Page 1 2009 SERVICE MANUAL FZ6RY(C) LIT-11616-22-77 36P-28197-10...
Page 3 EAS20050 FZ6RY(C) SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, December 2008 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-11616-22-77...
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 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. The manual is divided into chapters and each chapter is divided into sections.
Page 6: Symbols
EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Gear oil Serviceable with engine mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Wheel bearing grease Special tool Tightening torque...
Page 7: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 9: General Information
GENERAL INFORMATION IDENTIFICATION ...................1-1 VEHICLE IDENTIFICATION NUMBER............1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF FI SYSTEM................1-2 FI SYSTEM ....................1-3 INSTRUMENT FUNCTIONS..............1-4 IMPORTANT INFORMATION ................1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-7 REPLACEMENT PARTS .................1-7 GASKETS, OIL SEALS AND O-RINGS ...........1-7 LOCK WASHERS/PLATES AND COTTER PINS........1-7 BEARINGS AND OIL SEALS..............1-8 CIRCLIPS....................1-8 CHECKING THE CONNECTIONS ..............1-9...
Page 10: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 11: Features
FEATURES EAS20170 FEATURES EAS4B51038 OUTLINE OF 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. In a 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 chamber.
Page 12: Fi System
FEATURES EAS4B51039 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 245–255 kPa (2.45–2.55 kgf/ , 35.5–37.0 psi) higher than the intake manifold pressure.
Page 13: Instrument Functions
FEATURES Tachometer EAS20S1001 INSTRUMENT FUNCTIONS Multi-function meter unit 8 7 6 1. Tachometer 2. Tachometer red zone 1. Fuel meter The electric tachometer allows the rider to mon- 2. Coolant temperature display 3. Speedometer itor the engine speed and keep it within the ideal 4.
Page 14 FEATURES 4. Push the “SELECT” button, and the minute Fuel meter digits will start flashing. 5. Push the “RESET” button to set the minutes. 6. Push the “SELECT” button and then release it to start the clock. Odometer and tripmeter modes 1.
Page 15 FEATURES Self-diagnosis device 1. Error code display This model is equipped with a self-diagnosis de- vice for various electrical circuits. If a problem is detected in any of those circuits, the engine trouble warning light will come on and the display will indicate an error code. If the display indicates any error codes, note the code number, and then check the vehicle.
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 “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.
Page 18: Checking The Connections
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS ECA20S1001 NOTICE Electronic parts are very sensitive. Handle with care and do not give impact. When you check the electric system of a motor- cycle, check the battery voltage before. Mini- mum 11V is requested to check each component function.
Page 19: Removing The Quick Fastener
CHECKING THE CONNECTIONS If the pin “1” on the terminal is flattened, bend it If the contact seems not good, pull the terminal by hand and check its condition. When you check the voltage or electrical conti- nuity, insert the measuring probe from back side as you can insert from back side.
Page 20: Installing The Quick Fastener
CHECKING THE CONNECTIONS EAS21850 INSTALLING THE QUICK FASTENER To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cover and push the pin “a” in with screwdriver. Make sure that the pin is flush with the fastener’s head.
Page 21: 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 22 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Oil pressure adapter H 3-24 90890-03139 Compression gauge 5-18 90890-03081 Engine compression tester YU-33223 Steering nut wrench 3-18, 4-53 90890-01403 Spanner wrench YU-33975 Damper rod holder 4-46, 4-48 90890-01460 T-handle 4-46, 4-48 90890-01326 YM-01326 Fork seal driver weight...
Page 23 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Fork seal driver attachment (ø41) 4-48 90890-01381 Replacement 41 mm YM-A5142-2 Ring nut wrench 4-53 90890-01268 Spanner wrench YU-1268 Valve spring compressor 5-21, 5-26 90890-04019 YM-04019 Valve spring compressor attachment 5-21, 5-26 90890-04108 Valve spring compressor adapter 22 mm YM-04108...
Page 24 YS-01880-A Flywheel puller 5-30 90890-01362 Heavy duty puller YU-33270-B Flywheel puller attachment 5-30 90890-04089 Crankshaft protector YM-33282 Yamaha bond No. 1215 5-32, 5-34, (Three bond No.1215®) 5-61, 6-12 90890-85505 Camshaft wrench 5-34 90890-04143 YM-04143 Digital circuit tester 5-38, 7-10, 90890-03174...
Page 25 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-50, 5-54 90890-04086 YM-91042 Piston pin puller set 5-66 90890-01304 Piston pin puller YU-01304 YU-01304 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 1-16...
Page 26 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984 YU-33984 Mechanical seal installer 6-12 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Bearing driver 40 mm YM-04058 Fuel injector pressure adapter 90890-03210...
Page 27: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ...............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS.................2-9 ELECTRICAL SPECIFICATIONS..............2-12 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS......2-14 ENGINE TIGHTENING TORQUES............2-14 CHASSIS TIGHTENING TORQUES............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE....................2-22 CHASSIS....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS ........2-25 ENGINE OIL LUBRICATION CHART ............2-25 LUBRICATION DIAGRAMS ..............2-27 COOLING SYSTEM DIAGRAMS..............2-39 CABLE ROUTING..................2-41...
Page 28: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model FZ6RY 36P1 (U49) FZ6RY 36P4 (U49) FZ6RYC 36P2 (CAL) FZ6RYC 36P5 (CAL) Dimensions Overall length 2120 mm (83.5 in) Overall width 770 mm (30.3 in) Overall height 1185 mm (46.7 in) Seat height 785 mm (30.9 in) Wheelbase 1440 mm (56.7 in) Ground clearance...
Page 29: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 599.8 cm Cylinder arrangement Forward-inclined parallel 4-cylinder Bore × stroke 65.5 × 44.5 mm (2.58 × 1.75 in) Compression ratio 12.20 :1 Standard compression pressure (at sea level) 1550 kPa/400 r/min (15.5 kgf/cm /400 r/min, 220.5 psi/400 r/min)
Page 30 ENGINE SPECIFICATIONS Radiator core Width 300.0 mm (11.81 in) Height 197.0 mm (7.76 in) Depth 22.0 mm (0.87 in) Water pump Water pump type Single suction centrifugal pump 86/44 × 31/31 (1.955) Reduction ratio Spark plug (s) Manufacturer/model NGK/CR9E Spark plug gap 0.7–0.8 mm (0.028–0.031 in) Cylinder head Volume...
Page 31 ENGINE SPECIFICATIONS Valve clearance (cold) Intake 0.13–0.20 mm (0.0051–0.0079 in) Exhaust 0.23–0.30 mm (0.0091–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in) Valve head diameter A (exhaust) 21.90–22.10 mm (0.8622–0.8701 in) Valve face width B (intake) 1.210–2.490 mm (0.0476–0.0980 in) Valve face width B (exhaust) 1.210–2.490 mm (0.0476–0.0980 in)
Page 32 ENGINE SPECIFICATIONS Valve spring Free length (intake) 39.08 mm (1.54 in) Free length (exhaust) 39.08 mm (1.54 in) Installed length (intake) 33.40 mm (1.31 in) Installed length (exhaust) 33.40 mm (1.31 in) Spring rate K1 (intake) 25.05 N/mm (2.55 kgf/mm, 143.04 lb/in) Spring rate K2 (intake) 40.82 N/mm (4.16 kgf/mm, 233.08 lb/in) Spring rate K1 (exhaust)
Page 33 ENGINE SPECIFICATIONS Piston ring Top ring Ring type Barrel Dimensions (B × T) 0.90 × 2.45 mm (0.04 × 0.10 in) End gap (installed) 0.25–0.35 mm (0.0098–0.0138 in) Ring side clearance 0.030–0.065 mm (0.0012–0.0026 in) 2nd ring Ring type Barrel Dimensions (B ×...
Page 34 ENGINE SPECIFICATIONS Wear limit 2.80 mm (0.1102 in) Plate quantity 6 pcs Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) Wear limit 2.80 mm (0.1102 in) Plate quantity 1 pcs Friction plate thickness 2.94–3.06 mm (0.116–0.120 in) Water limit 2.84 mm (0.1118 in) Plate quantity 1 pcs Clutch plate thickness...
Page 35 ENGINE SPECIFICATIONS Output voltage (at idle) Adjusted by tachometer Idling condition Engine idling speed 1250–1350 r/min 4.5–5.5 % Intake vacuum 32.0 kPa (238 mmHg, 9.37 inHg) 95.0–105.0 °C (203.00–221.00 °F) Water temperature 75.0–85.0 °C (167.00–185.00 °F) Oil temperature Throttle cable free play 3.0–5.0 mm (0.12–0.20 in)
Page 36: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond 26.00 ° Caster angle Trail 103.5 mm (4.07 in) Front wheel Wheel type Cast wheel Rim size 17M/C x MT3.50 Rim material Aluminum Wheel travel 130.0 mm (5.12 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 37 CHASSIS SPECIFICATIONS Master cylinder inside diameter 16.00 mm (0.63 in) Caliper cylinder inside diameter 30.16 mm (1.19 in) Caliper cylinder inside diameter 25.40 mm (1.00 in) Recommended fluid DOT 4 Rear brake Type Single disc brake Operation Right foot operation Rear disc brake Disc outside diameter ×...
Page 38 CHASSIS SPECIFICATIONS Drive chain slack 45.0–55.0 mm (1.77–2.17 in) 15-link length limit 239.3 mm (9.42 in) 2-11...
Page 39: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS System voltage 12 V Ignition system Ignition system TCI (digital) Advancer type Digital 6.5 °/1300 r/min Ignition timing (B.T.D.C.) Engine control unit Model/manufacturer FUA0032/MITSUBISHI 248–372 Ω (Gy-B) Pickup coil resistance Ignition coil 248–372 Ω (Gy-B) Pickup coil resistance Minimum ignition spark gap 6.0 mm (0.24 in)
Page 40 ELECTRICAL SPECIFICATIONS Electric starting system System type Constant mesh Starter motor Power output 0.60 kW 0.0012–0.0022 Ω Armature coil resistance Brush overall length 10.0 mm (0.39 in) Limit 3.50 mm (0.14 in) Brush spring force 7.16–9.52 N (730–971 gf, 25.77–34.27 oz) Commutator diameter 28.0 mm (1.10 in) Limit...
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- A.
Page 42 TIGHTENING TORQUES Thread ’ Item Tightening torque Remarks size Thermostat cover bolt · · 12 Nm (1.2 m kgf, 8.7 ft lbf) · · Water jacket joint bolt 10 Nm (1.0 m kgf, 7.2 ft lbf) · · Water pump cover bolt 10 Nm (1.0 m kgf, 7.2 ft lbf)
Page 43 TIGHTENING TORQUES Thread ’ Item Tightening torque Remarks size Clutch cover bolt · · 10 Nm (1.0 m kgf, 7.2 ft lbf) · · Generator cover bolt 10 Nm (1.0 m kgf, 7.2 ft lbf) Apply oil Crankcase bolt (main journal) See TIP to threads and sur-...
Page 44 TIGHTENING TORQUES Thread ’ Item Tightening torque Remarks size · · Starter clutch screw 32 Nm (3.2 m kgf, 23 ft lbf) · · Starter motor assembly bolt 3.4 Nm (0.34 m kgf, 2.3 ft lbf) · · Clutch pressure plate screw 8 Nm (0.8 m kgf, 5.8 ft lbf)
Page 45: Chassis Tightening Torques
TIGHTENING TORQUES Cylinder head tightening sequence. Crankcase tightening sequence. EAS20350 CHASSIS TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size · · Upper bracket pinch bolt 20 Nm (2.0 m kgf, 14 ft lbf) · · Grip end 26 Nm (2.6 m kgf, 18 ft lbf) Left handlebar switch screw...
Page 46 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size · · Steering stem nut 110 Nm (11 m kgf, 80 ft lbf) · · Upper handlebar holder bolt 24 Nm (2.4 m kgf, 17 ft lbf) – · · Lower bracket pinch bolt 30 Nm (3.0 m kgf, 22 ft...
Page 47 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size · · Fuel pump and fuel tank 4 Nm (0.4 m kgf, 2.9 ft lbf) · · Ignition coil screw 1.5 Nm (0.15 m kgf, 1.1 ft lbf) · · Seat lock and frame 7 Nm (0.7 m kgf, 5.0 ft...
Page 48 TIGHTENING TORQUES Threa Item Q’ty Tightening torque Remarks d size · · Footrest bracket and frame 30 Nm (3.0 m kgf, 22 ft lbf) Rear brake ﬂuid reservoir and · · 3 Nm (0.3 m kgf, 2.2 ft lbf) bracket Rear master cylinder and footrest ·...
Page 49: Lubrication Points And Lubricant Types
LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings and bushes Crankshaft pins Piston surfaces Piston pins Connecting rod bolts Crankshaft journals Camshaft proﬁle journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surface Piston cooler (O-ring)
Page 50: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant ® Cylinder head cover semicircular Three bond No.1215B Crankcase mating surface ® Three bond No.1215 ® Generator rotor cover (stator coil assembly lead grommet) Three bond No.1215 Pickup rotor cover (crankshaft position sensor lead grommet) ®...
Page 51 LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Sidestand bracket and link mating surface 2-24...
Page 52: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump 3. Relief valve 4. Oil ﬁlter 5. Oil cooler 6. Main axle 7. Oil pipe 8. Drive axle 9. Main gallery 10. Oil nozzle 11. Timing chain tensioner 12. Intake camshaft 13.
Page 54: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil level switch 2. Oil cooler 3. Relief valve 4. Ventilation chamber cover 5. Oil delivery pipe 2-28...
