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Yamaha YZF-R1 1998 Service Manual

Yzf-r1 1998.
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Table of Contents
YZF-R1
'98
4XV1-AE1
SERVICE MANUAL

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Table of Contents

   Summary of Contents for Yamaha YZF-R1 1998

  • Page 1 YZF-R1 ’98 4XV1-AE1 SERVICE MANUAL...
  • Page 2 EB000000 YZF - R1 SERVICE MANUAL © 1997 by Yamaha Motor Co., Ltd. First edition, October 1997 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 3: Important Manual Information

    EB001000 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the tech- niques to repair these types of vehicles.
  • Page 4: How To Use This Manual

    EB003000 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Compre- hensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 5 EB004000 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis COOL CARB...
  • Page 6 CHAPTER TITLES GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING COOL CARBURETION CARB CHASSIS CHAS – ELECTRICAL ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 7 INFO...
  • Page 8: Table Of Contents

    INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL CODE ..................1-1 IMPORTANT INFORMATION ...............1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY .......1-2 REPLACEMENT PARTS ................1-2 GASKETS, OIL SEALS AND O-RINGS ..........1-2 USING A DYNAMOMETER ..............1-3 LOCK WASHERS/PLATES AND COTTER PINS ........1-3 BEARINGS AND OIL SEALS ..............1-3 CIRCLIPS ....................1-3 CHECKING THE CONNECTIONS ..............1-4...
  • Page 9 INFO...
  • Page 10: Chapter 1. General Information

    MOTORCYCLE IDENTIFICATION INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EB100020 MODEL CODE The model code label 1 is affixed to the frame.
  • Page 11: Important Information

    5. Keep all parts away from any source of fire. EB102010 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 12: Using A Dynamometer

    IMPORTANT INFORMATION INFO USING A DYNAMOMETER The YZF-R1 has a carbon muffler that may change color when exposed to high tem- peratures. Therefore, when using a dyna- mometer always use a fan to cool the muffler. EB102030 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/ plates 1 and cotter pins.
  • Page 13: Checking The Connections

    CHECKING THE CONNECTIONS INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →...
  • Page 14: Special Tools

    SPECIAL TOOLS INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 15 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench 90890-01426 This tool is needed to loosen or tighten the oil filter cartridge. Rod holder 90890-01434 This tool is used to support the damper adjusting rod. Rod puller Rod puller 90890-01437 Rod puller attachment Rod puller...
  • Page 16 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Engine tachometer 90890-03113 This tool is used to check engine speed. Timing light 90890-03141 This tool is used to check the ignition tim- ing. Carburetor angle driver 90890-03158 This tool is used to turn the pilot screw when adjusting the engine idling speed.
  • Page 17 Tool No. Tool name/Function Illustration Ignition checker 90890-06754 This tool is used to check the ignition sys- tem components. Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces). 1 - 8...
  • Page 18 SPEC...
  • Page 19 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ................2-1 ENGINE SPECIFICATIONS ................2-2 CHASSIS SPECIFICATIONS ...............2-11 ELECTRICAL SPECIFICATIONS ..............2-15 TIGHTENING TORQUES ................2-18 GENERAL TIGHTENING TORQUES ..........2-18 ENGINE TIGHTENING TORQUES .............2-19 CHASSIS TIGHTENING TORQUES ...........2-22 LUBRICATION POINTS AND LUBRICANT TYPES ........2-23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES .....2-23 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ...2-24 OIL FLOW DIAGRAMS ................2-25 COOLANT FLOW DIAGRAMS ..............2-29...
  • Page 20 SPEC...
  • Page 21: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Dimensions Overall length 2,035 mm (except for N, S, SF) ---- 2,095 mm (for N, S, SF) ---- Overall width 695 mm ---- Overall height 1,095 mm ---- Seat height 815 mm ---- Wheelbase 1,395 mm...
  • Page 22: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 998 cm ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 74 × 58 mm ---- Compression ratio 11.8:1 ---- Engine idling speed 1,050 ~ 1,150 r/min ---- Vacuum pressure at engine idling...
  • Page 23 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 180 ~ 220 kPa (1.8 ~ 2.2 kgf/cm ---- Oil pump Oil pump type Trochoidal ---- Inner-rotor-to-outer-rotor-tip 0.09 ~ 0.15 mm ---- clearance Outer-rotor-to-oil-pump-housing 0.03 ~ 0.08 mm...
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm ---- Camshaft journal diameter 24.437 ~ 24.450 mm ---- Camshaft-journal-to-camshaft- 0.050 ~ 0.084 mm ---- cap clearance Intake camshaft lobe dimensions Measurement A 32.5 ~ 32.6 mm 32.4 mm...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015 / 130 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.11 ~ 0.20 mm ---- Exhaust 0.21 ~ 0.30 mm ---- Valve dimensions Head Diameter Face Width Seat Width...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 38.9 mm ---- Exhaust 40.67 mm ---- Installed length (valve closed) Intake 34.5 mm ---- Exhaust 35 mm ---- Compressed spring force (installed) Intake 82 ~ 96 N (8.36 ~ 9.79 kgf) ---- Exhaust 110 ~ 126 N (11.22 ~ 12.85 kgf)
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons Piston-to-cylinder clearance 0.03 ~ 0.055 mm 0.12 mm Diameter D 73.955 ~ 73.970 mm ---- Height H 5 mm ---- Piston pin bore (in the piston) Diameter 17.002 ~ 17.013 mm ---- Offset 0.5 mm ---- Offset direction...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods Crankshaft-pin-to-big-end-bear- 0.016 ~ 0.040 mm ---- ing clearance Bearing color code –1 = Violet 0 = White 1 = Blue 2 = Black ---- Crankshaft Width A 52.40 ~ 57.25 mm ---- Width B 300.75 ~ 302.65 mm ----...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed ---- Primary reduction system Spur gear ---- Primary reduction ratio 68/43 (1.581) ---- Secondary reduction system Chain drive ---- Secondary reduction ratio 43/16 (2.688) ---- Operation Left-foot operation ---- Gear ratios 1st gear...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Starter jet 1 ---- Starter jet 2 ---- Butterfly valve size #100 ---- Fuel level (below the line on the 4.1 ~ 5.1 mm ---- float chamber) Max. EXUP cable free play (at the 1.5 mm ---- EXUP valve pulley)
  • Page 31: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 24˚ ---- Trail 92 mm ---- Front wheel Wheel type Cast wheel ---- 17 × MT3.50 Size ---- Material Aluminum ---- Wheel travel 135 mm ---- Wheel runout Max.
  • Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 190/50 ZR17 (73W) ---- Model (manufacturer) MEZ3 (METZELER) (for GB) ---- TX25 (MICHELIN) (for N, D, NL, B, E, P, I, GR) Tire pressure (cold) 0 ~ 90 kg 250 kPa (2.5 kg/cm , 2.5 bar) ----...
  • Page 33 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 135 mm ---- Spring Free length 255 mm ---- Spacer length 85 mm ---- Installed length 242.4 mm ---- Spring rate (K1) 7.35 N/mm (0.75 kgf/mm)
  • Page 34 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular ball bearings ---- Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly Coil spring/gas-oil damper ---- type Rear shock absorber assembly 65 mm ---- travel Spring Free length 176 mm ----...
  • Page 35: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition ---- Ignition timing 5˚ BTDC at 1,100 r/min ---- Advanced timing 55˚ BTDC at 5,000 r/min ---- Advancer type Throttle position sensor and electrical ---- 248 ~ 372 Ω...
  • Page 36 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) SM-13 (MITSUBA) ---- Power output 0.8 kW ---- Brushes Overall length 10 mm 5 mm Spring force 7.03 ~ 10.63 N (717 ~ 1,084 gf) ---- 0.025 ~ 0.035 Ω...
  • Page 37 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Temperature sender Model (manufacturer) 2YK (NIPPON SEIKI) ---- 47.5 ~ 56.8 Ω at 80 ˚C Resistance ---- 16.5 ~ 20.5 Ω at 115 ˚C Fuses (amperage × quantity) 30 A × 1 Main fuse ---- 20 A ×...
  • Page 38: Conversion Table

