99-02 R6 Service Manual

EB000000

YZF-R6SERVICE MANUAL

1998 by Yamaha Motor Co., Ltd.First edition, August 1998

All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand their qualified mechanics. it is not possible to include all the knowledge of a mechanic in one manu-al. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehiclesshould have a basic understanding of mechanics and the techniques to repair these types of vehicles.Repair and maintenance work attempted by anyone without this knowledge is likely to render the ve-hicle unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealersand will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EB002000

IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

NOTE: A NOTE provides key information to make procedures easier or clearer.

126

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EB003000

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage indicate the current chapter.Refer to “SYMBOLS”.

2 Each chapter is divided into sections. The current section title is shown at the top of each page,except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(-s) ap-pears.

3 Sub-section titles appear in smaller print than the section title.

4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly step.

6 Symbols indicate parts to be lubricated or replaced.Refer to “SYMBOLS”.

7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names ofparts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

22

1

3

5

7

9

2

4

8

6

24 25

2321

19 2018

16 1715

1413

11 12

10

GENINFO SPEC

ENG

CARB

ELECCHAS

COOL

CHKADJ

TRBLSHTG

EB004000

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 9 indicate the subject of eachchapter.

1 General information2 Specifications3 Periodic checks and adjustments4 Engine5 Cooling system6 Carburetor(-s)7 Chassis8 Electrical system9 Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening torque15 Wear limit, clearance16 Engine speed17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.

18 Engine oil19 Gear oil20 Molybdenum disulfide oil21 Wheel bearing grease22 Lithium soap base grease23 Molybdenum disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-cate the following.

24 Apply locking agent (LOCTITE )25 Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENT

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETORS

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENINFO 1SPEC 2

3ENG 4

COOL 5CARB 6CHAS 7ELEC 8TRBLSHTG 9

CHKADJ

INDEX

GENINFO

CHAPTER 1.GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBER 1-1. . . . . . . . . . . . . . . . . . . . . . . . . MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY 1-2. . . . . . . . . . REPLACEMENT PARTS 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS 1-2. . . . . . . . . . . . . . . . . . . . . . . . USING A DYNAMOMETER 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS 1-3. . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS 1-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEATURES 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INTAKE SYSTEM 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

MOTORCYCLE IDENTIFICATIONGENINFO

EB100000

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head pipe.

EB100020

MODEL CODEThe model code label 1 is affixed to the frame.This information will be needed to order spareparts.

1-2

IMPORTANT INFORMATIONGENINFO

EB102000

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DIS-ASSEMBLY1. Before removal and disassembly, remove all

dirt, mud, dust, and foreign material.

2. Use only the proper tools and cleaningequipment.Refer to “SPECIAL TOOLS”.

3. When disassembling, always keep matedparts together. This includes gears, cylin-ders, pistons and other parts that have been“mated” through normal wear. Mated partsmust always be reused or replaced as an as-sembly.

4. During disassembly, clean all of the partsand place them in trays in the order of disas-sembly. This will speed up assembly and al-low for the correct installation of all parts.

5. Keep all parts away from any source of fire.

EB102010

REPLACEMENT PARTSUse only genuine Yamaha parts for all replace-ments. Use oil and grease recommended byYamaha for all lubrication jobs.Other brands may be similar in function and ap-pearance, but inferior in quality.

EB102020

GASKETS, OIL SEALS AND O-RINGS1. When overhauling the engine, replace all

gaskets, seals, and O-rings. All gasket sur-faces, oil seal lips, and O-rings must becleaned.

2. During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease.

1-3

IMPORTANT INFORMATIONGENINFO

CAUTION:

USING A DYNAMOMETERThe YZF-R6 has a carbon muffler that maychange color when exposed to high tempera-tures. Therefore, when using a dynamometeralways use a fan to cool the muffler.

EB102030

LOCK WASHERS/PLATES AND COTTERPINSAfter removal, replace all lock washers/plates1 and cotter pins. After the bolt or nut has beentightened to specification, bend the lock washertabs and the cotter pin ends along a flat of thebolt or nut.

