Yamaha XV1700PCRC Service Manual

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XV1700PCR
XV1700PCRC
SUPPLEMENTARY
SERVICE MANUAL
LIT-11616-16-36
5PX-28197-11

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Table of Contents
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  Summary of Contents for Yamaha XV1700PCRC

  • Page 1 XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL LIT-11616-16-36 5PX-28197-11...
  • Page 2 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XV1700PCR/XV1700PCRC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10)
  • Page 3: Important Manual Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 5 EAS00009 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 8 indicate the INFO subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting TRBL...
  • Page 6: Table Of Contents

    CONTENTS SPECIFICATIONS ................... 1 GENERAL SPECIFICATIONS ..............1 ENGINE SPECIFICATIONS ..............1 CHASSIS SPECIFICATIONS ..............1 ELECTRICAL SPECIFICATIONS ............2 TIGHTENING TORQUES ................. 2 CHASSIS TIGHTENING TORQUES ............ 2 CABLE ROUTING ..................3 PERIODIC CHECKS AND ADJUSTMENTS ..........11 INTRODUCTION ..................11 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ..........
  • Page 7: Specifications

    GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PX4 (USA) ---- 5PX5 (California) ---- 5PX6 (CDN) ---- ENGINE SPECIFICATIONS Item Standard Limit Electronic fuel injection Model (manufacturer) INP-732 (NIPPON INJECTOR) ---- Quantity ---- Crankshaft Width A 132.8 ~ 133.2 mm (5.228 ~ 5.244 in) ----...
  • Page 8: Electrical Specifications

    ---- Secondary coil resistance 12 ~ 18 kΩ ---- Charging system System type AC magneto ---- Model (manufacturer) F5PX (YAMAHA) ---- Nominal output 14 V/31 A at 5,000 r/min ---- 0.13 ~ 0.19 Ω/W–W Stator coil resistance/color ---- TIGHTENING TORQUES...
  • Page 9: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Brake hose È Fasten the rectifier/regulator Ê Fasten the rear brake light 2 Clutch cable lead, horn lead, and rear brake switch lead, horn lead, and 3 Rectifier/regulator light switch lead with a plastic stator coil assembly lead with 4 Rectifier/regulator lead locking tie to the frame.
  • Page 10 SPEC CABLE ROUTING 1 Tachometer couplers È Secure the wire harness in the holder at the 2 Right handlebar switch coupler and speedome- white tape on the harness. É Route each lead behind the headlight assembly ter couplers 3 Main switch coupler bracket bolts.
  • Page 11 SPEC CABLE ROUTING 1 Throttle cable 1 and throttle cable 2 È Pass throttle cable 1 and throttle cable 2 through 2 Clutch cable the cable guide, and then fasten them with a 3 Atmospheric pressure sensor plastic holder. 4 Spark plug cap (ignition coil 1-L spark plug lead) É...
  • Page 12 SPEC CABLE ROUTING Ë Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking tie. Ì Fasten the starter motor lead and side stand switch lead with a plastic locking tie to the frame. Í...
  • Page 13 SPEC CABLE ROUTING 1 Ignition coil 1 È To the rectifier/regulator, horn 1, and rear brake 2 Atmospheric pressure sensor lead light switch. 3 Ignition coil 2 É 30 ~ 50 degrees 4 Ignition coil 2 lead Ê 40 ~ 60 degrees 5 Rear brake light switch coupler 6 Rectifier/regulator lead and horn lead 7 Linear control valve lead...
  • Page 14 SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 H Ignition coil 1-R spark plug lead 2 Fuel hose 0 Throttle cables I Lean angle cut-off switch lead 3 Spark plug cap (ignition coil 1-R A Brake hose J Crankshaft position sensor lead B Spark plug cap (ignition coil 2-R K Sidestand switch lead...
  • Page 15 SPEC CABLE ROUTING È To the battery box. Í Fasten the main wire harness, intake air pres- É Fasten the main wire harness and fuel hose with sure sensor lead #2, ignition coil 1-R spark plug a plastic locking tie to the frame. lead, and intake air temperature sensor coupler Ê...
  • Page 16 SPEC CABLE ROUTING Ð To the injector sub lead. × To the speed sensor. Ñ To the engine temperature sensor. Ø Fasten the crankshaft position sensor lead, side- Ò 10 30 mm (0.4 1.2 in) stand switch lead, lean angle cut-off switch lead, Ó...
  • Page 17: Periodic Checks And Adjustments

    Evaporative Emission control • Check control system for damage. √ √ system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. – 11 –...
  • Page 18: General Maintenance And Lubrication Chart

    √ √ √ √ — ing and cable free play if necessary. • Lubricate the throttle grip housing and cable. Yamaha Chain and • Apply chain lube thor- Cable Lube or √ √ √ √ √ √ 9 * Control cables oughly.
  • Page 19 Every 2,500 mi (4,000 km) • Adjust if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
  • Page 20: Chassis

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHASSIS EAS00156 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1.
  • Page 21: Adjusting The Rear Shock Absorber

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting knob 1 in direction a or Rebound damping is Direction a increased (suspension...
  • Page 22 CHAS FRONT AND REAR BRAKES CHASSIS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • •...
  • Page 23 CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 24: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 25 CHAS REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 26 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
  • Page 27 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Swingarm Dust cover Spacer Bearing For installation, reverse the removal...
  • Page 28: Engine

    ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENGINE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
  • Page 29 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 30: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH STATOR COIL ASSEMBLY 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 31 GENERATOR AND STARTER CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 32 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 33 XV1700P XV1700PC SERVICEMANUAL LIT-11616-15-37 5PX-28197-10...
  • Page 34 EAS00001 XV1700P/XV1700PC SERVICE MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. First edition, October 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-15-37...
  • Page 35 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 36 EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 37 EAS00009 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 8 indicate the INFO subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments CHAS 4 Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting TRBL...
  • Page 38 EAS00013 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 39: Table Of Contents

    CONTENTS CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL LABEL..................1-1 FEATURES ......................1-2 OUTLINE ....................1-2 FI SYSTEM ....................1-3 COMPONENTS ..................1-5 FUEL INJECTION SYSTEM ..............1-17 FIRST IDLE CONTROL SYSTEM ............1-28 COMPONENTS ..................1-29 IMPORTANT INFORMATION................1-32 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-32 REPLACEMENT PARTS .................1-32 GASKETS, OIL SEALS AND O-RINGS ..........1-32 LOCK WASHERS/PLATES AND COTTER PINS ........1-33...
  • Page 40: Table Of Contents

