Download  Print this page

Yamaha FZS1000N Service Manual

Hide thumbs
   

Advertisement

Quick Links

Table of Contents

Advertisement

Table of Contents
loading

  Also See for Yamaha FZS1000N

  Summary of Contents for Yamaha FZS1000N

  • Page 3 EAS00001 FZS1000N (C) SERVICE MANUAL 2001 by Yamaha Motor Corporation, U.S.A. First edition, January 2001 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-14-48...
  • Page 4: Important Information

    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed- eral environmental quality objectives.
  • Page 5: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.
  • Page 6 EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis COOL CARB...
  • Page 7: Table Of Contents

    EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETORS CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 8 INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
  • Page 9 INFO...
  • Page 10: 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. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
  • Page 11: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
  • Page 12: Bearings And Oil Seals

    IMPORTANT INFORMATION INFO EAS00024 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are vis- ible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips.
  • Page 13: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead 1 S coupler 2 S connector 3 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.
  • Page 14: 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 inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 15 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil Filter Wrench YU-38411 This tool is needed to loosen or tighten the oil filter cartridge. Rod Holder YM-01434 This tool is used to support the damper adjusting rod. Rod Puller Rod puller YM-01437 This tool is used to pull up the front fork damper rod.
  • Page 16 This tool is used to rebore the new valve guides. Dynamic Spark Tester YM-34487 This tool is used to check the ignition system components. Yamaha bond No. 1215 ACC-11001- 05-01 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
  • Page 18 SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
  • Page 19 SPEC...
  • Page 20: Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5LV5 (USA except for California) 5LV6 (CDN) 5LV7 (California) Dimensions Overall length 2,125 mm (83.7 in) Overall width 765 mm (30.1 in) Overall height 1,190 mm (46.9 in) Seat height 820 mm (32.3 in) Wheelbase 1,450 mm (57.1 in)
  • Page 21: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 998 cm Cylinder arrangement Forward-inclined parallel 4-cylinder Bore X stroke 74 X 58 mm (2.91 X 2.28 in) Compression ratio 11.4 : 1 1,050 X 1,150 r/min Engine idling speed Vacuum pressure at engine idling 30 kPa (225 mmHg, 8.86 in Hg)
  • Page 22 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) 180 X 220 kPa Bypass valve opening pressure (1.8 X 2.2 kg/cm , 25.6 X 31.3 psi) Oil pump Oil pump type Trochoidal 0.09 X 0.15 mm (0.004 X 0.006 in) Inner-rotor-to-outer-rotor-tip clearance 0.03 X 0.08 mm (0.001 X 0.003 in)
  • Page 23 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 24.500 X 24.521 mm Camshaft cap inside diameter (0.9646 X 0.9654 in) 24.459 X 24.472 mm Camshaft journal diameter (0.9630 X 0.9635 in) 0.028 X 0.062 mm (0.0011 X 0.0024 in) Camshaft-journal-to-camshaft- cap clearance Intake camshaft lobe dimensions...
  • Page 24 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015/130 Tensioning system Automatic Valves, valve seats, valve guides 0.11 X 0.20 mm (0.0043 X 0.0079 in) Valve clearance (cold) 0 21 X 0 25 mm (0 0083 X 0 0098 in) 0.21 X 0.25 mm (0.0083 X 0.0098 in) Intake Intake...
  • Page 25 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout 0.01 mm (0.0004 in) Valve seat width 0.9 X 1.1 mm (0.035 X 0.043 in) Intake 0.9 X 1.1 mm (0.035 X 0.043 in) Exhaust Valve springs Free length Intake 38.90 mm (1.53 in) Exhaust 40.67 mm (1.60 in) Installed length (valve closed)
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinders Cylinder arrangement Forward-inclined, parallel 4-cylinder Bore X stroke 74 X 58 mm (2.91 X 2.28 in) Compression ratio 11.4 : 1 74.00 X 74.01 mm (2.9134 X 2.9138 in) Bore Max. taper 0.05 mm (0.0016 in) Max.
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper Dimensions (B X T) 0.8 X 2.8 mm (0.031 X 0.110 in) 0.43 X 0.58 mm (0.017 X 0.023 in) End gap (installed) 0.020 X 0.055 mm (0.0008 X 0.0022 in) Ring side clearance Oil ring Dimensions (B X T)
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Friction plates 2.92 X 3.08 mm (0.115 X 0.121 in) Thickness 2.82 mm (0.111 in) Plate quantity 3.42 X 3.58 mm (0.135 X 0.141 in) Thickness 3.32 mm (0.131 in) Plate quantity Clutch plates 1.9 X 2.1 mm (0.075 X 0.083 in) Thickness Plate quantity...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Carburetors Model (manufacturer) X quantity BSR37 (MIKUNI) X 4 3 X 5 mm (0.12 X 0.20 in) Throttle cable free play (at the flange of the throttle grip) ID mark 5LV5 40 Main jet Carburetors 1 and 4: #132.5 Carburetors 2 and 3: #130 Main air jet...
  • Page 30: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle Caster angle Trail 104 mm (4.09 in) Front wheel Wheel type Cast wheel 17 X MT3.50 Size Material Aluminum Wheel travel 140 mm (5.51 in) Wheel runout Max.
  • Page 31 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 180/55 ZR17 (73W) Model (manufacturer) MEZ4Y (METZELER) BT020R U (BRIDGESTONE) Tire pressure (cold) 0 X 90 kg 270 kPa (2.7 kgf/cm , 39 bar) 90 X 201 kg 290 kPa (2.9 kgf/cm , 42 bar) High-speed riding...
  • Page 32 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil sprin Front fork travel 140 mm (5.51 in) Spring Free length 344.0 mm (13.5 in) Spacer length 66.0 mm (2.60 in) Installed length 320.0 mm (12.6 in) Spring rate (K1) 7.8 N/mm (0.78 kg/mm, 43.7 lb/in) Spring rate (K2)
  • Page 33 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular ball bearings Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 65 mm (2.56 in) travel Spring Free length 182.5 mm (7.19 in) Installed length 163 mm (6.42 in)
  • Page 34: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type Transistorized coil ignition Ignition timing 5_ BTDC at 1,100 r/min Advanced timing 55_ BTDC at 5,000 r/min Advancer type Throttle position sensor and electrical 248 X 372 Ω/Gy-B Pickup coil resistance/color Transistorized coil ignition unit...
  • Page 35 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light (voltage /wattage X quantity) 14 V 1.4 W X 1 Neutral indicator light 14 V 1.4 W X 1 High beam indicator light 14 V 1.4 W X 1 Oil level indicator light 14 V 1.4 W X 2 Turn signal indicator light 12 V 2 W X 1...
  • Page 36 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 30 A Headlight fuse 20 A Signaling system fuse 20 A Ignition fuse 20 A Radiator fan fuse 10 A Turn signal relay fuse 10 A Backup fuse (odometer) 10 A Reserve fuse 30 A...
  • Page 37: Tightening Torques

    SPEC TIGHTENING TORQUES EAS00030 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.
  • Page 38: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size size mSkg ftSlb Spark plugs – Cylinder head Cylinder head Cap nut Cylinder head Bolt Camshaft caps Bolt Cylinder head cover Bolt Cylinder head Stud bolt (exhaust pipe) Connecting rod caps Generator rotor...
  • Page 39 SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size size mSkg ftSlb AC magneto cover Bolt Drive sprocker cover Bolt Plate Bolt Clutch cover Bolt Timing chain cap bolt Bolt Shift shaft cover Bolt Breather plate Bolt Timing mark accessing screw Bolt Starter clutch idle gear shaft Bolt...
  • Page 40 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2-21...
  • Page 41: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Item Item Thread size Thread size Remarks Remarks m kg ft lb Upper bracket pinch bolt Upper bracket cap nut Upper bracket and handlebar holder Handlebar holder Lower bracket pinch bolt – Lower bracket ring nut See note Front brake master cylinder Front brake hose union bolt...
  • Page 42: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Clutch cover (crankcase mating surface) No.1215...
  • Page 43: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings, steering seal lips and ball race cover lips Pivot shaft Swing arm pivoting points and connecting arm bearings Connecting arm oil seal lips Swing arm oil seal lips Relay arm bearings Relay arm oil seal lips Rear shock absorber upper bolt...
  • Page 44: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Water pump 2-25...
  • Page 45 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Oil cooler 5 Water jacket joint 2-26...
  • Page 46 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator cap 2 Thermostat 3 Thermo unit 2-27...
  • Page 47 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator 2-28...
  • Page 48: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Exhaust camshaft Intake camshaft Main gallery Oil filter Main axle cooler Relief Strainer valve Drive axle 2-29...
  • Page 49: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil filter cartridge 3 Drain bolt 4 Oil level switch 5 Oil strainer 6 Oil pump 2-30...
  • Page 50 SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Oil cooler 4 Oil strainer 5 Oil pump 2-31...
  • Page 51 SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camsahft 3 Oil filter cartridge 4 Oil level switch 2-32...
  • Page 52 SPEC LUBRICATION DIAGRAMS 1 Cylinder head 2 Crankshaft 2-33...
  • Page 53 SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle 2-34...
  • Page 54: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING A Fasten the handlebar switch lead (right) and han- F Route the horn lead outside the motorcycle body, dlebar with a plastic band. and fasten with the under bracket. Do not loose be- B Route the handlebar switch lead (right) backward tween the horn and under bracket.
  • Page 55 SPEC CABLE ROUTING Fuel pump lead Handle crown Fuel pump Handlebar switch lead EXUP cable Brake hose guide Handlebar switch lead (right) Throttle cable 1 A Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speed Throttle cable 2 sensor lead, rear brake light switch lead and fuel pump with a plastic Water-carburetor hose clamp.
  • Page 56 SPEC CABLE ROUTING I Route the water-carburetor hose between the Q Insert the all couplers into the rubber cover. frame cross pipe and fan motor lead. R Route the rear brake light switch lead inside the J To the carburetor another leads.
  • Page 57 SPEC CABLE ROUTING Starter cable A Fasten the main switch lead and handlebar switch lead with a plastic Clutch cable guide. Handlebar switch lead (left) B Fasten the water-head hose and water-carburetor hose with a plastic Main switch lead band. EXUP servo motor C Fasten the clutch cable with a plastic band.
  • Page 58 SPEC CABLE ROUTING N Fasten the sidestand switch lead, oil level switch lead, and rectifier regulator lead. ACgenerator lead, starter motor lead, battery negative U Route the water carburetor hose outside the coolant lead and air cleaner case drain hose with a plastic clamp. hose.
  • Page 59 SPEC CABLE ROUTING Clutch cable Ignition coil lead Handlebar switch lead Battery Main switch lead Emergency engine stop switch Starter cable Flasher relay Thermo unit lead Fuse box Throttle cable 1 Igniter unit Throttle cable 2 Flasher light lead Handlebar switch lead (right) Taillight lead Coolant reservoir hose Alarm coupler (free)
  • Page 60 SPEC CABLE ROUTING A Fasten the flasher light lead and headlight lead with K Fasten the fuel hose and air induction system hose a plastic clamp. with a plastic clamp. B Route the rectifier / regulator lead upper the fan mo- L Route the coolant reservoir hose under the frame tor lead and EXUP servomotor lead.
  • Page 61 SPEC CABLE ROUTING T Fasten the ignition coil lead and frame cross pipe AA Put the seat lock cable into the groove on the rear with a plastic clamp. Do not fasten the red / black fender. lead and orange lead. AB Fasten the battery positive lead with a plastic band.
  • Page 62: Periodic Checks And

    CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM .
  • Page 63 ADJUSTING THE FRONT FORK LEGS ..... . . 3-43 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ..3-45 CHECKING THE TIRES .
  • Page 64: Periodic Checks And Adjustments

    √ system S Replace the entire air induction (See page 7-14) system if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS...
  • Page 65 √ √ S Correct if necessary. (See page 2-22) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. #1: Yamaha chain lube #2: Lithium-soap-based grease (all-purpose grease) #3: Ethylene glycol anti-freeze coolant...
  • Page 66: Front Cowling/Seat/Side Cover/Fuel Tank

    FRONT COWLING EAS00038 FRONT COWLING/SEAT/SIDE COVER/FUEL TANK FRONT COWLING Order Job/Part Q’ty Remarks Removing the fron cowling Remove the parts in the order listed. Inner panel Headlight/meter coupler Disconnect. Front cowling assembly Back view mirror Meter unit Headlight unit For installation, reverse the removal procedure.
  • Page 67: Seat, Side Cover And Fuel Tank

    SEAT, SIDE COVER AND FUEL TANK EAS00040 SEAT, SIDE COVER AND FUEL TANK 19 Nm (1.9 mDkg), 14 ftDlb 10 Nm (1.0 mDkg), 7.2 ftDlb 4 Nm (0.4 mDkg, 2.9 ftDlb) 10 Nm (1.0 mDkg, 7.2 ftDlb) Order Job/Part Q’ty Remarks Removing the seat, side cover and Remove the parts in the order listed.
  • Page 68: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: DValve clearance adjustment should be made on a cold engine, at room temperature. DWhen the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 69 ADJUSTING THE VALVE CLEARANCE A Front d. For each cylinder, starting with cylinder #1 at TDC, turn the crankshaft clockwise as speci- fied in the following table. B Degrees that the crankshaft is turned clockwise C Cylinder D Combustion cycle #2 Cylinder 180_ #4 Cylinder...
  • Page 70 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 71 ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED 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 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
  • Page 72 ADJUSTING THE VALVE CLEARANCE e. Install the new valve pad 1 and the valve lift- er 2 . NOTE: Apply molybdenum disulfide oil to the valve pad and the valve lifter. The valve lifter must turn smoothly when ro- tated by hand. Install the valve lifter and the valve pad in the correct place.
  • Page 73: Synchronizing The Carburetors

    SYNCHRONIZING THE CARBURETORS EAS00050 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand.
  • Page 74 SYNCHRONIZING THE CARBURETORS 6. Adjust: carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in ei- ther direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.
  • Page 75: 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 carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.
  • Page 76: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 5. 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 X 5 mm (0.12 X 0.20 in) EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY...
  • Page 77 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: throttle cable free play NOTE: When the motorcycle is accelerating, the accel- erator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.
  • Page 78: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS 4. Install: fuel tank seat EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: spark plug cap 2. Remove: spark plug CAUTION: Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from fal-...
  • Page 79: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 7. Install: spark plug 13 Nm (1.3 m kg, 9.4 ft lb) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: spark plug cap EAS00063 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system.
  • Page 80: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range Check the ignition system. NOTE: The ignition timing is not adjustable. 4.
  • Page 81 MEASURING THE COMPRESSION PRESSURE 6. Measure: compression pressure Above the maximum pressure Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure Squirt a few drops of oil into the affected cylinder and measure again. Refer to the following table.
  • Page 82: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00071 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Check: engine oil level The engine oil level should be between the minimum level marks a and maximum level marks b .
  • Page 83: 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 engine oil drain bolt 2 (along with the gasket) 4.
  • Page 84 CHANGING THE ENGINE OIL c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 m kg, 12 ft lb) 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.
  • Page 85: Adjusting The Clutch Cable Free Play

    CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY Oil gallery bolt 10 Nm (1.0 mSkg, 7.2 ftSlb) EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 2.
  • Page 86: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: seat fuel tank side cover cover 1 2. Remove: air filter case cover 1 air filter element 3. Clean: air filter element Apply compressed air to the outer surface of the air filter element.
  • Page 87: Checking The Carburetor Joints And Intake Manifolds

    CLEANING THE AIR FILTER ELEMENT / CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS / CHECKING THE FUEL HOSES AND FUEL FILTER NOTE: When installing the air filter element into the air filter case cover, be sure their sealing surfaces are aligned to prevent any air leaks. 6.
  • Page 88: Checking The Crankcase Breather Hose

    CHECKING THE FUEL HOSES AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM NOTE: Drain and flush the fuel tank if abrasive dam- age to any components of the fuel line is evi- dent. The arrow mark a on the fuel filter should face to the side of the fuel pump 1 .
  • Page 89: Checking The Canister

    CHECKING THE CANISTER/ ADJUSTING THE EXUP CABLES CHECKING THE CANISTER (for California only) 1. Remove: S seat S fuel tank 2. Check: S hose and canister Cracks/damage ! Replace. S vent hose Obstruction ! Clean. 3. Install: S fuel tank S seat EAS00101 ADJUSTING THE EXUP CABLES...
  • Page 90: Checking The Coolant Level

    ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 4. Check: EXUP cable free play a EXUP cable free play 1.5 mm (0.06 in) max. 5. Adjust: EXUP cable free play a. Loosen both locknuts 1 . b. Insert a 4 mm long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover.
  • Page 91 CHECKING THE COOLANT LEVEL CAUTION: Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and correct the antifreeze concentration of the coolant. Use only distilled water. Soft water may be used if distilled water is not available.
  • Page 92: Checking The Cooling System

    CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 water jacket inlet joint 6 water pump outlet joint 7 Cracks/damage Replace.
  • Page 93: Changing The Coolant

    CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove seat fuel tank front cowling rear suspension Refer to “REAR SHOCK ABSORBER AS- SEMBLY” in chapter 4. 2. Disconnect: coolant reservoir hose 1 3. Drain: coolant (from the coolant reservoir) 4. Remove: radiator cap 1 WARNING A hot radiator is under pressure.
  • Page 94: Cooling System

    CHANGING THE COOLANT 7. Check: copper washer 1 coolant drain bolt 2 Damage Replace. 8. Install: coolant drain bolt 7 Nm (0.7 m kg, 5.1 ft lb) 9. Connect: coolant reservoir hose 10. Fill: cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti...
  • Page 95 CHANGING THE COOLANT CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. S Use only distilled water. Soft water may be used if distilled water is not available.
  • Page 96: 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) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.
  • Page 97: 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 footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 40 mm (1.57 in) 2.
  • Page 98: 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 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright.
  • Page 99: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00122 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: front brake pad rear brake pad Wear indicator groove 1 almost disap- peared ! Replace the brake pads as a set.
  • Page 100: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check: brake hose 1 Cracks/damage/wear ! Replace. 2. Check: brake hose clamp 2 Loose connection ! Tighten.
  • Page 101: Adjusting The Shift Pedal

    BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL 2. Bleed: hydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2 .
  • Page 102: Adjusting The Drive Chain Slack

