Yamaha YZF-R7 Owner's Service Manual
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Yamaha YZF-R7 Owner's Service Manual

Yamaha YZF-R7 Owner's Service Manual

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Ofrecido por www.electromanuales.com
OWNER'S SERVICE MANUAL
YZF-R7
5FL-28199-E0

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  • Page 1 Ofrecido por www.electromanuales.com OWNER’S SERVICE MANUAL YZF-R7 5FL-28199-E0...
  • Page 2 Ofrecido por www.electromanuales.com EC010010 YZF-R7 OWNER’S SERVICE MANUAL ©1999 by Yamaha Motor Co., Ltd. 1st Edition, December 1998 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
  • Page 3 Ofrecido por www.electromanuales.com EAU00001 INTRODUCTION Welcome to the Yamaha world of motorcy- cling! As the owner of a YZF-R7, you are benefit- ing from Yamaha’s vast experience in and newest technology for the design and the manufacture high-quality products, which have earned Yamaha a reputation for dependability.
  • Page 4 EC060000 NOTICE Some data in this manual may become out- dated due to improvements made to this model in the future. If there is any question you have regarding this manual or your motorcycle, please consult your Yamaha dealer.

  • Page 5: General

    Ofrecido por www.electromanuales.com EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTEN- TION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the motorcycle.
  • Page 6 Ofrecido por www.electromanuales.com EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

  • Page 7: Specifications

    Ofrecido por www.electromanuales.com EB004000 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Overhauling the engine 5 Cooling system 6 Electronic fuel injection 7 Chassis COOL...
  • Page 8 Ofrecido por www.electromanuales.com...

  • Page 9: Table Of Contents

    Ofrecido por www.electromanuales.com INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS ADJUSTMENTS OVERHAULING THE ENGINE COOLING SYSTEM COOL ELECTRONIC FUEL INJECTION CHASSIS CHAS – ELECTRICAL ELEC...

  • Page 10: Table Of Contents

    Ofrecido por www.electromanuales.com EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION GIVE SAFETY THE RIGHT OF WAY ..1-1 DESCRIPTION ........... 1-2 INSTRUMENT AND CONTROL FUNCTIONS ..........1-4 OPERATION AND IMPORTANT RIDING POINTS ........1-12 INCLUDED ACCESSORIES ..... 1-14 MOTORCYCLE CARE AND STORAGE ..........

  • Page 11: Table Of Contents

    Ofrecido por www.electromanuales.com CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ........3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ...... 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ......3-2 FUEL TANK AND AIR FILTER ....3-4 COWLINGS ..........3-6 ENGINE ............. 3-9 CHASSIS ..........3-36 ELECTRICAL SYSTEM ......

  • Page 12: Table Of Contents

    Ofrecido por www.electromanuales.com CHAPTER 6 ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION ....6-1 CHAPTER 7 CHASSIS FRONT WHEEL AND BRAKE DISCS ..7-1 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET ......7-9 FRONT AND REAR BRAKES ....7-15 HYDRAULIC CLUTCH ......7-43 FRONT FORK ..........

  • Page 13: Give Safety The Right Of Way

    Ofrecido por www.electromanuales.com GIVE SAFETY THE RIGHT OF WAY GENERAL INFORMATION GIVE SAFETY THE RIGHT OF WAY Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. Howev- er, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of physics.

  • Page 14: Description

    Ofrecido por www.electromanuales.com DESCRIPTION DESCRIPTION Left view Right view 1112 1. Front fork compression damping force adjusting screw 2. Front fork rebound damping force adjusting screw 3. Front fork spring preload adjusting bolt 4. Air filter 5. Starter (choke) “ “...
  • Page 15 Ofrecido por www.electromanuales.com DESCRIPTION Controls/Instruments 3 45 9 10 1. Clutch lever 2. Left handlebar switches 3. Clutch reservoir 4. Digital speedometer 5. Main switch 6. Tachometer 7. Front brake reservoir 8. Right handlebar switches 9. Throttle grip 10. Front brake lever 1 - 3...

  • Page 16: Instrument And Control Functions

    Ofrecido por www.electromanuales.com INSTRUMENT AND CONTROL FUNCTIONS INSTRUMENT AND CONTROL FUNCTIONS EAU00029 EAU00040 1. Push Main switch/Steering lock LOCK 2. Turn The steering is locked in this position EW000016 The main switch controls the ignition and all electrical circuits are switched WARNING and lighting systems.
  • Page 17 Yamaha dealer to have the self- den acceleration or deceleration, but diagnostic systems checked. this is normal. The light will come on and symbol “...
  • Page 18 CB-75ECB-75E Turn the main switch to “ON”. Warning light comes on. After a few seconds: Warning light does not come on. Have a Yamaha dealer inspect Warning light goes off. Warning light does not go off. the electrical circuit. Symbol “...
  • Page 19 Turn the main switch to “ON”. Indicator does not come Indicator comes on. After a few seconds: Indicator does not go off. Indicator goes off. Have a Yamaha dealer Inspect the fuel level. inspect the electric circuit. OK. Go ahead with Fuel level is OK.
  • Page 20 SYSTEM USER MODE” in chapter 8. To prevent engine damage, be sure If some trouble should occur in an elec- to consult a Yamaha dealer as soon trical circuit the tachometer will repeat- as possible if the tachometer dis- edly display change in r/min.

  • Page 21: Handlebar Switches

    Ofrecido por www.electromanuales.com INSTRUMENT AND CONTROL FUNCTIONS EAU00134 Lights switch Turning the lights switch to “ ”, turns on the auxiliary light, meter lights and taillight. Turning the lights switch to “ ”, turns the headlight on also. EAU00121 Dimmer switch Turn the switch to “...
  • Page 22 Ofrecido por www.electromanuales.com INSTRUMENT AND CONTROL FUNCTIONS 1. Shift pedal 1. Lever position adjusting dial 1. Rear brake pedal 2. Arrow mark EAU00157 EAU00162 a. Lever distance Shift pedal Rear brake pedal EAU00161 Front brake lever This motorcycle is equipped with a con- The rear brake pedal is on the right stant-mesh 6-speed transmission.
  • Page 23 CLUTCH SWITCH IS OK. tane grade. SIDESTAND IS DOWN. CD-11E ENGINE WILL STALL. SIDESTAND SWITCH IS OK. EW000045 WARNING If improper operation is noted, con- sult a Yamaha dealer immediately. 1 - 11...

  • Page 24: Operation And Important Riding Points

    Consult The engine can be started only under Yamaha dealer regarding any one of the following conditions: control or function that you do The transmission is in neutral. not thoroughly understand. The sidestand is up, the transmis-...
  • Page 25 When the transmission is in neutral, the neutral indicator light should be on. If the light does not come on, ask a Yamaha dealer to inspect it. 3. Turn on the starter (choke) and completely close the throttle grip. 4. Start the engine by pushing the start switch.

  • Page 26: Included Accessories

    Yamaha may cause of periodic maintenance. However, loss of performance, and render it some other tools such as a torque unsafe for use. Consult a Yamaha wrench are also necessary to perform dealer before attempting any chang- the maintenance correctly.

  • Page 27: Motorcycle Care And Storage

    Ofrecido por www.electromanuales.com MOTORCYCLE CARE AND STORAGE MOTORCYCLE CARE AND STORAGE Care Before cleaning Cleaning 1. Cover up the muffler outlet with a After normal use The exposure of its technology makes plastic bag. Remove dirt with warm water, a neutral a motorcycle charming but also vulner- 2.
  • Page 28 NOTE: the excess oil. Reinstall the tank. To prevent corrosion, avoid Consult a Yamaha dealer for advice on 3. Remove the spark plug, pour damp cellars, stables (because what products to use. about one tablespoon of engine...

  • Page 29: Consumer Information

    Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehicle is sto- len. 1. Key identification number 1.

  • Page 30: Model Label

    Remove spark plugs and check electrodes. Engine doesn’t start, go to battery Dry. Ask a Yamaha dealer to inspect. check. 4. Battery Engine turns over Battery good. quickly. Engine doesn’t start, ask a Yamaha Use electric starter.
  • Page 31 Restart the engine. If the engine overheats again, ask a Level is OK. Yamaha dealer to inspect and repair the cooling system. NOTE: If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom- mended coolant as soon as possible.

  • Page 32: 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 33 Ofrecido por www.electromanuales.com IMPORTANT INFORMATION USING A DYNAMOMETER The YZF-R7 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...

  • Page 34: Checking The Connections

    Ofrecido por www.electromanuales.com CHECKING THE CONNECTIONS 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 35: Special Tools

    Ofrecido por www.electromanuales.com SPECIAL TOOLS 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 36 Ofrecido por www.electromanuales.com SPECIAL TOOLS Tool No. Tool name/Function Illustration Rod puller Rod puller 90890-01437 Rod puller attachment Rod puller attachment These tools are used to pull up the front 90890-01436 fork damper rod. Fork spring compressor 90890-01441 This tool is used to disassemble or assem- ble the front fork legs.
  • Page 37 Ofrecido por www.electromanuales.com SPECIAL TOOLS Tool No. Tool name/Function Illustration Compression Compression gauge gauge Adapter 90890-03081 Adapter These tools are used to measure engine 90890-04136 compression. Pocket tester 90890-03112 This tool is used to check the electrical system. Pressure Pressure gauge gauge Adapter 90890-03153...
  • Page 38 This tool is used to measure the vacuum pressure. Engine tachometer 90890-06760 This tool is used to check engine speed. Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces). 1 - 26...