EB102040

BEARINGS AND OIL SEALS1. Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-ible. When installing oil seals, lubricate theoil seal lips with a light coat of lithium soapbase grease. Oil bearings liberally wheninstalling, if appropriate.

1 Oil seal

Do not spin the bearing with compressed airbecause this will damage the bearing sur-faces.

1 Bearing

EB102050

CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips. Al-ways replace piston pin clips after one use.When installing a circlip 1 , make sure that thesharp-edged corner 2 is positioned oppositethe thrust 3 that the circlip receives.

4 Shaft

1-4

CHECKING THE CONNECTIONSGENINFO

NOTE:

NOTE:

NOTE:

EB103000

CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: leadcouplerconnector

2. Check: leadcouplerconnectorMoisture Dry with an air blower.Rust/stains Connect and disconnect sev-eral times.

3. Check:all connectionsLoose connection Connect properly.

If the pin 1 on the terminal is flattened, bend itup.

4. Connect: leadcouplerconnector

Make sure that all connections are tight.

5. Check:continuity(with the pocket tester)

Pocket tester90890-03112

If there is no continuity, clean the terminals.When checking the wire harness, performsteps (1) to (3).

As a quick remedy, use a contact revitalizeravailable at most part stores.

1-5

FEATURESGENINFO

Former thermostat

Tem

pera

ture

Time

New thermostat

Tem

pera

ture

Time

FEATURESAIR INTAKE SYSTEMSystem diagram

This system is designed to improve the power while riding a motorcycle at a high speed by increasingthe air intake efficiency by means of pressurizing the air filter case 2 where the air is taken in via the airduct 1 from the air intake port located under the headlight.The system also delivers air pressure from the air filter case to the carburetor side.The air pressure is operated to the fuel level in the carburetor to supply the appropriate fuel to increasethe power.The air chamber 3 is also installed between the air filter case and carburetor for delivery of stabilizedair pressure to the carburetor.

THERMOSTATCoolant flow is controlled by the thermostat ofwhich flow control valve 1 is newly developedfor avoiding quick temperature change.(Refer to the graphs)2 Notch groove

1-6

FEATURESGENINFO

1) 2)

3) 4)

1 CDI unit2 Voltage converter3 Condenser4 Ignition coil

5 Spark plug6 Ignition timing controller7 Pickup coil8 T. P. S.

9 Speed sensor10 Battery11 Rectifier / regulator12 AC magneto

13 Stator coil

Flow control operation1) When valve is closed

The lip 1 seals the coolant.2) When valve is set as low-lift

The 2nd lip 2 seals the coolant.To reduce the water temperature change,the coolant starts flowing through the notchdepending on its area at a section.

3) When the valve is set as middle-liftThe 3rd lip 3 seals the coolant.The coolant flows through the notch depend-ing on its area at b section.This flow rate is larger than the case of 2).

4) When the valve is set as high-liftIn the same way as the regular thermostatcontrol, the coolant flows through clearancec between the valve and flange.

IGNITION SYSTEM1. DC CDI1) Features* Battery is used as the power source.* Stabilized spark performance is provided in the range from a low speed to high speed since the

battery is used as the power source.* Compact AC magneto design is possible since the source coil is unnecessary.* Compact ignition coil design is possible since the condenser stores electricity.

Plug top ignition coil is equipped in which the plug cap and ignition coil are integrated.* Stator coil can supply power even if the battery is running out.2) Circuit diagram

1-7

FEATURESGENINFO

2. Ignition coilCompact and right weight design is providedsince the plug top ignition coil is equipped inwhich the plug cap ignition coil are inte-grated.High tension cord was cut an end to use andignition energy loss has become lower.

3. Spark plugThe 2-pole spark plug is applied to improvethe ignition quality and combustion efficien-cy.

1-8

SPECIAL TOOLSGENINFO

EB104000

SPECIAL TOOLSThe 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 inappropri-ate tools or improvised techniques.When placing an order, refer to the list provided below to avoid any mistakes.

Tool No. Tool name/Function Illustration

Flywheel puller90890-01362Adapter90890-04089

Flywheel pullerAdapter

This tool is used to remove the generator ro-tor.

