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Yamaha YZF-R1K Service Manual

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Table of Contents

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YZF-R1K
YZF-R1KC
SERVICE MANUAL
LIT-11616-11-25
4XV-28197-E0

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Summary of Contents for Yamaha YZF-R1K

  • Page 1 YZF-R1K YZF-R1KC SERVICE MANUAL LIT-11616-11-25 4XV-28197-E0...
  • Page 2 YZF-R1K/YZF-R1KC SERVICE MANUAL © 1998 by Yamaha Motor Corporation, U.S.A. First edition, January 1998 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-11616-11-25...

  • Page 3: Important Manual Information

    EB001001 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the tech- niques to repair these types of vehicles.

  • Page 4: How To Use This Manual

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

  • Page 7: Table Of Contents

    CONTENTS CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ..............1-1 VEHICLE IDENTIFICATION NUMBER ..........1-1 MODEL CODE ..................1-1 IMPORTANT INFORMATION ..............1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY ...... 1-2 REPLACEMENT PARTS ............... 1-2 GASKETS, OIL SEALS AND O-RINGS ..........1-2 USING A DYNAMOMETER ..............
  • Page 8 OIL FLOW DIAGRAMS ................2-25 COOLANT FLOW DIAGRAMS ..............2-29 CABLE ROUTING ..................2-33 INFO CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS SPEC INTRODUCTION ................... 3-1 PERIODIC MAINTENANCE CHART FOR EMISSION INSP CONTROL SYSTEM ................. 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-2 SEATS ......................
  • Page 9 CHECKING THE CARBURETOR JOINTS .......... 3-30 CHECKING THE FUEL HOSES AND FUEL FILTER ......3-31 CHECKING THE CRANKCASE BREATHER HOSE ......3-31 CHECKING THE EXHAUST SYSTEM ..........3-32 ADJUSTING THE EXUP CABLES ............3-33 CHECKING THE COOLANT LEVEL ............ 3-34 CHECKING THE COOLING SYSTEM ..........
  • Page 10 CHAPTER 4. OVERHAULING THE ENGINE ENGINE ......................4-1 INSTALLING THE ENGINE ..............4-7 INFO CAMSHAFTS ....................4-8 REMOVING THE CAMSHAFTS ............4-11 CHECKING THE CAMSHAFTS ............4-12 SPEC CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES ............4-13 CHECKING THE TIMING CHAIN TENSIONER ........
  • Page 11 CHECKING THE PRESSURE PLATE ..........4-45 CHECKING THE PULL LEVER SHAFT AND PULL ROD ....4-45 CHECKING THE STARTER CLUTCH ..........4-45 INSTALLING THE CLUTCH ..............4-46 SHIFT SHAFT ..................... 4-49 CHECKING THE SHIFT SHAFT ............4-50 CHECKING THE STOPPER LEVER ............ 4-50 INSTALLING THE SHIFT SHAFT ............
  • Page 12 TRANSMISSION ..................4-79 REMOVING THE TRANSMISSION ............ 4-85 CHECKING THE SHIFT FORKS ............4-85 CHECKING THE SHIFT DRUM ASSEMBLY ........4-86 CHECKING THE TRANSMISSION ............. 4-86 INSTALLING THE TRANSMISSION ..........4-87 INFO CHAPTER 5. COOLING SYSTEM SPEC RADIATOR ....................5-1 CHECKING THE RADIATOR ..............
  • Page 13 CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS ............7-1 REMOVING THE FRONT WHEEL ............7-3 DISASSEMBLING THE FRONT WHEEL ..........7-3 CHECKING THE FRONT WHEEL ............7-4 CHECKING THE BRAKE DISCS ............7-5 ASSEMBLING THE FRONT WHEEL ............ 7-6 INSTALLING THE FRONT WHEEL ............
  • Page 14 HANDLEBARS .................... 7-56 REMOVING THE HANDLEBARS ............7-58 CHECKING THE HANDLEBARS ............7-58 INSTALLING THE HANDLEBARS ............. 7-59 STEERING HEAD ..................7-61 INFO REMOVING THE LOWER BRACKET ..........7-63 CHECKING THE STEERING HEAD ............ 7-63 INSTALLING THE STEERING HEAD ..........7-64 SPEC REAR SHOCK ABSORBER ASSEMBLY ............
  • Page 15 CHECKING THE BULBS AND BULB SOCKETS ......... 8-8 TYPES OF BULBS ................8-8 CHECKING THE CONDITION OF THE BULBS ........8-8 CHECKING THE CONDITION OF THE BULB SOCKETS ....8-10 CHECKING THE LEDs ................ 8-10 IGNITION SYSTEM ..................8-11 CIRCUIT DIAGRAM ................8-11 TROUBLESHOOTING ................
  • Page 16 EXUP SYSTEM ................... 8-54 CIRCUIT DIAGRAM ................8-54 TROUBLESHOOTING ................ 8-55 SELF-DIAGNOSIS ..................8-58 TROUBLESHOOTING ................ 8-59 INFO CHAPTER 9. TROUBLESHOOTING SPEC STARTING PROBLEMS ................9-1 ENGINE ....................9-1 FUEL SYSTEM ..................9-1 INSP ELECTRICAL SYSTEMS ............... 9-1 INCORRECT ENGINE IDLING SPEED ............9-2 ENGINE ....................
  • Page 17 OVERCOOLING .................... 9-3 COOLING SYSTEM ................9-3 POOR BRAKING PERFORMANCE .............. 9-4 FAULTY FRONT FORK LEGS ..............9-4 LEAKING OIL ..................9-4 MALFUNCTION ..................9-4 UNSTABLE HANDLING ................9-4 FAULTY LIGHTING AND SIGNALING SYSTEMS ........9-5 HEADLIGHT DOES NOT LIGHT ............9-5 HEADLIGHT BULB BURNT OUT ............

  • Page 18: Chapter 1. General Information

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

  • Page 19: Important Information

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

  • Page 20: Using A Dynamometer

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

  • Page 21: Checking The Connections

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

  • Page 22: Special Tools

    SPECIAL TOOLS INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 23 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 Rod puller attachment Rod puller...
  • Page 24 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Inductive tachometer YU-8036-A This tool is used to check engine speed. Timing light YM-33277-A This tool is used to check the ignition tim- ing. Valve spring com- Valve spring compressor pressor Attachment YM-04019 Attachment These tools are used to remove or install...
  • Page 25 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Dynamic spark tester YM-34487 This tool is used to check the ignition sys- tem components. ® Quick Gasket ACC-11001-05- This sealant is used to seal two mating surfaces (e.g., crankcase mating surfaces). 1 - 8...

  • Page 26: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Dimensions Overall length 2,035 mm (80.1 in) ---- Overall width 695 mm (27.4 in) ---- Overall height 1,095 mm (43.1 in) ---- Seat height 815 mm (32.1 in) ---- Wheelbase 1,395 mm (54.9 in) ---- Minimum ground clearance 140 mm (5.51 in)

  • Page 27: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 998 cm ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11.8:1 ---- Engine idling speed 1,050 ~ 1,150 r/min...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) ---- Bypass valve opening pressure 180 ~ 220 kPa ---- (1.8 ~ 2.2 kgf/cm , 25.6 ~ 31.3 psi) Oil pump Oil pump type Trochoidal ---- Inner-rotor-to-outer-rotor-tip 0.09 ~ 0.15 mm (0.004 ~ 0.006 in) ---- clearance...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) ---- Camshaft cap inside diameter 24.500 ~ 24.521 mm ---- (0.9646 ~ 0.9654 in) Camshaft journal diameter 24.437 ~ 24.450 mm ---- (0.9621 ~ 0.9626 in) Camshaft-journal-to-camshaft- 0.050 ~ 0.084 mm (0.0020 ~ 0.0033 in) ---- cap clearance Intake camshaft lobe dimensions...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015 / 130 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.11 ~ 0.20 mm (0.0043 ~ 0.0079 in) ---- Exhaust 0.21 ~ 0.30 mm (0.0083 ~ 0.0118 in) ---- Valve dimensions Head Diameter...
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem runout ---- 0.01 mm (0.0004 in) Valve seat width Intake 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) ---- Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) ---- Valve springs Free length Intake 38.9 mm (1.53 in) ----...
  • Page 32 SPEC ENGINE SPECIFICATIONS Item Standard Limit Cylinders Cylinder arrangement Forward-inclined, parallel 4-cylinder ---- Bore × stroke 74 × 58 mm (2.91 × 2.28 in) ---- Compression ratio 11.8:1 ---- Bore 74.00 ~ 74.010 mm (2.9134 ~ 2.9138 in) ---- Max. taper ---- 0.05 mm (0.0016 in)
  • Page 33 SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper ---- Dimensions (B × T) 0.8 × 2.8 mm (0.031 × 0.110 in) ---- End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) ---- Ring side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) ---- Oil ring...
  • Page 34 SPEC ENGINE SPECIFICATIONS Item Standard Limit Friction plates Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm (0.110 in) Plate quantity ---- Clutch plates Thickness 1.9 ~ 2.1 mm (0.075 ~ 0.083 in) ---- Plate quantity ---- Max. warpage ---- 0.1 mm (0.004 in)
  • Page 35 SPEC ENGINE SPECIFICATIONS Item Standard Limit Carburetors Model (manufacturer) × quantity BDSR40 ( MIKUNI ) × 4 ---- Throttle cable free play (at the 3 ~ 5 mm (0.12 ~ 0.20 in) ---- flange of the throttle grip) ID mark 4XV4 20 ---- 4XV5 30 (for California)

  • Page 36: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 24˚ ---- Trail 92 mm (3.62 in) ---- Front wheel Wheel type Cast wheel ---- 17 × MT3.50 Size ---- Material Aluminum ---- Wheel travel 135 mm (5.31 in) ---- Wheel runout...
  • Page 37 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 190/50 ZR17 (73W) ---- Model (manufacturer) D207L (DUNLOP) ---- Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm , 3.6 psi) ---- 90 kg (198 lb) ~ Maximum load* 290 kPa (2.9 kg/cm , 4.1 psi)
  • Page 38 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 135 mm (5.31 in) ---- Spring Free length 255 mm (10.0 in) ---- Spacer length 85 mm (3.35 in) ---- Installed length 242.4 mm (9.54 in)
  • Page 39 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...

