Yamaha MTN320-A Manuals

Manuals and User Guides for Yamaha MTN320-A. We have 2 Yamaha MTN320-A manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha MTN320-A Service Manual (479 pages)

Brand: Yamaha | Category: Motorcycle | Size: 30 MB

Important Manual Information
3
How to Use this Manual
4
Table of Contents
7
General Information
9
Identification
10
Vehicle Identification Number
10
Model Label
10
Features
11
Multi-Function Meter Unit
11
Important Information
16
Preparation for Removal and Disassembly
16
Replacement Parts
16
Gaskets, Oil Seals and O-Rings
16
Lock Washers/Plates and Cotter Pins
16
Bearings and Oil Seals
17
Circlips
17
Rubber Parts
17
Basic Service Information
18
Quick Fasteners
18
Electrical System
19
Special Tools
24
Specifications
31
General Specifications
32
Engine Specifications
33
Chassis Specifications
38
Electrical Specifications
41
Tightening Torques
43
General Tightening Torque Specifications
43
Engine Tightening Torques
44
Chassis Tightening Torques
49
Lubrication Points and Lubricant Types
53
Engine
53
Chassis
55
Lubrication System Chart and Diagrams
56
Engine Oil Lubrication Chart
56
Lubrication Diagrams
58
Cable Routing
71
Periodic Checks and Adjustments
95
Periodic Maintenance
98
Introduction
98
Periodic Maintenance Chart for the Emission Control System
98
General Maintenance and Lubrication Chart
98
Checking the Fuel Line
101
Checking the Spark Plugs
101
Adjusting the Valve Clearance
102
Checking the Engine Idling Speed
105
Synchronizing the Throttle Bodies
105
Checking the Throttle Body Joint
107
Checking the Exhaust System
107
Adjusting the Exhaust Gas Volume
108
Checking the Crankcase Breather Hose
108
Checking the Air Induction System
108
Replacing the Air Filter Element and Cleaning the Check Hose
108
Adjusting the Clutch Lever Free Play
109
Checking the Brake Operation
110
Checking the Front Brake Pads
110
Checking the Rear Brake Pads
110
Checking the Front Brake Hoses
110
Checking the Rear Brake Hose
110
Bleeding the Hydraulic Brake System (Abs)
111
Checking the Brake Fluid Level
112
Checking the Wheels
112
Checking the Tires
112
Checking the Wheel Bearings
114
Checking the Swingarm Operation
114
Lubricating the Swingarm Pivot
114
Adjusting the Drive Chain Slack
114
Lubricating the Drive Chain
115
Checking and Adjusting the Steering Head
115
Lubricating the Steering Head
116
Checking the Chassis Fasteners
116
Lubricating the Brake Lever
117
Lubricating the Pedal
117
Lubricating the Clutch Lever
117
Checking the Sidestand
117
Lubricating the Sidestand
117
Checking the Sidestand Switch
117
Checking the Front Fork
117
Checking the Rear Shock Absorber Assembly
117
Adjusting the Rear Shock Absorber Assembly
117
Checking the Engine Oil Level
118
Changing the Engine Oil
119
Checking the Coolant Level
120
Checking the Cooling System
121
Changing the Coolant
121
Checking the Brake Light Switches
123
Adjusting the Rear Brake Light Switch
123
Checking and Lubricating the Cables
123
Checking the Throttle Grip Operation
123
Checking the Switches, Lights and Signals
124
Replacing the Headlight Bulbs
124
Adjusting the Headlight Beam
126
Chassis
127
General Chassis (1)
130
Removing the Center Cover
131
Installing the Battery
131
Installing the Rider Seat
131
Installing the Center Cover
131
Installing the Passenger Seat
131
General Chassis (2)
132
Removing the Side Panel Assemblies
135
Removing the Upper Tail Panel
135
Installing the Grab Bars
135
Installing the Upper Tail Panel
135
Installing the Side Panel Assemblies
135
Installing the Rear Side Cowling Assembly
136
General Chassis (3)
137
Removing the Air Scoops
138
Installing the Bottom Cowling
138
Installing the Air Scoops
138
Disassembling the Fuel Tank Cover Assembly
139
Assembling the Fuel Tank Cover Assembly
139
Installing the Fuel Tank Cover Assembly
140
General Chassis (4)
141
Installing the Headlight Assembly
143
Installing the Meter Assembly
143
General Chassis (5)
144
Installing the Air Filter Case
146
Front Wheel
147
Removing the Front Wheel
149
Disassembling the Front Wheel
149
Checking the Front Wheel
149
Rear Wheel
151
Removing the Rear Wheel
152
Disassembling the Rear Wheel
152
Checking the Rear Wheel
152
Checking the Rear Wheel Drive Hub
152