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK 2. Adjust: adjusting bolt length a. Loosen both locknuts 1 . b. Turn the adjusting bolt 2 in direction a or b to obtain the correct shift pedal position. Direction Shift pedal is raised. Direction Shift pedal is lowered.
  • Page 103 ADJUSTING THE DRIVE CHAIN SLACK 4. Adjust: drive chain slack a. Loosen the brake caliper bracket bolt. b. Loosen the wheel axle nut 1 . c. Loosen both locknuts 2 . d. Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is ob- tained.
  • Page 104: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
  • Page 105 CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5 . NOTE: Set the torque wrench at a right angle to the spanner wrench. Spanner wrench YU-33975 Lower ring nut (initial tightening torque)
  • Page 106: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK / ADJUSTING THE FRONT FORK LEGS Steering stem nut 110 Nm (11 m kg, 80 ft lb) Upper bracket pinch bolt 30 Nm (3.0 m kg, 22 ft lb) Handlebar holder bolt 23 Nm (2.3 m kg, 17 ft lb) EAS00149...
  • Page 107 ADJUSTING THE FRONT FORK LEGS 1. Adjust: S spring preload a. Turn the adjusting bolt 1 in direction a or Spring preload is Direction increased (suspension is harder). Spring preload is Direction decreased (suspension is softer). Adjusting positions Standard: 2 Minimum: 5* Maximum: 1 *fully turned out position...
  • Page 108 ADJUSTING THE FRONT FORK LEGS/ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or Compression damping is Direction increased (suspension is harder).
  • Page 109 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY a. Turn the adjusting ring 1 in direction a or b. Align the desired position on the adjusting ring with the stopper 2 . Spring preload is Direction Direction increased (s spension is increased (suspension is harder).
  • Page 110 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ CHECKING THE TIRES Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or Compression damping is Direction increased (suspension is harder).
  • Page 111 CHECKING THE TIRES Basic weight 231 kg (509 lb) (with oil and a 232 kg (512 lb) full fuel tank) (california) 189 kg (417 lb) Maximum 188 kg (415 lb) load* (california) Cold tire Front tire Rear tire pressure 250 kPa 270 kPa Up to 90 kg (2.5 kgf/cm...
  • Page 112 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer Type...
  • Page 113 CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING LUBRICATING 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 move- ment.
  • Page 114: Chk Adj

    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 poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: Wear protective eye gear when handling or working near batteries.
  • Page 115 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 116 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging S battery Ambient temperature 20_C (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Make sure that the battery vent is free of ob- structions.
  • Page 117 CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
  • Page 118 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
  • Page 119 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Check: battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: battery 8. Connect: battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 9.
  • Page 120 CHECKING THE FUSES Pocket tester measurement YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. 3. Replace: blown fuse a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational.
  • Page 121 REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: headlight coupler 1 bulb cover 2 2. Remove: headlight bulb holder 1 3. Remove: headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
  • Page 122 ADJUSTING THE HEADLIGHT BEAMS/ ADJUSTING THE DIGITAL CLOCK EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or Direction Headlight beam is raised. Direction Headlight beam is lowered.
  • Page 124 CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ......FRONT WHEEL ..........REMOVING THE FRONT WHEEL .
  • Page 125 CHAS FRONT FORK ..........4-46 REMOVING THE FRONT FORK LEGS .
  • Page 126: Front Wheel And Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 72 Nm (7.2 m kg, 52 ft lb) 40 Nm (4.0 m kg, 29 ft lb) 18 Nm (1.8 m kg, 13 ft lb) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed.
  • Page 127: Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure.
  • Page 128: 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 129: Disassembling The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00523 DISASSEMBLING THE FRONT WHEEL 1. Remove: oil seals wheel bearings a. Clean the outside of the front wheel hub. b. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.
  • Page 130: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS 4. Check: wheel bearings Front wheel turns roughly or is loose ! Re- place the wheel bearings. oil seals Damage/wear ! Replace. 5. Replace: wheel bearings oil seals a. Clean the outside of the front wheel hub. b.
  • Page 131 CHAS FRONT WHEEL AND BRAKE DISCS 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.1 mm (0.004 in) a. Place the motorcycle on a suitable stand so that the wheel is elevated.
  • Page 132: Assembling The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00539 ASSEMBLING THE FRONT WHEEL 1. Install: wheel bearings oil seals a. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing inner race 1 or balls 2 .
  • Page 133: Adjusting The Front Wheel Static Balance

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the front wheel static balance should be adjusted. S Adjust the front wheel static balance with the brake discs installed. 1.
  • Page 134 CHAS FRONT WHEEL AND BRAKE DISCS b. Turn the front wheel 90_ so that the heavy spot is positioned as shown. c. If the heavy spot does not stay in that posi- tion, install a heavier weight. d. Repeat steps (b) and (c) until the front wheel is balanced.
  • Page 135: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 150 Nm (15 m kg, 108 ft lb) 40 Nm (4.0 m kg, 29 ft lb) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 136 CHAS REAR WHEEL AND BRAKE DISC EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Spacer Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 4-11...
  • Page 137 CHAS REAR WHEEL AND BRAKE DISC 18 Nm (1.8 m kg, 13 ft lb) 69 Nm (6.9 m kg, 50 ft lb) Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel sprocket Brake disc Rear wheel sprocket Collar (left and right)
  • Page 138: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 139: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00565 CHECKING THE REAR WHEEL 1. Check: wheel axle rear wheel wheel bearings oil seals Refer to “FRONT WHEEL”. 2. Check: tire rear wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” in chapter 3.
  • Page 140: Checking The Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC Rear wheel sprocket self-locking 69 Nm (6.9 m kg, 50 ft lb) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. EAS00531 CHECKING THE BRAKE DISC 1. Check: brake disc Damage/galling ! Replace. 2.
  • Page 141: Installing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC 4. Adjust: S brake disc deflection 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 142: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 6 Nm (0.6 m kg, 4.3 ft lb) 40 Nm (4.0 m kg, 29 ft lb) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring...
  • Page 143 CHAS FRONT AND REAR BRAKES 40 Nm (4.0 m kg, 29 ft lb) 6 Nm (0.6 m kg, 4.3 ft lb) Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad...
  • Page 144: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require disas- sembly. Therefore, always follow these preventive measures: Never disassemble brake components un- less 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 reas- sembly.
  • Page 145 CHAS FRONT AND REAR BRAKES 2. Remove: brake pad clips 1 brake pad pins 2 brake pad spring 3 3. Remove: brake pads 1 (along with the brake pad shims) 4. Measure: brake pad wear limit Out of specification ! Replace the brake pads as a set.
  • Page 146: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES d. Install new brake pad shims onto the new brake pads. e. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. 6.
  • Page 147 CHAS FRONT AND REAR BRAKES 3. Measure: brake pad wear limit Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm (0.02 in) 4. Install: brake pad shims (onto the brake pads) brake pads brake pad spring NOTE: Always install new brake pads, brake pad...
  • Page 148 CHAS FRONT AND REAR BRAKES 5. Install: brake pad pins brake pad clips brake caliper 40 Nm (4.0 m kg, 29 ft lb) 6. Check: brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...
  • Page 149: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 m kg, 7.2 ft lb) 30 Nm (3.0 m kg, 22 ft lb) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain.
  • Page 150 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 4-25...
  • Page 151: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg, 22 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Side cover (right) Brake fluid...
  • Page 152 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake master Disassemble the parts in the order listed. cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 4-27...
  • Page 153: Removing And Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 REMOVING AND DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: brake switch coupler (from the brake switch) 2.
  • Page 154: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES 3. Remove: clip hose cotter pin washer 4. Remove: master cylinder 5. Remove: master cylinder boot circlip 6. Remove: master cylinder kit spring EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders.
  • Page 155: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 4. Check: front brake master cylinder reservoir 1 Cracks/damage ! Replace. front brake master cylinder reservoir dia- phragm 2 Damage/wear ! Replace. 5. Check: brake hoses Cracks/damage/wear ! Replace. EAS00598 ASSEMBLING INSTALLING FRONT BRAKE MASTER CYLINDER WARNING Before installation, all internal brake com- ponents should be cleaned and lubricated...
  • Page 156 CHAS FRONT AND REAR BRAKES 3. Install: S brake master cylinder 1 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Install the brake master cylinder holder with the “UP” mark facing up. S Align the end of the brake master cylinder hold- er with the punch mark a on the handlebar.
  • Page 157 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 perfor- mance.
  • Page 158: Assembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: spring master cylinder kit 2. Install: circlip master cylinder boot 3. Install: master cylinder 4. Install: washer cotter pin hose clip 5. Install: copper washers 1 brake hose 2 union bolt 3 30 Nm (3.0 m kg, 22 ft lb)
  • Page 159 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 perfor- mance.
  • Page 160: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 m kg, 4.3 ft lb) 40 Nm (4.0 m kg, 29 ft lb) 30 Nm (3.0 m kg, 22 ft lb) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed.
  • Page 161 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 m kg, 4.3 ft lb) Order Job/Part Q’ty Remarks Disassembling the front brake calipers Disassemble the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring...
  • Page 162: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft lb) 40 Nm (4.0 m kg, 29 ft lb) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.
  • Page 163 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 m kg, 4.3 ft lb) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw...
  • Page 164: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CAL- IPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE:...
  • Page 165: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00628 DISASSEMBLING THE REAR BRAKE CAL- IPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
  • Page 166: 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 Every two years and whenever the Brake fluid brake is disas- sembled.
  • Page 167: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING INSTALLING FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 168 CHAS FRONT AND REAR BRAKES 4. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
  • Page 169: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00644 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solevents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 170 CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S 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 perfor- mance.
  • Page 171: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 30 Nm (3.0 mSkg, 22 ftSlb) 25 Nm (2.5 mSkg, 18 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 172 CHAS FRONT FORK EAS00648 25 Nm (2.5 mSkg, 18 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) Order Job/Part Q’ty Remarks Disassembly the front fork Disassemble the parts in the order listed. Cap bolt O-ring Spacer Spring seat Fork spring Damper adjusting rod Dust seal Oil seal clip Damper rod bolt...
  • Page 173: 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 174 CHAS FRONT FORK 2. Remove: S spacer 1 S spring seat 2 S spring 3 S damper adjusting rod 4 3. Drain: S fork oil 4. Remove: S oil seal clip 1 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 5.
  • Page 175: Checking The Front Fork Legs