90890-01701

Sheave holder

This tool is used to hold the generator rotorwhen removing or installing the generator ro-tor bolt or pickup coil rotor bolt.

90890-01304

Piston pin puller

This tool is used to remove the piston pins.

90890-01312

Fuel level gauge

This tool is used to measure the fuel level inthe float chamber.

Radiator captester90890-01325Adapter90890-01352

Radiator cap testerAdapter

These tools are used to check the coolingsystem.

90890-01403

Steering nut wrench

This tool is used to loosen or tighten the steer-ing stem ring nuts.

90890-01425

Damper rod holder

This tool is used to hold the damper rod as-sembly when loosening or tightening thedamper rod assembly bolt.

90890-01471

Pivot shaft wrench

This tool is used to loosen or tighten the pivotadjust bolt and engine mount adjust bolt.

1-9



90890-01426

Oil filter wrench

This tool is needed to loosen or tighten the oilfilter cartridge.

90890-01434

Rod holder

This tool is used to support the damper ad-justing rod.

Rod puller90890-01437Rod puller attachment90890-01436

Rod pullerRod puller attachment

These tools are used to pull up the front forkdamper rod.

90890-01441

Fork spring compressor

This tool is used to disassemble or assemblethe front fork legs.

Fork seal driver90890-01376Fork seal driverattachment90890-01374

Fork seal driver weightFork seal driver attachment

This tool is used to install the front fork’s oilseal and dust seal.

90890-03008

Micrometer

This tool is used to measure the piston skirtdiameter.

90890-03017

Cylinder bore gauge (50~100mm)

This gauge is used to measure cylinder bore.

Vacuum gauge90890-03094Valve gaugeattachment90890-03060

Vacuum gaugeVacuum gauge attachment

This gauge is used to synchronize the carbu-retors.

Compressiongauge90890-03081Adapter90890-04136

Compression gaugeAdapter

These tools are used to measure enginecompression.

90890-03112

Pocket tester

This tool is used to check the electrical sys-tem.

1-10



90793-80009

Engine tachometer

This tool is used to check engine speed.

90890-03141

Timing light

This tool is used to check the ignition timing.

Oil pressure gauge90890-03153Adapter90890-03139

Oil pressure gaugeAdapter

These tools are used to measure engine oilpressure.

90890-04044

Piston ring compressor

This tool is used to compress piston ringswhen installing the cylinder.

90890-03158

Carburetor angle driver

This tool is used to turn the pilot screw whenadjusting the engine idling speed.

Valve spring compressor90890-04019Attachment90890-04108

Valve spring compressorAttachment

These tools are used to remove or install thevalve assemblies.

Middle driven shaftbearing driver90890-04058Mechanical seal in-staller90890-04078

Middle driven shaft bearing driverMechanical seal installer

These tools are used to install the water pumpseal.

90890-04086

Clutch holding tool

This tool is used to hold the clutch bosswhen removing or installing the clutch bossnut.

90890-04111

Valve guide remover

This tool is used to remove or install the valveguides.

1-11



90890-04112

Valve guide installer

This tool is used to install the valve guides.

90890-04113

Valve guide reamer

This tool is used to rebore the new valveguides.

90890-06754

Ignition checker

This tool is used to check the ignition systemcomponents.

90890-85505

Yamaha bond No. 1215

This bond is used to seal two mating surfaces(e.g., crankcase mating surfaces).

SPEC

CHAPTER 2.SPECIFICATIONS

GENERAL SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE SPECIFICATIONS 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS SPECIFICATIONS 2-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SPECIFICATIONS 2-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONVERSION TABLE 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL TIGHTENING TORQUES 2-18. . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES 2-19. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES 2-22. . . . . . . . . . . . . . . . . . . . . . . . . . .

LUBRICATION POINTS AND LUBRICANT TYPES 2-23. . . . . . . . . . . . . . . . ENGINE LUBRICATION POINTS AND LUBRICANT TYPES 2-23. . . . . CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES 2-24. . . .