    SPEC CONVERSION TABLE/TIGHTENING TORQUES EB201000 EB202001 CONVERSION TABLE TIGHTENING TORQUES All specification data in this manual are GENERAL TIGHTENING TORQUES listed in SI and METRIC UNITS. This chart specifies tightening torques for Use this table to convert METRIC unit data standard fasteners with a standard ISO to IMPERIAL unit data.
  • Page 39: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf Spark plugs – Cylinder head Cylinder head Cap nut Cylinder head Bolt Camshaft caps Bolt Cylinder head cover Bolt Oil passage check bolt Bolt Cylinder head (exhaust pipe) Stud bolt Connecting rod caps...
  • Page 40 SPEC TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf Clutch cover Bolt Pickup coil rotor cover Bolt Shift shaft cover Bolt Oil baffle plate Bolt Timing mark accessing screw – Starter clutch idle gear shaft Bolt Starter clutch Bolt Use a lock...
  • Page 41 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2 - 21...
  • Page 42: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kgf Upper bracket pinch bolts Steering stem nut 11.5 Handlebar pinch bolts Lower ring nut See NOTE. Lower bracket pinch bolts Brake fluid reservoir cap stopper Front brake hose union bolts Front brake master cylinder Engine mounting Left front mounting bolts...
  • Page 43: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Engine mounting bolts (rear) Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Clutch cover (crankcase mating surface) No.1215...
  • Page 44: Chassis Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB202010 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal Sidestand pivoting point and metal-to-metal moving parts...
  • Page 45: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EB203000 OIL FLOW DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump 2 - 25...
  • Page 46 SPEC OIL FLOW DIAGRAMS 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter 2 - 26...
  • Page 47 SPEC OIL FLOW DIAGRAMS 1 Cylinder head 2 Crankshaft 2 - 27...
  • Page 48 SPEC OIL FLOW DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle 2 - 28...
  • Page 49: Coolant Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EB203000 COOLANT FLOW DIAGRAMS 1 Thermostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint 2 - 29...
  • Page 50 SPEC OIL FLOW DIAGRAMS 1 Thermostat housing 2 Water pump 3 Radiator 4 Radiator fan 2 - 30...
  • Page 51 SPEC OIL FLOW DIAGRAMS 1 Radiator cap 2 Thermostat 3 Thermostat housing 4 Water pump 2 - 31...
  • Page 52 SPEC OIL FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Temperature sender 2 - 32...
  • Page 53: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Å Properly insert the meter assembly coupler and rubber boot 1 Throttle cables 2 Front brake hose into the meter assembly. ı Route the meter assembly lead through the left side of the 3 Clutch cable 4 Starter cable headlight housing.
  • Page 54 SPEC CABLE ROUTING Ï Fasten the auxiliary light leads with a plastic lock- Route the right handlebar switch lead in ing tie. front of the throttle cables. Ì Fasten the wire harness to the headlight housing Ò Make sure that the horn leads face out. ˜...
  • Page 55 SPEC CABLE ROUTING 1 Rear brake switch lead over the timing chain tensioner. Ç Insert the plastic clip through the hole in the 2 Charcoal canister (California only) 3 Rollover valve (California only) plastic frame panel and then fasten the wire har- 4 Thermostat assembly breather hose ness and coolant reservoir breather hose with it.
  • Page 56 SPEC CABLE ROUTING Å Route the air filter case breather hose to the inside of the 1 Air filter case breather hose 2 Water pump breather hose wire harness. ı Route the stator coil lead over all of the hoses and leads and 3 Sidestand switch lead 4 Oil level switch lead then fasten them with a plastic clip.
  • Page 57 SPEC CABLE ROUTING Ó 50 mm coolant reservoir breather hose to the inside È Fasten the sidestand switch lead, engine oil of the radiator outlet hose. Make sure that level switch lead, and water pump breather the ends of all of the hoses are below the hose with a plastic clip.
  • Page 58 SPEC CABLE ROUTING 1 Speed sensor lead 2 Charcoal canister (California only) 3 Neutral switch lead 4 EXUP cables Å Route the EXUP cables on the outside of the engine mount. ı Fasten the EXUP cables with a plastic locking tie. 2 - 38...
  • Page 59 SPEC CABLE ROUTING 1 Headlight sub-wire harness C Fuel tank overflow hose 2 Left handlebar switch lead D Fuel tank breather hose (except for California) 3 Main switch lead E Starter motor lead 4 Starter cable F Battery positive lead 5 Right handlebar switch coupler G Battery negative lead 6 Throttle cables...
  • Page 60 SPEC CABLE ROUTING Å Route the horn lead over the horn bracket wire harness with a plastic clamp. Ì Fasten the EXUP servomotor lead, fuel pump and make sure that the lead has no slack. ı Do not cross the throttle cables and right lead, speed sensor lead, neutral switch lead, handlebar switch lead.
  • Page 61 SPEC CABLE ROUTING Ô Route the wire harness and turn signal leads harness with a plastic locking tie. Ø Route the fuel tank overflow hose and fuel under the rear cowling mounting post on the tail/brake light bracket. tank breather hose in front of the crankcase Insert the tail/brake light coupler and turn sig- breather hose and under the fuel hose and nal leads between the tail/brake light and...
  • Page 62 SPEC CABLE ROUTING Œ Fasten the wire harness with a plastic clamp Ë Fasten the wire harness and radiator fan lead to and then insert the clamp into the frame. the plastic frame panel with a plastic locking tie.  Route the charcoal canister hose under the ◊...
  • Page 63 SPEC CABLE ROUTING Á Install the rubber baffle over the carburetor air funnels. Û The end of the plastic locking tie must face in and down. 2 - 43...
  • Page 64 SPEC 2 - 44...
  • Page 66 CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ...................3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ....3-1 SEATS ......................3-3 FUEL TANK ....................3-4 COWLINGS ....................3-5 REMOVAL .....................3-6 INSTALLATION ..................3-6 AIR FILTER CASE AND IGNITION COIL PLATE ..........3-7 REMOVAL .....................3-8 INSTALLATION ..................3-8 ENGINE ......................3-9 ADJUSTING THE VALVE CLEARANCE ..........3-9 VALVE PAD SELECTION TABLE ............3-13 SYNCHRONIZING THE CARBURETORS ...........3-14 ADJUSTING THE ENGINE IDLING SPEED ........3-16...
  • Page 67 CHECKING THE BRAKE PADS ............3-41 ADJUSTING THE REAR BRAKE LIGHT SWITCH ......3-41 CHECKING THE BRAKE HOSES ............3-42 BLEEDING THE HYDRAULIC BRAKE SYSTEM ........3-42 ADJUSTING THE SHIFT PEDAL ............3-44 ADJUSTING THE DRIVE CHAIN SLACK ...........3-44 LUBRICATING THE DRIVE CHAIN .............3-46 CHECKING AND ADJUSTING THE STEERING HEAD .....3-46 CHECKING THE FRONT FORK ............3-49 ADJUSTING THE FRONT FORK LEGS ..........3-50 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ....3-52...
  • Page 68: Chapter 3. Periodic Checks And Adjustments

    INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjust- ments. If followed, these preventive maintenance procedures will ensure more reliable vehi- cle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
  • Page 69 * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. NOTE: • The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.
  • Page 70: Seats

    SEATS EB302000 SEATS Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. Passenger seat Rider seat For installation, reverse the removal procedure. 3 - 3...
  • Page 71: Fuel Tank

    FUEL TANK EB302010 FUEL TANK Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Refer to “SEATS”. Bolt Bolt Fuel sender coupler Disconnect. NOTE: Fuel hose Before disconnecting the fuel hose, set the fuel cock to “OFF”. Fuel tank overflow hose Fuel tank breather hose Fuel tank...
  • Page 72: Cowlings

