................2-15 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-15 ENGINE TIGHTENING TORQUES............2-16 CHASSIS TIGHTENING TORQUES............2-20 LUBRICATION POINTS AND LUBRICANT TYPES ........2-24 ENGINE ....................2-24 CHASSIS ....................

  • Page 27: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XVS13AW 3D81 (USA) XVS13AWC 3D82 (California) XVS13AW 3D83 (CDN) XVS13CTW 5S61 (USA) XVS13CTWC 5S62 (California) XVS13CTW 5S63 (CDN) Dimensions Overall length 2490 mm (98.0 in) Overall width 980 mm (38.6 in) Overall height XVS13AW(C) 1115 mm (43.9 in)

  • Page 28: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, SOHC Displacement 1304.0 cm³ Cylinder arrangement V-type 2-cylinder Bore × stroke 100.0 × 83.0 mm (3.94 × 3.27 in) Compression ratio 9.50 :1 Standard compression pressure (at sea level) 1450 kPa/400 r/min (206.2 psi/400 r/min) (14.5 kgf/cm²/400 r/min) Minimum–maximum...
  • Page 29 93.3–122.7 kPa (13.5–17.8 psi) (0.93–1.23 kgf/cm²) Valve relief pressure 4.9 kPa (0.7 psi) (0.05 kgf/cm²) Thermostat Model/manufacturer 1AE/YAMAHA Valve opening temperature 80.5–83.5 °C (176.9–182.3 °F) Valve full open temperature 95.0 °C (203.0 °F) Valve lift (full open) 8.0 mm (0.31 in)
  • Page 30 ENGINE SPECIFICATIONS Limit 37.018 mm (1.4574 in) Timing chain Model/number of links 98XRH2010–132M/132 Tensioning system Automatic Rocker arm/rocker arm shaft Rocker arm inside diameter 12.000–12.018 mm (0.4724–0.4731 in) Rocker arm shaft outside diameter 11.976–11.991 mm (0.4715–0.4721 in) Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.042 mm (0.0004–0.0017 in) Limit 0.095 mm (0.0037 in) Valve, valve seat, valve guide...
  • Page 31 ENGINE SPECIFICATIONS Limit 6.050 mm (0.2382 in) Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in) Limit 0.100 mm (0.0039 in) Valve stem runout 0.010 mm (0.0004 in) Cylinder head valve seat width (intake) 1.00–1.20 mm (0.0394–0.0472 in) Limit 1.6 mm (0.06 in)
  • Page 32 ENGINE SPECIFICATIONS Height H 8.0 mm (0.31 in) Offset 0.50 mm (0.0197 in) Piston pin bore inside diameter 23.004–23.015 mm (0.9057–0.9061 in) Limit 23.045 mm (0.9073 in) Piston pin outside diameter 22.991–23.000 mm (0.9052–0.9055 in) Limit 22.971 mm (0.9044 in) Piston-pin-to-piston-pin-bore clearance 0.004–0.024 mm (0.00016–0.00094 in) Limit...
  • Page 33 ENGINE SPECIFICATIONS Small end inside diameter 23.015–23.028 mm (0.9061–0.9066 in) Crankshaft Width A 97.95–98.00 mm (3.856–3.858 in) Runout limit C 0.020 mm (0.0008 in) Big end side clearance D 0.320–0.474 mm (0.0126–0.0187 in) Big end radial clearance E 0.022–0.046 mm (0.0009–0.0018 in) Limit 0.09 mm (0.0035 in) Balancer...
  • Page 34 ENGINE SPECIFICATIONS 24/25 (0.960) Main axle runout limit 0.08 mm (0.0032 in) Drive axle runout limit 0.08 mm (0.0032 in) Shifting mechanism Shift mechanism type Guide bar Shift fork guide bar bending limit 0.025 mm (0.0010 in) Shift fork thickness 6.26–6.39 mm (0.2465–0.2516 in) Air filter Air filter element...

  • Page 35: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 32.70° Trail 145.0 mm (5.71 in) Front wheel Wheel type Cast wheel 16M/C × MT3.00 Rim size Rim material Aluminum Wheel travel 135.0 mm (5.31 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
  • Page 36 Spring stroke K1 0.0–135.0 mm (0.00–5.31 in) Inner tube outer diameter 41.0 mm (1.61 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 490.0 cm³ (16.57 US oz) (17.28 Imp.oz) Level 105.0 mm (4.13 in) Rear suspension Type...
  • Page 37 CHASSIS SPECIFICATIONS Spring rate K1 160.00 N/mm (913.60 lb/in) (16.32 kgf/mm) Spring stroke K1 0.0–48.0 mm (0.00–1.89 in) Optional spring available Enclosed gas/air pressure (STD) 1200 kPa (170.7 psi) (12.0 kgf/cm²) Spring preload adjusting positions Minimum Standard Maximum Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 1.0 mm (0.04 in)

  • Page 38: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Electric Ignition timing (B.T.D.C.) 5.0°/1000 r/min Engine control unit Model/manufacturer FUA0013/MITSUBISHI Ignition coil Model/manufacturer 2JN/MORIC Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
  • Page 39 ELECTRICAL SPECIFICATIONS Indicator light Neutral indicator light Turn signal indicator light Oil level warning light High beam indicator light Fuel level warning light Coolant temperature warning light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM13/MITSUBA Power output...
  • Page 40 ELECTRICAL SPECIFICATIONS 86.40–105.60 Ω Coil resistance Fuel pump relay Model/manufacturer G8R-30Y-U3/OMRON 162.0–198.0 Ω Coil resistance Fan motor relay Model/manufacturer ACM33211 M05/MATSUSHITA 86.40–105.60 Ω Coil resistance Fuses Main fuse 50.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A...

  • Page 41: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 42: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kg, 11 ft·lb) pipe) Oil check bolt 15 Nm (1.5 m·kg, 11 ft·lb) Cylinder head nut 65 Nm (6.5 m·kg, 47 ft·lb) Cylinder head bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) l = 30 mm...
  • Page 43 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Drain cock bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Coolant delivery pipe bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Oil/water pump driven sprocket 15 Nm (1.5 m·kg, 11 ft·lb) bolt Oil filter cartridge 17 Nm (1.7 m·kg, 12 ft·lb) Oil filter cartridge union bolt 70 Nm (7.0 m·kg, 50 ft·lb)
  • Page 44 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Oil baffle plate 2 bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Crankcase bearing retainer bolt 12 Nm (1.2 m·kg, 8.7 ft·lb) Primary drive gear bearing plate 10 Nm (1.0 m·kg, 7.2 ft·lb) bolt Starter clutch bolt 24 Nm (2.4 m·kg, 17 ft·lb)
  • Page 45 TIGHTENING TORQUES NOTE: Connecting rod bolt Tighten the connecting rod bolts to 15 Nm (1.5 m·kg, 11 ft·lb), and then tighten them further to reach the specified angle 125–135°. NOTE: Exhaust pipe cover screw clamp Do not retighten the exhaust pipe cover screw clamps; always replace them with new ones if they are loosened.

  • Page 46: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine bracket bolt (right front 48 Nm (4.8 m·kg, 35 ft·lb) upper side) Engine bracket bolt (left front up- 48 Nm (4.8 m·kg, 35 ft·lb) per side) Engine mounting bolt (front upper 30 Nm (3.0 m·kg, 22 ft·lb) side)
  • Page 47 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Lower bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) Front fork cap bolt 23 Nm (2.3 m·kg, 17 ft·lb) Damper rod bolt 30 Nm (3.0 m·kg, 22 ft·lb) Lower front fork cover bolt 18 Nm (1.8 m·kg, 13 ft·lb) Main switch and upper bracket 30 Nm (3.0 m·kg, 22 ft·lb)
  • Page 48 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Front brake caliper bracket bolt 40 Nm (4.0 m·kg, 29 ft·lb) Front brake caliper bolt 27 Nm (2.7 m·kg, 19 ft·lb) Front brake disc bolt 23 Nm (2.3 m·kg, 17 ft·lb) Bleed screw (front brake caliper) 6 Nm (0.6 m·kg, 4.3 ft·lb) Rear wheel axle nut...
  • Page 49 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake pedal arm bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake master cylinder bolt 23 Nm (2.3 m·kg, 17 ft·lb) Rear brake master cylinder 23 Nm (2.3 m·kg, 17 ft·lb) bracket bolt Rider footrest assembly bolt (left 64 Nm (6.4 m·kg, 46 ft·lb)

  • Page 50: Lubrication Points And Lubricant Types

    Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal (lip) Yamaha bond Crankcase (mating surface) No.1215 (Three Bond No.1215®) Yamaha bond Stator coil assembly lead grommet No.1215 (Three Bond...

  • Page 51: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing dust cover (lip) Lower bearing dust seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub oil seal (lip) Rear wheel drive hub (mating surface) Brake pedal shaft (pivoting point) Shift pedal (pivoting point)
  • Page 52 LUBRICATION POINTS AND LUBRICANT TYPES 2-26...

  • Page 53: Lubrication System Chart And Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-27...
  • Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil/water pump assembly 3. Oil delivery pipe 3 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7. Main axle 8. Main gallery 9. Crankcase 10. Front cylinder piston oil nozzle 11.

  • Page 55: Lubrication Diagrams

    LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-29...
  • Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil delivery pipe 3 3. Relief valve assembly 2-30...
  • Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
  • Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Oil nozzle 3. Crankshaft 2-32...
  • Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
  • Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil delivery pipe 1 2. Timing chain tensioner 2-34...
  • Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
  • Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Oil delivery pipe 2 3. Main axle 4. Oil delivery pipe 3 5. Oil/water pump assembly 6. Oil strainer 2-36...

  • Page 63: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-37...
  • Page 64 COOLING SYSTEM DIAGRAMS 1. Rear cylinder thermostat inlet pipe 1 2. Front cylinder thermostat inlet pipe 1 3. Coolant delivery cover 2 4. Coolant delivery cover 1 5. Drain cock 6. Oil/water pump assembly 2-38...
  • Page 65 COOLING SYSTEM DIAGRAMS 2-39...
  • Page 66 COOLING SYSTEM DIAGRAMS 1. Radiator outlet hose 2. Radiator outlet pipe 3. Coolant delivery pipe 4. Oil/water pump assembly 2-40...
  • Page 67 COOLING SYSTEM DIAGRAMS 2-41...
  • Page 68 COOLING SYSTEM DIAGRAMS 1. Rear cylinder thermostat inlet pipe 1 2. Front cylinder thermostat inlet pipe 1 3. Rear cylinder thermostat inlet hose 4. Front cylinder thermostat inlet hose 5. Coolant reservoir hose 6. Rear cylinder thermostat inlet pipe 2 7.