Page 56 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 57 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil pump 2. Exhaust camshaft 3. Intake camshaft 4. Oil strainer 5. Oil pipe 6. Oil delivery pipe 7. Timing chain tensioner 8. Oil check bolt 2-30...
Page 58 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 59 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil cooler 2. Oil strainer 3. Oil level switch 4. Oil pump 5. Oil pipe 6. Oil ﬁlter 2-32...
Page 60 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 61 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Oil pump 3. Relief valve 4. Oil pipe 5. Oil delivery pipe 2-34...
Page 62 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-35...
Page 63 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Cylinder head 2. Intake camshaft 3. Exhaust camshaft 4. Crankshaft 5. Oil nozzle 2-36...
Page 64 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-37...
Page 65 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Main axle 2. Drive axle 3. Oil pipe 2-38...
Page 66: Cooling System Diagrams
COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-39...
Page 67 COOLING SYSTEM DIAGRAMS 1. Radiator 2. Oil cooler 3. Water pump 4. Coolant reservoir 5. Fast idle plunger 6. Water pump breather hose 7. Water jacket joint 2-40...
Page 68: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING 2-41...
Page 69 CABLE ROUTING 1. Clutch cable 2. Throttle cable (accelerator side) 3. Throttle cable (decelerator side) A. Clamp the left handlebar switch lead, main switch lead, and throttle cables. Clamp the leads at the white tape position. Direct the end of clamp down and outward.
Page 70 CABLE ROUTING 2-43...
Page 71 CABLE ROUTING 1. Fuel tank drain hose 2. Rear mudguard assembly 3. ECU lead 4. Starter motor lead 5. Oil level switch lead 6. Sidestand switch lead 7. Sub-wire harness (throttle body) 8. Throttle body joint coupler 9. Wire harness A.
Page 72 CABLE ROUTING 2-45...
Page 73 CABLE ROUTING 1. Right handlebar switch lead 2. Radiator fan motor lead 3. Ignition coil #2, #3 connector 4. Main switch lead 2 5. Main switch lead 1 6. Left handlebar switch lead 7. Ignition coil #1, #4 connector 8. Throttle cables 9.
Page 74 CABLE ROUTING 2-47...
Page 75 CABLE ROUTING 1. Fuel tank breather hose 2. Rectifier/regulator 3. Battery negative lead 4. Starter relay 5. Battery positive lead 6. Starter motor lead 7. Fuel tank drain hose 8. Throttle body joint coupler A. To crankshaft position sensor B. To AC magneto C.
Page 76 CABLE ROUTING 2-49...
Page 77 CABLE ROUTING 1. Radiator fan motor relay 2. Relay unit 3. License plate light lead 4. Rear turn signal light leads (left/right) 5. Tail/brake light lead 6. Seat lock cable 7. Turn signal relay 8. Headlight relay 9. Lean angle sensor 10.
Page 78 CABLE ROUTING 2-51...
Page 79 CABLE ROUTING 1. Front brake hose 2. Front fork assembly A. Clamp it securely. The pawl must be directed toward the right side of the motorcycle. B. Insert it securely until it reaches its end position. C. Secure for 3 or more notches. The pawl must be directed toward the front of the vehicle.
Page 80 CABLE ROUTING 2-53...
Page 81 CABLE ROUTING 1. Rear brake caliper 2. Dust cover 3. Rear brake hose 4. Rear brake reservoir 5. Rear brake light switch lead 6. Frame complete 7. Swingarm 8. Fuel tank 9. Rollover valve (California only) 10. Canister purge hose (California only) 11.
Page 82 CABLE ROUTING 2-55...
Page 83 CABLE ROUTING 1. Clutch cable 2. Left handlebar switch lead 3. Horn lead 4. Throttle cables 5. Right handlebar switch lead 6. Cable guide A. Pass the horn lead front of the inner tube and clamp it on. Direct the end of clamp toward front side of the vehi- cle with its end pointing outside.
Page 84 CABLE ROUTING 2-57...
Page 85 CABLE ROUTING 1. Radiator fan motor lead 2. Crankshaft position sensor lead 3. Wire harness 4. Connector cover A. To meter B. To headlight C. Clamp the wire harness, right handlebar switch lead, and radiator fan motor lead. Clamp the right handlebar switch lead so that there is no slack when the handle is all the way turned to the left.
Page 86 CABLE ROUTING 2-59...
Page 87 CABLE ROUTING 1. Battery negative lead 2. Rear brake light switch lead 3. Fuel tank breather hose 4. Rear turn signal light lead (right/left) 5. License plate light lead 6. Tail/brake light lead 7. Neutral switch lead A. Install the wire harness inside frame from behind of the battery.
Page 88 CABLE ROUTING 2-61...
Page 89 CABLE ROUTING 1. Fuel tank cap 2. Fuel tank 3. Fuel pump 4. Fuel hose 5. Fuel tank breather hose (right side) 6. Fuel tank drain hose (left side) 7. Throttle body 8. Fuel hose connector 9. Fuel pump bracket 10.
Page 90 CABLE ROUTING 2-63...
Page 91 CABLE ROUTING 1. Synchronizing hose #1 2. Synchronizing hose #2 3. Synchronizing hose #3 4. Synchronizing hose #4 5. Fast idle plunger coolant hose 6. Throttle position sensor 7. Fuel injector #4 8. Intake air pressure sensor 9. Fuel injector #3 10.
Page 92 CABLE ROUTING 2-65...
Page 93 CABLE ROUTING 1. Synchronizing hose #1 2. Synchronizing hose #2 3. Canister purge hose (California only) 4. Synchronizing hose #3 5. Synchronizing hose #4 6. Fast idle plunger coolant hose 7. Throttle position sensor 8. Fuel injector #4 9. Intake air pressure sensor 10.
Page 94 CABLE ROUTING 2-67...
Page 95 CABLE ROUTING 1. Fast idle plunger coolant hose 2. Fast idle plunger 3. Synchronizing hose #1 4. Synchronizing hose #2 5. Fast idle plunger hose (fast idle plunger-throttle body #1) 6. Intake air pressure sensor 7. Throttle position sensor 8. Fast idle plunger hose (fast idle plunger-throttle body #4) 9.
Page 96 CABLE ROUTING 2-69...
Page 97 CABLE ROUTING 1. Air cut-off valve hose 1 2. Air cut-off valve hose 2 3. Air cut-off valve 4. Air cut-off valve hose 3 5. Air filter case 6. Bracket 7. Rubber cover 8. Reed valve A. Install the clamp with its end facing the right side of the vehicle.
Page 98 CABLE ROUTING 2-71...
Page 99: 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......3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS............3-4 ADJUSTING THE VALVE CLEARANCE ..........3-5 ADJUSTING THE ENGINE IDLING SPEED..........3-7 SYNCHRONIZING THE THROTTLE BODIES ........3-8 CHECKING THE CANISTER (for California only)........3-10 CHECKING THE AIR INDUCTION SYSTEM ..........3-10 CHECKING THE CRANKCASE BREATHER HOSE .......3-10...
Page 100 ADJUSTING THE HEADLIGHT BEAMS..........3-29 REPLACING THE HEADLIGHT BULBS ..........3-30...
Page 101: Periodic Maintenance
Check the air cut-off valve, reed valve, and hose for Air induction sys- √ √ damage. Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 102: General Maintenance And Lubrication Chart
PERIODIC MAINTENANCE EAU32185 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 8000 mi 12000 mi 16000 mi 20000 mi 600 mi 4000 mi ITEM ROUTINE (13000 (19000 (25000 (31000 (1000 km) (7000 km) 1 month 6 months 12 months 18 months 24 months 30 months 1 * Air ﬁlter element...
Page 103 Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 104: Checking The Fuel Line
PERIODIC MAINTENANCE 2. Disconnect: EAS21030 CHECKING THE FUEL LINE Spark plug caps The following procedure applies to all of the fuel, 3. Remove: vacuum and breather hoses. Spark plugs 1. Remove: ECA13320 Passenger seat/Rider seat NOTICE Refer to “GENERAL CHASSIS” on page 4-1. Before removing the spark plugs, blow away Fuel tank any dirt accumulated in the spark plug wells...
Page 105: Adjusting The Valve Clearance
PERIODIC MAINTENANCE 9. Connect: Spark plug caps 10.Install: Rubber cover Refer to “AIR INDUCTION SYSTEM” on page 7-11. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Passenger seat/Rider seat 4.
Page 106 PERIODIC MAINTENANCE 5. Remove: Thickness gauge Camshafts 90890-03079 Narrow gauge set Refer to “CAMSHAFTS” on page 5-8. YM-34483 When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase. 6.
Page 107: Adjusting The Engine Idling Speed
PERIODIC MAINTENANCE The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touch- es the valve lifter. Example: If the valve pad is marked “158”, the pad thickness is 1.58 mm (0.062 in) Lubricate the valve pad with molybdenum dis- ulfide grease.
Page 108: Synchronizing The Throttle Bodies
PERIODIC MAINTENANCE Spark plugs THROTTLE BODIES” on page 7-8. Air filter element If they cannot synchronized, replace the Throttle body joints throttle body assembly. Fuel hoses Air induction system Exhaust system Canister purge hose (for California only) Breather hoses Throttle body hoses Fast idle plunger outlet hose Fast idle plunger inlet hose 1.
Page 109 PERIODIC MAINTENANCE the throttle bodies. Vacuum gauge 90890-03094 Vacuum gauge Carburetor synchronizer 90890-03094 YU-44456 Carburetor synchronizer YU-44456 The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mmHg). 4. Install: Fuel tank Refer to “FUEL TANK” on page 7-1. 5.
Page 110: Checking The Canister (For California Only)
PERIODIC MAINTENANCE Cracks/damage → Replace. EAS21090 CHECKING THE CANISTER (for California Loose connection → Connect properly. only) ECA13450 1. Remove: NOTICE Right rear side cover Make sure the crankcase breather hose is Refer to “GENERAL CHASSIS” on page 4-1. routed correctly. 2.
Page 111: Adjusting The Clutch Cable Free Play
PERIODIC MAINTENANCE 3. Check: 2. Adjust: Air filter element Clutch cable free play Damage → Replace. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Handlebar side Replace the air filter element every 40000 km a. Turn the adjusting bolt “1” in direction “a” or of operation. “b” until the specified clutch cable free play is The air filter needs more frequent service if you obtained.
Page 112: Checking The Brake Fluid Level
PERIODIC MAINTENANCE EWA13090 WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.
Page 113: Checking The Front Brake Pads
PERIODIC MAINTENANCE EAS21190 ADJUSTING THE REAR DISC BRAKE 1. Check: Brake pedal position (distance “a” from the top of the rider footrest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (below the top of the rider footrest) 46.5 mm (1.83 in) EWA13060 WARNING...
Page 114: Checking The Rear Brake Pads
PERIODIC MAINTENANCE replaced. Locknut the brake fluid level is very low. 18 Nm (1.8 m·kgf, 13 ft·lbf) brake operation is faulty. EWA4S81005 WARNING Be careful not to spill any brake fluid or allow A soft or spongy feeling in the brake pedal the brake master cylinder reservoir or brake can indicate the presence of air in the brake fluid reservoir to overflow.
Page 115: Checking The Front Brake Hoses
PERIODIC MAINTENANCE e. Slowly apply the brake lever several times. several times. f. Fully pull the brake lever or fully press down 4. Check: the brake pedal and hold it in position. Brake hose Brake fluid leakage → Replace the damaged g.
Page 116 250 kPa (2.50 kgf/cm , 36 psi) en if a tire combination other than one Loading condition* approved by Yamaha is used on this vehicle. 90–188 kg (198–414 lb) (FZ6RY) 90–187 kg (198–412 lb) (FZ6RYC) Front tire Front Size 250 kPa (2.50 kgf/cm...
Page 117: Checking The Wheel Bearing
PERIODIC MAINTENANCE rear wheel is elevated. EWA13210 WARNING 2. Spin the rear wheel several times and find the New tires have a relatively low grip on the tightest position of drive chain. road surface until they have been slightly 3. Check: worn.
Page 118: Lubricating The Drive Chain
PERIODIC MAINTENANCE e. Tighten the wheel axle nut to specification. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Remove the lock washer “1”, the upper ring Wheel axle nut nut “2”, and the rubber washer “3”. 90 Nm (9.0 m·kgf, 64 ft·lbf) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21440 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.
Page 119: Adjusting The Handlebar Position
PERIODIC MAINTENANCE lower bearings. d. Hold the spring gauge at a 90° angle from the Refer to “STEERING HEAD” on page 4-51. handlebar, pull the spring gauge, and then e. Install the rubber washer “2”. record the measurement when the handlebar f.
Page 120: Lubricating The Levers
PERIODIC MAINTENANCE Upper handlebar holder bolt 24 Nm (2.4 m·kgf, 17 ft·lbf) ECA14250 NOTICE First, tighten the bolts on the front side of the handlebar holder, and then on the rear side. Turn the handlebar all the way to the left and right.
Page 121: Lubricating The Sidestand
PERIODIC MAINTENANCE Recommended lubricant Lithium-soap-based grease EAS20S13002 CHECKING THE SIDESTAND SWITCH Refer to “CHECKING THE SWITCHES” on page 8-75. EAS21530 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. EWA13120 WARNING Shift rod length 260.4–262.4 mm (10.25–10.33 in) Securely support the vehicle so that there is no danger of it falling over.
Page 122: Adjusting The Rear Shock Absorber Assembly
PERIODIC MAINTENANCE moving parts of the rear suspension. Recommended lubricant LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Molybdenum disulfide grease EAS20730 CHECKING THE ENGINE OIL LEVEL EAS21590 1. Stand the vehicle on a level surface. ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Place the vehicle on a suitable stand. EWA13120 WARNING Make sure the vehicle is upright.
Page 123: Changing The Engine Oil