    COWLINGS EB302020 COWLINGS Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Rider and passenger seats Refer to “SEATS”. Rear cowling Bottom cowling Front cowling inner panel (left) Front cowling inner panel (right) Left side cowling Right side cowling Windshield Rear view mirror...
  • Page 73: Removal

    COWLINGS REMOVAL 1. Remove: • rear cowling • side cowlings NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: • side cowlings • rear cowling NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a...
  • Page 74: Air Filter Case And Ignition Coil Plate

    AIR FILTER CASE AND IGNITION COIL PLATE EB302040 AIR FILTER CASE AND IGNITION COIL PLATE Order Job/Part Q’ty Remarks Removing the air filter case and igni- Remove the parts in the order listed. tion coil plate Rider seat and fuel tank Refer to “SEATS”...
  • Page 75: Removal

    AIR FILTER CASE AND IGNITION COIL PLATE REMOVAL 1. Remove: • rubber baffle NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: • rubber baffle NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the rubber baffle and push the pin a in with...
  • Page 76: Engine

    ADJUSTING THE VALVE CLEARANCE EB303001 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room tem- perature. • When the valve clearance is to be mea- sured or adjusted, the piston must be at top dead center (TDC) on the com- pression stroke.
  • Page 77 ADJUSTING THE VALVE CLEARANCE 4. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.11 ~ 0.20 mm Exhaust valve 0.21 ~ 0.30 mm a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the com- pression stroke, align...
  • Page 78 ADJUSTING THE VALVE CLEARANCE 5. Remove: • timing chain tensioner • timing chain guide (exhaust side) • intake camshaft caps • exhaust camshaft caps • timing chain (from the camshaft sprockets) • intake camshaft • exhaust camshaft NOTE: • Refer to “CAMSHAFTS” in chapter 4. •...
  • Page 79 ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad num- ber according to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm) Rounded value = 150 d.
  • Page 80: Valve Pad Selection Table

    ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE ı Å ORIGINAL VALVE PAD NUMBER MEASURED VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 ~ 0.07...
  • Page 81: Synchronizing The Carburetors

    ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS g. Measure the valve clearance again. h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 7. Install: • all removed parts NOTE: For installation, reverse the removal procedure.
  • Page 82 SYNCHRONIZING THE CARBURETORS 3. Remove: • bolts 1 • copper washers 4. Install: • vacuum gauge attachments (into the bolt holes) • vacuum gauge 1 (onto the vacuum gauge attachments) • engine tachometer 2 (onto the spark plug lead of cylinder #1) Vacuum gauge 90890-03094 Vacuum gauge attachment...
  • Page 83: Adjusting The Engine Idling Speed

    SYNCHRONIZING THE CARBURETORS/ ADJUSTING THE ENGINE IDLING SPEED NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carbure- tor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same.
  • Page 84 ADJUSTING THE ENGINE IDLING SPEED 2. Remove: • air filter case • quick fasteners 1 Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”. 3. Install: • engine tachometer (onto the spark plug lead of cylinder #1) Engine tachometer 90890-03113 4.
  • Page 85: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 7. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm EB303031 ADJUSTING THE THROTTLE CABLE FREE PLAY...
  • Page 86 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: • throttle cable free play NOTE: When the throttle is opened, the acceler- ator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the deceler- ator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.
  • Page 87: Checking The Spark Plugs

    CHECKING THE SPARK PLUGS EB303040 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • rider seat • fuel tank Refer to “SEATS” and “FUEL TANK”. • air filter case • ignition coil plate (along with the ignition coils) Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”.
  • Page 88: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 8. Install: • spark plug 13 Nm (1.3 m · kg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. EB303050 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system.
  • Page 89: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range → Check the ignition system. NOTE: The ignition timing is not adjustable. EB303060 MEASURING THE COMPRESSION PRESSURE...
  • Page 90 MEASURING THE COMPRESSION PRESSURE 5. Install: • compression gauge 1 Compression gauge 90890-03081 Adapter 90890-04136 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,350 kPa (13.5 kg/cm 13.5 bar) Standard 1,450 kPa (14.5 kg/cm...
  • Page 91: Checking The Engine Oil Level

    MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than with- Piston wear or damage → Repair. out oil Piston ring(-s), valve(-s), cylinder Same as without head gasket or piston possibly defective →...
  • Page 92: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CAUTION: ACHTUNG: • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. There- fore, do not add any chemical addi- tives or use engine oils with a grade of CD c or higher and do not use oils labeled “ENERGY CONSERVING II”...
  • Page 93 CHANGING THE ENGINE OIL b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. CAUTION: ACHTUNG: Make sure that the O-ring 3 is posi- tioned correctly in the groove of the oil filter cartridge.
  • Page 94 CHANGING THE ENGINE OIL 15.Check: • engine oil pressure a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.
  • Page 95: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm 2.
  • Page 96: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT/ CHECKING THE CARBURETOR JOINTS EB303130 CLEANING THE AIR FILTER ELEMENT 1. Remove: • fuel tank Refer to “FUEL TANK”. • air filter case cover 1 • air filter element 2. Clean: • air filter element Apply compressed air to the outer sur- face of the air filter element.
  • Page 97: Checking The Fuel Hoses And Fuel Filter

    CHECKING THE CARBURETOR JOINTS/ CHECKING THE FUEL HOSES AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE 2. Check: • carburetor joint 1 Cracks/damage → Replace. Refer to “CARBURETORS” in chapter 6. 3. Install: • carburetor assembly Refer to “CARBURETORS” in chapter 6. EB303181 CHECKING THE FUEL HOSES AND FUEL FILTER...
  • Page 98: Checking The Crankcase Breather Hose

    CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 2. Check: • crankcase breather hose 1 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: ACHTUNG: Make sure that the crankcase breather hose is routed correctly. 3. Install: • fuel tank Refer to “FUEL TANK”.
  • Page 99: Adjusting The Exup Cables

    ADJUSTING THE EXUP CABLES EB303210 ADJUSTING THE EXUP CABLES 1. Remove: • fuel tank • bottom cowling Refer to “FUEL TANK” and “COWL- INGS”. 2. Remove: • EXUP valve pulley cover 1 3. Check: • EXUP system operation a. Disconnect the EXUP servomotor coupler 1.
  • Page 100: Checking The Coolant Level

    ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 5. Adjust: • EXUP cable free play a. Loosen both locknuts 1. b. Insert a 4-mm long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover. c.
  • Page 101: Checking The Cooling System

    CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: • coolant level NOTE: Before checking the coolant level, wait a few minutes until the coolant has set- tled.
  • Page 102: Changing The Coolant

    CHANGING THE COOLANT EB303240 CHANGING THE COOLANT 1. Remove: • bottom cowling • right side cowling Refer to “COWLINGS”. 2. Disengage: • clutch cable holder 1 (from the coolant reservoir) 3. Remove: • coolant reservoir bolts 2 • coolant reservoir cap 3 NOTE: When draining the coolant from the coolant reservoir, be sure to tilt the res-...
  • Page 103 CHANGING THE COOLANT 8. Remove: • coolant drain bolt 1 (along with the copper washer) 9. Drain: • coolant 10.Check: • copper washer 1 • coolant drain bolt 2 Damage → Replace. 11.Install: • coolant drain bolt 7 Nm (0.7 m · kg) 12.Fill: •...
  • Page 104 CHANGING THE COOLANT CAUTION: ACHTUNG: • Adding water instead of coolant low- ers the antifreeze content of the cool- ant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the cool- ant. • Use only distilled water. However, soft water may be used if distilled water is not available.
  • Page 105: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever for- ward, turn the adjusting dial 1 until the brake lever is in the desired posi- tion.
  • Page 106 ADJUSTING THE REAR BRAKE 2. Adjust: • brake pedal position a. Loosen the locknut 1. b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Brake pedal is raised. Direction b Brake pedal is lowered.
  • Page 107: Checking The Brake Fluid Level

