Yamaha YZF-R1 2012 Manuals

Manuals and User Guides for Yamaha YZF-R1 2012. We have 2 Yamaha YZF-R1 2012 manuals available for free PDF download: Service Manual

Yamaha YZF-R1 2012 Service Manual

Yamaha YZF-R1 2012 Service Manual (557 pages)

Brand: Yamaha | Category: Motorcycle | Size: 27.71 MB

Table of Contents

Important
3
Important Manual Information
3
How to Use this Manual
4
Symbols
5
Table of Contents
7
General Information
9
Specifications
41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  50
- Electrical Specifications
  53
- General Tightening Torque Specifications
  56
- Tightening Torques
  56
- Engine Tightening Torques
  57
  - Connecting Rod Cap Bolt
    60
  - Crankcase Bolt (Main Journal)
    60
  - Cylinder Head Nut
    60
- Chassis Tightening Torques
  61
  - Front Wheel Axle Pinch Bolt
    63
  - Lower Bracket Pinch Bolt
    63
- Engine
  65
- Lubrication Points and Lubricant Types
  65
- Chassis
  67
- Engine Oil Lubrication Chart
  68
- Lubrication System Chart and Diagrams
  68
- Lubrication Diagrams
  70
- Cooling System Diagrams
  86
- Cable Routing
  90
Periodic Checks and Adjustments
117
- Introduction
  120
- Periodic Maintenance Chart for the Emission Control System
  120
- General Maintenance and Lubrication Chart
  121
- Checking the Fuel Line (Primary Injectior)
  123
- Checking the Fuel Line (Secondary Injector)
  123
- Checking the Spark Plugs
  123
- Adjusting the Valve Clearance
  124
- Valve Lapper
  127
- Checking the Throttle Body Synchronization
  128
- Synchronizing the Throttle Bodies
  128
- Adjusting the Throttle Body Synchronization
  129
- Checking the Crankcase Breather Hose
  130
- Checking the Exhaust System
  130
- Checking the Throttle Body Joints
  130
- Adjusting the Exhaust Gas Volume
  131
- Checking the Air Induction System
  132
- Replacing the Air Filter Element
  132
- Adjusting the Clutch Cable Free Play
  133
  - Engine Side
    133
  - Handlebar Side
    133
- Checking the Brake Fluid Level
  134
- Checking the Brake Operation
  134
- Adjusting the Front Disc Brake
  135
- Adjusting the Rear Disc Brake
  135
- Checking the Front Brake Pads
  135
- Bleeding the Hydraulic Brake System
  136
- Checking the Rear Brake Pads
  136
- Checking the Front Brake Hoses
  137
- Checking the Rear Brake Hose
  138
- Checking the Tires
  138
- Checking the Wheels
  138
- Adjusting the Drive Chain Slack
  140
- Checking the Swingarm Operation
  140
- Checking the Wheel Bearings
  140
- Checking and Adjusting the Steering Head
  141
- Lubricating the Drive Chain
  141
- Checking the Chassis Fasteners
  142
- Checking the Steering Damper
  142
- Lubricating the Brake Lever
  142
- Lubricating the Clutch Lever
  142
- Lubricating the Pedal
  142
- Adjusting the Shift Pedal
  143
- Checking the Front Fork
  143
- Checking the Sidestand Switch
  143
- Lubricating the Sidestand
  143
- Adjusting the Front Fork Legs
  144
- Rebound Damping
  144
- Adjusting the Rear Shock Absorber Assembly
  145
- Checking the Rear Shock Absorber Assembly
  145
- Checking the Connecting Arm and Relay Arm
  147
- Checking the Engine Oil Level
  147
- Changing the Engine Oil
  148
- Measuring the Engine Oil Pressure
  149
- Oil Pressure Adapter H
  149
- Checking the Coolant Level