  • Page 69: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING 2-43...
  • Page 70 CABLE ROUTING 1. Clutch switch lead 2. Clutch cable 3. Left handlebar switch lead 4. Right handlebar switch lead 5. Front brake hose 6. Throttle cable (accelerator cable) 7. Throttle cable (decelerator cable) 8. Front brake switch lead 9. Radiator fan motor lead 10.
  • Page 71 CABLE ROUTING 2-45...
  • Page 72 CABLE ROUTING 1. Wire harness 2. Front right turn signal light 3. Front left turn signal light 4. Main switch couplers 5. Front right turn signal light coupler 6. Front left turn signal light coupler 7. Meter assembly couplers 8. Air temperature sensor lead 9.
  • Page 73 CABLE ROUTING 11 12 D E F 2-47...
  • Page 74 CABLE ROUTING 1. Wire harness L. Fasten the rear brake light switch lead and horn lead with a plastic locking tie, making sure to align 2. Coolant reservoir hose the tie with the frame weld. Face the end of the 3.
  • Page 75 CABLE ROUTING 2-49...
  • Page 76 CABLE ROUTING 1. Horn 2. Rear brake light switch 3. Rear brake master cylinder 4. Brake fluid reservoir hose 5. Coolant reservoir breather hose 6. Rear brake hose 7. Rear brake caliper 8. Brake fluid reservoir A. Fasten the rear brake hose and brake fluid reservoir hose with the plastic bands, making sure to align the white paint marks on the brake fluid reservoir hose with the bands.
  • Page 77 CABLE ROUTING 4 5 6 7 8 9 11 12 2-51...
  • Page 78 CABLE ROUTING 1. Left handlebar switch lead L. Fasten the starter motor lead and sidestand switch lead with a plastic locking tie. Face the end of the 2. Clutch cable plastic locking tie rearward, and then cut off the 3. Front brake hose excess end of the tie.
  • Page 79 CABLE ROUTING 9 10 2-53...
  • Page 80 CABLE ROUTING 1. Headlight relay N. Fasten the starter motor lead to the frame with a plastic locking tie. Face the end of the plastic 2. Stator coil coupler locking tie downward, and then cut off the excess 3. Radiator fan motor relay end of the tie to 10 mm (0.39 in) or less.
  • Page 81 CABLE ROUTING 2-55...
  • Page 82 CABLE ROUTING 1. Wire harness K. Slide the boot over the neutral switch coupler and speed sensor coupler, making sure that they are 2. Coolant reservoir hose covered completely. 3. Throttle cable (accelerator cable) L. To tail/brake light assembly 4. Throttle cable (decelerator cable) M.
  • Page 83 CABLE ROUTING 2-57...
  • Page 84 CABLE ROUTING 1. Front cylinder intake air pressure sensor hose 2. Front cylinder intake air pressure sensor 3. Rear cylinder intake air pressure sensor hose 4. Rear cylinder intake air pressure sensor 5. Front cylinder thermostat inlet hose 6. Right handlebar switch lead 7.
  • Page 85 CABLE ROUTING 2-59...
  • Page 86 CABLE ROUTING 1. Rear cylinder thermostat inlet hose 2. Right handlebar switch lead 3. Wire harness 4. Front cylinder resonator hose 5. Front cylinder intake air pressure sensor hose 6. Canister purge hose (California only) 7. Throttle position sensor 8. Rear cylinder intake air pressure sensor hose 9.
  • Page 87 CABLE ROUTING 2-61...
  • Page 88 CABLE ROUTING 1. Fuel tank overflow hose 2. Fuel tank 3. Fuel tank breather hose (fuel tank to hose joint) 4. Air vent hose 5. Sub-fuel tank 6. Fuel pump 7. Fuel hose 8. Crankcase breather hose 9. Fuel cock hose 10.
  • Page 89 CABLE ROUTING 2-63...

  • Page 90: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE................3-1 INTRODUCTION..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM....................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART....... 3-1 ENGINE ......................3-4 ADJUSTING THE VALVE CLEARANCE ..........3-4 SYNCHRONIZING THE THROTTLE BODIES ......... 3-6 ADJUSTING THE THROTTLE CABLE FREE PLAY ........ 3-8 CHECKING THE SPARK PLUGS.............
  • Page 91 ELECTRICAL SYSTEM ................3-31 CHECKING AND CHARGING THE BATTERY........3-31 CHECKING THE FUSES ................ 3-31 REPLACING THE HEADLIGHT BULB ........... 3-31 ADJUSTING THE HEADLIGHT BEAM ........... 3-32...

  • Page 93: Periodic Maintenance

    √ damage. tem (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32183 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS...
  • Page 94 Front and rear √ √ √ √ √ √ 23 * • Check operation. brake switches • Apply Yamaha chain and ca- √ √ √ √ √ √ 24 * Control cables ble lube or engine oil SAE 10W-30 thoroughly.
  • Page 95 26 * and switches • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

  • Page 96: Engine

    ENGINE EAS20470 ENGINE EAS20530 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center 8.
  • Page 97 ENGINE M MMM M MMM M MMM M MMM M MMM Valve clearance (cold) Rear cylinder Intake a. Turn the crankshaft counterclockwise from 0.09–0.13 mm (0.0035–0.0051 in) the front cylinder piston TDC by 300 degrees. Exhaust b. When the rear cylinder piston is at TDC on 0.14–0.18 mm (0.0055–0.0071 in) the compression stroke, align the TDC mark “c”...

  • Page 98: Synchronizing The Throttle Bodies

    ENGINE 15.Install: Thickness gauge • Crankshaft end screw 90890-03180 (along with the O-ring Feeler gauge set • Timing mark accessing screw YU-26900-9 (along with the O-ring c. Turn the adjusting screw “3” in direction “a” or • Damper “b” with the tappet adjusting tool “4” until the •...
  • Page 99 ENGINE 4. Install: • Vacuum gauge “1” • Digital tachometer Vacuum gauge 90890-03094 Carburetor synchronizer YU-44456 5. Install: • Fuel tank Refer to “FUEL TANK” on page 7-1. 6. Adjust: • Throttle body synchronization M MMM M MMM M MMM M MMM M MMM a.

  • Page 100: Adjusting The Throttle Cable Free Play

    ENGINE Intake vacuum Throttle cable free play 32.0–37.3 kPa (9.4–11.0 inHg) 4.0–6.0 mm (0.16–0.24 in) (240–280 mmHg) 2. Remove: • Rider seat NOTE: Refer to “GENERAL CHASSIS” on page 4-1. The difference in vacuum pressure between two • Fuel tank throttle bodies should not exceed 1.33 kPa (10 Refer to “FUEL TANK”...

  • Page 101: Checking The Spark Plugs

    ENGINE d. Tighten the locknut. 7. Measure: e. Slide the throttle cable holder to its original • Spark plug gap “a” position. (with a wire thickness gauge) Out of specification → Regap. Spark plug gap 0.8–0.9 mm (0.031–0.035 in) L LLL L LLL L LLL L LLL...

  • Page 102: Measuring The Compression Pressure

    ENGINE NOTE: The ignition timing is not adjustable. L LLL L LLL L LLL L LLL L LLL 5. Install: • Timing mark accessing screw (along with the O-ring • Damper • Damper cover Timing mark accessing screw 3. Connect: 6 Nm (0.6 m·kg, 4.3 ft·lb) •...

  • Page 103: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into Compression gauge the cylinder) 90890-03081 Reading Diagnosis Engine compression tester YU-33223 Higher than without Piston ring(s) wear or damage → Repair. Piston, valves, cylin- der head gasket or Same as without oil piston possibly defec- tive →...

  • Page 104: Changing The Engine Oil

    ENGINE 4. Drain: Type • Engine oil YAMALUBE 4 (20W40) or (completely from the crankcase) SAE20W40 5. If the oil filter cartridge is also to be replaced, Recommended engine oil grade perform the following procedure. API service SG type or higher, M MMM M MMM M MMM...

  • Page 105: Adjusting The Clutch Lever Free Play

    ENGINE 7. Fill: b. Start the engine and keep it idling until engine • Crankcase oil starts to seep from the oil check bolts. If no (with the specified amount of the recom- engine oil comes out after one minute, turn mended engine oil) the engine off so that it will not seize.

  • Page 106: Replacing The Air Filter Element

    ENGINE 4. Install: Direction “a” • Right side panel Clutch lever free play is increased. • Left side panel Direction “b” Refer to “FUEL TANK” on page 7-1. Clutch lever free play is decreased. EAS20960 REPLACING THE AIR FILTER ELEMENT c.

  • Page 107: Checking The Intake Manifold Joints

    ENGINE ECA3D81009 NOTE: CAUTION: When installing the air filter element into the air Make sure the fuel tank breather hose and filter case, make sure that the sealing surfaces fuel tank overflow hose are routed correctly. are aligned to prevent any air leaks. EAS3D81008 CHECKING THE INTAKE MANIFOLD JOINTS 1.

  • Page 108: Checking The Exhaust System

    ENGINE • Rider seat Refer to “GENERAL CHASSIS” on page 4-1. EAS21080 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets. 1. Check: • Front cylinder exhaust pipe “1” • Rear cylinder exhaust pipe “2” •...

  • Page 109: Checking The Cooling System

    ENGINE NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. EAS21120 CHECKING THE COOLING SYSTEM 1. Remove: • Front cylinder exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. 2. Check: • Radiator cover “1” NOTE: •...
  • Page 110 ENGINE EWA13030 WARNING A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter-...
  • Page 111 ENGINE 13.Fill: • Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion in- hibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) 16.Install: Radiator capacity (including all • Coolant reservoir cap routes) 17.Start the engine, warm it up for several min- 2.10 L (2.22 US qt) (1.85 Imp.qt)

  • Page 112: Chassis

    CHASSIS EAS21140 EAS21190 CHASSIS ADJUSTING THE REAR DISC BRAKE 1. Check: • Brake pedal adjusting bolt position EAS21150 ADJUSTING THE FRONT BRAKE LEVER Check that the end “a” of the brake pedal ad- FREE PLAY justing bolt is visible through the hole “b”. 1.

  • Page 113: Checking The Brake Fluid Level

    CHASSIS 3. Adjust: • When refilling, be careful that water does • Rear brake light switch not enter the front brake master cylinder Refer to “ADJUSTING THE REAR BRAKE reservoir and brake fluid reservoir. Water LIGHT SWITCH” on page 3-22. will significantly lower the boiling point of the brake fluid and could cause vapor lock.

  • Page 114: Checking The Front Brake Hoses

    CHASSIS 2. Check: • Brake hose clamp Loose → Tighten the clamp bolt. 3. Hold the vehicle upright and apply the brake several times. 4. Check: • Brake hoses Brake fluid leakage → Replace the damaged hose. Refer to “REAR BRAKE” on page 4-34. EAS21280 EAS21330 CHECKING THE FRONT BRAKE HOSES...
  • Page 115 CHASSIS • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. 1. Remove: • Rider seat • Sub-fuel tank cover Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: •...