PERIODIC MAINTENANCE oils with a grade of CD “a” or higher and do not use oils labeled “ENERGY CONSERV- ING II” “b” or higher. Do not allow foreign materials to enter the crankcase. 4. Drain: Engine oil (completely from the crankcase) 5.
Page 124: Measuring The Engine Oil Pressure
PERIODIC MAINTENANCE oil pressure to increase. Therefore, be sure Oil filter cartridge to measure the engine oil pressure after 17 Nm (1.7 m·kgf, 12 ft·lbf) warming up the engine. 3. Remove: Main gallery bolt “1” LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EWA12980 6. Check: WARNING Engine oil drain bolt gasket The engine, muffler and engine oil are ex- 7.
Page 125: Checking The Coolant Level
PERIODIC MAINTENANCE Engine oil pressure Possible causes Faulty oil pump Clogged oil ﬁlter Leaking oil pas- Below speciﬁcation sage Broken or dam- aged oil seal Leaking oil pas- sage 3. Start the engine, warm it up for several min- Faulty oil ﬁlter Above speciﬁcation utes, and then turn it off.
Page 126: Changing The Coolant
PERIODIC MAINTENANCE 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 127: Checking The Front And Rear Brake Switch
PERIODIC MAINTENANCE 10.Install: Radiator cap Right side cowling Refer to “GENERAL CHASSIS” on page 4-1. 11.Fill: Coolant reservoir (with the recommended coolant to the maxi- mum level mark “a”) 8. Install: Coolant reservoir 9. Fill: Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol an-...
Page 128: Checking And Lubricating The Cables
PERIODIC MAINTENANCE rear brake light comes on at the proper time. nization should be adjusted properly. 1. Check: Direction “a” Throttle cable free play “a” Brake light comes on sooner. Out of specification → Adjust. Direction “b” Brake light comes on later. Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 2.
Page 129: Checking And Charging The Battery
PERIODIC MAINTENANCE use the adjusting nut on the handlebar side. Gusset bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) Left side cowling Refer to “GENERAL CHASSIS” on page 4-1. EWA4S81001 WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.
Page 130 PERIODIC MAINTENANCE “b”. Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. 3. Remove: Headlight bulb holder “1” 4. Remove: Headlight bulb “2” LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS21790 REPLACING THE HEADLIGHT BULBS 1. Disconnect: Headlight coupler “1” EWA13320 WARNING Since the headlight bulb gets extremely hot,...
Page 131: Chassis
CHASSIS GENERAL CHASSIS ..................4-1 FRONT WHEEL .....................4-6 REMOVING THE FRONT WHEEL ............4-8 CHECKING THE FRONT WHEEL ............4-8 ADJUSTING THE FRONT WHEEL STATIC BALANCE ......4-9 INSTALLING THE FRONT WHEEL ............4-10 REAR WHEEL....................4-11 REMOVING THE REAR WHEEL.............4-14 CHECKING THE REAR WHEEL .............4-14 CHECKING THE REAR WHEEL DRIVE HUB.........4-14 CHECKING AND REPLACING THE REAR WHEEL SPROCKET ..4-14 ADJUSTING THE REAR WHEEL STATIC BALANCE ......4-15...
Page 132 FRONT FORK ....................4-44 REMOVING THE FRONT FORK LEGS...........4-46 DISASSEMBLING THE FRONT FORK LEGS.........4-46 CHECKING THE FRONT FORK LEGS ...........4-47 ASSEMBLING THE FRONT FORK LEGS..........4-48 INSTALLING THE FRONT FORK LEGS ..........4-50 STEERING HEAD ..................4-51 REMOVING THE LOWER BRACKET .............4-53 CHECKING THE STEERING HEAD............4-53 INSTALLING THE STEERING HEAD............4-54 REAR SHOCK ABSORBER ASSEMBLY .............4-55 HANDLING THE REAR SHOCK ABSORBER.........4-56...
Page 133: General Chassis
GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the seats and covers 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 16 Nm (1.6 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf)
Page 134 GENERAL CHASSIS Removing the front cowling assembly 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 7 Nm (0.7 m kgf, 5.0 ft Ibf) • • 33 Nm (3.3 m kgf, 23 ft Ibf) • • 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) •...
Page 135 GENERAL CHASSIS Disassembling the front cowling assembly 15 Nm (1.5 m kgf, 1.1 ft Ibf) 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.0 ft Ibf) •...
Page 136 GENERAL CHASSIS Removing the air ﬁlter case 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 137 GENERAL CHASSIS Removing the battery 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Passenger seat/Rider seat 4-1. Refer to “GENERAL CHASSIS” on page Rider seat height position adjuster 4-1.
Page 138: Front Wheel
FRONT WHEEL EAS21880 FRONT WHEEL Removing the front wheel and brake discs 40Nm (4.0 m kgf, 28 ft Ibf) • • 65 Nm (6.5 m kgf, 46 ft Ibf) • • 19 Nm (1.9 m kgf, 13 ft Ibf) • •...
Page 139 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.
Page 140: Removing The Front Wheel
FRONT WHEEL 2. Check: EAS21900 REMOVING THE FRONT WHEEL Tire 1. Stand the vehicle on a level surface. Front wheel EWA13120 Damage/wear → Replace. WARNING Refer to “CHECKING THE TIRES” on page Securely support the vehicle so that there is 3-15 and “CHECKING THE WHEELS”...
Page 141: Adjusting The Front Wheel Static Balance
FRONT WHEEL brake disc installed. 1. Remove: Balancing weight(s) 2. Find: Front wheel’s heavy spot Place the front wheel on a suitable balancing stand. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM c. Remove the wheel bearings “3” with a gener- a. Spin the front wheel. al bearing puller. b.
Page 142: Installing The Front Wheel
FRONT WHEEL EAS22000 INSTALLING THE FRONT WHEEL The following procedure applies to both of the brake discs. 1. Lubricate: Wheel axle Oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: Collar Start with the lightest weight. Wheel axle b. Turn the front wheel 90° so that the heavy spot is positioned as shown.
Page 143: Rear Wheel
REAR WHEEL EAS22030 REAR WHEEL Removing the rear wheel 22 Nm (2.2 m kgf, 15 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf) • • 16 Nm (1.6 m kgf, 11 ft Ibf) • • 90 Nm (9.0 m kgf, 64 ft Ibf) •...
Page 144 REAR WHEEL Removing the rear brake disc and rear wheel sprocket 20 Nm (2.0 m kgf, 14 ft Ibf) • • 80 Nm (8.0 m kgf, 57 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel sprocket Collar Collar...
Page 145 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Oil seal Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-13...
Page 146: Removing The Rear Wheel
REAR WHEEL Oil seals EAS22040 REMOVING THE REAR WHEEL Refer to “CHECKING THE FRONT WHEEL” 1. Stand the vehicle on a level surface. on page 4-8. EWA13120 2. Check: WARNING Tire Securely support the vehicle so that there is Rear wheel no danger of it falling over.
Page 147: Adjusting The Rear Wheel Static Balance
REAR WHEEL 2. Replace: Collar Rear wheel sprocket Rear brake caliper assembly Rear wheel MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Indicator plate a. Remove the self-locking nuts and the rear Washer wheel sprocket. Rear wheel axle b. Clean the rear wheel drive hub with a clean 3.
Page 148: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 27 Nm (2.7 m kgf, 19 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Front brake caliper Brake pad Brake pad spring For installation, reverse the removal proce- dure.
Page 149 FRONT BRAKE Removing the front brake master cylinder 1.5 Nm (0.15 m kgf, 1.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.
Page 150 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Master cylinder kit Master cylinder For assembly, reverse the disassembly pro- cedure. 4-18...
Page 151 FRONT BRAKE Removing the front brake calipers 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 40 Nm (4.0 m kgf, 28 ft Ibf) 27 Nm (2.7 m...
Page 152 FRONT BRAKE Disassembling the front brake calipers 6 Nm (0.6 m kgf, 4.3 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake pad Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Brake pad spring Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 153: Introduction
FRONT BRAKE EAS22220 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM INTRODUCTION a. Place the vehicle on a suitable stand so that EWA14100 the front wheel is elevated. WARNING b. Before measuring the front brake disc deflec- Disc brake components rarely require disas- tion, turn the handlebar to the left or right to sembly.
Page 154: Replacing The Front Brake Pads
FRONT BRAKE bleed screw “2”. Put the other end of the hose Brake disc bolt into an open container. 18 Nm (1.8 m·kgf, 13 ft·lbf) b. Loosen the bleed screw and push the brake LOCTITE® caliper pistons into the brake caliper with your finger.
Page 155: Removing The Front Brake Calipers
FRONT BRAKE EAS22300 REMOVING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Union bolt “1” Copper washers “2” EWA4S81006 Brake hose “3”...
Page 156: Assembling The Front Brake Calipers
FRONT BRAKE EWA13600 Brake caliper bolt WARNING 27 Nm (2.7 m·kgf, 19 ft·lbf) Whenever a brake caliper is disassembled, Brake hose union bolt replace the piston seals. 32 Nm (3.2 m·kgf, 23 ft·lbf) EAS22410 EWA13530 ASSEMBLING THE FRONT BRAKE WARNING CALIPERS Proper brake hose routing is essential to in- EWA13620...
Page 157: Removing The Front Brake Master Cylinder
FRONT BRAKE deteriorate, causing leakage and poor 2. Remove: brake performance. Union bolt “1” Refill with the same type of brake fluid that Copper washers “2” is already in the system. Mixing brake flu- Brake hoses “3” ids may result in a harmful chemical reac- tion, leading to poor brake performance.
Page 158: Assembling The Front Brake Master Cylinder
FRONT BRAKE 3. Check: Brake master cylinder reservoir “1” Cracks/damage → Replace. Brake master cylinder reservoir diaphragm “2” Damage/wear → Replace. 2. Install: Copper washers“1” Brake hose “2” Union bolt “3” Brake hose union bolt 32 Nm (3.2 m·kgf, 23 ft·lbf) 4.
Page 159 FRONT BRAKE Recommended fluid DOT 4 EWA13540 WARNING Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake flu- ids may result in a harmful chemical reac- tion, leading to poor brake performance.
Page 160: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf)
Page 161 REAR BRAKE Removing the rear brake master cylinder 30 Nm (3.0 m kgf, 21 ft Ibf) • • 3 Nm (0.3 m kgf, 2.2 ft Ibf) • • 23 Nm (2.3 m kgf, 16 ft Ibf) • • 30 Nm (3.0 m kgf, 21 ft Ibf) •...
Page 162 REAR BRAKE Disassembling the rear brake master cylinder 14 Nm (1.4 m kgf, 10 ft Ibf) • • 18 Nm (1.8 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body Connector Bushing For installation, reverse the removal proce-...
Page 163 REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kgf, 22 ft Ibf) • • 27 Nm (2.7 m kgf, 19 ft Ibf) • • 22 Nm (2.2 m kgf, 15 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drain.
Page 164 REAR BRAKE Disassembling the rear brake caliper 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 2.5 Nm (0.25 m kgf, 1.8 ft Ibf) • • 17 Nm (1.7 m kgf, 12 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Screw plug...
Page 165: Introduction
REAR BRAKE 4. Adjust: EAS22560 INTRODUCTION Brake disc deflection EWA14100 Refer to “CHECKING THE FRONT BRAKE WARNING DISCS” on page 4-21. Disc brake components rarely require disas- sembly. Therefore, always follow these pre- Brake disc bolt ventive measures: 20 Nm (2.0 m·kgf, 14 ft·lbf) Never disassemble brake components un- LOCTITE®...
Page 166: Removing The Rear Brake Caliper
REAR BRAKE Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. EAS22590 REMOVING THE REAR BRAKE CALIPER Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: Union bolt “1” b. Loosen the bleed screw and push the brake Copper washers “2”...
Page 167: Checking The Rear Brake Caliper
REAR BRAKE Be careful not to get injured when the pis- ton is expelled from the brake caliper. Never try to pry out the brake caliper pis- ton. EWA13610 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals. 2.
Page 168 REAR BRAKE 4. Check that the brake caliper slide smoothly on the side way. Difficult → Apply the silicone grease to the brake caliper bolt. 5. Fill: Brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4 Brake hose union bolt...
Page 169: Removing The Rear Brake Master Cylinder
REAR BRAKE 8. Check: Brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. EAS22700 REMOVING THE REAR BRAKE MASTER CYLINDER 1. Remove: Union bolt “1” 2. Check: Copper washers “2”...
Page 170: Installing The Rear Brake Master Cylinder
REAR BRAKE Recommended fluid DOT 4 1. Install: Master cylinder kit Circlip EAS22740 INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: 1. Fill: Cotter pin “1” Brake fluid reservoir Copper washers “2” (to the maximum level mark “a”) Brake hose “3” Union bolt “4”...
Page 171 REAR BRAKE Below the minimum level mark “b” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-12. 4. Adjust: Brake pedal position “c” Refer to “ADJUSTING THE REAR DISC BRAKE”...
Page 172: Handlebar
HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 26 Nm (2.6 m kgf, 19 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • 26 Nm (2.6 m kgf, 19 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 173: Removing The Handlebars