OIL FLOW DIAGRAMS 2-25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COOLANT FLOW DIAGRAMS 2-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CABLE ROUTING 2-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard Limit

DimensionsOverall length

Overall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2025 mm (except for NOR, SWE, FIN, AUS NZL)2075 mm (for NOR, SWE, FIN, AUS, NZL)690 mm1105 mm820 mm1380 mm135 mm3400 mm

WeightWet (with oil and a full fuel tank)

Dry (without oil and fuel)

Maximum load (total of cargo, rider,passenger, and accessories)

188 kg

169 kg

375 kg

2-2

ENGINE SPECIFICATIONS SPEC

Temp.

ENGINE SPECIFICATIONS

Item Standard Limit

EngineEngine tipeDisplacementCylinder arrangementBore strokeCompression ratioEngine idling speedVacuum pressure at engine idlingspeedStandard compression pressure(at sea level)

Liquid-cooled, 4-stroke, DOHC600 cm3

Forward-inclined parallel 4-cylinder65.5 44.5 mm12.4 : 11,250 1,350 r/min24.0 kPa (0.24 kg/cm2)

1550 kPa (15.5 kgf/cm2) at 400 r/min

FuelRecommended fuelFuel tank capacityTotal (including reserve)Reserve only

Regular gasoline

17 L3.5 L

Engine oilLubrication systemRecommended oil

QuantityTotal amountWithout oil filter cartridgereplacementWith oil filter cartridge replacement

Oil pressure (hot)

Relief valve opening pressure

Wet sump

SAE20W40SE or SAE10W30SE

3.5 L2.5 L

2.7 L80 kPa at 1300 r/min(0.80 kgf/cm2 at 1300 r/min)450 550 kPa (4.5 5.5 kgf/cm2)

2-3


Item Standard Limit

Oil filterOil filter typeBypass valve opening pressure

Cartridge (paper)80 120 kPa (0.8 1.2 kgf/cm2)

Oil pumpOil pump typeInner-rotor-to-outer-rotor-tipclearanceOuter-rotor-to-oil-pump-housingclearance

Trochoidal0.03 0.09 mm

0.03 0.08 mm

0.15 mm

0.15 mm

Cooling systemRadiator capacityRadiator cap opening pressureRadiator coreWidthHeightDepth

Coolant reservoirCapacity

Water pumpWater pump typeReduction ratio

2.15 L110 140 kPa (1.10 1.40 kgf/cm2)

320 mm258 mm24 mm

0.44 L

Single-suction centrifugal pump86/44 31/31 (1.955)

Starting system type Electric starter

Spark plugsModel (manufacturer) quantitySpark plug gap

CR10EK/NGK 40.6 0.7 mm

Cylinder headMax. warpage 0.05 mm

2-4


Item Standard Limit

CamshaftsDrive systemCamshaft cap inside diameterCamshaft journal diameterCamshaft-journal-to-camshaftcap

clearanceIntake camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Exhaust camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Max. camshaft runout

Chain drive (right)23.000 23.021 mm22.967 22.980 mm0.020 0.054 mm

33.05 33.15 mm25.14 25.24 mm7.81 8.01 mm

32.55 32.65 mm25.07 25.17 mm7.38 7.58 mm

0.08 mm

33.0 mm25.09 mm

32.50 mm25.02 mm

0.06 mm

2-5


Head Diameter Face Width Seat Width Margin Thickness

Item Standard Limit

Timing chainModel/number of linksTensioning system

RH2015/120Automatic

Valves, valve seats, valve guidesValve clearance (cold)IntakeExhaust

Valve dimensions

0.11 0.20 mm0.21 0.30 mm

Valve head diameter AIntakeExhaust

Valve face width BIntakeExhaust

Valve seat width CIntakeExhaust

Valve margin thickness DIntakeExhaust

Valve stem diameterIntakeExhaust

Valve guide inside diameterIntakeExhaust

Valve-stem-to-valve-guide clearanceIntakeExhaust

Valve stem runout

Valve seat widthIntakeExhaust

24.9 25.1 mm21.9 22.1 mm

1.14 1.98 mm1.14 1.98 mm

0.9 1.1 mm0.9 1.1 mm

0.6 0.8 mm0.6 0.8 mm

3.975 3.990 mm3.960 3.975 mm

4.000 4.012 mm4.000 4.012 mm

0.010 0.037 mm0.025 0.052 mm

0.9 1.1 mm0.9 1.1 mm

1.6 mm1.6 mm

0.5 mm0.5 mm

3.950 mm3.935 mm

4.042 mm4.042 mm

0.08 mm0.1 mm0.04 mm

1.6 mm1.6 mm

2-6


Item Standard Limit

Valve springsFree lengthIntake (inner)