  • Page 116: Adjusting The Shift Pedal

    CHASSIS EWA13110 WARNING After bleeding the hydraulic brake system, check the brake operation. L LLL L LLL L LLL L LLL L LLL 5. Tighten: • Brake fluid reservoir bolt Bleed fluid reservoir bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) LOCTITE®...
  • Page 117 CHASSIS b. Loosen both locknuts “2”. Drive belt slack (on the side- c. Turn both adjusting bolts “3” in direction “a” or stand) “b” until the specified drive belt slack is ob- 5.0–7.0 mm (0.20–0.28 in) tained. Drive belt slack (on a suitable stand) Direction “a”...

  • Page 118: Checking And Adjusting The Steering Head

    CHASSIS EAS21510 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated.

  • Page 119: Checking The Front Fork

    CHASSIS Spring preload ECA13590 CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Remove: • Rear cylinder exhaust pipe • Coolant reservoir cover Refer to “ENGINE REMOVAL” on page 5-1. 2. Disconnect: L LLL L LLL L LLL L LLL L LLL •...

  • Page 120: Checking The Tires

    CHASSIS Tire air pressure (measured on cold tires) Loading condition 5 6 7 1 2 3 4 0–90 kg (0–198 lb) Front 250 kPa (36 psi) (2.50 kgf/cm²) Rear 280 kPa (41 psi) (2.80 kgf/cm²) Loading condition XVS13AW(C) 90–210 kg (198– 463 lb) L LLL L LLL...

  • Page 121: Checking The Wheels

    Never attempt to make any repairs to the en if a tire combination other than one wheel. approved by Yamaha is used on this vehicle. NOTE: Front tire After a tire or wheel has been changed or re- Size placed, always balance the wheel.

  • Page 122: Lubricating The Levers

    CHASSIS EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1. Check: • Outer cable Damage → Replace. 2. Check: • Cable operation Rough movement →...
  • Page 123 ELECTRICAL SYSTEM EAS21750 6. Remove: ELECTRICAL SYSTEM • Headlight bulb “6” EAS21760 CHECKING AND CHARGING THE BATTERY Refer to “ELECTRICAL COMPONENTS” on page 8-67. EAS21770 CHECKING THE FUSES Refer to “ELECTRICAL COMPONENTS” on page 8-67. EAS21790 REPLACING THE HEADLIGHT BULB EWA13320 1.
  • Page 124 ELECTRICAL SYSTEM EAS21810 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: • Headlight beam (vertically) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw “1” with a screw driver in direction “a” or “b”. Direction “a” Headlight beam is raised.
  • Page 125 ELECTRICAL SYSTEM 3-33...
  • Page 126 CHASSIS GENERAL CHASSIS ..................4-1 FRONT WHEEL ....................4-9 REMOVING THE FRONT WHEEL ............4-11 DISASSEMBLING THE FRONT WHEEL..........4-11 CHECKING THE FRONT WHEEL ............4-11 ASSEMBLING THE FRONT WHEEL............4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-12 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC) ....4-13 REAR WHEEL....................
  • Page 127 HANDLEBAR ....................4-45 REMOVING THE HANDLEBAR.............. 4-47 CHECKING THE HANDLEBAR .............. 4-47 INSTALLING THE HANDLEBAR ............4-47 FRONT FORK ....................4-50 REMOVING THE FRONT FORK LEGS..........4-54 DISASSEMBLING THE FRONT FORK LEGS........4-54 CHECKING THE FRONT FORK LEGS ..........4-55 ASSEMBLING THE FRONT FORK LEGS..........

  • Page 129: General Chassis

    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield (for XVS13CT) 23 Nm (2.3 m kg, 17 ft 48 Nm (4.8 m kg, 35 ft • • • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 130 Sidebag (left and right) tions to clean the leather on the sidebags. Polish the dry leather with a soft cloth, and then treat with Yamaha Mink Oil or another high-quality leather protectant for increased water resistance. Backrest...
  • Page 131 GENERAL CHASSIS Removing the rider seat and left side cover 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 132 GENERAL CHASSIS Removing the headlight 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Turn signal light bracket cover Headlight lens unit Headlight coupler Disconnect. Turn signal light coupler Disconnect.
  • Page 133 GENERAL CHASSIS Removing the battery 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Sub-fuel tank cover 4-1. Battery cover band Battery cover Tool kit Tool kit tray Negative battery lead Disconnect.
  • Page 134 GENERAL CHASSIS Removing the battery 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Battery box For installation, reverse the removal proce- dure.
  • Page 135 GENERAL CHASSIS Removing the air filter case 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Air filter case cover Air filter element Air filter case bracket Crankcase breather hose Disconnect.
  • Page 136 GENERAL CHASSIS Removing the relays 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Sub-fuel tank cover/Battery box 4-1.

  • Page 137: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • 23 Nm (2.3 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 138 FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-10...

  • Page 139: Removing The Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake calipers NOTE: Do not apply the brake lever when removing the L LLL L LLL L LLL...

  • Page 140: Assembling The Front Wheel

    FRONT WHEEL 4. Check: L LLL L LLL L LLL L LLL L LLL • Wheel bearings EAS21970 Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings. BALANCE • Oil seals NOTE: Damage/wear →...

  • Page 141: Installing The Front Wheel (Front Brake Disc)

    FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.
  • Page 142 FRONT WHEEL NOTE: Install the tire and wheel with the marks “1” pointing in the direction of wheel rotation. 5. Tighten: • Front wheel axle • Front wheel axle pinch bolt Front wheel axle 59 Nm (5.9 m·kg, 43 ft·lb) Front wheel axle pinch bolt 20 Nm (2.0 m·kg, 14 ft·lb) ECA3D81011...

  • Page 143: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear fender 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Rider seat/Passenger seat/Seat lock brack-...
  • Page 144 REAR WHEEL Removing the rear wheel 27 Nm (2.7 m kg, 19 ft • • 16 Nm (1.6 m kg, 11 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 145 REAR WHEEL Removing the rear wheel 27 Nm (2.7 m kg, 19 ft • • 16 Nm (1.6 m kg, 11 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 146 REAR WHEEL Removing the rear brake disc and rear wheel drive hub 23 Nm (2.3 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel pulley Oil seal Circlip Rear wheel drive hub Circlip Bearing Collar...
  • Page 147 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Oil seal Circlip Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-19...

  • Page 148: Removing The Rear Wheel (Disc)

    REAR WHEEL EAS28760 • Oil seals REMOVING THE REAR WHEEL (DISC) Refer to “CHECKING THE FRONT WHEEL” 1. Stand the vehicle on a level surface. on page 4-11. EWA13120 2. Check: WARNING • Tire Securely support the vehicle so that there is •...

  • Page 149: Assembling The Rear Wheel

    REAR WHEEL Rear wheel pulley self-locking Rear brake disc bolt 23 Nm (2.3 m·kg, 17 ft·lb) 95 Nm (9.5 m·kg, 68 ft·lb) LOCTITE® NOTE: NOTE: Tighten the self-locking nuts in stages and in a • Apply locking agent (LOCTITE®) to the crisscross pattern.

  • Page 150: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of...
  • Page 151 FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 152 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-24...
  • Page 153 FRONT BRAKE Removing the front brake calipers 40 Nm (4.0 m kg, 29 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Reflector Refer to “FRONT BRAKE”...
  • Page 154 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Front brake caliper retaining bolt Brake pad spring Brake pad...

  • Page 155: Introduction

    FRONT BRAKE EAS22220 INTRODUCTION Brake disc deflection limit EWA14100 0.12 mm (0.0047 in) WARNING Disc brake components rarely require disas- M MMM M MMM M MMM M MMM M MMM a. Place the vehicle on a suitable stand so that sembly.

  • Page 156: Replacing The Front Brake Pads

    FRONT BRAKE 2. Install: • Brake pads • Brake pad spring NOTE: Always install new brake pads and a new brake pad spring as a set. M MMM M MMM M MMM M MMM M MMM a. Connect a clear plastic hose “1” tightly to the bleed screw “2”.

  • Page 157: Removing The Front Brake Calipers

    FRONT BRAKE Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-21. LOWER M MMM M MMM M MMM M MMM M MMM a. Blow compressed air into the brake hose joint opening “a” to force out the piston from the 6.

  • Page 158: Assembling The Front Brake Calipers

    FRONT BRAKE • Brake caliper body “3” Front brake hose union bolt Cracks/damage → Replace the brake caliper 30 Nm (3.0 m·kg, 22 ft·lb) assembly. • Brake fluid delivery passages EWA13530 (brake caliper body) WARNING Obstruction → Blow out with compressed air. Proper brake hose routing is essential to in- EWA13600 sure safe vehicle operation.

  • Page 159: Removing The Front Brake Master Cylinder

    FRONT BRAKE • Refill with the same type of brake fluid that NOTE: is already in the system. Mixing brake fluids To collect any remaining brake fluid, place a may result in a harmful chemical reaction, container under the master cylinder and the end leading to poor brake performance.

  • Page 160: Installing The Front Brake Master Cylinder

    FRONT BRAKE EAS22530 INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder “1” • Front brake master cylinder holder “2” 30–50˚ Front brake master cylinder hold- er bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) 3. Fill: NOTE: •...
  • Page 161 FRONT BRAKE LOWER 6. Check: • Brake lever operation Soft or spongy feeling → Bleed the brake sys- tem. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. 4-33...

  • Page 162: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper Rear brake pad Brake pad spring For installation, reverse the removal proce-...
  • Page 163 REAR BRAKE Removing the rear brake master cylinder 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft 30 Nm (3.0 m kg, 22 ft •...
  • Page 164 REAR BRAKE Removing the rear brake master cylinder 16 Nm (1.6 m kg, 11 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft 30 Nm (3.0 m kg, 22 ft •...
  • Page 165 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-37...
  • Page 166 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-22. Rear brake hose union bolt Copper washer Rear brake hose...
  • Page 167 REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-39...

  • Page 168: Introduction

    REAR BRAKE EAS22560 Refer to “CHECKING THE FRONT BRAKE INTRODUCTION DISCS” on page 4-27. EWA14100 WARNING Brake disc thickness limit Disc brake components rarely require disas- 5.5 mm (0.22 in) sembly. Therefore, always follow these pre- ventive measures: 5. Adjust: •...

  • Page 169: Removing The Rear Brake Caliper

    REAR BRAKE Refer to “BLEEDING THE HYDRAULIC NOTE: BRAKE SYSTEM” on page 3-22. Always install new brake pads and brake pad springs as a set. EAS22590 REMOVING THE REAR BRAKE CALIPER M MMM M MMM M MMM M MMM M MMM a.