  • Page 40: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type Transistorized coil ignition ---- Ignition timing 5˚ BTDC at 1,100 r/min ---- Advanced timing 55˚ BTDC at 5,000 r/min ---- Advancer type Throttle position sensor and electrical ---- 248 ~ 372 Ω...
  • Page 41 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) SM-13 (MITSUBA) ---- Power output 0.8 kW ---- Brushes Overall length 10 mm (0.40 in) 5 mm (0.20 in) Spring force 7.03 ~ 10.63 N ---- (717 ~ 1,084 gf, 25.3 ~ 38.3 oz) 0.025 ~ 0.035 Ω...
  • Page 42 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Temperature sender Model (manufacturer) 2YK (NIPPON SEIKI) ---- 47.5 ~ 56.8 Ω at 80 ˚C (176˚F) Resistance ---- 16.5 ~ 20.5 Ω at 115 ˚C (239˚F) Fuses (amperage × quantity) 30 A × 1 Main fuse ---- 20 A ×...

  • Page 43: Tightening Torques

    SPEC TIGHTENING TORQUES EB202001 TIGHTENING TORQUES GENERAL TIGHTENING TORQUES This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifica- tions for special components or assemblies are provided for each chapter of this man- ual.

  • Page 44: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf ft·lb Spark plugs – Cylinder head Cylinder head Cap nut Cylinder head Bolt Camshaft caps Bolt Cylinder head cover Bolt Oil passage check bolt Bolt Cylinder head (exhaust pipe) Stud bolt...
  • Page 45 SPEC TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf ft·lb Clutch cover Bolt Pickup coil rotor cover Bolt Shift shaft cover Bolt Oil baffle plate Bolt Timing mark accessing screw – Starter clutch idle gear shaft Bolt Starter clutch Bolt...
  • Page 46 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2 - 21...

  • Page 47: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kgf ft·lb Upper bracket pinch bolts Steering stem nut 11.5 Handlebar pinch bolts Lower ring nut See NOTE. Lower bracket pinch bolts Brake fluid reservoir cap stopper Front brake hose union bolts Front brake master cylinder Engine mounting Left front mounting bolts...

  • Page 48: Lubrication Points And Lubricant Types

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EB202000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust)

  • Page 49: Chassis Lubrication Points And Lubricant Types

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

  • Page 50: Oil Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EB203000 OIL FLOW DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump 2 - 25...
  • Page 51 SPEC OIL FLOW DIAGRAMS 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter 2 - 26...
  • Page 52 SPEC OIL FLOW DIAGRAMS 1 Cylinder head 2 Crankshaft 2 - 27...
  • Page 53 SPEC OIL FLOW DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle 2 - 28...

  • Page 54: Coolant Flow Diagrams

    SPEC OIL FLOW DIAGRAMS EB203000 COOLANT FLOW DIAGRAMS 1 Thermostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint 2 - 29...
  • Page 55 SPEC OIL FLOW DIAGRAMS 1 Thermostat housing 2 Water pump 3 Radiator 4 Radiator fan 2 - 30...
  • Page 56 SPEC OIL FLOW DIAGRAMS 1 Radiator cap 2 Thermostat 3 Thermostat housing 4 Water pump 2 - 31...
  • Page 57 SPEC OIL FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Temperature sender 2 - 32...

  • Page 58: Cable Routing

    SPEC CABLE ROUTING EB206000 CABLE ROUTING Å Properly insert the meter assembly coupler and rubber boot 1 Throttle cables 2 Front brake hose into the meter assembly. ı Route the meter assembly lead through the left side of the 3 Clutch cable 4 Starter cable headlight housing.
  • Page 59 SPEC CABLE ROUTING Ï Fasten the auxiliary light leads with a plastic lock- Route the right handlebar switch lead in ing tie. front of the throttle cables. Ì Fasten the wire harness to the headlight housing Ò Make sure that the horn leads face out. ˜...
  • Page 60 SPEC CABLE ROUTING 1 Rear brake switch lead over the timing chain tensioner. Ç Insert the plastic clip through the hole in the 2 Charcoal canister (California only) 3 Rollover valve (California only) plastic frame panel and then fasten the wire har- 4 Thermostat assembly breather hose ness and coolant reservoir breather hose with it.
  • Page 61 SPEC CABLE ROUTING Å Route the air filter case breather hose to the inside of the 1 Air filter case breather hose 2 Water pump breather hose wire harness. ı Route the stator coil lead over all of the hoses and leads and 3 Sidestand switch lead 4 Oil level switch lead then fasten them with a plastic clip.
  • Page 62 SPEC CABLE ROUTING Ó 50 mm (1.97 in) coolant reservoir breather hose to the inside È Fasten the sidestand switch lead, engine oil of the radiator outlet hose. Make sure that level switch lead, and water pump breather the ends of all of the hoses are below the hose with a plastic clip.
  • Page 63 SPEC CABLE ROUTING 1 Speed sensor lead 2 Charcoal canister (California only) 3 Neutral switch lead 4 EXUP cables Å Route the EXUP cables on the outside of the engine mount. ı Fasten the EXUP cables with a plastic locking tie. 2 - 38...
  • Page 64 SPEC CABLE ROUTING 1 Headlight sub-wire harness C Fuel tank overflow hose 2 Left handlebar switch lead D Fuel tank breather hose (except for California) 3 Main switch lead E Starter motor lead 4 Starter cable F Battery positive lead 5 Right handlebar switch coupler G Battery negative lead 6 Throttle cables...
  • Page 65 SPEC CABLE ROUTING Å Route the horn lead over the horn bracket wire harness with a plastic clamp. Ì Fasten the EXUP servomotor lead, fuel pump and make sure that the lead has no slack. ı Do not cross the throttle cables and right lead, speed sensor lead, neutral switch lead, handlebar switch lead.
  • Page 66 SPEC CABLE ROUTING Ô Route the wire harness and turn signal leads harness with a plastic locking tie. Ø Route the fuel tank overflow hose and fuel under the rear cowling mounting post on the tail/brake light bracket. tank breather hose in front of the crankcase Insert the tail/brake light coupler and turn sig- breather hose and under the fuel hose and nal leads between the tail/brake light and...
  • Page 67 SPEC CABLE ROUTING Œ Fasten the wire harness with a plastic clamp Ë Fasten the wire harness and radiator fan lead to and then insert the clamp into the frame. the plastic frame panel with a plastic locking tie.  Route the charcoal canister hose under the ◊...
  • Page 68 SPEC CABLE ROUTING Á Install the rubber baffle over the carburetor air funnels. Û The end of the plastic locking tie must face in and down. 2 - 43...

  • Page 69: Chapter 3. Periodic Checks And Adjustments

    • Check control system for dam- sion control sys- √ √ age. tem (For California • Replace if necessary. only) * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. 3 - 1...

  • Page 70: General Maintenance And Lubrication Chart

    GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 km ITEM ROUTINE (600 mi) (4,400 mi) (8,200 mi) (12,000 mi) (15,800 mi) (19,600 mi) 1 month 7 month 13 month 19 month...
  • Page 71 * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. #1 : Yamaha chain and cable lube or SAE10W30 motor oil. #2 : Lithium soap base grease. #3 : Ethlene glycol anti-freeze coolant.

  • Page 72: Seats

    SEATS EB302000 SEATS Order Job/Part Q’ty Remarks Removing the seats Remove the parts in the order listed. Passenger seat Rider seat For installation, reverse the removal procedure. 3 - 4...

  • Page 73: Fuel Tank

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

  • Page 74: Cowlings

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

  • Page 75: Removal

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

  • Page 76: Air Filter Case And Ignition Coil Plate

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

  • Page 77: Removal

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

  • Page 78: Engine

    ADJUSTING THE VALVE CLEARANCE EB303001 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room tem- perature. • When the valve clearance is to be mea- sured or adjusted, the piston must be at top dead center (TDC) on the com- pression stroke.
  • Page 79 ADJUSTING THE VALVE CLEARANCE 4. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.11 ~ 0.20 mm (0.0043 ~ 0.0077 in) Exhaust valve 0.21 ~ 0.30 mm (0.0083 ~ 0.0116 in) a. Turn the crankshaft clockwise. b.
  • Page 80 ADJUSTING THE VALVE CLEARANCE 5. Remove: • timing chain tensioner • timing chain guide (exhaust side) • intake camshaft caps • exhaust camshaft caps • timing chain (from the camshaft sprockets) • intake camshaft • exhaust camshaft NOTE: • Refer to “CAMSHAFTS” in chapter 4. •...
  • Page 81 ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad num- ber according to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm) Rounded value = 150 d.

  • Page 82: Valve Pad Selection Table

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

  • Page 83: Synchronizing The Carburetors

    ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS g. Measure the valve clearance again. h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. 7. Install: • all removed parts NOTE: For installation, reverse the removal procedure.
  • Page 84 SYNCHRONIZING THE CARBURETORS 3. Remove: • bolts 1 • copper washers 4. Install: • vacuum gauge attachments (into the bolt holes) • vacuum gauge (onto the vacuum gauge attachments) • inductive tachometer (onto the spark plug lead of cylinder #1) Vacuum gauge YU-08030 Vacuum gauge attachment...