    CHAS FRONT FORK CAUTION: S Excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. S Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the...
  • Page 176: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00660 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Make sure that the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 177 Quantity (each front fork leg) 0.44 L (435 cm (15.3 Imp oz, 14.7 US oz) Recommended oil Yamaha suspension oil “01” or equivalent CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
  • Page 178 CHAS FRONT FORK 7. Install: S rod puller 1 (onto the damper rod 2 ) Rod puller YM-01437 8. After filling the front fork leg, slowly stroke the damper rod 1 up and down (at least ten times) to distribute the fork oil. NOTE: Be sure to stroke the damper rod slowly be- cause the fork oil may spurt out.
  • Page 179 CHAS FRONT FORK 12. Install: S spring 1 S spring seats 2 S spacer 3 S nut 4 S damper adjusting rod 5 S cap bolt 6 a. Install the fork spring, spring seats, and spacer. NOTE: Install the fork spring with the larger pitch a fac- ing up.
  • Page 180: 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: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder.
  • Page 181: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 23 Nm (2.3 mSkg, 17 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 26 Nm (2.6 mSkg, 19 ftSlb) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Front brake master cylinder Right handlebar switch Throotle cable...
  • Page 182: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S throttle cable housing 1 S throttle grip 2 3.
  • Page 183: Installing The Handlebar

    CHAS HANDLEBAR 3.Install: S handlebar grip a. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
  • Page 184 CHAS HANDLEBAR 5. Install: S left handlebar switch NOTE: Align the pins a on the right handlebar switch with the holes b in the handlebar. 6. Install: S clutch lever holder NOTE: Align the slit in the clutch lever holder with the punch mark a in the left handlebar.
  • Page 185: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD 110 Nm (11.0 mSkg, 80 ftSlb) 52 Nm (5.2 mSkg, 38 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) Order Job/Part Q’ty Remarks Removing the steering head Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL”...
  • Page 186: 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: S lower ring nut 1 (with the special tool 2 ) Steering nut wrench YU-1268 WARNING...
  • Page 187: Installing The Steering Head

    CHAS STEERING HEAD b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 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: S Always replace the bearings and bearing races as a set.
  • Page 188: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 40 Nm (4.0 mSkg, 29 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 48 Nm (4.8 mSkg, 35 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty...
  • Page 189: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.
  • Page 190: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 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 191: Checking The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. S spring Damage/wear ! Replace the rear shock ab- sorber assembly.
  • Page 192: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 125 Nm (12.5 mSkg, 90 ftSlb) 85 Nm (8.5 mSkg, 61 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Removing the swing arm and drive Remove the parts in the order listed. chain Rear wheel Refer to “REAR WHEEL”...
  • Page 193 CHAS SWINGARM AND DRIVE CHAIN 125 Nm (12.5 mSkg, 90 ftSlb) 85 Nm (8.5 mSkg, 61 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Bearing Spacer Shoft pedal assembly Drive sprocket cover Drive chain guide Drive sprocket Drive chain For installation, reverse the removal procedure.
  • Page 194: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EAS00703 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.
  • Page 195: Removing The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00704 REMOVING THE DRIVE CHAIN 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 196: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN 4. Check: S dust covers 1 S spacer 2 S oil seals 3 Damage/wear ! Replace. S bearings 4 Damage/pitting ! Replace. 5. Check: S connecting arms 1 S relay arm 2 Damage/wear ! Replace. S bearings 3 S oil seals 4 Damage/pitting ! Replace.
  • Page 197 CHAS SWINGARM AND DRIVE CHAIN 3. Clean: S drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosine and remove any remaining dirt. c. Remove the drive chain from the kerosine and completely dry it. CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain...
  • Page 198: Installing The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00713 INSTALLING THE DRIVE CHAIN 1. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Install: S drive chain 1 S drive sprocket 2 S lock washer 3 S drive sprocket nut 4 85 Nm (8.5 mSkg, 61 ftSlb) S drive chain guide 5...
  • Page 199 CHAS SWINGARM AND DRIVE CHAIN NOTE: Install the connecting arm front bolt 1 from the right. 3. Install: S rear shock absorber assembly S rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY” ”REAR WHEEL”. 4. Adjust: S drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...
  • Page 200: Eng

    CHAPTER 5 OVERHAULING THE ENGINE ENGINE ............DRIVE SPROCKET AND EXHAUST PIPE .
  • Page 201 CLUTCH ............5-36 CLUTCH COVER .
  • Page 202 TRANSMISSION ..........5-78 TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS...
  • Page 204: Overhauling The Engine

    ENGINE EAS00188 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET AND EXHAUST PIPE 10 Nm (1.0 m kg, 7.2 ft lb) 20 Nm (2.0 m kg, 14 ft lb) 85 Nm (8.5 m kg, 61 ft lb) 20 Nm (2.0 m kg, 14 ft lb) Order Job/Part Q’ty...
  • Page 205: Leads And Hoses

    ENGINE EAS00189 LEADS AND HOSES Order Job/Part Q’ty Remarks Removing the leads and hoses Remove the parts in the order listed. Cover Clutch cable Nuetral switch/speed sensor/pickup 1/1/1 Disconnect. coil lead Water head pipe Coolant outlet hose For installation, reverse the removal pro- cedure.
  • Page 206: Engine

    ENGINE EAS00191 ENGINE 55 Nm (5.5 m kg, 40 ft lb) 55 Nm (5.5 m kg, 40 ft lb) 24 Nm (2.4 m kg, 17 ft lb) 24 Nm (2.4 m kg, 17 ft lb) 33 Nm (3.3 m kg, 24 ft lb) Order Job/Part Q’ty...
  • Page 207: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: engine mount bolt 1 engine mount bolt 2 engine mount bolts 3 engine bracket 4 engine mount bolt 5 down tube 6 NOTE: Do not fully tighten the bolts. 2. Tighten the bolts in the following order. Engine mount bolt 1 55 Nm (5.5 m kg, 40 ft lb) Engine mount bolt 2...
  • Page 208: Camshaft

    CAMSHAFT EAS00194 CAMSHAFT CYLINDER HEAD COVER 13 Nm (1.3 m kg, 9.4 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Carburetor assembly Refer to “CARBURETORS”...
  • Page 209: Camshafts

    CAMSHAFT EAS00196 CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 24 Nm (2.4 m kg, 17 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty...
  • Page 210 CAMSHAFT 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 24 Nm (2.4 m kg, 17 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty...
  • Page 211: Removing The Camshafts

    CAMSHAFT EAS00198 REMOVING THE CAMSHAFTS 1. Remove: pickup rotor coil cover 2. Align: “T” mark on the pickup coil rotor a (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T”...
  • Page 212: Checking The Camshafts

    CAMSHAFT 7. Remove timing chain guide (exhaust side) 1 camshaft caps dowel pins CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 8.
  • Page 213 CAMSHAFT 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout Less than 0.03 mm (0.0012 in) 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ³ Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 X 0.062 mm (0.0011 X 0.0024 in) a.
  • Page 214: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

    CAMSHAFT EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: R timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set. 2.
  • Page 215: Installing The Camshafts

    CAMSHAFT 2. Check: R one-way cam operation Rough movement ! Replace the timing chain tensioner housing. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops.
  • Page 216 CAMSHAFT 3. Install: R camshaft cap bolts 10 Nm (1.0 mR kg, 7.2 ftR lb) NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and camshafts will result.
  • Page 217 CAMSHAFT d. Turn both camshafts opposite each other so that the punch marks c in the camshaft are aligned with the arrow marks d in the cam- shaft caps as shown. e. While holding the camshafts, temporarily tighten the camshaft sprocket bolts. 5.
  • Page 218 CAMSHAFT 7. Check: R “T” mark a Make sure that the “T” mark a on the pickup coil rotor is aligned with the crankcase mat- ing surface b . R camshaft punch marks c Make sure that the marks c on the camshaft are aligned with the arrow marks d in the comshaft caps.
  • Page 219: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 20 Nm (2.0 mSkg, 14 ftSlb) 20 Nm (2.0 mSkg, 14 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed.
  • Page 220: Removing The Cylinder Heads

    CYLINDER HEAD EAS00223 REMOVING THE CYLINDER HEADS 1. Remove: R cylinder head nuts R cylinder head cap nuts R cylinder head bolts NOTE: R Loosen the nuts in the proper sequence as shown. R Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.
  • Page 221: Installing The Cylinder Head

    CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: R gasket R dowel pins 2 2. Install: R cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: R cylinder head nuts 1 X 20 Nm (2.0 mR kg, 14 ftR lb) 50 Nm (5.0 mR kg, 36 ftR lb) R cylinder head bolt 11 12...
  • Page 222: 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”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal...
  • Page 223 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure.
  • Page 224: 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 that the valves properly seal. 1.
  • Page 225: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: R upper spring seat 1 R valve spring 2 R oil seal 3 R lower spring seat 4 R valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
  • Page 226 VALVES AND VALVE SPRINGS 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C in an oven. a. Remove the valve guide with a valve guide remover 1 .
  • Page 227: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 3. Eliminate: R carbon deposits (from the valve face and valve seat) 4. Check: R valve face Pitting/wear ! Grind the valve face. R valve stem end Mushroom shape or diameter larger than the body of the valve stem ! Replace the valve. 5.
  • Page 228 VALVES AND VALVE SPRINGS a. Apply Mechanic’s blueing dye (Dykem) 1 onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d.
  • Page 229: Checking The Valve Springs

    VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: R valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length Intake spring 38.9 mm (1.53 in) Exhaust spring 40.67 mm (1.60 in)
  • Page 230: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: R valve lifter Damage/scratches ! Replace the valve lift- ers and cylinder head. EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
  • Page 231 VALVES AND VALVE SPRINGS 4. Install: R valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and adapter 3 . Valve spring compressor set, Quick release YM-04019 Adapter Intake valve YM-4114 Exhaust valve YM-4108...
  • Page 232: Generator

    GENERATOR EB410000 GENERATOR 14 Nm (1.4 mSkg, 10 ftSlb) 65 Nm (6.5 mSkg, 47 ftSlb) + 60_ 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS”...
  • Page 233: Removing The Generator

    3 ) Alternator roter puller YM-01080-A INSTALLING THE GENERATOR 1. Apply: R sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 ACC-11001-05-01 2. Install: R generator rotor R washer R generator rotor bolt WARNING Always use a new generator rotor bolt.
  • Page 234 GENERATOR 3. Tighten: S generator rotor bolt 1 65 Nm (6.5 mSkg, 47 ftSlb) + 60_ NOTE: S While holding the generator rotor 2 with the universal magneto & rotor holder 3 , tighten the generator rotor bolt. S After tightening to 65 Nm (6.5 mSkg, 47 ftSlb), tighten another 60_.
  • Page 235: Pickup Coil

    PICKUP COIL PICKUP COIL 60 Nm (6.0 mR kg, 43 ftR lb) 12 Nm (1.2 mR kg, 8.7 ftR lb) 10 Nm (1.0 mR kg, 7.2 ftR lb) 15 Nm (1.5 mR kg, 11 ftR lb) Order Job/Part Q’ty Remarks Removing the pickup coil and Remove the parts in the order listed.
  • Page 236 PICKUP COIL 60 Nm (6.0 mR kg, 43 ftR lb) 12 Nm (1.2 mR kg, 8.7 ftR lb) 10 Nm (1.0 mR kg, 7.2 ftR lb) 15 Nm (1.5 mR kg, 11 ftR lb) Order Job/Part Q’ty Remarks Pickup coil coupler Disconnect.
  • Page 237: Removing The Plckup Coil Rotor

    PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remove: R pickup coil lead holder 1 R pickup coil rotor cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 238 Universal magneto & rotor holder YU-01235 3. Apply: R sealant (onto the pickup coil lead grommet) Yamaha bond No. 1215 ACC-11001-05-01 4. Install: R pickup coil rotor cover R pickup coil lead holder NOTE: R When installing the pickup coil rotor cover, align the timing chain guide (intake side) pin 1 with the hole 2 in the pickup coil rotor cover.
  • Page 239: Clutch

    CLUTCH EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3.
  • Page 240 CLUTCH EB405010 Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. 5-37...
  • Page 241: Clutch

    CLUTCH EAS00274 CLUTCH 12 Nm (1.2 mSkg, 8.7 ftSlb) 70 Nm (7.0 mSkg, 51 ftSlb) 8 Nm (0.8 mSkg, 5.8 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch cover Pull rod Friction plate Clutch plate Select.
  • Page 242 CLUTCH 12 Nm (1.2 mSkg, 8.7 ftSlb) 70 Nm (7.0 mSkg, 51 ftSlb) 8 Nm (0.8 mSkg, 5.8 ftSlb) Order Job/Part Q’ty Remarks Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear For installation, reverse the removal...
  • Page 243: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: R clutch boss nut 1 NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder YM-91042 3.
  • Page 244 CLUTCH 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness Friction plate a 3.42 X 3.58 mm (0.135 X 0.141 in) <Limit>: 3.32 mm (0.131 in) Friction plate b 2.92 X 3.08 mm...
  • Page 245: Checking The Clutch Plates

    CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: R clutch plate Damage ! Replace the clutch plates as a set. 2. Measure: R clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification ! Replace the clutch plates as a set.
  • Page 246: Checking The Clutch Housing

    CLUTCH EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: R clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: R bearing Damage/wear ! Replace the clutch hous- ing.
  • Page 247: Checking The Starter Clutch

    CLUTCH 2. Check: R pull rod bearing Damage/wear ! Replace. EAS00351 CHECKING THE STARTER CLUTCH 1. Check: R starter clutch rollers Damage/wear ! Replace. 2. Check: R starter clutch idle gear R starter clutch drive gear R starter clutch gear Burrs/chips/roughness/wear Replace the defective part(-s).
  • Page 248: Installing The Clutch

    CLUTCH 4. Check: starter clutch operation a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch drive gear clockwise A , the starter clutch and the start- er clutch drive gear should engage.
  • Page 249 CLUTCH 3. Bend the lock washer tab along a flat side of the nut. 4. Lubricate: S friction plates S clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 5. Install: S friction plates S clutch plates NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate.
  • Page 250 CLUTCH 7. Install: pressure plate 1 NOTE: Align the punch mark b in the pressure plate with the punch mark a in the clutch boss. 8. Install: clutch springs clutch spring bolts 8 Nm (0.8 m kg, 5.8 ft lb) NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern.
  • Page 251: Shift Shaft

    SHIFT SHAFT EAS00326 SHIFT SHAFT GENERATOR ROTOR COVER 12 Nm (1.2 m kg, 8.7 ft lb) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Drive sprocket cover Refer to “ENGINE”. Shift shaft cover Shift shaft cover gasket Dowel pin...
  • Page 252: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: shift shaft 1 Bends/damage/wear ! Replace. shift shaft spring 3 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.
  • Page 253: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 43 Nm (4.3 m kg,...
  • Page 254 OIL PAN AND OIL PUMP EB411001 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 43 Nm (4.3 m kg, 31 ft lb)
  • Page 255 OIL PAN AND OIL PUMP EAS00360 10 Nm (1.0 m kg, 7.2 ft lb) 15 Nm (1.5 m kg, 11 ft lb) Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. Oil/water pump assembly driven sprocket Washer Oil pump housing...
  • Page 256: Removing The Oil Pan

    OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: oil level switch 1 oil pan 2 engine oil drain bolt 3 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 257: Checking The Relief Valve

    OIL PAN AND OIL PUMP EAS00365 CHECKING THE RELIEF VALVE 1. Check: relief valve body 1 relief valve 2 spring 3 O-ring 4 Damage/wear ! Replace the defective part(-s). EAS00366 CHECKING THE OIL DELIVERY PIPE 1. Check: oil delivery pipe 1 oil pipe 2 Damage ! Replace.
  • Page 258: Installing The Oil Pump

    OIL PAN AND OIL PUMP 2. Install: pin 1 inner rotor 2 outer rotor 3 oil pump housing 4 Oil pump housing screw 10 Nm (1.0 m kg, 7.2 ft lb) NOTE: When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the in- ner rotor 2 .
  • Page 259: Installing The Oil Pan

    OIL PAN AND OIL PUMP EAS00380 INSTALLING THE OIL PAN 1. Install: dowel pins gasket oil pan 1 10 Nm (10 m kg, 7.2 ft lb) oil level switch 2 10 Nm (10 m kg, 7.2 ft lb) engine oil drain bolt 3 43 Nm (4.3 m kg, 31 ft lb) WARNING Always use new copper washers.
  • Page 260: Crankcase

    CRANKCASE EAS00381 CRANKCASE CRANKCASE 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”.
  • Page 261 CRANKCASE 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty Remarks Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin For installation, reverse the removal procedure. 5-58...
  • Page 262: Connecting Rods And Pistons

    CRANKCASE EAS00382 CONNECTING RODS AND PISTONS 36 Nm (3.6 m kg, 25 ft lb) Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod...
  • Page 263: Crankshaft

    CRANKCASE CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal procedure.
  • Page 264: Disassembling The Crankcase

    CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. 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 or- der (refer to the numbers in the illustration).
  • Page 265: Removing The Connecting Rods And Pistons

    CRANKCASE 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. 2.
  • Page 266: Removing The Crankshaft Assembly

    CRANKCASE 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. EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: crankshaft assembly 1 crankshaft journal upper bearings (from the upper crankcase)
  • Page 267: Checking The Cylinders And Pistons

    CRANKCASE EAS00256 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Check: piston wall cylinder wall Vertical scratches ! Rebore or replace the cylinder, and replace the piston and piston rings as a set. 2.
  • Page 268: Checking The Piston Rings