  • Page 170: Checking The Rear Brake Caliper

    REAR BRAKE b. Remove the brake caliper piston seals. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. L LLL L LLL L LLL L LLL L LLL EAS22640 CHECKING THE REAR BRAKE CALIPER Recommended fluid DOT 4 Recommended brake component replace- ment schedule...

  • Page 171: Removing The Rear Brake Master Cylinder

    REAR BRAKE 4. Fill: EAS22700 REMOVING THE REAR BRAKE MASTER • Brake fluid reservoir CYLINDER (with the specified amount of the recom- NOTE: mended brake fluid) Before removing the rear brake master cylinder, Recommended fluid drain the brake fluid from the entire brake sys- DOT 4 tem.

  • Page 172: Assembling The Rear Brake Master Cylinder

    REAR BRAKE EAS22730 EWA13090 ASSEMBLING THE REAR BRAKE MASTER WARNING CYLINDER • Use only the designated brake fluid. Other EWA13520 brake fluids may cause the rubber seals to WARNING deteriorate, causing leakage and poor • Before installation, all internal brake com- brake performance.
  • Page 173 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 174 HANDLEBAR Removing the handlebar 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft • • 28 Nm (2.8 m kg, 20 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 175: Handlebar

    HANDLEBAR EAS22860 • Turn the handlebar all the way to the left REMOVING THE HANDLEBAR and right. If there is any contact with the 1. Stand the vehicle on a level surface. fuel tank, adjust the handlebar position. EWA13120 WARNING NOTE: Securely support the vehicle so that there is Align the punch mark “a”...
  • Page 176 HANDLEBAR 5. Install: 7. Install: • Handlebar grip “1” • Right handlebar switch “1” M MMM M MMM M MMM M MMM M MMM NOTE: a. Apply a thin coat of rubber adhesive onto the Align the projection “a” on the right handlebar left end of the handlebar.
  • Page 177 HANDLEBAR 9. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. Clutch lever free play 5.0–10.0 mm (0.20–0.39 in) 10.Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CA- BLE FREE PLAY” on page 3-8. Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 4-49...

  • Page 178: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 18 Nm (1.8 m kg, 13 ft 110 Nm (11.0 m kg, 80 ft • • • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 179 FRONT FORK Removing the front fork legs 18 Nm (1.8 m kg, 13 ft 110 Nm (11.0 m kg, 80 ft • • • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft •...
  • Page 180 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer...
  • Page 181 FRONT FORK Disassembling the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Spring Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure.

  • Page 182: Removing The Front Fork Legs

    FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the 3.

  • Page 183: Checking The Front Fork Legs

    FRONT FORK ECA14200 CAUTION: • The front fork leg has a built-in damper ad- justing rod and a very sophisticated inter- nal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork.
  • Page 184 FRONT FORK 2. Lubricate: • Inner tube’s outer surface Recommended oil Yamaha fork oil 10WT 3. Install: • Inner tube (in the outer tube) 4. Install: • Copper washer 7. Install: • Damper rod bolt • Oil seal “1” 5. Tighten: (with the fork seal driver “2”)

  • Page 185: Installing The Front Fork Legs

    Imp.oz) Make sure the inner tube end is flush with the top Recommended oil of the upper bracket. Yamaha fork oil 10WT 11.Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the outer...
  • Page 186 FRONT FORK • Cap bolt Cap bolt 23 Nm (2.3 m·kg, 17 ft·lb) • Upper bracket pinch bolt Upper bracket pinch bolt 23 Nm (2.3 m·kg, 17 ft·lb) EWA13680 WARNING 2. Tighten: Make sure the brake hoses are routed prop- •...

  • Page 187: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 188 STEERING HEAD Removing the lower bracket 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 189: Removing The Lower Bracket

    STEERING HEAD EAS23110 M MMM M MMM M MMM M MMM M MMM REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering 1. Stand the vehicle on a level surface. head pipe with a long rod “1” and hammer. EWA13120 b.
  • Page 190 STEERING HEAD 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-26. 3. Install: • Front brake hose joint “1” •...

  • Page 191: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft • • 59 Nm (5.9 m kg, 43 ft •...
  • Page 192 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 48 Nm (4.8 m kg, 35 ft • • 48 Nm (4.8 m kg, 35 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Parts to remove Q’ty Remarks Spacer...

  • Page 193: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 NOTE: HANDLING THE REAR SHOCK ABSORBER Place the vehicle on a suitable stand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling •...

  • Page 194: Checking The Connecting Arm And Relay Arm

    REAR SHOCK ABSORBER ASSEMBLY • Spring Damage/wear → Replace the rear shock ab- sorber assembly. • Bushing Damage/wear → Replace. • Spacer Damage/scratches → Replace. • Bolts Bends/damage/wear → Replace. EAS23260 CHECKING THE CONNECTING ARM AND RELAY ARM 1. Check: •...
  • Page 195 REAR SHOCK ABSORBER ASSEMBLY Rear shock absorber assembly lower nut 48 Nm (4.8 m·kg, 35 ft·lb) 5. Install: • Connecting arms NOTE: When installing the connecting arms, lift up the swingarm. 4-67...

  • Page 196: Swingarm

    SWINGARM EAS23330 SWINGARM Removing the swingarm 85 Nm (8.5 m kg, 61 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 197 SWINGARM Removing the swingarm 85 Nm (8.5 m kg, 61 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty...

  • Page 198: Removing The Swingarm

    SWINGARM Bends → Replace. EAS23350 REMOVING THE SWINGARM EWA13770 1. Stand the vehicle on a level surface. WARNING EWA13120 Do not attempt to straighten a bent pivot WARNING shaft. Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated.
  • Page 199 SWINGARM 2. Swingarm A. Left side B. Right side Installed depth “a” 0–1.0 mm (0–0.04 in) 3. Install: • Pivot shaft nut Pivot shaft nut 85 Nm (8.5 m·kg, 61 ft·lb) 4. Install: • Rectifier/regulator NOTE: When installing the rectifier/regulator, first tight- en the upper bolt, then the lower bolt.

  • Page 200: Belt Drive

    BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt 10 Nm (1.0 m kg, 7.2 ft • • 140 Nm (14.0 m kg, 100 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 201: Removing The Drive Belt And Drive Pulley

    BELT DRIVE EAS23520 REMOVING THE DRIVE BELT AND DRIVE PULLEY NOTE: Loosen the drive pulley nut before removing the rear wheel. 1. Loosen: • Drive pulley nut NOTE: When loosening the drive pulley nut, press down 3. Check: on the brake pedal so the drive pulley does not •...
  • Page 202 BELT DRIVE 4. Tighten: • Drive pulley cover plate bolt NOTE: Tighten the drive pulley cover plate bolts tempo- rarily, and then tighten them in proper tightening sequence as shown. 5. Adjust: • Drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK”...
  • Page 203 BELT DRIVE 4-75...

  • Page 204: Engine

    ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE EXHAUST PIPE COVER SCREW CLAMPS ....5-2 INSTALLING THE CYLINDER COVERS..........5-5 INSTALLING THE SHIFT ARM..............5-5 INSTALLING THE ENGINE ..............5-10 CAMSHAFTS ....................5-12 REMOVING THE CAMSHAFT ASSEMBLIES ........5-15 REMOVING THE ROCKER ARMS AND CAMSHAFTS ......5-16 CHECKING THE CAMSHAFTS ..............
  • Page 205 CLUTCH ......................5-46 REMOVING THE CLUTCH ..............5-51 REMOVING THE PRIMARY DRIVE GEAR ..........5-51 CHECKING THE FRICTION PLATES ............ 5-51 CHECKING THE CLUTCH PLATES............5-52 CHECKING THE CLUTCH SPRING PLATE .......... 5-52 CHECKING THE CLUTCH HOUSING............ 5-52 CHECKING THE CLUTCH BOSS............5-52 CHECKING THE PRESSURE PLATE ............
  • Page 206 CRANKSHAFT....................5-76 REMOVING THE CONNECTING RODS ..........5-77 CHECKING THE CRANKSHAFT AND CONNECTING RODS....5-77 INSTALLING THE CONNECTING RODS..........5-79 INSTALLING THE CRANKSHAFT ASSEMBLY ........5-80 TRANSMISSION ................... 5-81 CHECKING THE SHIFT FORKS ............5-85 CHECKING THE SHIFT DRUM ASSEMBLY.......... 5-85 CHECKING THE TRANSMISSION............

  • Page 207: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipes 7 Nm (0.7 m kg, 5.1 ft • • 44 Nm (4.4 m kg, 32 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 6 Nm (0.6 m kg, 4.3 ft •...

  • Page 208: Installing The Exhaust Pipe Cover Screw Clamps

    ENGINE REMOVAL EAS3D81019 INSTALLING THE EXHAUST PIPE COVER SCREW CLAMPS 1. Install: • Exhaust pipe cover screw clamps Exhaust pipe cover screw clamp 6 Nm (0.6 m·kg, 4.3 ft·lb) NOTE: Do not retighten the exhaust pipe cover screw clamps; always replace them with new ones if they are loosened.
  • Page 209 ENGINE REMOVAL Removing the sidestand and drive pulley housing 64 Nm (6.4 m kg, 46 ft 8 Nm (0.8 m kg, 5.8 ft • • • • 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 210 ENGINE REMOVAL Removing the sidestand and drive pulley housing 64 Nm (6.4 m kg, 46 ft 8 Nm (0.8 m kg, 5.8 ft • • • • 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft •...

  • Page 211: Installing The Cylinder Covers

    ENGINE REMOVAL EAS3D81039 INSTALLING THE CYLINDER COVERS 1. Install: • Rear cylinder right cover “1” • Rear cylinder left cover “2” • Front cylinder right cover “3” • Front cylinder left cover “4” Cylinder cover bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) NOTE: Tighten the cover bolts temporarily, and then tighten the front bolt, then the rear bolt, to spec-...
  • Page 212 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Sub-fuel tank cover 4-1. Radiator Refer to “RADIATOR” on page 6-1. Thermostat Refer to “THERMOSTAT” on page 6-4. Intake manifold assembly Refer to “THROTTLE BODIES”...
  • Page 213 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Rubber cover For assembly, reverse the removal proce- dure.
  • Page 214 ENGINE REMOVAL Removing the down tube and engine 7 Nm (0.7 m kg, 5.1 ft 48 Nm (4.8 m kg, 35 ft • • • • 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 215 ENGINE REMOVAL Removing the down tube and engine 7 Nm (0.7 m kg, 5.1 ft 48 Nm (4.8 m kg, 35 ft • • • • 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft •...