  • Page 85: Adjusting The Engine Idling Speed

    SYNCHRONIZING THE CARBURETORS/ ADJUSTING THE ENGINE IDLING SPEED NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carbure- tor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same.
  • Page 86 ADJUSTING THE ENGINE IDLING SPEED 2. Remove: • air filter case • quick fasteners 1 Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”. 3. Install: • inductive tachometer (onto the spark plug lead of cylinder #1) Inductive tachometer YU-8036-A 4.

  • Page 87: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 7. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) EB303031 ADJUSTING THE THROTTLE CABLE FREE PLAY...
  • Page 88 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: • throttle cable free play NOTE: When the throttle is opened, the acceler- ator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the deceler- ator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.

  • Page 89: Checking The Spark Plugs

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

  • Page 90: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 8. 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. EB303050 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the...

  • Page 91: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range → Check the ignition system. NOTE: The ignition timing is not adjustable. EB303060 MEASURING THE COMPRESSION PRESSURE...
  • Page 92 MEASURING THE COMPRESSION PRESSURE 5. Install: • compression gauge 1 Compression gauge 90890-03081 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,350 kPa (13.5 kg/cm , 192 psi) Standard 1,450 kPa (14.5 kg/cm...

  • Page 93: Checking The Engine Oil Level

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

  • Page 94: Changing The Engine Oil

    CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CAUTION: ACHTUNG: • Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slip- page. • Do not allow foreign material to enter the crankcase. NOTE: Recommended engine oil classification;...
  • Page 95 CHANGING THE ENGINE OIL b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. CAUTION: ACHTUNG: Make sure that the O-ring 3 is posi- tioned correctly in the groove of the oil filter cartridge.
  • Page 96 CHANGING THE ENGINE OIL 15.Check: • engine oil pressure a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize.

  • Page 97: Adjusting The Clutch Cable Free Play

    ADJUSTING THE CLUTCH CABLE FREE PLAY EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.39 ~ 0.59 in) 2.

  • Page 98: Cleaning The Air Filter Element

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

  • Page 99: Checking The Fuel Hoses And Fuel Filter

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

  • Page 100: Checking The Crankcase Breather Hose

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

  • Page 101: Adjusting The Exup Cables

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

  • Page 102: Checking The Coolant Level

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

  • Page 103: Checking The Cooling System

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

  • Page 104: Changing The Coolant

    CHANGING THE COOLANT EB303240 CHANGING THE COOLANT 1. Remove: • bottom cowling • right side cowling Refer to “COWLINGS”. 2. Disengage: • clutch cable holder 1 (from the coolant reservoir) 3. Remove: • coolant reservoir bolts 2 • coolant reservoir cap 3 NOTE: When draining the coolant from the coolant reservoir, be sure to tilt the res-...
  • Page 105 CHANGING THE COOLANT 8. Remove: • coolant drain bolt 1 (along with the copper washer) 9. Drain: • coolant 10.Check: • copper washer 1 • coolant drain bolt 2 Damage → Replace. 11.Install: • coolant drain bolt 7 Nm (0.7 m · kg, 5.1 ft · lb) 12.Fill: •...
  • Page 106 CHANGING THE COOLANT CAUTION: ACHTUNG: • Adding water instead of coolant low- ers the antifreeze content of the cool- ant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the cool- ant. • Use only distilled water. However, soft water may be used if distilled water is not available.

  • Page 107: Chassis

    ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever for- ward, turn the adjusting dial 1 until the brake lever is in the desired posi- tion.
  • Page 108 ADJUSTING THE REAR BRAKE 2. Adjust: • brake pedal position a. Loosen the locknut 1. b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Brake pedal is raised. Direction b Brake pedal is lowered.

  • Page 109: Checking The Brake Fluid Level

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

  • Page 110: Checking The Brake Pads

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

  • Page 111: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EB304062 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose 1 Cracks/damage/wear → Replace. 2. Check: • brake hose clamp Loose →...
  • Page 112 BLEEDING THE HYDRAULIC BRAKE SYSTEM 5. Bleed: Å • hydraulic brake system a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the brake fluid reservoir dia- phragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2.

  • Page 113: Adjusting The Shift Pedal

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK EB304081 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Measure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 305 mm (12.0 in) 2.
  • Page 114 ADJUSTING THE DRIVE CHAIN SLACK 2. Rotate the rear wheel several times and check the drive chain to locate its tight- est point. 3. Measure: • drive chain slack a Out of specification → Adjust. Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) 4.

  • Page 115: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interact- ing parts. If the drive chain is not main- tained properly, it will wear out rapidly. Therefore, the drive chain should be ser- viced, especially when the motorcycle is used in dusty areas.
  • Page 116 CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • front brake fluid reservoir 1 • plastic caps 2 4. Loosen: • upper bracket pinch bolts 1 • handlebar pinch bolts 2 5. Remove: • upper bracket bolts 3 • handlebars (from the upper bracket) 6.
  • Page 117 CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut completely, then tighten it to specification. WARNING WARNING Do not overtighten the lower ring nut. Lower ring nut (final tighten- ing torque) 9 Nm (0.9 m • kg, 6.5 ft • lb) d.

  • Page 118: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK d. Hold the spring gauge at a 45˚ angle from the handlebar, pull the spring gauge, and record the measurement when the handlebar starts to turn. Steering head tension 200 ~ 500 g (7.06 ~ 17.65 oz) e.

  • Page 119: Adjusting The Front Fork Legs

    ADJUSTING THE FRONT FORK LEGS EB304153 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. •...
  • Page 120 ADJUSTING THE FRONT FORK LEGS Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping a. Turn the adjusting screw 1 in direc- tion a or b. Rebound damping is Direction a increased (suspension is harder).

  • Page 121: Adjusting The Rear Shock Absorber Assembly

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EB304162 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions.
  • Page 122 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping a. Turn the adjusting screw 1 in direc- tion a or b. Rebound damping is Direction a increased (suspension is harder).

  • Page 123: Checking The Tires

    CHECKING THE TIRES EB304170 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: • tire pressure Out of specification → Regulate. WARNING WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
  • Page 124 The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer Size...

  • Page 125: Checking The Wheels

    CHECKING THE TIRES/ CHECKING THE WHEELS Rear tire Manufacturer Size Model 190/50 ZR17 BT56R BRIDGESTONE (73W) BT57R 190/50 ZR17 MEZ1 METZELER (73W) RACING 190/50 ZR17 METZELER MEZ3 (73W) 190/50 ZR17 DUNLOP D207L (73W) 190/50 ZR17 MICHELIN TX25 (73W) 190/50 ZR17 MACADAM MICHELIN (73W)

  • Page 126: Checking And Lubricating The Cables

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

  • Page 127: Electrical System

    CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preven- tive measures: •...
  • Page 128 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific grav- ity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 129 CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (refer to the appropriate charging method illustration) WARNING WARNING Do not quick charge a battery. CAUTION: ACHTUNG: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage cur- rent into the battery quickly and can cause battery overheating and bat-...
  • Page 130 CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger 3 - 62...
  • Page 131 CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger 3 - 63...

  • Page 132: Checking The Fuses

    CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: ACHTUNG: First, connect the positive lead 1, then the negative lead 2. 8. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection →...
  • Page 133 CHECKING THE FUSES 3. Replace: • blown fuse a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage. c. Set the main switch to “ON” and ver- ify if the electrical circuit is opera- tional.

  • Page 134: Replacing The Headlight Bulbs

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

  • Page 135: Adjusting The Headlight Beams

    ADJUSTING THE HEADLIGHT BEAMS EB305061 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) a. Turn the adjusting screw 1 in direc- tion a or b. Direction a Headlight beam is raised. Headlight beam is low- Direction b ered.

  • Page 136: Chapter 4. Overhauling The Engine

    ENGINE EB400011 OVERHAULING THE ENGINE ENGINE Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed. Locknut Shift rod Drive sprocket cover Lock washer Drive sprocket Shift arm For installation, reverse the removal procedure. 4 - 1...
  • Page 137 ENGINE Order Job/Part Q’ty Remarks Removing the exhaust assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Bottom cowling and side cowlings Refer to “COWLINGS” in chapter 3. Coolant Drain.
  • Page 138 ENGINE Order Job/Part Q’ty Remarks Muffler EXUP cable holder EXUP valve cover Spacer EXUP valve Spacer For installation, reverse the removal procedure. 4 - 3...
  • Page 139 ENGINE Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Air filter case Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE” in chapter 3. Carburetor assembly and carburetor Refer to “CARBURETORS” in chapter 6. joints Engine oil and oil filter cartridge Drain.
  • Page 140 ENGINE Order Job/Part Q’ty Remarks Clutch cable Crankcase breather hose Starter motor lead Disconnect. Ground lead Disconnect. Starter motor Stator coil assembly coupler Disconnect. Pickup coil coupler Disconnect. Oil level switch connector Disconnect. Neutral switch Speed sensor For connecting, reverse the disconnec- tion procedure.
  • Page 141 ENGINE Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. Pinch bolt Loosen. Right front mounting bolt Washer Spacer Left front mounting bolt Washer Self-locking nut Rear mounting bolt Spacer For installation, reverse the removal...

  • Page 142: Installing The Engine

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

  • Page 143: Camshafts

    CAMSHAFTS EB401000 CAMSHAFTS Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Carburetor assembly Refer to “CARBURETORS” in chapter 6. Radiator assembly and thermostat Refer to “RADIATOR” and “THERMO- assembly STAT ASSEMBLY” in chapter 5. Spark plug Cylinder head cover Cylinder head cover gasket...
  • Page 144 CAMSHAFTS EB401011 Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Pickup coil rotor cover Refer to “PICKUP COIL”. Float chamber air vent hose holder Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap NOTE: Dowel pin...
  • Page 145 CAMSHAFTS Order Job/Part Q’ty Remarks Intake camshaft sprocket Exhaust camshaft sprocket Timing chain guide (intake side) For installation, reverse the removal procedure. 4 - 10...