(outer)Exhaust

Installed length (valve closed)Intake (inner)

(outer)Exhaust

Compressed spring force(installed)Intake (inner)

(outer)Exhaust

Spring tilt

Intake (inner)(outer)

Exhaust

Winding direction (top view)IntakeExhaust

37.0 mm38.4 mm41.7 mm

30.0 mm32.5 mm36.1 mm

69 79 N (7.0 8.0 kgf)114 132 N (11.6 13.4 kgf)160 184 N (16.3 18.7 kgf)

ClockwiseClockwise

35 mm36.5 mm39.5 mm

2.5 /1.6 mm2.5 /1.7 mm2.5 /1.8 mm

CylindersCylinder arrangementBore strokeCompression ratioBoreMax. taperMax. out-of-round

Forward-inclined, parallel 4-cylinder65.5 45.5 mm12.4 : 165.50 65.51 mm

0.05 mm0.05 mm

2-7


Item Standard Limit

PistonsPiston-to-cylinder clearanceDiameter D

Height HPiston pin bore (in the piston)DiameterOffsetOffset direction

Piston pinsOutside diameter

Piston-pin-to-piston-pin-boreclearance

Piston ringsTop ring

Ring typeDimensions (B T)End gap (installed)Ring side clearance

2nd ring

Ring typeDimensions (B T)End gap (installed)Ring side clearance

Oil ring

Dimensions (B T)End gap (installed)

0.025 0.050 mm65.460 65.475 mm

4 mm

16.002 16.013 mm0.35 0.65 mmIntake side0.5 mm15.991 16.000 mm0.002 0.022 mm

Barrel0.80 2.45 mm0.15 0.25 mm0.030 0.065 mm

Taper0.8 2.5 mm0.40 0.50 mm0.020 0.055 mm

1.5 2.3 mm0.10 0.35 mm

0.07 mm

0.072 mm

0.50 mm0.115 mm

0.85 mm0.115 mm

2-8


Item Standard Limit

Connecting rodsCrankshaft-pin-to-big-end-bearingclearanceBearing color code

0.028 0.052 mm

1 = Blue 2 = Black 3 = Brown 4 = Green

Crankshaft

Width BMax. runout CBig end side clearance DCrankshaft-journal-to-crankshaft-journal-bearing clearanceBearing color code

268.8 270.0 mm

0.160 0.262 mm0.034 0.058 mm

0 = White 1 = Blue2 = Black 3 = Brown4 = Green

0.03 mm

ClutchClutch typeClutch release methodClutch release method operationOperationClutch cable free play (at the endof the clutch lever)Friction platesThicknessPlate quantity

Clutch platesThicknessPlate quantityMax. warpage

Clutch plateThicknessPlate quantityMax. warpage

Clutch springsFree lengthSpring quantity

Wet, multiple discRack and pinion (pull rod type)Cable operationLeft hand operation10 15 mm

2.9 3.1 mm8

1.9 2.1 mm7

2.2 2.4 mm1

55 mm6

2.8 mm

0.1 mm

0.1 mm

54 mm

2-9


Item Standard Limit

TransmissionTransmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios1st gear2nd gear3rd gear4th gear5th gear6th gear

Max. main axle runoutMax. drive axle runout

Constant mesh, 6-speedSpur gear86/44 (1.9545)Chain drive48/16 (3.000)Left-foot operation

37/13 (2.846)37/19 (1.947)28/18 (1.555)32/24 (1.333)25/21 (1.190)26/24 (1.083)