  • Page 39: Specifications

    Ofrecido por www.electromanuales.com SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Dimensions Overall length 2,060 mm (81.1 in) ---- Overall width 720 mm (28.3 in) ---- Overall height 1,125 mm (44.3 in) ---- Seat height 840 mm (33.1 in) ---- Wheelbase 1,400 mm (55.1 in)

  • Page 40: Engine Specifications

    Ofrecido por www.electromanuales.com SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC ---- Displacement 749 cm ---- Cylinder arrangement Forward-inclined parallel 4-cylinder ---- Bore × stroke 72 × 46 mm (2.83 × 1.81 in) ---- Compression ratio 11.4:1 ----...
  • Page 41 Ofrecido por www.electromanuales.com 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 clear-...
  • Page 42 Ofrecido por www.electromanuales.com 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 24.452 ~ 24.465 mm ---- (0.9627 ~ 0.9632 in) Camshaft journal-to-camshaft cap 0.035 ~ 0.069 mm (0.0014 ~ 0.0027 in) ----...
  • Page 43 Ofrecido por www.electromanuales.com SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links DID219FTH3/100 ---- Tensioning system Automatic ---- Valves, valve seats, valve guides Valve clearance (cold) Intake 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ---- Exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ---- Valve dimensions Head Diameter...
  • Page 44 Ofrecido por www.electromanuales.com 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) 1.6 mm (0.06 in) Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 1.6 mm (0.06 in) Valve springs...
  • Page 45 Ofrecido por www.electromanuales.com SPEC ENGINE SPECIFICATIONS Item Standard Limit Outer springs Free length Intake 36.42 mm (1.43 in) 34.60 mm (1.36 in) Exhaust 33.91 mm (1.34 in) 32.21 mm (1.27 in) Installed length (valve closed) Intake 32.03 mm (1.26 in) ---- Exhaust 30.25 mm (1.19 in)
  • Page 46 Ofrecido por www.electromanuales.com SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons Piston-to-cylinder clearance 0.028 ~ 0.054 mm (0.0011 ~ 0.0021 in) 0.1 mm (0.004 in) Diameter D 71.954 ~ 71.972 mm ---- (2.8328 ~ 2.8335 in) Height H 10 mm (0.39 in) ---- Piston pin bore (in the piston) Diameter...
  • Page 47 Ofrecido por www.electromanuales.com SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil ring Dimensions (B × T) 1.5 × 2.5 mm (0.059 × 0.098 in) ---- End gap (installed) 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ---- Connecting rods Crankshaft pin-to-big end bearing 0.058 ~ 0.078 mm (0.0023 ~ 0.0031 in) ---- clearance...
  • Page 48 Ofrecido por www.electromanuales.com SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch plates Thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ---- Plate quantity ---- Maximum warpage ---- 0.1 mm (0.004 in) Clutch springs Free length 7.1 mm (0.280 in) ---- Spring quantity 1 spring per valve ----...

  • Page 49: Chassis Specifications

    Ofrecido por www.electromanuales.com SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond ---- Caster angle 22.7˚ ---- Trail 95 mm (3.74 in) ---- Front wheel Wheel type Cast wheel ---- 17 × MT3.50 Size ---- Material Aluminum ---- Wheel travel 120 mm (4.72 in)
  • Page 50 Ofrecido por www.electromanuales.com SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless ---- Size 180/55 ZR17 73W ---- Model (manufacturer) MTR08 (PIRELLI) ---- 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...
  • Page 51 Ofrecido por www.electromanuales.com SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork ---- Front fork type Coil spring/oil damper ---- Front fork travel 120 mm (4.72 in) ---- Spring Free length 240 mm (9.45 in) ---- Spacer length 127 mm (5.00 in) ---- Installed length...
  • Page 52 Ofrecido por www.electromanuales.com 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 63 mm (2.48 in) ---- travel Spring...

  • Page 53: Electrical Specifications

    Ofrecido por www.electromanuales.com SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V ---- Ignition system Ignition system type C.D.I. ---- 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 ---- 421 ~ 569 Ω...
  • Page 54 Ofrecido por www.electromanuales.com SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Electric starting system System type Constant mesh ---- Starter motor Model (manufacturer) SM-14 (MITSUBA) ---- Power output 0.6 kW ---- 0.0015 ~ 0.0025 Ω Armature coil resistance ---- Brushes Overall length 10 mm (0.40 in) 3.5 mm (0.14 in)

  • Page 55: Tightening Torques

    Ofrecido por www.electromanuales.com 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 56 Ofrecido por www.electromanuales.com 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 Cap bolt (timing chain tensioner) Bolt...
  • Page 57 Ofrecido por www.electromanuales.com SPEC TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Remarks Nm m·kgf ft·lb Shift shaft cover Bolt Oil baffle plate Bolt Timing mark accessing screw – Starter clutch Bolt Use a lock Clutch boss washer. Clutch spring Bolt Use a lock Drive sprocket...
  • Page 58 Ofrecido por www.electromanuales.com SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2 - 20...
  • Page 59 Ofrecido por www.electromanuales.com 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 Front brake hose union bolts Front brake master cylinder Engine mounting Spacer bolts...

  • Page 60: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No. 1215 Yamaha bond Cylinder head cover No. 1215...
  • Page 61 Ofrecido por www.electromanuales.com 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 62: Oil Flow Chart

    Ofrecido por www.electromanuales.com SPEC OIL FLOW CHART OIL FLOW CHART Pressure feed Timing chain area camshaft Valve lifter Check bolt Piston Connecting rod Big end bearing Crankshaft journal (#1) Nozzle Crankshaft journal (#2, #4) Nozzle Crankshaft journal (#3, #5) Main gallery Back torque limiter clutch Starter clutch Main axle...

  • Page 63: Coolant Flow Chart

    Ofrecido por www.electromanuales.com SPEC COOLANT FLOW CHART ELECTRICAL SPECIFICATIONS COOLANT FLOW CHART Thermostat assembly Coolant reservoir Upper radiator Water jacket Lower radiator Water pump Oil cooler Drain bolt 2 - 25...

  • Page 64: Cable Routing

    Ofrecido por www.electromanuales.com SPEC CABLE ROUTING CABLE ROUTING 1 Front turn signal coupler 2 Auxiliary light lead 3 Headlight lead 4 Throttle cable 5 Left handlebar switch lead 6 Clutch hose 7 Front brake hose 8 Right handlebar switch lead 9 Main switch lead 2 - 26...
  • Page 65 Ofrecido por www.electromanuales.com SPEC CABLE ROUTING Å Fasten the coolant reservoir breather hose, thermo 1 Rear brake switch coupler 2 Pickup coil lead switch lead and thermostat assembly breather hose 3 Thermo switch lead with a plastic locking tie. Do not crush the breather 4 Wire harness hoses with the plastic locking tie.
  • Page 66 Ofrecido por www.electromanuales.com SPEC CABLE ROUTING 1 Left handlebar switch lead 0 Horn lead 2 Starter cable A Headlight and meter sub-wire harness lead 3 Main relay B Throttle cable 4 Speed sensor C Clutch hose 5 Throttle stop screw D Wire harness (to headlight and meter sub-wire harness) 6 Sidestand switch lead E Wire harness...
  • Page 67 Ofrecido por www.electromanuales.com SPEC CABLE ROUTING ı Fasten the starter cable and wire harness with a plastic band. J Fuel tank breather hose Ç Fasten the oil level switch lead, speed sensor lead, sidestand K CDI unit L Fall detection switch switch lead and stator coil assembly lead with a plastic band.
  • Page 68 Ofrecido por www.electromanuales.com SPEC CABLE ROUTING 1 Ignition coil A ECU 2 Throttle position sensor coupler B Fuse box 3 Camshaft sensor C Fall detection switch 4 Injector 1 coupler D Starter relay 5 Starter motor E Main relay 6 Fuel tank overflow hose F Throttle stop screw cable 7 Fuel pump coupler G Fuel tank breather hose...
  • Page 69 Ofrecido por www.electromanuales.com SPEC CABLE ROUTING K Pickup coil lead U Neutral switch lead L Stator coil lead V Ground lead M Speed sensor lead W Coolant temperature sensor coupler N Sidestand switch lead X Throttle cable O Oil level switch lead Å...

  • Page 70: Periodic Checks And Adjustments

    Ofrecido por www.electromanuales.com INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjust- ments. If followed, these preventive maintenance procedures will ensure more reliable vehi- cle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.

  • Page 71: Periodic Maintenance And Lubrication

    * Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. NOTE: • The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.
  • Page 72 Ofrecido por www.electromanuales.com 3 - 3...