    CHECKING THE BRAKE FLUID LEVEL EB304020 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Check: Å • brake fluid level Below the minimum level mark a →...
  • Page 108: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EB304032 Å CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad • rear brake pad Brake pad wear limit a Wear limit reached →...
  • Page 109: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EB304062 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose 1 Cracks/damage/wear → Replace. 2. Check: • brake hose clamp Loose →...
  • Page 110 BLEEDING THE HYDRAULIC BRAKE SYSTEM 5. Bleed: Å • hydraulic brake system a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the brake fluid reservoir dia- phragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2.
  • Page 111: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EB304081 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Measure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 305 mm 2.
  • Page 112 ADJUSTING THE DRIVE CHAIN SLACK 2. Rotate the rear wheel several times and check the drive chain to locate its tight- est point. 3. Measure: • drive chain slack a Out of specification → Adjust. Drive chain slack 40 ~ 50 mm 4.
  • Page 113: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interact- ing parts. If the drive chain is not main- tained properly, it will wear out rapidly. Therefore, the drive chain should be ser- viced, especially when the motorcycle is used in dusty areas.
  • Page 114 CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • front brake fluid reservoir 1 • plastic caps 2 4. Loosen: • upper bracket pinch bolts 1 • handlebar pinch bolts 2 5. Remove: • upper bracket bolts 3 • handlebars (from the upper bracket) 6.
  • Page 115 CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut completely, then tighten it to specification. WARNING WARNING Do not overtighten the lower ring nut. Lower ring nut (final tighten- ing torque) 9 Nm (0.9 m • kg) d.
  • Page 116: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Hold the spring gauge at a 45˚ angle from the handlebar, pull the spring gauge, and record the measurement when the handlebar starts to turn. Steering head tension 200 ~ 500 g e.
  • Page 117: Adjusting The Front Fork Legs

    ADJUSTING THE FRONT FORK LEGS EB304153 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. •...
  • Page 118 ADJUSTING THE FRONT FORK LEGS Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping a. Turn the adjusting screw 1 in direc- tion a or b. Rebound damping is Direction a increased (suspension is harder).
  • Page 119: Adjusting The Rear Shock Absorber Assembly

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EB304162 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions.
  • Page 120 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping a. Turn the adjusting screw 1 in direc- tion a or b. Rebound damping is Direction a increased (suspension is harder).
  • Page 121: Checking The Tires

    CHECKING THE TIRES EB304170 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: • tire pressure Out of specification → Regulate. WARNING WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 122 The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer Size...
  • Page 123: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS Rear tire Manufacturer Size Model 190/50 ZR17 BT56R BRIDGESTONE (73W) BT57R 190/50 ZR17 MEZ1 METZELER (73W) RACING 190/50 ZR17 METZELER MEZ3 (73W) 190/50 ZR17 DUNLOP D207L (73W) 190/50 ZR17 MICHELIN TX25 (73W) 190/50 ZR17 MACADAM MICHELIN (73W)
  • Page 124: Checking And Lubricating The Cables

    CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION EB304200 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement.
  • Page 125: Electrical System

    CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preven- tive measures: •...
  • Page 126 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific grav- ity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 127 CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer to the appropriate charging method illustration) WARNING WARNING Do not quick charge a battery. CAUTION: ACHTUNG: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage cur- rent into the battery quickly and can cause battery overheating and bat-...
  • Page 128 CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger 3 - 61...
  • Page 129 CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger 3 - 62...
  • Page 130: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: ACHTUNG: First, connect the positive lead 1, then the negative lead 2. 8. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection →...
  • Page 131 CHECKING THE FUSES 3. Replace: • blown fuse a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage. c. Set the main switch to “ON” and ver- ify if the electrical circuit is opera- tional.
  • Page 132: Replacing The Headlight Bulbs

    REPLACING THE HEADLIGHT BULBS EB305051 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler 1 • headlight bulb holder cover 2 2. Detach: • headlight bulb holder 1 3. Remove: •...
  • Page 133: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS EB305061 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) a. Turn the adjusting screw 1 in direc- tion a or b. Direction a Headlight beam is raised. Headlight beam is low- Direction b ered.
  • Page 135 CHAPTER 4. OVERHAULING THE ENGINE ENGINE ......................4-1 INSTALLING THE ENGINE ..............4-7 CAMSHAFTS ....................4-8 REMOVING THE CAMSHAFTS ............4-11 CHECKING THE CAMSHAFTS ............4-12 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES ............4-13 CHECKING THE TIMING CHAIN TENSIONER ........4-14 INSTALLING THE CAMSHAFTS ............4-15 CYLINDER HEAD ..................4-18 REMOVING THE CYLINDER HEAD ............4-19 CHECKING THE CYLINDER HEAD .............4-19...
  • Page 136 SHIFT SHAFT ....................4-49 CHECKING THE SHIFT SHAFT ............4-50 CHECKING THE STOPPER LEVER .............4-50 INSTALLING THE SHIFT SHAFT ............4-50 OIL PAN AND OIL PUMP ................4-51 REMOVING THE OIL PAN ..............4-54 CHECKING THE OIL PUMP ..............4-54 CHECKING THE RELIEF VALVE ............4-55 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE ......4-55 CHECKING THE OIL STRAINER ............4-55 ASSEMBLING THE OIL PUMP ............4-55 INSTALLING THE OIL PUMP .............4-56...
  • Page 137: Chapter 4. Overhauling The Engine

    ENGINE EB400011 OVERHAULING THE ENGINE ENGINE Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. Locknut Shift rod Drive sprocket cover Lock washer Drive sprocket Shift arm For installation, reverse the removal procedure. 4 - 1...
  • Page 138 ENGINE Order Job/Part Q’ty Remarks Removing the exhaust assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Bottom cowling and side cowlings Refer to “COWLINGS” in chapter 3. Coolant Drain.
  • Page 139 ENGINE Order Job/Part Q’ty Remarks Muffler EXUP cable holder EXUP valve cover Spacer EXUP valve Spacer For installation, reverse the removal procedure. 4 - 3...
  • Page 140 ENGINE Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Air filter case Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE” in chapter 3. Carburetor assembly and carburetor Refer to “CARBURETORS” in chapter 6. joints Engine oil and oil filter cartridge Drain.
  • Page 141 ENGINE Order Job/Part Q’ty Remarks Clutch cable Crankcase breather hose Starter motor lead Disconnect. Ground lead Disconnect. Starter motor Stator coil assembly coupler Disconnect. Pickup coil coupler Disconnect. Oil level switch connector Disconnect. Neutral switch Speed sensor For connecting, reverse the disconnec- tion procedure.
  • Page 142 ENGINE Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. Pinch bolt Loosen. Right front mounting bolt Washer Spacer Left front mounting bolt Washer Self-locking nut Rear mounting bolt Spacer For installation, reverse the removal...
  • Page 143: Installing The Engine

    ENGINE EB400700 INSTALLING THE ENGINE 1. Install: • spacer 1 • rear mounting bolts 2 • self-locking nuts 3 • washers 4 • left front mounting bolts 5 • spacer 6 • washer 7 • right front mounting bolt 8 NOTE: •...
  • Page 144: Camshafts

    CAMSHAFTS EB401000 CAMSHAFTS Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Carburetor assembly Refer to “CARBURETORS” in chapter 6. Radiator assembly and thermostat Refer to “RADIATOR” and “THERMO- assembly STAT ASSEMBLY” in chapter 5. Spark plug Cylinder head cover Cylinder head cover gasket...
  • Page 145 CAMSHAFTS EB401011 Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Pickup coil rotor cover Refer to “PICKUP COIL”. Float chamber air vent hose holder Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap NOTE: Dowel pin...
  • Page 146 CAMSHAFTS Order Job/Part Q’ty Remarks Intake camshaft sprocket Exhaust camshaft sprocket Timing chain guide (intake side) For installation, reverse the removal procedure. 4 - 10...
  • Page 147: Removing The Camshafts