  150
- Checking the Cooling System
  150
- Changing the Coolant
  151
- Adjusting the Rear Brake Light Switch
  152
- Adjusting the Throttle Cable Free Play
  153
- Checking and Charging the Battery
  153
- Checking and Lubricating the Cables
  153
- Checking the Fuses
  153
- Lubricating the Rear Suspension
  153
- Adjusting the Headlight Beams
  154
- Replacing the Headlight Bulbs
  154
Chassis
157
- Removing the Seats and Battery
  160
- General Chassis
  160
- Removing the Side Cowlings
  161
- Removing the ECU and Rectifier/Regulator
  162
- Removing the Air Ducts
  163
- Removing the Front Cowling Assembly
  164
- General Chassis
  164
- Removing the Meter and Headlight
  165
- Removing the Rear Fender
  167
- Disassembling the License Plate/Turn Signal Light Assembly
  168
- Installing the Quick Fastener (Push Type)
  169
- Removing the Quick Fastener (Push Type)
  169
- Removing the Quick Fastener (Screw Type)
  169
- Installing the Quick Fastener (Screw Type)
  169
- Installing the Quick Fastener (Pull Type)
  170
- Installing the Passenger Seat Lock Cylinder
  170
- Removing the Front Turn Signal Lights
  170
- Installing the Front Turn Signal Lights
  170
- Removing the Lower Cowlings
  171
- Installing the Lower Cowlings
  171
- Removing the Side Cowling Inner Panels
  171
- Installing the Side Cowling Inner Panels
  171
- Installing the Air Intake Ducts
  172
- Installing the Air Chamber Covers
  172
- Installing the Intake Air Duct Covers
  172
- Removing the Intake Air Duct Covers
  172
- Removing the Windshield
  173
- Installing the Windshield
  173
- Installing the Mirror Fitting Plates
  173
- Removing the Upper Tail Cover
  173
- Installing the Upper Tail Cover
  174
- Installing the Tail/Brake Light
  174
- Adjusting the Rider Footrests
  174
- Removing the Front Wheel and Brake Discs
  176
- Front Wheel
  176
- Disassembling the Front Wheel
  177
- Removing the Front Wheel
  178
- Checking the Front Wheel
  178
- Maintenance of the Front Speed Sensor and Sensor Rotor
  179
- Adjusting Thr Front Wheel Static Balance
  181
- Installing the Front Wheel (Front Brake Discs)
  182
- Rear Wheel
  184
- Removing the Rear Wheel
  184
- Removing the Brake Disc and Rear Wheel Sprocket
  185
- Disassembling the Rear Wheel
  186
- Checking the Rear Wheel
  187
- Assembling the Rear Wheel
  188
- Checking the Rear Wheel Drive Hub
  188
- Checking and Replacing the Rear
  188
- Adjusting the Rear Wheel Static Balance
  189
- Installing the Rear Wheel
  189
- Front Brake
  190
- Removing the Front Brake Pads
  190
- Removing the Front Brake Master Cylinder
  191
- Disassembling the Front Brake Master Cylinder
  192
- Removing the Front Brake Calipers
  193
- Disassembling the Front Brake Calipers
  194
- Checking the Front Brake Discs
  195
- Replacing the Front Brake Pads
  196
- Checking the Front Brake Calipers
  199
- Installing Teh Front Brake Calipers
  199
- Assembling the Front Brake Calipers
  199
- Checking the Front Brake Master Cylinder
  201
- Assembling the Front Brake Master Cylinder
  201
- Installing the Front Brake Master Cylinder
  201
- Removing the Rear Brake Pads
  203
- Rear Brake
  203
- Removing the Rear Brake Master Cylinder
  204