    TIGHTENING TORQUES ................2-21 ENGINE TIGHTENING TORQUES ............2-21 CHASSIS TIGHTENING TORQUES ............2-24 LUBRICATION POINTS AND LUBRICANT TYPES........2-27 ENGINE ....................2-27 CHASSIS ....................2-28 ENGINE OIL LUBRICATION CHART ............2-29 ENGINE OIL FLOW DIAGRAMS ..............2-30 TRANSFER GEAR OIL FLOW DIAGRAMS ..........2-34 CABLE ROUTING ..................2-36 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1 PERIODIC MAINTENANCE CHART...
  • Page 41 ENGINE......................3-11 ADJUSTING THE VALVE CLEARANCE..........3-11 SYNCHRONIZING THE THROTTLE BODIES ........3-15 ADJUSTING THE ENGINE IDLING SPEED ...........3-17 ADJUSTING THE THROTTLE CABLE FREE PLAY.......3-18 CHECKING THE SPARK PLUGS ............3-20 CHECKING THE IGNITION TIMING ............3-22 MEASURING THE COMPRESSION PRESSURE ........3-23 CHECKING THE ENGINE OIL LEVEL ............3-26 CHANGING THE ENGINE OIL..............3-27 MEASURING THE ENGINE OIL PRESSURE ........3-31 CHECKING THE TRANSFER GEAR OIL LEVEL ........3-32...
  • Page 42 INSTRUMENT FUNCTIONS................3-70 ODOMETER AND TRIPMETER..............3-70 ADJUSTING THE METER LIGHT ............3-71 ADJUSTING THE CLOCK ...............3-71 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ............4-1 REMOVING THE FRONT WHEEL ............4-4 CHECKING THE FRONT WHEEL ............4-4 CHECKING THE BRAKE DISCS ..............4-6 INSTALLING THE FRONT WHEEL ............4-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE......4-9 REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY.....4-11 REMOVING THE REAR WHEEL ............4-17...
  • Page 43 FRONT FORK....................4-55 REMOVING THE FRONT FORK LEGS ..........4-58 DISASSEMBLING THE FRONT FORK LEGS ........4-58 CHECKING THE FRONT FORK LEGS...........4-60 ASSEMBLING THE FRONT FORK LEGS ..........4-62 INSTALLING THE FRONT FORK LEGS..........4-67 HANDLEBAR....................4-69 REMOVING THE HANDLEBAR ..............4-71 CHECKING THE HANDLEBAR...............4-71 INSTALLING THE HANDLEBAR.............4-71 STEERING HEAD..................4-75 REMOVING THE LOWER BRACKET .............4-77 CHECKING THE STEERING HEAD ............4-77...
  • Page 44 CHAPTER 5 ENGINE ENGINE......................5-1 INSTALLING THE ENGINE ...............5-9 INSTALLING THE MUFFLER AND EXHAUST PIPES......5-10 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ......5-11 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS..................5-16 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS..5-16 CHECKING THE ROCKER ARM BASES ..........5-18 CHECKING THE PUSH RODS ...............5-18 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES..5-18 BLEEDING A VALVE LIFTER ..............5-19...
  • Page 45 CLUTCH......................5-56 CLUTCH COVER ..................5-56 CLUTCH ....................5-59 REMOVING THE CLUTCH ..............5-61 REMOVING THE PRIMARY DRIVE GEAR ..........5-62 CHECKING THE FRICTION PLATES .............5-62 CHECKING THE CLUTCH PLATES ............5-62 CHECKING THE CLUTCH PLATE SPRING ...........5-63 CHECKING THE CLUTCH HOUSING ............5-63 CHECKING THE CLUTCH BOSS ............5-63 CHECKING THE PRESSURE PLATE ............5-64 CHECKING THE PULL LEVER SHAFT AND PULL ROD.......5-64 CHECKING THE PRIMARY DRIVE ............5-64...
  • Page 46 CRANKCASE ....................5-93 DISASSEMBLING THE CRANKCASE ............5-96 CHECKING THE CRANKCASE ..............5-97 CHECKING THE BEARINGS AND OIL SEALS ........5-98 CHECKING THE OIL DELIVERY PIPE ...........5-98 CHECKING THE ENGINE OIL PUMP DRIVE.........5-98 ASSEMBLING THE CRANKCASE ............5-99 ENGINE OIL PUMP ..................5-102 CHECKING THE OIL PUMP ..............5-105 CHECKING THE RELIEF VALVE ............5-105 CHECKING THE OIL STRAINER............5-106 ASSEMBLING THE OIL PUMP .............5-106...
  • Page 47 AIR INDUCTION SYSTEM ................6-43 AIR INJECTION ..................6-43 AIR CUT-OFF VALVE ................6-43 AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES............6-44 REED VALVES..................6-45 CHECKING THE PRESSURE REGULATOR..........6-46 CHECKING THE AIR INDUCTION SYSTEM ..........6-46 CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS................7-1 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ....................7-3 CHECKING SWITCH CONTINUITY ..............7-8 CHECKING THE SWITCHES ................7-10...
  • Page 48 LIGHTING SYSTEM ..................7-38 CIRCUIT DIAGRAM ................7-38 TROUBLESHOOTING................7-39 CHECKING THE LIGHTING SYSTEM ............7-40 SIGNALING SYSTEM..................7-44 CIRCUIT DIAGRAM ................7-44 TROUBLESHOOTING................7-46 CHECKING THE SIGNALING SYSTEM ..........7-47 FUEL INJECTION SYSTEM ................7-54 CIRCUIT DIAGRAM ................7-54 TROUBLESHOOTING................7-56 CHECKING THE FUEL PUMP ..............7-64 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ..........7-64 CHAPTER 8 TROUBLESHOOTING STARTING FAILURES ..................8-1...
  • Page 49 OVERHEATING ....................8-4 ENGINE .....................8-4 FUEL SYSTEM ..................8-4 CHASSIS ....................8-4 ELECTRICAL SYSTEMS ................8-4 POOR BRAKING PERFORMANCE..............8-4 FAULTY FRONT FORK LEGS................8-4 LEAKING OIL ....................8-4 MALFUNCTION ..................8-4 UNSTABLE HANDLING..................8-5 FAULTY LIGHTING OR SIGNALING SYSTEM..........8-6 HEADLIGHT DOES NOT COME ON ............8-6 HEADLIGHT BULB BURNT OUT ..............8-6 TAIL/BRAKE LIGHT DOES NOT COME ON ..........8-6 TAIL/BRAKE LIGHT LED BURNT OUT ............8-6 TURN SIGNAL DOES NOT COME ON.............8-6...
  • Page 50: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label 1 is affixed to the frame. This information will be needed to order spare parts.
  • Page 51 FEATURES INFO FEATURES OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the com- bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber.
  • Page 52 FEATURES INFO FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 2.55 kg/cm higher than the intake manifold pres- sure. Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.
  • Page 53 FEATURES INFO Fuel control block The fuel control block consists of the following main components: Component Function Control block Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure adjustment Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Engine temperature sensor...
  • Page 54 FEATURES INFO COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the seat, above the battery box. The main functions of the ECU are ignition control, fuel control, self-diagnosis, and load control. • ECU’s internal construction and functions The main components and functions of the ECU can be broadly divided into the following four items: A.
  • Page 55 FEATURES INFO • Ignition control The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position sensor (to detect the speed of the engine) and the speed sensor. This control establishes an ignition timing that suits the operating condition of the engine through compensations made to the basic ignition timing control map.
  • Page 56 FEATURES INFO • Self-diagnosis function The ECU is equipped with a self-diagnosis function to ensure that the engine control system is operating normally. The ECU mode functions include a diagnosis mode in addition to the normal mode. Normal mode • To check for any blown bulbs, this mode illuminates a warning light while the main switch is turned ON, and while the starter switch is being pressed.
  • Page 57 FEATURES INFO Fuel pump The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel system downstream of the pump.
  • Page 58 FEATURES INFO Pressure regulator It regulates the fuel pressure that is applied to the injectors that supply fuel to the cylinders in order to maintain a constant pressure. The fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve.
  • Page 59 FEATURES INFO Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The needle that is integrated with the bottom of the core keeps the fuel passage closed. When the current flows to the coil in accordance with the signal from the ECU, the core is drawn upward, allowing the flange that is integrated with the needle to move to the spacer.
  • Page 60 FEATURES INFO Crankshaft position sensor The crankshaft position sensor uses the signals of the crankshaft position sensor that is mounted on the left side of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the projections on the rotor to pass by the crankshaft position sensor, an electromotive force is generated in the coil.
  • Page 61 FEATURES INFO Cylinder identification sensor The cylinder identification sensor is installed on the camshaft drive gear cover. When the cam of cyl- inder #1 rotates, the pickup rotor installed on the cam also rotates. When the pickup rotor passes by the sensor, trigger poles on the rotor generate a signal and send it to the ECU.
  • Page 62 FEATURES INFO Throttle position sensor The throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board. In actual operation, the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve.
  • Page 63 FEATURES INFO Intake air pressure sensor and atmospheric pressure sensor • Intake air pressure sensor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake air volume can be measured by measuring the intake air pressure.
  • Page 64 FEATURES INFO Engine temperature sensor The signals from the engine temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The engine temperature sensor converts the temperature of the engine into electrical signals and sends them to the ECU. È...
  • Page 65 FEATURES INFO Lean angle cut-off switch The lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 V (low level).
  • Page 66 FEATURES INFO FUEL INJECTION SYSTEM Operation and control The fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con- trolled by the ECU. To determine the basic injection timing, the ECU calculates the intake air volume through the signals from the intake air pressure sensor, throttle position sensor, cylinder identifica- tion sensor, and crankshaft position sensor.
  • Page 67 FEATURES INFO Fuel injection duration during linear control valve operation The linear control valve supplies air to the intake manifold when starting or during engine warm up. The intake air volume determines the basic injection duration. As the intake air increases through the linear control valve, the intake air volume corrects the basic injection duration.
  • Page 68 FEATURES INFO Determining the final injection duration The intake air volume determines the basic injection duration. However, at a given intake air vol- ume, the volume of fuel that is required varies by the engine operating conditions such as accelera- tion or deceleration, or by weather conditions.
  • Page 69 FEATURES INFO Reactive injection duration: A lag is created between the time the ECU outputs a fuel injection signal to the injector and the time the injector actually opens. Therefore, the ECU calculates this lag in advance before sending the actuation signal to the injector.
  • Page 70 FEATURES INFO Fuel control during normal driving In synchronous injection during normal driving, fuel is injected on a cylinder-by-cylinder basis when all of the conditions below are met: 1 Other than the stop mode 2 Cylinder identification completed 3 Other than overrun To determine the injection timing, the ECU calculates the injection timing through the use of the 3D control map provided in the ECU, which is based on the throttle position and the engine speed.
  • Page 71 FEATURES INFO • Fuel injection control during normal driving È É Ê Ë È #1 cylinder fuel injection timing É Basic injection duration Ê Various types of fuel injection duration compensations Ë Final injection duration (É + Ê) 1 - 22...
  • Page 72 FEATURES INFO Fuel injection compensation control • Starting injection control The engine temperature is used for determining the injection duration in order to ensure proper start ability. To suit the engine’s operating conditions, the starting injection duration is determined by applying a starting compensation coefficient to the basic injection duration, which forms the basis of the injection duration.
  • Page 73 FEATURES INFO • After-start enrichment After-start enrichment provides enrichment compensation during a prescribed duration following the starting (firing) of the engine. While the amount of fuel enrichment is determined by the after-start enrichment coefficient, the coefficient varies by the engine temperature. Although the engine tem- perature determines the initial starting enrichment coefficient, the coefficient subsequently changes in accordance with the damping factor.
  • Page 74 FEATURES INFO • Warm-up enrichment When the engine temperature is low, a warm-up coefficient is applied in accordance with the signals from the engine temperature sensor in order to effect fuel enrichment. Because the engine temper- ature determines the coefficient, the coefficient changes with the fluctuations in the engine tempera- ture.
  • Page 75 FEATURES INFO • Acceleration enrichment Acceleration enrichment is provided in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to accelerate the motorcycle from a constant speed, the throt- tle position sensor actuates in unison with the accelerator. The ECU interprets that acceleration has taken place through the throttle position sensor signal and executes acceleration enrichment.
  • Page 76 FEATURES INFO • Deceleration control Deceleration control is effected in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to decelerate the motorcycle that is in motion, the throttle position sensor actuates in unison with the accelerator. When the engine speed is greater than a prescribed value with the throttle fully closed (thus applying engine braking), the ECU executes a deceleration fuel cut-off.
  • Page 77 FEATURES INFO FIRST IDLE CONTROL SYSTEM This system temporarily increases the fuel injection volume of the injectors when starting a cold engine and until the engine is warm. The system improves startability and stabilizes engine speed during engine warm up. Basic operation The ECU receives a signal from the engine temperature sensor and determines the temperature of the engine with the collected data.
  • Page 78 FEATURES INFO COMPONENTS Linear control valve The linear control valve sends air from the silencer box to the intake manifold to increase the intake air volume. The linear control valve consists of a stepper motor that operates the valve, a valve unit that is attached to the motor, and a main body that distributes the intake air.
  • Page 79 FEATURES INFO Instrument panel Function indication The indications of the self-diagnosis function can be checked and inspection operations can be per- formed through the use of the tachometer on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the tachometer. Then, the conditions of the sensors appear on the clock and trip/odometer display of the tachome- ter.
  • Page 80 FEATURES INFO 2. DIAG mode inspection and adjustment (multi-function meter) Mode Selection (Make sure to disconnect the coupler from the fuel pump.) DIAG mode Normal mode 1. While keeping both the SELECT and Turn “ON” the main switch. RESET buttons pressed, turn “ON” the * The self-diagnostic function starts a sys- main switch.
  • Page 81: Important Information