  • Page 216: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • Engine bracket (front upper side) “1” • Engine bracket bolts (front upper side) “2” Engine bracket bolt (front upper side) 30 Nm (3.0 m·kg, 22 ft·lb) 2. Install: • Engine “3” 3.
  • Page 217 ENGINE REMOVAL 4. Tighten: • Engine mounting bolts (front right upper side) “4” • Engine mounting bolts (front left upper side) “5” • Engine mounting nut (rear lower side) “11” • Engine mounting nut (rear upper side) “13” • Engine mounting nut (front lower side) “16” Engine mounting bolt (front right upper side) 48 Nm (4.8 m·kg, 35 ft·lb)

  • Page 218: Camshafts

    CAMSHAFTS EAS23740 CAMSHAFTS Removing the cylinder head covers 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm (0.6 m kg, 4.3 ft •...
  • Page 219 CAMSHAFTS Removing the camshaft assemblies 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 220 CAMSHAFTS Removing the rocker arms and camshafts 14 Nm (1.4 m kg, 10 ft • • 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the camshaft assemblies Locknut Loosen.

  • Page 221: Removing The Camshaft Assemblies

    CAMSHAFTS EAS3D81020 REMOVING THE CAMSHAFT ASSEMBLIES 1. Align: • “I” mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder camshaft carrier) M MMM M MMM M MMM M MMM M MMM Front cylinder a. Turn the crankshaft counterclockwise. 3.

  • Page 222: Removing The Rocker Arms And Camshafts

    CAMSHAFTS 5. Align: EAS3D81034 REMOVING THE ROCKER ARMS AND • “I” mark on the rear cylinder camshaft sprock- CAMSHAFTS The following procedure applies to all of the (with the arrow mark on the rear cylinder rocker arms and camshafts. camshaft carrier) 1.

  • Page 223: Checking The Camshafts

    CAMSHAFTS EAS23840 EAS23870 CHECKING THE CAMSHAFTS CHECKING THE CAMSHAFT SPROCKETS 1. Check: 1. Check: • Camshaft lobes • Camshaft sprockets Blue discoloration/pitting/scratches → Re- More than 1/4 tooth wear “a” → Replace the place the camshaft. camshaft sprocket and the timing chain as a 2.

  • Page 224: Checking The Timing Chain Tensioners

    CAMSHAFTS 4. Measure: • Rocker arm shaft outside diameter “a” Out of specification → Replace. Rocker arm shaft outside diame- 11.976–11.991 mm (0.4715– 0.4721 in) 1. Timing chain tensioner rod 2. Timing chain tensioner spring seat 3. Timing chain tensioner inner spring 4.

  • Page 225: Installing The Camshafts And Rocker Arms

    CAMSHAFTS b. Install the timing chain tensioner inner spring, EAS24040 INSTALLING THE CAMSHAFTS AND timing chain tensioner spring seat, and timing ROCKER ARMS chain tensioner rod. The following procedure applies to all of the c. Squeeze timing chain tensioner clip 2 “1”, rocker arms and camshafts.

  • Page 226: Installing The Camshaft Assemblies

    CAMSHAFTS ECA3D81017 CAUTION: Make sure the cotouts in the rocker arm shafts faces inward. A. Intake side B. Exhaust side 3. Install: • Front cylinder camshaft sprocket EAS3D81021 INSTALLING THE CAMSHAFT ASSEMBLIES M MMM M MMM M MMM M MMM M MMM Front cylinder 1.
  • Page 227 CAMSHAFTS • When installing the front cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the exhaust side. d. Remove the wire from the timing chain. L LLL L LLL L LLL L LLL L LLL 4.
  • Page 228 CAMSHAFTS • When installing the rear cylinder camshaft sprocket, be sure to keep the timing chain as tight as possible on the intake side. A. Intake side B. Exhaust side 8. Install: d. Remove the wire from the timing chain. •...

  • Page 229: Installing The Cylinder Head Covers

    CAMSHAFTS • Front cylinder head cover bracket “1” Front cylinder head cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Bolts “2”: l = 30 mm (1.18 in) Bolts “3”: l = 45 mm (1.77 in) Bolts “4”: l = 55 mm (2.17 in) A.

  • Page 230: Cylinder Heads

    CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads 13 Nm (1.3 m kg, 9.4 ft 13 Nm (1.3 m kg, 9.4 ft • • • • 15 Nm (1.5 m kg, 11 ft • • 65 Nm (6.5 m kg, 47 ft •...

  • Page 231: Removing The Cylinder Heads

    CYLINDER HEADS EAS24150 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Cylinder head nuts NOTE: • Loosen the nuts and bolts in the proper se- quence as shown. • Loosen each nut and bolt 1/2 of a turn at a time.
  • Page 232 CYLINDER HEADS Cylinder head nut 65 Nm (6.5 m·kg, 47 ft·lb) Cylinder head bolt 13 Nm (1.3 m·kg, 9.4 ft·lb) NOTE: • Lubricate the cylinder head nuts and washers with engine oil. • Tighten the cylinder head nuts and bolts in the proper tightening sequence as shown and torque them in two stages.
  • Page 233 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-24. Valve cotter Upper spring seat Valve spring Intake valve...

  • Page 234: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal. 1.
  • Page 235 VALVES AND VALVE SPRINGS b. Install the new valve guide with the valve Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover ance (intake) “1”. 0.010–0.037 mm (0.0004–0.0015 Valve guide position Limit 14.5–14.9 mm (0.571–0.587 in) 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 mm (0.0010–0.0020...

  • Page 236: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 4. Check: 1. Eliminate: • Valve face • Carbon deposits Pitting/wear → Grind the valve face. (from the valve face and valve seat) • Valve stem end 2. Check: Mushroom shape or diameter larger than the •...

  • Page 237: Checking The Valve Springs

    VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve NOTE: face and repeat the above steps. After replacing the cylinder head or replacing the f. After every lapping procedure, be sure to valve and valve guide, the valve seat and valve clean off all of the lapping compound from the face should be lapped.

  • Page 238: Installing The Valves

    VALVES AND VALVE SPRINGS 2. Measure: EAS24340 INSTALLING THE VALVES • Compressed valve spring force “a” The following procedure applies to all of the Out of specification → Replace the valve valves and related components. spring. 1. Deburr: Installed compression spring •...
  • Page 239 VALVES AND VALVE SPRINGS • Valve stem seal “2” • Valve “3” • Valve spring “4” • Upper spring seat “5” (into the cylinder head) NOTE: • Make sure each valve is installed in its original place. • Install the valve springs with the larger pitch “a” facing up.

  • Page 240: Cylinders And Pistons

    CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-24. Timing chain guide Front cylinder Rear cylinder Front cylinder gasket Rear cylinder gasket Dowel pin Circlip Piston pin...

  • Page 241: Removing The Pistons

    CYLINDERS AND PISTONS EAS24380 NOTE: REMOVING THE PISTONS When removing a piston ring, open the end gap The following procedure applies to all of the pis- with your fingers and lift the other side of the ring tons. over the piston crown. 1.

  • Page 242: Checking The Piston Rings

    CYLINDERS AND PISTONS EAS24430 CHECKING THE PISTON RINGS The following procedure applies to all of the pis- ton rings. 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston b.

  • Page 243: Checking The Piston Pins

    CYLINDERS AND PISTONS Piston pin outside diameter 22.991–23.000 mm (0.9052– 0.9055 in) Limit 22.971 mm (0.9044 in) a. 10 mm (0.39 in) 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. NOTE: 3. Measure: The oil ring expander spacer end gap cannot be •...

  • Page 244: Installing The Pistons And Cylinders

    CYLINDERS AND PISTONS EAS24460 INSTALLING THE PISTONS AND CYLINDERS The following procedure applies to all of the pis- tons and cylinders. 1. Install: • Top ring “1” • 2nd ring “2” • Oil ring expander “3” • Lower oil ring rail “4” •...
  • Page 245 CYLINDERS AND PISTONS 6. Install: • Cylinder “1” NOTE: • While compressing the piston rings with one hand, install the cylinder with the other hand. • Pass the timing chain and timing chain guide through the timing chain cavity. 5-39...

  • Page 246: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • (12) 6 Nm (0.6 m kg, 4.3 ft 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 247 GENERATOR AND STARTER CLUTCH Removing the stator coil 10 Nm (1.0 m kg, 7.2 ft • • (12) 6 Nm (0.6 m kg, 4.3 ft 7 Nm (0.7 m kg, 5.1 ft 10 Nm (1.0 m kg, 7.2 ft • •...
  • Page 248 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 90 Nm (9.0 m kg, 65 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Parts to remove Q’ty Remarks Generator rotor Starter clutch Woodruff key Starter clutch gear Torque limiter Starter clutch idle gear shaft...

  • Page 249: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer • Starter clutch bolts “2” NOTE: • While holding the generator rotor “3” with the sheave holder “4”, loosen the generator rotor bolt. •...

  • Page 250: Checking The Torque Limiter

    GENERATOR AND STARTER CLUTCH M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear “1” onto the gen- erator rotor “2” and hold the generator rotor. b. When turning the starter clutch gear clock- wise “A”, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.
  • Page 251 GENERATOR AND STARTER CLUTCH 3. Apply: • Sealant (onto the crankshaft position sensor/stator assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 5-45...

  • Page 252: Clutch

    CLUTCH EAS25060 CLUTCH Removing the clutch cover 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Muffler/Coolant reservoir cover Refer to “ENGINE REMOVAL” on page 5-1. Drain.
  • Page 253 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing For installation, reverse the removal proce- dure. 5-47...
  • Page 254 CLUTCH Removing the clutch 10 Nm (1.0 m kg, 7.2 ft • • 125 Nm (12.5 m kg, 90 ft • • 14 13 12 11 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer Clutch spring plate...
  • Page 255 CLUTCH Removing the clutch 10 Nm (1.0 m kg, 7.2 ft • • 125 Nm (12.5 m kg, 90 ft • • 14 13 12 11 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Parts to remove Q’ty Remarks Clutch housing Collar...
  • Page 256 CLUTCH Removing the primary drive gear 100 Nm (10.0 m kg, 72 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (12) 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...

  • Page 257: Removing The Clutch

    CLUTCH EAS25080 • Do not allow the sheave holder to touch the REMOVING THE CLUTCH projection on the generator rotor. 1. Loosen: • Clutch boss nut “1” Sheave holder NOTE: 90890-01701 While holding the clutch boss “2” with the univer- Primary clutch holder sal clutch holder “3”, loosen the clutch boss nut.

  • Page 258: Checking The Clutch Plates

    CLUTCH EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage → Replace. 2. Check: • Clutch spring plate seat Damage → Replace. EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch housing.

  • Page 259: Checking The Pressure Plate

    CLUTCH • Pull rod teeth “2” Damage/wear → Replace the pull rod and pull lever shaft pinion gear as a set. EAS25170 CHECKING THE PRESSURE PLATE 1. Check: • Pressure plate 2. Check: Cracks/damage → Replace. • Pull rod bearing Damage/wear →...