  • Page 146: Removing The Camshafts

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

  • Page 147: Checking The Camshafts

    CAMSHAFTS EB401401 CHECKING THE CAMSHAFTS 1. Check: • camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft lobe dimensions limit Intake camshaft a 32.40 mm (1.2756 in) b 24.85 mm (0.9783 in) Exhaust camshaft a 32.85 mm (1.2933 in)

  • Page 148: And Timing Chain Guides

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

  • Page 149: Checking The Timing Chain Tensioner

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

  • Page 150: Installing The Camshafts

    CAMSHAFTS EB401701 INSTALLING THE CAMSHAFTS 1. Install: • timing chain guide (intake side) 1 2. Install: • intake camshaft sprocket 24 Nm (2.4 m · kg, 17 ft · lb) • exhaust camshaft sprocket 24 Nm (2.4 m · kg, 17 ft · lb) 3.
  • Page 151 CAMSHAFTS 4. Install: • timing chain guide (exhaust side) 5. Install: • timing chain tensioner a. Lightly press the timing chain ten- sioner rod into the timing chain ten- sioner housing by hand. b. While pressing the timing chain ten- sioner rod, wind it clockwise with a thin screwdriver 1 until it stops.
  • Page 152 CAMSHAFTS 7. Check: • TDC mark a Make sure that the TDC mark is aligned with the crankcase mating sur- face b. • camshaft punch mark c Make sure that the camshaft punch mark is aligned with the arrow mark d on the camshaft cap.

  • Page 153: Cylinder Head

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

  • Page 154: Removing The Cylinder Head

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

  • Page 155: Installing The Cylinder Head

    CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. EB402702 INSTALLING THE CYLINDER HEAD 1.

  • Page 156: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EB403000 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal...
  • Page 157 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 158: Removing The Valves

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

  • Page 159: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 3. Remove: • valve cotters 1 NOTE: Remove the valve cotters by compress- ing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor YM-04019 Attachment (for the intake valve) YM-4114 (for the exhaust valve) YM-4108 4.
  • Page 160 VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and instal- lation, and to maintain the correct fit, heat the cylinder head to 100 ˚C (212 ˚F) in an oven. a. Remove the valve guide with a valve guide remover 1.

  • Page 161: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness 0.5 ~ 0.9 mm (0.020 ~ 0.035 in) 6. Measure: • valve stem runout Out of specification → Replace the valve.
  • Page 162 VALVES AND VALVE SPRINGS a. Apply Mechanic’s blueing (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d.

  • Page 163: Checking The Valve Springs

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

  • Page 164: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS 2. Measure: • compressed spring force a Out of specification → Replace the valve spring. b Installed length Compressed spring force (installed) Intake valve spring 8.36 ~ 9.79 kg at 34.5 mm (18.4 ~ 21.5 lb at 1.36 in) Exhaust valve spring 11.22 ~ 12.85 kg at 35.0 mm (24.7 ~ 28.3 lb at 1.38 in)
  • Page 165 VALVES AND VALVE SPRINGS 3. Install: • lower spring seat 1 • oil seal 2 • valve 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) NOTE: • Make sure that each valve is installed in its original place.
  • Page 166 VALVES AND VALVE SPRINGS 6. Lubricate: • valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 7. Install: • valve pad • valve lifter NOTE: • The valve lifter must move smoothly when rotated with a finger. • Each valve lifter and valve pad must be reinstalled in its original position.

  • Page 167: Generator

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

  • Page 168: Removing The Generator

    GENERATOR EB410110 REMOVING THE GENERATOR 1. Remove: • generator rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.
  • Page 169 GENERATOR 3. Tighten: • generator rotor bolt 1 95 Nm (9.5 m · kg, 68 ft · lb) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the generator rotor bolt. Rotor holding tool YU-01235 4.

  • Page 170: Pickup Coil

    PICKUP COIL PICKUP COIL Order Job/Part Q’ty Remarks Removing the pickup coil and Remove the parts in the order listed. pickup coil rotor Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Bottom cowling and right side cowl- Refer to “COWLINGS”...
  • Page 171 PICKUP COIL Order Job/Part Q’ty Remarks Pickup coil coupler Disconnect. Pickup coil Pickup coil rotor For installation, reverse the removal procedure. 4 - 36...

  • Page 172: Removing The Pickup Coil Rotor

    PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remove: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 173 PICKUP COIL 2. Tighten: • pickup coil rotor bolt 1 60 Nm (6.0 m · kg, 43 ft · lb) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the pickup coil rotor bolt. Rotor holding tool YU-01235 3.

  • Page 174: Clutch

    CLUTCH EB405000 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Bottom cowling and right side cowl- Refer to “COWLINGS” in chapter 3. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Clutch cable Clutch cover Clutch cover gasket...
  • Page 175 CLUTCH EB405010 Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. 4 - 40...
  • Page 176 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Inside diameter =124 mm (4.88 in) Clutch plate Lock washer Wire circlip Clutch plate...
  • Page 177 CLUTCH Order Job/Part Q’ty Remarks Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear For installation, reverse the removal procedure. 4 - 42...

  • Page 178: Removing The Clutch

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

  • Page 179: Checking The Clutch Plates

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

  • Page 180: Checking The Clutch Boss

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

  • Page 181: Installing The Clutch

    CLUTCH 2. Check: • starter clutch operation a. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch gear clockwise Å, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced.
  • Page 182 CLUTCH 3. Install: • lock washer • clutch boss nut 1 70 Nm (7.0 m · kg, 50 ft · lb) NOTE: While holding the clutch boss 2 with the clutch holding tool 3, tighten the clutch boss nut. Clutch holding tool YM-91042 4.
  • Page 183 CLUTCH 9. Install: • clutch cover 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: • When installing the clutch cover, push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover.

  • Page 184: Shift Shaft

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

  • Page 185: Checking The Shift Shaft

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

  • Page 186: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP EB411000 OIL PAN AND OIL PUMP Order Job/Part Q’ty Remarks Removing the oil pan and oil pump Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Coolant Drain.
  • Page 187 OIL PAN AND OIL PUMP EB411001 Order Job/Part Q’ty Remarks Drain pipe Oil strainer Oil pipe Oil delivery pipe Oil/water pump assembly drive sprocket cover Dowel pin Oil/water pump assembly Relief valve assembly For installation, reverse the removal procedure. 4 - 52...
  • Page 188 OIL PAN AND OIL PUMP EB411003 Order Job/Part Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Oil/water pump assembly driven sprocket Washer Oil pump housing Bearing Oil pump outer rotor Oil pump inner rotor For installation, reverse the removal procedure.

  • Page 189: Removing The Oil Pan

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

  • Page 190: Checking The Relief Valve

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

  • Page 191: Installing The Oil Pump

    OIL PAN AND OIL PUMP 2. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. EB411710 INSTALLING THE OIL PUMP 1. Install: • oil pump 1 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Install the oil/water pump assembly drive chain onto the oil/water pump assembly driven sprocket.

  • Page 192: Crankcase

    CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Pickup coil and pickup coil rotor Refer to “PICKUP COIL”. Stator coil assembly Refer to “GENERATOR”. Clutch housing and starter clutch Refer to “CLUTCH”.
  • Page 193 CRANKCASE Order Job/Part Q’ty Remarks Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin For installation, reverse the removal procedure. 4 - 58...
  • Page 194 CRANKCASE Order Job/Part Q’ty Remarks Removing the oil baffle plates and Remove the parts in the order listed. oil filter bolt Connecting rod assemblies Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Refer to “CRANKSHAFT”. Transmission Refer to “TRANSMISSION”. Oil baffle plate Oil baffle plate Oil delivery pipe Bearing...

  • Page 195: Disassembling The Crankcase

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

  • Page 196: Checking The Crankcase

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

  • Page 197: Assembling The Crankcase

    CRANKCASE EB412743 ASSEMBLING THE CRANKCASE 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) ® Quick Gasket ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings.
  • Page 198 CRANKCASE 6. Install: • lower crankcase 1 (onto the upper crankcase 2) CAUTION: ACHTUNG: Before tightening the crankcase bolts, make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. 7. Install: • crankcase bolts NOTE: •...

  • Page 199: Connecting Rods And Pistons

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

  • Page 200: Removing The Connecting Rods And Pistons

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

  • Page 201: Checking The Cylinders And Pistons

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

  • Page 202: Checking The Piston Rings

    CONNECTING RODS AND PISTONS e. Calculate the piston-to-cylinder clear- ance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.001 ~ 0.002 in) <Limit>: 0.12 mm (0.005 in) f.

  • Page 203: Checking The Piston Pins

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

  • Page 204: Checking The Big End Bearings

    CONNECTING RODS AND PISTONS 4. Calculate: • piston-pin-to-piston-pin-bore clear- ance Out of specification → Replace the pis- ton pin. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter Piston-pin-to-piston-pin-bore clearance 0.002 ~ 0.022 mm (0.00008 ~ 0.00087 in) <Limit>: 0.072 mm (0.0028 in) CHECKING THE BIG END BEARINGS...
  • Page 205 CONNECTING RODS AND PISTONS ® c. Put a piece of Plastigauge 1 on the crankshaft pin. d. Assemble the connecting rod halves. NOTE: • Do not move the connecting rod or crankshaft until the clearance mea- surement has been completed. •...

  • Page 206: Installing The Pistons And Connecting Rods

    CONNECTING RODS AND PISTONS 2. Select: • big end bearings (“P ”~ “P ”) NOTE: • The numbers stamped into the crank- shaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. •...
  • Page 207 CONNECTING RODS AND PISTONS 2. Install: • piston 1 (onto the respective connecting rod 2) • piston pin 3 • piston pin clip 4 NOTE: • Apply engine oil onto the piston pin. • Make sure that the “Y” mark a on the connecting rod faces left when the arrow mark b on the piston is pointing up.
  • Page 208 CONNECTING RODS AND PISTONS 6. Lubricate: • crankshaft pins • big end bearings • connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crank- shaft pin) •...

