Page 1 FJR1300R FJR1300RC SERVICE MANUAL LIT-11616-16-18 5JW-28197-10...
Page 2 EAS00001 FJR1300R/FJR1300RC SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. First edition, June 2002 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-11616-16-18...
Page 3 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: Periodic Checks And
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: General Information
EAS00008 SYMBOLS The following symbols are not relevant to SPEC every vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information CHAS 2 Specifications 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Fuel injection system COOL 8 Electrical system...
Page 7: Table Of Contents
EAS00013 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
Page 8 CONTENTS CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER .............1-1 MODEL CODE...................1-1 FEATURES ......................1-2 OUTLINE ....................1-2 FI SYSTEM ....................1-3 COMPONENTS ..................1-5 FUEL INJECTION SYSTEM ..............1-17 THREE-WAY CATALYTIC CONVERTER SYSTEM .......1-26 AIR INDUCTION SYSTEM ..............1-30 COMPONENTS ..................1-31 IMPORTANT INFORMATION................1-35 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-35 REPLACEMENT PARTS .................1-35 GASKETS, OIL SEALS AND O-RINGS ..........1-35...
Page 9 TIGHTENING TORQUES ................2-19 ENGINE TIGHTENING TORQUES ............2-19 CHASSIS TIGHTENING TORQUES ............2-23 LUBRICATION POINTS AND LUBRICANT TYPES........2-25 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES....2-25 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES ....2-27 OIL FLOW DIAGRAMS .................2-28 COOLING SYSTEM DIAGRAMS ..............2-38 CABLE ROUTING ..................2-42 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION....................3-1...
Page 10 ENGINE......................3-16 ADJUSTING THE VALVE CLEARANCE..........3-16 SYNCHRONIZING THE THROTTLE BODIES ........3-22 ADJUSTING THE ENGINE IDLING SPEED ...........3-25 ADJUSTING THE THROTTLE CABLE FREE PLAY.......3-26 CHECKING THE SPARK PLUGS ............3-28 CHECKING THE IGNITION TIMING ............3-29 MEASURING THE COMPRESSION PRESSURE ........3-31 CHECKING THE ENGINE OIL LEVEL ............3-33 CHANGING THE ENGINE OIL..............3-35 MEASURING THE ENGINE OIL PRESSURE ........3-37 ADJUSTING THE CLUTCH LEVER ............3-39...
Page 11 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ............4-1 REMOVING THE FRONT WHEEL ............4-3 CHECKING THE FRONT WHEEL ............4-3 CHECKING THE BRAKE DISCS ..............4-5 INSTALLING THE FRONT WHEEL ............4-6 ADJUSTING THE FRONT WHEEL STATIC BALANCE......4-7 REAR WHEEL AND BRAKE DISC ..............4-9 REMOVING THE REAR WHEEL ............4-11 CHECKING THE REAR WHEEL .............4-11 INSTALLING THE REAR WHEEL ............4-12...
Page 12 FRONT FORK....................4-60 REMOVING THE FRONT FORK LEGS ..........4-63 DISASSEMBLING THE FRONT FORK LEGS ........4-63 CHECKING THE FRONT FORK LEGS...........4-65 ASSEMBLING THE FRONT FORK LEGS ..........4-66 INSTALLING THE FRONT FORK LEGS..........4-70 HANDLEBARS ....................4-72 LEFT HANDLEBAR .................4-72 RIGHT HANDLEBAR................4-73 REMOVING THE HANDLEBARS............4-74 CHECKING THE HANDLEBARS ............4-74 INSTALLING THE HANDLEBARS ............4-75 STEERING HEAD..................4-78...
Page 13 CHAPTER 5 ENGINE ENGINE......................5-1 MUFFLERS AND EXHAUST PIPE ASSEMBLY ........5-1 LEADS AND HOSES .................5-2 ENGINE .....................5-4 INSTALLING THE ENGINE ...............5-6 CAMSHAFTS....................5-8 CYLINDER HEAD COVER ................5-8 CAMSHAFTS.....................5-9 REMOVING THE CAMSHAFTS ..............5-11 CHECKING THE CAMSHAFTS ..............5-12 CHECKING THE CAMSHAFT SPROCKETS..........5-13 CHECKING THE TIMING CHAIN TENSIONER ........5-14 INSTALLING THE CAMSHAFTS ............5-14 CYLINDER HEAD..................5-19 REMOVING THE CYLINDER HEAD ............5-20...
Page 14 CLUTCH......................5-44 CLUTCH COVER ..................5-44 CLUTCH ....................5-45 REMOVING THE CLUTCH ..............5-47 CHECKING THE FRICTION PLATES .............5-48 CHECKING THE CLUTCH PLATES ............5-49 CHECKING THE CLUTCH SPRING PLATE ...........5-49 CHECKING THE CLUTCH HOUSING ............5-49 CHECKING THE CLUTCH BOSS ............5-50 CHECKING THE PRESSURE PLATE ............5-50 CHECKING THE CLUTCH PUSH RODS..........5-50 CHECKING THE PRIMARY DRIVEN GEAR...........5-50 INSTALLING THE CLUTCH ..............5-51...
Page 15 CONNECTING RODS AND PISTONS ............5-91 REMOVING THE CONNECTING RODS AND PISTONS .......5-92 CHECKING THE CYLINDERS AND PISTONS........5-93 CHECKING THE PISTON RINGS ............5-94 CHECKING THE PISTON PINS ..............5-95 CHECKING THE CONNECTING RODS ..........5-97 INSTALLING THE CONNECTING RODS AND PISTONS......5-99 CRANKSHAFT ....................5-103 REMOVING THE CRANKSHAFT............5-104 CHECKING THE CRANKSHAFT ............5-104 INSTALLING THE CRANKSHAFT ............5-107...
Page 16 CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ................7-1 WIRING DIAGRAM..................7-2 ECU’S SELF-DIAGNOSTIC FUNCTION ...........7-3 SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION)................7-7 TROUBLESHOOTING................7-8 THROTTLE BODIES ................7-33 CHECKING THE INJECTOR..............7-37 CHECKING THE THROTTLE BODY ............7-37 CHECKING THE PRESSURE REGULATOR..........7-37 CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION..........7-38 AIR INDUCTION SYSTEM ................7-40 AIR INJECTION ..................7-40...
Page 17: Troubleshooting
ELECTRIC STARTING SYSTEM ..............8-14 CIRCUIT DIAGRAM ................8-14 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ......8-15 TROUBLESHOOTING................8-16 STARTER MOTOR ..................8-20 CHECKING THE STARTER MOTOR .............8-23 ASSEMBLING THE STARTER MOTOR ..........8-25 CHARGING SYSTEM ..................8-26 CIRCUIT DIAGRAM ................8-26 TROUBLESHOOTING................8-27 LIGHTING SYSTEM ..................8-29 CIRCUIT DIAGRAM ................8-29 TROUBLESHOOTING................8-30 CHECKING THE LIGHTING SYSTEM ............8-32 SIGNALING SYSTEM..................8-36...
Page 18 INCORRECT ENGINE IDLING SPEED............9-2 ENGINE .....................9-2 FUEL SYSTEM ..................9-2 ELECTRICAL SYSTEMS ................9-2 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE .........9-3 ENGINE .....................9-3 FUEL SYSTEM ..................9-3 FAULTY GEAR SHIFTING ................9-3 SHIFTING IS DIFFICULT ................9-3 SHIFT PEDAL DOES NOT MOVE ............9-3 JUMPS OUT OF GEAR ................9-3 FAULTY CLUTCH ...................9-4 CLUTCH SLIPS ..................9-4 CLUTCH DRAGS ..................9-4...
Page 19: 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 CODE The model code label 1 is affixed to the frame.
Page 20: Features
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 21: Fi System
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 22 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 Coolant temperature sensor...
Page 23: Components
FEATURES INFO COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the seat, below the toolbox. 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 24 FEATURES INFO • Ignition control The ignition control function of the ECU controls the ignition timing and the duration of ignition energizing. The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position sensor and speed sensor (to detect the speed of the engine).
Page 25 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 26 FEATURES INFO Pressure regulator It regulates the fuel pressure that is applied to the injectors that are provided in the cylinders in order to maintain a constant pressure difference with the pressure in the intake manifold. 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 27 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 28 FEATURES INFO Crankshaft position sensor The crankshaft position sensor uses the signals of the pickup coil that is mounted on the right 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 pickup coil, an electromotive force is generated in the coil.
Page 29 FEATURES INFO Cylinder identification sensor The cylinder identification sensor is mounted on the exhaust head cover of the #4 cylinder. When the exhaust cam of the #4 cylinder rotates and the lift of the cam passes by the sensor, the sensor generates a signal and sends it to the ECU.
Page 30 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 31 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 32 FEATURES INFO Coolant temperature sensor The signals from the coolant temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The coolant temperature sensor converts the temperature of the coolant into electrical signals and sends them to the ECU. 15.5 0.322 1 Connector...
Page 33 FEATURES INFO sensor The O sensor has been adopted to enable the catalyst to function at a high degree of efficiency by maintaining the air-fuel mixture near the stoichiometric ratio (14.7:1). This sensor, which is a zirco- nia type, utilizes the oxygen ion conductivity of the solid electrolyte for detecting the oxygen concen- tration levels.
Page 34 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 35: Fuel Injection System
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 36 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 37 FEATURES INFO Composition of final injection duration 1 Injection at start *1 6 Fuel cut-off È RPM Ð Start 2 After-start enrichment É Injection duration Ñ After start Deceleration compen- Ê Cranking sation *5 3 Warm-up enrichment 7 Basic injection dura- Ë...
Page 38 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 39 FEATURES INFO Fuel injection compensation control • Starting injection control The coolant 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 40 FEATURES INFO • Starting cylinder control #1/4 1 Injectors #1,4 È Cylinder identification Ê Injection 2 Injectors #2,3 Ë Stop sensor 3 Starting asynchro- É Crankshaft position Ì Synchronous injection nous injection sensor 4 Group injection • After-start enrichment After-start enrichment provides enrichment compensation during a prescribed duration following the starting (firing) of the engine.
Page 41 FEATURES INFO • Warm-up enrichment When the coolant temperature is low, a warm-up coefficient is applied in accordance with the sig- nals from the coolant temperature sensor in order to effect fuel enrichment. Because the coolant temperature determines the coefficient, the coefficient changes with the fluctuations in the coolant temperature.
Page 42 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 43 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 acutates 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 44: Three-Way Catalytic Converter System
FEATURES INFO THREE-WAY CATALYTIC CONVERTER SYSTEM System outline This is a highly efficient exhaust gas cleaning system that effects air-fuel control through a joint effort by the FI system, O sensor, and the three-way catalytic converter system. By effecting com- prehensive control of the air-fuel ratio in this manner, this system reduces the CO, HC, and NOx in the exhaust gases.
Page 45 FEATURES INFO Functions of components Equipment Functions Main components Catalyzer (honeycomb Simultaneously reduces • Catalytic converter type) CO, HC, and NOx emis- • Catalyst case sions. Air-fuel compensation Reduces CO, HC, and NOx • O sensor equipment emissions. The catalyst pri- •...
Page 46 FEATURES INFO Large amounts of both CO and HC are generated when the mixture is rich (as indicated by insuffi- region A). Conversely, large amounts of NOx are generated when the mixture is lean (as cient O region B). Under these conflicting characteristics, the system maintains indicated by excessive O the mixture within an extremely narrow range C of stoichiometric ratio (14.7:1).
Page 47 FEATURES INFO Air-fuel ratio compensation equipment An O sensor is provided in the exhaust pipe upstream of the catalyst, to enable the catalyst to operate at a high degree of efficiency. The O sensor detects the level of concentration of the oxy- gen remaining in the exhaust gases.
Page 48: Air Induction System
FEATURES INFO AIR INDUCTION SYSTEM The air induction system (AI system) introduces fresh air into the exhaust port in order to burn the unburned gas (which is present in the exhaust gas) in the exhaust pipe. The burning of the unburned gases in this manner enhances the efficiency of the catalyst and results in cleaner exhaust gases.
Page 49: Components
FEATURES INFO COMPONENTS 1.Air cut-off valve The air cut-off valve consists of a plunger that is mounted inside the core of a solenoid coil, and a valve at the end of the plunger for opening and closing the air passage. Due to the force of a spring, the valve is in constant contact with valve block A, and thus keeps the air passage open.
Page 50 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 multi-function meter on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the multi-function meter.
Page 51 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 52 FEATURES INFO Km/h TRIP mile TRIP mile SELECT RESET 1 Clock 2 TRIP meter 3 RESET button 4 SELECT button 5 Engine trouble warning light 1 - 34...
Page 53: 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 54: Lock Washers/Plates And Cotter Pins
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 55: Checking The Connections
IMPORTANT INFORMATION 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 56: 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 57 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Spanner wrench YU-33975 This tool is needed to loosen and tighten the steering stem ring nut. Oil filter wrench YU-38411 This tool is needed to remove and install the oil filter. Fork seal installer YM-01442 This tool is needed when installing the slide metal, oil seal and dust seal into...
Page 58 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Carburetor synchronizer YU-08030 This gauge is needed for throttle bodies synchronization. Dial indicator YU-03097 This tool is used to measure the middle gear backlash. Pocket tester YU-03112 This instrument is needed for checking the electrical system.
Page 59 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration 40 and 50 mm bearing driver 40 and 50 mm bearing Water pump seal installer driver YM-04058 Water pump seal installer These tools are needed to install the YM-33221 water pump seal. Universal clutch holder YM-91042 This tool is needed to hold the clutch...
Page 60 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Mity vac YB-35956 This tool used to measure the vacuum pressure. Inductive tachometer YU-8036-B This tool is used for check engine speed. ® Quick Gasket ACC-11001-05-01 This sealant is used to seal two mating surfaces (e.
Page 61: Spec
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5JW7 (USA) ---- 5JW8 (California) ---- Dimensions Overall length 2,195 mm (86.4 in) ---- Overall width 760 mm (29.9 in) ---- Overall height 1,420 mm (55.9 in) ---- Seat height 805 mm (31.7 in) ---- Wheelbase...
Page 62: Engine Specifications
SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 1,298 cm (79.2 cu.in) ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) ---- Compression ratio 10.8 : 1 ---- Engine idling speed...
Page 63 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 78.4 ~ 117.6 kPa ---- (0.78 ~ 1.18 kg/cm , 11.15 ~ 16.72 psi) Oil pump Oil pump type Trochoid ---- Inner-rotor-to-outer-rotor-tip clearance 0.03 ~ 0.08 mm (0.0012 ~ 0.0031 in) 0.16 mm (0.0063 in) Outer-rotor-to-oil-pump-housing...
Page 64 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm (0.9646 ~ 0.9654 in) ---- Camshaft journal diameter 24.459 ~ 24.472 mm (0.9630 ~ 0.9635 in) ---- Camshaft-journal-to-camshaft-cap 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) ---- clearance Intake camshaft lobe dimensions...
Page 65 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015/136 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) ---- Exhaust 0.18 ~ 0.25 mm (0.0071 ~ 0.0098 in) ---- Valve dimensions Head Diameter...
Page 66 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout ---- 0.01 mm (0.0004 in) Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) Valve springs Free length...
Page 67 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinders Cylinder arrangement Forward inclined parallel 4-cylinder ---- Bore × stroke 79.0 × 66.2 mm (3.11 × 2.61 in) ---- Compression ratio 10.8 : 1 ---- Bore 79.00 ~ 79.01 mm (3.1102 ~ 3.1106 in) ---- Max.
Page 68 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 1.0 × 2.9 mm (0.039 × 0.114 in) ---- End gap (installed) 0.75 ~ 0.85 mm (0.030 ~ 0.033 in) 1.2 mm (0.047 in) Ring side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm...
Page 69 SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc ---- Clutch release method Hydraulic inner push ---- Operation Left-hand operation ---- Clutch cable free play (at the end of 1.9 ~ 20.7 mm (0.075 ~ 0.815 in) ---- the clutch lever) Friction plates...
Page 70 SPEC ENGINE SPECIFICATIONS Item Standard Limit Fuel pump Pump type Electrical ---- Model (manufacturer) 5JW (DENSO) ---- Consumption amperage <max> 5.5 A ---- Output pressure 294 kPa (2.94 kgf/cm 41.81 psi) ---- Throttle bodies Model (manufacturer) × quantity 42EHS (MIKUNI) × 4 ---- Intake vacuum pressure 33.3 kPa (250 mm Hg, 9.8 in Hg)
Page 71: Chassis Specifications
SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 26° ---- Trail 109 mm (4.29 in) ---- Front wheel Wheel type Cast wheel ---- 17 M/C × MT 3.50 Size ---- Material Aluminum ---- Wheel travel 135 mm (5.31 in) ----...
Page 72 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 180/55 ZR 17 M/C (73 W) ---- Model (manufacturer) MEZ4J (METZELER)/ ---- BT020R N (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm , 36 psi) ---- 90 ~ 202 kg (198 ~ 445 lb) (USA)
Page 73 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Clutch Recommended fluid DOT 4 ---- Master cylinder inside diameter 14 mm (0.55 in) ---- Release cylinder inside diameter 33.6 mm (1.32 in) ---- Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel...
Page 74 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular ---- Lock to lock angle (left) 34° ---- Lock to lock angle (right) 34° ---- Rear suspension Suspension type Swingarm (link suspension) ---- Rear shock absorber assembly type Coil spring/gas-oil damper ---- Rear shock absorber assembly travel 60 mm (2.36 in) ----...
Page 75: Electrical Specifications
SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition (digital) ---- Ignition timing 5° BTDC at 1,050 r/min ---- Advancer type Electric ---- 420 ~ 569 Ω/Gy–B Crankshaft position sensor resis- ---- tance/color Transistorized coil ignition unit model...
Page 76 14 V 1.12 W × 4 Meter light ---- Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) 5JW (YAMAHA) ---- Power output 0.8 kW ---- Brushes Overall length 10.8 mm (0.43 in) 3.65 mm (0.14 in) Spring force 5.28 ~ 7.92 N...