    5. Keep all parts away from any source of fire. EAS00021 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 82 IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu-...
  • Page 83: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 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 84: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
  • Page 85 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve spring compressor set YM-04019 This tool is used to remove or install the valve assemblies. Bearing driver YM-04058 This tool is needed when installing the crankshaft journal bearing. Valve guide remover (ø6) YM-04064-A This tool is used to remove or install the valve guides.
  • Page 86 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Dynamic spark tester YM-34487 This tool is used to check the ignition system components. Valve adjuster YM-8035 This tool is used to adjust the valve clearance. Universal clutch holder YM-91042 This tool is used to hold the clutch boss when removing or installing the clutch boss nut.
  • Page 87 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Carburetor synchronizer YU-08030 This gauge is needed for throttle bodies synchronization. Compression gauge set 14/18 mm Compression gauge Compression gauge adapter 12 mm YU-33223 Compression gauge adapter These tools are used to measure YU-33223-3 engine compression.
  • Page 88 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Pivot shaft wrench YM-01485 This tool is needed to loosen or tighten the spacer bolt. 1 - 39...
  • Page 89: General Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PX1 (USA) ---- 5PX2 (California) ---- 5PX3 (CDN) ---- Dimensions Overall length 2,385 mm (93.9 in) ---- Overall width 955 mm (37.6 in) ---- Overall height 1,120 mm (44.1 in) ---- Seat height 725 mm (28.5 in)
  • Page 90: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-stroke, OHV ---- Displacement 1,670 cm (101.9 cu.in) ---- Cylinder arrangement V-type 2-cylinder ---- Bore × stroke 97 × 113 mm (3.82 × 4.45 in) ---- Compression ratio 8.36 : 1 ---- Engine idling speed...
  • Page 91 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transfer gear oil Recommended oil SAE 80 API “GL-4” hypoid gear oil ---- Total amount 0.49 L (0.43 Imp qt, 0.52 US qt) ---- Periodic oil replacement 0.4 L (0.35 Imp qt, 0.42 US qt) ---- Oil filter Oil filter type...
  • Page 92 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Gear drive ---- Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) ---- Camshaft cover hole inside diameter 28.000 ~ 28.021 mm (1.1024 ~ 1.1032 in) ---- Camshaft journal diameter 24.937 ~ 24.950 mm (0.9818 ~ 0.9823 in) ---- (crankcase side)
  • Page 93 SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arms, Rocker arm shafts Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 18.036 mm (0.7101 in) Rocker arm shaft outside diameter 17.976 ~ 17.991 mm (0.7077 ~ 0.7083 in) 14.970 mm (0.5894 in) Rocker arm to rocker arm shaft clear- 0.009 ~ 0.042 mm (0.0004 ~ 0.0017 in)
  • Page 94 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem diameter Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm (0.2341 in) Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.920 mm (0.2331 in) Valve guide inside diameter Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.05 mm (0.2382 in)
  • Page 95 SPEC ENGINE SPECIFICATIONS Item Standard Limit Compressed spring force (installed) Intake 63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb) ---- Exhaust 63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb) ---- Spring tilt Intake ---- 2.5°/2.4 mm...
  • Page 96 SPEC ENGINE SPECIFICATIONS Item Standard Limit Spring tilt Intake ---- 2.5°/2.4 mm (2.5°/0.094 in) Exhaust ---- 2.5°/2.4 mm (2.5°/0.094 in) Winding direction (top view) Intake Clockwise ---- Exhaust Clockwise ---- Valve lifters Valve lifter outside diameter 22.9680 ~ 22.9744 mm ---- (0.9043 ~ 0.9045 in) Valve lifter case inside diameter...
  • Page 97 SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm (0.006 in) Diameter D 96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in) ---- Height H 5 mm (0.20 in) ---- Piston pin bore (in the piston) Diameter 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm (0.8679 in)
  • Page 98 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) ---- End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.8 mm (0.031 in) Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm...
  • Page 99 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc ---- Clutch release method Outer pull, rack and pinion (pull rod type) ---- Clutch release method operation Cable operation ---- Operation Left-hand operation ---- Clutch cable free play (at the end of 10 ~ 15 mm (0.39 ~ 0.59 in) ---- the clutch lever)
  • Page 100 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 5-speed ---- Primary reduction system Spur gear ---- Primary reduction ratio 72/47 (1.532) ---- Secondary reduction system Belt drive ---- 35/32 × 70/32 (2.393) Secondary reduction ratio ---- Operation Left-foot operation ---- Gear ratios...
  • Page 101: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle ---- Caster angle 29.5° ---- Trail 130 mm (5.12 in) ---- Front wheel Wheel type Cast wheel ---- 18 M/C × MT 3.50 Size ---- 18 × MT 3.50 Material Aluminum ----...
  • Page 102 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 200/50 ZR 17 M/C (75 W) ---- 200/50 ZR 17 (75 W) Model (manufacturer) D220ST (DUNLOP)/ ---- BT020R (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm , 36 psi) ----...
  • Page 103 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Single-disc brake ---- Operation Right-foot operation ---- Brake pedal free play (P) 0 mm (0 in) ---- Brake pedal position 80 mm (3.2 in) ---- (from the top of the rider footrest to the top of the brake pedal) Recommended fluid DOT 4...
  • Page 104 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 50 mm (1.97 in) ---- Spring Free length 188 mm (7.4 in) 183 mm (7.2 in) Installed length...
  • Page 105 Resin ---- Resistance 10 kΩ ---- Charging system System type AC magneto ---- Model (manufacturer) F5PX/YAMAHA ---- Nominal output 14 V/31 A at 5,000 r/min ---- 0.12 ~ 0.20 Ω/W–W Stator coil resistance/color ---- Rectifier/regulator Regulator type Semiconductor, short circuit...
  • Page 106 ---- LED × 1 Tachometer light ---- Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5PX (YAMAHA) ---- Power output 0.9 kW ---- 0.0081 ~ 0.0099 Ω Armature coil resistance ---- Brushes Overall length 9.8 mm (0.39 in) 5 mm (0.2 in)
  • Page 107 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Headlight relay Model/manufacturer ACM33211 M04/MATSUSHITA ---- 86.4 ~ 105.6 Ω Coil resistance ---- Fuel injection system relay Model/manufacturer G8R-30Y-S/OMRON ---- 162 ~ 198 Ω Coil resistance ---- Throttle position sensor Resistance 4 ~ 6 kΩ/L-B ---- Output voltage (at idle) 0.605 ~ 0.755 V...
  • Page 108: General Tightening Torque Specifications

    CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
  • Page 109: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Spark plug — Front cylinder head cover Bolt Rear cylinder head cover Bolt Front rocker arm base Bolt Front rocker arm base Bolt Rear rocker arm base Bolt...
  • Page 110 SPEC TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Intake manifold Bolt Throttle body joint Screw Pressure regulator Bolt Intake vacuum hose bracket Bolt Intake air pressure sensor bracket 2 Bolt A.I.S. bracket Bolt Resonator Screw Air cut-off valve assembly Bolt Air cut-off valve assembly...
  • Page 111 SPEC TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Cover Bolt Cover Bolt Oil tank left cover Bolt Oil tank left cover Bolt Oil strainer Bolt Transfer gear case Bolt Transfer gear case cover Transfer gear oil checking bolt Bolt Transfer gear oil pump cover Bolt...
  • Page 112 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering shaft 11.5 Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) 2.9 See NOTE.
  • Page 113 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Rear fender bracket and frame Rear fender bracket and rear fender Fuel tank and fuel filter Fuel tank bracket and frame Fuel tank and frame Sub fuel tank and frame Seat bracket and frame Side cover and side cover bracket Side cover bracket and frame...
  • Page 114 SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Damper rod assembly bolt — Reflector bracket (front) Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Rear brake bracket and brake pedal Shift shaft and shift pedal NOTE: 1.
  • Page 115: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Connecting rod bolts and nuts Connecting rod small end and big end Crankshaft pins Crankshaft journals Piston surfaces Piston pins Camshaft cam lobes and camshaft journals Valve push rods Valve push rod end balls...
  • Page 116 SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Steering bearing cover Steering head pipe lower oil seal Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Shift pedal Rear footrest pivot...
  • Page 117: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Pressure feed Rear cylinder intake valve Front cylinder intake valve Rear cylinder Crankshaft journal Piston Connecting rod Crank pin (left) Valve stem Rocker Push Valve Rear lifter camshaft Front cylinder Valve stem Rocker Push Valve...
  • Page 118: Engine Oil Flow Diagrams