  • Page 73: Fuel Tank And Air Filter

    Ofrecido por www.electromanuales.com FUEL TANK AND AIR FILTER EB302010 FUEL TANK AND AIR FILTER Order Job/Part Q’ty Remarks Removing the fuel tank and air filter Remove the parts in the order listed. Fuel Drain. Fuel tank breather hose Bolt Bolt Fuel pump coupler Disconnect.
  • Page 74 Ofrecido por www.electromanuales.com FUEL TANK AND AIR FILTER REMOVAL 1. Drain: • fuel (completely from the fuel tank) NOTE: Remove the fuel tank cap and use a pump to remove the fuel from the fuel tank. The fuel tank must be drained to avoid leakage at the fuel pump outlet.

  • Page 75: Cowlings

    Ofrecido por www.electromanuales.com COWLINGS EB302020 COWLINGS Order Job/Part Q’ty Remarks Removing the front cowling Remove the parts in the order listed. Bottom cowling Rear view mirror Front turn signal coupler Disconnect. Front cowling Windshield Front turn signal For installation, reverse the removal procedure.
  • Page 76 Ofrecido por www.electromanuales.com COWLINGS Order Job/Part Q’ty Remarks Removing the rear cowling Remove the parts in the order listed. Rear fender Rear fender panel Tail/brake light connector Disconnect. Rear turn signal connector Disconnect. Rear cowling For installation, reverse the removal procedure.
  • Page 77 Ofrecido por www.electromanuales.com COWLINGS REMOVAL 1. Remove: • rear cowling NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: • 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 78: Engine

    Ofrecido por www.electromanuales.com 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 Ofrecido por www.electromanuales.com ADJUSTING THE VALVE CLEARANCE 5. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) Exhaust valve 0.25 ~ 0.30 mm (0.0098 ~ 0.0119 in) a.
  • Page 80 Ofrecido por www.electromanuales.com ADJUSTING THE VALVE CLEARANCE 6. 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: •...
  • Page 81 Ofrecido por www.electromanuales.com 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: Adjusting The Valve Clearance

    Ofrecido por www.electromanuales.com 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 ~ 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0.02 ~ 0.07...
  • Page 83 Ofrecido por www.electromanuales.com ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES 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. 8.
  • Page 84 Ofrecido por www.electromanuales.com SYNCHRONIZING THE THROTTLE BODIES 4. Install: • vacuum gauge attachments (into the bolt holes) • vacuum gauge (onto the vacuum gauge attachments) • engine tachometer (onto the ignition coil of cylinder #1) Vacuum gauge 90890-03094 Vacuum gauge attachment 90890-03060 Engine tachometer 90890-06760...
  • Page 85 Ofrecido por www.electromanuales.com SYNCHRONIZING THE THROTTLE BODIES/ ADJUSTING THE ENGINE IDLING SPEED Vacuum pressure at engine idling speed 15.8 ~ 18.4 kPa (120 ~ 140 mm Hg, 4.72 ~ 5.51 in Hg) NOTE: The difference in vacuum pressure between two throttle bodies should not exceed 1.33 kPa (10 mm Hg, 0.4 in Hg).
  • Page 86 Ofrecido por www.electromanuales.com ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Install: • engine tachometer (onto the ignition coil of cylinder #1) Engine tachometer 90890-06760 NOTE: Refer to “SYNCHRONIZING THE THROT- TLE BODIES” for the engine tachometer installation.
  • Page 87 Ofrecido por www.electromanuales.com ADJUSTING THE THROTTLE CABLE FREE PLAY 1. Measure: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm (0.12 ~ 0.20 in) 2.
  • Page 88 Ofrecido por www.electromanuales.com ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS Handlebar side a. Loosen the locknut 4. b. Turn the adjusting nut 5 in direction c or d until the specified throttle cable free play is obtained. Throttle cable free play Direction c is increased.
  • Page 89 Ofrecido por www.electromanuales.com CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 5. Check: • electrodes 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7.
  • Page 90 Ofrecido por www.electromanuales.com MEASURING THE COMPRESSION PRESSURE 3. Remove: • fuel tank • air filter case cover Refer to “FUEL TANK AND AIR FIL- TER”. • air filter case • throttle body assembly Refer to “ELECTRONIC FUEL INJEC- TION” in chapter 6. •...
  • Page 91 Ofrecido por www.electromanuales.com MEASURING THE COMPRESSION PRESSURE WARNING WARNING To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm , 14 psi). c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits.
  • Page 92 Ofrecido por www.electromanuales.com CHECKING THE ENGINE OIL LEVEL EB303070 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Start the engine, let it idle for several minutes, and then stop it.
  • Page 93 Ofrecido por www.electromanuales.com CHANGING THE ENGINE OIL EB303081 CHANGING THE ENGINE OIL 1. Remove: • bottom cowling • front cowling Refer to “COWLINGS”. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the engine oil drain bolt.
  • Page 94 Ofrecido por www.electromanuales.com CHANGING THE ENGINE OIL 9. Fill: • crankcase (with the specified amount of the rec- ommended engine oil) Quantity Total amount 3.6 L (3.2 lmp qt, 3.8 US qt) Without oil filter cartridge replacement 2.6 L (2.3 lmp qt, 2.7 US qt) With oil filter cartridge replacement 2.8 L (2.5 lmp qt, 3.0 US qt)
  • Page 95 Ofrecido por www.electromanuales.com CHANGING THE ENGINE OIL/ CHECKING THE CLUTCH FLUID LEVEL 15.Install: • front cowling • bottom cowling Refer to “COWLINGS”. EB303100 CHECKING THE CLUTCH FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand.
  • Page 96 Ofrecido por www.electromanuales.com BLEEDING THE HYDRAULIC CLUTCH SYSTEM BLEEDING THE HYDRAULIC CLUTCH SYSTEM WARNING WARNING Bleed the hydraulic clutch system whenever: • the clutch system was disassembled, • a clutch hose was loosened, discon- nected or replaced, • the clutch fluid level is very low, •...
  • Page 97 Ofrecido por www.electromanuales.com BLEEDING THE HYDRAULIC CLUTCH SYSTEM/ CLEANING THE AIR FILTER ELEMENT j. Tighten the bleed screw to specifica- tion. Bleed screw 6 Nm (0.6 m • kg, 4.3 ft • lb) k. Fill the clutch fluid reservoir to the proper level with the recommended clutch fluid.
  • Page 98 Ofrecido por www.electromanuales.com CHECKING THE FUEL HOSES/ CHECKING THE CRANKCASE BREATHER HOSE CHECKING THE FUEL HOSES The following procedure applies to all of the fuel hoses. 1. Remove: • fuel tank • air filter case cover Refer to “FUEL TANK AND AIR FIL- TER”.
  • Page 99 Ofrecido por www.electromanuales.com CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 3. Install: • fuel tank Refer to “FUEL TANK AND AIR FIL- TER”. EB303200 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1.
  • Page 100 Ofrecido por www.electromanuales.com CHECKING THE COOLANT LEVEL EB303220 CHECKING THE COOLANT 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. Remove: • bottom cowling •...
  • Page 101 Ofrecido por www.electromanuales.com CHECKING THE COOLING SYSTEM EB303230 CHECKING THE COOLING SYSTEM 1. Remove: • bottom cowling • front cowling Refer to “COWLINGS”. 2. Check: • upper radiator 1 • lower radiator 2 • radiator inlet hose 3 • radiator outlet hose 4 •...
  • Page 102 Ofrecido por www.electromanuales.com CHANGING THE COOLANT EB303240 CHANGING THE COOLANT 1. Remove: • bottom cowling • front cowling Refer to “COWLINGS”. 2. Remove: • coolant reservoir bolts 1 • coolant reservoir cap 2 NOTE: When draining the coolant from the coolant reservoir, be sure to tilt the res- ervoir so that coolant cannot flow through the coolant reservoir breather...
  • Page 103 Ofrecido por www.electromanuales.com CHANGING THE COOLANT 8. Check: • copper washer 1 • coolant drain bolt 2 Damage → Replace. 9. Install: • coolant drain bolt 7 Nm (0.7 m · kg, 5.1 ft · lb) 10.Fill: • cooling system (with the specified amount of the rec- ommended coolant) Recommended antifreeze...
  • Page 104 Ofrecido por www.electromanuales.com 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.

  • Page 105: Chassis

    Ofrecido por www.electromanuales.com ADJUSTING THE REAR BRAKE EB304001 CHASSIS EB304010 ADJUSTING THE REAR BRAKE 1. Measure: • brake pedal position (distance a from the top of the brake pedal to the bottom of the rider foot- rest bracket) Out of specification → Adjust. Brake pedal position (from the top of the brake pedal to the center of the rider footrest...
  • Page 106 Ofrecido por www.electromanuales.com ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CAUTION: ACHTUNG: After adjusting the brake pedal position, make sure that there is no brake drag. 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”.
  • Page 107 Ofrecido por www.electromanuales.com 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 108 Ofrecido por www.electromanuales.com 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.
  • Page 109 Ofrecido por www.electromanuales.com BLEEDING THE HYDRAULIC BRAKE SYSTEM 1. 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 110 Ofrecido por www.electromanuales.com 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 294 mm (11.57 in) 2.