HANDLEBAR EAS22860 REMOVING THE HANDLEBARS 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: Handlebar grip “1” EAS22880 Blow compressed air between the left handlebar CHECKING THE HANDLEBAR and the handlebar grip, and gradually push the 1.
Page 174 HANDLEBAR 4. Tighten: Lower handlebar holder nuts Lower handlebar holder nut 32 Nm (3.2 m·kgf, 23 ft·lbf) 5. Install: Throttle grip “1” Throttle cables Right handlebar switch “2” Align the projections “a” on the handlebar switch with the holes “b” in the handlebar. ECA14250 NOTICE First, tighten the bolts on the front side of...
Page 175 HANDLEBAR MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Apply a thin coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag. EWA13700 WARNING Do not touch the handlebar grip until the rub-...
Page 176: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 20 Nm (2.0 m kgf, 14 ft Ibf) • • 24 Nm (2.4 m kgf, 17 ft Ibf) • • 30 Nm (3.0 m kgf, 21 ft Ibf) • • 6 Nm (0.6 m kgf, 4.3 ft Ibf)
Page 177 FRONT FORK Disassembling the front fork legs 24 Nm (2.4 m kgf, 17 ft Ibf) • • 23 Nm (2.3 m kgf, 16 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Cap bolt/O-ring Spacer Spring seat Front fork spring Dust seal Oil seal clip Damper rod assembly bolt/Copper washer...
Page 178: Removing The Front Fork Legs
FRONT FORK 2. Drain: EAS22970 REMOVING THE FRONT FORK LEGS Fork oil The following procedure applies to both of the front fork legs. Stroke the inner tube several times while drain- 1. Stand the vehicle on a level surface. ing the fork oil. EWA13120 WARNING 3.
Page 179: Checking The Front Fork Legs
FRONT FORK vise with soft jaws. Fork spring free length c. Separate the inner tube from the outer tube 365.1 mm (14.37 in) by pulling the inner tube forcefully but careful- Limit 357.8 mm (14.09 in) ECA14190 NOTICE Excessive force will damage the oil seal and bushing.
Page 180: Assembling The Front Fork Legs
FRONT FORK EAS23020 ASSEMBLING THE FRONT FORK LEGS While holding the damper rod assembly with the The following procedure applies to both of the damper rod holder “2” and T-handle “3”, tighten front fork legs. the damper rod assembly bolt. EWA13660 WARNING Damper rod holder...
Page 181 FRONT FORK Before installing the oil seal, lubricate its lips with lithium soap base grease. Lubricate the outer surface of the inner tube with fork oil. Before installing the oil seal, cover the top of the front fork leg with a plastic bag “2” to protect the oil seal during installation.
Page 182: Installing The Front Fork Legs
FRONT FORK top of the handlebar holder. 2. Tighten: Lower bracket pinch bolt “1” Lower bracket pinch bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) Cap bolt “2” Cap bolt 24 Nm (2.4 m·kgf, 17 ft·lbf) 10.Install: Spring “1” Upper bracket pinch bolt “3” Spring seat “2”...
Page 183: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kgf, 79 ft Ibf) • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks...
Page 184 STEERING HEAD Removing the lower bracket 110 Nm (11.0 m kgf, 79 ft Ibf) • • 1st 52 Nm (5.2 m kg, 37 ft • • 2nd 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Bearing inner race...
Page 185: Removing The Lower Bracket
STEERING HEAD Bearing races “2” EAS23110 REMOVING THE LOWER BRACKET Damage/pitting → Replace. 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: Steering stem nut Washer Lock washer Upper ring nut “1”...
Page 186: Installing The Steering Head
STEERING HEAD Steering stem nut 110 Nm (11.0 m·kgf, 79 ft·lbf) LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Check: Upper bracket Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: Upper bearing Lower bearing Bearing races Recommended lubricant Lithium-soap-based grease 2.
Page 187: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 51 Nm (5.1 m kgf, 36 ft Ibf) • • 55 Nm (5.5 m kgf, 39 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 188: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23180 EAS23210 HANDLING THE REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER ASSEMBLY EWA13740 WARNING 1. Stand the vehicle on a level surface. This rear shock absorber contains highly EWA13120 WARNING compressed nitrogen gas. Before handling the rear shock absorber, read and make sure Securely support the vehicle so that there is you understand the following information.
Page 189: Installing The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY Gas leaks/oil leaks → Replace the rear shock Rear shock absorber assembly lower nut “2” absorber assembly. Rear shock absorber assembly Spring lower nut Damage/wear → Replace the rear shock ab- 55 Nm (5.5 m·kgf, 39 ft·lbf) sorber assembly.
Page 190: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm 7 Nm (0.7 m kgf, 5 ft Ibf) • • 110 Nm (11.0 m kgf, 79 ft Ibf) • • 7 Nm (0.7 m kgf, 5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper...
Page 191: Removing The Swingarm
SWINGARM EAS23340 EAS23370 REMOVING THE SWINGARM CHECKING THE SWINGARM 1. Stand the vehicle on a level surface. 1. Check: EWA13120 Swingarm WARNING Bends/cracks/damage → Replace. Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 192: Installing The Swingarm
SWINGARM 3. Install: Swingarm Pivot shaft “1” Pivot shaft nut “2” Pivot shaft nut 110 Nm (11.0 m·kgf, 79 ft·lbf) EAS23380 INSTALLING THE SWINGARM 1. Lubricate: Bearings Spacers Oil seals Dust covers Pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: Bearing “1”...
Page 193: Chain Drive
CHAIN DRIVE EAS23400 CHAIN DRIVE Removing the drive chain 110 Nm (11.0 m kgf, 79 ft Ibf) • • 7 Nm (0.7 m kgf, 5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL” on page 5-1. Shift rod Refer to “ENGINE REMOVAL”...
Page 194: Removing The Drive Chain
CHAIN DRIVE 2. Check: EAS23410 REMOVING THE DRIVE CHAIN Drive chain 1. Stand the vehicle on a level surface. Stiffness → Clean and lubricate or replace. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Page 195: Checking The Drive Sprocket
CHAIN DRIVE b. Correct 1. Drive chain roller 2. Drive chain sprocket LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS23470 4. Check: CHECKING THE REAR WHEEL SPROCKET O-rings “1” Refer to “CHECKING AND REPLACING THE Damage → Replace the drive chain. REAR WHEEL SPROCKET” on page 4-14. Drive chain rollers “2”...
Page 196 CHAIN DRIVE 4-64...
Page 197: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE ENGINE ..............5-6 INSTALLING THE DRIVE CHAIN ............5-7 CAMSHAFTS ....................5-8 REMOVING THE CAMSHAFTS ..............5-10 CHECKING THE CAMSHAFTS ...............5-11 CHECKING THE TIMING CHAIN AND CAMSHAFT SPROCKET ..5-12 CHECKING THE TIMING CHAIN GUIDES..........5-12 CHECKING THE TIMING CHAIN TENSIONER ........5-12 INSTALLING THE CAMSHAFTS .............5-13 CYLINDER HEAD ..................5-16 REMOVING THE CYLINDER HEAD ............5-17...
Page 198 CHECKING THE OIL NOZZLES..............5-44 CHECKING THE OIL PUMP DRIVE CHAIN..........5-44 ASSEMBLING THE OIL PUMP..............5-44 INSTALLING THE OIL PUMP ..............5-45 INSTALLING THE OIL STRAINER ............5-45 INSTALLING THE OIL PAN ..............5-45 CLUTCH ......................5-47 REMOVING THE CLUTCH ..............5-50 CHECKING THE FRICTION PLATES .............5-51 CHECKING THE CLUTCH PLATES............5-51 CHECKING THE CLUTCH SPRINGS .............5-52 CHECKING THE CLUTCH HOUSING.............5-52...
Page 199: Engine Removal
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the drive sprocket 16 Nm (1.6 m kgf, 11 ft Ibf) • • 9 Nm (0.9 m kgf, 6.5 ft Ibf) • • 85 Nm (8.5 m kgf, 61 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 200 ENGINE REMOVAL Removing the exhaust pipe 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 20 Nm (2.0 m kgf, 14 ft Ibf) •...
Page 201 ENGINE REMOVAL Disconnecting the leads and hoses 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Passenger seat/Rider seat 4-1.
Page 202 ENGINE REMOVAL Disconnecting the leads and hoses 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Speed sensor coupler Disconnect. For assembly, reverse the removal proce- dure.
Page 203 ENGINE REMOVAL Removing the engine 55 Nm (5.5 m kgf, 39 ft Ibf) • • 55 Nm (5.5 m kgf, 39 ft Ibf) • • 55 Nm (5.5 m kgf, 39 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Left footrest bracket assembly Right front engine mounting bolt...
Page 204: Installing The Engine
ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: Rear engine mounting bolts “1” Lubricate the rear engine mounting bolt threads with engine oil. 4. Tighten: Left front engine mounting bolts “5” Left front mounting bolt 55 Nm (5.5 m·kgf, 40 ft·lbf) 2.
Page 205: Installing The Drive Chain
ENGINE REMOVAL 7. Install: Shift arm bolt “8” Shift arm bolt 16 Nm (1.6 m·kgf, 11 ft·lbf) Before installing, make sure to align the mark “a” of the shift shaft with the punch mark “b” of the shift arm. 3. Install: Clutch push lever assembly Refer to “CLUTCH”...
Page 206: Camshafts
Throttle body Refer to “THROTTLE BODIES” on page 7-4. Spark plug cap Spark plug Cylinder head cover Cylinder head cover gasket Dowel pin Timing chain guide (top side) For installation, reverse the removal proce- dure. *Yamaha bond No.1215 (Three Bond No.1215®)
Page 207 CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 20 Nm (2.0 m kgf, 15 ft Ibf) • • 20 Nm (2.0 m kgf, 15 ft Ibf) •...
Page 208: Removing The Camshafts
CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Remove: Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-33. 2. Align: “T” mark “a” on the pickup rotor (with the crankcase mating surface “b”) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- 5.
Page 209: Checking The Camshafts
CAMSHAFTS 3. Measure: 7. Remove: Camshaft runout Camshaft sprockets Out of specification → Replace. EAS23850 Camshaft runout limit CHECKING THE CAMSHAFTS 0.060 mm (0.0024 in) 1. Check: Camshaft lobes Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: Camshaft lobe dimensions “A” and “B” Out of specification →...
Page 210: Checking The Timing Chain And Camshaft Sprocket
CAMSHAFTS chain and camshaft sprocket as a set. Camshaft cap bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) d. Remove the camshaft caps and then mea- sure the width of the Plastigauge® “2”. 2. Check: Camshaft sprocket More than 1/4 tooth wear “a” → Replace the camshaft sprocket and the timing chain as a set.
Page 211: Installing The Camshafts
CAMSHAFTS Timing chain tensioner outer spring “5” Timing chain tensioner housing “6” Squeeze the timing chain tensioner clip “4”, and then remove the timing chain tensioner springs and timing chain tensioner rod. c. Hook the clip “4” to the timing chain tensioner rod “3”.
Page 212 CAMSHAFTS “a” with the crankcase mating surface “b”. E1 E1 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2. Install: Exhaust camshaft “1” Intake camshaft “2” (with the camshaft sprockets temporarily tightened) Make sure the match mark “a” on the camshaft 4. Install: sprockets is aligned with the cylinder head edge Camshaft cap bolts “b”.
Page 213 CAMSHAFTS Timing chain tensioner bolt 12 Nm (1.2 m·kgf, 8.6 ft·lbf) EWA5D01008 WARNING Always use a new gasket. ECA5D01011 NOTICE Be sure to install the timing chain tensioner gasket so that its section with the “L” mark “a” is protruding from the lower left side of the timing chain tensioner.
Page 214: Cylinder Head
CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 19 Nm (1.9 m kgf, 13 ft Ibf) • • 50 Nm (5.0 m kgf, 36 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) +120˚ • • 18 Nm (1.8 m kgf, 12 ft Ibf)
Page 215: Removing The Cylinder Head
CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD 1. Remove: Cylinder head bolts Loosen the bolts in the proper sequence as shown. Loosen each bolts 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.
Page 216: Measuring The Compression Pressure
CYLINDER HEAD 2. Install: EAS20710 MEASURING THE COMPRESSION Cylinder head PRESSURE The following procedure applies to all of the cyl- Pass the timing chain through the timing chain inders. cavity. 3. Tighten: Insufficient compression pressure will result in a Cylinder head bolts “1” – “10” loss of performance.
Page 217 CYLINDER HEAD 7. Measure: Spark plug Compression pressure 13 Nm (1.3 m·kgf, 9.4 ft·lbf) Out of specification → Refer to steps (c) and (d). 9. Connect: Spark plug caps Standard compression pressure 10.Install: (at sea level) Rubber cover 1550 kPa/400 r/min (15.5 kgf/cm /400 r/min, 220.5 psi/400 Refer to “AIR INDUCTION SYSTEM”...
Page 218: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-16. Intake valve lifter/Exhaust valve lifter Intake valve pad/Exhaust valve pad Intake valve cotter/Exhaust valve cotter 16/16 Intake valve upper spring seat/Exhaust valve...
Page 219: Removing The Valves
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve springs with the valve spring compressor valves and related components. “2” and the valve spring compressor attachment “3”.
Page 220 VALVES AND VALVE SPRINGS guide. Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” - Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 mm (0.0004–0.0015 Limit b. Install the new valve guide with the valve 0.080 mm (0.0032 in) guide installer “2” and valve guide remover Valve-stem-to-valve-guide clear- “1”.