  • Page 209: Crankshaft

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

  • Page 210: Removing The Crankshaft

    CRANKSHAFT EB412110 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 • crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EB412403 CHECKING THE CRANKSHAFT 1.
  • Page 211 CRANKSHAFT a. Clean the crankshaft journal bearings, crankshaft journals, and bearing por- tions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a on the crank- shaft journal upper bearings with the...
  • Page 212 CRANKSHAFT g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure compressed Plasti- ® width c on each crankshaft gauge journal. If the clearance is out of specification, select replacement crankshaft jour- nal bearings. 2. Select: • crankshaft journal bearings (J NOTE: •...

  • Page 213: Installing The Crankshaft

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

  • Page 214: Transmission

    TRANSMISSION EB413000 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE”. Stopper lever Refer to “SHIFT SHAFT”. Drive axle assembly Circlip Oil seal Bearing Shift drum retainer Shift fork guide bar...
  • Page 215 TRANSMISSION Order Job/Part Q’ty Remarks Shift drum assembly Shift fork “C” Main axle assembly For installation, reverse the removal procedure. 4 - 80...
  • Page 216 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle assem- Remove the parts in the order listed. 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gears 5th pinion gear Collar 4 - 81...
  • Page 217 TRANSMISSION Order Job/Part Q’ty Remarks Main axle/1st pinion gear Bearing Main axle bearing housing For installation, reverse the removal procedure. 4 - 82...
  • Page 218 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle assem- Remove the parts in the order listed. Washer 1st wheel gear Spacer 5th wheel gear Circlip Washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 4 - 83...
  • Page 219 TRANSMISSION Order Job/Part Q’ty Remarks 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer For installation, reverse the removal procedure. 4 - 84...

  • Page 220: Removing The Transmission

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

  • Page 221: Checking The Shift Drum Assembly

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

  • Page 222: Installing The Transmission

    TRANSMISSION 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmis- sion axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(-s). 6. Check: • circlips Bends/damage/looseness →...

  • Page 223: Chapter 5. Cooling System

    COOL RADIATOR EB500000 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”...
  • Page 224 COOL RADIATOR Order Job/Part Q’ty Remarks Thermo switch Temperature sender Thermostat assembly breather hose Disconnect. Radiator inlet hose Oil cooler outlet hose Disconnect. Water pump breather hose Radiator outlet hose Water pump inlet pipe Radiator fan motor coupler Disconnect. Horn bracket Radiator Radiator fan For installation, reverse the removal...

  • Page 225: Checking The Radiator

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

  • Page 226: Installing The Radiator

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

  • Page 227: Oil Cooler

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

  • Page 228: Checking The Oil Cooler

    COOL OIL COOLER EB501010 CHECKING THE OIL COOLER 1. Check: • oil cooler Cracks/damage → Replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace. 3. Check: • water jacket joint • water jacket joint inlet hose •...
  • Page 229 COOL OIL COOLER 4. Fill: • cooling system (with the specified amount of the rec- ommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. • crankcase (with the specified amount of the rec- ommended engine oil) Refer to “CHANGING THE ENGINE OIL”...

  • Page 230: Thermostat Assembly

    COOL THERMOSTAT ASSEMBLY EB502000 THERMOSTAT ASSEMBLY Order Job/Part Q’ty Remarks Removing the thermostat assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”...
  • Page 231 COOL THERMOSTAT ASSEMBLY Order Job/Part Q’ty Remarks Thermostat assembly Thermostat assembly inlet pipe (left) Thermostat assembly inlet pipe (right) For installation, reverse the removal procedure. 5 - 9...
  • Page 232 COOL THERMOSTAT ASSEMBLY EB502010 Order Job/Part Q’ty Remarks Disassembling the thermostat Remove the parts in the order listed. assembly Thermostat housing cover Thermostat Thermostat housing For assembly, reverse the disassembly procedure. 5 - 10...

  • Page 233: Checking The Thermostat

    COOL THERMOSTAT ASSEMBLY EB502020 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 71 ~ 85 ˚C (159.8 ~ 185 ˚F) → Replace. a. Suspend the thermostat in a con- tainer filled with water. b. Slowly heat the water. c.

  • Page 234: Installing The Thermostat Assembly

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

  • Page 235: Water Pump

    COOL WATER PUMP EB503000 WATER PUMP Order Job/Part Q’ty Remarks Removing the impeller shaft Remove the parts in the order listed. NOTE: • The water pump and oil pump are combined into one unit (oil/water pump assembly). • It is not necessary to remove the impeller shaft unless the coolant level is extremely low or coolant leaks from the oil pan.
  • Page 236 COOL WATER PUMP Order Job/Part Q’ty Remarks Water pump seal Oil seal Bearing For installation, reverse the removal procedure. 5 - 14...

  • Page 237: Disassembling The Water Pump

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

  • Page 238: Assembling The Water Pump

    NOTE: • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3. Mechanical seal installer 4 YM-33221 Middle driven shaft bearing...
  • Page 239 COOL WATER PUMP 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: ACHTUNG: Make sure that the rubber damper and rubber damper holder are flush with the impeller. Max. impeller shaft tilt 0.15 mm (0.006 in) 1 Straightedge 2 Impeller 5 - 17...

  • Page 240: Carb

    CARB CARBURETORS EB600001 CARBURETORS CARBURETORS Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3. Air filter case and rubber baffle Refer to “AIR FILTER CASE AND IGNI- TION COIL PLATE”...
  • Page 241 CARB CARBURETORS EB600010 Order Job/Part Q’ty Remarks Separating the carburetors Remove the parts in the order listed. Starter plunger link Connecting bolt R = 245 mm (9.65 in) Copper washer R = 270 mm (10.6 in) Connecting bolt Spacer R = 43 mm (1.69 in) R = 38 mm (1.50 in) Spacer R = 36 mm (1.42 in)
  • Page 242 CARB CARBURETORS Order Job/Part Q’ty Remarks R = 37 mm (1.46 in) Fuel feed pipe R = 32 mm (1.26 in) Fuel feed pipe Fuel feed pipe R = 29 mm (1.14 in) R = 73 mm (2.87 in) Pipe R = 68 mm (2.68 in) Pipe Pipe...
  • Page 243 CARB CARBURETORS EB600021 Order Job/Part Q’ty Remarks Disassembling the carburetor Remove the parts in the order listed. NOTE: The following procedure applies to all of the carburetors. Starter plunger Air funnel Air funnel joint Pilot air jet Vacuum chamber cover Piston valve spring Jet needle holder Jet needle kit...
  • Page 244 CARB CARBURETORS Order Job/Part Q’ty Remarks Float chamber Float pivot pin Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet For assembly, reverse the disassembly procedure. 6 - 5...

  • Page 245: Checking The Carburetors

    CARB CARBURETORS EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: • carburetor body • float chamber Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. a. Wash the carburetor in a petroleum- based solvent.
  • Page 246 CARB CARBURETORS 8. Check: • piston valve 1 Damage/scratches/wear → Replace. • piston valve diaphragm 2 Cracks/tears → Replace. 9. Check: • vacuum chamber cover 1 • piston valve spring 2 • jet needle holder 3 • jet needle spring 4 Cracks/damage →...

  • Page 247: Assembling The Carburetors

    CARB CARBURETORS 13.Check: • fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. EB600043 ASSEMBLING THE CARBURETORS The following procedure applies to all of the carburetors. CAUTION: ACHTUNG: • Before assembling the carburetors, wash all of the parts in a petroleum- based solvent.
  • Page 248 CARB CARBURETORS 2. Install: • pipes • fuel feed pipes • vacuum chamber pipe • vacuum chamber air vent hose • springs • float chamber air vent hoses • hose joints • spacers • copper washer • connecting bolts NOTE: •...

  • Page 249: Installing The Carburetors

    CARB CARBURETORS EB600051 INSTALLING THE CARBURETORS 1. Adjust: • carburetor synchronization Refer to “SYNCHRONIZING THE CAR- BURETORS” in chapter 3. 2. Adjust: • engine idling speed Engine idling speed 1,050 ~ 1,150 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 3.

  • Page 250: Measuring And Adjusting The Fuel Level

    CARB CARBURETORS EB600063 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level (below the line on the float chamber) 4.1 ~ 5.1 mm (0.161 ~ 0.201 in) a. Stand the motorcycle on a level sur- face.

  • Page 251: Checking And Adjusting The Throttle Position Sensor

    CARB CARBURETORS EB600072 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor (installed on the carburetor) a. Disconnect the throttle position sen- sor coupler.
  • Page 252 CARB CARBURETORS 2. Check: • throttle position sensor (removed from the carburetor) a. Disconnect the throttle position sen- sor coupler. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Tester positive probe →...
  • Page 253 CARB CARBURETORS 3. Adjust: • throttle position sensor angle a. Set the main switch to “ON”. b. Disconnect the throttle position sen- sor coupler. c. Reconnect the throttle position sen- sor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjust- ment mode.

  • Page 254: Checking The Fuel Pump

    CARB CARBURETORS EB600090 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Disconnect the fuel-pump-to-carbure- tor fuel hose 2 from the carburetor. c. Connect the fuel-tank-to-fuel-pump fuel hose to the fuel tank and then set the fuel cock to “ON”.

  • Page 255: Chapter 7. Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EB700002 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is ele- vated.
  • Page 256 CHAS FRONT WHEEL AND BRAKE DISCS EB700010 Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure. 7 - 2...