  • Page 111: Adjusting The Drive Chain Slack

    Ofrecido por www.electromanuales.com 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 112: Lubricating The Drive Chain

    Ofrecido por www.electromanuales.com 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 113 Ofrecido por www.electromanuales.com CHECKING AND ADJUSTING THE STEERING HEAD 3. Remove: • bottom cowling • front cowling Refer to “COWLINGS”. 4. Remove: • front brake fluid reservoir 1 • clutch fluid reservoir 2 5. Loosen: • upper bracket pinch bolts 1 •...
  • Page 114 Ofrecido por www.electromanuales.com 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 tightening torque) 9 Nm (0.9 m • kg, 6.5 ft • lb) d.
  • Page 115 Ofrecido por www.electromanuales.com 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 116 Ofrecido por www.electromanuales.com 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 117: Adjusting The Front Fork Legs

    Ofrecido por www.electromanuales.com 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 118: Adjusting The Rear Shock Absorber Assembly

    Ofrecido por www.electromanuales.com 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 119 Ofrecido por www.electromanuales.com 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...
  • Page 120 Ofrecido por www.electromanuales.com 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 121 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 122 Ofrecido por www.electromanuales.com CHECKING THE TIRES/CHECKING THE WHEELS WARNING WARNING After mounting a new tire, ride conser- vatively for a while to become accus- tomed to the “feel” of the new tire and to allow the tire to seat itself properly in the rim.
  • Page 123 Ofrecido por www.electromanuales.com 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 124: Electrical System

    Ofrecido por www.electromanuales.com 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 125 Ofrecido por www.electromanuales.com 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 gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measur- ing the voltage at the battery terminals.
  • Page 126 Ofrecido por www.electromanuales.com CHECKING AND CHARGING THE BATTERY 5. Charge: • battery (68 ˚F) (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 127 Ofrecido por www.electromanuales.com CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger 3 - 58...
  • Page 128 Ofrecido por www.electromanuales.com CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger 3 - 59...
  • Page 129 Ofrecido por www.electromanuales.com 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 →...

  • Page 130: Electronic Fuel Injection

    Ofrecido por www.electromanuales.com 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 131 Ofrecido por www.electromanuales.com REPLACING THE HEADLIGHT BULBS EB305051 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler 1 2. Remove: • headlight bulb 1 WARNING WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.
  • Page 132 Ofrecido por www.electromanuales.com 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 133 Ofrecido por www.electromanuales.com ENGINE EB400011 OVERHAULING THE ENGINE ENGINE 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the drive sprocket Remove the parts in the order listed.
  • Page 134 Ofrecido por www.electromanuales.com ENGINE 10 Nm (1.0 m kg, 7.2 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Speed sensor Drive sprocket cover Oil seal support plate Dowel pin Push rod #2...
  • Page 135 Ofrecido por www.electromanuales.com ENGINE 38 Nm (3.8 m kg, 27 ft • • 20 Nm (2.0 m kg, 14 ft • • 28 Nm (2.8 m kg, 20 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft •...
  • Page 136 Ofrecido por www.electromanuales.com ENGINE Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FILTER COVER” in chapter 3. Air filter case and throttle body Refer to “ELECTRONIC FUEL INJEC- assembly TION”...
  • Page 137 Ofrecido por www.electromanuales.com ENGINE Order Job/Part Q’ty Remarks Crankcase breather hose Ignition coil Camshaft sensor Starter motor lead Disconnect. Ground lead Disconnect. Starter motor Pickup coil coupler Disconnect. Plastic clip Stator coil assembly coupler Disconnect. Sidestand switch coupler Oil level switch connector Disconnect.
  • Page 138 Ofrecido por www.electromanuales.com 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 Left front mounting bolt Washer Self-locking nut Spacer bolt Loosen.
  • Page 139 Ofrecido por www.electromanuales.com ENGINE EB400700 INSTALLING THE ENGINE 1. Install: • mounting bracket 1 • spacers 2 • rear mounting bolts 3 • washers 4 • left front mounting bolts 5 • right front mounting bolts 6 NOTE: Do not fully tighten the bolts. 2.

  • Page 140: Camshafts

    Ofrecido por www.electromanuales.com 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”...
  • Page 141 Ofrecido por www.electromanuales.com 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”. Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap “I” Intake camshaft cap “R”...
  • Page 142 Ofrecido por www.electromanuales.com CAMSHAFTS Order Job/Part Q’ty Remarks Intake camshaft Exhaust camshaft Intake camshaft sprocket Exhaust camshaft sprocket Timing chain guide (intake side) For installation, reverse the removal procedure. 4 - 10...
  • Page 143 Ofrecido por www.electromanuales.com 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 144 Ofrecido por www.electromanuales.com 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 33.31 mm (1.3114 in) b 24.90 mm (0.9803 in) Exhaust camshaft...
  • Page 145 Ofrecido por www.electromanuales.com CAMSHAFTS a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). ® b. Position a strip of Plastigauge onto the camshaft journal as shown. c. Install the dowel pins and camshaft caps. NOTE: •...
  • Page 146 Ofrecido por www.electromanuales.com 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: •...
  • Page 147 Ofrecido por www.electromanuales.com CAMSHAFTS EB401701 INSTALLING THE CAMSHAFTS 1. Install: • timing chain guide (intake side) 2. Install: • camshaft sprockets 1 24 Nm (2.4 m · kg, 17 ft · lb) (with the flywheel puller 2) Flywheel puller 90890-01080 3.
  • Page 148 Ofrecido por www.electromanuales.com 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 149 Ofrecido por www.electromanuales.com 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 150: Cylinder Head

    Ofrecido por www.electromanuales.com 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 151 Ofrecido por www.electromanuales.com 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 pattern.
  • Page 152 Ofrecido por www.electromanuales.com CYLINDER HEAD 3. Measure: • cylinder head warpage Out of specification → Resurface the cylinder head. Maximum cylinder head warpage 0.06 mm (0.0024 in) a. Place a straightedge 1 and a thick- ness gauge 2 across the cylinder head.

  • Page 153: Valves And Valve Springs

    Ofrecido por www.electromanuales.com 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 outer valve spring...
  • Page 154 Ofrecido por www.electromanuales.com 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 outer valve spring Exhaust inner valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal...
  • Page 155 Ofrecido por www.electromanuales.com 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 156 Ofrecido por www.electromanuales.com VALVES AND VALVE SPRINGS 3. Remove: • valve cotters 1 NOTE: Remove the valve cotters by compress- ing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor 90890-04019 Attachment (for the intake valve) 90890-04114 (for the exhaust valve) 90890-04108...
  • Page 157 Ofrecido por www.electromanuales.com 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 158 Ofrecido por www.electromanuales.com VALVES AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness Intake 0.9 ~ 1.2 mm (0.028 ~ 0.047 in) Exhaust 1.0 ~ 1.3 mm (0.039 ~ 0.051 in) 6.
  • Page 159 Ofrecido por www.electromanuales.com 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.
  • Page 160 Ofrecido por www.electromanuales.com 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.
  • Page 161 Ofrecido por www.electromanuales.com VALVES AND VALVE SPRINGS 2. Measure: • compressed spring force a Out of specification → Replace the valve spring. b Installed length Compressed spring force (installed) Inner spring Intake valve spring 10.30 ~ 11.93 kg at 27.96 mm (22.7 ~ 26.3 lb at 1.10 in) Exhaust valve spring 10.81 ~ 12.44 kg at...
  • Page 162 Ofrecido por www.electromanuales.com VALVES AND VALVE SPRINGS EB403702 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil...
  • Page 163 Ofrecido por www.electromanuales.com VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor 90890-04019 Attachment (for the intake valve spring) 9080-04114 (for the exhaust valve spring) 90890-04108...

  • Page 164: Generator

    Ofrecido por www.electromanuales.com GENERATOR EB410000 GENERATOR Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL”...
  • Page 165 Flywheel puller 90890-01080 EB410700 INSTALLING THE GENERATOR 1. Apply: • sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 2. Install: • generator rotor • washer • generator rotor bolt WARNING WARNING Always use a new generator rotor bolt.
  • Page 166 Ofrecido por www.electromanuales.com GENERATOR 3. Tighten: • generator rotor bolt 1 65 Nm (6.5 m · kg, 47 ft · lb) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the generator rotor bolt. Rotor holding tool 90890-01235 4.

  • Page 167: Pickup Coil

    Ofrecido por www.electromanuales.com PICKUP COIL PICKUP COIL 45 Nm (4.5 m kg, 32 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 15 Nm (1.5 m kg, 11 ft •...
  • Page 168 Ofrecido por www.electromanuales.com PICKUP COIL 45 Nm (4.5 m kg, 32 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 15 Nm (1.5 m kg, 11 ft • •...
  • Page 169 Ofrecido por www.electromanuales.com PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remove: • pickup coil lead holder 1 • pickup coil rotor cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 170 Rotor holding tool 90890-01235 3. Apply: • sealant (onto the pickup coil lead grommet) Yamaha bond No. 1215 90890-85505 4. Install: • pickup coil rotor cover • pickup coil lead holder • clutch cable holder NOTE: •...