    CAMSHAFTS EB401101 REMOVING THE CAMSHAFTS 1. Align: • TDC mark on the pickup coil rotor (with the crankcase mating surface) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the com- pression stroke, align mark a on the pickup coil rotor with the crankcase mating surface b.
  • Page 148: Checking The Camshafts

    CAMSHAFTS EB401401 CHECKING THE CAMSHAFTS 1. Check: • camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft lobe dimensions limit Intake camshaft a 32.40 mm b 24.85 mm Exhaust camshaft a 32.85 mm...
  • Page 149: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

    CAMSHAFTS NOTE: • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when mea- suring the camshaft-journal-to-cam- shaft-cap clearance with ® Plastigauge Camshaft cap bolt 10 Nm (1.0 m •...
  • Page 150: Checking The Timing Chain Tensioner

    CAMSHAFTS 2. Check: • camshaft sprocket More than 1/4 tooth wear a → Replace the camshaft sprockets and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3. Check: • timing chain guide (exhaust side) 1 •...
  • Page 151: Installing The Camshafts

    CAMSHAFTS EB401701 INSTALLING THE CAMSHAFTS 1. Install: • timing chain guide (intake side) 1 2. Install: • intake camshaft sprocket 24 Nm (2.4 m · kg) • exhaust camshaft sprocket 24 Nm (2.4 m · kg) 3. Install: • exhaust camshaft •...
  • Page 152 CAMSHAFTS 4. Install: • timing chain guide (exhaust side) 5. Install: • timing chain tensioner a. Lightly press the timing chain ten- sioner rod into the timing chain ten- sioner housing by hand. b. While pressing the timing chain ten- sioner rod, wind it clockwise with a thin screwdriver 1 until it stops.
  • Page 153 CAMSHAFTS 7. Check: • TDC mark a Make sure that the TDC mark is aligned with the crankcase mating sur- face b. • camshaft punch mark c Make sure that the camshaft punch mark is aligned with the arrow mark d on the camshaft cap.
  • Page 154: Cylinder Head

    CYLINDER HEAD EB402000 CYLINDER HEAD Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Engine Refer to “ENGINE”. Intake and exhaust camshafts Refer to “CAMSHAFTS”. Cylinder head Cylinder head gasket Dowel pin For installation, reverse the removal procedure.
  • Page 155: Removing The Cylinder Head

    CYLINDER HEAD EB402102 REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head bolts • cylinder head nuts NOTE: Loosen each bolt and nut 1/2 of a turn at a time, in stages and in a crisscross pat- tern. After all of the bolts and nuts are fully loosened, remove them.
  • Page 156: Installing The Cylinder Head

    CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. EB402702 INSTALLING THE CYLINDER HEAD 1.
  • Page 157 VALVES AND VALVE SPRINGS EB403000 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal...
  • Page 158: Valves And Valve Springs

    VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure.
  • Page 159: Removing The Valves

    VALVES AND VALVE SPRINGS EB403100 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal.
  • Page 160: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3. Remove: • valve cotters 1 NOTE: Remove the valve cotters by compress- ing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor 90890-04019 Attachment (for the intake valve) 90890-04114 (for the exhaust valve) 90890-04108 4.
  • Page 161 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and instal- lation, and to maintain the correct fit, heat the cylinder head to 100 ˚C in an oven. a. Remove the valve guide with a valve guide remover 1.
  • Page 162: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness 0.5 ~ 0.9 mm 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide.
  • Page 163 VALVES AND VALVE SPRINGS a. Apply Mechanic’s blueing (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d.
  • Page 164: Checking The Valve Springs

    VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g.
  • Page 165: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: • compressed spring force a Out of specification → Replace the valve spring. b Installed length Compressed spring force (installed) Intake valve spring 8.36 ~ 9.79 kg at 34.5 mm Exhaust valve spring 11.22 ~ 12.85 kg at 35.0 mm 3.
  • Page 166 VALVES AND VALVE SPRINGS 3. Install: • lower spring seat 1 • oil seal 2 • valve 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) NOTE: • Make sure that each valve is installed in its original place.
  • Page 167 VALVES AND VALVE SPRINGS 6. Lubricate: • valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 7. Install: • valve pad • valve lifter NOTE: • The valve lifter must move smoothly when rotated with a finger. • Each valve lifter and valve pad must be reinstalled in its original position.
  • Page 168: Generator

    GENERATOR EB410000 GENERATOR Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Bottom cowling Refer to “COWLINGS” in chapter 3. Engine oil Drain.
  • Page 169: Removing The Generator

    Flywheel puller 90890-01080 EB410700 INSTALLING THE GENERATOR 1. Apply: • sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 2. Install: • generator rotor • washer • generator rotor bolt WARNING WARNING Always use a new generator rotor bolt.
  • Page 170 GENERATOR 3. Tighten: • generator rotor bolt 1 95 Nm (9.5 m · kg) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the generator rotor bolt. Rotor holding tool 90890-01235 4. Install: • generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern.
  • Page 171: Pickup Coil

    PICKUP COIL PICKUP COIL Order Job/Part Q’ty Remarks Removing the pickup coil and Remove the parts in the order listed. pickup coil rotor Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Bottom cowling and right side cowl- Refer to “COWLINGS”...
  • Page 172 PICKUP COIL Order Job/Part Q’ty Remarks Pickup coil coupler Disconnect. Pickup coil Pickup coil rotor For installation, reverse the removal procedure. 4 - 36...
  • Page 173: Removing The Pickup Coil Rotor

    PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remove: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 174 Rotor holding tool 90890-01235 3. Apply: • sealant (onto the pickup coil lead grommet) Yamaha bond No. 1215 90890-85505 4. Install: • pickup coil rotor cover • pickup coil lead holder • clutch cable holder NOTE: •...
  • Page 175: Clutch

    CLUTCH EB405000 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Bottom cowling and right side cowl- Refer to “COWLINGS” in chapter 3. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Clutch cable Clutch cover Clutch cover gasket...
  • Page 176 CLUTCH EB405010 Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. 4 - 40...
  • Page 177 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Inside diameter =124 mm Clutch plate Lock washer Wire circlip Clutch plate Friction plate...
  • Page 178 CLUTCH Order Job/Part Q’ty Remarks Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear For installation, reverse the removal procedure. 4 - 42...
  • Page 179: Removing The Clutch

    CLUTCH EB405102 REMOVING THE CLUTCH 1. Remove: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Straighten the lock washer tab. 3.
  • Page 180: Checking The Clutch Plates

    CLUTCH EB405410 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification →...
  • Page 181: Checking The Clutch Boss

    CLUTCH EB405450 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EB405460 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage →...
  • Page 182: Installing The Clutch

    CLUTCH 2. Check: • starter clutch operation a. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch gear clockwise Å, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.
  • Page 183 CLUTCH 3. Install: • lock washer • clutch boss nut 1 70 Nm (7.0 m · kg) NOTE: While holding the clutch boss 2 with the clutch holding tool 3, tighten the clutch boss nut. Clutch holding tool 90890-04086 4. Bend the lock washer tab along a flat side of the nut.
  • Page 184 CLUTCH 9. Install: • clutch cover 12 Nm (1.2 m · kg) NOTE: • When installing the clutch cover, push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged.
  • Page 185: Shift Shaft

    SHIFT SHAFT EB408000 SHIFT SHAFT Order Job/Part Q’ty Remarks Removing the shift shaft and stop- Remove the parts in the order listed. per lever Drive sprocket cover Refer to “ENGINE”. Throttle stop screw holder Shift shaft cover Shift shaft cover gasket Dowel pin Shift shaft Shift shaft spring...
  • Page 186: Checking The Shift Shaft