- Disassembling the Rear Brake Master Cylinder
  205
- Removing the Rear Brake Calipers
  206
- Disassembling the Rear Brake Caliper
  207
- Checking the Rear Brake Disc
  208
- Replacing the Rear Brake Pads
  208
- Removing the Rear Brake Caliper
  210
- Checking the Rear Brake Caliper
  210
- Assembling the Rear Brake Caliper
  211
- Installing the Rear Brake Caliper
  211
- Checking the Rear Brake Master Cylinder
  212
- Assembling the Rear Brake Master Cylinder
  213
- Installing the Rear Brake Master Cylinder
  213
- Handlebars
  215
- Removing the Handlebars
  215
- Checking the Handlebars
  217
- Installing the Handlebars
  217
- Front Fork
  220
- Removing the Front Fork Legs
  220
- Disassembling the Front Fork Legs
  221
- Front Fork
  223
- Checking the Front Fork Legs
  225
- Assembling the Front Fork Legs
  225
- Installing the Front Fork Legs
  229
- Steering Head
  231
- Removing the Lower Bracket
  231
- Checking the Steering Head
  233
- Installing the Steering Head
  234
- Checking the Steering Damper
  234
- Rear Shock Absorber Assembly
  235
- Removing the Rear Shock Absorber Assembly
  235
- Checking the Rear Shock Absorber Assembly
  236
- Disposing of a Rear Shock Absorber
  236
- Handling the Rear Shock Absorber
  236
- Checking the Connecting Arm and Relay Arm
  237
- Installing the Relay Arm
  237
- Installing the Rear Shock Absorber Assembly
  237
- Swingarm
  239
- Removing the Swingarm
  239
- Checking the Swingarm
  242
- Installing the Swingarm
  242
- Chain Drive
  244
- Removing the Drive Sprocket and Drive Chain
  244
- Removing the Drive Chain
  245
- Checking the Drive Chain
  245
- Checking the Drive Sprocket
  246
- Installing the Drive Chain
  246
Engine
249
- Engine Inspection
  252
- Measuring the Compression Pressure
  252
- Engine Removal
  254
  - Removing the Exhaust Pipe and Muffler
    254
  - Disconnecting the Leads and Hoses
    257
  - Removing the Engine
    259
- Installing the Engine
  261
- Pivot Shaft Wrench Adapter
  261
- Installing the Exhaust Pipe and Muffler
  262
- Camshafts
  264
  - Removing the Cylinder Head Cover
    264
  - Removing the Camshafts
    265
- Removing the Camshafts
  267
- Checking the Camshafts
  268
- Checking the Timing Chain and Sprocket
  269
- Checking the Timing Chain Guides
  270
- Checking the Timing Chain Tensioner
  270
- Installing the Camshafts
  270
- Cylinder Head
  275
- Removing the Cylinder Head
  275
- Checking the Cylinder Head
  276
- Installing the Cylinder Head
  276
  - Removing the Valves and Valve Springs
    278
  - Valves and Valve Springs
    278
- Removing the Valves
  280
- Valves and Valve Springs
  280
- Checking the Valves and Valve Guides
  281
- Checking the Valve Seats
  282
- Checking the Valve Springs
  284
- Checking the Valve Filters
  285
- Installing the Valves
  285
- Generator
  287
- Removing the Generator
  287
- Installing the Generator
  288
- Removing the Generator
  288
- Removing the Starter Clutch
  290
- Starter Clutch
  290
- Checking the Starter Clutch
  291
- Installing the Starter Clutch
  291
- Pickup Rotor
  293
- Removing the Pickup Rotor
  293
- Installing the Pickup Rotor
  294
- Electric Starter
  296
  - Removing the Starter Motor
    296
  - Disassembling the Starter Motor