  • Page 171: Clutch

    Ofrecido por www.electromanuales.com CLUTCH EB405000 CLUTCH Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL”...
  • Page 172 Ofrecido por www.electromanuales.com 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 Push rod #1 Ball Push rod #2 Friction plate #1 3.00 mm (0.12 in) Clutch plate Friction plate #2...
  • Page 173 Ofrecido por www.electromanuales.com CLUTCH Order Job/Part Q’ty Remarks Back torque limiter outer boss Back torque limiter bearing Back torque limiter inner boss Thrust plate Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear For installation, reverse the removal procedure.
  • Page 174 Ofrecido por www.electromanuales.com 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.
  • Page 175 Ofrecido por www.electromanuales.com 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 176 Ofrecido por www.electromanuales.com 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: •...
  • Page 177 Ofrecido por www.electromanuales.com CLUTCH 2. Check: • back torque limiter clutch a. Install the back torque limiter bearing and back torque limiter outer boss onto the back torque limiter inner boss and hold the back torque limiter inner boss. b. When turning the back torque limiter outer boss clockwise Å, the back torque limiter inner boss and back torque limiter outer boss should...
  • Page 178 Ofrecido por www.electromanuales.com CLUTCH EB405703 INSTALLING THE CLUTCH 1. Install: • clutch housing NOTE: • Make sure that the slots a in the clutch housing align with the tabs b on the oil/water pump assembly drive sprocket. • Make sure that the primary driven gear teeth and primary drive gear teeth mesh correctly.
  • Page 179 Ofrecido por www.electromanuales.com CLUTCH 4. Bend the lock washer tab along a flat side of the nut. 5. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 6. Install: • friction plates 1 - 3.00 mm (0.12 in) •...

  • Page 180: Shift Shaft

    Ofrecido por www.electromanuales.com 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”. Shift shaft cover Shift shaft cover gasket Dowel pin Shift shaft Shift shaft spring...
  • Page 181 Ofrecido por www.electromanuales.com 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 →...

  • Page 182: Oil Pan And Oil Pump

    Ofrecido por www.electromanuales.com 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”...
  • Page 183 Ofrecido por www.electromanuales.com OIL PAN AND OIL PUMP EB411001 Order Job/Part Q’ty Remarks Drain pipe Oil strainer Oil pipe Oil delivery pipe Dowel pin Oil/water pump assembly Relief valve assembly For installation, reverse the removal procedure. 4 - 51...
  • Page 184 Ofrecido por www.electromanuales.com 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 185 Ofrecido por www.electromanuales.com 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.
  • Page 186 Ofrecido por www.electromanuales.com 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 •...
  • Page 187 Ofrecido por www.electromanuales.com 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 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: Install the oil/water pump assembly drive chain onto the oil/water pump...

  • Page 188: Crankcase

    Ofrecido por www.electromanuales.com 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”.
  • Page 189 Ofrecido por www.electromanuales.com CRANKCASE Order Job/Part Q’ty Remarks Oil/water pump assembly drive sprocket Washer Lower crankcase Dowel pin For installation, reverse the removal procedure. 4 - 57...
  • Page 190 Ofrecido por www.electromanuales.com 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...
  • Page 191 Ofrecido por www.electromanuales.com 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 192 Ofrecido por www.electromanuales.com 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. •...
  • Page 193 Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm (0.08 ~ 0.12 in) of the...
  • Page 194 Ofrecido por www.electromanuales.com 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: •...

  • Page 195: Connecting Rods And Pistons

    Ofrecido por www.electromanuales.com 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...
  • Page 196 Ofrecido por www.electromanuales.com 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 • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
  • Page 197 Ofrecido por www.electromanuales.com 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 198 Ofrecido por www.electromanuales.com 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 0.028 ~ 0.054 mm (0.0011 ~ 0.0021 in) <Limit>: 0.1 mm (0.004 in) f.

  • Page 199: Connecting Rods And Pistons

    Ofrecido por www.electromanuales.com 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 200 Ofrecido por www.electromanuales.com CONNECTING RODS AND PISTONS 4. Calculate: • piston pin-to-piston pin bore clearance 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 0.004 ~ 0.020 mm...
  • Page 201 Ofrecido por www.electromanuales.com 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 202 Ofrecido por www.electromanuales.com 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 203 Ofrecido por www.electromanuales.com 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 204 Ofrecido por www.electromanuales.com CONNECTING RODS AND PISTONS NOTE: Apply only thin even layer MOLYKOTE‚ “G-n” paste, otherwise the correct tightening torque cannot be achieved. 6. Lubricate: • crankshaft pins • big end bearings • connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil...
  • Page 205 Ofrecido por www.electromanuales.com CONNECTING RODS AND PISTONS 9. Tighten: • connecting rod nuts • Tighten the connecting rod nuts in the following way. NOTE: • How much the connecting rod nut is tightened depends on how much the connecting rod bolt stretches. •...

  • Page 206: Crankshaft

    Ofrecido por www.electromanuales.com 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 207 Ofrecido por www.electromanuales.com 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 208 Ofrecido por www.electromanuales.com 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.
  • Page 209 Ofrecido por www.electromanuales.com 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.
  • Page 210 Ofrecido por www.electromanuales.com 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. •...

  • Page 211: Transmission

    Ofrecido por www.electromanuales.com 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...
  • Page 212 Ofrecido por www.electromanuales.com 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 213 Ofrecido por www.electromanuales.com 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 214 Ofrecido por www.electromanuales.com 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 215 Ofrecido por www.electromanuales.com 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 216 Ofrecido por www.electromanuales.com 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 217 Ofrecido por www.electromanuales.com 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.
  • Page 218 Ofrecido por www.electromanuales.com 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 219 Ofrecido por www.electromanuales.com 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: •...

  • Page 220: Cooling System

    Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT EB500000 COOLING SYSTEM RADIATOR AND THERMOSTAT Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3. Coolant Drain. Refer to “CHANGING THE COOLANT”...
  • Page 221 Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT Order Job/Part Q’ty Remarks Radiator outlet hose Lower radiator guard Lower radiator Lower radiator breather hose Radiator joint hose Plastic band Oil cooler outlet hose Disconnect. Radiator inlet hose Horn Upper radiator Radiator fan Upper radiator bracket Lower radiator bracket For installation, reverse the removal...
  • Page 222 Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT EB502000 RADIATOR AND THERMOSTAT 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 223 Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT Order Job/Part Q’ty Remarks Thermostat assembly breather hose Coolant temperature sensor Copper washer Plastic band Thermostat assembly inlet pipe For installation, reverse the removal procedure. 5 - 4...
  • Page 224 Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT EB502010 10 Nm (1.0 m kg, 7.2 ft • • 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.
  • Page 225 Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT 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.
  • Page 226 Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT 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.
  • Page 227 Ofrecido por www.electromanuales.com COOL RADIATOR AND THERMOSTAT INSTALLING THE THERMOSTAT ASSEMBLY AND 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 →...

  • Page 228: Oil Cooler

    Ofrecido por www.electromanuales.com 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 AND THERMO- STAT”. Exhaust pipe assembly Refer to “ENGINE” in chapter 4. Engine oil Drain.
  • Page 229 Ofrecido por www.electromanuales.com 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 •...
  • Page 230 Ofrecido por www.electromanuales.com COOL OIL COOLER 3. 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 231: Water Pump

    Ofrecido por www.electromanuales.com 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). •...
  • Page 232 Ofrecido por www.electromanuales.com COOL WATER PUMP Order Job/Part Q’ty Remarks Water pump seal Oil seal Bearing For installation, reverse the removal procedure. 5 - 13...
  • Page 233 Ofrecido por www.electromanuales.com 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 234 NOTE: • Install the water pump seal with the special tools. • Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3. Mechanical seal installer 4 90890-04078 Middle driven shaft bearing...
  • Page 235 Ofrecido por www.electromanuales.com 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...
  • Page 236 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION ELECTRONIC FUEL INJECTION Order Job/Part Q’ty Remarks Removing the injector 2 assembly Remove the parts in the order listed. and air filter case Air filter case cover Refer to “FUEL TANK AND AIR FIL- TER”...
  • Page 237 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION Order Job/Part Q’ty Remarks Intake air temperature sensor Copper washer Air filter case breather hose Disconnect. Negative pressure hose Disconnect. Air funnel rubber seat Air filter case For installation, reverse the removal procedure. 6 - 2...

  • Page 238: Electronic Fuel Injection Efi

    Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION 8 Nm (0.8 m kg, 5.8 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 30 Nm (3.0 m kg, 22 ft • • 8 Nm (0.8 m kg, 5.8 ft •...