  • Page 260: Installing The Clutch

    CLUTCH • Lubricate the primary drive gear nut threads with engine oil. Sheave holder 90890-01701 Primary clutch holder YS-01880-A 2. Install: • Clutch housing “1” NOTE: • Fit the projections “a” on the oil/water pump drive sprocket into the grooves “b” in the clutch housing.
  • Page 261 CLUTCH 6. Install: • Friction plates 2 “1” • Clutch plates • Friction plate 1 “2” NOTE: • First, install a friction plate and then alternate between a clutch plate and a friction plate. • Align the cutout in the tab of each friction plate 2 “1”...
  • Page 262 CLUTCH 9. Adjust: • Clutch lever free play Refer to “ADJUSTING THE CLUTCH LEVER FREE PLAY” on page 3-13. 5-56...

  • Page 263: Shift Shaft

    SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 22 Nm (2.2 m kg, 16 ft • • Order Job/Parts to remove Q’ty Remarks Drive pulley cover Refer to “BELT DRIVE” on page 4-72. Shift arm Refer to “ENGINE REMOVAL” on page 5-1. Primary drive gear cover Refer to “CLUTCH”...

  • Page 264: Checking The Shift Shaft

    SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.

  • Page 265: Balancer Gears

    BALANCER GEARS EAS3D81023 BALANCER GEARS Removing the right balancer assembly 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Primary drive gear Refer to “CLUTCH” on page 5-46. Straight key Right balancer drive gear Right balancer assembly...
  • Page 266 BALANCER GEARS Removing the left balancer assembly 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator rotor/Starter clutch idle gear CLUTCH”...

  • Page 267: Checking The Right Balancer Gears

    BALANCER GEARS EAS3D81024 2. Install: CHECKING THE RIGHT BALANCER GEARS • Left balancer drive gear “1” 1. Check: NOTE: • Right balancer drive gear • Align the punch mark “a” in the left balancer • Right balancer driven gear driven gear with the punch mark “b” in the left •...

  • Page 268: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Starter motor For installation, reverse the removal proce- dure.
  • Page 269 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Lock washer Washer set Oil seal Bearing Armature assembly Washer set Starter motor rear cover Gasket Brush set (along with the brushes) Brush holder (along with the brushes) Brush holder bracket Starter motor yoke For assembly, reverse the disassembly pro-...

  • Page 270: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Pocket tester 1. Check: 90890-03112 • Commutator Analog pocket tester Dirt → Clean with 600 grit sandpaper. YU-03112-C 2. Measure: • Commutator diameter “1” Armature coil Out of specification → Replace the starter Commutator resistance “1”...

  • Page 271: Assembling The Starter Motor

    ELECTRIC STARTER 7. Check: • Gear teeth Damage/wear → Replace the gear. 8. Check: • Bearing Damage/wear → Replace the defective part(s). EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush seat NOTE: Align the tab “a” on the brush seat with the slot “b”...

  • Page 272: Crankcase

    CRANKCASE EAS25540 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 273 CRANKCASE Removing the oil delivery pipes and timing chains 10 Nm (1.0 m kg, 7.2 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 20 Nm (2.0 m kg, 14 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 274 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 36 Nm (3.6 m kg, 25 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 275 CRANKCASE Removing the oil seal and bearings 12 Nm (1.2 m kg, 8.7 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Oil/water pump assembly Refer to “OIL PUMP” on page 5-73. Crankshaft Refer to “CRANKSHAFT”...

  • Page 276: Disassembling The Crankcase

    CRANKCASE EAS25560 EAS25580 DISASSEMBLING THE CRANKCASE CHECKING THE CRANKCASE 1. Remove: 1. Thoroughly wash the crankcase halves in a • Crankcase bolts mild solvent. 2. Thoroughly clean all the gasket surfaces and NOTE: crankcase mating surfaces. Loosen each bolt 1/4 of a turn at a time, in stag- 3.

  • Page 277: Installing The Bearing Retainers

    • M6 × 80 mm bolts: “3” 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) NOTE: Do not allow any sealant to come into contact with the oil gallery.
  • Page 278 CRANKCASE A. Right crankcase B. Left crankcase 5. Apply: • Engine oil (onto the crankshaft pin bearings and oil de- livery holes) 6. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-72...

  • Page 279: Oil Pump

    OIL PUMP EAS24910 OIL PUMP Removing the oil/water pump assembly 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 9 10 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 280: Checking The Oil Pump

    OIL PUMP EAS24960 CHECKING THE OIL PUMP 1. Check: • Oil pump housing • Water pump housing Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • Inner-rotor-to-outer-rotor-tip clearance “a” • Outer-rotor-to-oil-pump-housing clearance “b” • Oil-pump-housing-to-inner-rotor-and-outer- rotor clearance “c” Out of specification → Replace the oil/water pump assembly.

  • Page 281: Checking The Oil Strainer

    OIL PUMP 3. Check: EAS24990 CHECKING THE OIL STRAINER • Oil pump operation 1. Check: Refer to “CHECKING THE OIL PUMP” on • Oil strainer “1” page 5-74. Damage → Replace. Contaminants → Clean with solvent. EAS25020 INSTALLING THE OIL/WATER PUMP ASSEMBLY 1.

  • Page 282: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft 1st 15 Nm (1.5 m kg, 11 ft • • 2nd Specified angle 125–135˚ Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Crankshaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce-...

  • Page 283: Removing The Connecting Rods

    CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS Oil clearance (using plasti- 1. Remove: gauge®) • Connecting rod caps “1” 0.030–0.054 mm (0.0012–0.0021 • Connecting rods • Big end bearings The following procedure applies to all of the NOTE: connecting rods. Identify the position of each big end bearing so ECA13930 that it can be reinstalled in its original place.
  • Page 284 CRANKSHAFT NOTE: NOTE: • Do not move the connecting rod or crankshaft • The numbers “a” stamped into the crankshaft until the clearance measurement has been web and the numbers “b” on the connecting completed. rods are used to determine the replacement •...

  • Page 285: Installing The Connecting Rods

    CRANKSHAFT 5. Measure: NOTE: • Crankshaft journal diameter “a” Calculate the clearance by subtracting the Out of specification → Replace the crank- crankshaft journal diameter from the crankshaft shaft. journal bearing inside diameter. NOTE: Measure the diameter of each crankshaft journal Crankshaft-journal-to-crankshaft- at two places.

  • Page 286: Installing The Crankshaft Assembly

    CRANKSHAFT Connecting rod bolt (final) Specified angle 125–135° EWA3D81006 WARNING When a bolt is tightened more than the spec- ified angle, do not loosen and then retighten Replace the bolt with a new one and perform the procedure again. 4. Tighten: ECA3D81012 •...
  • Page 287 TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Main axle assembly Drive axle assembly...
  • Page 288 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Circlip 3rd/4th pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure. 5-82...
  • Page 289 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 4th wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 3rd wheel gear Toothed spacer Toothed washer Circlip Dog clutch...

  • Page 290: Transmission

    TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks 2nd wheel gear Collar Drive axle For assembly, reverse the disassembly pro- cedure. 5-84...

  • Page 291: Checking The Shift Forks

    TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the shift 1. Check: forks and shift fork guide bars. • Shift drum grooves Damage/scratches/wear → Replace the shift 1. Check: •...

  • Page 292: Assembling The Main Axle And Drive Axle

    TRANSMISSION 3. Check: 2. Install: • Transmission gears • Toothed lock washer retainer “1” Blue discoloration/pitting/wear → Replace • Toothed lock washer “2” the defective gear(s). NOTE: • Transmission gear dogs • With the toothed lock washer retainer “1” in the Cracks/damage/rounded edges →...
  • Page 293 TRANSMISSION 2. Check: • Transmission Rough movement → Repair. NOTE: • Apply engine oil to each gear and bearing thor- oughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-87...

  • Page 294: Cooling System

    COOLING SYSTEM RADIATOR...................... 6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 THERMOSTAT....................6-4 CHECKING THE THERMOSTAT ............. 6-6 INSTALLING THE THERMOSTAT ASSEMBLY ........6-6 WATER PUMP ....................6-7 DISASSEMBLING THE WATER PUMP ........... 6-9 CHECKING THE WATER PUMP.............. 6-9 ASSEMBLING THE WATER PUMP ............
  • Page 295 RADIATOR EAS26380 RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft •...

  • Page 296: Radiator

    RADIATOR Removing the radiator 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 2 Nm (0.2 m kg, 1.4 ft •...

  • Page 297: Checking The Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 298: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft •...
  • Page 299 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 300: Checking The Thermostat

    THERMOSTAT EAS26450 2. Check: CHECKING THE THERMOSTAT • Thermostat housing cover 1. Check: • Thermostat housing • Thermostat • Thermostat pipes Does not open at 82–95 °C (179.6–203.0 °F) • Thermostat hoses → Replace. • Radiator inlet hose • Radiator filler pipe Cracks/damage/wear →...

  • Page 301: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 302 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft 10 Nm (1.0 m kg, 7.2 ft • • • • 10 Nm (1.0 m kg, 7.2 ft •...

  • Page 303: Disassembling The Water Pump

    • Install the water pump seal with the special Remove the bearing and oil seal from the inside tools. of the water pump housing. • Before installing the water pump seal, apply Yamaha bond No.1215 (Three Bond No.1215®) “2” to the water pump housing “3”.
  • Page 304 0.15 mm (0.006 in) Water pump seal installer YM-33221-A Middle driven shaft bearing driv- 90890-04058 Bearing driver 40 mm YM-04058 Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 1. Straightedge 2. Impeller A. Push down 4. Mechanical seal installer 5. Middle driven shaft bearing driver 3.
  • Page 305 WATER PUMP 6-11...

  • Page 306: Fuel System

    FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK..............7-5 REMOVING THE FUEL PUMP ..............7-5 CHECKING THE FUEL COCK..............7-5 CHECKING THE FUEL COCK OPERATION ........... 7-5 CHECKING THE FUEL PUMP BODY ............7-5 CHECKING THE ROLLOVER VALVE ............7-5 INSTALLING THE FUEL PUMP..............

  • Page 307: Fuel Tank

    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 23 Nm (2.3 m kg, 17 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 308 FUEL TANK Removing the fuel tank 23 Nm (2.3 m kg, 17 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 309 FUEL TANK Removing the sub-fuel tank 10 Nm (1.0 m kg, 7.2 ft • • ( 3 ) ( 3 ) ( 3 ) ( 6 ) 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
  • Page 310 FUEL TANK Removing the rollover valve and canister 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Fuel tank/Side panels Refer to “FUEL TANK” on page 7-1. Front cylinder covers Refer to “ENGINE REMOVAL” on page 5-1. Canister purge hose California only Fuel tank breather hose (rollover valve to canis-...