    297
- Checking the Starter Motor
  298
- Assembling the Starter Motor
  299
- Oil Pump
  301
  - Removing the Oil Pan and Oil/Water Pump Assembly
    301
  - Disassembling the Oil Pump
    303
- Checking the Oil Pump
  304
- Checking the Sprocket and Chain
  304
- Removing the Oil Pan
  304
- Checking the Oil Delivery Pipes
  305
- Checking the Oil Strainer
  305
- Checking the Relief Valve
  305
- Assembling the Oil Pump
  306
- Installing the Oil/Water Pump Assembly
  306
- Installing the Oil Pan
  307
- Clutch
  309
  - Removing the Clutch Cover
    309
  - Removing the Pull Lever Shaft
    310
  - Removing the Clutch
    311
- Removing the Clutch
  313
- Checking the Clutch Plates
  314
- Checking the Friction Plates
  314
- Checking the Clutch Housing
  315
- Checking the Clutch Springs
  315
- Checking the Clutch Boss
  316
- Checking the Pressure Plate
  316
- Checking the Primary Drive Gear
  316
- Checking the Primary Driven Gear
  316
- Checking the Pull Lever Shaft and Pull Rod
  316
- Installing the Clutch
  316
- Removing the Shift Shaft and Stopper Lever
  319
- Shift Shaft
  319
- Checking the Shift Shaft
  320
- Checking the Stopper Lever
  320
- Installing the Shift Shaft
  320
- Crankcase
  321
- Separating the Crankcase
  321
- Assembling the Crankcase
  323
- Checking the Crankcase
  323
- Disassembling the Crankcase
  323
  - Connecting Rods and Pistons
    325
  - Removing the Connecting Rods and Pistons
    325
- Checking the Cylinder and Piston
  326
- Connecting Rods and Pistons
  326
- Removing the Connecting Rods and Pistons
  326
- Checking the Piston Rings
  327
- Checking the Piston Pin
  328
- Checking the Connecting Rods
  329
- Installing the Connecting Rod and Piston
  332
- Crankshaft
  336
- Removing the Crankshaft
  336
- Checking the Crankshaft
  337
- Checking the Oil Nozzles
  337
- Removing the Crankshaft and Balancer Shaft
  337
- Checking the Balancer Shaft
  339
- Installing the Crankshaft
  340
- Installing the Balancer Assembly
  341
- Removing the Transmission, Shift Drum Assembly, and Shift Forks
  342
- Transmission
  342
  - Disassembling the Main Axle Assembly
    343
  - Disassembling the Drive Axle Assembly
    344
- Checking the Shift Forks
  346
- Removing the Transmission
  346
- Checking the Shift Drum Assembly
  347
- Checking the Transmission
  347
- Assembling the Main Axle and Drive Axle
  348
- Installing the Transmission
  348
Cooling System
351
- Radiator
  352
- Removing the Radiator
  352
- Checking the Radiator
  354
- Installing the Radiator
  354
- Oil Cooler
  356
- Removing the Oil Cooler
  356
- Checking the Oil Cooler
  358
- Installing the Oil Cooler
  358
- Thermostat
  359
- Removing the Thermostat
  359
- Assembling the Thermostat Assembly
  361
- Checking the Thermostat
  361
- Installing the Thermostat Assembly
  362
- Water Pump
  363
- Disassembling the Water Pump
  363
- Checking the Water Pump
  364
- Assembling the Water Pump
  364
Fuel System
367
General Information
395
Electrical System
395
- Ignition System
  398
- Circuit Diagram
  398
- Engine Stopping Due to Sidestand Operation
  400
- Troubleshooting
  402
- Electric Starting System
  404
- Starting Circuit Cut-Off System Operation
  406