0.02 mm0.02 mm

Shifting mechanismShift mechanism typeMax. shift fork guide bar bendinginstalled shift rod length

Cam drum

242 mm

0.05 mm

Air filter type Dry element

Fuel pumpPump typeModel (manufacturer)Output pressure

Electrical5EB (MITSUBISHI)15 20 kPa (0.15 0.2 kgf/cm2)

CarburetorsModel (manufacturer) quantityThrottle cable free play (at theflange of the throttle grip)ID markMain jet

Main air jetJet needleNeedle jetPilot air jetPilot outletPilot jetBypass 1Bypass 2Bypass 3Pilot screw turns outValve seat size

CVRD37 (MIKUNI) 46 8 mm

5EB00, 5EB200 (G), 5EB300 (F)Carburetors 1 and 4: #152Carburetors 2 and 3: #148#110N7RA2.6#1100.9#380.80.80.821.2

2-10


Item Standard Limit

Starter jet 1Starter jet 2Butterfly valve sizeFuel level (below the line on thefloat chamber)

#500.6#11017.5 18.5 mm

2-11

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

FrameFrame typeCaster angleTrail

Diamond2481 mm

Front wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 MT3.50Aluminum130 mm

1 mm0.5 mm

Rear wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 MT5.50Aluminum120 mm

1 mm0.5 mm

Front tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg90 197 kgHigh-speed riding

Min. tire tread depth

Tubeless120/60ZR17 (55W)BRIDGESTON BT56F.EDUNLOP D207F.J

250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

1.6 mm

2-12


Item Standard Limit

Rear tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg90 197 kgHigh-speed riding

Min. tire tread depth

Tubeless180/55 ZR17 (73 W)BRIDGESTON BT56R.EDUNLOP D207.N

250 kPa (2.5 kg/cm2, 2.5 bar)290 kPa (2.9 kg/cm2, 2.9 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

1.6 mm

Front brakesBrake typeOperationRecommended fluidBrake discsDiameter thicknessMin. thicknessMax. deflectionBrake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Dual-disc brakeRight-hand operationDOT 4

298 5 mm

5.5 mm

14 mm30.2 mm and 27 mm

4.5 mm0.1 mm0.5 mm

Rear brakeBrake typeOperationBrake pedal position (from the topof the brake pedal to the bottom ofthe rider footrest bracket bolt center.)Recommended fluidBrake discsDiameter thicknessMin. thicknessMax. deflectionBrake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Single-disc brakeRight-foot operation4.3 9.3 mm

DOT 4

220 5 mm

5 mm

12.7 mm27.0 mm and 22.2 mm

4.5 mm0.1 mm0.8 mm

2-13

CHASSIS SPECIFICATION SPEC

Item Standard Limit

Front suspensionSuspension typeFront fork typeFront fork travelSpringFree lengthSpacer lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableFork oilRecommended oilQuantity (each front fork leg)Level (from the top of the innertube, with the inner tube fullycompressed, and without thefork spring)

Damper adjusting rod locknut distanceSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjusting positions Minimum*

Standard*Maximum*

Compression damping adjustingpositions

Minimum*Standard*Maximum*

*from the fully turned-in position

Telescopic forkCoil spring/oil damper130 mm

251.8 mm125 mm247.8 mm7.5 N/mm (0.75 kgf/mm)0 130 mmNo

Suspension oil “01” or equivalent476 cm3

107 mm

25 mm

851

1161

1261

246 mm

2-14


Item Standard Limit

SteeringSteering bearing type Angular ball bearings

Rear suspensionSuspension typeRear shock absorber assemblytypeRear shock absorber assemblytravelSpringFree lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableStandard spring preload gas/airpressureSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjusting positions Minimum*

Standard* Maximum*Compression damping adjustingpositions

Minimum*Standard*Maximum*

*from the fully turned-in position

Swingarm (link suspension)Coil spring/gas-oil damper60 mm

169.5 mm159 mm95.1 N/mm (9.51 kgf/mm)0 60 mmNo1,200 kPa (12 kgf/cm2)