  • Page 311: Removing The Fuel Tank

    FUEL TANK EAS3D81001 2. Check: REMOVING THE FUEL TANK • Fuel cock strainer 1. Extract the fuel in the fuel tank through the Obstruction → clean. fuel tank cap with a pump. Blow out the jets with compressed air. 2. Remove: Damage →...

  • Page 312: Installing The Fuel Pump

    FUEL TANK • To install the fuel hose onto the fuel pump, slide the fuel hose connector cover “1” on the end of the hose in the direction of the arrow shown. EAS3D81007 INSTALLING THE FUEL PUMP 1. Install: • Fuel pump Fuel pump bolt EAS3D81040 INSTALLING THE FUEL TANK HOSES...
  • Page 313 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body and ISC (idle speed control) unit 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Rider seat/Air filter case 4-1.

  • Page 314: Throttle Bodies

    THROTTLE BODIES Removing the throttle body and ISC (idle speed control) unit 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Throttle position sensor For installation, reverse the removal proce- dure.
  • Page 315 THROTTLE BODIES Removing the intake manifold assembly 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 4 Nm (0.4 m kg, 2.9 ft •...
  • Page 316 THROTTLE BODIES Disassembling the intake manifold 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Front cylinder injector coupler Disconnect. Rear cylinder injector coupler Disconnect. Sub-wire harness Injector Fuel pipe Intake manifold For assembly, reverse the disassembly pro- cedure.

  • Page 317: Checking The Injectors

    THROTTLE BODIES EAS26980 CHECKING THE INJECTORS Pressure gauge 1. Check: 90890-03153 • Injectors YU-03153 Damage → Replace. Fuel pressure adapter 90890-03176 EAS26990 YM-03176 CHECKING THE THROTTLE BODIES 1. Check: • Throttle bodies Cracks/damage → Replace the throttle bod- ies as a set. 2.

  • Page 318: Installing The Intake Manifold Assembly

    THROTTLE BODIES c. Turn the main switch to “ON”. NOTE: d. Measure the throttle position sensor output Make sure that the projection “b” on the rear cyl- voltage. inder intake manifold joint contacts the projec- e. Adjust the throttle position sensor angle so tion “c”...
  • Page 319 THROTTLE BODIES 7-13...

  • Page 320: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................. 8-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION....... 8-3 TROUBLESHOOTING ................8-4 ELECTRIC STARTING SYSTEM..............8-7 CIRCUIT DIAGRAM .................. 8-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-9 TROUBLESHOOTING ................8-11 CHARGING SYSTEM ................... 8-13 CIRCUIT DIAGRAM ................
  • Page 321 ELECTRICAL COMPONENTS ..............8-67 CHECKING THE SWITCHES ..............8-71 CHECKING THE BULBS AND BULB SOCKETS ........8-74 CHECKING THE FUSES ................ 8-75 CHECKING AND CHARGING THE BATTERY........8-75 CHECKING THE RELAYS ..............8-79 CHECKING THE TURN SIGNAL RELAY ..........8-80 CHECKING THE DIODES ..............

  • Page 323: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
  • Page 324 IGNITION SYSTEM 3. Main fuse 5. Main switch 6. Battery 12.Relay unit 16.Neutral switch 18.Sidestand switch 20.Crankshaft position sensor 24.Lean angle sensor 27.ECU (engine control unit) 28.Rear cylinder ignition coil 29.Front cylinder ignition coil 30.Spark plug 65.Engine stop switch 73.Ignition fuse...

  • Page 325: Engine Stopping Due To Sidestand Operation

    IGNITION SYSTEM EAS3D81009 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.

  • Page 326: Troubleshooting

    IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Battery box 5. Headlight lens unit NG →...
  • Page 327 IGNITION SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-71. OK ↓ NG → 9. Check the engine stop switch. Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES”...
  • Page 328 IGNITION SYSTEM...

  • Page 329: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM Sb/W L/W R Sb/W L/W L R/L L/R L/G L/Y Sb B/W B/W (GRAY) (BLACK) B L/G (BLACK) (BLACK) R/L B (DARK GREEN) L W/Y P O/R (BLACK) Br/L (BLACK) Br/W R/W R/W (BLACK)
  • Page 330 ELECTRIC STARTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 8. Starter relay 9. Starter motor 10.Diode 1 12.Relay unit 13.Starting circuit cut-off relay 15.Diode 2 16.Neutral switch 18.Sidestand switch 52.Clutch switch 65.Engine stop switch 66.Start switch 73.Ignition fuse...

  • Page 331: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
  • Page 332 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEUTRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.

  • Page 333: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Headlight lens unit NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s).
  • Page 334 ELECTRIC STARTING SYSTEM NG → 8. Check the diode 2. Refer to “CHECKING THE DI- Replace the diode 2. ODES” on page 8-81. OK ↓ NG → 9. Check the starter relay. Refer to “CHECKING THE RE- Replace the starter relay. LAYS”...

  • Page 335: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM Sb/W L/W R Sb/W L/W L L/G L/Y Sb B/W B/W (GRAY) (BLACK) B L/G (BLACK) (BLACK) R/L B (DARK GREEN) L W/Y P O R (BLACK) Br/L (BLACK) B /W R/W R/W (BLACK) Br/W (BLACK)
  • Page 336 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Main fuse 6. Battery 8-14...

  • Page 337: Troubleshooting

    CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Rectifier/regulator cover NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES”...
  • Page 338 CHARGING SYSTEM 8-16...

  • Page 339: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-17...
  • Page 340 LIGHTING SYSTEM 3. Main fuse 5. Main switch 6. Battery 27.ECU (engine control unit) 38.Multi-function meter 41.High beam indicator light 43.Meter light 49.Headlight relay 51.Dimmer switch 57.Front right turn signal light 58.Front left turn signal light 59.Headlight 60.Accessory light (OPTION) 67.License plate light 68.Tail/brake light 72.Headlight fuse...

  • Page 341: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position light, meter light and accessory light (OPTION). NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3.
  • Page 342 LIGHTING SYSTEM NG → 7. Check the entire lighting system’s wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem’s wiring. page 8-17. OK ↓ Replace the ECU or meter assembly. 8-20...

  • Page 343: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-21...
  • Page 344 SIGNALING SYSTEM 3. Main fuse 4. Backup fuse (odometer and clock) 5. Main switch 6. Battery 12.Relay unit 16.Neutral switch 19.Speed sensor 25.Coolant temperature sensor 27.ECU (engine control unit) 35.Fuel level warning light 36.Oil level warning light 37.Neutral indicator light 38.Multi-function meter 40.Coolant temperature warning light 42.Turn signal indicator light...

  • Page 345: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The speedometer fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1.
  • Page 346 SIGNALING SYSTEM NG → 3. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-21. OK ↓ This circuit is OK. The brake light fails to come on. NG → 1.
  • Page 347 SIGNALING SYSTEM NG → 3. Check the turn signal relay. Refer to “CHECKING THE RE- Replace the turn signal relay. LAYS” on page 8-79. OK ↓ NG → 4. Check the entire signaling system’s wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”...
  • Page 348 SIGNALING SYSTEM The fuel level warning light fails to come. NG → 1. Check the fuel sender. Refer to “CHECKING THE FUEL Replace the fuel sender. SENDER” on page 8-87. OK ↓ NG → 2. Check the entire signaling system’s wiring.

  • Page 349: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-27...
  • Page 350 COOLING SYSTEM 3. Main fuse 5. Main switch 6. Battery 11.Radiator fan motor fuse 25.Coolant temperature sensor 27.ECU (engine control unit) 69.Radiator fan motor 71.Radiator fan motor relay 73.Ignition fuse 8-28...

  • Page 351: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING The radiator fan motor fails to turn. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Headlight lens unit NG → 1. Check the fuses. (Main, ignition and radiator fan mo- tor) Replace the fuse(s).
  • Page 352 COOLING SYSTEM 8-30...

  • Page 353: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-31...
  • Page 354 FUEL INJECTION SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 12.Relay unit 14.Fuel pump relay 15.Diode 2 16.Neutral switch 17.Fuel pump 18.Sidestand switch 19.Speed sensor 20.Crankshaft position sensor 21.Throttle position sensor 22.Rear cylinder intake air pressure sensor 23.Front cylinder intake air pressure sensor 24.Lean angle sensor 25.Coolant temperature sensor...

  • Page 355: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 356: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS27380 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.
  • Page 357 FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Rear cylinder intake Rear cylinder intake air pressure air pressure sensor sensor: open or short circuit de- Able Able (open or short circuit) tected.

  • Page 358: Troubleshooting Method

    FUEL INJECTION SYSTEM Communication error with the meter Able / un- Fault Able / un- Item Symptom able to code No. able to start drive ECU internal malfunc- No signals are received from the Er-1 tion Unable Unable ECU. (output signal error) ECU internal malfunc- No signals are received from the Er-2...

  • Page 359: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Press and hold the “RESET” switch “1” and the “ ”...
  • Page 360 FUEL INJECTION SYSTEM NOTE: If the engine stop switch is set to “ ”, set it to “ ”, and then set it to “ ” again. 8. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code table Fault Diagnostic code...
  • Page 361 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. The vehicle has over- • Overturned. turned. • Malfunction in ECU. • Open or short circuit in wire harness. Malfunction detected in the • Malfunction in front cylinder ignition coil. primary wire of the front •...
  • Page 362 FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. • Malfunction in meter. No signals are received Er-1 • Malfunction in ECU. — from the ECU. • Defective wire connection of the ECU cou- pler.
  • Page 363 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Vehicle speed pulse 0–999 Check that the number in- creases when the rear wheel is rotated. The num- ber is cumulative and does not reset each time the wheel is stopped. Lean angle sensor Remove the lean angle sensor and incline it more...
  • Page 364 FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code erasure • No history — • History exists Up to 25 fault codes To erase the history, set the engine stop switch to “ ”. Control number 0–255 —...