  • Page 239: Electronic Fuel Injection

    Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION 8 Nm (0.8 m kg, 5.8 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 30 Nm (3.0 m kg, 22 ft • • 8 Nm (0.8 m kg, 5.8 ft •...
  • Page 240 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION Order Job/Part Q’ty Remarks Removing the throttle body assem- Remove the parts in the order listed. Fuel hose Throttle position sensor coupler Cylinder #4 – injector 1 coupler Cylinder #3 – injector 1 coupler Cylinder #2 –...
  • Page 241 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION Order Job/Part Q’ty Remarks Gasket Spacer For installation, reverse the removal procedure. 6 - 6...
  • Page 242 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION Order Job/Part Q’ty Remarks Removing the injector 1 and throttle Remove the parts in the order listed. body Negative pressure hose Pressure regulator Union bolt Washer Injector fuel pipe 1 Injector fuel pipe 2 Washer Fuel distributor Injector 1...
  • Page 243 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION Order Job/Part Q’ty Remarks Throttle position sensor Throttle cable holder Starter link lever screw Starter link Starter link lever Front connecting plate Throttle body Starter plunger Air screw For installation, reverse the removal procedure. 6 - 8...
  • Page 244 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION CAUTION: ACHTUNG: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Check: • injector 1 • injector 2 Damage → Replace. CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage →...
  • Page 245 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION CHECKING THE PRESSURE REGULATOR 1. Check: • pressure regulator Damage → Replace. EAS00502 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1.
  • Page 246 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION d. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Positive tester probe → yellow terminal 3 Negative tester probe → black/blue terminal 2 e. While slowly opening the throttle, check that the throttle position sensor resistance is within the specified range.
  • Page 247 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION d. Measure the maximum throttle posi- tion sensor resistance. Out of specification → Replace the throttle position sensor. Maximum throttle position sensor resistance 4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F) (blue — black/blue) e.
  • Page 248 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION 3. Adjust: • throttle position sensor angle a. Disconnect the throttle position sen- sor coupler from the throttle position sensor. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Positive tester probe → blue terminal 1 Negative tester probe →...
  • Page 249 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation a. Remove the fuel tank and air filter case cover. Refer to “FUEL TANK AND AIR FIL- TER” in chapter 3. b.
  • Page 250 Ofrecido por www.electromanuales.com ELECTRONIC FUEL INJECTION i. Use the mity vac to adjust the fuel pressure in relation to the vacuum pressure as described below. NOTE: The vacuum pressure should not exceed 100 kPa (1 mmHg, 0.04 in. Hg). Increase the vacuum pressure. → Fuel pressure is decreased.

  • Page 251: Front Wheel And Brake Discs

    Ofrecido por www.electromanuales.com 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 252 Ofrecido por www.electromanuales.com 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.
  • Page 253 Ofrecido por www.electromanuales.com 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 254 Ofrecido por www.electromanuales.com CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 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) 4.
  • Page 255 Ofrecido por www.electromanuales.com CHAS FRONT WHEEL AND BRAKE DISCS EB700416 CHECKING THE BRAKE DISCS The following procedure applies to both of the brake discs. 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.
  • Page 256 Ofrecido por www.electromanuales.com CHAS FRONT WHEEL AND BRAKE DISCS Brake disc bolt 18 Nm (1.8 m • kg, 13 ft • lb) ® LOCTITE d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.
  • Page 257 Ofrecido por www.electromanuales.com CHAS FRONT WHEEL AND BRAKE DISCS 4. Install: • brake calipers 40 Nm (4.0 m · kg, 29 ft · lb) WARNING WARNING Make sure that the brake hose is routed properly. EB700901 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: •...
  • Page 258 Ofrecido por www.electromanuales.com CHAS FRONT WHEEL AND BRAKE DISCS 3. Adjust: • front wheel static balance a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b. Turn the front wheel 90˚ so that the heavy spot is positioned as shown.

  • Page 259: Rear Wheel, Brake Disc, And Rear Wheel Sprocket

    Ofrecido por www.electromanuales.com 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 260 Ofrecido por www.electromanuales.com 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 261 Ofrecido por www.electromanuales.com 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 - 11...
  • Page 262 Ofrecido por www.electromanuales.com 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 263 Ofrecido por www.electromanuales.com 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.
  • Page 264 Ofrecido por www.electromanuales.com 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...

  • Page 265: Front And Rear Brakes

    Ofrecido por www.electromanuales.com 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...
  • Page 266 Ofrecido por www.electromanuales.com 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 267 Ofrecido por www.electromanuales.com 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 268 Ofrecido por www.electromanuales.com 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 →...
  • Page 269 Ofrecido por www.electromanuales.com 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 270 Ofrecido por www.electromanuales.com 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 271 Ofrecido por www.electromanuales.com CHAS FRONT AND REAR BRAKES 5. Install: • brake pad pins • brake pad clips • brake caliper 40 Nm (4.0 m · kg, 29 ft · lb) 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
  • Page 272 Ofrecido por www.electromanuales.com 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...
  • Page 273 Ofrecido por www.electromanuales.com 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...
  • Page 274 Ofrecido por www.electromanuales.com 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.
  • Page 275 Ofrecido por www.electromanuales.com 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 276 Ofrecido por www.electromanuales.com 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.
  • Page 277 Ofrecido por www.electromanuales.com 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...
  • Page 278 Ofrecido por www.electromanuales.com 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...
  • Page 279 Ofrecido por www.electromanuales.com 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 280 Ofrecido por www.electromanuales.com 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 281 Ofrecido por www.electromanuales.com 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 282 Ofrecido por www.electromanuales.com 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 283 Ofrecido por www.electromanuales.com 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...
  • Page 284 Ofrecido por www.electromanuales.com 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 - 34...
  • Page 285 Ofrecido por www.electromanuales.com 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.
  • Page 286 Ofrecido por www.electromanuales.com 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 Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Plastic clamp...
  • Page 287 Ofrecido por www.electromanuales.com 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 - 37...
  • Page 288 Ofrecido por www.electromanuales.com 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 •...
  • Page 289 Ofrecido por www.electromanuales.com CHAS FRONT AND REAR BRAKES 2. Check: Å • brake master cylinder kit Damage/scratches/wear → Replace. Å Front ı Rear ı 3. Check: Å • brake fluid reservoir 1 Cracks/damage → Replace. • brake fluid reservoir diaphragm 2 Cracks/damage →...
  • Page 290 Ofrecido por www.electromanuales.com 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 291 Ofrecido por www.electromanuales.com 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 292 Ofrecido por www.electromanuales.com 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 293: Hydraulic Clutch

    Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH .EAS00305 HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Removing the clutch master cylin- Remove the parts in the order listed. Clutch fluid Drain. Clutch fluid reservoir cap Clutch fluid reservoir diaphragm holder Clutch fluid reservoir diaphragm Clutch fluid reservoir Clutch fluid reservoir hose Dust seat...
  • Page 294 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Copper washer Clutch hose Clutch master cylinder holder Clutch master cylinder Clutch switch For installation, reverse the removal procedure. 7 - 44...
  • Page 295 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch master Remove the parts in the order listed. cylinder Push rod Clutch master cylinder kit Clutch master cylinder For assembly, reverse the disassembly procedure. 7 - 45...
  • Page 296 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH EAS00307 CAUTION: ACHTUNG: Clutch components rarely require disas- sembly. Therefore, always follow these preven- tive measures: • Never disassemble clutch components unless absolutely necessary. • If any connection on the hydraulic clutch system is disconnected, the entire clutch system must be disas- sembled, drained, cleaned, properly filled, and bled after reassembly.
  • Page 297 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH 3. Check: • clutch fluid reservoir 1 Cracks/damage → Replace. • clutch fluid reservoir diaphragm 2 Cracks/damage → Replace. 4. Check: • clutch hose Cracks/damage/wear → Replace. ASSEMBLING AND INSTALLING THE CLUTCH MASTER CYLINDER WARNING WARNING •...
  • Page 298 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH 2. Install: • copper washers • clutch hose 1 • union bolt 2 26 Nm (2.6 m · kg, 19 ft · lb) WARNING WARNING Proper clutch hose routing is essential to insure safe motorcycle operation. Refer to “CABLE ROUTING”.
  • Page 299 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH 4. Bleed: • clutch system Refer to “BLEEDING THE HYDRAULIC CLUTCH SYSTEM” in chapter 3. 5. Check: • clutch fluid level Below the minimum level mark a → Add the recommended clutch fluid to the proper level.
  • Page 300 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH EAS00311 Order Job/Part Q’ty Remarks Removing the clutch release cylin- Remove the parts in the order listed. Bottom cowling Refer to “COWLINGS” in chapter 3. Clutch fluid Drain. Starter knob Union bolt Copper washer Clutch hose Clutch release cylinder assembly Dowel pin...
  • Page 301 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH EAS00312 Order Job/Part Q’ty Remarks Disassembling the clutch release Remove the parts in the order listed. cylinder Dust seal Clutch release cylinder piston Spring Oil seal Bleed screw For assembly, reverse the disassembly procedure. 7 - 51...
  • Page 302 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH EAS00313 DISASSEMBLING THE CLUTCH RELEASE CYLINDER 1. Remove: • dust seal 1 • clutch release cylinder piston 2 • spring 3 • oil seal 4 a. Blow compressed air into the clutch hose joint opening a to force out the piston from the clutch release cylin- der.
  • Page 303 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH EAS00315 ASSEMBLING AND INSTALLING THE CLUTCH RELEASE CYLINDER WARNING WARNING • Before installation, all internal clutch components must be cleaned and lubricated with clean or new clutch fluid. • Never use solvents on internal clutch components as they will cause the oil seal and dust seal to swell and distort.
  • Page 304 Ofrecido por www.electromanuales.com CHAS HYDRAULIC CLUTCH • When refilling, be careful that water does not enter the reservoir. Water will significantly lower the boiling point of the clutch fluid and could cause vapor lock. CAUTION: ACHTUNG: Clutch fluid may damage painted sur- faces or plastic parts.