Page 77 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuel pump maximum amperage 5.5 A ---- Fuel injection system relay model ACM33211 M05 (MATSUSHITA) ---- (manufacturer) Radiator fan Model (manufacturer) 5JW (DENSO) ---- Running rpm 3,300 r/min ---- Fan motor relay Model (manufacturer) ACM33211 M05 (OMRON) ---- Atmospheric pressure sensor...
Page 78: Conversion Table
CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EB201000 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 79: Tightening Torques
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size m·kg ft·lb Spark plug — Camshaft sensor Bolt Cylinder head cover Bolt Camshaft cap Bolt Camshaft sprocket Bolt Timing chain tensioner Bolt Timing chain tensioner cap Bolt...
Page 80 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size m·kg ft·lb Oil pipe Bolt Oil strainer Bolt Oil pump assembly Bolt Oil pump housing cover Bolt Left middle gear cover Bolt Right middle gear cover Bolt Middle driven shaft assembly Bolt...
Page 81 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Part name Q’ty Remarks size m·kg ft·lb Thermostat assembly Torx screw Thermostat housing cover Bolt Water pump Bolt Water pump housing cover Bolt Coolant drain bolt — Muffler joint Bolt Muffler Bolt Exhaust pipe...
Page 82 SPEC TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence: 2 - 22...
Page 83 SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Thread Part to be tightened Remarks size m·kg ft·lb Engine mounting: Rear lower mounting bolt Spacer bolt Rear upper mounting bolt and nut Front mounting bolt Pinch bolt Bolt (engine bracket 1 and frame) Bolt (engine bracket 1 and engine) Bolt (engine bracket 2 and engine) Bolt (engine bracket 2 and frame)
Page 84 SPEC TIGHTENING TORQUES Tightening torque Thread Part to be tightened Remarks size m·kg ft·lb Connecting arm and swingarm Connecting arm and relay arm Rear shock assembly and relay arm Rear shock assembly and frame Relay arm and frame Swingarm pivot shaft and locknut 11.5 Swingarm pivot shaft and pivot shaft nut 12.5...
Page 85: Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Balancer weights and shafts Valve stems (intake and exhaust)
Page 86 SPEC LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Cylinder head cover mating surface Sealant Cylinder head cover Sealant Crankcase mating surface Sealant Clutch cover (crankcase mating surface) Sealant Generator cover (crankcase mating surface) Sealant Pickup coil rotor cover (crankcase mating surface) Sealant Left middle gear cover (crankcase mating surface) Sealant...
Page 87: Chassis Lubrication Points And Lubricant Types
SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal pivot Footrest pivoting point...
Page 88: Oil Flow Diagrams
SPEC LUBRICATION POINTS AND LUBRICANT TYPES OIL FLOW DIAGRAMS 1 Crankshaft 2 Oil pump 3 Oil pipe 4 Relief valve 5 Oil filter cartridge 6 Main axle 2 - 28...
Page 89 SPEC OIL FLOW DIAGRAMS 1 Crankshaft 2 Main axle 3 Drive axle 2 - 29...
Page 90 SPEC OIL FLOW DIAGRAMS 1 Oil nozzle 2 Main gallery bolt 3 Crankshaft 2 - 30...
Page 91 SPEC OIL FLOW DIAGRAMS 1 Main axle 2 Drive axle 3 Oil delivery pipe 2 - 31...
Page 92 SPEC OIL FLOW DIAGRAMS 1 Exhaust camshaft 2 Oil check bolt 3 Intake camshaft 2 - 32...
Page 93 SPEC OIL FLOW DIAGRAMS 1 Oil check bolt 2 Crankshaft 3 Oil cooler 4 Oil pump 5 Oil strainer 6 Oil pipe 2 - 33...
Page 94 SPEC OIL FLOW DIAGRAMS 1 Crank pin 2 Crankshaft 2 - 34...
Page 95 SPEC OIL FLOW DIAGRAMS 1 Rear balancer 2 Oil delivery pipe 3 Crankshaft 4 Front balancer 5 Crank pin 2 - 35...
Page 96 SPEC OIL FLOW DIAGRAMS 1 Oil strainer 2 Oil delivery pipe 3 Oil cooler 4 Engine oil drain bolt 5 Oil level switch 6 Oil filter cartridge 7 Oil pan 8 Oil pipe 9 Oil pump 2 - 36...
Page 97 SPEC OIL FLOW DIAGRAMS 1 Main axle 2 Drive axle 3 Middle drive shaft 2 - 37...
Page 98: Cooling System Diagrams
SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 1 Radiator 2 - 38...
Page 99 SPEC COOLING SYSTEM DIAGRAMS 1 Water jacket joint 2 Oil cooler 2 - 39...
Page 100 SPEC COOLING SYSTEM DIAGRAMS 1 Thermostat assembly 2 Coolant reservoir 3 Radiator 4 Oil cooler 2 - 40...
Page 101 SPEC COOLING SYSTEM DIAGRAMS 1 Coolant reservoir 2 Radiator 3 Water pump 2 - 41...
Page 102: Cable Routing
SPEC CABLE ROUTING CABLE ROUTING 1 Throttle cable 0 Rectifier/regulator 2 Brake cable A Plate 3 Clutch cable B Plunger control unit hose 2 4 Main switch lead C Radiator 5 Headlight lead D Radiator fan coupler 6 Fuse box 7 Thermostat assembly breather hose 8 Coolant reservoir hose 9 Hazard switch...
Page 103 SPEC CABLE ROUTING È Pass the right handlebar switch lead under the Ì After passing the coolant reservoir hose through handlebar. the two hose guides behind the plate, pass the É Pass the left handlebar switch lead under the hose through the right hole of the plate. Í...
Page 104 SPEC CABLE ROUTING 1 Brake cable B Ignition coil (#1, #4) 2 Right handlebar switch lead C Coolant reservoir 3 Throttle cable D Coolant reservoir breather hose 4 Starter relay E Coolant reservoir hose 5 Battery F Pickup coil lead 6 Positive battery lead G Starter motor lead 7 Main fuse...
Page 105 SPEC CABLE ROUTING È Fasten the positive battery lead with a plastic Í Pass the brake cable through the brake cable locking tie to the battery stay. guide. É Fasten the positive battery lead and main fuse Î Pass the coolant reservoir hose through the hole lead with a plastic locking tie to the battery stay.
Page 106 SPEC CABLE ROUTING Ñ Support the coolant reservoir hose and coolant Ô Pass the wire harness, spark plug leads #1, #2, reservoir breather hose with the hose holder #3, and #4 through the right slit of the battery located under the coolant reservoir. bracket.
Page 107 SPEC CABLE ROUTING 1 Tail/brake light lead 2 - 47...
Page 108 SPEC CABLE ROUTING 1 Main switch lead A Oil level switch lead 2 Left handlebar switch lead B Brake cable 3 Hazard switch C Coolant reservoir hose 4 Rectifier/regulator D Thermostat assembly breather hose 5 Clutch cable E Headlight lead 6 Fuel tank overflow hose F Radiator fan lead 7 Fuel tank breather hose...
Page 109 SPEC CABLE ROUTING È To the radiator fan Î Attach the clutch cable to the frame using the É Pass the wire harness, stator coil lead, coolant clutch cable holders. Ï Insert the harness holder into the hole on the reservoir hose, thermostat...
Page 110 SPEC CABLE ROUTING 1 ECU Ì Pass the tail/brake light lead between the rear 2 Tail/brake light lead cover and frame. 3 Seat lock cable Í Pass the wire harness on the inside of the seat 4 Fuel tank breather hose lock cable.
Page 111 SPEC CABLE ROUTING 1 Air cut-off valve A Spark plug lead #1 2 Clutch cable B Spark plug lead #4 3 Left handlebar switch lead C Cable guide 4 Headlight lead D Throttle position sensor 5 Main switch lead E Fuel return hose 6 Throttle cable F Sidestand switch lead 7 Right handlebar switch lead...
Page 112 SPEC CABLE ROUTING È Connect the wire harness and right handlebar Ì To the cylinder identification sensor Í To the fuel tank switch lead. É Pass the left handlebar switch lead, main switch Î Pass the cylinder identification sensor lead lead, headlight lead, and clutch cable through through the lead guide of throttle body.
Page 113 SPEC CABLE ROUTING Ò Support the throttle cables with the T-bar located Ô To the left slit of the plate behind the cable guide. Ó Pass the throttle cables under spark plug leads #1, #2, #3, and #4, and the wire harness, head- light lead, main switch lead, right handlebar switch lead, and left handlebar switch lead.
Page 114 SPEC CABLE ROUTING 1 Engine stop switch 2 Starting circuit cut-off relay 3 Atmospheric pressure sensor 4 CYCLELOCK coupler 5 Seat lock cable 2 - 54...
Page 115 SPEC CABLE ROUTING È To the rear brake light switch É Pass the engine stop switch through the lead guide attached to the frame. Ê Pass the CYCLELOCK coupler through the inside of the storage box of the U-lock. Ë Pass the CYCLELOCK coupler through the lead guide.
Page 116 SPEC CABLE ROUTING Canister (California only) 1 Fuel tank È To the left front of the fuel tank 2 Fuel tank breather hose É To the left rear of the fuel tank 3 Fuel tank overflow hose Ê To the throttle bodies 4 Canister charge hose Ë...
Page 117: Chk Adj
Air induction sys- √ √ hose for damage. • Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAS00037 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS...
Page 118 • Replace if necessary. √ √ √ √ √ 22 * Tires • Check air pressure. • Correct if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 3 - 2...
Page 119 GENERAL MAINTENANCE AND LUBRICATION CHART 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. • Air filter • The air filter element needs to be replaced more frequently when riding in unusually wet or dusty areas.
Page 120: Seats And Fuel Tank
SEATS AND FUEL TANK EAS00039 SEATS AND FUEL TANK SEATS Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. Rider seat Passenger seat For installation, reverse the removal procedure. 3 - 4...
Page 121: Fuel Tank
SEATS AND FUEL TANK EAS00040 FUEL TANK Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Rider seat Fuel Drain. Fuel tank side panel (left and right) Bolt Fuel sender coupler Fuel pump coupler Fuel tank overflow hose Fuel tank breather hose Hose holder...
Page 122: T-Bar
SEATS AND FUEL TANK T-BAR Order Job/Part Q’ty Remarks Removing the T-bar Remove the parts in the order listed. Rider seat/fuel tank Refer to “SEATS AND FUEL TANK”. Left rubber cover Right rubber cover T-bar Rubber sheet For installation, reverse the removal procedure.
Page 123: Removing The Fuel Tank
SEATS AND FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: • fuel return hose • fuel hose CAUTION: Although the fuel has been removed from the fuel tank be careful when removing the fuel hoses, since there may be fuel remain- ing in it.
Page 124: Installing The Fuel Pump
SEATS AND FUEL TANK INSTALLING THE FUEL PUMP 1. Install: • fuel pump 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: • Do not damage the installation surfaces of the fuel tank when installing the fuel pump. •...
Page 125: Air Filter Case
AIR FILTER CASE EAS00043 AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seats/fuel tank Refer to “SEATS AND FUEL TANK”. Side covers (left and right) Refer to “COWLINGS AND COVERS”. Air shroud Air filter case cover Air filter element...
Page 126 AIR FILTER CASE Order Job/Part Q’ty Remarks Air induction system hose 5 Disconnect. Clamp screw Loosen. Air filter case Air filter case breather hose For installation, reverse the removal procedure. 3 - 10...
Page 127: Cowlings And Covers
COWLINGS AND COVERS EAS00041 COWLINGS AND COVERS COWLINGS 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Rider seat/fuel tank Refer to “SEATS AND FUEL TANK”. Left side cowling Right side cowling Front bottom cowling...
Page 128 COWLINGS AND COVERS ( 7 ) Order Job/Part Q’ty Remarks Disassembling the front cowling Remove the parts in the order listed. assembly Windshield outer bracket Windshield Grommet Windshield inner bracket Rear view mirror (left and right) Panel Front cowling Auxiliary light coupler Headlight coupler For assembly, reverse the disassembly procedure.
Page 129 COWLINGS AND COVERS Order Job/Part Q’ty Remarks Removing the headlight assembly Remove the parts in the order listed. Headlight assembly For installation, reverse the removal procedure. 3 - 13...
Page 130 COWLINGS AND COVERS Order Job/Part Q’ty Remarks Removing the windshield drive unit, Remove the parts in the order listed. meter assembly and relays Windshield drive unit Windshield drive unit coupler Meter assembly Meter assembly coupler Headlight relay 1 Headlight relay 2 Fuel injection system relay Turn signal relay Radiator fan motor relay...
Page 131: Covers
COWLINGS AND COVERS COVERS Order Job/Part Q’ty Remarks Removing the covers Remove the parts in the order listed. Seats Refer to “SEATS AND FUEL TANK”. Left side cover Right side cover Rear carrier Rear cover For installation, reverse the removal procedure.
Page 132: Engine
ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
Page 133 ADJUSTING THE VALVE CLEARANCE 3. Remove: • hose holder 1 • lead holder 2 • pickup coil rotor cover 3 4. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.15 ~ 0.22 mm (0.0059 ~ 0.0087 in) Exhaust valve 0.18 ~ 0.25 mm (0.0071 ~ 0.0098 in)
Page 134 ADJUSTING THE VALVE CLEARANCE É Degrees that the crankshaft is turned counter- clockwise Ê Cylinder Ë Combustion cycle Cylinder #2 180° Cylinder #4 360° Cylinder #3 540° L LLL L LLL L LLL L LLL L LLL 5. Remove: • rubber plug 1 •...
Page 135 ADJUSTING THE VALVE CLEARANCE NOTE: • Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. • Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place.
Page 136 ADJUSTING THE VALVE CLEARANCE e. Install the new valve pad 1 and the valve lifter 2. NOTE: • Lubricate the valve pad with molybdenum disulfide grease. • Lubricate the valve lifter with molybdenum disulfide oil. • The valve lifter must turn smoothly when rotated by hand.
Page 137 ADJUSTING THE VALVE CLEARANCE INTAKE MEASURED ORIGINAL VALVE PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...
Page 138: Synchronizing The Throttle Bodies
ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES 9. Install: • all removed parts NOTE: For installation, reverse the removal proce- dure. EAS00050 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.
Page 139 SYNCHRONIZING THE THROTTLE BODIES 7. Measure: • engine idling speed Out of specification → Adjust. Refer “ADJUSTING ENGINE IDLING SPEED”. Engine idling speed 1,000 ~ 1,100 r/min 8. Adjust: • throttle body synchronization M MMM M MMM M MMM M MMM M MMM a.
Page 140 SYNCHRONIZING THE THROTTLE BODIES 11.Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 12.Remove: • engine tachometer •...
Page 141: Adjusting The Engine Idling Speed
ADJUSTING THE ENGINE IDLING SPEED EAS00052 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 142: Adjusting The Throttle Cable Free Play
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 7. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 8.
Page 143 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: • throttle cable free play NOTE: When the throttle is opened, the accelerator cable 1 is pulled. M MMM M MMM M MMM M MMM M MMM Throttle body side a. Loosen the locknut 2 on the decelerator cable.
Page 144: Checking The Spark Plugs
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change.
Page 145: Checking The Ignition Timing
CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 5. Check: • electrodes 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 146 CHECKING THE IGNITION TIMING 1. Remove: • rider seat • fuel tank • T-bar Refer to “SEATS AND FUEL TANK”. • right side cowling Refer to “COWLINGS AND COVERS”. • timing mark accessing screw 1 2. Attach: • timing light 1 •...
Page 147: Measuring The Compression Pressure
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 5. Remove: • fuel tank • engine tachometer • timing light 6. Install: • timing mark accessing screw • right side cowling Refer to “COWLINGS AND COVERS”. • T-bar • fuel tank •...
Page 148 MEASURING THE COMPRESSION PRESSURE 6. Install: • compression gauge adapter 1 • compression gauge 2 Compression gauge set 14/18 mm YU-33223 Compression gauge adapter 12 mm YU-33223-3 7. Install: • fuel tank 8. Measure: • compression pressure Out of specification → Refer to steps (c) and (d).
Page 149: Checking The Engine Oil Level
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than with- Piston wear or damage → Repair. out oil Piston ring(s), valves, cylinder Same as without oil head gasket or pis- ton possibly defec- tive →...
Page 150 CHECKING THE ENGINE OIL LEVEL 3. Check: • engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b. Below the minimum level mark → Add the recommended engine oil to the proper level. Recommended oil Yamalube 4 (20W40) or SAE 20W40 type SE motor oil...
Page 151: Changing The Engine Oil
CHANGING THE ENGINE OIL EAS00073 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: • engine oil filler cap 1 •...
Page 152 CHANGING THE ENGINE OIL 6. Check: • engine oil drain bolt gasket Damage → Replace. 7. Install: • engine oil drain bolt 43 Nm (4.3 m · kg, 31 ft · lb) 8. Fill: • crankcase (with the specified amount of the recom- mended engine oil) Quantity Total amount...
Page 153: Measuring The Engine Oil Pressure
CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE 13.Check: • engine oil pressure M MMM M MMM M MMM M MMM M MMM a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt.
Page 154 MEASURING THE ENGINE OIL PRESSURE 4. Remove: • main gallery bolt WARNING The engine, muffler and engine oil are extremely hot. 5. Install: • pressure gauge 1 • oil pressure adapter B 2 Pressure gauge 90890-03153 Oil pressure adapter B 90890-03124 6.
Page 155: Adjusting The Clutch Lever
ADJUSTING THE CLUTCH LEVER/ CHECKING THE CLUTCH FLUID LEVEL EAS00082 ADJUSTING THE CLUTCH LEVER 1. Adjust: • clutch lever position (distance a from the handlebar grip to the clutch lever) M MMM M MMM M MMM M MMM M MMM a.
Page 156: Bleeding The Hydraulic Clutch System
CHECKING THE CLUTCH FLUID LEVEL/ BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance. • Refill with the same type of clutch fluid that is already in the system.
Page 157 BLEEDING THE HYDRAULIC CLUTCH SYSTEM NOTE: • Be careful not to spill any clutch fluid or allow the clutch master cylinder reservoir to over- flow. • When bleeding the hydraulic clutch system, make sure there is always enough clutch fluid before applying the clutch lever. Ignor- ing this precaution could allow air to enter the hydraulic clutch system, considerably length- ening the bleeding procedure.
Page 158: Cleaning The Air Filter Element
BLEEDING THE HYDRAULIC CLUTCH SYSTEM/ CLEANING THE AIR FILTER ELEMENT k. Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL”. WARNING After bleeding the hydraulic clutch system, check the clutch operation. L LLL L LLL L LLL L LLL...
Page 159: Checking The Throttle Body Joints
CLEANING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINTS 6. Install: • air filter element • air filter case cover CAUTION: Never operate the engine without the air fil- ter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine.
Page 160: Checking The Fuel And Vacuum Hoses
CHECKING THE FUEL AND VACUUM HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND VACUUM HOSES The following procedure applies to all of the fuel and vacuum hoses. 1. Remove: • rider seat • fuel tank Refer to “SEATS AND FUEL TANK”. 2.
Page 161: Checking The Exhaust System
CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • side cowlings Refer to “COWLINGS AND COVERS”. 2. Check: • exhaust pipe 1 • muffler 2 Cracks/damage →...
Page 162: Checking The Coolant Level
CHECKING THE COOLANT LEVEL EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Remove: • right side cowling Refer to “COWLINGS AND COVERS”. 3.
Page 163: Checking The Cooling System
CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: • rider seat • fuel tank Refer to “SEATS AND FUEL TANK”. • side cowlings • front cowling assembly Refer to “COWLINGS AND COVERS”. 2. Check: • radiator 1 •...
Page 164: Changing The Coolant
CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Remove: • side cowlings • front cowling assembly Refer to “COWLINGS AND COVERS”.