149

2591

1371

SwingarmFree play (at the end of the swingarm)RadialAxial

1 mm1 mm

Drive chainModel (manufacturer)Link quantityDrive chain slackMaximum ten-link section

532ZLV KAI (DID)11640 50 mm149 mm

2-15

ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage 12 V

Ignition systemIgnition system typeIgnition timingAdvanced timingAdvancer typePickup coil resistance/colorTransistorized coil ignition unit model

(manufacturer)

C.D.I.10 BTDC at 1700 r/min55 BTDC at 5250 r/minThrottle position sensor and electrical248 372 Ω /Gy-BF8T354 (MITSUBISHI)

Ignition coilsModel (manufacturer)Minimum ignition spark gapPrimary coil resistanceSecondary coil resistance

F6T549 (MITSUBISHI)6 mm0.238 0.322 Ω8.16 11.04 kΩ

Throttle position sensor standardresistance

4 6 kΩ

Charging systemSystem typeModel (manufacturer)Nominal outputStator coil resistance

AC magnetoF4T366 (MITSUBISHI)14 V/320W at 5,000 r/min0.27 0.33 Ω at 20C

Voltage regulatorRegulator typeModel (manufacturer)No-load regulated voltage

Semiconductor, short circuit typeSH650A-12 (SHINDENGEN)14.1 14.9 V

RectifierModelRectifier capacityWithstand voltage

SH650A-1218 A200 V

BatteryBattery typeBattery voltage/capacity

GT12B-412 V/10 AH

Headlight type Halogen bulb

Indicator light type quantity LED 5

Bulbs (voltage/wattage quantity)HeadlightAuxiliary lightTail /brake lightTurn signal light

12 V 60 W/55 W 212 V 5 W 212 V 5 W/21 W 212 V 21 W 4

2-16


Item Standard Limit

License plate lightMeter light

12 V 5 W 212 V 1.4 W 2

Electric starting systemSystem typeStarter motorModel (manufacturer)Power outputBrushesOverall lengthSpring force

Commutator resistanceCommutator diameterMica undercut

Constant mesh

SM-14 (MITSUBA)0.6 kW

10 mm7.16 9.52 N (730 970 gf)0.012 0.022 Ω28 mm0.7 mm

3.5 mm

27 mm

Starter relayModel (manufacturer)AmperageCoil resistance

MS5F-631 (JIDECO)180 A4.18 4.62 Ω

HornHorn typeModel (manufacturer) quantityMax. amperage

PlainYF-12 (NIKKO) 13 A

Flasher relayRelay typeModel (manufacturer)Self-cancelling device built-inTurn signal blinking frequencyWattage

Full-transistorFE246BH (DENSO)No75 95 cycles/min.21 W 2 + 3.4 W

Oil level switch model (manufacturer) 4XV (DENSO)

Fuel senderModel (manufacturer)Resistance

1UF (NIPPON SEIKI)0.7 1.1 kΩ GW-B

Sidestand relayModelCoil resistance

G8R-30Y-K162 198 Ω

Fuel pump maximum amperage 1 A

Fuel pump relay model (manufacturer)Resistance

G8R-30Y-K (OMRON)162 198 Ω

Radiator fan model (manufacturer) 4XV (TOYO RADIATOR)

Thermo switch model (manufacturer) 5EB (NIPPON THERMOSTAT)

Headlight relay (manufacturer)Resistance

ACA12115 (MATSUSHITA)72 88 Ω

2-17


Item Standard Limit

Temperature senderModel (manufacturer)Resistance

11H (NIPPON SEIKI)50.6 64.2 Ω at 80C16.1 17.3 Ω at 120C

Fuses (amperage quantity)Main fuseHeadlight fuseSignaling system fuseIgnition fuseRadiator fan fuseBackup fuse (odometer)

30 A 120 A 120 A 115 A 17.5 A 17.5 A 1

2-18

CONVERSION TABLE/TIGHTENING TORQUES SPEC

EB202001

TIGHTENING TORQUESGENERAL TIGHTENING TORQUESThis chart specifies tightening torques for standardfasteners with a standard ISO thread pitch. Tighten-ing torque specifications for special components orassemblies are provided for each chapter of thismanual. To avoid warpage, tighten multi-fastenerassemblies in a crisscross pattern and progressivestages until the specified tightening torque isreached. Unless otherwise specified, tighteningtorque specifications require clean, dry threads.Components should be at room temperature.