  • Page 305: Front Fork

    Ofrecido por www.electromanuales.com CHAS FRONT FORK EB703001 FRONT FORK 25 Nm (2.5 m kg, 18 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 26 Nm (2.6 m kg, 19 ft • • 11 Nm (1.1 m kg, 8.0 ft •...
  • Page 306 Ofrecido por www.electromanuales.com 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 Straight key Washer Damper adjusting rod Spring seat Spacer Fork spring...
  • Page 307 Ofrecido por www.electromanuales.com CHAS FRONT FORK Order Job/Part Q’ty Remarks Damper rod assembly Inner tube For assembly, reverse the disassembly procedure. 7 - 57...
  • Page 308 Ofrecido por www.electromanuales.com 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 309 Ofrecido por www.electromanuales.com CHAS FRONT FORK • nut 2 • spring seat 3 • spacer a. Press down on the spacer with the fork spring compressor 4. b. Install the rod holder 5 between the nut 2 and the spring seat 3. Fork spring compressor 90890-01441 Rod holder...
  • Page 310 Ofrecido por www.electromanuales.com CHAS FRONT FORK 5. Remove: • damper rod assembly (with the damper rod holder 1) Damper rod holder 90890-01473 EB703401 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: •...
  • Page 311 Be careful not to damage the inner tube. NOTE: Be sure that the clip 3 is still correctly installed. 2. Lubricate: • inner tube’s outer surface Recommended lubricant Yamaha fork and shock oil M1 or equivalent 7 - 61...
  • Page 312 Ofrecido por www.electromanuales.com CHAS FRONT FORK 3. Tighten: • damper rod assembly 48 Nm (4.8 m · kg, 35 ft · lb) (with the damper rod holder 1) Damper rod holder 90890-01473 4. Install: • dust seal 1 • oil seal clip 2 •...
  • Page 313 Quantity (each front fork leg) 460 cm (16.2 Imp oz, 15.6 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 314 Ofrecido por www.electromanuales.com 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 315 Ofrecido por www.electromanuales.com CHAS FRONT FORK c. Install the fork spring, spacer, spring seat and nut. NOTE: Finger tighten the nut onto the winding at the damper rod end. d. Install the rod puller and adapter onto the damper rod. Rod puller 90890-01437 Adapter...
  • Page 316 Ofrecido por www.electromanuales.com CHAS FRONT FORK 17.Install: • outer tube (onto the cap bolt) 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 317: Handlebars

    Ofrecido por www.electromanuales.com CHAS HANDLEBARS EB704001 HANDLEBARS 13 Nm (1.3 m kg, 9.4 ft • • 115 Nm (11.5 m kg, 85 ft 4 Nm (0.4 m kg, 2.9 ft • • • • 26 Nm (2.6 m kg, 19 ft •...
  • Page 318 Ofrecido por www.electromanuales.com CHAS HANDLEBARS 13 Nm (1.3 m kg, 9.4 ft • • 115 Nm (11.5 m kg, 85 ft 4 Nm (0.4 m kg, 2.9 ft • • • • 26 Nm (2.6 m kg, 19 ft • •...
  • Page 319 Ofrecido por www.electromanuales.com 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 320 Ofrecido por www.electromanuales.com CHAS HANDLEBARS 2. Install: • right handlebar switch 1 NOTE: Align the projection a on the right han- dlebar switch with the hole b in the right handlebar. 3. Install: • throttle grip 1 • throttle cable housing 2 •...
  • Page 321 Ofrecido por www.electromanuales.com CHAS HANDLEBARS 6. Install: • handlebar grip a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. b. Slide the handlebar grip over the end of the left handlebar. c. Wipe off any excess rubber adhesive with a clean rag.

  • Page 322: Steering Head

    Ofrecido por www.electromanuales.com CHAS STEERING HEAD EB705001 STEERING HEAD 115 Nm (11.5 m kg, 85 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 19 Nm (1.9 m kg, 13 ft • • 1st. 18 Nm (1.8 kg m, 13 ft •...
  • Page 323 Ofrecido por www.electromanuales.com CHAS STEERING HEAD 115 Nm (11.5 m kg, 85 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 19 Nm (1.9 m kg, 13 ft • • 1st. 18 Nm (1.8 kg m, 13 ft •...
  • Page 324 Ofrecido por www.electromanuales.com 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 90890-01403...
  • Page 325 Ofrecido por www.electromanuales.com CHAS STEERING HEAD EB705700 INSTALLING THE STEERING HEAD 1. Lubricate: • upper bearing • lower bearing • bearing races • O-ring • dust seat lips • bearing cover lips • steering stem shreads Recommended lubricant Lithium soap base grease 2.

  • Page 326: Rear Shock Absorber Assembly

    Ofrecido por www.electromanuales.com 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 Bolt Self-locking nut/bolt Self-locking nut/bolt Self-locking nut/bolt Rear shock absorber assembly Self-locking nut/bolt Connecting arm Spacer/oil seal/bearing...
  • Page 327 Ofrecido por www.electromanuales.com 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 328 Ofrecido por www.electromanuales.com 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 329: Rear Shock Absorber Assembly

    Ofrecido por www.electromanuales.com 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...

  • Page 330: Swingarm And Drive Chain

    Ofrecido por www.electromanuales.com 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 331 Ofrecido por www.electromanuales.com CHAS SWINGARM AND DRIVE CHAIN Order Job/Part Q’ty Remarks Pivot shaft Left pivot shaft boss Swingarm Spacer Drive chain Drive chain guard 2 Drive chain guide Dust cover Bearing Spacer Bearing For installation, reverse the removal procedure. 7 - 81...
  • Page 332 Ofrecido por www.electromanuales.com 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.
  • Page 333 Ofrecido por www.electromanuales.com 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 334 Ofrecido por www.electromanuales.com 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 →...
  • Page 335 Ofrecido por www.electromanuales.com 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 336 Ofrecido por www.electromanuales.com CHAS SWINGARM AND DRIVE CHAIN EB707700 INSTALLING THE SWINGARM 1. Lubricate: • bearings • spacers • dust covers • pivot shaft Recommended lubricant Molybdenum disulfide grease 2. Install: • spacers • swingarm • pivot shaft bosses • pivot shaft •...

  • Page 337: Electrical Components

    Ofrecido por www.electromanuales.com – ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS B ECU M Speed sensor 1 Wire harness C CDI unit N Sidestand switch 2 Main switch D Fuse box O Stator coil assembly 3 Front brake light switch E Fall detection switch P Oil level switch 4 Ignition coils...

  • Page 338: Switches

    Ofrecido por www.electromanuales.com – 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: Never insert the tester probes into the cou- pler terminal slots 1.

  • Page 339: Checking The Switches

    Ofrecido por www.electromanuales.com – 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 →...

  • Page 340: Checking The Bulbs And Bulb Sockets

    Ofrecido por www.electromanuales.com – 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 341 Ofrecido por www.electromanuales.com – 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: • Be sure to hold the socket firmly when removing the bulb.
  • Page 342 Ofrecido por www.electromanuales.com – 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 90890-03112 NOTE:...

  • Page 343: Ignition System

    Ofrecido por www.electromanuales.com – ELEC IGNITION SYSTEM EB802001 IGNITION SYSTEM CIRCUIT DIAGRAM 8 - 7...

  • Page 344: Ignition System

    Ofrecido por www.electromanuales.com – ELEC IGNITION SYSTEM TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). No good Check the main and ECU fuses for Replace. continuity. C0NTINUITY No good Check the condition of the bat- Recharge or replace. tery.
  • Page 345 Ofrecido por www.electromanuales.com – ELEC IGNITION SYSTEM Replace the ECU. NOTE: • Before troubleshooting, remove the following part(-s): 1) fuel tank 2) air filter case 3) bottom cowling 4) front cowling 5) rear cowling • Troubleshoot with the following special tool(-s). Ignition checker 90890-06754 Pocket tester...
  • Page 346 Ofrecido por www.electromanuales.com – ELEC IGNITION SYSTEM MEASURING THE IGNITION COIL RESISTANCE The following procedure applies to all of the ignition coils. • Remove the ignition coil from the cylinder head. • Connect the pocket tester (Ω × 1) to the ignition coil as shown.
  • Page 347 Ofrecido por www.electromanuales.com – ELEC IGNITION SYSTEM CHECKING THE DIODE • Remove the diode from the coupler. • Connect the pocket tester (Ω × 1) to the diode as shown. • Check the diode for continuity. Tester positive probe → blue/white 1 Continu- Tester negative probe →...