Page 221: Checking The Valve Seats
VALVES AND VALVE SPRINGS LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 3. Eliminate: Carbon deposits (from the valve face and valve seat) 4. Check: Valve face Pitting/wear → Grind the valve face. Valve stem end Mushroom shape or diameter larger than the EAS24300 body of the valve stem → Replace the valve. CHECKING THE VALVE SEATS 5.
Page 222 VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. c. Install the valve into the cylinder head. c. Press the valve through the valve guide and d. Turn the valve until the valve face and valve onto the valve seat to make a clear impres- seat are evenly polished, then clean off all of sion.
Page 223: Checking The Valve Springs
VALVES AND VALVE SPRINGS sion. j. Measure the valve seat width “c” again. If the valve seat width is out of specification, reface and lap the valve seat. b. Installed length Installed compression spring force (intake) 132.40–152.40 N (13.50–15.54 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL kgf, 29.76–34.26 lbf) Installed compression...
Page 224: Checking The Valve Lifters
VALVES AND VALVE SPRINGS Lower spring seat “2” EAS24320 CHECKING THE VALVE LIFTERS Valve stem seal “3” The following procedure applies to all of the Valve spring “4” valve lifters. Upper spring seat “5” 1. Check: (into the cylinder head) Valve lifter Damage/scratches →...
Page 225 VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: Valve pad “1” Valve lifter “2”...
Page 226: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS4S81014 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 75 Nm (7.5 m kgf, 54 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 227 GENERATOR AND STARTER CLUTCH Removing the generator and starter clutch 75 Nm (7.5 m kgf, 54 ft Ibf) • • 32 Nm (3.2 m kgf, 23 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf)
Page 228: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR Make sure the flywheel puller is centered over 1. Remove: the generator rotor. Passenger seat/Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Flywheel puller Fuel tank 90890-01362 Refer to “FUEL TANK” on page 7-1. Heavy duty puller 2.
Page 229: Installing The Starter Clutch
GENERATOR AND STARTER CLUTCH 2. Check: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Starter clutch idler gear “1” Starter clutch drive gear “2” EAS24600 Burrs/chips/roughness/wear → Replace the INSTALLING THE STARTER CLUTCH defective part(s). 1. Install: 3. Check: Starter clutch Starter clutch gear’s contacting surfaces “a” Starter clutch bolt Damage/pitting/wear →...
Page 230 Passenger seat/Rider seat YS-01880-A Refer to “GENERAL CHASSIS” on page 4-1. 3. Apply: Sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 4. Install: Stator coil Stator coil bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE®...
Page 231: Pickup Rotor
PICKUP ROTOR EAS4S81015 PICKUP ROTOR Removing the pickup rotor 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 35 Nm (3.5 m kgf, 25 ft Ibf) • • 15 Nm (1.5 m kgf, 10 ft Ibf) •...
Page 232: Removing The Pickup Rotor
“4”, loosen the pickup rotor bolt. Camshaft wrench 90890-04143 YM-04143 3. Apply: Sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) EAS4S81042 INSTALLING THE PICKUP ROTOR 1. Install: Pickup rotor “1” Washer...
Page 233 PICKUP ROTOR 4. Install: Pickup rotor cover gasket Pickup rotor cover Pickup rotor cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® When installing the pickup rotor cover, align the timing chain guide pins “1” with the holes “2” in the pickup rotor cover. Tighten the pickup rotor cover bolts in stages and in a crisscross pattern.
Page 234: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Passenger seat/Rider seat 4-1.
Page 235 ELECTRIC STARTER Disassembling the starter motor 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 3.4 Nm (0.34 m kgf, 2.4 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover...
Page 236: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR Digital circuit tester 90890-03174 1. Check: Model 88 Multimeter with tachom- Commutator eter Dirt → Clean with 600 grit sandpaper. YU-A1927 2. Measure: Commutator diameter “a” Out of specification → Replace the starter Armature coil motor.
Page 237: Assembling The Starter Motor
ELECTRIC STARTER 7. Check: Gear teeth EAS24810 Damage/wear → Replace the gear. INSTALLING THE STARTER MOTOR 8. Check: 1. Install: Bearing Starter motor Oil seal Starter motor bolts Damage/wear → Replace the defective Starter motor bolt part(s). 10 Nm (1.0 m·kgf, 7.2 ft·lbf) EAS24800 ASSEMBLING THE STARTER MOTOR 2.
Page 238: Oil Pump
OIL PUMP EAS24920 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) •...
Page 239 OIL PUMP Removing the oil pan and oil pump 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • 43 Nm (4.3 m kgf, 30 ft Ibf) 10 Nm (1.0 m...
Page 240 OIL PUMP Disassembling the oil pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Oil pump cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump rotor housing Oil pump driven sprocket For assembly, reverse the removal proce- dure.
Page 241: Removing The Oil Pan
OIL PUMP EAS24930 REMOVING THE OIL PAN Inner-rotor-to-outer-rotor-tip clearance 1. Remove: Less than 0.12 mm (0.0047 in) Oil level switch lead holder Limit Oil level switch “1” 0.20 mm (0.0079 in) Oil pan “2” Outer-rotor-to-oil-pump-housing Oil pan gasket clearance 0.090–0.150 mm Loosen each bolt 1/4 of a turn at a time, in stag- (0.0035–0.0059 in) es and in a crisscross pattern.
Page 242: Checking The Oil Delivery Pipes
OIL PUMP Obstruction → Blow out with compressed air. EAS24980 CHECKING THE OIL DELIVERY PIPES 1. Check: EAS25620 Oil delivery pipe “1” CHECKING THE OIL PUMP DRIVE CHAIN Oil pipe “2” 1. Check: Damage → Replace. Oil pump drive chain “1” Obstruction →...
Page 243: Installing The Oil Pump
OIL PUMP Oil pump housing screw 10 Nm (1.0 m·kgf, 7.2 ft·lbf) When installing the inner rotor, align the pin “4” in the oil pump shaft with the groove in the inner rotor “5”. EAS25050 INSTALLING THE OIL PAN 1. Install: Oil pipe Oil pipe bolt 12 Nm (1.2 m·kgf, 7.2 ft·lbf)
Page 244 OIL PUMP 5-46...
Page 245: Clutch
CLUTCH EAS25060 CLUTCH Removing the clutch cover 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Right side cowling 4-1.
Page 246 CLUTCH Removing the push lever shaft 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Drive sprocket cover Refer to “ENGINE REMOVAL” on page 5-1. Push lever case Oil seal Dowel pin...
Page 247 CLUTCH Removing the clutch 95 Nm (9.5 m kgf, 68 ft Ibf) • • 8 Nm (0.8 m kgf, 5.8 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Compression spring Pressure plate Push rod 2 Friction plate 1 Clutch plate Friction plate 2 Clutch boss nut...
Page 248: Removing The Clutch
CLUTCH Clutch boss nut “1” EAS25070 REMOVING THE CLUTCH 1. Remove: While holding the clutch boss “2” with the univer- Right side cowling sal clutch holder, loosen the clutch boss nut. Refer to “GENERAL CHASSIS” on page 4-1. Clutch cover “1” Universal clutch holder Gasket 90890-04086...
Page 249: Checking The Friction Plates
CLUTCH 7. Remove: EAS25100 CHECKING THE FRICTION PLATES Clutch plate 2 “1” The following procedure applies to all of the fric- Friction plate 3 “2” tion plates. 1. Check: Friction plate Damage/wear → Replace the friction plates as a set. 2.
Page 250: Checking The Clutch Springs
CLUTCH EAS25140 2. Check: CHECKING THE CLUTCH SPRINGS Bearing The following procedure applies to all of the Damage/wear → Replace the bearing and clutch springs. clutch housing. 1. Check: Clutch spring EAS25160 Damage → Replace the clutch springs as a CHECKING THE CLUTCH BOSS set.
Page 251: Checking The Clutch Push Rods
CLUTCH EAS25190 CHECKING THE CLUTCH PUSH RODS 1. Check: O-ring Push rod 2 “1” Ball “2” Push rod 1 “3” Cracks/damage/wear → Replace the defec- tive part(s). Push rod bearing Damage/wear → Replace. 3. Install: Friction plate 3 “1” Clutch plate 2 “2” Lubricate the engine oil.
Page 252 CLUTCH 6. Tighten: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Clutch boss nut Install the clutch plate and friction plate as shown in the illustration. Clutch boss nut 95 Nm (9.5 m·kgf, 68 ft·lbf) Clutch plate : t=2.0 mm (0.08 in) “ ” Friction plate 2 “...
Page 253 CLUTCH 13.Adjust: Clutch spring bolt Push lever position 8 Nm (0.8 m·kgf, 5.8 ft·lbf) MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Loosen locknut “1” of push rod “2”. b. Return or tighten adjusting nut “3” until the Align the punch mark “a” in the pressure plate mark of push lever matches the mark of push with the punch mark “b”...
Page 254: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever 16 Nm (1.6 m kgf, 11 ft Ibf) • • 22 Nm (2.2 m kgf, 15 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Clutch assembly Refer to “CLUTCH”...
Page 255: Removing The Shift Shaft
SHIFT SHAFT EAS5D01019 REMOVING THE SHIFT SHAFT 1. Remove: Clutch assembly Refer to “CLUTCH” on page 5-47 2. Remove: Shift arm Shift rod Refer to “ENGINE REMOVAL” on page 5-1 3. Remove: Circlip “1” Washer “2” (left side of the engine) EAS25420 CHECKING THE SHIFT SHAFT 1.
Page 256 SHIFT SHAFT Stopper lever “2” Refer to “ENGINE REMOVAL” on page 5-1. Washer “3” 5. Install: Circlip “4” Clutch assembly Stopper lever spring “5” Refer to “CLUTCH” on page 5-47. 2. Install: Shift shaft assembly “1” Mesh the stopper lever with the shift drum seg- ment assembly.
Page 257: Crankcase
CRANKCASE EAS25540 CRANKCASE Separating the crankcase 17 Nm (1.7 m kgf, 12 ft Ibf) 70 Nm (7.0 m kgf, 50 ft Ibf) • • • • 24 Nm (2.4 m kgf,17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 258 CRANKCASE Separating the crankcase 17 Nm (1.7 m kgf, 12 ft Ibf) 70 Nm (7.0 m kgf, 50 ft Ibf) • • • • 24 Nm (2.4 m kgf,17 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) •...
Page 259: Disassembling The Crankcase
(with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: Sealant (onto the crankcase mating surfaces) 3. Remove: Yamaha bond No. 1215 Lower crankcase 90890-85505 ECA13900 NOTICE (Three Bond No.1215®) Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced...
Page 260 CRANKCASE 23 25 3. Install: Dowel pin 4. Set the shift drum assembly and transmis- sion gears in the neutral position. 5. Install: Lower crankcase “1” (onto the upper crankcase “2”) ECA13980 NOTICE Before tightening the crankcase bolts, make 7. Tighten: sure the transmission gears shift correctly Crankcase bolts “1”–“10”...
Page 261 CRANKCASE 23 25 8. Tighten: Crankcase bolts “11”–“27” Crankcase bolt (M8 × × × × 65 mm) “11, 12” 24 Nm (2.4 m·kgf, 17 ft·lbf) Crankcase bolt (M6 × × × × 65 mm) “13, 14” 12 Nm (1.2 m·kgf, 8.6 ft·lbf) Crankcase bolt (M6) “15–27”...
Page 262: Crankshaft
CRANKSHAFT EAS25950 CRANKSHAFT Removing the connecting rods and pistons 15 Nm (1.5 m kgf, 11 ft Ibf) • • +120˚ Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-59. Connecting rod cap Big end lower bearing Big end upper bearing Piston pin clip Piston pin...
Page 263 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-59. Connecting rods and connecting rod caps Refer to “CRANKSHAFT” on page 5-64. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal proce- dure.
Page 264: Removing The Connecting Rods And Pistons
CRANKSHAFT EAS26030 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the con- necting rods and pistons. 1. Remove: Connecting rod cap “1” Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place. 3.
Page 265: Checking The Cylinder And Piston
CRANKSHAFT EAS24390 CHECKING THE CYLINDER AND PISTON 1. Check: Piston wall Cylinder wall Vertical scratches → Replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: Piston-to-cylinder clearance MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. 5 mm (0.20 in) from the bottom edge of the piston a.
Page 266: Checking The Piston Pins
CRANKSHAFT Top ring Top ring Ring side clearance End gap (installed) 0.030–0.065 mm 0.25–0.35 mm (0.0098–0.0138 in) (0.0012–0.0026 in) Limit Limit 0.60 mm (0.0236 in) 0.115 mm (0.0045 in) 2nd ring 2nd ring End gap (installed) Ring side clearance 0.65–0.80 mm (0.0256–0.0315 in) 0.030–0.065 mm Limit (0.0012–0.0026 in)
Page 267: Checking The Big End Bearings
CRANKSHAFT EAS4S81037 CHECKING THE BIG END BEARINGS 1. Measure: Crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. clearance (using plasti- gauge®) 0.038–0.062 mm (0.0015–0.0024 in) 4. Calculate: Piston-pin-to-piston-pin-bore clearance MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Out of specification → Replace the piston pin The following procedure applies to all of the and piston as a set.
Page 268 CRANKSHAFT d. Assemble the connecting rod halves. Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Lubricate the bolt threads and seats with mo- lybdenum disulfide grease. Make sure that the “Y” mark “c” on the connect- ing rod faces towards the left side of the crank- shaft.
Page 269: Installing The Connecting Rod And Piston
CRANKSHAFT 2. Install: Piston “1” (onto the respective connecting rod “2”) Piston pin “3” Piston pin clips “4” Apply engine oil onto the piston pin. Make sure that the “Y” mark “a” on the con- necting rod faces left when the arrow mark “b” on the piston is pointing up as shown.