Page 165 CHANGING THE COOLANT 8. Check: • copper washer 1 (coolant drain bolt 2) Damage → Replace. 9. Install: • coolant drain bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) 10.Connect: • coolant reservoir hose 11.Fill: • cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze...
Page 166 CHANGING THE COOLANT CAUTION: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, if dis- tilled water is not available, soft water may be used.
Page 167: Chassis
ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) NOTE: • While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.
Page 168: Adjusting The Rear Brake
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 (below the top of the rider footrest) 42 mm (1.65 in) 2.
Page 169: Checking The Brake Fluid Level
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 È CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: •...
Page 170: Checking The Brake Pads
CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH 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 171: Adjusting The Rear Brake Light Switch
ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE BRAKE HOSES 1. Check: • rear brake light operation timing Incorrect → Adjust. 2. Adjust: • rear brake light operation timing M MMM M MMM M MMM M MMM M MMM a. Remove the right footrest bracket bolts 1. b.
Page 172: Bleeding The Hydraulic Brake System
BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00134 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system when- ever: the system is disassembled, a brake hose loosened, disconnected replaced, the brake fluid level is very low, brake operation is faulty. NOTE: •...
Page 173: Adjusting The Shift Pedal
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h.
Page 174: Checking The Final Drive Oil Level
ADJUSTING THE SHIFT PEDAL/CHECKING THE FINAL DRIVE OIL LEVEL/CHANGING THE FINAL DRIVE OIL NOTE: Make sure that the mark on the shift pedal is between the marks on the frame. c. Tighten both locknuts. L LLL L LLL L LLL L LLL L LLL EAS00144...
Page 175: Changing The Final Drive Oil
CHANGING THE FINAL DRIVE OIL/ CHECKING AND ADJUSTING THE STEERING HEAD 3. Check: • final drive housing oil drain bolt gasket Damage → Replace. 4. Install: • final drive housing oil drain bolt · 23 Nm (2.3 m · kg, 17 ft 5.
Page 176 CHECKING AND ADJUSTING THE STEERING HEAD 4. Remove: • steering stem nut 1 • washer • upper bracket 2 (with the handlebars) 5. 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.
Page 177: Checking The Front Fork
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK g. Finger tighten the upper ring nut, then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h.
Page 178: Adjusting The Front Fork Legs
ADJUSTING THE FRONT FORK LEGS EAS00155 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 179 ADJUSTING THE FRONT FORK LEGS 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 is harder). Rebound damping is Direction b decreased (suspension is softer).
Page 180: Adjusting The Rear Shock Absorber Assembly
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00157 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload 1. Adjust: • spring preload M MMM M MMM M MMM M MMM M MMM a.
Page 181 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES Adjusting positions Minimum: 20 clicks out* Standard: 10 clicks out* Maximum: 3 clicks out* * from the fully turned-in position a L LLL L LLL L LLL L LLL L LLL EAS00162 CHECKING THE TIRES The following procedure applies to both of the tires.
Page 182: Checking The Tires
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 183: Checking The Wheels
CHECKING THE TIRES/ CHECKING THE WHEELS Front tire Manufacturer Model Size MEZ4J 120/70 ZR17 M/C METZELER FRONT (58W) BT020F 120/70 ZR17 M/C BRIDGESTONE (58W) Rear tire Manufacturer Model Size 180/55 ZR17 M/C METZELER MEZ4J (73W) BT020R 180/55 ZR17 M/C BRIDGESTONE (73W) WARNING New tires have a relatively low grip on the...
Page 184: Checking And Lubricating The Cables
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement.
Page 185: Lubricating The Centerstand
LUBRICATING THE CENTERSTAND/ LUBRICATING THE REAR SUSPENSION EAS00173 LUBRICATING THE CENTERSTAND Lubricate the pivoting point and metal-to-metal moving parts of the centerstand. Recommended lubricant Lithium soap base grease EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Lithium soap base grease 3 - 69...
Page 186: 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 187 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 188 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature • battery 20 °C (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. • Never remove the MF battery sealing caps.
Page 189 CHECKING AND CHARGING THE BATTERY Charging method using a variable 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 190 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 191: Checking The Fuses
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • 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: • battery terminals Dirt →...
Page 192 CHECKING THE FUSES NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester YU-03112 b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL 3. Replace: • blown fuse M MMM M MMM M MMM...
Page 193: Replacing The Headlight Bulbs
CHECKING THE FUSES/ REPLACING THE HEADLIGHT BULBS WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rat- ing may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.
Page 194: Adjusting The Headlight Beams
REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAMS 5. Install: • headlight bulb Secure the new headlight bulb with the headlight bulb holder. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adversely affected.
Page 195 ADJUSTING THE HEADLIGHT BEAMS 2. Adjust: • headlight beam (horizontally) M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting screw 1 in direction a or b. Left headlight Headlight beam moves Direction a to the right. Headlight beam moves Direction b to the left.
Page 196 ADJUSTING THE HEADLIGHT BEAMS 3 - 80...
Page 197: Chas
CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. Brake caliper (left and right) Refer to “REMOVING/ Wheel axle pinch bolt...
Page 198 CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal Wheel bearing Spacer For assembly, reverse the disassembly procedure. 4 - 2...
Page 199: Removing The Front Wheel
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 200 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 201: Checking The Brake Discs
CHAS FRONT WHEEL AND BRAKE DISCS EAS00533 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 202: Installing The Front Wheel
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 203: Adjusting The Front Wheel Static Balance
CHAS FRONT WHEEL AND BRAKE DISCS 3. Install: • brake caliper 40 Nm (4.0 m · kg, 29 ft · lb) WARNING Make sure the brake hose is routed prop- erly. EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the front wheel static...
Page 204 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 205: Rear Wheel And Brake Disc
CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC Order Job/Part Q’ty Remarks Removing the rear wheel and brake Remove the parts in the order listed. disc NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. Brake torque rod nut/bolt Refer to “INSTALLING Wheel axle nut...
Page 206 CHAS REAR WHEEL AND BRAKE DISC AS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Dust cover Rear wheel drive hub Dust seal Wheel bearing Rear wheel drive hub damper Oil seal Circlip Wheel bearing Spacer Collar...
Page 207: Removing The Rear Wheel
CHAS REAR WHEEL AND BRAKE DISC EEAS00562 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 208: Installing The Rear Wheel
CHAS REAR WHEEL AND BRAKE DISC 3. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL AND BRAKE DISCS”. EEAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips Recommended lubricant Lithium soap base grease 2.
Page 209: Front And Rear Brakes
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake hose holder bolt Brake caliper bolt Brake pad clip...
Page 210: Rear Brake Pads
CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Retaining bolt Brake pad Brake pad shim Bleed screw For installation, reverse the removal procedure. 4 - 14...
Page 211: Replacing The Front Brake Pads
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 212 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pins 2 • brake pad spring 3 • brake pads (along with the brake pad shims) 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set.
Page 213: Replacing The Rear Brake Pads
CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pins • brake pad clips • brake caliper 40 Nm (4.0 m · kg, 29 ft · lb) • brake hose holder 7 Nm (0.7 m · kg, 5.1 ft · lb) 6.
Page 214 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4. Install: • brake pad springs • brake pad shims (onto the brake pads) •...
Page 215 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 pedal operation Soft or spongy feeling →...
Page 216: Front Brake Master Cylinder
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. Brake master cylinder reservoir cap Brake master cylinder reservoir dia- phragm holder Brake master cylinder reservoir dia- phragm...
Page 217 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Union bolt Refer to “DISASSEMBLING/ Copper washer ASSEMBLING AND Brake hose Disconnect. INSTALLING THE Brake master cylinder holder FRONT BRAKE MASTER Brake master cylinder CYLINDER”. Front brake light switch For installation, reverse the removal procedure.
Page 218 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 4 - 22...
Page 219: Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder Side cover (right) Refer to “COWLINGS AND COVERS” in chapter 3. Brake fluid Drain.
Page 220 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Union bolt Refer to “DISASSEMBLING/ Copper washer ASSEMBLING THE Brake hose Disconnect. REAR BRAKE MASTER CYLINDER”. Cotter pin Brake master cylinder For installation, reverse the removal procedure. 4 - 24...
Page 221 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Push rod Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure.
Page 222: Disassembling The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the...
Page 223: Checking The Front And Rear Brake Master Cylinders
CHAS FRONT AND REAR BRAKES EAS00592 È CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder 1 Damage/scratches/wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction →...
Page 224: Assembling And Installing The Front Brake Master Cylinder
CHAS FRONT AND REAR BRAKES 5. Check: • brake hoses Cracks/damage/wear → Replace. EAS00606 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •...
Page 225 CHAS FRONT AND REAR BRAKES CAUTION: When installing the brake hose onto the brake master cylinder, make sure the brake pipe touches the projection a as shown. NOTE: Turn the handlebars to the left and to the right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads).
Page 226: Assembling The Rear Brake Master Cylinder
CHAS FRONT AND REAR BRAKES 5. 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. 6. Check: • brake lever operation Soft or spongy feeling →...
Page 227 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 228 CHAS FRONT AND REAR BRAKES 6. Adjust: • rear brake light operation timing Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH” in chapter 3. 4 - 32...
Page 229: Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid Drain. Brake hose holder bolt Refer to Union bolt “DISASSEMBLING/...
Page 230 CHAS FRONT AND REAR BRAKES EAS00615 Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad/brake pad shim Brake caliper piston...
Page 231: Rear Brake Caliper
CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Disconnect. Refer to Retaining bolt Loosen. “DISASSEMBLING/ Brake torque rod ASSEMBLING AND...
Page 232 CHAS FRONT AND REAR BRAKES EAS00617 Order Job/Part Q’ty Remarks Disassembling the rear brake cali- Remove the parts in the order listed. Retaining bolt Brake pad/brake pad shim Brake pad spring Rear brake caliper bracket Brake caliper piston Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”.
Page 233: Disassembling The Front Brake Calipers
CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake sys- tem. 1. Remove: • union bolt 1 •...
Page 234 CHAS FRONT AND REAR BRAKES EAS00626 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 235: Checking The Front And Rear Brake Calipers
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 two years È Every years and whenever the Brake fluid brake is disassem- bled 1.
Page 236: Assembling And Installing The Front Brake Calipers
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 237 CHAS FRONT AND REAR BRAKES 3. Install: • brake pads • brake pad spring • brake caliper 40 Nm (4.0 m · kg, 29 ft · lb) • brake hose holder 7 Nm (0.7 m · kg, 5.1 ft · lb) Refer “REPLACING FRONT...
Page 238: Assembling And Installing The Rear Brake Caliper
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 239 CHAS FRONT AND REAR BRAKES 2. Tighten: • brake torque rod 30 Nm (3.0 m · kg, 22 ft · lb) • wheel axle nut 125 Nm (12.5 m · kg, 90 ft · lb) • wheel axle pinch bolt 16 Nm (1.6 m ·...
Page 240 CHAS FRONT AND REAR BRAKES 6. 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 241 CHAS FRONT AND REAR BRAKES 9. Check: • brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4 - 45...
Page 242: Hydraulic Clutch
CHAS HYDRAULIC CLUTCH EAS00305 HYDRAULIC CLUTCH CLUTCH MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the clutch master cylin- Remove the parts in the order listed. Clutch fluid Drain. Clutch master reservoir cap Clutch master reservoir diaphram holder Clutch master reservoir diaphram Clutch lever Bushing Clutch switch coupler...
Page 243 CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Union bolt Refer to “DISASSEMBLING/ Copper washer ASSEMBLING AND Clutch hose Disconnect. INSTALLING THE Clutch master cylinder holder CLUTCH MASTER CYLINDER”. Clutch master cylinder Refer to “ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER”. Clutch switch For installation, reverse the removal procedure.
Page 244: Disassembling The Clutch Master Cylinder
CHAS HYDRAULIC CLUTCH EAS00306 Order Job/Part Q’ty Remarks Disassembling the clutch master Remove the parts in the order listed. cylinder Clutch master cylinder push rod Dust seal Circlip Washer Clutch master cylinder kit Clutch master cylinder For assembly, reverse the disassembly procedure.
Page 245 CHAS HYDRAULIC CLUTCH EAS00307 CAUTION: Clutch components rarely require disas- sembly. Therefore, always follow these preventive measures: • Never disassemble clutch components unless absolutely necessary. • If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
Page 246: Checking The Clutch Master Cylinder
CHAS HYDRAULIC CLUTCH EAS00308 CHECKING THE CLUTCH MASTER CYLINDER Recommended clutch component replacement schedule Piston seals Every two years Clutch hose Every two years Every years and whenever the Clutch fluid clutch is disassem- bled 1. Check: • clutch master cylinder body 1 Cracks/damage →...
Page 247: Assembling And Installing The Clutch Master Cylinder
CHAS HYDRAULIC CLUTCH EAS00309 EAS00310 ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER WARNING • Before installation, all internal clutch components must be cleaned and lubri- cated with clean or new clutch fluid. • Never use solvents on internal clutch components as they will cause the piston seals to swell and distort.
Page 248 CHAS HYDRAULIC CLUTCH CAUTION: When installing the clutch hose onto the clutch master cylinder, make sure the clutch pipe touches the projection a as shown. NOTE: Turn the handlebars to the left and to the right to make sure the clutch hose does not touch other parts (e.g., wire harness, cables, leads).
Page 249 CHAS HYDRAULIC CLUTCH 4. Bleed: • clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 5. Check: • clutch fluid level Below the minimum level mark a → Add the recommended clutch fluid to the proper level. Refer to “CHECKING THE CLUTCH FLUID LEVEL”...
Page 250: Clutch Release Cylinder
CHAS HYDRAULIC CLUTCH EAS00311 CLUTCH RELEASE CYLINDER Order Job/Part Q’ty Remarks Removing the clutch release cylin- Remove the parts in the order listed. Clutch fluid Drain. Union bolt Refer to “DISASSEMBLING/ Copper washer ASSEMBLING AND Clutch hose Disconnect. INSTALLING THE CLUTCH MASTER CYLINDER”.
Page 251: Disassembling The Clutch Release Cylinder
CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch release Remove the parts in the order listed. cylinder Clutch release cylinder piston Refer to “DISASSEMBLING THE Clutch release cylinder spring CLUTCH RELEASE CYLINDER”. Clutch release cylinder piston seal Bleed screw For assembly, reverse the disassembly procedure.
Page 252 CHAS HYDRAULIC CLUTCH EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER NOTE: Before disassembling the clutch release cylin- der, drain the clutch fluid from the entire clutch system. 1. Remove: • union bolt 1 • copper washers 2 • clutch hose 3 NOTE: Put the end of the clutch hose into a container and pump out the clutch fluid carefully.
Page 253: Checking The Clutch Release Cylinder
CHAS HYDRAULIC CLUTCH EAS00314 CHECKING THE CLUTCH RELEASE CYLINDER Recommended clutch component replacement schedule Piston seal Every two years Clutch hose Every two years Every years and whenever the Clutch fluid clutch is disassem- bled 1. Check: • clutch release cylinder body 1 Cracks/damage →...
Page 254 CHAS HYDRAULIC CLUTCH 2. Fill: • clutch master cylinder reservoir (with the specified amount of the recom- mended clutch fluid) Recommended clutch fluid Brake fluid DOT 4 WARNING • Use only the designated clutch fluid. Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance.
Page 255 CHAS HYDRAULIC CLUTCH 5. Check: • clutch lever operation Soft or spongy feeling → Bleed the clutch system. Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 4 - 59...
Page 256: Front Fork
CHAS FRONT FORK EAS00647 FRONT FORK Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front cowling assembly Refer to “COWLINGS” AND “COVERS” in chapter 3.
Page 257 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 Damper adjusting rod Spacer Washer Refer to “DISASSEMBLING/ Fork spring ASSEMBLING THE FRONT FORK LEGS”.
Page 258 CHAS FRONT FORK Order Job/Part Q’ty Remarks Damper rod assembly Refer to “DISASSEMBLING/ ASSEMBLING THE FRONT FORK Inner tube LEGS”. Oil seal Seal spacer Refer to “ASSEMBLING THE FRONT Outer tube bushing FORK LEGS”. Inner tube bushing Oil flow stopper Outer tube For assembly, reverse the disassembly procedure.
Page 259: Removing The Front Fork Legs
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 260 CHAS FRONT FORK 4. Remove: • dust seal 1 • oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. NOTE: • Do not remove the fork leg protector from the outer tube. • If the front fork leg protector must be removed, always install a new one.
Page 261: Checking The Front Fork Legs
CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.
Page 262: Assembling The Front Fork Legs
2 until it pro- trudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 01 or equivalent 4 - 66...
Page 263 CHAS FRONT FORK 3. Tighten: • damper rod assembly bolt 1 35 Nm (3.5 m · kg, 25 ft · lb) NOTE: • If the washer has not been removed during disassembly, strike the washer lightly, and then remove it. •...