  • Page 257: Removing The Front Wheel

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

  • Page 258: Checking The Front Wheel

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

  • Page 259: Checking The Brake Discs

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

  • Page 260: Assembling The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Min. brake disc thickness Front: 4.5 mm (0.18 in) Rear: 4.5 mm (0.18 in) 4.

  • Page 261: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EB700725 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium soap base grease 2. Install: • brake discs 18 Nm (1.8 m · kg, 13 ft • lb) NOTE: ®...
  • Page 262 CHAS FRONT WHEEL AND BRAKE DISCS 1. Remove: • balancing weight(-s) 2. Find: • front wheel’s heavy spot a. Place the front wheel on a suitable balancing stand. b. Spin the front wheel. c. When the front wheel stops, put an “X ”...
  • Page 263 CHAS FRONT WHEEL AND BRAKE DISCS 4. Check: • front wheel static balance a. Turn the front wheel and make sure that it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.

  • Page 264: Rear Wheel, Brake Disc, And Rear Wheel Sprocket

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701000 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is ele- vated.
  • Page 265 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701010 Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel sprocket Brake disc Rear wheel sprocket Oil seal cover (left and right) Spacer (left and right) Oil seal Bearing...
  • Page 266 REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Spacer Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 7 - 12...

  • Page 267: Removing The Rear Wheel

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

  • Page 268: Checking The Rear Wheel Drive Hub

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET 3. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL”. Over the specified limits → Replace. Max. radial wheel runout 1.0 mm (0.04 in) Max. lateral wheel runout 0.5 mm (0.02 in) EB701430 CHECKING THE REAR WHEEL DRIVE HUB...

  • Page 269: Installing The Rear Wheel

    REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS SPROCKET EB701710 INSTALLING THE REAR WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips Recommended lubricant Lithium soap base grease 2. Adjust: • drive chain slack a Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 270: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EB702001 FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad...
  • Page 271 CHAS FRONT AND REAR BRAKES EB702002 Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw For installation, reverse the removal procedure.

  • Page 272: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EB702100 CAUTION: ACHTUNG: Disc brake components rarely require disassembly. Therefore, always follow these preven- tive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disas- sembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 273 CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pin 2 • brake pad spring 3 • brake pads (along with the brake pad shims) 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set.

  • Page 274: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pin • brake pad clips • brake caliper 40 Nm (4.0 m · kg, 2.9 ft · lb) 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 275 CHAS FRONT AND REAR BRAKES 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.5 mm (0.02 in) 4. Install: • brake pad shims (onto the brake pads) •...
  • Page 276 CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pins • brake pad clips • brake pad cover • 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.
  • Page 277 CHAS FRONT AND REAR BRAKES EB702200 Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder and brake fluid reservoir Brake fluid Drain. Brake fluid reservoir cap stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir...
  • Page 278 CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Brake hose Brake master cylinder holder Brake master cylinder Front brake switch For installation, reverse the removal procedure. 7 - 24...
  • Page 279 CHAS FRONT AND REAR BRAKES EB702201 Order Job/Part Q’ty Remarks Disassembling the front brake mas- Remove the parts in the order listed. ter cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 7 - 25...
  • Page 280 CHAS FRONT AND REAR BRAKES EB702202 Order Job/Part Q’ty Remarks Removing the rear brake master cyl- Remove the parts in the order listed. inder and brake fluid reservoir Brake fluid Drain. Brake fluid reservoir cap stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm...
  • Page 281 CHAS FRONT AND REAR BRAKES EB702203 Order Job/Part Q’ty Remarks Disassembling the rear brake mas- Remove the parts in the order listed. ter cylinder Brake master cylinder kit Brake master cylinder For assembly, reverse the disassembly procedure. 7 - 27...

  • Page 282: Disassembling The Front Brake Master Cylinder

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

  • Page 283: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES 2. Check: Å • brake master cylinder kit Damage/scratches/wear → Replace. Å Front ı Rear ı 3. Check: Å ı • brake fluid reservoir 1 Cracks/damage → Replace. • brake fluid reservoir diaphragm 2 Cracks/damage → Replace. 4.
  • Page 284 CHAS FRONT AND REAR BRAKES 1. Install: • brake master cylinder 1 13 Nm (1.3 m · kg, 9.4 ft · lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. • Align the end of the brake master cyl- inder holder with the punch mark a in the right handlebar.

  • Page 285: Assembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES CAUTION: ACHTUNG: Brake fluid may damage painted sur- faces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5.
  • Page 286 CHAS FRONT AND REAR BRAKES 2. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance. •...
  • Page 287 CHAS FRONT AND REAR BRAKES EB702301 Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal...
  • Page 288 CHAS FRONT AND REAR BRAKES EB702303 Order Job/Part Q’ty Remarks Disassembling the front brake cali- Remove the parts in the order listed. pers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston...
  • Page 289 CHAS FRONT AND REAR BRAKES EB702304 Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal procedure. 7 - 35...
  • Page 290 CHAS FRONT AND REAR BRAKES EB702305 Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly procedure.

  • Page 291: Disassembling The Front Brake Calipers

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

  • Page 292: Disassembling The Rear Brake Caliper

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

  • Page 293: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702343 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Every two years and whenever the Brake fluid brake is disassem- bled 1.

  • Page 294: Assembling And Installing The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EB702376 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.
  • Page 295 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the rec- ommended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance.

  • Page 296: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EB702378 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the pis- ton seals to swell and distort.
  • Page 297 CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the rec- ommended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance.

  • Page 298: Front Fork

    CHAS FRONT FORK EB703001 FRONT FORK Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 299 CHAS FRONT FORK EB703002 Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Spring seat Fork spring Damper adjusting rod Outer tube Dust seal Oil seal clip...
  • Page 300 CHAS FRONT FORK Order Job/Part Q’ty Remarks Damper rod assembly bolt Copper washer Damper rod assembly Inner tube For assembly, reverse the disassembly procedure. 7 - 46...

  • Page 301: Removing The Front Fork Legs

    CHAS FRONT FORK EB703100 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 302 CHAS FRONT FORK NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring compressor WARNING WARNING The fork spring is compressed. f.

  • Page 303: Checking The Front Fork Legs

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

  • Page 304: Assembling The Front Fork Legs

    2 until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil 01 or equivalent 7 - 50...
  • Page 305 CHAS FRONT FORK 3. Tighten: • damper rod assembly bolt 1 40 Nm (4.0 m · kg, 29 ft · lb) NOTE: While holding the damper rod with the damper rod holder 2, tighten the damper rod assembly bolt. Damper rod holder YM-1423 4.
  • Page 306 Quantity (each front fork leg) 477 cm (16.8 Imp oz, 16.1 US oz) Recommended oil Yamaha fork and shock oil 01 or equivalent CAUTION: ACHTUNG: • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
  • Page 307 CHAS FRONT FORK 13.Slowly stroke the outer tube 1 up and down to distribute the fork oil once more (1 stroke = about 100 mm, 3.94 in). NOTE: Be careful not to stroke the inner tube over 100 mm as this will cause air to enter.
  • Page 308 CHAS FRONT FORK c. Install the rod puller and adapter onto the damper rod. Rod puller YM-01437 Adapter 90890-01436 d. Install the fork spring, spring seat, and spacer. NOTE: Install the spring with the smaller pitch a facing up Å . e.

  • Page 309: Installing The Front Fork Legs

    CHAS FRONT FORK 17.Install: • outer tube (onto the inner tube) NOTE: Temporarily tighten the cap bolt. EB703710 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the upper and lower bracket pinch bolts.

  • Page 310: Handlebars

    CHAS HANDLEBARS EB704001 HANDLEBARS Order Job/Part Q’ty Remarks Removing the handlebars Remove the parts in the order listed. Left grip end Handlebar grip Clutch switch connector Disconnect. Left handlebar switch Starter cable Disconnect. Starter lever Clutch cable Disconnect. Clutch lever Right grip end Throttle cable housing Throttle cable...
  • Page 311 CHAS HANDLEBARS Order Job/Part Q’ty Remarks Front brake switch connector Disconnect. Right handlebar switch Brake master cylinder holder Brake master cylinder Handlebar pinch bolt Upper bracket bolt Upper bracket pinch bolt Steering stem nut Upper bracket Left handlebar Right handlebar For installation, reverse the removal procedure.

  • Page 312: Removing The Handlebars

    CHAS HANDLEBARS EB704101 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip NOTE: Blow compressed air between the left handlebar and the handlebar grip, and gradually push the grip off the handle- bar.

  • Page 313: Installing The Handlebars

    CHAS HANDLEBARS EB704704 INSTALLING THE HANDLEBARS 1. Install: • right handlebar switch 1 NOTE: Align the projection a on the right han- dlebar switch with the hole b in the right handlebar. 2. Install: • brake master cylinder holder 1 CAUTION: ACHTUNG: •...
  • Page 314 CHAS HANDLEBARS 5. Install: • left handlebar switch 1 NOTE: Align the projection a on the left han- dlebar switch with the hole b in the left handlebar. 6. Install: • handlebar grip a. Apply a thin coat of rubber adhesive onto the end of the left handlebar.

  • Page 315: Steering Head

    CHAS STEERING HEAD EB705001 STEERING HEAD Order Job/Part Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”. Front fork legs Refer to “FRONT FORK”. Main switch coupler Disconnect.
  • Page 316 CHAS STEERING HEAD Order Job/Part Q’ty Remarks Lower ring nut Lower bracket Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race For installation, reverse the removal procedure. 7 - 62...

  • Page 317: Removing The Lower Bracket

    CHAS STEERING HEAD EB705100 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • lower ring nut 1 (with the special tool 2) Ring nut wrench YU-33975 WARNING...

  • Page 318: Installing The Steering Head

    CHAS STEERING HEAD b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new dust seal and new bear- ing races. CAUTION: ACHTUNG: If the bearing race is not installed prop- erly, the steering head pipe could be damaged.
  • Page 319 CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the upper and lower bracket pinch bolts, and handlebar pinch bolts.