Checking and Replacing the Rear Wheel Sprocket
153
Maintenance of the Rear Wheel Sensor and Sensor Rotor
153
Assembling the Rear Wheel
154
Adjusting the Rear Wheel Static Balance
154
Installing the Rear Wheel (Rear Brake Disc)
154
Front Brake
157
Introduction
162
Checking the Front Brake Disc
162
Replacing the Front Brake Pads
163
Removing the Front Brake Caliper
164
Disassembling the Front Brake Caliper
164
Checking the Front Brake Caliper
165
Assembling the Front Brake Caliper
165
Installing the Front Brake Caliper
165
Removing the Front Brake Master Cylinder
166
Checking the Front Brake Master Cylinder
166
Assembling the Front Brake Master Cylinder
167
Installing the Front Brake Master Cylinder
167
Rear Brake
169
Introduction
175
Checking the Rear Brake Disc
175
Replacing the Rear Brake Pads
175
Removing the Rear Brake Caliper
177
Disassembling the Rear Brake Caliper
177
Checking the Rear Brake Caliper
177
Assembling the Rear Brake Caliper
178
Installing the Rear Brake Caliper
178
Removing the Rear Brake Master Cylinder
179
Checking the Rear Brake Master Cylinder
179
Assembling the Rear Brake Master Cylinder
180
Installing the Rear Brake Master Cylinder
180
Abs (Anti-Lock Brake System)
182
Removing the Hydraulic Unit Assembly
185
Checking the Hydraulic Unit Assembly
185
Installing the Hydraulic Unit Assembly
185
Hydraulic Unit Operation Tests
187
Checking the Abs Warning Light
190
Handlebar
191
Removing the Handlebar
193
Checking the Handlebar
193
Installing the Handlebar
193
Front Fork
196
Removing the Front Fork Legs
199
Disassembling the Front Fork Legs
199
Checking the Front Fork Legs
200
Assembling the Front Fork Legs
200
Installing the Front Fork Legs
203
Steering Head
205
Removing the Lower Bracket
207
Checking the Steering Head
207
Installing the Steering Head
207
Swingarm and Rear Shock Absorber Assembly
209
Removing the Rear Shock Absorber Assembly
211
Checking the Rear Shock Absorber Assembly
211
Removing the Swingarm
211
Checking the Swingarm
211
Installing the Swingarm
212
Installing the Rear Shock Absorber Assembly
212
Chain Drive
214
Removing the Drive Chain
215
Checking the Drive Chain
215
Checking the Drive Sprocket
216
Checking the Rear Wheel Sprocket
216
Checking the Rear Wheel Drive Hub
216
Installing the Drive Sprocket
216
Installing the Drive Chain
217
Engine
218
Engine Inspection
221
Measure the Compression Pressure
221
Engine Removal
223
Installing the Engine
230
Assembling the Muffler
231
Installing the Exhaust Pipe and Muffler Assembly
231
Camshafts
233
Removing the Camshafts
235
Checking the Camshafts
236
Checking the Camshaft Sprockets
237
Checking the Timing Chain Tensioner
237
Installing the Camshafts
238
Installing the Cylinder Head Cover
241
Cylinder Head
242
Removing the Cylinder Head
245
Checking the Timing Chain Guide (Exhaust Side)
245
Checking the Cylinder Head
245
Installing the Cylinder Head
245
Valves and Valve Springs
247
Removing the Valves
248
Checking the Valves and Valve Guides
248
Checking the Valve Seats
250
Checking the Valve Springs
251
Checking the Valve Lifters
252
Installing the Valves
252
Cylinder and Pistons
255
Removing the Pistons
256
Checking the Cylinders and Pistons
256
Checking the Piston Rings
257
Checking the Piston Pins
258
Installing the Pistons and Cylinder
258
Generator and Starter Clutch
261
Removing the Generator
263
Removing the Starter Clutch
263
Checking the Starter Clutch
263
Installing the Starter Clutch
264
Installing the Generator
265
Electric Starter
266
Checking the Starter Motor
268
Assembling the Starter Motor
269
Installing the Starter Motor
269
Clutch
270
Removing the Clutch
273
Checking the Friction Plates
273
Checking the Clutch Plates
274
Checking the Clutch Springs
274
Checking the Clutch Housing
274
Checking the Clutch Boss
274
Checking the Pressure Plate
275
Checking the Primary Drive Gear
275
Checking the Primary Driven Gear
275
Checking the Pull Lever Shaft and Pull Rod
275
Installing the Clutch
275
Shift Shaft
278
Checking the Shift Shaft
281
Checking the Stopper Lever
281
Installing the Shift Shaft
281
Installing the Shift Rod
281
Oil Pump
283
Checking the Oil Pump Idle Gear
285
Checking the Oil Pump
285
Checking the Relief Valve
285
Assembling the Oil Pump
285