Page 264 CHAS FRONT FORK 6. Install: • oil seal clip 1 NOTE: Adjust the oil seal clip so that it fits into the groove of the outer tube. 7. Install: • dust seal 1 (with the fork seal driver) 8. Fully compress the front fork leg. 9.
Page 265 CHAS FRONT FORK 11.Slowly stroke the inner tube 1 up and down. 12.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. NOTE: Be sure to bleed the front fork leg of any resid- ual air.
Page 266: Installing The Front Fork Legs
CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg NOTE: • Make sure that the inner tube end is flush with the top of the upper bracket. •...
Page 267 CHAS FRONT FORK 3. Install: • collar 1 • collar 2 • front fender 3 • front fender bolts 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: • Install the collar 1 from the outside of the front fender.
Page 268: Handlebars
CHAS HANDLEBARS EAS00665 HANDLEBARS LEFT HANDLEBAR Order Job/Part Q’ty Remarks Removing the left handlebar Remove the parts in the order listed. Clutch switch coupler Disconnect. Clutch master cylinder holder Clutch master cylinder Refer to “REMOVING/INSTALLING THE Left handlebar switch HANDLEBARS”. Grip end Handlebar grip Left handlebar...
Page 269: Right Handlebar
CHAS HANDLEBARS RIGHT HANDLEBAR Order Job/Part Q’ty Remarks Removing the right handlebar Remove the parts in the order listed. Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Grip end Refer to “REMOVING/ Throttle cable housing INSTALLING THE HANDLEBARS”.
Page 270: Removing The Handlebars
CHAS HANDLEBARS EAS00667 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip NOTE: Blow compressed air between the left handle- bar and the handlebar grip, and gradually push the grip off the handlebar.
Page 271: Installing The Handlebars
CHAS HANDLEBARS EAS00674 INSTALLING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Install: • right handlebar switch 1 NOTE: Align the projection a on the right handlebar switch with the hole b in the right handlebar.
Page 272 CHAS HANDLEBARS 4. 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. • First, tighten the upper bolt, and then the lower bolt.
Page 273 CHAS HANDLEBARS 7. Install: • clutch master cylinder • clutch master cylinder holder 1 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the slit in the clutch master cylinder holder with the punch mark a in the left han- dlebar.
Page 274: Steering Head
CHAS STEERING HEAD EAS00676 STEERING HEAD Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. Front fork legs Refer to “FRONT FORK”. Handlebars Refer to “HANDLEBARS”. Lead guide Main switch coupler Disconnect.
Page 275 CHAS STEERING HEAD Order Job/Part Q’ty Remarks Lock washer Upper ring nut Refer to “REMOVING THE LOWER Rubber washer BRACKET” and “INSTALLING THE STEERING HEAD”. Lower ring nut Lower bracket Bearing cover Bearing inner race Upper bearing Lower bearing Bearing outer race Dust seal For installation, reverse the removal procedure.
Page 276: Removing The Lower Bracket
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: • lower ring nut 1 (with the special tool 2) Spanner wrench YU-33975 WARNING...
Page 277: Installing The Steering Head
CHAS STEERING HEAD b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new rubber seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: •...
Page 278 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 and upper bracket pinch bolts. 5. Tighten: •...
Page 279: Rear Shock Absorber Assembly And Relay Arm
REAR SHOCK ABSORBER ASSEMBLY AND RELAY CHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM 64 Nm (6.4 m kg, 46 ft • • 40 Nm (4.0 m kg, 29 ft • • 13 10 13 12 40 Nm (4.0 m kg, 29 ft •...
Page 280 REAR SHOCK ABSORBER ASSEMBLY AND RELAY CHAS 64 Nm (6.4 m kg, 46 ft • • 40 Nm (4.0 m kg, 29 ft • • 13 10 13 12 40 Nm (4.0 m kg, 29 ft • • 55 Nm (5.5 m kg, 40 ft •...
Page 281: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY AND RELAY CHAS 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 282: Checking The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY AND RELAY CHAS 2. Remove: • rear shock absorber assembly lower bolt 1 • connecting arms NOTE: While removing the connecting arm bolt, hold the swingarm so that it does not drop down. 3. Remove: • rear shock absorber assembly upper bolt 1 •...
Page 283: Installing The Relay Arm
REAR SHOCK ABSORBER ASSEMBLY AND RELAY CHAS 2. Check: • bearings • oil seals Damage/pitting → Replace. 3. Check: • spacers Damage/scratches → Replace. INSTALLING THE RELAY ARM 1. Lubricate: • spacers • bearings Recommended lubricant Lithium soap base grease 2.
Page 284: Swingarm
CHAS SWINGARM EAS00701 SWINGARM Order Job/Part Q’ty Remarks Removing the swingarm Remove the parts in the order listed. Mufflers Refer to “ENGINE” in chapter 5. Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. Final drive assembly/universal joint Refer to “SHAFT DRIVE”. Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER ASSEMBLY AND RELAY ARM”.
Page 285 CHAS SWINGARM Order Job/Part Q’ty Remarks Oil seal Bearing Refer to “INSTALLING THE SWINGARM”. Spacer Oil seal Bushing Oil seal Circlip Bearing Spacer Bearing Refer to “INSTALLING THE SWINGARM”. For installation, reverse the removal procedure. 4 - 89...
Page 286: Removing The Swingarm
CHAS SWINGARM EAS00702 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2.
Page 287: Installing The Swingarm
CHAS SWINGARM 2. Check: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent pivot shaft. 3. Wash: • pivot shaft • spacers • bushing • bearings Recommended cleaning solvent Kerosene 4.
Page 288 CHAS SWINGARM 3. Install: • bearing 1 (to the swingarm) Installed depth a 4.0 mm (0.16 in) 4 - 92...
Page 289: Shaft Drive
CHAS SHAFT DRIVE EAS00715 SHAFT DRIVE TROUBLESHOOTING Symptom Possible cause 1. A pronounced hesitation or jerky movement A. Bearing damage during acceleration, deceleration or sustained B. Improper gear backlash speeds. (not to be confused with engine surg- C. Damaged gear teeth ing or transmission-related movements.) D.
Page 290 CHAS SHAFT DRIVE Inspection notes 1. Investigate any unusual noises. M MMM M MMM M MMM M MMM M MMM The following noises may indicate a mechanical defect: a. A rolling “rumble” during coasting, accelera- tion or deceleration (increases with the rear wheel speed, but does not increase with higher engine or transmission speeds).
Page 291 CHAS SHAFT DRIVE EAS00716 Troubleshooting chart When causes (A) or (B) shown in the table at the beginning of the “TROUBLESHOOTING” section exist, check the following points. Place the motorcycle on a suitable stand so YES Replace the wheel bearing. that the front wheel is elevated and then Refer to “FRONT WHEEL AND BRAKE spin the front wheel.
Page 292: Checking The Final Drive Oil For Contamination And Checking The Shaft Drive For Leaks
CHAS SHAFT DRIVE EAS00717 CHECKING THE FINAL DRIVE OIL FOR CONTAMINATION AND CHECKING THE SHAFT DRIVE FOR LEAKS 1. Drain: • final drive oil (from the final drive housing) Refer to “CHANGING THE FINAL DRIVE OIL” in chapter 3. 2. Check: •...
Page 293: Measuring The Ring Gear Backlash
CHAS SHAFT DRIVE EAS00719 MEASURING THE RING GEAR BACKLASH 1. Secure the final drive assembly in a vise. 2. Remove: • final drive oil drain bolt 3. Drain: • final drive oil (from the final drive assembly) 4. Measure: • ring gear backlash Out of specification →...
Page 294: Adjusting The Ring Gear Backlash
CHAS SHAFT DRIVE EAS00720 ADJUSTING THE RING GEAR BACKLASH 1. Remove: • ring gear bearing housing nuts • ring gear bearing housing bolts NOTE: Working in a crisscross pattern, loosen each nut 1/4 of a turn. After all of the nuts are fully loosened, remove them and the bolts.
Page 295: Measuring The Ring-Gear-To-Stopper-Bolt Clearance
CHAS SHAFT DRIVE EAS00721 MEASURING THE RING-GEAR-TO- STOPPER-BOLT CLEARANCE 1. Remove: • ring gear bearing housing (along with the ring gear) Refer to “ADJUSTING THE RING GEAR BACKLASH”. 2. Measure: • ring-gear-to-stopper-bolt clearance a Out of specification → Adjust. Ring-gear-to-stopper-bolt clear- ance 0.30 ~ 0.60 mm (0.01 ~ 0.02 in) 1 Stopper bolt...
Page 296 CHAS SHAFT DRIVE 3. Install: • stopper bolt shim(s) 1 • stopper bolt 2 9 Nm (0.9 m · kg, 6.5 ft · lb) • ring gear 3 • ring gear bearing housing CAUTION: • The stopper bolt has left-hand threads. To tighten the stopper bolt, turn it counter- clockwise.
Page 297 CHAS SHAFT DRIVE EAS00718 Order Job/Part Q’ty Remarks Removing the final drive assembly Remove the parts in the order listed. Final gear oil Drain. Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. Final drive assembly Refer to “INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY”.
Page 298 CHAS SHAFT DRIVE Order Job/Part Q’ty Remarks Removing the universal joint Remove the parts in the order listed. Final drive assembly Shift arm Refer to “INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY”. Left footrest bracket Refer to “REMOVING THE LEFT FOOTREST BRACKET”.
Page 299 CHAS SHAFT DRIVE EAS00723 Order Job/Part Q’ty Remarks Disassembling the final drive Remove the parts in the order listed. assembly Circlip Oil seal Drive shaft Spring Ring gear bearing housing/oil seal Dust cover Ring gear/bearing Refer to “ALIGNING Ring gear shim(s) THE FINAL DRIVE PINION GEAR AND Thrust washer...
Page 300 CHAS SHAFT DRIVE Order Job/Part Q’ty Remarks Left-hand threads. Refer to “DISASSEMBLING Gear coupling THE FINAL DRIVE Bearing retainer/oil seal Left-hand threads. ASSEMBLY” and Final drive pinion gear/bearing “ALIGNING THE Final drive pinion gear shim(s) FINAL DRIVE Bearing PINION GEAR AND Bearing RING GEAR”.
Page 301: Removing The Left Footrest Bracket
CHAS SHAFT DRIVE REMOVING THE LEFT FOOTREST BRACKET 1. Remove: • left footrest bracket bolt 1 (with the T50 torx wrench) EAS00724 DISASSEMBLING THE FINAL DRIVE ASSEMBLY 1. Remove: • ring gear bearing housing nuts • ring gear bearing housing bolts NOTE: Working in a crisscross pattern, loosen each nut 1/4 of a turn.
Page 302: Removing And Installing The Ring Gear Bearings
CHAS SHAFT DRIVE 4. Remove: • bearing retainer (with the piston bearing retainer remover Piston bearing retainer remover YU-04050 CAUTION: The bearing retainer has left-hand threads. To loosen the bearing retainer, turn it clockwise. 5. Remove: • final drive pinion gear WARNING Always use new bearings.
Page 303 • oil seal 2 • bearing 3 (with a suitable press tool 4 and an appro- priate support for the final drive housing) NOTE: The bearing can be reused, but Yamaha rec- ommends installing a new one. 4 - 107...
Page 304: Aligning The Final Drive Pinion Gear And Ring Gear
CHAS SHAFT DRIVE EAS00726 ALIGNING THE FINAL DRIVE PINION GEAR AND RING GEAR NOTE: Aligning the final drive pinion gear and ring gear is necessary when any of the following parts are replaced: • Final drive housing • Ring gear bearing housing •...
Page 305 CHAS SHAFT DRIVE Therefore, the calculated final drive pinion gear shim thickness is 0.51 mm (0.02 in). Shim sizes are supplied in the following thicknesses. Final drive pinion gear shims Thickness (mm) 0.30 0.40 0.50 Since the final drive pinion gear shims are only available in 0.10 mm (0.004 in) increments, round off to the hundredths digit.
Page 306 CHAS SHAFT DRIVE Example: If the final drive housing is marked “51”, the ring gear bearing housing is marked “35”, the ring gear is marked “– 05”, and “f” is 13.00: B = (45 + 51/100) + (3 + 35/100) – [(35.40 –...
Page 307 CHAS SHAFT DRIVE 2. Install: • shims (as calculated) • final drive pinion gear • bearing retainer 110 Nm (11.0 m · kg, 80 ft · lb) (with the piston bearing retainer remover CAUTION: The bearing retainer has left-hand threads. To tighten the bearing retainer, turn it counterclockwise.
Page 308 CHAS SHAFT DRIVE 7. Measure: • ring-gear-to-thrust-washer clearance M MMM M MMM M MMM M MMM M MMM a. Remove the ring gear bearing housing (along with the ring gear). ® b. Place four pieces of Plastigauge between the original thrust washer and the ring gear. c.
Page 309: Checking The Drive Shaft
CHAS SHAFT DRIVE EAS00727 CHECKING THE DRIVE SHAFT 1. Check: • drive shaft splines Damage/wear → Replace the drive shaft. EAS00728 INSTALLING THE UNIVERSAL JOINT AND FINAL DRIVE ASSEMBLY 1. Lubricate: • universal joint splines • drive shaft splines Recommended lubricant Lithium soap base grease 2.
Page 310: Eng
ENGINE EAS00188 ENGINE ENGINE MUFFLERS AND EXHAUST PIPE ASSEMBLY Order Job/Part Q’ty Remarks Removing the mufflers and exhaust Remove the parts in the order listed. pipe assembly Seats/fuel tank/T-bar/rubber seat Refer to “SEATS AND FUEL TANK” in chapter 3. Side cowlings/front cowling assembly Refer to “COWLINGS”...
Page 311: Leads And Hoses
ENGINE LEADS AND HOSES Order Job/Part Q’ty Remarks Removing the leads and hoses Remove the parts in the order listed. Air filter case Refer to “AIR FILTER CASE” in chapter Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. Air cut-off valve assembly/hoses/reed Refer to “AIR INDUCTION SYSTEM”...
Page 312 ENGINE Order Job/Part Q’ty Remarks Left footrest bracket/dust cover Refer to “SHAFT DRIVE” in chapter 4. Clutch release cylinder Dowel pin Sidestand switch coupler Disconnect. Crankcase breather hose Starter motor lead Disconnect. Stator assembly coupler Disconnect. Oil level sensor connector Disconnect.
Page 313 ENGINE EAS00191 ENGINE 45 Nm (4.5 m kg, 32 ft • • 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • 45 Nm (4.5 m kg, 32 ft • • 55 Nm (5.5 m kg, 40 ft •...
Page 314 ENGINE 45 Nm (4.5 m kg, 32 ft • • 55 Nm (5.5 m kg, 40 ft • • 55 Nm (5.5 m kg, 40 ft • • 45 Nm (4.5 m kg, 32 ft • • 55 Nm (5.5 m kg, 40 ft •...
Page 315: Installing The Engine
ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: • spacer 1 • spacer bolt 2 • rear lower mounting bolt 3 • rear upper mounting bolt 4 • front mounting bolts 5, 6 • engine bracket 2 7 • engine bracket 1 8 NOTE: Do not fully tighten the bolts.
Page 316 ENGINE 4. Tighten the bolts in the following order. • bolts (engine bracket 2 and engine) 1 36 Nm (3.6 m · kg, 25 ft · lb) • bolts (engine bracket 2 and frame) 2 16 Nm (1.6 m · kg, 11 ft · lb) 5.
Page 317: Camshafts
CAMSHAFTS EAS00194 CAMSHAFTS CYLINDER HEAD COVER 10 Nm (1.0 m kg, 7.2 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed.
Page 318: Camshafts
CAMSHAFTS EAS00196 CAMSHAFTS Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. Pickup coil rotor cover Refer to “PICKUP COIL ROTOR”. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Refer to “REMOVING/INSTALLING THE Exhaust camshaft cap...
Page 319 CAMSHAFTS Order Job/Part Q’ty Remarks Timing chain guide (exhaust side) Timing chain guide (intake side) For installation, reverse the removal procedure. 5 - 10...
Page 320: Removing The Camshafts
CAMSHAFTS EAS00198 REMOVING THE CAMSHAFTS 1. Align: • “T” mark on the pickup coil rotor (with the crankcase mating surface) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T”...
Page 321: Checking The Camshafts
CAMSHAFTS 5. Remove: • intake camshaft 1 • exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3. EAS00204 CHECKING THE CAMSHAFTS 1. Check: • camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft.
Page 322: Checking The Camshaft Sprockets
CAMSHAFTS M MMM M MMM M MMM M MMM M MMM a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). 1 onto the ® b. Position a strip of Plastigauge camshaft journal as shown. c.
Page 323: Checking The Timing Chain Tensioner
CAMSHAFTS EAS00210 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage/rough movement → Replace. M MMM M MMM M MMM M MMM M MMM a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1.
Page 324 CAMSHAFTS 2. Install: • exhaust camshaft 1 • intake camshaft 2 (with the camshaft sprockets) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T”...
Page 325 CAMSHAFTS 4. Install: • camshaft cap bolts 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. CAUTION: • Lubricate the camshaft cap bolts with the engine oil.
Page 326 CAMSHAFTS d. Remove the screwdriver, make sure the tim- ing chain tensioner rod releases, and then tighten the cap bolt to the specified torque. Cap bolt 10 Nm (1.0 m · kg, 7.2 ft · lb) L LLL L LLL L LLL L LLL L LLL...
Page 327 CAMSHAFTS 9. Install: • cylinder head cover gasket • cylinder head cover 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Out of specification → Adjust. • Apply bond T1541 1 onto the mating sur- faces of the cylinder head cover and cylinder head cover gasket.
Page 328: Cylinder Head
CYLINDER HEAD EAS00221 CYLINDER HEAD (10) 12 Nm (1.2 m kg, 8.7 ft • • 20 Nm (2.0 m kg, 14 ft • • Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Radiator Refer to “RADIATOR”...
Page 329: Removing The Cylinder Head
CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head bolts NOTE: Loosen each bolt 1/2 of a turn at a time. After all of the bolt are fully loosened, remove them. EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: •...
Page 330: Installing The Cylinder Head
CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. L LLL L LLL L LLL L LLL L LLL...
Page 331 CYLINDER HEAD d. Loosen and retighten the cylinder head bolts in the proper tightening sequence as shown. Cylinder head bolt (M10) 25 Nm (2.5 m · kg, 18 ft · lb) e. Tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence as shown.
Page 332: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Valve lifter Valve pad Valve cotter Upper spring seat Valve spring Refer to “REMOVING/INSTALLING THE VALVES”.
Page 333: Removing The Valves
VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.
Page 334: Checking The Valves And Valve Guides
VALVES AND VALVE SPRINGS 3. Remove: • valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor set 2 and attachment 3. Valve spring compressor set YM-03153 Attachment YM-04108 4. Remove: • upper spring seat 1 •...
Page 335 VALVES AND VALVE SPRINGS 1. Measure: • valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter a – Valve stem diameter b Out of specification → Replace the valve guide. Valve-stem-to-valve-guide clear- ance Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.0031 in) Exhaust 0.025 ~ 0.052 mm...
Page 336: Checking The Valve Seats
VALVES AND VALVE SPRINGS 3. Eliminate: • carbon deposits (from the valve face and valve seat) 4. Check: • valve face Pitting/wear → Grind the valve face. • valve stem end Mushroom shape or diameter larger than the body of the valve stem → Replace the valve.
Page 337 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) <Limit>: 1.6 mm (0.0630 in) Exhaust: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) M MMM...
Page 338: Checking The Valve Springs
VALVES AND VALVE SPRINGS c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.
Page 339: Checking The Valve Lifters
VALVES AND VALVE SPRINGS 2. Measure: • compressed valve spring force a Out of specification → Replace the valve spring. b Installed length Compressed valve spring force (installed) 13.9 ~ 16.1 kg at 33 mm (30.6 ~ 35.5 lb at 1.30 in) 3.
Page 340: Installing The Valves
VALVES AND VALVE SPRINGS EAS00249 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 341 VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor set 2 and attachment 3. Valve spring compressor set YM-04019 Attachment YM-04108 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
Page 342: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH EAS00343 GENERATOR AND STARTER CLUTCH GENERATOR ROTOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Removing the generator rotor and Remove the parts in the order listed. starter clutch Fuel tank/seats/T-bar/rubber seat Refer to “SEATS AND FUEL TANK” in chapter 3.