  • Page 365: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the radiator fan mo- tor relay for five cycles of five seconds. (ON 2 seconds, Check the operating sound Radiator fan motor relay OFF 3 seconds) of the radiator fan motor re- Illuminates the engine trou- lay five times.
  • Page 366 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check for looseness or pinching. Cranking the tion sensor.
  • Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder intake air pressure sensor: open or short circuit detected. Diagnostic code No. Front cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 368 FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Front cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Front cylinder intake air pressure sen- •...
  • Page 369 FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
  • Page 370 FUEL INJECTION SYSTEM Fault code No. Symptom A break or disconnection of the blue/black lead of the ECU is detected. Diagnostic code No. Sidestand switch Order Item/components and probable Check or maintenance job Reinstatement cause method Connection • Execute the diagnostic mode. If the transmis- •...
  • Page 371 FUEL INJECTION SYSTEM Fault code No. Symptom Air temperature sensor: open or short circuit detected. Diagnostic code No. Air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of air temperature Check for looseness or pinching. Turning the sensor.
  • Page 372 FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of O sensor. Check for looseness or pinching. Starting the en- gine and oper- Connections •...
  • Page 373 FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder intake air pressure sensor: open or short circuit detected. Diagnostic code No. Rear cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 374 FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Rear cylinder intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Rear cylinder intake air pressure sen- •...
  • Page 375 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the front cylin- der ignition coil. Diagnostic code No. 30, 32 Front cylinder ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
  • Page 376 FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the rear cylin- der ignition coil. Diagnostic code No. 31, 33 Rear cylinder ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections •...
  • Page 377 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling. Diagnostic code No. ISC valve Order Item/components and probable Check or maintenance job Reinstatement cause method Throttle valve does not fully close. • Check the throttle bodies. ISC valve re- Refer to “THROTTLE BODIES”...
  • Page 378 FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 379 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 380 FUEL INJECTION SYSTEM Fault code No. Symptom A. No normal signals are received from the speed sensor. B. Open circuit is detected in the neutral switch. Diagnostic code No. Speed sensor Neutral switch Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 381 FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel system voltage Order Item/components and probable Check or maintenance job Reinstatement cause method...
  • Page 382 FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connection • Check the coupler for any pins Starting the en- •...
  • Page 383 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...
  • Page 384 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Data from the ECU cannot be received correctly. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Turning the •...

  • Page 385: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-63...
  • Page 386 FUEL PUMP SYSTEM 3. Main fuse 5. Main switch 6. Battery 7. Fuel injection system fuse 14.Fuel pump relay 15.Diode 2 17.Fuel pump 27.ECU (engine control unit) 65.Engine stop switch 73.Ignition fuse 8-64...

  • Page 387: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING The fuel pump fails to operate. NOTE: • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Tool kit tray 3. Fuel tank 4. Battery box 5. Headlight lens unit NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s).
  • Page 388 FUEL PUMP SYSTEM NG → 8. Check the entire fuel pump sys- tem’s wiring. Properly connect or repair the fuel pump Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 8-63. OK ↓ Replace the ECU. 8-66...

  • Page 389: Electrical Components

    ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-67...
  • Page 390 ELECTRICAL COMPONENTS 1. Coolant temperature sensor 2. Front cylinder intake air pressure sensor 3. Rear cylinder intake air pressure sensor 4. Rear cylinder ignition coil 5. Front cylinder ignition coil 6. Sub-wire harness 7. ECU (engine control unit) 8. Turn signal relay 9.
  • Page 391 ELECTRICAL COMPONENTS 8-69...
  • Page 392 ELECTRICAL COMPONENTS 1. Main switch 2. Rectifier/regulator 3. Fuse box 4. Headlight fuse 5. Backup fuse 6. Radiator fan motor fuse 7. Taillight fuse 8. Ignition fuse 9. Signaling system fuse 10. Main fuse 11. Battery 12. Lean angle sensor 13.

  • Page 393: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES Br/L L/B L/Y Br/L (BLACK) L/Y B/Y (BLACK) (BLACK) Ch Br/W Dg B Y/R Y/G B/Y RESET L/Y B Br/W (BLUE) P/W P/B B/Y P 8-71...
  • Page 394 ELECTRICAL COMPONENTS 1. Main switch 2. Rear brake light switch 3. Front brake light switch 4. Reset switch 5. Select switch 6. Engine stop switch 7. Start switch 8. Neutral switch 9. Dimmer switch 10. Turn signal switch 11. Horn switch 12.
  • Page 395 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 CAUTION: Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 396: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB WARNING SOCKETS Since the headlight bulb gets extremely hot, Check each bulb and bulb socket for damage or keep flammable products and your hands wear, proper connections, and also for continuity away from the bulb until it has cooled down.

  • Page 397: Checking The Fuses

    ELECTRICAL COMPONENTS Checking the condition of the bulb sockets 3. Replace: The following procedure applies to all of the bulb • Blown fuse sockets. M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “OFF”. 1.
  • Page 398 ELECTRICAL COMPONENTS • Charge batteries in a well-ventilated area. ECA3D81022 CAUTION: • Keep batteries away from fire, sparks or First, disconnect the negative battery lead open flames (e.g., welding equipment, “1”, then the positive battery lead “2”. lighted cigarettes). • DO NOT SMOKE when charging or han- dling batteries.
  • Page 399 ELECTRICAL COMPONENTS • When charging a battery, be sure to remove it from the vehicle. (If charging has to be done with the battery mounted on the vehi- cle, disconnect the negative battery lead from the battery terminal.) • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
  • Page 400 ELECTRICAL COMPONENTS b. Connect a charger and ammeter to the bat- NOTE: tery and start charging. If the current is lower than the standard charging NOTE: current written on the battery, this type of battery Set the charging voltage to 16–17 V. If the set- charger cannot charge the MF battery.

  • Page 401: Checking The Relays

    ELECTRICAL COMPONENTS 10.Install: Relay unit (starting circuit cut-off relay) • Rider seat • Tool kit tray Refer to “GENERAL CHASSIS” on page 4-1. EAS28040 CHECKING THE RELAYS Check each relay for continuity with the pocket tester. If the continuity reading is incorrect, re- Sb/W L /W L R/L L/R...

  • Page 402: Checking The Turn Signal Relay

    ELECTRICAL COMPONENTS Headlight relay M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → brown “1”...

  • Page 403: Checking The Diodes

    ELECTRICAL COMPONENTS Continuity Positive tester probe → sky blue “1” Negative tester probe → black/yellow “2” No continuity Positive tester probe → black/yellow “2” Negative tester probe → sky blue “1” Continuity b. Turn the main switch to “ON”. Positive tester probe → sky blue c.

  • Page 404: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the relay Pocket tester unit terminals as shown. 90890-03112 c. Check the relay unit (diode) for continuity. Analog pocket tester d. Check the relay unit (diode) for no continuity. YU-03112-C L LLL L LLL...

  • Page 405: Checking The Spark Plug Caps

    ELECTRICAL COMPONENTS NOTE: If the ignition spark gap is within specification, the ignition system circuit is operating normally. M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the spark plug. b. Connect the ignition checker “1” as shown. Ignition checker 90890-06754 c.

  • Page 406: Checking The Crankshaft Position Sensor

    ELECTRICAL COMPONENTS • Positive tester probe → Secondary coil resistance gray “1” 8.64–12.96 k.Ω • Negative tester probe → black “2” M MMM M MMM M MMM M MMM M MMM a. Disconnect the spark plug cap from the igni- tion coil.

  • Page 407: Checking The Starter Motor Operation

    ELECTRICAL COMPONENTS EAS28150 CHECKING THE STATOR COIL 1. Disconnect: • Stator coil coupler (from the wire harness) 2. Check: • Stator coil resistance Out of specification → Replace the crank- shaft position sensor/stator assembly. Stator coil resistance 0.112–0.168 Ω c. Turn the main switch to “ON”. d.

  • Page 408: Checking The Horn

    ELECTRICAL COMPONENTS • Positive tester probe → Charging voltage horn terminal “1” 14 V at 5000 r/min • Negative tester probe → horn terminal “2” M MMM M MMM M MMM M MMM M MMM a. Attach the engine tachometer to the spark plug lead of the front cylinder.

  • Page 409: Checking The Fuel Sender

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the oil Pocket tester 90890-03112 level switch terminal as shown. Analog pocket tester Pocket tester YU-03112-C 90890-03112 Analog pocket tester •...

  • Page 410: Checking The Oil Level Warning Light

    ELECTRICAL COMPONENTS EAS3D81015 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis de- vice for the oil level detection circuit. 1. Check: • Oil level warning light “1” (Turn the main switch to “ON”.) Warning light comes on for a few seconds, then goes off →...

  • Page 411: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS • Never subject the coolant temperature sen- Resistance sor to strong shocks. If the coolant temper- 4.0–6.0 kΩ ature sensor is dropped, replace it. 2. Check: M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 1k) to the •...

  • Page 412: Checking The Air Temperature Sensor

    ELECTRICAL COMPONENTS Pocket tester 90890-03112 Analog pocket tester YU-03112-C • Positive tester probe → pink “1” or pink/white • Negative tester probe → black/blue “2” b. Immerse the air temperature sensor “1” in a container filled with water “2”. NOTE: Make sure that the air temperature sensor termi- nals do not get wet.
  • Page 413 ELECTRICAL COMPONENTS 8-91...

  • Page 414: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ............... 9-1 STARTING FAILURES ................9-1 INCORRECT ENGINE IDLING SPEED ............ 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......9-2 FAULTY GEAR SHIFTING ............... 9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................

  • Page 415: Troubleshooting

    TROUBLESHOOTING EAS28450 4. Throttle body(-ies) TROUBLESHOOTING • Deteriorated or contaminated fuel • Sucked-in air EAS28460 GENERAL INFORMATION Electrical system NOTE: 1. Battery The following guide for troubleshooting does not • Discharged battery cover all the possible causes of trouble. It should •...

  • Page 416: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING Fuel system • Bent shift fork guide bar 1. Throttle body(-ies) Transmission • Damaged or loose throttle body joint • Seized transmission gear • Improperly synchronized throttle bodies • Foreign object between transmission gears • Improper throttle cable free play •...

  • Page 417: Overheating

    TROUBLESHOOTING EAS28600 EAS28610 OVERHEATING OVERCOOLING Engine Cooling system 1. Clogged coolant passages 1. Thermostat • Cylinder head(s) and piston(s) • Thermostat stays open • Heavy carbon buildup EAS28620 2. Engine oil POOR BRAKING PERFORMANCE • Incorrect oil level • Worn brake pad •...

  • Page 418: Faulty Lighting Or Signaling System

    TROUBLESHOOTING • Unevenly tensioned fork spring (both front • Faulty battery fork legs) • Incorrectly adjusted rear brake light switch • Broken fork spring • Tail/brake light bulb life expired • Bent or damaged inner tube Turn signal does not come on •...
  • Page 419 XVS13AW(C)/XVS13CTW(C) 2007 WIRING DIAGRAM WIRE HARNESS SUB WIREHARNESS WIRE HARNESS SUB WIREHARNESS WIRE HARNESS TAIL BRAKE LIGHT WIRE HARNESS (GRAY) (BLACK) (BLACK) (BLACK) (DARK GREEN) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (DARK GRAY) (DARK GREEN) ( GRAY) (BLACK) RESET (BLACK) (BLACK) (BLUE) (BLUE) (BLACK)

  • Page 420: Wiring Diagram

    EAS28740 53. Turn signal switch EAS28750 WIRING DIAGRAM COLOR CODE 54. Horn switch Black 55. Rear right turn signal light XVS13AW(C)/XVS13CTW(C) Brown 56. Rear left turn signal light 2007 Chocolate 57. Front right turn signal light 1. AC magneto Dark green 58.
  • Page 422 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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