Installing the Oil Pump
286
Oil Pan
287
Checking the Oil Strainer
289
Installing the Oil Pan
289
Crankcase
290
Disassembling the Crankcase
293
Checking the Balancer Drive Gear
294
Checking the Timing Chain and Timing Chain Guide (Intake Side)
294
Checking the Crankcase
294
Checking the Oil Nozzles
294
Assembling the Crankcase
294
Installing the Oil Pressure Switch and Gear Position Switch
297
Crankshaft and Balancer Shaft
299
Removing the Balancer Shaft Journal Bearings
302
Removing the Crankshaft Journal Bearings
302
Removing the Connecting Rods
302
Checking the Balancer Shaft
302
Checking the Crankshaft
304
Checking the Connecting Rods
305
Installing the Connecting Rods
307
Installing the Crankshaft
308
Assembling the Balancer Shaft Assembly
308
Installing the Balancer Shaft Assembly
309
Transmission
310
Checking the Shift Forks
314
Checking the Shift Drum Assembly
314
Checking the Transmission
314
Assembling the Main Axle and Drive Axle
315
Installing the Transmission
315
Cooling System
318
Radiator
319
Checking the Radiator
321
Installing the Radiator
321
Thermostat
323
Checking the Thermostat
324
Installing the Thermostat
324
Water Pump
325
Disassembling the Water Pump
327
Checking the Water Pump
327
Assembling the Water Pump
327
Installing the Clutch Cover
328
Fuel System
330
Fuel Tank
332
Removing the Fuel Tank
333
Removing the Fuel Pump
333
Checking the Fuel Pump Body
333
Installing the Fuel Pump
333
Installing the Fuel Tank
334
Throttle Bodies
335
Checking the Injectors (before Removing)
338
Removing the Injectors
338
Checking the Injectors
338
Checking the Throttle Bodies
338
Checking the Throttle Bodies and Isc (Idle Speed Control) Unit
338
Checking the Throttle Body Joint
341
Installing the Fuel Injectors
341
Checking the Injector Pressure
341
Checking the Fuel Pressure
342
Installing the Throttle Body Joint
342
Replacing the Throttle Bodies
343
Air Induction System
345
Checking the Air Induction System
348
Installing the Air Induction System
348
Electrical System
350
Ignition System
353
Circuit Diagram
353
Engine Stopping Due to Sidestand Operation
355
Troubleshooting
356
Electric Starting System
359
Circuit Diagram
359
Starting Circuit Cut-Off System Operation
361
Troubleshooting
362
Charging System
365
Circuit Diagram
365
Troubleshooting
367
Lighting System
369
Circuit Diagram
369
Troubleshooting
371
Signaling System
373
Circuit Diagram
373
Troubleshooting
375
Cooling System
381
Circuit Diagram
381
Troubleshooting
383
Fuel Injection System
385
Circuit Diagram
385
Ecu Self-Diagnostic Function
387
Troubleshooting Method
387
Yamaha Diagnostic Tool
388
Troubleshooting Details
391
Fuel Pump System
425
Abs Coupler Location Chart
431
Maintenance of the Abs Ecu
433
Abs Troubleshooting Outline
433
Basic Instructions for Troubleshooting
434
Basic Process for Troubleshooting
435
[A] Checking the Abs Warning Light
437
Electrical Components
441
Checking the Switches
445
Checking the Fuses
449
Checking and Charging the Battery
450
Checking the Relays
453
Checking the Diodes
454
Checking the Spark Plug Caps
455
Checking the Ignition Coils
456
Checking the Ignition Spark Gap
456
Checking the Lean Angle Sensor
457
Checking the Crankshaft Position Sensor
457
Checking the Starter Motor Operation
458
Checking the Stator Coil
458
Checking the Rectifier/Regulator
458
Checking the Fuel Sender
459
Checking the Radiator Fan Motor
460
Checking the Coolant Temperature Sensor
460
Checking the Air Induction System Solenoid
461
Checking the Gear Position Switch
461
Checking the Fuel Injectors
462
Troubleshooting
464
Troubleshooting
465
General Information
465
Starting Failure
465
Incorrect Engine Idling Speed
465
Poor Medium-And-High-Speed Performance
466
Faulty Gear Shifting
466
Shift Pedal Does Not Move
466
Jumps out of Gear
466
Faulty Clutch
466
Overheating
467
Overcooling
467
Poor Braking Performance
467
Faulty Front Fork Legs
467
Unstable Handling
467
Faulty Lighting or Signaling System
468
Self-Diagnostic Function and Diagnostic Code Table
469
Self-Diagnostic Function Table
469
Communication Error with the Meter or Yamaha Diagnostic Tool
469
Diagnostic Code: Sensor Operation Table
470
Diagnostic Code: Actuator Operation Table
472
Wiring Diagram
475
Color Code
475