- Charging System
  410
- Lighting System
  414
- Signaling System
  418
- Cooling System Circuit Diagram
  426
- Fuel Injection System
  430
- Ecu Self-Diagnostic Function
  432
- Engine Trouble Warning Light Indication and FI System Operation
  432
- Checking the Engine Trouble Warning Light
  432
- ECU Detects an Abnormal Signal from a Sensor
  433
- The Engine Operation Is Not Normal but the Engine Trouble Warning Light Does Not Comeon
  434
- Troubleshooting Method
  434
- The Engine Operation Is Not Normal and the Engine Trouble Warning Light Comes on
  434
- Diagnostic Mode
  435
- Sensor Operation Table
  437
- Troubleshooting Details
  443
- Clutch Switch System Malfunction
  484
- Fuel Pump System
  504
- Immobilizer System
  508
- General Information
  510
- Standby Mode
  511
- Code Re-Registering Key Registration
  511
- Part Replacement and Key Code Registration Requirements
  511
- Standard Key Registration
  512
- Voiding the Standard Key Code
  513
- Standard Key Code Voiding Method
  513
- Self-Diagnosis Fault Code Indication
  515
- Immobilizer System Indicator Light Fault Code Indication
  516
- Electrical Components
  518
- Checking the Switches
  522
- Checking the Condition of the Bulb Sockets
  525
- Checking the Condition of the Bulbs
  525
- Types of Bulbs
  525
- Checking the Bulbs and Bulb Sockets
  525
- Checking the Fuses
  526
- Checking and Charging the Battery
  526
- Charging Method Using a Variable-Current (Voltage) Charger
  529
- Charging Method Using a Constant Voltage Charger
  529
- Checking the Relays
  530
- Relay Unit (Starting Circuit Cut-Off Relay)
  530
- Starter Relay
  530
- Headlight Relay
  531
- Relay Unit (Fuel Pump Relay)
  531
- Radiator Fan Motor Relay
  531
- Checking the Turn Signal/Hazard Relay
  531
- Checking the Relay Unit (Diode)
  532
- Checking the Crankshaft Position Sensor
  534
- Checking the Lean Angle Sensor
  535
- Checking the Starter Motor Operation
  535
- Checking the Stator Coil
  536
- Checking the Rectifier/Regulator
  536
- Checking the Horn
  537
- Checking the Oil Level Switch
  537
- Checking the Fuel Sender
  538
- Checking the Rear Speed Sensor
  538
- Checking the Radiator Fan Motor
  539
- Checking the Coolant Temperature Sensor
  539
- Checking the Throttle Position Sensor
  540
- Checking the Accelerator Position Sensor
  540
- Checking the Throttle Servo Motor
  541
- Checking the Air Induction System Solenoid
  541
- Checking the Atmospheric Pressure Sensor
  542
- Checking the Cylinder Identification Sensor
  542
- Checking the Intake Air Temperature Sensor
  543
- Checking the Intake Air Pressure Sensor
  543
- Checking the Steering Damper Solenoid
  544
- Checking the Gear Position Sensor
  544
- Checking the Fuel Injectors
  545
Troubleshooting
547
- Troubleshooting
  548
- Starting Failures
  548
- Incorrect Engine Idling Speed
  548
- Faulty Clutch
  549
- Jumps out of Gear
  549
- Shift Pedal Does Not Move
  549
- Poor Medium-And-High-Speed Performance
  549
- Overcooling
  550
- Poor Braking Performance
  550
- Faulty Front Fork Legs
  550
- Unstable Handling
  550
- Cooling System
  550
- Faulty Lighting or Signaling System
  551
- Wiring Diagram YZF-R1(B)
  552
- Color Code
  552
- Wiring Diagram
  555