  • Page 320: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EB706000 REAR SHOCK ABSORBER ASSEMBLY Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Self-locking nut/bolt Bolt R = 54 mm (2.13 in) Bolt R = 80 mm (3.15 in) Self-locking nut/bolt 1/1/1 Bolt R = 65 mm (2.56 in) Self-locking nut/bolt/spacer...

  • Page 321: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER ASSEMBLY EB706101 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING WARNING This rear shock absorber and gas cylin- der contain highly compressed nitro- gen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.

  • Page 322: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EB706204 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 323: Checking The Relay Arm And Connecting Arm

    CHAS REAR SHOCK ABSORBER ASSEMBLY CHECKING THE RELAY ARM AND CONNECTING ARM 1. Check: • relay arm 1 • connecting arm 2 Damage/wear → Replace. • bearings • oil seals Damage/pitting → Replace. • spacers Damage/scratches → Replace. EB706701 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1.

  • Page 324: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EB707000 SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order listed. chain Drive sprocket Refer to “ENGINE” in chapter 4. Rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET”.
  • Page 325 CHAS SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Remarks Drive chain Dust cover Drive chain guide Spacer Left bearing Right bearing For installation, reverse the removal procedure. 7 - 71...

  • Page 326: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EB707100 NOTE: Before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a ten- link section of the drive chain. EB707111 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that...

  • Page 327: Removing The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EB707120 REMOVING THE DRIVE CHAIN 1. Remove: • drive chain (with the drive chain cutter) Drive chain cutter 90890-01286 NOTE: Only cut the drive chain if it or the swin- garm is to be replaced. EB707400 CHECKING THE SWINGARM 1.

  • Page 328: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN 4. Check: • dust covers • spacer • oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EB707410 CHECKING THE DRIVE CHAIN 1. Measure: • ten-link section a of the drive chain Out of specification → Replace the drive chain.
  • Page 329 CHAS SWINGARM AND DRIVE CHAIN c. Remove the drive chain from the ker- osine and completely dry it. CAUTION: ACHTUNG: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use high- pressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain.

  • Page 330: Installing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EB707700 INSTALLING THE SWINGARM 1. Lubricate: • bearings • spacers • dust covers • pivot shaft Recommended lubricant Lithium soap base grease 2. Install: • swingarm • pivot shaft • washer • pivot shaft nut 125 Nm (12.5 m ·...

  • Page 331: Electrical Components

    – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS A Starter relay K Oil level switch 1 Wire harness B Main fuse L Pickup coil 2 Main switch C Oil level relay M Radiator fan 3 Front brake light switch D Battery N Horn 4 Ignition coils E Rectifier/regulator...

  • Page 332: 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 trans- mission is in neutral. High beam indicator light “...

  • Page 333: Combination Meter

    – ELEC INSTRUMENT FUNCTIONS Coolant Display Conditions What to do temperature Symbol is on and 0 ˚C ~ 40 ˚C Go ahead with riding. “LO” is displayed. Symbol is on and 41 ˚C ~ 117 ˚C temperature is dis- Go ahead with riding. played.
  • Page 334 – ELEC INSTRUMENT FUNCTIONS When the fuel level indicator light comes on the odometer display will automatically change to the fuel reserve trip meter mode “TRIP F” and start counting the distance traveled from that point. Push “SELECT” button to change between the fuel odometer, trip odometer and odometer modes in the following order: “TRIP F”...

  • Page 335: Switches

    – ELEC SWITCHES EB801000 SWITCHES 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: ACHTUNG: Never insert the tester probes into the coupler terminal slots 1.

  • Page 336: Checking The Switches

    – ELEC CHECKING THE SWITCHES EB801010 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect. Incorrect continuity reading →...
  • Page 337 – ELEC CHECKING THE SWITCHES 1 Main switch 8 Front brake light switch 2 Dimmer switch 9 Fuse 3 Turn signal switch 0 Sidestand switch 4 Horn switch A Rear brake light switch 5 Clutch switch B Neutral switch 6 Engine stop switch C Oil level switch 7 Start switch 8 - 7...

  • Page 338: Checking The Bulbs And Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for dam- age or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
  • Page 339 – ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: ACHTUNG: • Be sure to hold the socket firmly when removing the bulb.

  • Page 340: Checking The Condition Of The Bulb Sockets

    – ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE:...

  • Page 341: Ignition System

    – ELEC IGNITION SYSTEM EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 11...

  • Page 342: Troubleshooting

    – ELEC IGNITION SYSTEM EB802011 EB802401 TROUBLESHOOTING 2.Battery The ignition system fails to operate (no • Check the condition of the battery. spark or intermittent spark). Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: Min. open-circuit voltage 1.
  • Page 343 – ELEC IGNITION SYSTEM EB802405 Spark plug cap resistance 4.Ignition spark gap 10 kΩ at 20 ˚C (68 ˚F) The following procedure applies to all of • Is the spark plug cap OK? the spark plugs. • Disconnect the spark plug cap from the spark plug.
  • Page 344 – ELEC IGNITION SYSTEM EB802411 8.Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? Replace the main switch. Secondary coil resistance 12 ~ 18 kΩ at 20 ˚C (68 ˚F) •...
  • Page 345 – ELEC IGNITION SYSTEM EB802415 EB802416 12.Relay unit 13.Wiring • Remove the relay unit from the wire har- • Check the entire ignition system’s wir- ness. ing. • Connect the pocket tester (Ω × 1) to the Refer to “CIRCUIT DIAGRAM”. relay unit terminals as shown.

  • Page 346: Electric Starting System

    – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 16...

  • Page 347: Starting Circuit Cutoff System Operation

    – ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...

  • Page 348: Troubleshooting

    – ELEC ELECTRIC STARTING SYSTEM EB803020 EB802401 TROUBLESHOOTING 2.Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses Open-circuit voltage 2.
  • Page 349 – ELEC ELECTRIC STARTING SYSTEM EB803402 EB803403 4.Starting circuit cutoff relay 5.Relay unit • Disconnect the relay unit from the cou- • Disconnect the relay unit from the cou- pler. pler. • Connect the pocket tester (Ω × 1) and •...
  • Page 350 – ELEC ELECTRIC STARTING SYSTEM EB803404 EB802412 6.Starter relay 8.Engine stop switch • Disconnect the starter relay from the • Check the engine stop switch for conti- coupler. nuity. • Connect the pocket tester (Ω × 1) and Refer to “CHECKING THE SWITCHES”. battery (12 V) to the starter relay coupler •...
  • Page 351 – ELEC ELECTRIC STARTING SYSTEM EB803406 12.Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? Replace right handlebar switch. EB803408 13.Wiring • Check the entire starting system’s wir- ing. Refer to “CIRCUIT DIAGRAM”.

  • Page 352: Starter Motor

    – ELEC STARTER MOTOR EB803500 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Rider seat Refer to “SEATS” in chapter 3. Fuel tank Refer to “FUEL TANK” in chapter 3. Left side cowling Refer to “COWLINGS”...
  • Page 353 – ELEC STARTER MOTOR EB803501 Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Starter motor front cover Lock washer Oil seal Bearing Washer set Starter motor rear cover Washer set Armature assembly Brush seat (along with the brushes) Brush holder (along with the brushes) O-ring Starter motor yoke...

  • Page 354: Checking The Starter Motor

    – ELEC STARTER MOTOR EB803511 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter 27 mm (1.06 in) 3.

  • Page 355: Assembling The Starter Motor

    – ELEC STARTER MOTOR 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Min. brush length 5 mm (0.20 in) 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 7.03 ~ 10.63 N (717 ~ 1,084 gf, 25.3 ~ 38.3 oz)

  • Page 356: Charging System

    – ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM Br/L Br/L Br/L Br/L (BLACK) Br R/W R/W B/R B R/B R/W B L G/Y B/W L/W (BLACK) (BLACK) Br/L Br/L Br/L 3 Rectifier/regulator 4 Generator 5 Battery 6 Main fuse Br Br/R B Br/W Br/W...

  • Page 357: Troubleshooting

    – ELEC CHARGING SYSTEM EB804010 EB802401 TROUBLESHOOTING 2.Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse Open-circuit voltage 2. battery 12.8 V or more at 20 ˚C (68 ˚F) 3.
  • Page 358 – ELEC CHARGING SYSTEM EB804404 5.Wiring NOTE: Make sure that the battery is fully • Check the wiring connections of the charged. entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging voltage within specifica- tion? • Is the charging system’s wiring properly connected and without defects? The charging circuit is OK.

  • Page 359: Lighting System

    – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 29...

  • Page 360: Troubleshooting

    – ELEC LIGHTING SYSTEM EB805010 EB802401 TROUBLESHOOTING 2.Battery Any of the following fail to light: head- • Check the condition of the battery. light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. position light or meter light. Open-circuit voltage Check: 12.8 V or more at 20 ˚C (68 ˚F)

  • Page 361: Checking The Lighting System

    – ELEC LIGHTING SYSTEM EB805401 EB805410 CHECKING THE LIGHTING SYSTEM 4.Dimmer switch 1. The headlight and the high beam indi- • Check the dimmer switch for continuity. cator light fail to come on. Refer to “CHECKING THE SWITCHES”. 1.Headlight bulb and socket •...
  • Page 362 – ELEC LIGHTING SYSTEM Headlight Tester positive probe → black/yellow 1 or black/blue 2 Tester negative probe → black 3 High beam indicator light Tester positive probe → white/yellow 4 Tester negative probe → black 5 Meter assembly coupler (wire harness side) •...
  • Page 363 – ELEC LIGHTING SYSTEM • Set the main switch to “ON”. • Set the main switch to “ON”. • Measure the voltage (12 V) of blue/red 1 • Measure the voltage (12 V) of blue 1 on the meter assembly coupler (wire har- on the tail/brake light coupler (wire har- ness side).
  • Page 364 – ELEC LIGHTING SYSTEM • Set the main switch to “ON”. • Measure the voltage (12 V) of blue/red 1 on the front turn signal/position light connectors (wire harness side). • Is the voltage within specification? This circuit is OK. The wiring circuit from main...