Yamaha MTN320-A Owner's Manual (94 pages)

Brand: Yamaha | Category: Motorcycle | Size: 7 MB

Table of Contents
5
Safety Information

7
Description

12
- Left View
  12
- Right View
  13
- Controls and Instruments
  14
Instrument and Control Functions

15
- Main Switch/Steering Lock
  15
- Indicator Lights and Warning Lights
  16
- Multi-Function Meter Unit
  18
- Handlebar Switches
  24
- Clutch Lever
  25
- Shift Pedal
  26
- Brake Lever
  26
- Brake Pedal
  27
- Abs
  27
- Fuel Tank Cap
  28
- Fuel
  29
- Fuel Tank Overflow Hose
  30
- Catalytic Converter
  31
- Seats
  31
- Helmet Holders
  33
- Storage Compartment
  34
- Adjusting the Shock Absorber Assembly
  34
- Luggage Strap Holders
  35
- Sidestand
  36
- Ignition Circuit Cut-Off System
  36
For Your Safety - Pre-Operation Checks

38
Operation and Important Riding Points

40
- Engine Break-In
  40
- Starting the Engine
  41
- Shifting
  42
- Tips for Reducing Fuel Consumption
  43
- Parking
  44
Periodic Maintenance and Adjustment

45
- Tool Kit
  46
- Periodic Maintenance Charts
  47
- Periodic Maintenance Chart for the Emission Control System
  47
- General Maintenance and Lubrication Chart
  48
- Checking the Spark Plugs
  51
- Canister
  52
- Engine Oil and Oil Filter Cartridge
  52
- Why Yamalube
  55
- Coolant
  56
- Replacing the Air Filter Element and Cleaning the Check Hose
  57
- Checking the Throttle Grip Free Play
  59
- Valve Clearance
  59
- Tires
  60
- Cast Wheels
  62
- Adjusting the Clutch Lever Free Play
  62
- Checking the Brake Lever Free Play
  63
- Brake Light Switches
  64
- Checking the Front and Rear Brake Pads
  64
- Checking the Brake Fluid Level
  65
- Changing the Brake Fluid
  66
- Drive Chain Slack
  67
- Cleaning and Lubricating the Drive Chain
  68
- Checking and Lubricating the Cables
  69
- Checking and Lubricating the Throttle Grip and Cable
  69
- Checking and Lubricating the Brake and Shift Pedals
  70
- Checking and Lubricating the Brake and Clutch Levers
  70
- Checking and Lubricating the Sidestand
  71
- Lubricating the Swingarm Pivots
  71
- Checking the Front Fork
  72
- Checking the Steering
  72
- Checking the Wheel Bearings
  73
- Battery
  73
- Replacing the Fuses
  75
- Vehicle Lights
  77
  - Replacing the License Plate Light Bulb
    77
  - Supporting the Motorcycle
    78
  - Troubleshooting
    79
  - Troubleshooting Chart
    80
Motorcycle Care and Storage

82
- Matte Color Caution
  82
- Care
  82
- Storage
  85
Specifications

87
Consumer Information

89
- Identification Numbers
  89
- Diagnostic Connector
  90
- Vehicle Data Recording
  90
Index

91

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Yamaha MTN320-A Manuals

Yamaha MTN320-A Service Manual (479 pages)

Table of Contents

Yamaha MTN320-A Owner's Manual (94 pages)

Table of Contents

Safety Information

Description

Instrument and Control Functions

For Your Safety - Pre-Operation Checks

Operation and Important Riding Points

Periodic Maintenance and Adjustment

Motorcycle Care and Storage

Specifications

Consumer Information

Index

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Yamaha Categories