    SPEC ENGINE OIL FLOW DIAGRAMS ENGINE OIL FLOW DIAGRAMS 1 Oil tank 2 Dipstick 3 Oil delivery pipe 4 Push rod 5 Oil filter cartridge 2 - 30...
  • Page 119 SPEC ENGINE OIL FLOW DIAGRAMS 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft 2 - 31...
  • Page 120 SPEC ENGINE OIL FLOW DIAGRAMS 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt (engine) 2 - 32...
  • Page 121 SPEC ENGINE OIL FLOW DIAGRAMS 1 Main axle È To oil filter cartridge 2 Drive axle 3 Engine oil pump 4 Oil strainer È 2 - 33...
  • Page 122: Transfer Gear Oil Flow Diagrams

    SPEC TRANSFER GEAR OIL FLOW DIAGRAMS TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle driven shaft 2 Transfer gear oil pump 2 - 34...
  • Page 123 SPEC TRANSFER GEAR OIL FLOW DIAGRAMS 1 Transfer gear oil pump 2 Middle driven shaft 2 - 35...
  • Page 124 SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Brake hose È Fasten Ê Fasten the rear brake light rectifier/regulator 2 Clutch cable lead, horn lead, and rear brake switch lead, horn lead, and sta- 3 Rectifier/regulator light switch lead with a plastic tor coil assembly lead with a 4 Rectifier/regulator lead locking tie to the frame.
  • Page 125 SPEC CABLE ROUTING 1 Clutch cable È Fasten the left handlebar switch lead with a plas- 2 Left handlebar switch lead tic holder. 3 Right handlebar switch lead É Fasten the right handlebar switch lead with a 4 Throttle cable 1 plastic holder.
  • Page 126 SPEC CABLE ROUTING 1 Throttle cables È Pass throttle cable 1 and throttle cable 2 through 2 Clutch cable the cable guide, and then fasten them with a 3 Atmospheric pressure sensor plastic holder. 4 Spark plug cap (ignition coil 1-L spark plug lead) É...
  • Page 127 SPEC CABLE ROUTING Ë Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking tie. Ì Fasten the starter motor lead, and side stand switch lead with a plastic locking tie to the frame. Í...
  • Page 128 SPEC CABLE ROUTING 1 Ignition coil 1 È To the rectifier/regulator, horn 1 and rear brake 2 Atmospheric pressure sensor lead light switch. 3 Ignition coil 2 É 30 ~ 50 degrees 4 Ignition coil 2 lead Ê 40 ~ 60 degrees 5 Rear brake light switch coupler 6 Rectifier/regulator lead and horn lead 7 Linear control valve lead...
  • Page 129 SPEC CABLE ROUTING 1 Tail/brake light lead È Be sure to position the ECU leads and sensor 2 Fuel pump lead leads toward the left side of the frame, and then 3 Sidestand switch lead fasten the wire harness protector with a plastic 4 Starter motor lead locking tie.
  • Page 130 SPEC CABLE ROUTING Ë Fasten the decompression solenoid lead, speed sensor lead, cylinder identification sensor lead, sidestand switch lead, crankshaft position sensor lead, neutral switch lead, and fuel pump lead with a plastic band. Ì Position the gray mark on the starter motor lead at the center of the bolt. Fit the starter motor lead and sid- estand switch lead into the groove in the frame, and then fasten them with a plastic locking tie.
  • Page 131 SPEC CABLE ROUTING 1 Fuse box A Cut-off relay 2 ECU lead B Turn signal relay 3 Battery C Headlight relay 4 Starter motor lead 5 ECU ground lead È Clamp the fuel tank/air filter breather hose, and 6 Fuel tank/air filter breather hose fuel tank/air filter drain hose with a plastic clamp.
  • Page 132 SPEC CABLE ROUTING 1 Roll over valve A Fuel tank drain hose 2 Fuel tank breather hose B Fuel tank/air filter breather hose 3 Fuel hose joint 1 C Ignition coil 1 4 Fuel hose 5 Fuel inlet hose È Make sure that the white paint mark is facing for- 6 Fuel outlet hose ward.
  • Page 133 SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 H Ignition coil 1-R spark plug lead 2 Fuel hose 0 Throttle cables I Lean angle cut-off switch lead 3 Spark plug cap (ignition coil 1-R A Brake hose J Crankshaft position sensor lead B Spark plug cap (ignition coil 2-R K Sidestand switch lead...
  • Page 134 SPEC CABLE ROUTING È To the battery box. Í Fasten the main wire harness, intake air pres- É Fasten the main wire harness, and fuel hose sure sensor lead #2, ignition coil 1-R spark plug with a plastic locking tie to the frame. lead, and intake air temperature sensor coupler Ê...
  • Page 135 SPEC CABLE ROUTING Ð To the injector sub lead. × To the speed sensor. Ñ To the engine temperature sensor. Ø Fasten the crankshaft position sensor lead, side- Ò 10 30 mm (0.4 1.2 in) stand switch lead, lean angle cut-off switch lead, Ó...
  • Page 136 SPEC CABLE ROUTING 1 Ignition coil 2-R spark plug lead 8 ECU 2 Ignition coil 1-R spark plug lead 9 Fuel hose 3 Main wire harness 0 Ignition coil 1-L spark plug lead 4 Negative battery ground lead A Ignition coil 2-L spark plug lead 5 Fuse box 6 Main fuse coupler È...
  • Page 137 SPEC CABLE ROUTING 1 Canister (California only) 0 Pressure regulator 2 Canister purge hose (California only) A A.I.S. vacuum hose 3 Intake vacuum hose B Silencer air filter case drain hose 4 Liner control valve inlet hose 5 Liner control valve outlet hose 6 Throttle position sensor 7 Fuel hose 8 Throttle stop screw...
  • Page 138 SPEC CABLE ROUTING Canister (California only) 1 Canister charge hose È To the fuel tank. 2 Canister purge hose É To the silencer air filter case. 3 Starter motor lead Ê To the throttle bodies. 4 Canister 5 Fuel tank drain hose 6 Regulator lead 7 Horn lead 8 Rear brake light switch lead...
  • Page 139: For The Emission Control System

    Evaporative Emission control • Check control system for damage. √ √ system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 3 - 1...
  • Page 140 SAE 80 API “GL-4” • Replace every Change. Check. Change. (See page 3-32.) hypoid gear oil 16,000 mi (25,000 km) or 24 months. Yamaha chain and Control cables • Apply chain lube thor- √ √ √ √ √ √ cable lube or (See page 3-58.)
  • Page 141 (See page 3-47.) • Adjust if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
  • Page 142: Seat And Side Covers

    SEAT AND SIDE COVERS EAS00038 SEAT AND SIDE COVERS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 143: Headlight And Meter Assemblies

    HEADLIGHT AND METER ASSEMBLIES HEADLIGHT AND METER ASSEMBLIES 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 144 BATTERY BATTERY Order Job/Part Q’ty Remarks Removing the battery Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS”. Battery cover Negative battery lead Positive battery lead Battery Belt For installation, reverse the removal procedure. 3 - 6...
  • Page 145: Fuel Tank

    FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS”. Air induction system cover Air duct Fuel hose joint 1...
  • Page 146: Air Filter Case

    AIR FILTER CASE EAS00043 AIR FILTER CASE 3 Nm (0.3 m kg, 2.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK”.
  • Page 147 SILENCER AIR FILTER CASE EAS00043 SILENCER AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the silencer air filter case Remove the parts in the order listed.
  • Page 148 SILENCER AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Intake air pressure sensor 1 coupler Disconnect.
  • Page 149 ADJUSTING THE VALVE CLEARANCE EAS00047 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • The valve clearance automatically adjusted by the hydraulic valve lifter. How- ever, there are times that the valve clearance is needed to be adjusted manually.
  • Page 150: Adjusting The Valve Clearance

    ADJUSTING THE VALVE CLEARANCE 4. Remove: • engine left side cover 1 5. Remove: • timing mark accessing screw 1 • crankshaft end cover 2 6. Remove: • decompression solenoid cover 1 • camshaft sprocket cover 2 7. Measure: • valve clearance Out of specification →...
  • Page 151 ADJUSTING THE VALVE CLEARANCE M MMM M MMM M MMM M MMM M MMM Piston #1 TDC (rear cylinder) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch/crankshaft position sensor rotor cover.
  • Page 152 ADJUSTING THE VALVE CLEARANCE 8. Adjust: • valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. c.
  • Page 153 SYNCHRONIZING THE THROTTLE BODIES EAS00051 SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand.
  • Page 154 SYNCHRONIZING THE THROTTLE BODIES 7. Adjust: • throttle body synchronization M MMM M MMM M MMM M MMM M MMM a. With throttle body #1 as standard, adjust throttle body #2 using the air screw 1. NOTE: Rev the engine two or three times, each time for less than a second, and check the synchro- nization again.
  • Page 155 ADJUSTING THE ENGINE IDLING SPEED EAS00053 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element should be clean, and the engine should have ade- quate compression.
  • Page 156 ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 4 ~ 6 mm (0.16 ~ 0.24 in)
  • Page 157 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: ® Apply locking agend (LOCKTITE ) to the threads of the locknut 2. e. Loosen the locknut 4 on the accelerator cable. f. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained.
  • Page 158 CHECKING THE SPARK PLUGS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”.
  • Page 159 CHECKING THE SPARK PLUGS 5. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7.
  • Page 160 CHECKING THE IGNITION TIMING EAS00061 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition sys- tem. Make sure all connections are tight and free of corrosion. 1. Remove: • engine left side cover 1 2.
  • Page 161 CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 5. Install: • timing mark accessing screw 6. Install: • engine left side cover EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance.
  • Page 162: Measuring The Compression Pressure