    CRANKCASE c. Measure piston skirt diameter “P” with the micrometer. a 5 mm (0.20 in) from the bottom edge of the piston. Piston size “P” 73.955 X 73.970 mm (2.9118 X 2.9122 in) d. If out of specification, replace the piston and piston rings as a set.
  • Page 269: Checking The Piston Pins

    CRANKCASE 2. Install: piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the pis- ton crown as shown. a 5 mm (0.20 in) 3. Measure: piston ring end gap Out of specification ! Replace the piston ring.
  • Page 270: Checking The Crankshaft And Connecting Rods

    CRANKCASE 3. Measure: piston pin bore inside diameter Out of specification → Replace the piston. Piston pin bore inside diameter 17.002 X 17.013 mm (0.6694 X 0.6698 in) 4. Calculate: piston-pin-to-piston clearance Out of specification ! Replace the piston pin and piston as a set.
  • Page 271 CRANKCASE 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 crank- shaft journal bearings must be installed in their original positions. a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase.
  • Page 272 CRANKCASE f. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase. Crankcase bolt Bolt 1 X 1st: 15 Nm (1.5 mSkg, 11 ftSlb) 2nd: 15 Nm (1.5 mSkg, 11 ftSlb) + 45 X 50_ Bolt 12 Nm (1.2 mSkg, 8.7 ftSlb) Bolt 14 Nm (1.4 mSkg, 10 ftSlb)
  • Page 273 CRANKCASE CRANKSHAFT JOURNAL BEARING COLOR CODE –1 Pink/violet Pink/white Pink/blue Pink/black Pink/brown 5. Measure: crankshaft-pin-to-big-end-bearing clear- ance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.031 X 0.055 mm (0.0012 X 0.0022 in) The following procedure applies to all of the connecting rods.
  • Page 274 CRANKCASE  c. Put a piece of Plastigauge 1 on the crank- shaft pin. d. Assemble the connecting rod halves. NOTE: Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Apply molybdenum disulfide grease onto the bolts, threads, and nut seats.
  • Page 275: Checking The Crankcase

    CRANKCASE 6. Select: big end bearings (P NOTE: The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. “P1” X “P5” refer to the bearings shown in the crankshaft illustration.
  • Page 276: Checking The Sprockets And Chains

    CRANKCASE CHECKING THE SPROCKETS AND CHAINS 1. Check: crankshaft sprocket 1 oil/water pump assembly drive sprocket 2 Cracks/damage/wear ! Replace the de- fective part(-s). 2. Check: timing chain 1 Damage/stiffness ! Replace the timing chain and crankshaft sprocket as a set. oil/water pump assembly drive chain 2 Damage/stiffness ! Replace the oil/water pump assembly drive chain and oil/water...
  • Page 277: Installing The Connecting Rod And Piston

    CRANKCASE EAS00268 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons. 1. Install: top ring 1 2nd ring 2 upper oil ring rail 3 oil ring expander 4 lower oil ring rail 5 NOTE: Be sure to install the piston rings so that the manufacturer’s marks or numbers a face up.
  • Page 278 CRANKCASE 5. Lubricate: crankshaft pins big end bearings connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6. Install: big end bearings connecting rod assembly (into the cylinder and onto the crankshaft pin). connecting rod cap (onto the connecting rod) NOTE: Align the projections on the big end bearings...
  • Page 279: Assembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 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 X 3 mm of the crankshaft journal bearings.
  • Page 280 CRANKCASE 6. Install: S upper crankcase 1 (onto the lower crankcase 2 ) CAUTION: Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 7. Install: S crankcase bolts NOTE: S Lubricate the bolt threads with engine oil.
  • Page 281: Transmission

    TRANSMISSION EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate.
  • Page 282 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassembly the parts in the order listed. assembly 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gears 5th pinion gear Collar 5-79...
  • Page 283 TRANSMISSION Order Job/Part Q’ty Remarks Main axle/1st pinion gear Bearing Main axle bearing housing For assembly, reverse the disassembly procedure. 5-80...
  • Page 284 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Disassembly the parts in the order listed. assembly Washer 1st wheel gear Spacer 5th wheel gear Circlip Washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 5-81...
  • Page 285 TRANSMISSION Order Job/Part Q’ty Remarks 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer For assembly, reverse the disassembly procedure. 5-82...
  • Page 286: Removing The Transmission

    TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: main axle assembly 1  (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crank- case surface.
  • Page 287: Checking The Shift Drum Assembly

    TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: shift drum grooves Damage/scratches/wear ! Replace the shift drum. shift drum segment 1 Damage/wear ! Replace. shift drum bearing 2 Damage/pitting ! Replace. EAS00425 CHECKING THE TRANSMISSION 1. Measure: main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main axle.
  • Page 288: Installing The Transmission

    TRANSMISSION EAS00428 INSTALLING THE TRANSMISSION main axle assembly shift fork “C” shift drum assembly shift fork “R” shift fork “L” springs shift fork guide bars drive axle assembly NOTE: Carefully position the shift forks so that they are installed correctly into the transmission gears.
  • Page 290: Cool

    COOL CHAPTER 6 COOLING SYSTEM RADIATOR ........... . CHECKING THE RADIATOR .
  • Page 291 COOL...
  • Page 292: Cooling System

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Coolant Drain. Water inlet hose Carburetor hose Oil cooler hose Water outlet hose Radiator Fan motor For installation, reverse the removal procedure.
  • Page 293: Checking The Radiator

    COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.
  • Page 294: Installing The Radiator

    COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. a.
  • Page 295: Thermostat

    COOL THERMOSTAT EAS00460 THERMOSTAT Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Front cowling Refer to “FRONT COWLING” in chapter 3. Coolant reservoir hose Water inlet hose Water outlet hose Thermostat housing For installation, reverse the removal procedure.
  • Page 296 COOL THERMOSTAT EAS00461 15 Nm (1.5 mSkg, 11 ftSlb) Order Job/Part Q’ty Remarks Disassembling the thermostat housing Disassemble the parts in the order listed. Thermostat housing cover Thermostat /O-ring Thermostat housing Thermo unit For assembly, reverse the disassembly procedure.
  • Page 297: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat Does not open at 71 X 85_C (160 X 185_F) ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.
  • Page 298: Installing The Thermostat

    COOL THERMOSTAT 2. Install: thermo unit 1 15 Nm (1.5 m kg, 11 ft lb) CAUTION: Use extreme care when handling the thermo unit. Replace any part that was dropped or subjected to a strong impact. EAS00466 INSTALLING THE THERMOSTAT 1.
  • Page 299: Water Pump

    COOL WATER PUMP EAS00469 WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. NOTE: The water pump and oil pump are combined into one unit (oil/water pump assembly).
  • Page 300 COOL WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty Remarks Water pump seal Oil seal Bearing For assembly, reverse the disassembly procedure.
  • Page 301: Disassembling The Water Pump

    COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: oil sesal 1 bearing 2 NOTE: Tap out the bearing and oil seal from the outside of the water pump housing.
  • Page 302: Assembling The Water Pump

    NOTE: Install the water pump seal with the water pump seal installers. Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Water pump seal installer 4 YM-33221 40 and 50 mm Bearing driver 5 YM-4058 Yamaha bond No.1215...
  • Page 303 COOL WATER PUMP 3. Install: rubber damper rubber damper holder NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: tilt Out of specification ! Repeat steps (3) and (4). CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler.
  • Page 304: Carb

    CARB CHAPTER 7 CARBURETORS CARBURETORS ..........AIR FILTER CASE .
  • Page 305 CARB...
  • Page 306 CARB CARBURETORS CARBURETORS CARBURETORS AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seat, fueltank and sidecovers Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. Drain the coolant Refer to “CHANGING THE COOLANT”...
  • Page 307 CARB CARBURETORS EAS00481 Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Throttle position sensor lead Disconnect. Air filter joint screw Carburetors joint screw Carburetor inlet/outlet hose Carburetors assembly Starter cable Throttle cable For installation, reverse the removal procedure.
  • Page 308 CARB CARBURETORS EAS00482 Order Job/Part Q’ty Remarks Separating the carburetor Remove the parts in the order listed. Throttle stop screw Coolant hose Starter plunger link Connecting bolt Spacer Connecting bolt Spacer Fuel inlet pipe Fuel feed pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Throttle position sensor bracket...
  • Page 309 CARB CARBURETORS EAS00484 Order Job/Part Q’ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. NOTE: The following procedure applies to all of the carburetors. Starter plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Fuel drain bolt...
  • Page 310 CARB CARBURETORS Order Job/Part Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet For assembly, reverse the disassembly procedure.
  • Page 311 CARB CARBURETORS EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleum-based solvent.
  • Page 312 CARB CARBURETORS 8. Check: S piston valve 1 Damage/scratches/wear! Replace. S rubber diaphragm 2 Cracks/tears ! Replace. 9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 Cracks/damage ! Replace. 10. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S main jet holder 4...
  • Page 313 CARB CARBURETORS EAS00489 ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent. S Always use a new gasket. 1. Install: S jet needle kit 2.
  • Page 314 CARB CARBURETORS d. If either the needle valve seat or needle valve is worn, replace them both. e. If both the needle valve seat and needle valve are fine, adjust the float height by bend- ing the float tang 1 . f.
  • Page 315 CARB CARBURETORS EAS00495 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust. Fuel level (below the line on the float chamber) 3.0 X 4.0 mm (0.118 X 0.157 in) a. Stand the motorcycle on a level surface. b.
  • Page 316 CARB CARBURETORS EAS00500 CHECKING ADJUSTING THROTTLE POSITION SENSOR NOTE: S Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. S When installing the throttle position sensor, adjust its angle according to the RPM which is displayed on the tachometer.
  • Page 317 CARB CARBURETORS 2. Adjust: throttle position sensor angle a. Turn the main switch to “ON”. b. Disconnect the throttle position sensor cou- pler. c. Reconnect the throttle position sensor cou- pler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode.
  • Page 318 CARB CARBURETORS EAS00504 CHECKING THE FUEL PUMP 1. Check: fuel pump 1 a. Place a container under the end of the fuel hose. b. Start the engine and check if fuel flows from the fuel hose 2 . Fuel flows. Fuel pump is OK.
  • Page 319: Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex- haust gases by injecting fresh air (secondary 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 320 CARB AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Carburetor joint (cylinder #4) A To the air cutoff valve B To cylinder #1 C To cylinder #2 D To cylinder #3 E To cylinder #4 7-15...
  • Page 321 CARB 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 1 _fibre reed stopper _reed valve seat Cracks/damage ! Replace the reed valve. 3.
  • Page 322: Elec

    ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ........ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS .
  • Page 323 ELEC EXUP SYSTEM ..........8-51 CIRCUT DIAGRAM .
  • Page 324: Electrical

    ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Main switch Starting circuit cutoff relay Oil level gauge Fuel sender Flasher relay Ignition coil Rear brake switch Speed sensor Rectifier/ Regulator Battery Sidestand switch Thermo unit Ignitor unit Neutral switch Horn Starter relay Emargency stop switch Fan motor relay...
  • Page 325: Arrangement Of The Electrical Components And Couplers

    ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS Thermo unit T.P.S. Starter motor Pickup rotor Pickup coil...
  • Page 326 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Ignitor unit Fuse box Battery Fuel pump Fuel pump coupler Brake light switch coupler Newtral switch coupler Pickup coil coupler Speed sensor coupler...
  • Page 327 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Ignition coil #2.3 Ignition coil #1.4 Rectifier/ regulator Stator coil...
  • Page 328 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Emargency stop switch Flasher relay Starter relay Fan motor relay Starting circuit cutoff relay Stator coil coupler Sidestand switch coupler Fuel sender coupler Oil level switch coupler...
  • Page 329: Instrument Functions

    ELEC INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS INDICATOR LIGHTS Turn indicator light “ ” “ ” This indicator flashes when the turn switch is moved to the left or right. Neutral indicator light “ ” This indicator comes on when the transmis- sion is in neutral.
  • Page 330 ELEC INSTRUMENT FUNCTIONS DIGITAL CLOCK Clock To set the clock: 1. Push both the “SELECT” 1 and “RESET” 2 buttons for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button 2 to set the hours. 3.
  • Page 331: 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 incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1 .
  • Page 332: 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 termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.
  • Page 333: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING BULBS BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect.
  • Page 334: Checking The Condition Of The Bulbs

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING CONDITION BULBS The following procedure applies to all of the bulbs. 1. Remove: bulb 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 re- moving the bulb.
  • Page 335: 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 measurement YU-03112-C NOTE: Check each bulb socket for continuity in the...
  • Page 336: Ignition System

    ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Ignitor Ignition coil Spark plug Pickup coil Engine stop switch Fuse (ignition) 8-13...
  • Page 337: Troubleshooting

    ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING THE BATTERY” in spark or intermittent spark). CHAPTER 3. Check: Minimum open-circuit voltage 1. Main and ignition fuses 12.8 V or more at 20_C (68_F) 2.
  • Page 338 ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 kΩ at 20_C (68_F) The following procedure applies to all of the S Is the spark plug cap OK? spark plugs. S Disconnect the spark plug cap from the spark plug.
  • Page 339 ELEC IGNITION SYSTEM EAS00748 Secondary coil resistance 9. Pickup coil resistance 12 X 18 kΩ at 20_C (68_F) S Disconnect the pickup coil coupler from the S Is the ignition coil OK? wire harness. S Connect the pocket tester (Ω 100) to the pickup coil terminal as shown.
  • Page 340: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Starter relay Fuse (main) Starter motor Starting circuit cutoff relay Side stand switch Neutral switch Engine stop switch Start switch Clutch switch Fuse (ignition) 8-17...
  • Page 341: Starting Circuit Cutoff System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUTOFF SYSTEM OP- ERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: The transmission is in neutral (the neutral switch is closed).
  • Page 342: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING THE BATTERY” in Check: CHAPTER 3. 1. Main and ignition fuses Minimum open-circuit voltage 2. Battery 12.8 V or more at 20_C (68_F) 3.
  • Page 343 ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cutoff relay Disconnect the starting circuit cutoff relay coupler from the wire harness. Connect the pocket tester (Ω X 1) and bat- tery (12 V) to the starting circuit cutoff relay coupler as shown. Positive battery lead ! red/black Negative battery lead ! black/yellow Does the starter relay have continuity be-...
  • Page 344 ELEC ELECTRIC STARTING SYSTEM EAS00751 EAS00766 8. Neutral switch 12. Wiring Check the neutral switch for continuity. Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. Is the neutral switch OK? Is the starting system’s wiring properly con- nected and without defects? Replace the neutral switch.
  • Page 345: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Carburetor Refer to “CARBURETOR” in chapter 7. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. 8-22...
  • Page 346 ELEC ELECTRIC STARTING SYSTEM EAS00768 5 Nm (0.5 m kg, 3.6 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassemble the parts in the order listed. Starter motor front cover Lock washer Refer to “ASSEMBLING THE STARTER Oil seal...
  • Page 347: Checking The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600-grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.
  • Page 348: Assembling The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM b. If any resistance is out of specification, re- place the starter motor. 5. Measure: brush length a Out of specification ! Replace the brushes as a set. Brush length wear limit 4 mm (0.16 in) 6.
  • Page 349 ELEC ELECTRIC STARTING SYSTEM 2. Install: starter motor front cover 1 starter motor rear cover 2 O-ring 3 NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers. 8-26...
  • Page 350: Charging System

    ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM Rectifire/ reguretor AC magneto Battery Fuse (main) 8-27...
  • Page 351: Troubleshooting

    ELEC CHARGING SYSTEM EAS00774 TROUBLESHOOTING The battery is not being charged. S Clean the battery terminals. Check: S Recharge 1. Main fuse place the battery. 2. Battery 3. Charging voltage 4. Stator coil resistance EAS00775 3. Charging voltage 5. Wiring connections (of the entire charging system) S Connect inductive...
  • Page 352 ELEC CHARGING SYSTEM EAS00776 4. Stator coil resistance S Remove the generator cover. S Connect the pocket tester (Ω 1) to the sta- tor coils as shown. Positive tester probe ! white Negative tester probe ! white Positive tester probe ! white Negative tester probe ! white S Measure the stator coil resistances.
  • Page 353: Lighting System

    ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM Main switch Front turn signal light (right) Headlight Battery Tail/ brake light Fuse (main) Hi-beam indicator light Fuse (ignition) Fuse (headlight) Meter light Headlight relay (dimmer) Dimmer switch Front turn signal light (left) 8-30...
  • Page 354: Troubleshooting

    ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Any of the following fail to light: headlight, S Clean the battery high beam indicator light, taillight, auxilia- terminals. ry light or meter light. S Recharge Check: place the battery. 1. Main, ignition and headlight fuses 2.
  • Page 355 ELEC LIGHTING SYSTEM EAS00787 5. Headlight relay (dimmer) 6. Wiring Disconnect the headlight relay (dimmer) Check entire lighting system’s wiring. from the coupler. Refer to “CIRCUIT DIAGRAM”. Connect the pocket tester (Ω X 1) and bat- tery (12 V) to the headlight relay (dimmer) Is the lighting system’s wiring properly con- coupler as shown.
  • Page 356 ELEC LIGHTING SYSTEM EAS00788 Set the main switch to “ON”. CHECKING THE LIGHTING SYSTEM Set the dimmer switch to “ ” or “ ”. 1. The headlight and the high beam indicator Measure the voltage (12 V) (wire harness light fail to come on. side).
  • Page 357 ELEC LIGHTING SYSTEM Set the main switch to “ON”. Set the main switch to “ON”. Measure the voltage (12 V) of blue on the Measure the voltage (12 V) of blue/red meter light coupler (wire harness side). the tail/brake light coupler (tail/brake light side).
  • Page 358: Signal System

    ELEC SIGNAL SYSTEM EAS00793 SIGNAL SYSTEM CIRCUIT DIAGRAM 8-35...
  • Page 359 ELEC SIGNAL SYSTEM 1 Main switch 5 Battery 7 Fuse (main) 9 Starting circuit cutoff relay Neutral switch Fuel level warning light Oil level warning light Neutral indicator light Combination meter Fuel gauge Turn signal indicator light (left) Turn signal indicator light (right) Oil level gauge Fuel sender Turn signal relay...
  • Page 360: Troubleshooting