  • Page 348: Electric Starting System

    Ofrecido por www.electromanuales.com – ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8 - 12...

  • Page 349: Electric Starting System

    Ofrecido por www.electromanuales.com – ELEC ELECTRIC STARTING SYSTEM TROUBLESHOOTING The starter motor fails to turn. No good Check the main and ECU fuses for Replace. continuity. C0NTINUITY No good Check the condition of the bat- Recharge or replace. tery. C0NTINUITY No good Check the starter motor.
  • Page 350 Ofrecido por www.electromanuales.com – ELEC ELECTRIC STARTING SYSTEM NOTE: • Before troubleshooting, remove the following part(-s): 1) fuel tank4) bottom cowling 2) air filter case5) front cowling 3) throttle body assembly6) rear cowling • Troubleshoot with the following special tool(-s). Pocket tester 90890-03112 CHECKING THE RELAY UNIT...
  • Page 351 Ofrecido por www.electromanuales.com – ELEC ELECTRIC STARTING SYSTEM CHECKING THE STARTER RELAY • Disconnect the starter relay from the cou- pler. • Connect the pocket tester (Ω × 1) and bat- tery (12 V) to the starter relay coupler as shown.

  • Page 352: Charging System

    Ofrecido por www.electromanuales.com – ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 8 - 16...

  • Page 353: Charging System

    Ofrecido por www.electromanuales.com – ELEC CHARGING SYSTEM TROUBLESHOOTING The battery is not being charged. No good Check the main fuse for continu- Replace. ity. C0NTINUITY No good Check the condition of the bat- Recharge or replace. tery. C0NTINUITY Measure the charging voltage. The charging circuit is OK.
  • Page 354 Ofrecido por www.electromanuales.com – ELEC CHARGING SYSTEM MEASURING THE CHARGING VOLTAGE • Connect the engine tachometer to the ignition coil of cylinder #1. Refer to “SYNCHRONIZING THE THROT- TLE BODIES” in chapter 3. • Connect the pocket tester (DC 20V) to the battery as shown.

  • Page 355: Lighting System

    Ofrecido por www.electromanuales.com – ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 8 - 19...

  • Page 356: Lighting System

    Ofrecido por www.electromanuales.com – ELEC LIGHTING SYSTEM TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. Check the main and headlight No good Replace. fuses for continuity. C0NTINUITY No good Check the condition of the bat- Recharge or replace.

  • Page 357: Signaling System

    Ofrecido por www.electromanuales.com – ELEC SIGNALING SYSTEM EB806000 SIGNALING SYSTEM CIRCUIT DIAGRAM 8 - 21...
  • Page 358 Ofrecido por www.electromanuales.com – ELEC SIGNALING SYSTEM TROUBLE SHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. Check the main and signal system fuses continuity. No good Replace.
  • Page 359 Ofrecido por www.electromanuales.com – ELEC SIGNALING SYSTEM NOTE: • Before troubleshooting, remove the following part(-s): 1) fuel tank 2) bottom cowling 3) front cowling 4) rear cowling • Troubleshoot with the following special tool(-s). Pocket tester 90890-03112 CHECKING THE RELAY UNIT •...

  • Page 360: Cooling System

    Ofrecido por www.electromanuales.com – ELEC COOLING SYSTEM EB807000 COOLING SYSTEM CIRCUIT DIAGRAM 8 - 24...
  • Page 361 Ofrecido por www.electromanuales.com – ELEC COOLING SYSTEM TROUBLESHOOTING • The radiator fan motor fails to turn. • The coolant temperature meter needle fails to move when the engine is warm. No good Check the main and radiator fan Replace. motor fuses for continuity. C0NTINUITY No good Check the condition of the bat-...
  • Page 362 Ofrecido por www.electromanuales.com – ELEC COOLING SYSTEM CHECKING THE THERMO SWITCH • Remove the thermo switch from the radia- tor. • Connect the pocket tester (Ω × 1) to the thermo switch 1 as shown. • Immerse the thermo switch in a container filled with coolant 2.
  • Page 363 Ofrecido por www.electromanuales.com – ELEC 8 - 27...

  • Page 364: Electronic Fuel Injection System

    Ofrecido por www.electromanuales.com – ELEC ELECTRONIC FUEL INJECTION SYSTEM ELECTRONIC FUEL INJECTION SYSTEM CIRCUIT DIAGRAM 8 - 28...
  • Page 365 Ofrecido por www.electromanuales.com – ELEC ELECTRONIC FUEL INJECTION SYSTEM 1 Main switch 5 Battery 6 Main fuse C Camshaft sensor D Throttle position sensor E Intake air pressure sensor F Atmospheric pressure sensor G Intake air temperature sensor H Coolant temperature sensor I Pickup coil J ECU K Cylinder #1-injector 1...

  • Page 366: Electrical Control System

    Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM ELECTRICAL CONTROL SYSTEM The YZF-R7 features an electrical control system with the following modes: • user mode • diagnosis mode • CO emission adjustment mode NOTE: The vehicle is normally in user mode. Special tools are needed to switch to a diagnosis mode or to the CO emission adjustment mode.
  • Page 367 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM Tachometer display sequence (engine not running) 1 10,000 r/min for 2.0 seconds 2 First condition code (13 = intake air pressure sensor) 3 Second condition code (42 = speed sensor) 4 1st digit of condition code for 1.0 second 5 10,000 r/min for 0.5 second 6 2nd digit of condition code for 1.0 second Revolution...
  • Page 368 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM Condition code list Condition Circuit Defect(s) System response code Camshaft sensor • No incoming sig- The ECU pairs the ignition of cyl- inders #1 and #4 and cylinders #2 and #3. The motorcycle can be ridden.
  • Page 369 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM DIAGNOSIS MODE There are two operation methods for this mode: one is performed using the CO, diagnosis switch box, the other is performed using the test coupler adapter. With the CO, diagnosis switch box method, the switches on the CO, diagnosis switch box are used.
  • Page 370 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM Operation after entering the diagnosis mode • Select a diagnosis code by holding down the MODE switch while pressing either the UP or DOWN switch. Refer to the diag- nosis code list. First, press the UP switch once to select diagnosis code 01 or press the DOWN switch once to select diagnosis code 31.
  • Page 371 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM Test coupler adapter method • Remove the bottom cowling and the front cowling. Refer to “COWLINGS” in chapter 3. • Remove the protection cap 1 from the EFI test coupler 2. • Connect the test coupler adapter 3 to the EFI test coupler 2.
  • Page 372 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM Diagnosis code list Diagnosis Tachometer display Inspected item System response code (0 ~ 10,000 r/min) — — — Voltage The tachometer displays the volt- 0 r/min (0 V) – age × 500. 10,000 r/min (20 V) Example: If the voltage is 12.5 V, the tachome-...
  • Page 373 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM Diagnosis Tachometer display Inspected item System response code (0 ~ 10,000 r/min) Main relay CO, diagnosis switch box method Within one second after the MODE switch is released, the main relay is switched on once every second for the next five seconds.
  • Page 374 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM Diagnosis Tachometer display Inspected item System response code (0 ~ 10,000 r/min) Injector 1 for cyl- CO, diagnosis switch box method inder #1 Before selecting a code, discon- nect the fuel pump coupler from Injector 1 for cyl- the wire harness.
  • Page 375 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM CO EMISSION ADJUSTMENT MODE With the CO emission adjustment mode, the amount of fuel injected by the injector can be adjusted. NOTE: Prior to adjusting the CO emission, the throttle bodies must be properly synchro- nized.
  • Page 376 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM • Within 4 seconds, press the following switches on the CO, diagnosis switch box in the order indicated to enter the CO emission adjustment mode. 6 MODE switch = 1 7 UP switch = 2 8 DOWN switch = 3 1 →...
  • Page 377 Ofrecido por www.electromanuales.com – ELEC ELECTRICAL CONTROL SYSTEM • Adjust all four cylinders to specification. Standard CO concentration 3.5 % • To select a different cylinder, hold down the MODE switch while pressing either the UP switch or the DOWN switch. 8 - 41...
  • Page 378 Ofrecido por www.electromanuales.com YZF-R7 WIRING DIAGRAM 1 Main switch £ ECU fuse § Radiator fan motor fuse 2 Rectifier/regulator • Thermo switch 3 Generator ¶ Radiator fan motor 4 Backup fuse (odometer) 5 Battery 6 Main fuse 7 Starter relay...
  • Page 379 YZF-R7 WIRING DIAGRAM Sb B/Y B B/R Y/R Br/R P/W R/L R/L L Y W/Y R/G L R/G Dg B/L B/L G/R Gy/R P/L R/L R/L L W Y/B Lg Lg/R Lg/R Lg (BLACK) (BLACK) (GRAY) (BLACK) (GRAY) (BLACK) WIRE HARNESS...
  • Page 380 Ofrecido por www.electromanuales.com...
  • Page 381 Ofrecido por www.electromanuales.com YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 98 · 12 - 0.5 × 1 CR PRINTED ON RECYCLED PAPER 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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