Page 270 CRANKSHAFT Nut seats Connecting rod bolt (with the recommended lubricant) 15 Nm (1.5 m·kgf, 11 ft·lbf) + 120° ° ° ° Recommended lubricant Molybdenum disulfide oil MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM EWA12890 WARNING 6. Lubricate: Replace the connecting rod bolts with new Crankshaft pins ones.
Page 271: Checking The Crankshaft
CRANKSHAFT d. After the installation, check that the section Crankshaft pin surfaces shown “a” is flush with each other by touching Bearing surfaces Scratches/wear → Replace the crankshaft. the surface. EAS4S81039 CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1. Measure: Crankshaft-journal-to-crankshaft-journal bearing clearance Out of specification →...
Page 272 CRANKSHAFT LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 2. Select: Crankshaft journal bearings (J1–J5) The numbers “A” stamped into the crankshaft web and the numbers “1” stamped into the low- er crankcase are used to determine the re- placement crankshaft journal bearing sizes. “J1–J5” refer to the bearings shown in the e.
Page 273: Installing The Crankshaft
CRANKSHAFT EAS4S81040 INSTALLING THE CRANKSHAFT 1. Install: Crankshaft journal upper bearings “1” (into the upper crankcase) Align the projections “a” on the crankshaft jour- nal upper bearings with the notches “b” in the upper crankcase. Be sure to install each crankshaft journal upper bearing in its original place.
Page 274: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the drive axle 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 12 Nm (1.2 m kgf, 8.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Lower crankcase Refer to “CRANKCASE” on page 5-59. Drive axle assembly Circlip Oil seal...
Page 275 TRANSMISSION Removing the main axle and shift drum 12 Nm (1.2 m kgf, 8.6 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Shift fork guide bar retainer Shift fork guide bar Shift drum assembly Bearing housing Bearing...
Page 276 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip 6th wheel gear 5-78...
Page 277 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Circlip Washer 2nd wheel gear Collar Oil seal Collar Bearing Circlip Drive axle For installation, reverse the removal proce- dure. 5-79...
Page 278 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle Bearing housing Bearing For installation, reverse the removal proce- dure.
Page 279: Removing The Transmission
TRANSMISSION EAS26250 REMOVING THE TRANSMISSION 1. Remove: Drive axle assembly Main axle assembly “1” (with the Torx® wrench) 2. Check: Shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends → Replace. EWA12840 WARNING Do not attempt to straighten a bent shift fork MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM guide bar.
Page 280: Checking The Transmission
TRANSMISSION 4. Check: EAS26300 Transmission gear engagement CHECKING THE TRANSMISSION (each pinion gear to its respective wheel 1. Measure: gear) Main axle runout Incorrect → Reassemble the transmission (with a centering device and dial gauge “1”) Out of specification → Replace the main axle. axle assemblies.
Page 281: Installing The Transmission
TRANSMISSION Transmission bearing housing screw 12 Nm (1.2 m·kgf, 8.6 ft·lbf) LOCTITE® Shift fork-C “3” Shift drum assembly “4” Shift fork guide bar “5” Shift fork guide bar retainer Shift fork guide bar retainer bolt 2. Install: 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Toothed lock washer retainer “1”...
Page 282 TRANSMISSION Shift fork guide bar retainer bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LOCTITE® Install shift fork-L into the groove in the 6th wheel gear and shift fork-R into the groove in the 5th wheel gear on the drive axle. Make sure that the drive axle bearing circlip “a”...
Page 283: Cooling System
COOLING SYSTEM RADIATOR.....................6-1 CHECKING THE RADIATOR..............6-3 INSTALLING THE RADIATOR..............6-3 OIL COOLER ....................6-4 CHECKING THE OIL COOLER ...............6-5 INSTALLING THE OIL COOLER .............6-5 THERMOSTAT....................6-6 CHECKING THE THERMOSTAT ............6-7 INSTALLING THE THERMOSTAT ASSEMBLY ........6-7 WATER PUMP ....................6-9 DISASSEMBLING THE WATER PUMP ..........6-11 CHECKING THE WATER PUMP.............6-11 ASSEMBLING THE WATER PUMP ............6-11 INSTALLING THE WATER PUMP............6-12...
Page 284: Radiator
RADIATOR EAS26380 RADIATOR Removing the radiator 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”...
Page 285 RADIATOR Removing the radiator 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Coolant reservoir cover/Coolant reservoir Coolant reservoir cap For installation, reverse the removal proce-...
Page 286: Checking The Radiator
RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.
Page 287: Oil Cooler
OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 63 Nm (6.3 m kgf, 45 ft Ibf) • • ’ Order Job/Parts to remove Remarks “RADIATOR” on page 6-1 Coolant reservoir Refer to “RADIATOR”...
Page 288: Checking The Oil Cooler
OIL COOLER page 3-26. EAS26420 CHECKING THE OIL COOLER Crankcase 1. Check: (with the specified amount of the recom- Oil cooler mended engine oil) Cracks/damage → Replace. Refer to “CHANGING THE ENGINE OIL” on page 3-23. 4. Check: Cooling system Leaks →...
Page 289: Thermostat
THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 12 Nm (1.2 m kgf, 8.6 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Passenger seat/Rider seat 4-1. Refer to “GENERAL CHASSIS” on page Left side cowling 4-1.
Page 290: Checking The Thermostat
THERMOSTAT EAS26450 CHECKING THE THERMOSTAT 1. Check: LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Thermostat “1” 2. Check: Does not open at 71–85°C (160–185°F) → Thermostat housing cover “1” Cracks/damage → Replace. Replace. EAS26490 INSTALLING THE THERMOSTAT ASSEMBLY 1. Install: Thermostat MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Suspend the thermostat “3” in a container “4” filled with water.
Page 291 THERMOSTAT Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3.
Page 292: Water Pump
WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.
Page 293 WATER PUMP Disassembling the water pump 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Water pump cover O-ring Circlip Impeller shaft Water pump seal Oil seal Bearing Water pump housing O-ring For assembly, reverse the disassembly pro- cedure.
Page 294: Disassembling The Water Pump
WATER PUMP Gasket “6” EAS26510 DISASSEMBLING THE WATER PUMP (from the impeller shaft, with a thin, flat-head 1. Remove: screwdriver) Water pump cover O-ring Do not scratch the impeller shaft. Circlip Impeller shaft 2. Remove: Water pump seal “1” Remove the water pump seal from the inside of the water pump housing “2”.
Page 295: Installing The Water Pump
Make sure the bushing and gasket are flush tools. with the impeller. Before installing the water pump seal, apply Yamaha bond No.1215 “2” to the water pump Impeller shaft tilt limit housing “3”. 0.15 mm (0.006 in) Mechanical seal installer...
Page 296 WATER PUMP Water pump assembly “1” Refer to “CHECKING THE RADIATOR” on page 6-3. Align the slit “a” on the impeller shaft with the projection “b” on the oil pump shaft. Lubricate the O-ring with a thin coat of lithi- um-soap-based grease.
Page 297: Fuel System
FUEL SYSTEM FUEL TANK ....................7-1 REMOVING THE FUEL TANK..............7-2 REMOVING THE FUEL PUMP ..............7-2 CHECKING THE FUEL PUMP BODY .............7-2 CHECKING THE FUEL PUMP OPERATION ..........7-2 INSTALLING THE FUEL PUMP...............7-2 INSTALLING THE FUEL TANK ...............7-3 THROTTLE BODIES..................7-4 CHECKING THE THROTTLE BODY JOINTS .........7-5 CHECKING THE FUEL INJECTORS............7-7 INSTALLING THE INJECTORS...............7-7 CHECKING THE INJECTOR PRESSURE ..........7-7...
Page 298: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 7 Nm (0.7 m kgf, 5.1 ft Ibf) 12 Nm (1.2 m kgf, 8.7 ft Ibf) • • • • 4 Nm (0.4 m kgf, 2.9 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks...
Page 299: Removing The Fuel Tank
FUEL TANK sender. EAS26630 REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the EAS26670 fuel tank cap with a pump. CHECKING THE FUEL PUMP BODY 2. Remove: 1. Check: Fuel sender coupler Fuel pump body Obstruction →...
Page 300: Installing The Fuel Tank
FUEL TANK A. Forward EAS4S81001 INSTALLING THE FUEL TANK 1. Install: Fuel hose ECA4S81001 NOTICE When installing the fuel hose, make sure that it is securely connected, and that the fuel hose holders are in the correct position, oth- erwise the fuel hose will not be properly in- stalled.
Page 301 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle bodies 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • 2.8 Nm (0.28 m kgf, 2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Passenger seat/Rider seat 4-1.
Page 302: Throttle Bodies
THROTTLE BODIES EAS21010 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joints and intake manifolds. 1. Remove: Throttle bodies Refer to “THROTTLE BODIES” on page 7-4. 2. Check: Throttle body joints “1” Cracks/damage → Replace. 3.
Page 303 THROTTLE BODIES Removing the injectors 5 Nm (0.5 m kgf, 3.6 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • 3.5 Nm (0.35 m kgf, 2.5 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Throttle position sensor coupler Disconnect.
Page 304: Checking The Fuel Injectors
THROTTLE BODIES EAS26980 EAS2S31098 CHECKING THE FUEL INJECTORS CHECKING THE INJECTOR PRESSURE EWA2S31037 WARNING After installing the injectors, perform the follow- Check the injectors in a well-ventilated area ing steps to check the injector pressure. free of combustible materials. Make sure Do not allow any foreign materials to enter the that there is no smoking or use of electric fuel lines.
Page 305: Checking And Cleaning The Throttle Bodies
THROTTLE BODIES the injector. ed as so. Do not touch the synchronizing screw “a”; LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL otherwise, the throttle body synchroniza- tion will be affected. EAS2S31095 Do not touch the throttle adjust screw “b”. CHECKING AND CLEANING THE THROTTLE BODIES EWA2S31033 WARNING If the throttle bodies are subjected to strong shocks or dropped during cleaning, replace...
Page 306: Checking The Fuel Pressure
THROTTLE BODIES Do not apply any petroleum-based solvent to pressed air. the portions of the throttle valve shafts be- LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL tween the throttle bodies. 4. Check: e. Remove the carbon deposits from the inside Fuel pulsation damper of each throttle body in a downward direction, Cracks/damage →...
Page 307: Adjusting The Throttle Position Sensor
THROTTLE BODIES Faulty → Replace the fuel pump. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS27030 ADJUSTING THE THROTTLE POSITION SENSOR Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: Throttle position sensor e. After adjusting the throttle position sensor an- Refer to “CHECKING THE THROTTLE PO- gle, tighten the throttle position sensor SITION SENSOR”...
Page 308: Air Induction System
AIR INDUCTION SYSTEM EAS27040 AIR INDUCTION SYSTEM 7-11...
Page 309 AIR INDUCTION SYSTEM 1. Air ﬁlter case 2. Air cut-off valve hose (air ﬁlter case—air cut-off valve) 3. Air cut-off valve 4. Air cut-off valve hose (air cut-off valve—reed valve) 5. Air cut-off valve hose (air cut-off valve—reed valve) 6. Reed valve 7-12...
Page 310 AIR INDUCTION SYSTEM Removing the air cut-off valve assembly and hoses 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • 10 Nm (1.0 m kgf, 7.2 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Passenger seat/Rider seat 4-1.
Page 311: Checking The Air Induction System
AIR INDUCTION SYSTEM 1. Check: EAS27060 CHECKING THE AIR INDUCTION SYSTEM Hoses Air injection Loose connections → Connect properly. The air induction system burns unburned ex- Cracks/damage → Replace. haust gases by injecting fresh air (secondary air) Pipes into the exhaust port, reducing the emission of Cracks/damage →...
Page 312: Canister (For California)
CANISTER (FOR CALIFORNIA) CANISTER (FOR CALIFORNIA) Removing the canister (For California) 16 Nm (1.6 m kgf, 11 ft Ibf) • • 7 Nm (0.7 m kgf, 5.1 ft Ibf) • • Order Job/Parts to remove Q’ty Remarks Right footrest assembly Refer to “REAR BRAKE”...
Page 313: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM ..................8-1 CIRCUIT DIAGRAM .................8-1 TROUBLESHOOTING ................8-3 ELECTRIC STARTING SYSTEM..............8-5 CIRCUIT DIAGRAM .................8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......8-7 TROUBLESHOOTING ................8-9 CHARGING SYSTEM ..................8-11 CIRCUIT DIAGRAM .................8-11 TROUBLESHOOTING ................8-13 LIGHTING SYSTEM..................8-15 CIRCUIT DIAGRAM .................8-15 TROUBLESHOOTING ................8-17 SIGNALING SYSTEM ..................8-19 CIRCUIT DIAGRAM .................8-19 TROUBLESHOOTING ................8-21 COOLING SYSTEM ..................8-25...