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Yamaha YZF-R1 2012 Service Manual

Yamaha YZF-R1 2012 Service Manual (556 pages)

Brand: Yamaha | Category: Motorcycle | Size: 62.55 MB

Table of Contents

Table of Contents

7
- How to Use this Manual
  4
- Symbols
  5
- 1 General Information
  9
  - Identification
    10
    
    Vehicle Identification Number
    10
    
    Model Label
    10
  - Features
    11
    
    Outline of the Fi System
    11
    
    Fi System
    12
    
    YCC-T (Yamaha Chip Controlled Throttle) YCC-I (Yamaha Chip Controlled Intake)
    13
    
    OUTLINE of the TCS (Traction Control System)
    17
    
    Instrument Functions
    21
  - Important Information
    29
    
    Preparation for Removal and Disassembly
    29
    
    Replacement Parts
    29
    
    Gaskets, Oil Seals and O-Rings
    29
    
    Lock Washers/Plates and Cotter Pins
    29
    
    Bearings and Oil Seals
    30
    
    Circlips
    30
  - Checking the Connections
    31
  - Handling the Electronic Parts
    32
  - Special Tools
    33
Specifications

41
- General Specifications
  42
- Engine Specifications
  43
- Chassis Specifications
  50
- Electrical Specifications
  53
- Tightening Torques
  56
- Lubrication Points and Lubricant Types
  65
  - Engine
    65
  - Chassis
    67
- Lubrication System Chart and Diagrams
  68
  - Engine Oil Lubrication Chart
    68
  - Lubrication Diagrams
    70
- Cooling System Diagrams
  86
- Cable Routing
  90
Periodic Checks and Adjustments

117
- Introduction
  120
- Periodic Maintenance
  120
- Periodic Maintenance Chart for the Emission Control System
  120
- General Maintenance and Lubrication Chart
  121
- CHECKING the FUEL LINE (Primary Injector)
  123
- CHECKING the FUEL LINE (Secondary Injector)
  123
- Checking the Spark Plugs
  123
- Adjusting the Valve Clearance
  124
- Synchronizing the Throttle Bodies
  128
- Checking the Crankcase Breather Hose
  130
- Checking the Exhaust System
  130
- Checking the Throttle Body Joints
  130
- Adjusting the Exhaust Gas Volume
  131
- Checking the Air Induction System
  132
- Replacing the Air Filter Element
  132
- Adjusting the Clutch Cable Free Play
  133
- Checking the Brake Fluid Level
  134
- Checking the Brake Operation
  134
- Adjusting the Front Disc Brake
  135
- Adjusting the Rear Disc Brake
  135
- Checking the Front Brake Pads
  135
- Bleeding the Hydraulic Brake System
  136
- Checking the Rear Brake Pads
  136
- Checking the Front Brake Hoses
  137
- Checking the Rear Brake Hose
  138
- Checking the Tires
  138
- Checking the Wheels
  138
- Adjusting the Drive Chain Slack
  140
- Checking the Swingarm Operation
  140
- Checking the Wheel Bearings
  140
- Checking and Adjusting the Steering Head
  141
- Lubricating the Drive Chain
  141
- Checking the Chassis Fasteners
  142
- Checking the Steering Damper
  142
- Lubricating the Brake Lever
  142
- Lubricating the Clutch Lever
  142
- Lubricating the Pedal
  142
- Adjusting the Shift Pedal
  143
- Checking the Front Fork
  143
- Checking the Sidestand
  143
- Checking the Sidestand Switch
  143
- Lubricating the Sidestand
  143
- Adjusting the Front Fork Legs
  144
- Adjusting the Rear Shock Absorber Assembly
  145
- Checking the Rear Shock Absorber Assembly
  145
- Checking the Connecting Arm and Relay Arm
  147
- Checking the Engine Oil Level
  147
- Changing the Engine Oil
  148
- Measuring the Engine Oil Pressure
  149
- Checking the Coolant Level
  150
- Checking the Cooling System
  150
- Changing the Coolant
  151
- Adjusting the Rear Brake Light Switch
  152
- Checking the Front Brake Light Switch
  152
- Adjusting the Throttle Cable Free Play
  153
- Checking and Charging the Battery
  153
- Checking and Lubricating the Cables
  153
- Checking the Fuses
  153
- Lubricating the Rear Suspension
  153
- Adjusting the Headlight Beams
  154
- Replacing the Headlight Bulbs
  154
- Chassis
  157
  - General Chassis
    164
  - Front Brake
    192
  - Rear Brake
    208
  - Front Fork
    223
Engine

249
- Engine Inspection
  
  252
  - Measuring the Compression Pressure
    252
- Engine Removal
  
  254
  - Installing the Engine
    261
  - Installing the Exhaust Pipe and Muffler
    262
- Camshafts
  
  264
  - Removing the Camshafts
    267
  - Checking the Camshafts
    268
  - Checking the Timing Chain and Sprocket
    269
  - Checking the Timing Chain Guides
    270
  - Checking the Timing Chain Tensioner
    270
  - Installing the Camshafts
    270
- Cylinder Head
  