Page 343 GENERATOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Starter clutch idle gear shaft starter clutch idle gear Generator rotor Refer to “REMOVING/INSTALLING THE GENERATOR”. Woodruff key Starter clutch gear Refer to “REMOVING/INSTALLING THE STARTER CLUTCH”. Starter clutch For installation, reverse the removal procedure.
Page 344: Stator Assembly
GENERATOR AND STARTER CLUTCH STATOR ASSEMBLY Order Job/Part Q’ty Remarks Removing the stator assembly Remove the parts in the order listed. Lead holder Refer to “INSTALLING THE GENERA- Stator assembly TOR”. For installation, reverse the removal procedure. 5 - 35...
Page 345: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS00346 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 346: Removing The Starter Clutch
GENERATOR AND STARTER CLUTCH REMOVING THE STARTER CLUTCH 1. Remove: • starter clutch bolts 1 • starter clutch NOTE: While holding the generator rotor with the pri- mary sheave holder, remove the starter clutch bolts. Primary sheave holder YS-01880-A EAS00351 CHECKING THE STARTER CLUTCH 1.
Page 347: Installing The Starter Clutch
GENERATOR AND STARTER CLUTCH b. When turning the starter clutch drive gear clockwise È, the starter clutch and the starter clutch drive gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch drive gear counterclockwise É, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
Page 348 GENERATOR AND STARTER CLUTCH 2. Install: • stator assembly 1 10 Nm (1.0 m · kg, 7.2 ft · lb) • lead holder 2 6 Nm (0.6 m · kg, 4.3 ft · lb) 3. Install: • woodruff key • generator rotor •...
Page 349: Pickup Coil Rotor
PICKUP COIL ROTOR PICKUP COIL ROTOR Order Job/Part Q’ty Remarks Removing the pickup coil rotor Remove the parts in the order listed. Fuel tank/seats/T-bar/rubber seat Refer to “SEATS AND FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter Side covers/front cowling assembly Refer to “COWLINGS AND COVERS”...
Page 350 PICKUP COIL ROTOR Order Job/Part Q’ty Remarks Dowel pin Crankshaft position sensor coupler Disconnect. Crankshaft position sensor Refer to “INSTALLING THE PICKUP COIL ROTOR”. Pickup coil rotor Refer to “REMOVING/INSTALLING THE PICKUP COIL ROTOR”. For installation, reverse the removal procedure. 5 - 41...
Page 351: Removing The Pickup Coil Rotor
PICKUP COIL ROTOR REMOVING THE PICKUP COIL ROTOR 1. Remove: • pickup coil rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
Page 352 PICKUP COIL ROTOR 2. Tighten: • pickup coil rotor bolt 1 45 Nm (4.5 m · kg, 32 ft · lb) NOTE: While holding the generator rotor 2 with the primary sheave holder 3, tighten the pickup coil rotor bolt. Primary sheave holder YS-01880-A 3.
Page 353: Clutch
CLUTCH EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 m kg, 8.7 ft • • (10) 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Right side cowling Refer to “COWLINGS AND COVERS”...
Page 354: Clutch
CLUTCH EAS00274 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch release cylinder Refer to “HYDRAULIC CLUTCH” in chap- ter 4. Rear balancer Refer to “BALANCERS”. Oil guide plate Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate...
Page 355 CLUTCH Order Job/Part Q’ty Remarks Lock washer Clutch boss Wire circlip Clutch plate 2 Friction plate 3 Refer to “REMOVING/INSTALLING THE CLUTCH”. Clutch damper spring Clutch damper spring seat Thrust washer Spacer Clutch housing For installation, reverse the removal procedure. 5 - 46...
Page 356: Removing The Clutch
CLUTCH EAS00275 EAS00277 REMOVING THE CLUTCH 1. Remove: • rear balancer weight Refer to “BALANCERS”. 2. Remove: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 357: Checking The Friction Plates
CLUTCH 6. Remove: • spacer 1 NOTE: • Insert a cross-headed screwdriver into one of the holes of the clutch housing and primary driven gear, and then rotate the inner pri- mary driven gear until both primary driver gears are aligned. The teeth of both primary driven gears must be aligned for installation.
Page 358: Checking The Clutch Plates
CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification →...
Page 359: Checking The Clutch Boss
CLUTCH EAS00285 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EAS00286 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage →...
Page 360: Installing The Clutch
CLUTCH EAS00294 INSTALLING THE CLUTCH 1. Install: • clutch housing 1 NOTE: • Make sure that the slots a into the clutch housing align with the tabs b onto the oil pump drive sprocket. • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly.
Page 361 CLUTCH 4. Install: • thrust washer • clutch boss 1 • lock washer • clutch boss nut 2 90 Nm (9.0 m · kg, 65 ft · lb) NOTE: While holding the clutch boss with the univer- sal clutch holder 3, tighten the clutch boss nut.
Page 362 CLUTCH 9. Install: • friction plates • clutch plates NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate. 10.Install: • pressure plate 1 • clutch spring plate seat 2 • clutch spring plate 3 •...
Page 363: Shift Shaft
SHIFT SHAFT EAS00326 SHIFT SHAFT Order Job/Part Q’ty Remarks Removing the shift shaft Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Clutch housing Refer to “CLUTCH”. Oil baffle plate Shift arm Circlip Shift shaft...
Page 364 SHIFT SHAFT Order Job/Part Q’ty Remarks Stopper lever spring Refer to “INSTALLING THE SHIFT SHAFT”. Stopper lever Circlip Collar Shift shaft spring stopper For installation, reverse the removal procedure. 5 - 55...
Page 365: Checking The Shift Shaft
SHIFT SHAFT EAS00329 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 • shift shaft pawl 2 Bends/damage/wear → Replace. • shift shaft spring 3 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage →...
Page 366 SHIFT SHAFT 3. Install: • shift arm 1 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the punch mark a in the shift shaft with the slot in the shift arm. 5 - 57...
Page 367: Oil Pan And Oil Pump
OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed. Exhaust pipe assembly Refer to “ENGINE”. Air filter case Refer to “AIR FILTER CASE” in chapter Engine oil Drain.
Page 368 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Oil strainer Refer “INSTALLING STRAINER”. Dowel pin Oil pump Refer to “INSTALLING THE OIL PUMP”. Relief valve assembly For installation, reverse the removal procedure. 5 - 59...
Page 369: Oil Pump
OIL PAN AND OIL PUMP EAS00360 OIL PUMP Order Job/Part Q’ty Remarks Disassembling the oil pump Remove the parts in the order listed. Oil pump housing cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump shaft Oil pump housing For assembly, reverse the disassembly procedure.
Page 370: Removing The Oil Pan
OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: • oil level switch 1 • oil pan 2 • gasket • dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
Page 371: Checking The Relief Valve
OIL PAN AND OIL PUMP 3. Check: • oil pump operation Rough movement → Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 • relief valve 2 •...
Page 372: Installing The Oil Pump
OIL PAN AND OIL PUMP 2. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. EAS00376 INSTALLING THE OIL PUMP 1. Install: • oil pump 1 12 Nm (1.2 m · kg, 8.7 ft · lb) WARNING Align the projection a on the oil pump with the slit b on the impeller shaft.
Page 373 OIL PAN AND OIL PUMP WARNING Always use new copper washers. NOTE: • Tighten the oil pan bolts in stages and in a crisscross pattern. • Lubricate the oil level switch O-ring with engine oil. 5 - 64...
Page 374: Middle Gear
MIDDLE GEAR EAS00431 MIDDLE GEAR Order Job/Part Q’ty Remarks Removing the middle gear Remove the parts in the order listed. Engine Refer to “ENGINE”. Oil pan/oil pump Refer to “OIL PAN AND OIL PUMP”. Left middle gear cover Left middle gear cover gasket Dowel pin Right middle gear cover Bearing...
Page 375 MIDDLE GEAR Order Job/Part Q’ty Remarks Middle drive pinion gear nut Refer to “REMOVING THE MIDDLE Lock washer GEAR” and “INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY”. Middle drive pinion gear Middle drive shaft assembly Spacer Middle driven gear Bearing retainer Refer to “REMOVING THE MIDDLE GEAR”...
Page 376 MIDDLE GEAR Order Job/Part Q’ty Remarks Disassembling the middle drive Remove the parts in the order listed. shaft assembly Spring retainer Refer “DISASSEMBLING/ASSEM- BLING THE MIDDLE DRIVE SHAFT ASSEMBLY”. Spring seat Damper spring Damper driven cam Damper drive cam Middle drive shaft For assembly, reverse the disassembly procedure.
Page 377 MIDDLE GEAR Order Job/Part Q’ty Remarks Disassembling the middle driven Remove the parts in the order listed. shaft assembly Middle driven pinion gear nut Middle driven shaft Middle driven pinion gear Bearing retainer Refer “DISASSEMBLING/ASSEM- BLING THE MIDDLE DRIVEN SHAFT ASSEMBLY”.
Page 378: Removing The Middle Gear
MIDDLE GEAR EAS00432 REMOVING THE MIDDLE GEAR 1. Straighten the punched point of the middle driven shaft nut. 2. Loosen: • middle driven shaft nut 1 NOTE: While holding the middle drive shaft 2. 3. Straighten the lock washer tab. 4.
Page 379: Disassembling The Middle Drive Shaft Assembly
MIDDLE GEAR EAS00433 DISASSEMBLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Remove: • spring retainers 1 NOTE: While compressing the spring with the spring compressor push plate 2, remove the spring retainers. Spring compressor push plate YM-33286 DISASSEMBLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1.
Page 380: Checking The Middle Driven Shaft Assembly
MIDDLE GEAR EAS00439 CHECKING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Check: • middle driven gear Galling/pitting/wear → Replace the middle driven shaft assembly. 2. Check: • bearings Damage/pitting → Replace the middle drive shaft bearing housing assembly. 3. Check: • O-ring •...
Page 381: Installing The Middle Drive Shaft Assembly
MIDDLE GEAR NOTE: Lock the threads on the bearing retainer by staking them with a center punch. 2. Install: • middle driven shaft nut 1 NOTE: Temporarily tighten the middle driven shaft nut. INSTALLING THE MIDDLE DRIVE SHAFT ASSEMBLY 1. Install: •...
Page 382: Installing The Middle Driven Shaft Assembly
MIDDLE GEAR NOTE: While holding the middle drive shaft 2. 3. Bend the lock washer tab along a flat side of the nut. INSTALLING THE MIDDLE DRIVEN SHAFT ASSEMBLY 1. Install: • middle driven shaft assembly 1 • middle driven shaft shims 2 •...
Page 383: Measuring The Middle Gear Backlash
MIDDLE GEAR 3. Tighten: • middle driven shaft bearing housing bolts 25 Nm (2.5 m · kg, 18 ft · lb) NOTE: Before tightening the bolts: 1. Adjust the middle gear backlash. Refer to “ADJUSTING THE MIDDLE GEAR BACKLASH”. 2. Check that the middle driven gear turns smoothly.
Page 384: Adjusting The Middle Gear Backlash
MIDDLE GEAR d. While gently turning the middle driven shaft back and forth, measure the middle gear backlash. NOTE: Measure the middle gear backlash at four positions. Rotate the middle driven shaft 90° each time and observe the reading on the dial gauge.
Page 385 MIDDLE GEAR NOTE: • Tighten the middle driven shaft bearing housing bolts carefully, one thread turn at a time only. Push in the middle driven shaft bearing housing and then tighten the bolts to specification. • Clearance between the crankcase and the middle driven shaft bearing housing should be approximately 2 mm (0.08 in), when mea- sured with a thickness gauge 1.
Page 386 MIDDLE GEAR 7. Select: • shim(s) 1 M MMM M MMM M MMM M MMM M MMM a. Shims can only be selected in 0.05 mm (0.002 in) increments, therefore round off to the hundredth’s digit of the calculated thick- ness and select the appropriate shim with the following chart.
Page 387: Aligning The Middle Gear
MIDDLE GEAR EAS00452 ALIGNING THE MIDDLE GEAR NOTE: Aligning the middle gear is necessary when any of the following parts are replaced: • Crankcase • Middle drive shaft • Middle driven shaft bearing housing 1. Select: • middle drive shaft shim(s) 1 •...
Page 388 MIDDLE GEAR NOTE: In the above example, the calculated number is 0.51. The chart instructs you to round off the 1 to 0. Thus, the shim thickness is 0.50 mm (0.002 in). Hundredth Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thick- nesses.
Page 389 MIDDLE GEAR Hundredth Rounded value 0, 1, 2 3, 4, 5, 6, 7 8, 9 Shims are supplied in the following thick- nesses. Middle drive shaft shim 0.10 0.15 0.30 Thickness (mm) 0.40 0.50 0.60 L LLL L LLL L LLL L LLL L LLL 5 - 80...
Page 390: Crankcase
CRANKCASE CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”.
Page 391 CRANKCASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Collar Spacer Neutral switch Speed sensor Lower crankcase Refer “DISASSEMBLING/ASSEM- BLING THE CRANKCASE”. Dowel pin For installation, reverse the removal procedure.
Page 392 CRANKCASE 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Removing the oil baffle plates and Remove the parts in the order listed. bearings Connecting rod assemblies Refer to “CONNECTING RODS AND...
Page 393 CRANKCASE 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Part Q’ty Remarks Oil seal Bearing Upper crankcase Bearing Oil filter bolt Lower crankcase For installation, reverse the removal procedure.
Page 394: Disassembling The Crankcase
CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • Loosen the bolts in decreasing numerical order (refer to the numbers in the illustra- tion).
Page 395: Checking The Crankcase
CRANKCASE EAS00399 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • crankcase Cracks/damage → Replace. • oil delivery passages Obstruction → Blow out with compressed air.
Page 396: Checking The Timing Chain And Oil Pump Drive Chain
CRANKCASE EAS00208 CHECKING THE TIMING CHAIN AND OIL PUMP DRIVE CHAIN The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: • timing chain 1 Damage/stiffness → Replace the timing chain and camshaft sprockets as a set. •...
Page 397 CRANKCASE 2. 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 or crankshaft journal bear- ings. Do not apply sealant to within 2 ~ 3 mm (0.08 ~ 0.12 in) of the crankshaft journal bear- ings.
Page 398 CRANKCASE 6. Install: • crankcase bolts NOTE: • Lubricate the bolt threads and washers with engine oil. • Finger tighten the crankcase bolts. 1 ~ 0 M9 × 115 mm bolts: M8 × 65 mm bolts: M8 × 50 mm bolts: M, O M6 ×...
Page 399 CRANKCASE c. Tighten the crankcase bolts further to reach the specified angle 120° in the proper tight- ening sequence as shown. Crankcase bolt 1 ~ 0 Final Specified angle 120° WARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it.
Page 400 CONNECTING RODS AND PISTONS EAS00252 CONNECTING RODS AND PISTONS Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Crankcase Separate. Refer to “CRANKCASE”. Connecting rod cap Big end lower bearing Piston pin clip Piston pin Refer to “REMOVING THE CONNECT- Piston...
Page 401: Removing The Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap 1 • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
Page 402: Checking The Cylinders And Pistons
CONNECTING RODS AND PISTONS 3. Remove: • top ring • 2nd ring • oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. EAS00258 CHECKING THE CYLINDERS AND PISTONS...
Page 403: Checking The Piston Rings
CONNECTING RODS AND PISTONS c. Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.20 in) from the bottom edge of the pis- Piston size “P” 78.965 ~ 78.980 mm Standard (3.1089 ~ 3.1094 in) d. If out of specification, replace the piston and piston rings as a set.
Page 404: Checking The Piston Pins
CONNECTING RODS AND PISTONS 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown. a 5 mm (0.20 in) 3. Measure: • piston ring end gap Out of specification → Replace the piston ring.
Page 405 CONNECTING RODS AND PISTONS 2. Measure: • piston pin outside diameter a Out of specification → Replace the piston pin. Piston pin outside diameter 18.991 ~ 19.000 mm (0.7477 ~ 0.7480 in) <Limit>: 19.045 mm (0.7498 in) 3. Measure: • piston pin bore diameter (in the piston) b Out of specification →...
Page 406: Checking The Connecting Rods
CONNECTING RODS AND PISTONS EAS00396 CHECKING THE CONNECTING RODS 1. Measure: • crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-end-bear- ing clearance 0.021 ~ 0.039 mm (0.0008 ~ 0.0015 in) M MMM M MMM M MMM M MMM M MMM The following procedure applies to all of the...
Page 407 CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Refer to “INSTALLING THE CONNECTING RODS AND PISTONS”. f. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS”. ® g. Measure the compressed Plastigauge width e on the crankshaft pin.
Page 408: Installing The Connecting Rods And Pistons
CONNECTING RODS AND PISTONS EAS00271 EAS00404 INSTALLING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the pistons and connecting rods. 1. Install: • top ring • 2nd ring • oil ring NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
Page 409 CONNECTING RODS AND PISTONS 4. Lubricate: • piston • piston rings • cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Lubricate: • bolt threads • nut seats (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 6. Lubricate: •...
Page 410 CONNECTING RODS AND PISTONS • Make sure the “Y” marks a on the connect- ing rods face towards the left side of the crankshaft. • Make sure the characters b on both the con- necting rod and connecting rod cap are aligned.
Page 411 CONNECTING RODS AND PISTONS WARNING When the nuts are tightened more than the specified angle, do not loosen the nut and then retighten it. Replace the nut with a new one and per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the nut to the specified angle.
Page 412: Crankshaft
CRANKSHAFT EAS00381 CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Refer to “REMOVING/INSTALLING THE Crankshaft journal lower bearing CRANKSHAFT”.
Page 413: Removing The Crankshaft
CRANKSHAFT EAS00387 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 • crankshaft journal lower bearings (from the lower crankcase) • crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal bearing so that it can be reinstalled in its origi- nal place.
Page 414 CRANKSHAFT CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crankshaft journal bearings must installed in their original positions. M MMM M MMM M MMM M MMM M MMM a.
Page 415 CRANKSHAFT ® h. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. L LLL L LLL L LLL L LLL L LLL 4. Select: •...
Page 416: Installing The Crankshaft
CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearings (into the upper crankcase) • crankshaft journal lower bearings (into the lower crankcase) NOTE: • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase.
Page 417: Transmission
TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE”. Drive axle assembly Bearing Washer Shift drum retainer Refer to “INSTALLING THE TRANSMIS- Long shift fork guide bar SION”.
Page 418 TRANSMISSION Order Job/Part Q’ty Remarks Shift drum assembly Refer to “INSTALLING THE TRANSMIS- SION”. Shift fork “C” Main axle assembly Refer to “REMOVING/INSTALLING THE TRANSMISSION”. For installation, reverse the removal procedure. 5 - 109...
Page 419 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle assem- Remove the parts in the order listed. 2nd pinion gear Toothed lock washer Toothed lock washer retainer 5th pinion gear Toothed spacer Toothed washer Circlip 3rd pinion gear 4th pinion gear Collar 5 - 110...