    MEASURING THE COMPRESSION PRESSURE 7. Remove: • spark plug CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 8. Install: •...
  • Page 163 MEASURING THE COMPRESSION PRESSURE c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. d. Carbon deposits → Eliminate. e. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again.
  • Page 164 CHECKING THE ENGINE OIL LEVEL EAS00071 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 165 CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 6. Install: • dipstick 7. Start the engine, warm it up for several min- utes, and then turn it off. 8. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
  • Page 166 CHANGING THE ENGINE OIL 5. If the oil filter cartridge is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a. Remove the oil filter cartridge 1 with an oil filter wrench 2. Oil filter wrench YU-38411 b.
  • Page 167 CHANGING THE ENGINE OIL 8. Fill: • oil tank (with the specified amount of the recom- mended engine oil) Quantity Total amount 5.0 L (4.40 Imp qt, 5.29 US qt) Without oil filter cartridge replacement 3.7 L (3.26 Imp qt, 3.91 US qt) With oil filter cartridge replacement 4.1 L (3.61 Imp qt, 4.33 US qt)
  • Page 168 CHANGING THE ENGINE OIL 10.Install: • dipstick 11.Start the engine, warm it up for several min- utes, and then turn it off. 12.Check: • engine (for engine oil leaks) 13.Check: • engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.
  • Page 169 MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: • engine oil level Below the minimum level mark → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several min- utes, and then turn it off.
  • Page 170 MEASURING THE ENGINE OIL PRESSURE/ CHECKING THE TRANSFER GEAR OIL LEVEL 5. Measure: • engine oil pressure (at the following conditions) Engine oil pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm 5.688 ~ 11.376 psi) Engine speed Approx. 900 r/min Engine oil temperature 70 ~ 90 °C (158 ~ 194 °F) Engine oil pressure...
  • Page 171 CHECKING THE TRANSFER GEAR OIL LEVEL/ CHANGING THE TRANSFER GEAR OIL 4. Check: • transfer gear oil level The transfer gear oil level should be up to the brim 2 of the hole. Below the brim → Add the recommended transfer gear oil to the proper level.
  • Page 172 CHECKING THE TRANSFER GEAR OIL LEVEL 6. Install: • transfer gear oil drain bolt 18 Nm (1.8 m • kg, 13 ft • lb) 7. Fill: • transfer gear case (with the specified amount of the recom- mended transfer gear oil) Quantity Total amount 0.49 L (0.43 Imp qt, 0.52 US qt)
  • Page 173 ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.39 ~ 0.59 in) 2.
  • Page 174 CLEANING THE AIR FILTER ELEMENTS EAS00088 CLEANING THE AIR FILTER ELEMENTS The following procedure applies to both air fil- ter elements. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”.
  • Page 175 CHECKING THE THROTTLE BODY JOINTS/ CHECKING THE FUEL HOSES EAS00094 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joint. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. •...
  • Page 176 CHECKING THE FUEL HOSES/ CHECKING THE CYLINDER HEAD BREATHER HOSE AND OIL TANK BREATHER HOSE 2. Check: • fuel hose 1 Cracks/damage → Replace. Loose connection → Connect properly. 3. Install: • air induction system cover Refer to “FUEL TANK”. EAS00098 CHECKING THE CYLINDER HEAD BREATHER HOSE AND OIL TANK...
  • Page 177 CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: • exhaust pipe 1 • muffler 2 Cracks/damage → Replace. • gasket 3 Exhaust gas leaks → Replace. 2.
  • Page 178 ADJUSTING THE FRONT BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm (0.08 ~ 0.20 in) 2.
  • Page 179 ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (from the top of the rider footrest to the top of the brake pedal) 80 mm (3.2 in)
  • Page 180 ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CAUTION: After adjusting the brake pedal position, make sure there is no brake drag. L LLL L LLL L LLL L LLL L LLL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”.
  • Page 181 CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS/ CHECKING THE REAR BRAKE PADS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.
  • Page 182 ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
  • Page 183 CHECKING THE FRONT AND REAR BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM È 4. Check: • brake hose Brake fluid leakage → Replace the dam- aged hose. Refer to “FRONT AND REAR BRAKES” in chapter 4. È Front É Rear É...
  • Page 184 BLEEDING THE HYDRAULIC BRAKE SYSTEM È 1. Bleed: • hydraulic brake system M MMM M MMM M MMM M MMM M MMM a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).
  • Page 185 ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE BELT SLACK EAS00137 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 368 ~ 372 mm (14.49 ~ 14.65 in) 2.
  • Page 186 ADJUSTING THE DRIVE BELT SLACK 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on the sidestand and or on a suitable stand so that the rear wheel is elevated.
  • Page 187 ADJUSTING THE DRIVE BELT SLACK 4. Adjust: • drive belt slack M MMM M MMM M MMM M MMM M MMM NOTE: Place the motorcycle on the suitable stand so that the rear wheel is elevated. a. Loosen the brake caliper bracket bolt 1. b.
  • Page 188 CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 189 CHECKING AND ADJUSTING THE STEERING HEAD 6. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. b. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5.
  • Page 190 CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 7. Install: • upper bracket • washer • steering stem nut 115 Nm (11.5 m • kg, 85 ft • lb) 8. Tighten: • upper bracket pinch bolt 26 Nm (2.6 m • kg, 19 ft • lb) 9.
  • Page 191 ADJUSTING THE FRONT FORK LEGS EAS00152 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. •...
  • Page 192 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00156 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1.
  • Page 193 CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 194 Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
  • Page 195: Checking The Tires

    CHECKING THE TIRES Front tire Manufacturer Model Size 120/70 ZR 18 M/C (59 W) BRIDGESTONE BT020FG 120/70 ZR 18 (59 W) 120/70 ZR 18 M/C (59 W) DUNLOP D220FST 120/70 ZR 18 (59 W) Rear tire Manufacturer Model Size 200/50 ZR 17 M/C (75 W) BRIDGESTONE BT020R...
  • Page 196: Checking The Wheels

    CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.
  • Page 197 LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.
  • Page 198: Electrical System

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
  • Page 199 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 200 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit voltage. CAUTION: • Never remove the MF battery sealing caps.
  • Page 201 CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before measuring its open-circuit voltage. voltage prior to charging. Charger Ammeter NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
  • Page 202 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
  • Page 203 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery Refer to “BATTERY”. 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: •...
  • Page 204 CHECKING THE FUSES 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω...
  • Page 205 CHECKING THE FUSES 3. Replace: • blown fuse M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational.
  • Page 206 REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: • screws 1 • headlight lens unit 2 2. Disconnect: • headlight coupler 1 3. Remove: • headlight bulb holder cover 2 4. Detach: • headlight bulb holder 1 5.
  • Page 207 REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 7. Attach: • headlight bulb holder 8. Install: • headlight bulb holder cover 9. Connect: • headlight coupler 10.Install: • headlight lens unit • screws EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: •...
  • Page 208: Instrument Functions

    INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS ODOMETER AND TRIPMETER 1 Tachometer 2 Clock 3 Odometer/trip meter/fuel reserve trip meter 4 “RESET” button 5 “SELECT” button Pushing the “SELECT” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order: “ODO”...
  • Page 209 INSTRUMENT FUNCTIONS ADJUSTING THE METER LIGHT 1. Adjust: • meter light M MMM M MMM M MMM M MMM M MMM a. Turn the key to “OFF”. b. Push and hold the “SELECT” button. c. Turn the key to “ON”, and then after five seconds, release the “SELECT”...
  • Page 210: Front Wheel And Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 40 Nm (4.0 m kg, 29 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 211 CHAS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 40 Nm (4.0 m kg, 29 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •...
  • Page 212 CHAS FRONT WHEEL AND BRAKE DISCS 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. 4 - 3...
  • Page 213 CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 214 CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4.
  • Page 215 CHAS FRONT WHEEL AND BRAKE DISCS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.
  • Page 216 CHAS FRONT WHEEL AND BRAKE DISCS 4. Adjust: • brake disc deflection M MMM M MMM M MMM M MMM M MMM a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.
  • Page 217 CHAS FRONT WHEEL AND BRAKE DISCS 2. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium-soap-based grease 3. Install: • collars • front wheel • front wheel axle 4. Tighten: • front wheel axle 1 72 Nm (7.2 m • kg, 52 ft • lb) •...
  • Page 218 CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the front wheel static balance should adjusted. • Adjust the front wheel static balance with the brake discs installed. 1.
  • Page 219 CHAS FRONT WHEEL AND BRAKE DISCS 3. Adjust: • front wheel static balance M MMM M MMM M MMM M MMM M MMM a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b.
  • Page 220 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00550 REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY 40 Nm (4.0 m kg, 29 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •...
  • Page 221 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 222 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •...
  • Page 223 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00556 Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel pulley Brake disc cover Brake disc Rear wheel pulley Refer to “INSTALLING THE REAR WHEEL”.
  • Page 224 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY Order Job/Part Q’ty Remarks Collar Bearing Collar Bearing Rear wheel drive hub damper Rear wheel For installation, reverse the removal procedure. 4 - 15...
  • Page 225 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Oil seal Bearing Refer to “ASSEMBLING THE REAR WHEEL”. Spacer Bearing Rear wheel For assembly, reverse the disassembly procedure.
  • Page 226 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 227 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub 1 Cracks/damage → Replace. • rear wheel drive hub dampers 2 Damage/wear → Replace. EAS00568 CHECKING AND REPLACING THE REAR WHEEL PULLEY 1.
  • Page 228 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: • oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: • rear wheel drive hub dampers 1 3. Install: • rear wheel drive hub assembly 1 4.
  • Page 229 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 6. Install: • brake caliper bracket 1 • washer • brake caliper bracket bolt 2 NOTE: Temporarily tighten the brake caliper bracket bolt. 7. Install: • collars • rear wheel • adjusting plates •...
  • Page 230 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 12.Install: • upper drive belt cover plate 1 7 Nm (0.7 m • kg, 5.1 ft • lb) • upper drive belt cover 2 7 Nm (0.7 m • kg, 5.1 ft • lb) 13.Install: •...
  • Page 231 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.
  • Page 232 CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.
  • Page 233 CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper retaining bolt Brake caliper Brake pad...
  • Page 234 CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 235 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pin 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) • brake pad shims 4. Measure: •...
  • Page 236 CHAS FRONT AND REAR BRAKES d. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. L LLL L LLL L LLL L LLL L LLL 6.
  • Page 237 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pads 1 (along with the brake pad shims) • brake pad springs 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4.
  • Page 238 CHAS FRONT AND REAR BRAKES 5. Install: • brake caliper retaining bolt 1 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 239 CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Rear view mirror (right) Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm...
  • Page 240: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Front brake light switch connector Disconnect. Refer to “REMOVING THE Union bolt FRONT BRAKE MASTER Brake hose Disconnect. CYLINDER” and “ASSEM- BLING AND INSTALLING Copper washer THE FRONT BRAKE MAS- Brake master cylinder holder TER CYLINDER”.
  • Page 241 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Refer to “ASSEMBLING AND INSTALL- Circlip ING THE FRONT BRAKE MASTER CYL- Brake master cylinder kit INDER”.
  • Page 242 CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the brake fluid reservoir Remove the parts in the order listed. Brake fluid Drain. Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 243 CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 244 CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •...
  • Page 245 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder For assembly, reverse the disassembly procedure.
  • Page 246 CHAS FRONT AND REAR BRAKES EAS00588 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the...
  • Page 247 CHAS FRONT AND REAR BRAKES É 2. Check: È • brake master cylinder kit Damage/scratches/wear → Replace. È Front É Rear 3. Check: • rear brake fluid reservoir 1 Cracks/damage → Replace. • rear brake fluid reservoir diaphragm 2 Cracks/damage → Replace. 4.
  • Page 248 CHAS FRONT AND REAR BRAKES 1. Install: • brake master cylinder • brake master cylinder holder 1 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. •...
  • Page 249 CHAS FRONT AND REAR BRAKES WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
  • Page 250 CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers 1 • brake hoses 2 • union bolt 3 30 Nm (3.0 m • kg, 22 ft • lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
  • Page 251 CHAS FRONT AND REAR BRAKES 3. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 252 CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 40 Nm (4.0 m kg, 29 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
  • Page 253 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...
  • Page 254 CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Union bolt Refer to “DISASSEM- BLING THE REAR BRAKE...
  • Page 255 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. caliper Brake caliper piston Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”. Brake caliper piston seal Bleed screw For assembly, reverse the disassembly...
  • Page 256 CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 •...
  • Page 257 CHAS FRONT AND REAR BRAKES EAS00627 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 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
  • Page 258 CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Every years and whenever the Brake fluid brake is disassem- bled È...
  • Page 259 CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...
  • Page 260 CHAS FRONT AND REAR BRAKES 3. Install: • brake pads • brake pad spring • brake caliper bolt 40 Nm (4.0 m • kg, 29 ft • lb) • brake hose holder 8 Nm (0.8 m • kg, 5.8 ft • lb) 4.
  • Page 261 CHAS FRONT AND REAR BRAKES 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: • brake lever operation Soft or spongy feeling →...
  • Page 262 CHAS FRONT AND REAR BRAKES 1. Install: • brake caliper 1 (temporarily) • copper washers 2 • brake hose 3 • union bolt 4 30 Nm (3.0 m • kg, 22 ft • lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
  • Page 263 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 264: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 265 CHAS FRONT FORK EAS00648 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 Refer to “DISASSEMBLING THE FRONT FORK LEGS”...
  • Page 266 CHAS FRONT FORK Order Job/Part Q’ty Remarks Oil seal clip Oil seal Washer Refer to “DISASSEMBLING THE FRONT Damper rod assembly bolt FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”. Copper washer Damper rod assembly Inner tube For assembly, reverse the disassembly procedure.
  • Page 267 CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 268 CHAS FRONT FORK NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring com- pressor. WARNING The fork spring is compressed. f.
  • Page 269 CHAS FRONT FORK 4. Remove: • damper rod assembly bolt • copper washer NOTE: While holding the damper rod with the damper rod holder 1, loosen the damper rod assem- bly bolt. Damper rod holder YM-01423 EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
  • Page 270 CHAS FRONT FORK 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air. CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu- larly sensitive to foreign material.
  • Page 271 CHAS FRONT FORK EAS00660 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 272 CHAS FRONT FORK 3. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION: Make sure the numbered side of the oil seal faces down. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
  • Page 273 Quantity (each front fork leg) 476 cm (16.8 Imp qt, 16.1 US qt) Recommended oil Yamaha suspension oil “01” CAUTION: • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
  • Page 274 CHAS FRONT FORK 12.Slowly stroke the outer tube 1 up and down to distribute the fork oil once more (1 stroke = about 150 mm (8.12 in)). NOTE: Be careful not to stroke the outer tube over 150 mm (8.12 in) as this will cause air to enter. If the outer tube is stroke more than 150 mm (8.12 in), repeat steps (11) and (12).
  • Page 275 CHAS FRONT FORK 15.Install: • nut 1 • fork spring 2 • spring seat 3 • spacer 4 • cap bolt 5 M MMM M MMM M MMM M MMM M MMM a. Remove the rod puller. b. Install the nut 1. c.
  • Page 276: Front Fork

    CHAS FRONT FORK k. Remove the rod holder and fork spring com- pressor. CAUTION: The fork spring is compressed. Always use a new cap bolt O-ring. L LLL L LLL L LLL L LLL L LLL 16.Install: • cap bolt (onto the outer tube) NOTE: Temporary tighten the cap bolt.
  • Page 277 CHAS FRONT FORK 3. Adjust: • spring preload Refer to “ADJUSTING THE FRONT FORK LEGS” in chapter 3. 4 - 68...
  • Page 278 CHAS HANDLEBAR EAS00664 HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Rear view mirror (left and right) Plastic clamp Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Refer to “INSTALLING THE Right handlebar switch HANDLEBAR”.
  • Page 279 CHAS HANDLEBAR Order Job/Part Q’ty Remarks Left handlebar switch Handlebar grip Refer to “REMOV- ING THE HANDLE- BAR”. Refer to “INSTALL- Clutch cable Disconnect. ING THE HANDLE- Clutch lever holder BAR”. Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal procedure.
  • Page 280 CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
  • Page 281 CHAS HANDLEBAR 3. Install: • handlebar 1 • upper handlebar holders 2 28 Nm (2.8 m • kg, 20 ft • lb) CAUTION: • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side.
  • Page 282 CHAS HANDLEBAR 7. Install: • left handlebar switch NOTE: Align the end a of the left handlebar switch with the punch mark b on the handlebar. 8. Connect: • clutch switch coupler 9. Install: • handlebar grip M MMM M MMM M MMM M MMM M MMM...
  • Page 283 CHAS HANDLEBAR 13.Install: • brake master cylinder • brake master cylinder holder 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. • Align the end of the brake master cylinder holder with the punch mark a in the handle- bar.
  • Page 284: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD 23 Nm (2.3 m kg, 17 ft 1st 52 Nm (5.2 m kg, 37 ft • • • • 2nd 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 285 CHAS STEERING HEAD 23 Nm (2.3 m kg, 17 ft 1st 52 Nm (5.2 m kg, 37 ft • • • • 2nd 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • •...
  • Page 286 CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • ring nut 1 (with the spanner wrench 2) Spanner wrench YU-33975 WARNING...
  • Page 287 CHAS STEERING HEAD 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM M MMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.
  • Page 288 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the lower bracket pinch bolts. 5. Tighten: • steering stem nut 115 Nm (11.5 m •...
  • Page 289 CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 290 CHAS REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •...
  • Page 291 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
  • Page 292 CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Swingarm Dust cover Spacer Bearing For installation, reverse the removal...
  • Page 293 CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber.
  • Page 294 CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00703 REMOVING THE REAR SHOCK ABSORBER AND SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 295 CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00696 CHECKING THE REAR SHOCK ABSORBER 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...
  • Page 296 CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Wash: • pivot shaft • dust covers • spacer • bearings Recommended cleaning solvent Kerosine 4. Check: • dust covers • spacer • oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EAS00711 INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM...
  • Page 297: Rear Shock Absorber And Swingarm

    CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Install: • bolt (shock absorber-connecting arm- frame) 1 NOTE: When installing the bolt (shock absorber-con- necting arm-frame), hold the swingarm so that it does not drop down. 4. Adjust: • drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK”...
  • Page 298 CHAS DRIVE BELT AND DRIVE SPROCKET DRIVE BELT AND DRIVE SPROCKET Order Job/Part Q’ty Remarks Removing the drive belt and drive Remove the parts in the order listed. sprocket Rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY”. Rear shock absorber and swingarm Refer to “REAR SHOCK ABSORBER assembly...
  • Page 299 CHAS DRIVE BELT AND DRIVE SPROCKET REMOVING THE DRIVE BELT AND DRIVE SPROCKET NOTE: Loosen the drive sprocket nut before remove the rear wheel. 1. Straighten the lock washer tab. 2. Loosen: • drive sprocket nut 1 NOTE: When loosening the drive sprocket nut, press down on the brake pedal so the drive sprocket does not move.
  • Page 300 CHAS DRIVE BELT AND DRIVE SPROCKET 3. Check: • drive sprocket • rear wheel pulley Bent teeth → Replace the drive belt and pulleys as a set. INSTALLING THE DRIVE BELT AND DRIVE SPROCKET 1. Install: • drive sprocket 1 •...
  • Page 301 ENGINE EAS00188 ENGINE ENGINE 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft • • 53 Nm (5.3 m kg, 38 ft • • 12 Nm (1.2 m kg, 8.7 ft •...
  • Page 302 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the oil filter bracket and Remove the parts in the order listed.
  • Page 303 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Engine oil/oil filter cartridge Drain.
  • Page 304 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Rectifier/regulator coupler Disconnect.
  • Page 305 ENGINE 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Spark plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Plastic clamp...
  • Page 306 ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the ignition coil and Remove the parts in the order listed. linear control valve Hose bracket Wire harness bracket Ignition coil connector Disconnect.
  • Page 307 ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •...
  • Page 308 ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •...
  • Page 309 ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: • spacer bolt 1 • lower front mounting bolt 2 • lower rear mounting bolt 3 2. Tighten: • spacer bolt 1 18 Nm (1.8 m • kg, 13 ft • lb) NOTE: •...
  • Page 310 ENGINE 6. Connect: • oil tank breather hose 1 • cylinder head breather hose 2 • spark plug caps 3 NOTE: Refer to “CABLE ROUTING” in chapter 2. INSTALLING THE MUFFLER AND EXHAUST PIPES 1. Install: • gaskets • exhaust pipes NOTE: Finger tighten the exhaust pipe nuts and bolts.
  • Page 311 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • •...
  • Page 312 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 313 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing cylinder head covers Remove the parts in the order listed. Ignition coil/rectifier/regulator/ Refer to “ENGINE”. liner control valve Cylinder head breather hose Oil tank breather hose Bolt = 60 mm (2.36 in)
  • Page 314 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the push rods and rocker Remove the parts in the order listed.
  • Page 315 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the valve lifters Remove the parts in the order listed. Push rod cover O-ring Seal...
  • Page 316 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark a on the crankshaft position sensor rotor (with the pointer b on the clutch/crankshaft position sensor rotor cover) M MMM M MMM M MMM M MMM...
  • Page 317 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: • rocker arm inside diameter a Out of specification → Replace. Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 4.
  • Page 318 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS CHECKING THE ROCKER ARM BASES 1. Check: • rocker arm base Cracks/damage → Replace. CHECKING THE PUSH RODS 1. Check: • push rod • push rod end Bends/damage → Replace. 2. Measure: • push rod runout Out of specification →...
  • Page 319 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 3. Measure: • valve lifter outside diameter a Out of specification → Replace. Valve lifter outside diameter 22.9680 ~ 22.9744 mm (0.9043 ~ 0.9045 in) 4. Measure: • valve lifter case inside diameter a Out of specification →...
  • Page 320 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Bleed: • valve lifter M MMM M MMM M MMM M MMM M MMM a. Fill a container with kerosene and place the valve lifter into the container as shown. Pump the plunger side of the valve lifter with a press a number of times to let in kero- sene.
  • Page 321 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS h. Rotate the crankshaft unit the mark (on the camshaft driven gear) for the valve lifter to be bled aligns with the camshaft drive gear as shown. Example: For bleeding the cylinder #2 intake valve lifter, align mark 2 as shown.
  • Page 322 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin- ders. 1. Install: • rocker arms 1 • rocker arm shafts 2 (onto rocker arm base) NOTE: The thread hole a of the rocker arm shaft must face to the outside.
  • Page 323 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS c. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern. Rocker arm base bolt 1 10 Nm (1.0 m • kg, 7.2 ft • lb) Rocker arm base bolt 2 24 Nm (2.4 m •...
  • Page 324 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Install: • canister (for California only) NOTE: Refer to “CABLE ROUTING” in chapter 2. 3. Install: • spark plugs 4. Connect: • spark plug caps NOTE: Refer to “CABLE ROUTING” in chapter 2. È...
  • Page 325 CAMSHAFTS EAS00196 CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 52 Nm (5.2 m kg, 37 ft • • Order Job/Part Q’ty Remarks...
  • Page 326 CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 52 Nm (5.2 m kg, 37 ft • • Order Job/Part Q’ty Remarks Camshaft driven gear Straight key...
  • Page 327 CAMSHAFTS REMOVING THE CAMSHAFTS 1. Loosen: • front cylinder camshaft end cover bolts 1 • camshaft drive gear bolt 2 NOTE: • Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. •...
  • Page 328 CAMSHAFTS EAS00204 CHECKING THE CAMSHAFTS 1. Check: • cam Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • cam dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimension limit Intake camshaft a 38.231 ~ 38.331 mm (1.5052 ~ 1.5091 in) b 32.013 ~ 32.113 mm (1.2604 ~ 1.2643 in)
  • Page 329 CAMSHAFTS 5. Measure: • crankcase hole inside diameter c Out of specification → Replace the crank- case. Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 6. Measure: • camshaft cover hole inside diameter d Out of specification → Replace the cam- shaft cover.
  • Page 330 CAMSHAFTS 9. Check: • camshaft drive gears • camshaft driven gears Chips/pitting/roughness/wear → Replace the defective part(s). CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the camshaft.
  • Page 331 CAMSHAFTS INSTALLING THE CAMSHAFTS 1. Install: • camshafts (to the camshaft cover) • front cylinder camshaft end cover NOTE: • Lubricate molybdenum disulfide oil onto the camshaft journals and lobes. • Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft.
  • Page 332 CAMSHAFTS 4. Install: • front cylinder camshaft end cover 1 NOTE: • Align the projection a on the front cylinder camshaft end cover with the hole b on the front cylinder camshaft. • Finger tighten the place bolts. 5. Install: •...
  • Page 333 CAMSHAFTS 6. Tighten: • camshaft driven gear nut 1 52 Nm (5.2 m • kg, 37 ft • lb) NOTE: • Place a folded copper washer 2 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. •...
  • Page 334 CYLINDER HEADS EAS00221 CYLINDER HEADS 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 39 Nm (3.9 m kg, 28 ft • • 60 Nm (6.0 m kg, 43 ft • •...
  • Page 335 CYLINDER HEADS 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 39 Nm (3.9 m kg, 28 ft • • 60 Nm (6.0 m kg, 43 ft • • 21 Nm (2.1 m kg, 15 ft •...
  • Page 336 CYLINDER HEADS REMOVING THE CYLINDER HEADS 1. Remove: • cylinder head NOTE: • Loosen the nuts in the proper sequence. • Follow the numerical order shown in the illus- tration. Loosen each bolt 1/4 of a turn at a time until all of the nuts are loose. EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to each cylin-...
  • Page 337 CYLINDER HEADS CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Damage → Replace. Obstruction → Wash and blow out with compressed air. EAS00232 INSTALLING THE CYLINDER HEAD 1. Install: • cylinder head gasket 1 • dowel pins 2 2.
  • Page 338 CYLINDER HEADS 6. Install: • washer • engine temperature sensor 1 20 Nm (2.0 m • kg, 14 ft • lb) 5 - 38...
  • Page 339: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs The following procedure applies to both cylinders. Cylinder head Refer to “CYLINDER HEADS”. Valve cotter Upper spring seat Outer valve spring Inner valve spring...
  • Page 340 VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
  • Page 341 VALVES AND VALVE SPRINGS 3. Remove: • upper spring seat 1 • outer valve spring 2 • inner valve spring 3 • valve 4 • valve stem seal 5 • lower spring seat 6 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
  • Page 342 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.
  • Page 343 VALVES AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness 0.7 ~ 1.3 mm (0.0276 ~ 0.0512 in) 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: •...
  • Page 344 VALVES AND VALVE SPRINGS 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) M MMM M MMM M MMM...
  • Page 345 VALVES AND VALVE SPRINGS 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. M MMM M MMM M MMM M MMM M MMM a.
  • Page 346 VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification → Replace the valve spring. Valve spring free length Intake valve spring 38.26 mm (1.51 in) <Limit>: 36.26 mm (1.43 in) Exhaust valve spring...
  • Page 347 VALVES AND VALVE SPRINGS EAS00246 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
  • Page 348 VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor set 1. Valve spring compressor set YM-04019 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
  • Page 349 CYLINDERS AND PISTONS EAS00252 CYLINDERS AND PISTONS Order Job/Part Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEADS”. Front cylinder Rear cylinder Cylinder gasket Dowel pin Refer to “INSTALL- Piston pin clip ING THE PIS- Refer to “REMOV-...