  275
  - Removing the Cylinder Head
    276
  - Checking the Cylinder Head
    276
  - Installing the Cylinder Head
    276
- Valves and Valve Springs
  
  280
  - Removing the Valves
    280
  - Checking the Valves and Valve Guides
    281
  - Checking the Valve Seats
    282
  - Checking the Valve Springs
    284
  - Checking the Valve Lifters
    285
  - Installing the Valves
    285
- Generator
  
  287
  - Removing the Generator
    288
  - Installing the Generator
    288
- Starter Clutch
  
  290
  - Removing the Starter Clutch
    291
  - Checking the Starter Clutch
    291
  - Installing the Starter Clutch
    291
- Pickup Rotor
  
  293
  - Removing the Pickup Rotor
    294
  - Installing the Pickup Rotor
    294
- Electric Starter
  
  296
  - Checking the Starter Motor
    298
  - Assembling the Starter Motor
    299
- Oil Pump
  
  301
  - Removing the Oil Pan
    304
  - Checking the Sprocket and Chain
    304
  - Checking the Oil Pump
    304
  - Checking the Relief Valve
    305
  - Checking the Oil Delivery Pipes
    305
  - Checking the Oil Strainer
    305
  - Assembling the Oil Pump
    306
  - Installing the Oil/Water Pump Assembly
    306
  - Installing the Oil Pan
    307
- Clutch
  
  309
  - Removing the Clutch
    313
  - Checking the Friction Plates
    314
  - Checking the Clutch Plates
    314
  - Checking the Clutch Springs
    315
  - Checking the Clutch Housing
    315
  - Checking the Clutch Boss
    316
  - Checking the Pressure Plate
    316
  - Checking the Primary Drive Gear
    316
  - Checking the Primary Driven Gear
    316
  - Checking the Pull Lever Shaft and Pull Rod
    316
  - Installing the Clutch
    316
- Shift Shaft
  
  319
  - Checking the Shift Shaft
    320
  - Checking the Stopper Lever
    320
  - Installing the Shift Shaft
    320
- Crankcase
  
  321
  - Disassembling the Crankcase
    323
  - Checking the Crankcase
    323
  - Assembling the Crankcase
    323
- Connecting Rods and Pistons
  
  326
  - Removing the Connecting Rods and Pistons
    326
  - Checking the Cylinder and Piston
    326
  - Checking the Piston Rings
    327
  - Checking the Piston Pin
    328
  - Checking the Connecting Rods
    329
  - Installing the Connecting Rod and Piston
    332
- Crankshaft
  
  336
  - Removing the Crankshaft and Balancer Shaft
    337
  - Checking the Oil Nozzles
    337
  - Checking the Crankshaft
    337
  - Checking the Balancer Shaft
    339
  - Installing the Crankshaft
    340
  - Installing the Balancer Assembly
    341
- Transmission
  
  346
  - Removing the Transmission
    346
  - Checking the Shift Forks
    346
  - Checking the Shift Drum Assembly
    347
  - Checking the Transmission
    347
  - Assembling the Main Axle and Drive Axle
    348
  - Installing the Transmission
    348
Cooling System

351
- Radiator
  
  352
  - Checking the Radiator
    354
  - Installing the Radiator
    354
- Oil Cooler
  
  356
  - Checking the Oil Cooler
    358
  - Installing the Oil Cooler
    358
- Thermostat
  
  359
- Water Pump
  
  363
  - Disassembling the Water Pump
    364
  - Checking the Water Pump
    364
  - Assembling the Water Pump
    364
  - Fuel System
    367
    
    Fuel Tank
    369
    
    Air Induction System
    388
  - Electrical System
    395
  - General Information
    395
    
    Ignition System
    398
    
    Electric Starting System
    404
    
    Charging System
    410
    
    Lighting System
    414
    
    Signaling System
    418
    
    Fuel Injection System
    430
    
    Fuel Pump System
    504
    
    Immobilizer System
    508
  - Specifications
    544
  - Troubleshooting
    547
    
    Troubleshooting
    548

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