    SHIFT SHAFT EB408401 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. EB408410 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
  • Page 187: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP EB411000 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Coolant Drain.
  • Page 188 OIL PAN AND OIL PUMP EB411001 Order Job/Part Q’ty Remarks Drain pipe Oil strainer Oil pipe Oil delivery pipe Oil/water pump assembly drive sprocket cover Dowel pin Oil/water pump assembly Relief valve assembly For installation, reverse the removal procedure. 4 - 52...
  • Page 189 OIL PAN AND OIL PUMP EB411003 Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Oil/water pump assembly driven sprocket Washer Oil pump housing Bearing Oil pump outer rotor Oil pump inner rotor For installation, reverse the removal procedure.
  • Page 190: Removing The Oil Pan

    OIL PAN AND OIL PUMP EB411100 REMOVING THE OIL PAN 1. Remove: • oil level switch 1 • oil pan 2 • oil pan gasket • dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 191: Checking The Relief Valve

    OIL PAN AND OIL PUMP 3. Check: • oil pump operation Unsmooth → Repair or replace the defective part(-s). Refer to “WATER PUMP” in chapter 5. EB411410 CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 • relief valve 2 •...
  • Page 192: Installing The Oil Strainer

    OIL PAN AND OIL PUMP 2. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. EB411710 INSTALLING THE OIL PUMP 1. Install: • oil pump 1 10 Nm (1.0 m · kg) NOTE: Install the oil/water pump assembly drive chain onto the oil/water pump assembly driven sprocket.
  • Page 193: Crankcase

    CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Pickup coil and pickup coil rotor Refer to “PICKUP COIL”. Stator coil assembly Refer to “GENERATOR”. Clutch housing and starter clutch Refer to “CLUTCH”.
  • Page 194 CRANKCASE Order Job/Part Q’ty Remarks Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin For installation, reverse the removal procedure. 4 - 58...
  • Page 195 CRANKCASE Order Job/Part Q’ty Remarks Removing the oil baffle plates and Remove the parts in the order listed. oil filter bolt Connecting rod assemblies Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Oil baffle plate Oil baffle plate Oil delivery pipe Bearing...
  • Page 196: Disassembling The Crankcase

    CRANKCASE EB412100 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pat- tern. After all of the bolts are fully loos- ened, remove them. •...
  • Page 197: Checking The Crankcase

    CRANKCASE EB412420 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • upper crankcase • lower crankcase Cracks/damage → Replace. • oil delivery passages Obstruction →...
  • Page 198: Assembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm of the crankshaft jour- nal bearings.
  • Page 199 CRANKCASE 6. Install: • lower crankcase 1 (onto the upper crankcase 2) CAUTION: ACHTUNG: Before tightening the crankcase bolts, make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. 7. Install: • crankcase bolts NOTE: •...
  • Page 200: Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EB404001 CONNECTING RODS AND PISTONS Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Crankcase Separate. Refer to “CRANKCASE”. Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod...
  • Page 201: Removing The Connecting Rods And Pistons

    CONNECTING RODS AND PISTONS EB412131 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap 1 • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 202: Checking The Cylinders And Pistons

    CONNECTING RODS AND PISTONS EB404403 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: • piston wall • cylinder wall Vertical scratches → Replace the crankcases, and the piston and piston rings as a set.
  • Page 203: Checking The Piston Rings

    CONNECTING RODS AND PISTONS e. Calculate the piston-to-cylinder clear- ance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.030 ~ 0.055 mm <Limit>: 0.12 mm f. If out of specification, replace the crankcases, and the pistons and pis- ton rings as a set.
  • Page 204: Checking The Piston Pins

    CONNECTING RODS AND PISTONS 3. Measure: • piston ring end gap Out of specification → Replace the pis- ton ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings.
  • Page 205: Checking The Big End Bearings

    CONNECTING RODS AND PISTONS 4. Calculate: • piston-pin-to-piston-pin-bore clear- ance Out of specification → Replace the pis- ton pin. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter Piston-pin-to-piston-pin-bore clearance 0.002 ~ 0.022 mm <Limit>: 0.072 mm CHECKING THE BIG END BEARINGS 1.
  • Page 206 CONNECTING RODS AND PISTONS ® c. Put a piece of Plastigauge 1 on the crankshaft pin. d. Assemble the connecting rod halves. NOTE: • Do not move the connecting rod or crankshaft until the clearance mea- surement has been completed. •...
  • Page 207: Installing The Pistons And Connecting Rods

    CONNECTING RODS AND PISTONS 2. Select: • big end bearings (“P ”~ “P ”) NOTE: • The numbers stamped into the crank- shaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. •...
  • Page 208 CONNECTING RODS AND PISTONS 2. Install: • piston 1 (onto the respective connecting rod 2) • piston pin 3 • piston pin clip 4 NOTE: • Apply engine oil onto the piston pin. • Make sure that the “Y” mark a on the connecting rod faces left when the arrow mark b on the piston is pointing up.
  • Page 209 CONNECTING RODS AND PISTONS 6. Lubricate: • crankshaft pins • big end bearings • connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crank- shaft pin) •...
  • Page 210: Crankshaft

    CRANKSHAFT EB412000 CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal procedure.
  • Page 211: Removing The Crankshaft

    CRANKSHAFT EB412110 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 • crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EB412403 CHECKING THE CRANKSHAFT 1.
  • Page 212 CRANKSHAFT a. Clean the crankshaft journal bearings, crankshaft journals, and bearing por- tions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a on the crank- shaft journal upper bearings with the...
  • Page 213 CRANKSHAFT g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure compressed Plasti- ® width c on each crankshaft gauge journal. If the clearance is out of specification, select replacement crankshaft jour- nal bearings. 2. Select: • crankshaft journal bearings (J NOTE: •...
  • Page 214: Installing The Crankshaft

    CRANKSHAFT EB412720 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearings (into the upper crankcase) NOTE: • Align the projections a on the crank- shaft journal upper bearings with the notches b in the upper crankcase. • Be sure to install each crankshaft jour- nal upper bearing in its original place.
  • Page 215: Transmission

    TRANSMISSION EB413000 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE”. Stopper lever Refer to “SHIFT SHAFT”. Drive axle assembly Circlip Oil seal Bearing Shift drum retainer Shift fork guide bar...
  • Page 216 TRANSMISSION Order Job/Part Q’ty Remarks Shift drum assembly Shift fork “C” Main axle assembly For installation, reverse the removal procedure. 4 - 80...
  • Page 217 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle assem- Remove the parts in the order listed. 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gears 5th pinion gear Collar 4 - 81...
  • Page 218 TRANSMISSION Order Job/Part Q’ty Remarks Main axle/1st pinion gear Bearing Main axle bearing housing For installation, reverse the removal procedure. 4 - 82...
  • Page 219 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle assem- Remove the parts in the order listed. Washer 1st wheel gear Spacer 5th wheel gear Circlip Washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 4 - 83...
  • Page 220 TRANSMISSION Order Job/Part Q’ty Remarks 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer For installation, reverse the removal procedure. 4 - 84...
  • Page 221: Removing The Transmission

    TRANSMISSION EB413100 REMOVING THE TRANSMISSION 1. Remove: • main axle assembly 1 ® (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crankcase surface.
  • Page 222: Checking The Shift Drum Assembly

    TRANSMISSION 3. Check: • shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift fork(-s) and shift fork guide bar as a set. EB413410 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage/scratches/wear →...
  • Page 223: Installing The Transmission