Page 420 TRANSMISSION Order Job/Part Q’ty Remarks Main axle/1st pinion gear Bearing Main axle bearing housing For assembly, reverse the disassembly procedure. 5 - 111...
Page 421 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly Middle drive gear Bearing Washer 2nd wheel gear Collar washer 5th wheel gear Circlip Toothed washer 3rd wheel gear 5 - 112...
Page 422 TRANSMISSION Order Job/Part Q’ty Remarks Toothed spacer Toothed lock washer Toothed lock washer retainer 4th wheel gear Washer 1st wheel gear Bearing Washer Drive axle For assembly, reverse the disassembly procedure. 5 - 113...
Page 423: Removing The Transmission
TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: • bearing housing bolts 1 (with the Torx wrench T30) 2. Remove: • main axle assembly (from the clutch side) NOTE: Remove the main axle assembly with the slide hammer bolt 1 and weight. Slide hammer bolt YU-01083-1 Weight...
Page 424: Checking The Shift Drum Assembly
TRANSMISSION 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat surface. Bends → Replace. WARNING Do not attempt to straighten a bent shift fork guide bar. 3. Check: • shift fork movement (along the shift fork guide bar) Rough movement →...
Page 425 TRANSMISSION 2. Measure: • drive axle runout (with a centering device and dial gauge 1) Out of specification → Replace the drive axle. Drive axle runout limit 0.08 mm (0.003 in) 3. Check: • transmission gears Blue discoloration/pitting/wear → Replace the defective gear(s).
Page 426: Installing The Transmission
TRANSMISSION INSTALLING THE TRANSMISSION 1. Install: • main axle assembly 12 Nm (1.2 m · kg, 8.7 ft · lb) • shift fork “C” • shift drum assembly • shift fork “R” • shift fork “L” • shift fork guide bars •...
Page 427: Balancers
BALANCERS BALANCERS FRONT BALANCER Order Job/Part Q’ty Remarks Removing the front balancer Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Balancer lever Balancer shaft Washer Refer to “INSTALLING THE FRONT Bearing BALANCER”. Balancer gear Absorber Balancer weight For installation, reverse the removal procedure.
Page 428: Rear Balancer
BALANCERS REAR BALANCER Order Job/Part Q’ty Remarks Removing the rear balancer Remove the parts in the order listed. Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. Clutch cover Refer to “CLUTCH”. Balancer cover Balancer cover gasket Balancer lever Balancer shaft Washer Refer to “INSTALLING THE REAR BAL-...
Page 429: Checking The Balancer
BALANCERS CHECKING THE BALANCER 1. Check: • front balancer gear Damage/wear → Replace the front bal- ancer gear and crankshaft. • rear balancer gear Damage/wear → Replace the rear balancer gear and primary driven gear. 2. Check: • balancer shaft 1 Cracks/damage/wear →...
Page 430 BALANCERS 3. Install: • balancer shaft 1 NOTE: • Align the punch mark a in the balancer weight with the oil hole b in the upper crank- case. • Make sure that the front balancer gear teeth and the primary drive gear teeth mesh cor- rectly.
Page 431: Installing The Rear Balancer
BALANCERS 7. Start the engine and check that there is no abnormal noise coming from the balancer gear. If noise is abnormal, adjust the gear lash by turning the balancer shaft. NOTE: With each adjustment, turn the balancer shaft one scale. Clockwise Decrease gear lash Counterclockwise...
Page 432 BALANCERS 3. Install: • balancer shaft 1 NOTE: • Align the punch marks a in the balancer weight with the oil hole b in the upper crank- case. • Make sure that the rear balancer gear teeth and the primary driven gear teeth mesh cor- rectly.
Page 433 BALANCERS 5. Tighten: • balancer shaft 1 0.4 Nm (0.04 m · kg, 0.29 ft · lb) NOTE: Tighten the balancer shaft to the specified torque by turning it counterclockwise, and then turn it two scales back on the balancer lever scale.
Page 434: Cool
COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat/fuel tank Refer to “SEATS AND FUEL TANK” in chapter 3. Side cowlings/front cowling assembly Refer to “COWLINGS AND COVERS” in chapter 3.
Page 435 COOL RADIATOR Order Job/Part Q’ty Remarks Radiator outlet hose Thermostat assembly breather hose Disconnect. Conduit Conduit hose Radiator inlet hose Disconnect. Plunger control unit hose 2 Disconnect. Oil cooler outlet hose Disconnect. Horn connector Disconnect. Radiator fan motor coupler Disconnect. Radiator Horn bracket (left and right) Radiator fan...
Page 436: Checking The Radiator
COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radi- ator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.
Page 437: Installing The Radiator
COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3.
Page 438: Oil Cooler
COOL OIL COOLER EAS00457 OIL COOLER Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Radiator assembly Refer to “RADIATOR”. Water pump outlet hose Water pump outlet pipe Water jacket joint inlet hose Water jacket joint...
Page 439: Checking The Oil Cooler
COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: • oil cooler Cracks/damage → Replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thin- ner)
Page 440 COOL OIL COOLER 4. Check: • cooling system Leaks → Repair or replace any faulty part. 5. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR”. 6 - 7...
Page 441: Thermostat
COOL THERMOSTAT EAS00460 THERMOSTAT Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Side cowlings/front cowling assembly Refer to “COWLINGS AND COVERS” in chapter 3. Coolant Drain. Refer to “CHANGING THE COOLANT” in chapter 3. Air cut-off valve assembly/hoses Refer to “AIR INDUCTION SYSTEM”...
Page 442 COOL THERMOSTAT EAS00461 Order Job/Part Q’ty Remarks Disassembling thermostat Remove the parts in the order listed. assembly Thermostat housing cover Refer to “ASSEMBLING THE THERMO- Thermostat STAT ASSEMBLY”. Thermostat housing For assembly, reverse the disassembly procedure. 6 - 9...
Page 443: Checking The Thermostat
COOL THERMOSTAT EAS00463 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 71 ~ 85 °C (159.8 ~ 185.0 °F) → Replace. MMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMMM a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c.
Page 444: Assembling The Thermostat Assembly
COOL THERMOSTAT EAS00464 ASSEMBLING THE THERMOSTAT ASSEMBLY 1. Install: • thermostat housing 1 • thermostat 2 • thermostat housing cover NOTE: Install the thermostat with its breather hole a a facing up. EAS00466 INSTALLING THE THERMOSTAT ASSEMBLY 1. Lubricate: • O-ring (thermostat assembly and thermo- stat assembly inlet pipe) Recommended lubricant 2.
Page 445: Water Pump
COOL WATER PUMP EAS00468 WATER PUMP Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless coolant level extremely low or the coolant contains engine oil.
Page 446 COOL WATER PUMP Order Job/Part Q’ty Remarks Water pump breather hose Disconnect. Radiator outlet hose Disconnect. Water pump outlet hose Disconnect. Water pump Refer to “INSTALLING THE WATER PUMP”. For installation, reverse the removal procedure. 6 - 13...
Page 447 COOL WATER PUMP EAS00469 Order Job/Part Q’ty Remarks Disassembling the water pump Remove the parts in the order listed. Water pump housing cover O-ring Circlip Impeller shaft Rubber damper holder Refer to “ASSEMBLING THE WATER Rubber damper PUMP”. Water pump seal Oil seal Bearing Water pump housing...
Page 448: Disassembling The Water Pump
COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flat-head screwdriver) NOTE: Do not scratch the impeller shaft. 2. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing 2.
Page 449: Assembling The Water Pump
COOL WATER PUMP EAS00475 ASSEMBLING THE WATER PUMP 1. Install: • oil seal 1 (into the water pump housing 2) NOTE: • Before installing the oil seal, apply tap water or coolant onto its out surface. • Install the oil seal with a socket that matches its outside diameter.
Page 450 COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: Make sure the rubber damper and rubber damper holder are flush with the impeller. Max. impeller shaft tilt 0.15 mm (0.006 in) 1 Straightedge 2 Impeller 5.
Page 451: Installing The Water Pump
COOL WATER PUMP EAS00478 INSTALLING THE WATER PUMP 1. Install: • O-ring • water pump assembly 1 12 Nm (1.2 m · kg, 8.7 ft · lb) WARNING • Align the slit a on the impeller shaft with the projection b on the oil pump shaft. •...
Page 452: Fuel Injection System
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Ignition coil 8 Intake air pressure D Coolant temperature J Atmospheric pressure 2 Air filter case sensor sensor sensor 3 Intake temperature 9 Throttle position sensor E Spark plug K Fuel injection system 0 Fuel injector F Cylinder identifica- sensor...
Page 453: Wiring Diagram
FUEL INJECTION SYSTEM WIRING DIAGRAM 7 - 2...
Page 454: Ecu's Self-Diagnostic Function
FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 455 FUEL INJECTION SYSTEM Engine trouble warning light indication and FI system operating conditions (normal mode) Warning light ECU’s operating FI operating condition Starting and driving indication condition ON and OFF *1 Self-diagnostic func- FI function in operation Able tion in operation Blinking *2 Warning control when Operation stopped...
Page 456 FUEL INJECTION SYSTEM Function to check for blown warning light bulb The engine trouble warning light illuminates 1 for 1.4 seconds after the main switch has been turned “ON” and while the starter switch is being pressed. If the warning light does not illuminate under these conditions, a problem may have possibly occurred, such as a blown warning light bulb.
Page 457 FUEL INJECTION SYSTEM * Table of self-diagnostic fault code numbers displayed on meter Able/ Able/ Able/ Able/ Symptom unable to unable to Symptom unable to unable to start drive start drive No normal signals are received The motorcycle has overturned. from the cylinder identification Able Able...
Page 458: Substitute Characteristics Operation Control (Fail-Safe Action)
FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction.
Page 459: Troubleshooting
FUEL INJECTION SYSTEM TROUBLESHOOTING Diagnosis mode troubleshooting 1 (self-diagnostic malfunction detected) By entering a diagnostic code in the ECU through the use of the “SELECT” and “RESET” buttons on the multi-function meter, the sensor output values can be displayed and the actuators can be oper- ated in accordance with the code that has been entered.
Page 460 FUEL INJECTION SYSTEM Verifying the operation of various sensors and actuators 1. Disconnect the wiring harness coupler from the fuel pump. 2. Turn the engine stop switch “OFF”. · Turn the engine stop switch “ON” if diag- nostic code numbers 03 and 09 are TRIP TRIP mile...
Page 461 FUEL INJECTION SYSTEM Erase the codes appearing on the meter upon the completion of the operation (reinstating the ECU). * Verify reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera- tion that is applicable to the malfunctioning item.
Page 462 FUEL INJECTION SYSTEM Self-diagnostic fault codes, symptoms, and probable causes Diagnostic code indication Code No. Symptom Probable cause of malfunction Diagnostic code No normal signals are received from • Open or short circuit in wiring sub lead. the cylinder identification sensor. •...
Page 463 FUEL INJECTION SYSTEM Code No. Symptom Probable cause of malfunction Diagnostic code Atmospheric pressure sensor - open • Open or short circuit in wiring harness. or short circuit detected. • Defective atmospheric pressure sensor. • Improperly installed sensor. • Malfunction in ECU. No normal signals are received from •...
Page 464 FUEL INJECTION SYSTEM Sensor operation data display verification table NOTE: • Check the intake temperature and coolant temperature as close as possible to the area in which the respective sensor is mounted. • If it is not possible to check it with an atmospheric pressure gauge, judge it by using 760 mm Hg (29.92 in Hg) as the standard.
Page 465 FUEL INJECTION SYSTEM Actuator operation verification table Data displayed on meter Diag code Item Description of action (reference value) Ignition coil #1, 4 After 1 second has elapsed from the time the engine stop Check that spark is generated, switch has been turned from OFF to ON, it actuates ignition 5 times with the engine stop coils #1, and 4 for five times every second and illuminates the switch ON.
Page 466 FUEL INJECTION SYSTEM Troubleshooting Basic procedure 1 Inspect battery and fuse Replace fuse Recharge or replace battery Check engine trouble warning light After main switch is turned ON, light turns ON 1.4 seconds and then turns OFF. Light does not turn OFF. Check the starting disable warning function through the engine trouble warning light.
Page 467 FUEL INJECTION SYSTEM Troubleshooting details Troubleshooting the self-diagnostic fault code Code No. Symptom No normal signals are received from the cylinder identification sensor. Used diagnostic code No. Inspection operation item Operation item and countermeasure Reinstatement method Installed state of sensor Check the installed area for looseness or Reinstated by pinching.
Page 468 FUEL INJECTION SYSTEM Code No. Symptom Intake air pressure sensor - open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective intake air pressure sensor Replace if defective.
Page 469 FUEL INJECTION SYSTEM Code No. Symptom 1 Intake air pressure sensor - pipe system malfunction (clogged or detached hose). 2 Intake air pressure sensor - open or short circuit detected. 3 Stuck throttle position sensor detected. Used diagnostic code No. 03 (intake air pressure sensor) No.
Page 470 FUEL INJECTION SYSTEM Code No. Symptom Throttle position sensor - open or short circuit detected. Used diagnostic code No. 01 (throttle position sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective throttle position sensor. Replace if defective. Reinstated by turn- Refer to “FUEL INJECTION SYSTEM”...
Page 471 FUEL INJECTION SYSTEM Code No. Symptom 1 Stuck throttle position sensor detected. 2 Intake air pressure sensor - pipe system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) No. 02 (atmospheric pressure sensor) No. 01 (throttle position sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method...
Page 472 FUEL INJECTION SYSTEM Code No. Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective sidestand switch Replace if defective.
Page 473 FUEL INJECTION SYSTEM Code No. Symptom Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective atmospheric pressure sensor. Replace if defective.
Page 474 FUEL INJECTION SYSTEM Code No. Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective lean angle cut-off switch Replace if defective. Reinstated by turn- ing the main switch The motorcycle has overturned.
Page 475 FUEL INJECTION SYSTEM Code No. Symptom The amount of air-fuel ratio feedback compensation is maintained contin- uously in the vicinity of the lower limit (air-fuel ratio is rich). Used diagnostic code No. 01 (throttle position sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective O...
Page 476 FUEL INJECTION SYSTEM Code No. Symptom Malfunction detected in the primary wire of the ignition coil (#1, 4). Used diagnostic code No. 30 (ignition coil #1, 4) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Defective ignition coil (test the primary and Replace if defective.
Page 477 FUEL INJECTION SYSTEM Code No. Symptom 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) No. 21 (neutral switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1 Defective speed sensor...
Page 478 FUEL INJECTION SYSTEM Code No. Symptom Faulty ECU memory. (When this malfunction is detected in the ECU, the fault code number might not appear on the meter.) Used diagnostic code No. Inspection operation item and probable cause Operation item and countermeasure Reinstatement method Malfunction in ECU...
Page 479 FUEL INJECTION SYSTEM Diagnosis mode troubleshooting 2 (self-diagnostic malfunction not detected) Even if the malfunctions of some of the sensors do not appear on the meter because they are not detected by the self-diagnostic function, they can be inspected in the diagnosis mode. Basic procedure Check the condition and the symptom of the malfunction of the motorcycle.
Page 480 FUEL INJECTION SYSTEM Symptom The headlight does not turn ON or OFF. Probable mal- • Malfunction in the headlight relay 1 function area • Malfunction in the headlight • Open or short circuit in the headlight wiring harness • Malfunction in the handlebar switch •...
Page 481 FUEL INJECTION SYSTEM Symptom Fan does not operate. Probable mal- • Malfunction in radiator fan motor relay function area • Malfunction in fan • Open or short circuit in fan wiring harness Inspection method 1 Inspection method 2 Inspection by diagnosis mode Inspection of a malfunction that cannot be identified in the diagnosis mode, and in case the area of the malfunction has been narrowed down in the inspection method 1 given on the...
Page 482 FUEL INJECTION SYSTEM Symptom Clock LCD displays “Er-2”. (No signals are received from the ECU within the specified duration.) Probable mal- • Improper operation of communication line function area • Malfunction in meter • Malfunction in ECU Inspection method 1 Inspection method 2 Inspection by diagnosis mode Inspection of a malfunction that cannot be identified in the...
Page 483 FUEL INJECTION SYSTEM Symptom Sidestand switch does not function (the engine does not stop when the stand is extended). Probable mal- • Short circuit in the input line to ECU function area • Malfunction in the starter circuit cut-off relay Inspection method 1 Inspection method 2 Inspection by diagnosis mode...
Page 484: Throttle Bodies
FUEL INJECTION SYSTEM THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seats/fuel tank/T-bar/rubber sheet Refer to “SEATS AND FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter Coolant Drain.
Page 485 FUEL INJECTION SYSTEM Order Job/Part Q’ty Remarks Throttle cable Disconnect. Plunger control unit hose 1 Disconnect. Plunger control unit hose 2 Disconnect. Throttle body joint For installation, reverse the removal procedure. 7 - 34...
Page 486 FUEL INJECTION SYSTEM Order Job/Part Q’ty Remarks Removing the injector Remove the parts in the order listed. Canister purge hose Disconnect. Throttle position sensor coupler Disconnect. Intake air pressure sensor Disconnect. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Cylinder #3-injector coupler Disconnect.
Page 487 FUEL INJECTION SYSTEM Order Job/Part Q’ty Remarks Intake air pressure sensor Fuel distributor Injector Throttle position sensor For installation, reverse the removal procedure. 7 - 36...
Page 488: Checking The Injector
FUEL INJECTION SYSTEM CAUTION: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Check: • injector Damage → Replace. CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle bodies. 2. Check: •...
Page 489: Checking The Fuel Pump And Pressure Regulator Operation
FUEL INJECTION SYSTEM CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation M MMM M MMM M MMM M MMM M MMM a. Remove the fuel tank. Refer to “SEATS AND FUEL TANK” in chap- ter 3.
Page 490 FUEL INJECTION SYSTEM h. Use the mity vac set to adjust the fuel pres- sure in relation to the vacuum pressure as described below. NOTE: The vacuum pressure should not exceed 100 kPa (1 mm Hg, 0.039 in Hg). Increase the vacuum pressure → Fuel pressure is decreased Decrease the vacuum pressure →...
Page 491: Air Induction System
AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.