  • Page 350 CYLINDERS AND PISTONS EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
  • Page 351 CYLINDERS AND PISTONS EAS00258 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 cylinder, and the piston and piston rings as a set. 2.
  • Page 352 CYLINDERS AND PISTONS Piston size “P” 96.960 ~ 96.975 mm Standard (3.8173 ~ 3.8179 in) d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C”...
  • Page 353 CYLINDERS AND PISTONS 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown. a 10 mm (0.39 in) 3. Measure: • piston ring end gap Out of specification → Replace the piston ring.
  • Page 354 CYLINDERS AND PISTONS 3. Measure: • piston pin bore diameter (in the piston) b Out of specification → Replace the piston pin. Piston pin bore diameter (in the piston) 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) <Limit>: 22.045 mm (0.8679 in) 4.
  • Page 355 CYLINDERS AND PISTONS 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 NOTE: • Apply engine oil onto the piston pin. • Make sure the “arrow” mark a on the piston faces towards the front of the motorcycle. •...
  • Page 356 CLUTCH EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Left side cover Refer to “SEAT AND SIDE COVERS”...
  • Page 357 CLUTCH 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Shift arm Clutch cable holder Refer to “REMOV- Refer to “INSTALL- Clutch cover ING THE CLUTCH”. ING THE CLUTCH”. Clutch cover gasket Dowel pin For installation, reverse the removal...
  • Page 358 CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the pull lever shaft and Remove the parts in the order listed. crankshaft position sensor Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Crankshaft position sensor lead holder Refer to “INSTALLING THE CRANK-...
  • Page 359 CLUTCH EAS00274 CLUTCH 18 19 80 Nm (8.0 m kg, 58 ft • • 9 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed.
  • Page 360 CLUTCH 18 19 80 Nm (8.0 m kg, 58 ft • • 9 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Clutch damper spring Refer to “REMOV- Clutch damper spring seat ING THE CLUTCH”.
  • Page 361 CLUTCH EAS00277 REMOVING THE CLUTCH 1. Remove: • clutch cable holder 1 • clutch cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 362 CLUTCH EAS00279 REMOVING THE PRIMARY DRIVE GEAR 1. Remove: • crankshaft position sensor rotor bolt 1 NOTE: While holding the generator rotor 2 with the sheave holder 3, loosen the crankshaft posi- tion sensor rotor bolt. Primary sheave holder YS-01880-A EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the...
  • Page 363 CLUTCH 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification → Replace the clutch plates as a set. Clutch plate warpage limit 0.2 mm (0.008 in) EAS00283 CHECKING THE CLUTCH PLATE SPRING 1. Check: •...
  • Page 364 CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • pull lever shaft pinion gear teeth a •...
  • Page 365 CLUTCH 2. Install: • crankshaft position sensor 7 Nm (0.7 m • kg, 5.1 ft • lb) • crankshaft position sensor lead holder 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: ® Apply locking agent (LOCTITE ) to the threads of the crankshaft position sensor bolts and crankshaft position sensor lead holder bolts.
  • Page 366 CLUTCH EAS00293 INSTALLING THE CLUTCH 1. Install: • dowel pin 1 • oil pump drive gear 2 • plate 3 • circlip 4 2. Install: • clutch housing 1 • thrust washer 2 NOTE: • Lubricate the clutch housing bearings with engine oil.
  • Page 367 CLUTCH 4. Install: • clutch boss 1 • lock washer • clutch boss nut 2 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: While holding the clutch boss with the univer- sal clutch holder 3, tighten the clutch boss nut.
  • Page 368 CLUTCH 8. Install: • pressure plate 1 NOTE: Align the punch mark a in the pressure plate with the punch mark b in the clutch boss. 9. Install: • clutch spring plate seat 1 • clutch spring plate 2 • clutch spring plate retainer 3 8 Nm (0.8 m •...
  • Page 369 CLUTCH 13.Install: • shift arm 1 12 Nm (1.2 m • kg, 8.7 ft • lb) NOTE: Align the mark a in the shift shaft with the slot in the shift arm. 14.Install: • pull lever spring • pull lever 12 Nm (1.2 m •...
  • Page 370 SHIFT SHAFT AND STOPPER LEVER EAS00327 SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the shift shaft and Remove the parts in the order listed. stopper lever Engine oil Drain.
  • Page 371 SHIFT SHAFT AND STOPPER LEVER EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 • shift lever spring 2 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
  • Page 372 SHIFT SHAFT AND STOPPER LEVER 3. Install: • shift shaft spring • circlips • shift shaft 1 NOTE: Install the end of the shift shaft spring onto the shift shaft spring stopper 2. 5 - 72...
  • Page 373 GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH STATOR COIL ASSEMBLY 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 374 GENERATOR AND STARTER CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 48 Nm (4.8 m kg, 35 ft •...
  • Page 375 GENERATOR AND STARTER CLUTCH EAS00343 GENERATOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Removing the generator rotor Remove the parts in the order listed. Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Woodruff key...
  • Page 376 GENERATOR AND STARTER CLUTCH EAS00347 REMOVING THE GENERATOR 1. Remove: • generator cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 377 GENERATOR AND STARTER CLUTCH 2. Check: • starter clutch operation M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch. b. When turning the starter clutch gear clock- wise È, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be...
  • Page 378 GENERATOR AND STARTER CLUTCH 3. Apply: • sealant (onto the stator coil assembly lead grom- met) ® Quick Gasket ACC-11001-05-01 4. Install: • stator coil assembly 1 7 Nm (0.7 m • kg, 5.2 ft • lb) • stator coil assembly lead holder 10 Nm (1.0 m •...
  • Page 379 TRANSFER GEAR CASE TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •...
  • Page 380 TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft •...
  • Page 381 TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Disassembling the transfer gear Remove the parts in the order listed. case oil pump Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly procedure.
  • Page 382 TRANSFER GEAR CASE FUEL PUMP 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the fuel pump Remove the parts in the order listed. Seat/cover Refer to “SEAT AND SIDE COVERS” in chapter 3. Fuel tank Refer to “FUEL TANK”...
  • Page 383 TRANSFER GEAR CASE REMOVING THE FUEL PUMP 1. Remove: • fuel pump CAUTION: • Do not drop the fuel pump or give it a strong shock. • Do not touch the base section of the fuel sender. INSTALL THE FUEL PUMP 1.
  • Page 384 TRANSFER GEAR CASE SUB FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Part Q’ty Remarks Removing the sub fuel tank Remove the parts in the order listed. Fuel pump Refer to “FUEL PUMP”.
  • Page 385 TRANSFER GEAR CASE 50 Nm (5.0 m kg, 36 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the transfer gear case Remove the parts in the order listed. Seat/right side cover Refer to “SEAT AND SIDE COVERS”...
  • Page 386 TRANSFER GEAR CASE 50 Nm (5.0 m kg, 36 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Oil seal Transfer gear case Dowel pin Bearing Bearing housing For installation, reverse the removal procedure.
  • Page 387 TRANSFER GEAR CASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Disassembling the oil tank Remove the parts in the order listed. Oil temperature sensor Oil tank left cover Oil tank left cover gasket...
  • Page 388 TRANSFER GEAR CASE REMOVING THE MIDDLE DRIVEN SHAFT NOTE: Loosen the middle drive gear nut before remove the drive sprocket. 1. Straighten the lock washer tab. 2. Loosen: • middle drive gear nut 1 NOTE: When loosening the middle drive gear nut, press down on the brake pedal so the middle drive gear does not move.
  • Page 389 TRANSFER GEAR CASE CHECKING THE OIL STRAINER 1. Check: • oil strainer Damage → Replace. Contaminants → Clean with engine oil. CHECKING THE OIL PUMP 1. Check: • oil pump housing 1 • oil pump cover 2 Cracks/damage/wear → Replace the defec- tive part(-s).
  • Page 390 TRANSFER GEAR CASE CHECKING THE OIL PIPE 1. Check: • oil pipe Damage → Replace. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.
  • Page 391 TRANSFER GEAR CASE 4. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. INSTALLING THE TRANSFER GEAR CASE 1. Install: • middle driven shaft 1 • middle drive gear 2 • primary chain 3 (into the transfer gear case) •...
  • Page 392 TRANSFER GEAR CASE 4. Install: • lock washer • middle drive gear nut 1 100 Nm (10.0 m • kg, 72 ft • lb) 5. Bend the lock washer tab along a flat side of the nut. 6. Remove: • drive sprocket nut 7.
  • Page 393 CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Camshafts Refer to “CAMSHAFTS”. Pistons Refer to “CYLINDERS AND PISTONS”. Shift shaft Refer to “SHIFT SHAFT AND STOPPER LEVER”. Generator rotor Refer to “GENERATOR AND STARTER CLUTCH”.
  • Page 394 CRANKCASE Order Job/Part Q’ty Remarks Engine oil pump driven gear Left crankcase Dowel Joint pipe Right crankcase For installation, reverse the removal procedure. 5 - 94...
  • Page 395 CRANKCASE Order Job/Part Q’ty Remarks Removing the baffle plate and Remove the parts in the order listed. bearings Crankshaft Refer to “CRANKSHAFT AND CON- NECTING RODS”. Transmission Refer to “TRANSMISSION”. Baffle plate Oil seal Bearing For installation, reverse the removal procedure.
  • Page 396 CRANKCASE EAS00386 DISASSEMBLING THE CRANKCASE NOTE: Loosen the generator shaft bolt before remov- ing the generator rotor. 1. Remove: • generator shaft bolt 1 NOTE: While the holding the generator rotor 2 with the primary sheave holder 3, loosen the gen- erator shaft bolt.
  • Page 397 CRANKCASE 3. Turn: • shift drum segment NOTE: Turn the shift drum segment 1 to the position shown in the illustration. In this position, the shift drum segment’s teeth will not contact the crankcase during crankcase separation. 4. Remove: • right crankcase CAUTION: •...
  • Page 398 CRANKCASE EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Check: • oil seals Damage/wear → Replace. CHECKING THE OIL DELIVERY PIPE 1.
  • Page 399 CRANKCASE EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • sealant (onto the crankcase mating surfaces) ® Quick Gasket ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery. 2. Install: • dowel pins 1 • joint pipe 2 3.