    ELEC SIGNAL SYSTEM EAS00794 EAS00749 TROUBLESHOOTING 3. Main switch S Any of the following fail to come on: turn S Check the main switch for continuity. signal light, brake light or indicator light. Refer to “CHECKING THE SWITCHES”. S The horn fails to sound. S Is the main switch OK? Check: 1.
  • Page 361 ELEC SIGNAL SYSTEM Positive tester probe ! brown 4. Voltage Negative tester probe ! black Connect the pocket tester (DC 20 V) to the horn connector at the black terminal as shown. Positive tester probe ! black Negative tester probe ! ground Set the main switch to “ON”.
  • Page 362 ELEC SIGNAL SYSTEM 3. Voltage 2. Turn signal switch Connect the pocket tester (DC 20 V) to the Check the turn signal switch for continuity. tail/brake light coupler (wire harness side) Refer to “CHECKING THE SWITCHES”. as shown. Is the turn signal switch OK? Positive tester probe ! yellow Negative tester probe ! black Replace the left han-...
  • Page 363 ELEC SIGNAL SYSTEM 4. Voltage Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown. Positive tester probe ! brown/white Negative tester probe ! ground Set the main switch to “ON”. Set the turn signal switch to “ ”...
  • Page 364 ELEC SIGNAL SYSTEM 3. Voltage 2. Engine oil level switch Connect the pocket tester (DC 20 V) to the Drain the engine oil and remove the engine meter light bulb coupler (wire harness side) oil level switch from the oil pan. as shown.
  • Page 365 ELEC SIGNAL SYSTEM EAS00804 S Set the main switch to “ON”. 5. The fuel level gauge fails to operate. S Measure the voltage (12 V) of brown 1. Fuel sender the meter light coupler (wire harness side). S Remove the fuel sender from the fuel tank. S Is the voltage within specification? S Connect the pocket tester to the fuel sender coupler (wire harness side) as shown.
  • Page 366: Cooling System

    ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Thermo unit Combination meter Water temp warning light Fues (fan) Fan motor relay Fan motor 8-43...
  • Page 367: Troubleshooting

    ELEC COOLING SYSTEM EAS00808 S Is the battery OK? TROUBLESHOOTING S The radiator fan motor fails to turn. S The water temperature gauge needle fails to move when the engine is warm. S Clean the battery terminals. Check: S Recharge 1.
  • Page 368 ELEC COOLING SYSTEM EAS00812 EAS00759 5. Thermo unit 6. Fan motor relay S Remove the thermo unit from the thermostat S Disconnect the fan motor relay coupler from housing. the wire harness. S Connect the pocket tester (Ω  1) to the ter- S Connect the pocket tester (Ω...
  • Page 369: Fuel Pump System

    ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starting circuit cutoff relay Fuel pump Ignitor Engine stop switch Fuse (ignition) 8-46...
  • Page 370: Fuel Pump Circuit Operation

    ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP CIRCUIT OPERATION Battery The ignitor unit includes the control unit for the Main fuse fuel pump. Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump 8-47...
  • Page 371: Troubleshooting

    ELEC FUEL PUMP SYSTEM EAS00816 EAS00749 TROUBLESHOOTING 3. Main switch S Check the main switch for continuity. If the fuel pump fails to operate. Refer to “CHECKING THE SWITCHES”. Check: S Is the main switch OK? 1. Main and ignition fuses 2.
  • Page 372 ELEC FUEL PUMP SYSTEM EAS00817 6. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel pump coupler as shown. Positive tester probe  black/blue Negative tester probe  black S Measure the fuel pump resistance.
  • Page 373: Checking The Fuel Pump

    ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: Stop the engine before refuelling. Do not smoke, and keep away from open flames, sparks, or any other source of fire.
  • Page 374: Exup System

    ELEC EXUP SYSTEM EAS00827 EXUP SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) EXUP servomotor Ignitor Fuse (ignition) 8-51...
  • Page 375: Troubleshooting

    ELEC EXUP SYSTEM EAS00828 EAS00829 Procedure 1 TROUBLESHOOTING 1. EXUP servomotor operation (with the When the engine speed changes, the EXUP servomotor coupler connected to EXUP servomotor does not operate. the wire harness) Procedure 1 Disconnect the EXUP cables at the EXUP Check: servomotor pulley side.
  • Page 376 ELEC EXUP SYSTEM EAS00831 3. EXUP servomotor operation (with the servomotor coupler disconnected to the wire harness) Disconnect the EXUP cables from the EXUP servomotor pulley. Disconnect the EXUP servomotor coupler from the wire harness. Connect the battery leads to the EXUP ser- vomotor coupler as shown.
  • Page 377 ELEC EXUP SYSTEM Procedure 2 EAS00750 4. Engine stop switch EAS00738 1. Main and ignition fuses S Check the engine stop switch for continuity. S Check the main and ignition fuses for conti- Refer to “CHECKING THE SWITCHES”. nuity. S Is the engine stop switch OK? Refer to “CHECKING THE FUSES”...
  • Page 378: Self-Diagnosis

    ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The FZS1000 features a self-diagnosing system for the following circuit(-s): Throttle position sensor EXUP Speed sensor Emargency stop switch If any of these circuits are defective, their respective condition codes will be displayed on the tachome- ter when the main switch is set to “ON” (irrespective of whether the engine is running or not) Circuit Defect(-s) System response...
  • Page 379 ELEC SELF-DIAGNOSIS Tachometer display sequence Revolution 0 r / min ... 3 seconds r / min) Condition code ... 2.5 seconds Tachometer display Engine speed ... 3 seconds Engine speed Time (seconds) When more than one item is being monitored, the tachometer needle displays the condition codes in ascending order, cycling through the sequence repeatedly.
  • Page 380 ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The tachometer starts to display the self- Check the wire harness for continuity. diagnosis sequence. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? Check: 1. Throttle position sensor 2. EXUP 3. Speed sensor 4.
  • Page 381 ELEC SELF-DIAGNOSIS 2. EXUP 2. EXUP servomotor CIRCUIT DIAGRAM Check the EXUP servomotor for continuity. Refer to “EXUP SYSTEM”. Is the EXUP servomotor OK? Replace the ignitor Replace the EXUP unit. servomotor. EXUP servomotor Ignitor unit 1. Wire harness Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”.
  • Page 382 ELEC SELF-DIAGNOSIS 3. Speed sensor 1. Wire harness CIRCUIT DIAGRAM Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? Replace the speed sensor. Replace the ignitor Repair or replace the unit. wire harness. lgnitor unit Speed sensor 8-59...
  • Page 383 ELEC SELF-DIAGNOSIS 4. Emargency stop switch 1. Wire harness CIRCUIT DIAGRAM Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Is the wire harness OK? Replace the emar- gency stop switch. Replace the ignitor Repair or replace the unit. wire harness.
  • Page 384: Trbl Shtg

    TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING PROBLEMS ENGINE ........... FUEL SYSTEM .
  • Page 385 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT ......HEADLIGHT BULB BURNT OUT .
  • Page 386: Troubleshooting

    TRBL TROUBLESHOOTING 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 manual for checks, adjustments, and replacement of parts.
  • Page 387: Electrical Systems

    TRBL TROUBLESHOOTING SHTG ELECTRICAL SYSTEMS Battery Ignition system S Discharged battery S Faulty ignitor unit S Faulty battery S Faulty pickup coil S Broken generator rotor woodruff key Fuse(s) S Blown, damaged or incorrect fuse Switches and wiring S Improperly installed fuse S Faulty main switch S Faulty engine stop switch S Broken or shorted wiring...
  • Page 388: Fuel System

    TRBL TROUBLESHOOTING SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE FUEL SYSTEM Air filter Carburetor(s) S Clogged air filter element S Faulty diaphragm S Incorrect fuel level S Loose or clogged main jet Fuel pump S Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT...
  • Page 389: Faulty Clutch Clutch Slips

    TRBL TROUBLESHOOTING SHTG EAS00851 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch S Improperly assembled clutch S Unevenly tensioned clutch springs S Improperly adjusted clutch cable S Warped pressure plate S Loose or fatigued clutch spring S Bent clutch plate S Worn friction plate S Swollen friction plate S Worn clutch plate...
  • Page 390: Overcooling Cooling System

    TRBL TROUBLESHOOTING SHTG EAS00856 OVERCOOLING COOLING SYSTEM Thermostat S Thermostat stays open EAS00857 POOR BRAKING PERFORMANCE S Worn brake pad S Worn brake disc S Air in hydraulic brake system S Leaking brake fluid S Faulty brake caliper seal S Loose union bolt S Damaged brake hose S Oil or grease on the brake disc S Oil or grease on the brake pad...
  • Page 391: Unstable Handling

    TRBL TROUBLESHOOTING SHTG EAS00862 UNSTABLE HANDLING Handlebar Rear shock absorber assembly(-ies) S Bent or improperly installed handlebar S Faulty rear shock absorber spring S Leaking oil or gas Steering head components S Improperly installed upper bracket Tire(s) S Improperly installed lower bracket S Uneven tire pressures (front and rear) S Incorrect tire pressure (improperly tightened ring nut)
  • Page 392: Faulty Lighting Or Signaling System

    TRBL TROUBLESHOOTING SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT TURN SIGNAL DOES NOT LIGHT S Wrong headlight bulb S Faulty turn signal switch S Too many electrical accessories S Faulty turn signal relay S Hard charging S Burnt-out turn signal bulb S Incorrect connection S Incorrect connection...
  • Page 394 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

This manual is also suitable for:

Fzs1000nc