Page 314 CHECKING THE IGNITION SPARK GAP ..........8-85 CHECKING THE SPARK PLUG CAPS ...........8-86 CHECKING THE IGNITION COIL............8-86 CHECKING THE CRANKSHAFT POSITION SENSOR ......8-87 CHECKING THE LEAN ANGLE SENSOR ..........8-87 CHECKING THE STARTER MOTOR OPERATION........8-88 CHECKING THE STATOR COIL .............8-88 CHECKING THE RECTIFIER/REGULATOR...........8-89 CHECKING THE HORN................8-89 CHECKING THE ENGINE OIL LEVEL SWITCH ........8-89 CHECKING THE AIR INDUCTION SYSTEM SOLENOID.......8-90...
Page 316: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 317 IGNITION SYSTEM 3. Battery 4. Main fuse 10. Main switch 13. Relay unit 14. Starting circuit cut-off relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 31. Crankshaft position sensor 32. ECU (engine control unit) 37. Ignition coil #1,4 38.
Page 318: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1.Passenger seat/Rider seat 2.Fuel tank 3.Side cowling 1. Check the fuses. (Main and ignition) → Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 319 IGNITION SYSTEM OK↓ 11.Check the clutch switch. → Refer to Replace the clutch switch. “CHECKING THE SWITCHES” on page 8-75 OK↓ 12.Check the starting circuit cut-off relay. → Replace the relay unit. Refer to “CHECKING THE RELAYS” on page 8-83 OK↓...
Page 320: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 321 ELECTRIC STARTING SYSTEM 3. Battery 4. Main fuse 5. Starter relay 6. Starter motor 10. Main switch 13. Relay unit 14. Starting circuit cut-off relay 16. Neutral switch 17. Sidestand switch 21. Engine stop switch 22. Start switch 53. Clutch switch 65.
Page 322: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed).
Page 323 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL 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 324: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. Before troubleshooting, remove the following part(s): 1.Passenger seat/Rider seat 2.Rear side cover 3.Fuel tank 1. Check the fuses. (Main and ignition) → Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-79 OK↓...
Page 325 ELECTRIC STARTING SYSTEM OK↓ 11.Check the start switch. → Refer to Replace the right handlebar switch. “CHECKING THE SWITCHES” on page 8-75 OK↓ 12.Check the entire starting system ’ Properly connect or repair the starting wiring. → Refer to “CIRCUIT DIAGRAM” on page system’s wiring.
Page 326: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11...
Page 327 CHARGING SYSTEM 1. AC magneto 2. Rectifier/regulator 3. Battery 4. Main fuse 8-12...
Page 328: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. Before troubleshooting, remove the following part(s): 1.Passenger seat/Rider seat 2.Rear side cover 3.Fuel tank 1. Check the fuse. (Main) → Replace the fuse. Refer to “CHECKING THE FUSES” on page 8-79 OK↓...
Page 329 CHARGING SYSTEM 8-14...
Page 330: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15...
Page 331 LIGHTING SYSTEM 3. Battery 4. Main fuse 10. Main switch 32. ECU (engine control unit) 48. High beam indicator light 50. Meter light 54. Dimmer switch 60. Front left turn signal light 61. Front right turn signal light 62. License plate light 63.
Page 332: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license light or meter light. Before troubleshooting, remove the following part(s): 1.Passenger seat/Rider seat 2.Fuel tank 1. Check the each bulbs and bulb sockets condition.
Page 333 LIGHTING SYSTEM 8-18...
Page 334: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19...
Page 335 SIGNALING SYSTEM 3. Battery 4. Main fuse 10. Main switch 13. Relay unit 16. Neutral switch 18. Rear brake light switch 20. Front brake light switch 24. Fuel sender 28. Coolant temperature sensor 30. Speed sensor 32. ECU (engine control unit) 42.
Page 336: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING Any of the following fail to light: turn signal light, brake light or an indicator light. The horn fails to sound. Before troubleshooting, remove the following part(s): 1.Passenger seat/Rider seat 2.Rear side cover 3.Fuel tank 1. Check the fuses. (Main, ignition and signal) →...
Page 337 SIGNALING SYSTEM The tail/brake light fails to come on. 1. Check the tail/brake light bulb and Replace the tail/brake light bulb, socket or socket. → Refer to “CHECKING THE BULBS both. AND BULB SOCKETS” on page 8-78 OK↓ 2. Check the front brake light switch. →...
Page 338 SIGNALING SYSTEM The neutral indicator light fails to come. Replace the neutral indicator light bulb, 1. Check the neutral indicator light bulb → and socket. socket or both. OK↓ 2. Check the neutral switch. → Refer to Replace the neutral switch. “CHECKING THE SWITCHES”...
Page 339 SIGNALING SYSTEM The speedometer fails to operate. 1. Check the speed sensor. → Refer to Replace the speed sensor. “CHECKING THE SPEED SENSOR” on page 8-91 OK↓ 2. Check the entire signaling system ’ Properly connect or repair the signaling wiring.
Page 340: Cooling System
COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25...
Page 341 COOLING SYSTEM 3. Battery 4. Main fuse 9. Radiator fan fuse 10. Main switch 11. Radiator fan motor relay 12. Radiator fan motor 28. Coolant temperature sensor 32. ECU (engine control unit) 65. Ignition fuse 8-26...
Page 342: Troubleshooting
COOLING SYSTEM EAS27320 TROUBLESHOOTING Before troubleshooting, remove the following part(s): 1.Passenger seat/Rider seat 2.Side cowling 3.Fuel tank 1. Check the fuses. (Main, ignition and radiator fan) → Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 8-79 OK↓ 2. Check the battery. Clean the battery terminals.
Page 343 COOLING SYSTEM 8-28...
Page 344: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29...
Page 345 FUEL INJECTION SYSTEM 3. Battery 4. Main fuse 7. Fuel injection system fuse 10. Main switch 11. Radiator fan motor relay 13. Relay unit 14. Starting circuit cut-off relay 15. Fuel injection system relay 16. Neutral switch 17. Sidestand switch 21.
Page 346: 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 347 FUEL INJECTION SYSTEM The ECU takes fail-safe actions in two ways: one in which the sensor output is set to a prescribed value, and the other in which the ECU directly operates an actuator. Details on the fail-safe actions are given in the table below.
Page 348: Trouble Shooting Chart
FUEL INJECTION SYSTEM EAS20S1002 TROUBLE SHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come The engine trouble warning light comes on.
Page 349: Diagnostic Mode
FUEL INJECTION SYSTEM EAS27411 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. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
Page 350: Troubleshooting Details
FUEL INJECTION SYSTEM EAS27451 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display ac- cording to the reinstatement method.
Page 351 FUEL INJECTION SYSTEM Fault code No. Symptom Normal signals are not received from the crank position sensor. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring — code No. Meter display — Checking method — Item/components and Check or maintenance Sensor inspection Order probable cause...
Page 352 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring code No.
Page 353 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring code No. When engine is stopped: Make sure that the atmospheric pressure is Meter display indicated.
Page 354 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. The intake air pressure sensor has failed (due to clogging of hole or Symptom sensor disconnection). Engine startup: Possible Fail-safe action Riding: Possible...
Page 355 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitoring code No. Display the throttle opening (between 0 and 125 degrees). Meter display When throttle is fully closed: 14 to 20 degrees When throttle is fully opened: 91 to 95 degrees...
Page 356 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitoring code No. Display the throttle opening (between 0 and 125 degrees). Meter display When throttle is fully closed: 14 to 20 degrees When throttle is fully opened: 91 to 95 degrees...
Page 357 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitoring code No. Display the throttle opening (between 0 and 125 degrees). Meter display When throttle is fully closed: 14 to 20 degrees When throttle is fully opened: 91 to 95 degrees...
Page 358 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring code No. Sidestand retracted: ON indication Meter display Sidestand extended: OFF indication Make sure that the ON and OFF indication is switched when the sidestand Checking method is retracted and extended.
Page 359 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring code No. Sidestand retracted: ON indication Meter display Sidestand extended: OFF indication Make sure that the ON and OFF indication is switched when the sidestand Checking method is retracted and extended.
Page 360 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of coolant temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring code No. -30 to 120° ° ° ° C During cold starting: A temperature close to the ambient temperature is Meter display indicated.
Page 361 FUEL INJECTION SYSTEM *Check the sensor only when the engine is cold. Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring code No. -30 to 120° ° ° ° C During cold starting: A temperature close to the ambient temperature is Meter display indicated.
Page 362 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring code No. -30 to 120° ° ° ° C During cold starting: A temperature close to the ambient temperature is Meter display indicated.
Page 363 FUEL INJECTION SYSTEM Fault code No. Symptom Turnover of vehicle Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring code No. The lean angle sensor value is indicated. 0 to 5.0 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.4 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees, and Checking method...
Page 364 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylinders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitoring code No. Each ignition coil turns On or Off 5 times per second. Meter display The engine warning light ﬂashes according to the On/Off switching.
Page 365 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylinders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitoring code No. Each ignition coil turns On or Off 5 times per second. Meter display The engine warning light ﬂashes according to the On/Off switching.
Page 366 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylinders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitoring code No. Each ignition coil turns On or Off 5 times per second. Meter display The engine warning light ﬂashes according to the On/Off switching.
Page 367 FUEL INJECTION SYSTEM Fault code No. Symptom Ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylinders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitoring code No. Each ignition coil turns On or Off 5 times per second. Meter display The engine warning light ﬂashes according to the On/Off switching.
Page 368 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring code No. The lean angle sensor value is indicated. 0 to 5.0 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.4 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees, and...
Page 369 FUEL INJECTION SYSTEM Fault code No. Symptom A. Normal signals are not received from the speed sensor. B. Open or short circuit of neutral switch lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring 07 (Speed sensor) code No. Meter display Vehicle speed pulses: 0–999 Make sure that the indication value increases when the rotation speed of...
Page 370 FUEL INJECTION SYSTEM A. Speed sensor system malfunction Item/components and Check or maintenance Sensor inspection Order probable cause procedure Poor connection ⇒ Con- Connection of speed Start the engine, and sensor (meter) coupler nect it securely, or repair/ check the connection of Check the connection of replace the wire harness.
Page 371 FUEL INJECTION SYSTEM B. Neutral switch system malfunction Item/components and Check or maintenance Sensor inspection Order probable cause procedure Poor connection ⇒ Connection of neutral Start the engine, and switch coupler Reconnect or repair the check the secure con- Check the connection of coupler.
Page 372 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring code No. The relay turns On or Off 5 times per second. Meter display The engine warning light ﬂashes according to the On/Off switching.
Page 373 FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring code No. The in self diagnostic code 44 detected EEP-ROM errors are indicated. If there are multiple errors, they are indicated in 2 seconds intervals Meter display 00 indication: Normal status 01 indication: CO concentration adjusted for cylinders #1 and #4...
Page 374 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitoring — code No. Meter display — Checking method — Item/components and Check or maintenance Sensor inspection Order probable cause procedure Poor connection ⇒...