  • Page 365: Signaling System

    – ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 36...
  • Page 366 – ELEC SIGNALING SYSTEM 1 Main switch 5 Battery 6 Main fuse D Fuel sender K Neutral switch O Fuel level indicator light P Oil level/coolant temperature warning light Q Neutral indicator light R Tachometer S Combination meter V Turn signal indicator light Z Horn switch [ Horn ] Turn signal switch...

  • Page 367: Troubleshooting

    – ELEC SIGNALING SYSTEM EB806010 EB802401 TROUBLESHOOTING 2.Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING THE BATTERY” in light. chapter 3. •...

  • Page 368: Checking The Signaling System

    – ELEC SIGNALING SYSTEM EB806410 3.Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the black connector at the horn terminal. 1.Horn switch • Connect a jumper lead 1 to the horn ter- minal and ground the jumper lead. •...
  • Page 369 – ELEC SIGNALING SYSTEM EB806411 • Set the main switch to “ON”. 2. A tail/brake light fails to come on. • Pull in the brake lever or push down on 1.Tail/brake light bulb and socket the brake pedal. • Measure the voltage (12 V) of yellow at •...
  • Page 370 – ELEC SIGNALING SYSTEM Tester positive probe → brown/white 1 3.Turn signal switch Tester negative probe → ground • Check the turn signal switch for continu- ity. Refer to “CHECKING THE SWITCHES”. • Is the turn signal switch OK? Replace the left han- dlebar switch.
  • Page 371 – ELEC SIGNALING SYSTEM • Set the main switch to “ON”. 3.Voltage • Set the turn signal switch to “ ” or • Connect the pocket tester (DC 20V) to “ ”. the meter assembly coupler (wire har- • Measure the voltage (12V) of chocolate 1 ness side) as shown.
  • Page 372 – ELEC SIGNALING SYSTEM 2.Oil level switch 4.Voltage • Connect the pocket tester (DC 20V) to • Drain the engine oil and remove the oil level switch from the oil pan. the meter assembly coupler (wire har- • Check the oil level switch for continuity. ness side) as shown.
  • Page 373 – ELEC SIGNALING SYSTEM 2.Fuel sender • Set the main switch to “ON”. • Measure the voltage (12V). • Disconnect the fuel sender coupler from • Is the voltage within specification? the wire harness. • Drain the fuel from the fuel tank and remove the fuel sender from the fuel tank.

  • Page 374: Cooling System

    – ELEC COOLING SYSTEM EB807000 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 45...

  • Page 375: Troubleshooting

    – ELEC COOLING SYSTEM EB807010 • Is the battery OK? TROUBLESHOOTING • The radiator fan motor fails to turn. • The coolant temperature meter needle fails to move when the engine is warm. • Clean the battery terminals. Check: • Recharge or 1.
  • Page 376 – ELEC COOLING SYSTEM EB807400 Coolant temperature Test 5.Radiator fan motor (test 2) Continuity step Thermo switch • Disconnect the thermo switch coupler. 0 ~ 98 ˚C (0 ~ 208.4 ˚F) • Set the main switch to “ON”. • Connect the brown 1 and blue 2 termi- More than 105 ±...
  • Page 377 – ELEC COOLING SYSTEM • Does the thermo switch operate prop- erly as described above? Replace the thermo switch. 7.Temperature sender WARNING WARNING • Remove the temperature sender from Handle the temperature sender with spe- the radiator. • Connect the pocket tester (Ω × 10) to the cial care.

  • Page 378: Fuel Pump System

    – ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 8 - 49...

  • Page 379: Fuel Pump Circuit Operation

    – ELEC FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump. 1 Battery 2 Main fuse 3 Main switch 4 Ignition fuse 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump 8 - 50...

  • Page 380: Troubleshooting

    – ELEC FUEL PUMP SYSTEM EB808020 EB802401 TROUBLESHOOTING 2.Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses Open-circuit voltage 2.
  • Page 381 – ELEC FUEL PUMP SYSTEM • Measure the fuel pump resistance. 5.Fuel pump relay Fuel pump resistance • Disconnect the relay unit from the cou- 4 ~ 30 Ω at 20 ˚C (68 ˚F) pler. • Connect the pocket tester (Ω × 1) and •...

  • Page 382: Checking The Fuel Pump

    – ELEC FUEL PUMP SYSTEM EB808410 CHECKING THE FUEL PUMP WARNING 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 follow- ing points: • Stop the engine before refuelling. •...

  • Page 383: Exup System

    – ELEC EXUP SYSTEM EB811000 EXUP SYSTEM CIRCUIT DIAGRAM 8 - 54...

  • Page 384: Troubleshooting

    – ELEC EXUP SYSTEM EB811010 TROUBLESHOOTING When the engine speed changes, the EXUP servomotor does not operate. Procedure 1 Check: 1. Exup servomotor operation (with the EXUP servomotor coupler connected to the wire harness) 2. voltage • Does the EXUP servomotor pulley turn? 3.
  • Page 385 – ELEC EXUP SYSTEM EB811402 3.EXUP servomotor operation (with the servomotor coupler disconnected from the wire harness) • Disconnect the EXUP cables from the EXUP servomotor pulley. • Disconnect the EXUP servomotor cou- pler from the wire harness. • Connect the battery leads to the EXUP servomotor coupler (servomotor side) as shown.
  • Page 386 – ELEC EXUP SYSTEM EB811404 EB802411 5.Wiring 3.Main switch • Check the entire EXUP system’s wiring. • Check the main switch for continuity. Refer to “CIRCUIT DIAGRAM”. Refer to “CHECKING THE SWITCHES”. • Is the EXUP system’s wiring properly • Is the main switch OK? connected and without defects? Replace the main Replace the ignitor...

  • Page 387: Self-Diagnosis

    – ELEC SELF-DIAGNOSIS EB812000 SELF-DIAGNOSIS The YZF-R1 features a self-diagnosing system for the following circuit(-s): • throttle position sensor • EXUP • fuel level indicator light If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to “ON”...
  • Page 388 – ELEC SELF-DIAGNOSIS EB812010 1.Wire harness TROUBLESHOOTING • Check the wire harness for continuity. The tachometer starts to display the self- Refer to “CIRCUIT DIAGRAM”. diagnosis sequence. • Is the wire harness OK? Check: 1. throttle position sensor 2. Exup 3.
  • Page 389 – ELEC SELF-DIAGNOSIS EB812030 EB812402 2. EXUP 2.EXUP servomotor CIRCUIT DIAGRAM • Check the EXUP servomotor for continu- ity. Refer to “EXUP SYSTEM”. • Is the EXUP servomotor OK? Replace the ignitor Replace the EXUP B/R L Y/L B/R unit. servomotor.
  • Page 390 – ELEC SELF-DIAGNOSIS EB812040 EB812403 3. Fuel level indicator light 1.Fuel level indicator light LED CIRCUIT DIAGRAM • Check the LED of the fuel level indicator light. Refer to “CHECKING THE LEDs”. • Is the fuel level indicator light LED OK? R/G Dg WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS...
  • Page 391 – ELEC SELF-DIAGNOSIS EB812405 3.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? Replace the ignitor Replace or replace unit. the wire harness. 8 - 62...

  • Page 392: Troubleshooting

    TRBL STARTING PROBLEMS SHTG EB900000 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 proce- dure in this manual for checks, adjustments, and replacement of parts. STARTING PROBLEMS FUEL SYSTEM ENGINE...

  • Page 393: Incorrect Engine Idling Speed

    INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND- TRBL HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING SHTG EB901000 INCORRECT ENGINE IDLING SPEED ENGINE ELECTRICAL SYSTEMS Cylinders and cylinder head Battery • Incorrect valve clearance • Faulty battery • Damaged valve train components • Discharged battery Air filter Spark plugs •...

  • Page 394: Faulty Clutch

    TRBL FAULTY CLUTCH/OVERHEATING/OVERCOOLING SHTG EB904000 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch • Incorrectly assembled clutch • Unevenly tensioned clutch spring plate • Incorrectly adjusted clutch cable • Warped pressure plate • Loose or fatigued clutch spring • Bent clutch plate •...

  • Page 395: Poor Braking Performance

    POOR BRAKING PERFORMANCE/FAULTY FRONT FORK TRBL LEGS/UNSTABLE HANDLING SHTG EB907000 POOR BRAKING PERFORMANCE • Worn brake pad • Loose union bolt • Worn brake disc • Damaged brake hose • Air in hydraulic brake system • Oil or grease on the brake disc •...

  • Page 396: Faulty Lighting And Signaling Systems

    TRBL FAULTY LIGHTING AND SIGNALING SYSTEMS SHTG EB910000 FAULTY LIGHTING AND SIGNALING SYSTEMS TURN SIGNAL BLINKS SLOWLY HEADLIGHT DOES NOT LIGHT • Wrong headlight bulb • Faulty turn signal relay • Faulty main switch • Too many electrical accessories • Faulty turn signal switch •...
  • Page 397 YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
  • Page 398 YZF-R1 WIRING DIAGRAM (For USA and CDN) 1 Main switch 2 Backup fuse (odometer) 3 Rectifier/regulator 4 Generator 5 Battery R/G Dg 6 Main fuse 7 Starter relay WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS WIRE HARNESS IGNITION COIL SUB-WIRE HARNESS 8 Starter motor 9 Relay unit 0 Starting circuit cutoff relay A Fuel pump relay...

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