    TRANSMISSION 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmis- sion axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(-s). 6. Check: • circlips Bends/damage/looseness →...
  • Page 224 4 - 88...
  • Page 225 COOL...
  • Page 226 COOL CHAPTER 5. COOLING SYSTEM RADIATOR .....................5-1 CHECKING THE RADIATOR ..............5-3 INSTALLING THE RADIATOR ..............5-4 OIL COOLER ....................5-5 CHECKING THE OIL COOLER ..............5-6 INSTALLING THE OIL COOLER ............5-6 THERMOSTAT ASSEMBLY .................5-8 CHECKING THE THERMOSTAT ............5-11 ASSEMBLING THE THERMOSTAT ASSEMBLY ......5-11 INSTALLING THE THERMOSTAT ASSEMBLY .........5-12 WATER PUMP .....................5-13 DISASSEMBLING THE WATER PUMP ..........5-15...
  • Page 227 COOL...
  • Page 228: Chapter 5. Cooling System

    COOL RADIATOR EB500000 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”...
  • Page 229 COOL RADIATOR Order Job/Part Q’ty Remarks Thermo switch Temperature sender Thermostat assembly breather hose Disconnect. Radiator inlet hose Oil cooler outlet hose Disconnect. Water pump breather hose Radiator outlet hose Water pump inlet pipe Radiator fan motor coupler Disconnect. Horn bracket Radiator Radiator fan For installation, reverse the removal...
  • Page 230: Checking The Radiator

    COOL RADIATOR EB500010 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: •...
  • Page 231: Installing The Radiator

    COOL RADIATOR EB500020 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the rec- ommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part.
  • Page 232: Oil Cooler

    COOL OIL COOLER EB501000 OIL COOLER Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Radiator assembly Refer to “RADIATOR”. Exhaust pipe assembly Refer to “ENGINE” in chapter 4. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL”...
  • Page 233: Checking The Oil Cooler

    COOL OIL COOLER EB501010 CHECKING THE OIL COOLER 1. Check: • oil cooler Cracks/damage → Replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace. 3. Check: • water jacket joint • water jacket joint inlet hose •...
  • Page 234 COOL OIL COOLER 4. Fill: • cooling system (with the specified amount of the rec- ommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. • crankcase (with the specified amount of the rec- ommended engine oil) Refer to “CHANGING THE ENGINE OIL”...
  • Page 235: Thermostat Assembly

    COOL THERMOSTAT ASSEMBLY EB502000 THERMOSTAT ASSEMBLY Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”...
  • Page 236 COOL THERMOSTAT ASSEMBLY Order Job/Part Q’ty Remarks Thermostat assembly Thermostat assembly inlet pipe (left) Thermostat assembly inlet pipe (right) For installation, reverse the removal procedure. 5 - 9...
  • Page 237 COOL THERMOSTAT ASSEMBLY EB502010 Order Job/Part Q’ty Remarks Disassembling the thermostat Remove the parts in the order listed. assembly Thermostat housing cover Thermostat Thermostat housing For assembly, reverse the disassembly procedure. 5 - 10...
  • Page 238: Checking The Thermostat

    COOL THERMOSTAT ASSEMBLY EB502020 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 71 ~ 85 ˚C → Replace. a. Suspend the thermostat in a con- tainer filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.
  • Page 239: Installing The Thermostat Assembly

    COOL THERMOSTAT ASSEMBLY EB502040 INSTALLING THE THERMOSTAT ASSEMBLY 1. Fill: • cooling system (with the specified amount of the rec- ommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part.
  • Page 240: Water Pump

    COOL WATER PUMP EB503000 WATER PUMP Order Job/Part Q’ty Remarks Removing the impeller shaft Remove the parts in the order listed. NOTE: • The water pump and oil pump are combined into one unit (oil/water pump assembly). • It is not necessary to remove the impeller shaft unless the coolant level is extremely low or coolant leaks from the oil pan.
  • Page 241 COOL WATER PUMP Order Job/Part Q’ty Remarks Water pump seal Oil seal Bearing For installation, reverse the removal procedure. 5 - 14...
  • Page 242: Disassembling The Water Pump

    COOL WATER PUMP EB503020 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: • oil seal 1 •...
  • Page 243: Assembling The Water Pump

    NOTE: • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3. Mechanical seal installer 4 90890-04078 Middle driven shaft bearing...
  • Page 244 COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: ACHTUNG: Make sure that the rubber damper and rubber damper holder are flush with the impeller. Max. impeller shaft tilt 0.15 mm 1 Straightedge 2 Impeller 5 - 17...
  • Page 245 COOL 5 - 18...
  • Page 246 CARB...
  • Page 247 CARB CHAPTER 6. CARBURETORS CARBURETORS ....................6-1 CHECKING THE CARBURETORS ............6-6 ASSEMBLING THE CARBURETORS ...........6-8 INSTALLING THE CARBURETORS ............6-10 MEASURING AND ADJUSTING THE FUEL LEVEL ......6-11 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ..................6-12 CHECKING THE FUEL PUMP .............6-15...
  • Page 248 CARB...
  • Page 249 CARB CARBURETORS EB600001 CARBURETORS CARBURETORS Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case and rubber baffle Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”...
  • Page 250 CARB CARBURETORS EB600010 Order Job/Part Q’ty Remarks Separating the carburetors Remove the parts in the order listed. Starter plunger link R = 245 mm Connecting bolt Copper washer R = 270 mm Connecting bolt R = 43 mm Spacer R = 38 mm Spacer R = 36 mm Spacer...
  • Page 251 CARB CARBURETORS Order Job/Part Q’ty Remarks R = 37 mm Fuel feed pipe R = 32 mm Fuel feed pipe R = 29 mm Fuel feed pipe Pipe R = 73 mm R = 68 mm Pipe R = 66 mm Pipe Throttle stop screw Throttle position sensor...
  • Page 252 CARB CARBURETORS EB600021 Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. NOTE: The following procedure applies to all of the carburetors. Starter plunger Air funnel Air funnel joint Pilot air jet Vacuum chamber cover Piston valve spring Jet needle holder Jet needle kit...
  • Page 253 CARB CARBURETORS Order Job/Part Q’ty Remarks Float chamber Float pivot pin Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet For assembly, reverse the disassembly procedure. 6 - 5...
  • Page 254 CARB CARBURETORS EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: • carburetor body • float chamber Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. a. Wash the carburetor in a petroleum- based solvent.
  • Page 255 CARB CARBURETORS 8. Check: • piston valve 1 Damage/scratches/wear → Replace. • piston valve diaphragm 2 Cracks/tears → Replace. 9. Check: • vacuum chamber cover 1 • piston valve spring 2 • jet needle holder 3 • jet needle spring 4 Cracks/damage →...
  • Page 256 CARB CARBURETORS 13.Check: • fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. EB600043 ASSEMBLING THE CARBURETORS The following procedure applies to all of the carburetors. CAUTION: ACHTUNG: • Before assembling the carburetors, wash all of the parts in a petroleum- based solvent.
  • Page 257 CARB CARBURETORS 3. Install: • pipes • fuel feed pipes • vacuum chamber pipe • vacuum chamber air vent hose • springs • float chamber air vent hoses • hose joints • spacers • copper washer • connecting bolts NOTE: •...
  • Page 258 CARB CARBURETORS EB600051 INSTALLING THE CARBURETORS 1. Adjust: • carburetor synchronization Refer to “SYNCHRONIZING THE CAR- BURETORS” in chapter 3. 2. Adjust: • engine idling speed Engine idling speed 1,050 ~ 1,150 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 3.
  • Page 259 CARB CARBURETORS EB600063 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level (below the line on the float chamber) 4.1 ~ 5.1 mm a. Stand the motorcycle on a level sur- face.
  • Page 260 CARB CARBURETORS EB600072 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor (installed on the carburetor) a. Disconnect the throttle position sen- sor coupler.
  • Page 261 CARB CARBURETORS 2. Check: • throttle position sensor (removed from the carburetor) a. Disconnect the throttle position sen- sor coupler. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Tester positive probe →...
  • Page 262 CARB CARBURETORS 3. Adjust: • throttle position sensor angle a. Set the main switch to “ON”. b. Disconnect the throttle position sen- sor coupler. c. Reconnect the throttle position sen- sor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjust- ment mode.
  • Page 263 CARB CARBURETORS EB600090 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Disconnect the fuel-pump-to-carbure- tor fuel hose 2 from the carburetor. c. Connect the fuel-tank-to-fuel-pump fuel hose to the fuel tank and then set the fuel cock to “ON”.
  • Page 264 CARB 6 - 16...
  • Page 265 CHAS...
  • Page 266 CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS ............7-1 REMOVING THE FRONT WHEEL ............7-3 DISASSEMBLING THE FRONT WHEEL ..........7-3 CHECKING THE FRONT WHEEL ............7-4 CHECKING THE BRAKE DISCS ............7-5 ASSEMBLING THE FRONT WHEEL ............7-6 INSTALLING THE FRONT WHEEL ............7-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......7-7 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET ....7-10 REMOVING THE REAR WHEEL ............7-13...
  • Page 267 CHAS HANDLEBARS .....................7-56 REMOVING THE HANDLEBARS ............7-58 CHECKING THE HANDLEBARS ............7-58 INSTALLING THE HANDLEBARS ............7-59 STEERING HEAD ..................7-61 REMOVING THE LOWER BRACKET ..........7-63 CHECKING THE STEERING HEAD .............7-63 INSTALLING THE STEERING HEAD ..........7-64 REAR SHOCK ABSORBER ASSEMBLY .............7-66 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER ..............7-67 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER ..............7-67...
  • Page 268: Chapter 7. Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EB700002 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is ele- vated.
  • Page 269 CHAS FRONT WHEEL AND BRAKE DISCS EB700010 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure. 7 - 2...
  • Page 270: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EB700102 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 271: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EB700400 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING WARNING Do not attempt to straighten a bent wheel axle. 2. Check: •...
  • Page 272: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS c. Remove the wheel bearings 3 with a general bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disas- sembly. CAUTION: ACHTUNG: Do not contact the wheel bearing center race 4 or balls 5.
  • Page 273: Assembling The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Min. brake disc thickness Front: 4.5 mm Rear: 4.5 mm 4. Adjust: • brake disc deflection a.
  • Page 274: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EB700725 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium soap base grease 2. Install: • brake discs 18 Nm (1.8 m · kg) NOTE: ® • Apply LOCTITE 648 to the threads of the brake disc bolts.
  • Page 275 CHAS FRONT WHEEL AND BRAKE DISCS 1. Remove: • balancing weight(-s) 2. Find: • front wheel’s heavy spot a. Place the front wheel on a suitable balancing stand. b. Spin the front wheel. c. When the front wheel stops, put an “X ”...
  • Page 276 CHAS FRONT WHEEL AND BRAKE DISCS 4. Check: • front wheel static balance a. Turn the front wheel and make sure that it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.
  • Page 277: Rear Wheel, Brake Disc, And Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701000 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is ele- vated.
  • Page 278 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701010 Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel sprocket Brake disc Rear wheel sprocket Oil seal cover (left and right) Spacer (left and right) Oil seal Bearing...
  • Page 279 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Spacer Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 7 - 12...
  • Page 280: Removing The Rear Wheel