Page 375 FUEL INJECTION SYSTEM Fault code No. Symptom ECU memory malfunction Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitoring — code No. Meter display — Checking method — Item/components and Check or maintenance Sensor inspection Order probable cause procedure...
Page 376 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal is received from the ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring — code No. Meter display — Checking method — Item/components and Check or maintenance Sensor inspection Order probable cause procedure...
Page 377 FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signal is sent from ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring — code No. Meter display — Checking method — Item/components and Check or maintenance Sensor inspection Order probable cause procedure Poor connection ⇒...
Page 378 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Correct data cannot be received from the ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring — code No. Meter display — Checking method — Item/components and Check or maintenance Sensor inspection Order probable cause procedure...
Page 379 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom No registration data can be received from the meter unit. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitoring — code No. Meter display — Checking method — Item/components and Check or maintenance Sensor inspection Order probable cause...
Page 380: Other Diagnostic Monitoring Codes
FUEL INJECTION SYSTEM EAS20S18001 OTHER DIAGNOSTIC MONITORING CODES This table shows diagnostic monitoring codes which are not linked to the fault code symptoms. Diagnostic code table Diagnos tic code Item Meter display Checking method Fuel system voltage Compare with the actually (battery voltage) Approximately 12.0 measured battery voltage.
Page 381 FUEL INJECTION SYSTEM Diagnos tic code Item Meter display Checking method Malfunction code reinstate No malfunction code — Malfunction code exists Fault code 24 To reinstate, set the engine (If more than one code stop switch to “ ”. number is detected, the display changes every two seconds to show all the detected code num-...
Page 382: Fuel Pump System
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-67...
Page 383 FUEL PUMP SYSTEM 3. Battery 4. Main fuse 7. Fuel injection system fuse 10. Main switch 13. Relay unit 15. Fuel injection system relay 21. Engine stop switch 23. Fuel pump 32. ECU (engine control unit) 65. Ignition fuse 8-68...
Page 384: Troubleshooting
FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. Before troubleshooting, remove the following part(s): 1.Passenger seat/Rider seat 2.Fuel tank 1. Check the fuses. (Main, ignition and fuel injection sys- → tem) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 385 FUEL PUMP SYSTEM 8-70...
Page 386: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 8-71...
Page 387 ELECTRICAL COMPONENTS 1. Front brake light switch 2. Clutch switch 3. Air induction system solenoid 4. Battery 5. Starter relay 6. Fuse box 7. Neutral switch 8. Rear brake light switch 9. Sidestand switch 10. Speed sensor 11. Oil level switch 12.
Page 388 ELECTRICAL COMPONENTS 8-73...
Page 389 ELECTRICAL COMPONENTS 1. Fuel injector 2. Intake air temperature sensor 3. Fuel pump 4. Intake air pressure sensor 5. Lean angle sensor 6. Relay unit 7. Turn signal relay 8. Radiator fan motor relay 9. Headlight relay 10. ECU (engine control unit) 11.
Page 390: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 8-75...
Page 391 ELECTRICAL COMPONENTS 1. Main switch 2. Horn switch 3. Turn signal switch 4. Dimmer switch 5. Clutch switch 6. Sidestand switch 7. Start switch 8. Engine stop switch 9. Front brake light switch 10. Oil level switch 11. Neutral switch 12.
Page 392 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 393: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB Bulb SOCKETS EWA4B51012 WARNING Do not check any of the lights that use LEDs. Since the headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continu- down.
Page 394: Checking The Fuses
ELECTRICAL COMPONENTS Digital circuit tester 90890-03174 LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL Model 88 Multimeter with tachom- Checking the condition of the bulb sockets eter The following procedure applies to all of the bulb YU-A1927 sockets. 1. Check: b. If the digital circuit tester indicates no continu- Bulb socket (for continuity) ity, replace the fuse.
Page 395: Checking And Charging The Battery
ELECTRICAL COMPONENTS 4. Install: 1. Remove: Passenger seat/Rider seat Passenger seat/Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Battery band “1” Battery cover “2” EAS28030 Refer to “GENERAL CHASSIS” on page 4-1. CHECKING AND CHARGING THE BATTERY 2. Disconnect: This model is equipped with a VRLA (Valve Battery leads Regulated Lead Acid) battery.
Page 396 ELECTRICAL COMPONENTS vehicle, 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. Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
Page 397 ELECTRICAL COMPONENTS charger cannot charge the VRLA battery. A vari- Set the charging voltage to 16–17 V. If the set- able voltage charger is recommended. ting is lower, charging will be insufficient. If too d. Charge the battery until the battery’s charg- high, the battery will be over-charged.
Page 398: Checking The Relays
ELECTRICAL COMPONENTS EAS28040 CHECKING THE RELAYS Result Continuity Check each switch for continuity with the digital (between “3” and “4”) circuit tester. If the continuity reading is incor- rect, replace the relay. Relay unit (fuel injection system relay) Digital circuit tester 90890-03174 Model 88 Multimeter with tachom- eter...
Page 399: Checking The Turn Signal Relay
ELECTRICAL COMPONENTS Radiator fan motor relay Br/W Br/B b. Turn the main switch to “ON”. c. Measure the turn signal relay input voltage. 1. Positive battery terminal 2. Negative battery terminal 3. Positive tester probe LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 4. Negative tester probe 2.
Page 400: Checking The Relay Unit (Diode)
ELECTRICAL COMPONENTS EAS28050 CHECKING THE RELAY UNIT (DIODE) 1. Check: Relay unit (diode) Out of specification → Replace. Pocket tester 90890-03112 Analog pocket tester L/W L/Y R/W L/B B/R Sb B/Y Lg YU-03112-C MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM The pocket tester and the analog pocket tester a.
Page 401: Checking The Spark Plug Caps
ELECTRICAL COMPONENTS c. Measure the spark plug cap resistance. 1. Ignition checker 2. Spark plug cap LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL c. Turn the main switch to “ON” and set the en- gine stop switch to “ ”. EAS28080 CHECKING THE IGNITION COIL d. Measure the ignition spark gap “a”. 1.
Page 402: Checking The Crankshaft Position Sensor
ELECTRICAL COMPONENTS 2. Check: MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Connect the digital circuit tester (Ω × 100) to Secondary coil resistance Out of specification → Replace. the crankshaft position sensor coupler as shown. Secondary coil resistance 12.00–18.00 kΩ Ω Ω Ω Digital circuit tester 90890-03174 MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Model 88 Multimeter with tachom-...
Page 403: Checking The Starter Motor Operation
ELECTRICAL COMPONENTS Positive tester probe → Yellow/Green “1” Negative tester probe → Black/Blue “2” 65 ˚ 65 ˚ b. Check the starter motor operation. Y / R LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28150 CHECKING THE STATOR COIL c. Set the main switch to “ON”. 1.
Page 404: Checking The Rectifier/Regulator
ELECTRICAL COMPONENTS d. Measure the rectifier/regulator output volt- age. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL EAS28180 CHECKING THE HORN 1. Check: W W W Horn resistance Out of specification → Replace. b. Measure the stator coil resistance. Coil resistance 1.07–1.11 Ω Ω Ω Ω LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.
Page 405: Checking The Air Induction System Solenoid
ELECTRICAL COMPONENTS Engine oil level gauge Air induction system solenoid resistance Out of specification → Replace. (from the oil pan) 3. Check: Solenoid resistance Engine oil level gauge resistance 20.5–24.0Ω Ω Ω Ω Out of specification → Replace. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM Engine oil level gauge Minimum level position resis- a.
Page 406: Checking The Speed Sensor
ELECTRICAL COMPONENTS assembly. Fuel sender coupler Fuel pump coupler Sender unit resistance (full) Refer to “FUEL TANK” on page 7-1. 19.0–21.0 Ω Ω Ω Ω Sender unit resistance (empty) EAS28240 139.0–141.0 Ω Ω Ω Ω CHECKING THE SPEED SENSOR 1. Check: Speed sensor output voltage MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a.
Page 407: Checking The Coolant Temperature Sensor
ELECTRICAL COMPONENTS from the wire harness. b. Immerse the coolant temperature sensor “1” b. Connect the battery (DC 12 V) as shown. in a container filled with coolant “2”. Positive battery terminal → Make sure the coolant temperature sensor ter- Blue “1”...
Page 408: Checking The Intake Air Pressure Sensor
ELECTRICAL COMPONENTS Tester positive lead → Positive tester probe → Blue “1” Pink/white “1” Tester negative lead → Negative tester probe → Black/Blue “2” Black/blue “2” B/L P/W L b. Turn the main switch to “ON”. b. Measure the throttle position sensor maxi- c.
Page 409 ELECTRICAL COMPONENTS Positive tester probe Black/Blue “1” Negative tester probe Brown/White “2” b. Measure the intake air temperature sensor resistance. LLLLLLLLLLLLLLLLLLLLLLLLLLLLLLLL 8-94...
Page 410 ELECTRICAL COMPONENTS 8-95...
Page 411: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ...................9-1 GENERAL INFORMATION ..............9-1 STARTING FAILURES................9-1 INCORRECT ENGINE IDLING SPEED ...........9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE......9-2 FAULTY GEAR SHIFTING...............9-2 SHIFT PEDAL DOES NOT MOVE............9-2 JUMPS OUT OF GEAR ................9-2 FAULTY CLUTCH ..................9-2 OVERHEATING ..................9-2 OVERCOOLING..................9-3 POOR BRAKING PERFORMANCE............9-3 FAULTY FRONT FORK LEGS..............9-3 UNSTABLE HANDLING................9-3 FAULTY LIGHTING OR SIGNALING SYSTEM........9-3...
Page 412: Troubleshooting
TROUBLESHOOTING Faulty battery EAS28450 TROUBLESHOOTING 2. Fuse(s) Blown, damaged or incorrect fuse EAS28460 GENERAL INFORMATION Improperly installed fuse 3. Spark plug(s) The following guide for troubleshooting does not Incorrect spark plug gap cover all the possible causes of trouble. It should Incorrect spark plug heat range Fouled spark plug be helpful, however, as a guide to basic trouble-...
Page 413: Poor Medium-And-High-Speed Performance
TROUBLESHOOTING Faulty battery Transmission 2. Spark plug(s) Worn gear dog Incorrect spark plug gap EAS28560 Incorrect spark plug heat range FAULTY CLUTCH Fouled spark plug Clutch slips Worn or damaged electrode 1. Clutch Worn or damaged insulator Improperly assembled clutch Faulty spark plug cap Improperly adjusted clutch cable 3.
Page 414: Overcooling
TROUBLESHOOTING Hose(s) and pipe(s) Cracked or damaged cap bolt O-ring Damaged hose Malfunction Improperly connected hose Bent or damaged inner tube Damaged pipe Bent or damaged outer tube Improperly connected pipe Damaged fork spring Fuel system Worn or damaged outer tube bushing 1.
Page 415 TROUBLESHOOTING Incorrect connection Improperly grounded circuit Poor contacts (main or light switch) Burnt-out headlight bulb Headlight bulb burnt out Wrong headlight bulb Faulty battery Faulty rectifier/regulator Improperly grounded circuit Faulty main switch Faulty light switch Headlight bulb life expired Tail/brake light does not come on Wrong tail/brake light bulb Too many electrical accessories Incorrect connection...
Page 416 EAS28740 50.Meter light EAS4S81047 WIRING DIAGRAM COLOR CODE 51.Oil level switch FZ6RY(C) 2009 Black 52.Left handlebar switch 1.AC magneto 53.Clutch switch Brown 2.Rectifier/regulator 54.Dimmer switch Chocolate 3.Battery 55.Turn signal switch Dark green 4.Main fuse 56.Horn switch Green 5.Starter relay 57.Horn Gray 6.Starter motor 58.Rear left turn signal light...
Page 418 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN...
Page 419 FZ6RY(C) 2009 XJ6N 2009 WIRING DIAGRAM SCHÉMA DE CÂBLAGE...
Page 420 FZ6RY(C) 2009 XJ6N 2009 WIRING DIAGRAM SCHÉMA DE CÂBLAGE...

This manual is also suitable for:

Fz6ry 2009 fz6rc 2009 fz6ry

Yamaha FZ6RC Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Chain Drive

Engine

Engine Removal

Camshafts

Removing the Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Removing the Pickup Rotor

Electric Starter

Oil Pump

Clutch

Shift Shaft

Crankcase

Crankshaft

Transmission

Cooling System

Radiator

Oil Cooler

Thermostat

Water Pump

Fuel System

Fuel Tank

Throttle Bodies

Air Induction System

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Cooling System

Fuel Injection System

Fuel Pump System

Electrical Components

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Yamaha FZ6RC