Page 492: Air Induction System Diagrams
AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve È To cylinder #4 2 Reed valve É To cylinder #3 3 Air-filter case Ê To cylinder #2 Ë To cylinder #1 7 - 41...
Page 493: Air Cut-Off Valve Assembly And Air Induction System Hoses
AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES Order Job/Part Q’ty Remarks Removing the air cut-off valve Remove the parts in the order listed. assembly and hoses Rider seat/fuel tank/T-bar/rubber sheet Refer to “SEATS AND FUEL TANK” in chapter 3.
Page 494: Reed Valves
AIR INDUCTION SYSTEM REED VALVES Order Job/Part Q’ty Remarks Removing the reed valves Remove the parts in the order listed. Air cut-off valve assembly/hoses Thermostat assembly Refer to “THERMOSTAT” in chapter 6. Spark plug caps Reed valve cover (1) Reed valve cover (2, 3) Reed valve cover (4) Reed valve assembly Plate...
Page 495: Checking The Air Induction System
AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Check: • fibre reed • fibre reed stopper • reed valve seat Cracks/damage → Replace the reed valve assembly.
Page 496: Canister (For California Only)
CANISTER (FOR CALIFORNIA ONLY) CANISTER (FOR CALIFORNIA ONLY) Order Job/Part Q’ty Remarks Removing the canister Remove the parts in the order listed. Seats/fuel tank/T-bar/rubber sheet Refer to “SEATS AND FUEL TANK” in chapter 3. Air filter case Refer to “AIR FILTER CASE” in chapter Clamp Canister charge hose Disconnect.
Page 497: Elec
– ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS 1 Windshield drive unit 9 Wire harness 2 Battery 0 Neutral switch 3 Starter relay A Sidestand switch 4 Fuel injection system fuse B Oil level switch 5 Front brake switch C Rear brake switch 6 Clutch switch D Horn 7 Fuse box...
Page 498 – ELEC ELECTRICAL COMPONENTS 1 Coolant temperature sensor 9 Cylinder identification sensor 2 Intake air pressure sensor sensor 3 Intake air temperature sensor A Crankshaft position sensor 4 Atmospheric pressure sensor B Headlight relay 1 5 Lean angle cut-off switch C Headlight relay 2 6 ECU D Fuel injection system relay...
Page 499: Checking Switch Continuity
– ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.
Page 500: Checking The Switches
– ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace. Improperly connected → Properly connect. Incorrect continuity reading →...
Page 501 – ELEC CHECKING THE SWITCHES 1 Main fuse 2 Main switch 3 Clutch switch 4 Dimmer switch 5 Horn switch 6 Windshield position switch 7 Turn signal switch 8 Front brake light switch 9 Engine stop switch 0 Start switch A Rear brake light switch B Neutral switch C Sidestand switch...
Page 502: Checking The Bulbs And Bulb Sockets
– ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
Page 503 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb.
Page 504: Checking The Condition Of The Bulb Sockets
– ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE:...
Page 505: Ignition System
– ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM 1 Main switch 5 Main fuse 6 Battery A Starting circuit cut-off relay C Sidestand switch J Lean angle cut-off switch M Crankshaft position sensor N ECU T Cylinder #1, #4 – ignition coil U Cylinder #2, #3 –...
Page 506: Troubleshooting
– ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark). THE BATTERY” in chapter 3. Procedure Minimum open-circuit voltage Check: 12.8 V or more at 20 °C (68 °F) 1.
Page 507 – ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plug. • Disconnect the spark plug cap from the spark plug. • Connect the ignition checker 1 as shown. 2 Spark plug cap •...
Page 508 – ELEC IGNITION SYSTEM Tester negative probe → Crankshaft position sensor resis- spark plug lead 1 tance 420.8 ~ 569.3 Ω at 20 °C (68 °F) Tester positive probe → spark plug lead 2 (between gray and black) • Is the crankshaft position sensor OK? Replace the crank- shaft position sensor.
Page 509 – ELEC IGNITION SYSTEM EAS00752 NOTE: 11.Sidestand switch When you switch the positive and negative • Check the sidestand switch for continuity. tester probes, the readings in the above chart Refer to “CHECKING THE SWITCHES”. will be reversed. • Is the sidestand switch OK? •...
Page 510: Circuit Diagram
– ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 1 Main switch 5 Main fuse 6 Battery 8 Starter relay 9 Starter motor 0 Diode A Starting circuit cut-off relay B Neutral switch C Sidestand switch e Clutch switch } Ignition fuse §...
Page 511: Starting Circuit Cut-Off System Operation
– ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 512: Troubleshooting
– ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Minimum open-circuit voltage 2.
Page 513 – ELEC ELECTRIC STARTING SYSTEM EAS00759 Tester positive probe → 4. Starting circuit cut-off relay sky blue 1 • Disconnect the starting circuit cut-off relay Tester negative probe → from the wire harness. light green 2 • Connect the pocket tester (Ω × 1) and bat- Tester positive probe →...
Page 514 – ELEC ELECTRIC STARTING SYSTEM EAS00749 NOTE: 7. Main switch When you switch the tester’s positive and • Check the main switch for continuity. negative probes, the readings in the above Refer to “CHECKING THE SWITCHES”. chart will be reversed. •...
Page 515 – ELEC ELECTRIC STARTING SYSTEM EAS00763 11.Clutch switch • Check the clutch switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the clutch switch OK? Replace the clutch switch. EAS00764 12.Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”.
Page 516: Starter Motor
– ELEC STARTER MOTOR EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Throttle bodies Refer to “FUEL INJECTION SYSTEM” in chapter 7. Starter motor lead Disconnect. Starter motor For installation, reverse the removal procedure.
Page 517 – ELEC STARTER MOTOR 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Disassembly the starter motor Remove the parts in the order listed. O-ring Starter motor front cover Brush Brush seat Washer Lock washer Oil seal Bearing Starter motor rear cover Collar...
Page 518 – ELEC STARTER MOTOR 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks O-ring Starter motor yoke Armature assembly For assembly, reverse the disassembly procedure. 8 - 22...
Page 519: Checking The Starter Motor
– ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 23.5 mm (0.93 in) 3.
Page 520 – ELEC STARTER MOTOR 4. Measure: • armature assembly resistances (commuta- tor and insulation) Out of specification → Replace the starter motor. M MMM M MMM M MMM M MMM M MMM a. Measure the armature assembly resis- tances with the pocket tester. Pocket tester YU-03112 Armature coil...
Page 521: Assembling The Starter Motor
– ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • brush seat 1 NOTE: Align the slot a on the brush seat with the tab b in the starter motor front cover. 2. Install: • starter motor yoke 1 •...
Page 522: Charging System
– ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM Lg R/B L/G L/Y (BLACK) (GRAY) (BLUE) Br/L (BLUE) (RED) (RED) Br/L ¢ R/W L/W £ § Br R/W • ¶ L/W Y (BLACK) (BLACK) † Br/Y Br/L ç å Br/B Br/L Br/B Br/B...
Page 523: Troubleshooting
– ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. The battery is not being charged. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse Minimum open-circuit voltage 2. battery 12.8 V or more at 20 °C (68 °F) 3.
Page 524 – ELEC CHARGING SYSTEM EAS00779 NOTE: 5. Wiring Make sure the battery is fully charged. • Check the wiring connections of the entire charging system. • Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? The charging circuit is OK.
Page 525: Lighting System
– ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 1 Main switch n Headlight relay 1 5 Main fuse o Headlight relay 2 6 Battery q Headlight N ECU s Tail/brake light ] High beam indicator light { Tail/position light b Meter light ~ Headlight fuse f Dimmer switch...
Page 526: Troubleshooting
– ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. Any of the following fail to light: head- Refer to “CHECKING AND CHARGING light, high beam indicator light, taillight THE BATTERY” in chapter 3. or meter light.
Page 527 – ELEC LIGHTING SYSTEM EAS00784 4. Dimmer switch 6. Headlight relay 2 • Check the dimmer switch for continuity. • Disconnect the headlight relay 2 from the Refer to “CHECKING THE SWITCHES”. wire harness. • Connect the pocket tester (Ω × 1) and bat- •...
Page 528: Checking The Lighting System
– ELEC LIGHTING SYSTEM EAS00788 Battery positive terminal → green/black 3 CHECKING THE LIGHTING SYSTEM Battery negative terminal → black 4 1. The headlight and the high beam indicator light fail to come on. Tester positive probe → green/blue 5 Tester negative probe →...
Page 529 – ELEC LIGHTING SYSTEM EAS00789 High beam indicator light 2. The meter light fails to come on. Tester positive probe → yellow 4 1. Meter light bulb and socket Tester negative probe → black/white 5 • Check the meter light bulb and socket for Meter assembly coupler continuity.
Page 530 – ELEC LIGHTING SYSTEM EAS00790 3. The tail/brake light fails to come on. 1. Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. • Are the tail/brake light bulb and socket OK? Replace the tail/ brake light bulb, socket or both.
Page 531 – ELEC LIGHTING SYSTEM 8 - 35...
Page 532: Signaling System
– ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 36...
Page 533 – ELEC SIGNALING SYSTEM 1 Main switch 4 Backup fuse (odometer, clock and windshield) 5 Main fuse 6 Battery A Starting circuit cut-off relay B Neutral switch D Fuel pump Y Oil level warning light Z Neutral indicator light [ Multi-function meter \ Engine trouble warning light _ Left turn signal indicator light a Right turn signal indicator light...
Page 534: Troubleshooting
– ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • Any of the following fail to light: flasher Refer to “CHECKING AND CHARGING light, brake light or an indicator light. THE BATTERY” in chapter 3. •...
Page 535: Checking The Signaling System
– ELEC SIGNALING SYSTEM EAS00796 3. Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the black connector at the horn terminal. 1. Horn switch • Connect a jumper lead 1 to the horn termi- • Check the horn switch for continuity. nal and ground the jumper lead.
Page 536 – ELEC SIGNALING SYSTEM EAS00797 3. Voltage 2. The tail/brake light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket tail light assembly coupler (wire harness • Check the tail/brake light bulb and socket side) as shown.
Page 537 – ELEC SIGNALING SYSTEM EAS00799 3. Voltage 3. The turn signal light, turn signal indicator light or both fail to blink. • Connect the pocket tester (DC 20 V) to the turn signal relay coupler as shown. 1. Turn signal indicator light bulb and socket Tester positive probe →...
Page 538 – ELEC SIGNALING SYSTEM • Set the main switch to “ON”. • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Set the turn signal switch to “ ” or “ ”.
Page 539 – ELEC SIGNALING SYSTEM EAS00753 4. Voltage 3. Starting circuit cut-off relay • Connect the pocket tester (DC 20 V) to the • Disconnect the starting circuit cut-off relay meter assembly coupler as shown. from the wire harness. • Connect the pocket tester (Ω × 1) to the Tester positive probe →...
Page 540 – ELEC SIGNALING SYSTEM EAS00802 3. Voltage 5. The oil level warning light fails to come on. • Connect the pocket tester (DC 20 V) to the 1. Oil level warning light bulb and socket meter assembly coupler as shown. •...
Page 541 – ELEC SIGNALING SYSTEM EAS00804 2. Voltage 6. The fuel level gauge fails to operate. • Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler as shown. • Drain the fuel from the fuel tank and remove Tester positive probe →...
Page 542: Cooling System
– ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM 1 Main switch N ECU 5 Main fuse y Radiator fan motor 6 Battery z Radiator fan motor relay L Coolant temperature } Ignition fuse ç Radiator fan motor fuse sensor 8 - 46...
Page 543: Troubleshooting
– ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. • The radiator fan motor fails to turn. Refer to “CHECKING AND CHARGING • The coolant temperature gauge needle THE BATTERY” in chapter 3. fails to move when the engine is warm.
Page 544 – ELEC COOLING SYSTEM EAS00809 6. Radiator fan motor relay 4. Radiator fan motor (test 1) • Disconnect the radiator fan motor relay • Disconnect the radiator fan motor coupler from the wire harness. from the wire harness. • Connect the pocket tester (Ω × 1) and bat- •...
Page 545 – ELEC COOLING SYSTEM EAS00811 7. Coolant temperature sensor • Remove the coolant temperature sensor from the thermostat assembly inlet pipe. • Connect the pocket tester (Ω × 1) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2.
Page 546 – ELEC COOLING SYSTEM EAS00813 8. Wiring • Check the entire cooling system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the cooling system’s wiring properly con- nected and without defects? Replace the ECU. Properly connect or repair the cooling system’s wiring. 8 - 50...
Page 547: Fuel Injection System
– ELEC FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM 8 - 51...
Page 548: Troubleshooting
– ELEC FUEL INJECTION SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery • Check the condition of the battery. If the fuel injection system fails to oper- Refer to “CHECKING AND CHARGING ate. THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.
Page 549 – ELEC FUEL INJECTION SYSTEM EAS00759 EAS00817 5. Fuel injection system relay 6. Fuel pump resistance • Disconnect the fuel injection system relay • Disconnect the fuel pump coupler from the from the wire harness. fuel pump. • Connect the pocket tester (Ω × 1) and bat- •...
Page 550 – ELEC FUEL INJECTION SYSTEM 9. Speed sensor output voltage Crankshaft position sensor resis- tance • Measure the speed sensor output voltage. 420 ~ 569 Ω at 20 °C (68 °F) • Connect the pocket tester (DC 20 V) to the (between gray and black) speed sensor coupler terminal as shown.
Page 551 – ELEC FUEL INJECTION SYSTEM EAS00811 10.Coolant temperature sensor • Remove the coolant temperature sensor from the thermostat assembly inlet pipe. • Connect the pocket tester (Ω × 1) to the coolant temperature sensor 1 as shown. • Immerse the coolant temperature sensor in a container filled with coolant 2.
Page 552 – ELEC FUEL INJECTION SYSTEM 11.Intake air temperature sensor resistance 12.Intake air pressure sensor output voltage • Remove the intake air temperature sensor • Connect the pocket tester (DC 20 V) to the from the air filter case. intake air intake air pressure sensor coupler •...
Page 553 – ELEC FUEL INJECTION SYSTEM 13.Atmospheric pressure sensor output volt- 14.AI system solenoid • Remove the AI system solenoid coupler • Connect the pocket tester (DC 20 V) to the from the wire harness. • Connect the pocket tester (Ω × 1) to the AI atmospheric pressure sensor coupler termi- nal as shown.
Page 554: Checking The Fuel Pump
– ELEC FUEL INJECTION SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. •...
Page 555: Checking And Adjusting The Throttle
– ELEC FUEL INJECTION SYSTEM EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor (installed on the throttle body) M MMM M MMM M MMM M MMM...
Page 556 – ELEC FUEL INJECTION SYSTEM Throttle position sensor resis- tance (520 ~ 900 Ω) ~ (4.0 ~ 6.0 kΩ) at 20 °C (68 °F) (yellow — black/blue) L LLL L LLL L LLL L LLL L LLL 2. Check: • throttle position sensor (removed from the throttle body) M MMM M MMM...
Page 557 – ELEC FUEL INJECTION SYSTEM e. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Tester positive probe → yellow terminal 3 Tester negative probe → black/blue terminal 2 f. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range.
Page 558 – ELEC FUEL INJECTION SYSTEM Example: If the maximum resistance = 5 kΩ, then the throttle position sensor’s maximum resistance when the throttle is fully closed should be: 5 kΩ × (0.13 ~ 0.15) = 650 ~ 750 Ω Lift the throttle body assembly slightly out of the intake manifolds.
Page 559: Windshield Drive System
– ELEC WINDSHIELD DRIVE SYSTEM WINDSHIELD DRIVE SYSTEM CIRCUIT DIAGRAM 1 Main switch 4 Backup fuse (odometer, clock and windshield) 5 Main fuse 6 Battery A Starting circuit cut-off relay B Neutral switch Z Neutral indicator light g Windshield position switch x Windshield drive unit †...
Page 560 – ELEC WINDSHIELD DRIVE SYSTEM TROUBLESHOOTING EAS00739 2. Battery The windshield fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, windshield motor and backup fuses 2. battery Minimum open-circuit voltage 3.
Page 561 – ELEC WINDSHIELD DRIVE SYSTEM EAS00795 5. Wiring • Check the entire windshield drive system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the windshield drive system’s wiring properly connected and without defects? Replace the wind- Properly connect or shield drive unit. repair the windshield drive system’s wiring.
Page 562: Troubleshooting
TRBL STARTING PROBLEMS SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this man- ual for checks, adjustments, and replacement of parts.
Page 563: Trbl Shtg
STARTING PROBLEMS/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty ECU • Faulty battery • Faulty crankshaft position sensor Fuse(s) • Broken generator rotor woodruff key • Blown, damaged or incorrect fuse Switches and wiring •...
Page 564: Poor Medium-And-High-Speed Performance
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE FUEL SYSTEM Air filter Fuel pump • Clogged air filter element • Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”.
Page 565: Faulty Clutch
TRBL FAULTY CLUTCH/OVERHEATING SHTG EAS00852 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch • Improperly assembled clutch • Air in hydraulic clutch system • Improperly assembled clutch master cylin- • Unevenly tensioned clutch springs • Warped pressure plate • Improperly assembled clutch release cylin- •...
Page 566: Poor Braking Performance
POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS SHTG EAS00857 POOR BRAKING PERFORMANCE • Worn brake pad • Loose union bolt • Worn brake disc • Damaged brake hose • Air in hydraulic brake system • Oil or grease on the brake disc •...
Page 567: Unstable Handling
UNSTABLE HANDLING/ TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00863 UNSTABLE HANDLING Handlebars Rear shock absorber assembly(-ies) • Bent or improperly installed right handlebar • Faulty rear shock absorber spring • Bent or improperly installed left handlebar • Leaking oil or gas Steering head components Tire(s) •...
Page 568: Turn Signal Blinks Quickly
TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG TURN SIGNAL BLINKS QUICKLY • Incorrect turn signal bulb • Faulty turn signal relay • Burnt-out turn signal bulb HORN DOES NOT SOUND • Improperly adjusted horn • Damaged or faulty horn • Faulty main switch •...
Page 569 FJR1300R/FJR1300RC WIRING DIAGRAM (For USA) 1 Main switch ~ Headlight fuse 2 Rectifier/regulator å Signaling system fuse 3 Generator ç Radiator fan motor fuse 4 Backup fuse (odometer, clock and windshield) † Windshield motor fuse 5 Main fuse ¢ Right handlebar switch 6 Battery £...
Page 571 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
Page 572 FJR1300R/FJR1300RC WIRING DIAGRAM (BLACK) (BLACK) SUB-WIRE SUB-WIRE SUB-WIRE SUB-WIRE SUB-WIRE (For USA) WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS WIRE HARNESS HARNESS 1 HARNESS 1 HARNESS 1 HARNESS 2 HARNESS 2 (BLACK) (GRAY) R/L R/B (GRAY) (BLUE) (DARK GRAY)