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701100 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 281: Checking The Rear Wheel Drive Hub

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 3. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL”. Over the specified limits → Replace. Max. radial wheel runout 1.0 mm Max. lateral wheel runout 0.5 mm EB701430 CHECKING THE REAR WHEEL DRIVE HUB 1.
  • Page 282: Installing The Rear Wheel

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701710 INSTALLING THE REAR WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips Recommended lubricant Lithium soap base grease 2. Adjust: • drive chain slack a Drive chain slack 40 ~ 50 mm Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
  • Page 283: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EB702001 FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad...
  • Page 284 CHAS FRONT AND REAR BRAKES EB702002 Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw For installation, reverse the removal procedure.
  • Page 285: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EB702100 CAUTION: ACHTUNG: Disc brake components rarely require disassembly. Therefore, always follow these preven- tive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disas- sembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 286 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pin 2 • brake pad spring 3 • brake pads (along with the brake pad shims) 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set.
  • Page 287: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pin • brake pad clips • brake caliper 40 Nm (4.0 m · kg) 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 288 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: • brake pad shims (onto the brake pads) •...
  • Page 289 CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pins • brake pad clips • brake pad cover • brake caliper 40 Nm (4.0 m · kg) 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 290 CHAS FRONT AND REAR BRAKES EB702200 Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder and brake fluid reservoir Brake fluid Drain. Brake fluid reservoir cap stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir...
  • Page 291 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake hose Brake master cylinder holder Brake master cylinder Front brake switch For installation, reverse the removal procedure. 7 - 24...
  • Page 292 CHAS FRONT AND REAR BRAKES EB702201 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 7 - 25...
  • Page 293 CHAS FRONT AND REAR BRAKES EB702202 Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder and brake fluid reservoir Brake fluid Drain. Brake fluid reservoir cap stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 294 CHAS FRONT AND REAR BRAKES EB702203 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 7 - 27...
  • Page 295: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EB702210 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hoses 3 NOTE: To collect any remaining brake fluid, place a container under the master cylin-...
  • Page 296: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 2. Check: Å • brake master cylinder kit Damage/scratches/wear → Replace. Å Front ı Rear ı 3. Check: Å ı • brake fluid reservoir 1 Cracks/damage → Replace. • brake fluid reservoir diaphragm 2 Cracks/damage → Replace. 4.
  • Page 297 CHAS FRONT AND REAR BRAKES 1. Install: • brake master cylinder 1 13 Nm (1.3 m · kg) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. • Align the end of the brake master cyl- inder holder with the punch mark a in the right handlebar.
  • Page 298: Assembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES CAUTION: ACHTUNG: Brake fluid may damage painted sur- faces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5.
  • Page 299 CHAS FRONT AND REAR BRAKES 2. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance. •...
  • Page 300 CHAS FRONT AND REAR BRAKES EB702301 Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal...
  • Page 301 CHAS FRONT AND REAR BRAKES EB702303 Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston...
  • Page 302 CHAS FRONT AND REAR BRAKES EB702304 Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal procedure. 7 - 35...
  • Page 303 CHAS FRONT AND REAR BRAKES EB702305 Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly procedure.
  • Page 304: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702317 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake cali- per, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 •...
  • Page 305: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EB702322 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose NOTE: Put the end of the brake hose into a con- tainer and pump out the brake fluid carefully.
  • Page 306: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702343 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Every two years and whenever the Brake fluid brake is disassem- bled 1.
  • Page 307: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702376 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.
  • Page 308 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the rec- ommended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance.
  • Page 309: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EB702378 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the pis- ton seals to swell and distort.
  • Page 310 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the rec- ommended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance.
  • Page 311: Front Fork

    CHAS FRONT FORK EB703001 FRONT FORK Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 312 CHAS FRONT FORK EB703002 Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Spring seat Fork spring Damper adjusting rod Outer tube Dust seal Oil seal clip...
  • Page 313 CHAS FRONT FORK Order Job/Part Q’ty Remarks Damper rod assembly bolt Copper washer Damper rod assembly Inner tube For assembly, reverse the disassembly procedure. 7 - 46...
  • Page 314: Removing The Front Fork Legs

    CHAS FRONT FORK EB703100 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 315 CHAS FRONT FORK NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring compressor WARNING WARNING The fork spring is compressed. f.
  • Page 316: Checking The Front Fork Legs

    CHAS FRONT FORK EB703401 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
  • Page 317: Assembling The Front Fork Legs

    2 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 01 or equivalent 7 - 50...
  • Page 318 CHAS FRONT FORK 3. Tighten: • damper rod assembly bolt 1 40 Nm (4.0 m · kg) NOTE: While holding the damper rod with the damper rod holder 2, tighten the damper rod assembly bolt. Damper rod holder 90890-01423 4. Install: •...
  • Page 319 (with the specified amount of the rec- ommended fork oil) Quantity (each front fork leg) 477 cm Recommended oil Yamaha fork and shock oil 01 or equiv