This manual is also suitable for:

Fjr1300rc Fjr1300 Fjr1300n

Yamaha FJR1300R Service Manual

General Information

Specifications

Periodic Checks and Adjustments

Chassis

Engine

Cooling System

Fuel Injection System

Electrical System

Troubleshooting

Chapter 1 General Information

Motorcycle Identification

Features

Important Information

Special Tools

Chapter 2 Specifications

Spec

General Specifications

Engine Specifications

Chassis Specifications

Electrical Specifications

Conversion Table

General Tightening Torque Specifications

Lubrication Points and Lubricant Types

Oil Flow Diagrams

Cooling System Diagrams

Cable Routing

Chapter 3 Periodic Checks and Adjustments

Introduction

Periodic Maintenance Chart for the Emission Control System

General Maintenance and Lubrication Chart

Chk Adj

Seats and Fuel Tank

Air Filter Case

Cowlings and Covers

Engine

Chassis

Electrical System

Chapter 4 Chassis

Front Wheel and Brake Discs

Chas

Rear Wheel and Brake Disc

Front and Rear Brakes

Hydraulic Clutch

Front Fork

Handlebars

Steering Head

Rear Shock Absorber Assembly and Relay Arm

Swingarm

Shaft Drive

Chapter 5 Engine

Eng

Camshafts

Cylinder Head

Valves and Valve Springs

Generator and Starter Clutch

Pickup Coil Rotor

Clutch

Shift Shaft

Oil Pan and Oil Pump

Middle Gear

Crankcase

Crankshaft

Transmission

Balancers

Quick Links

Troubleshooting

Related Manuals for Yamaha FJR1300R

Summary of Contents for Yamaha FJR1300R