A: Width across flats

B: Thread diameter

ftlb

61

4.3

11

22

40

94

A(nut)

B(bolt)

General tighteningtorques

10 mm

12 mm

14 mm

18 mm

19 mm

22 mm

6 mm

8 mm

10 mm

12 mm

14 mm

16 mm

Nm mkg6

15

30

55

85

130

0.6

1.5

3.0

5.5

8.5

13.0

EB201000

CONVERSION TABLEAll specification data in this manual arelisted in SI and METRIC UNITS.Use this table to convert METRIC unit datato IMPERIAL unit data.Ex.

METRIC MULTIPLIER IMPERIAL

**mm 0.03937 = **in

2 mm 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Tighten-ingtorque

mkgmkgcmkgcmkg

7.23386.7940.07230.8679

ftlbinlbftlbinlb

Weight kgg

2.2050.03527

lboz

Speed km/hr 0.6214 mph

Distance

kmmmcmmm

0.62143.2811.0940.39370.03937

miftydinin

Volume/cc (cm3)cc (cm3)

0.035270.06102

oz (IMP liq.)cuin

Capacity( )

lt (liter)lt (liter)

0.87990.2199

qt (IMP liq.)gal (IMP liq.)

Misc.

kg/mmkg/cm2

Centigrade(C)

55.99714.22349/5 + 32

lb/ inpsi (lb / in2)Fahrenheit(F)

2-19

TIGHTENING TORQUES SPEC

NOTE:

ENGINE TIGHTENING TORQUES

Item Fastener Thread size Q’tyTightening

torque RemarksyNm nkgf

Spark plugsCylinder headCylinder headCamshaft capsCylinder head coverOil passage check boltCylinder head (exhaust pipe)

–BoltBoltBoltBoltBolt

Stud bolt

M10M10M6M6M6M8M8

4102

20618

13511010102015

1.35.11.01.01.02.01.5

Connecting rod caps Nut M7 See NOTEGenerator rotorPickup rotorCap bolt (timing chain tensioner)Timing chain tensioner boltCamshaft sprocketOil pumpOil coolerEngine oil drain boltOil pump assembly driven sprocketcoverOil pipeOil filter boltOil filter cartridgeExhaust pipesMuffler clampExhaust pipe emission check boltsExhaust pipe bracketCrankcaseCrankcaseCrankcaseGenerator rotor coverDrive sprocket cover

BoltBoltBoltBoltBoltBoltBolt

–Bolt

BoltBolt

–NutBoltBoltBoltBoltBoltBoltBoltBolt

M12M8M6M6M7M6

M20M14M6

M6M20M20M8M8M6M8M6M6M8M6M6

111243112

21181412

121295

653510122412634310

158017202010201412241210

6.53.51.01.22.41.26.34.31,0

1.58.01.72.02.01.02.01.41.22.41.21.0

After tightening to 15 Nm (1.5mkg), tighten another 90

2-20


Item Fastener Threadsize

Q’tyTightening

torque Remarkssize

yNm mkgf

Clutch coverPickup coil rotor coverShift shaft coverBreather plate 2Starter clutchClutch boss

Clutch springsDrive sprocket

Main axle bearing housingShift bar stopperShift shaft spring stopperShift rod locknut

Oil level switchShift armStator coilIgnitor unitNeutral switchPickup coilThermo unitThermo switch

BoltBoltBolt

–BoltNut

BoltNut

ScrewBoltBoltNut

BoltBoltBoltBolt

ScrewBolt

––

M6M6M6M6M8

M20

M6M18

M6M6M8M6M8M6M6M6M6M6M5

PT1/8M18 1.5

1056331

61

3211121312211

121212123270

870

1210227

10101010104.0101528

1.21.21.21.23.27.0

0.87.0

1.21.02.20.71.01.01.01.01.00.41.01.52.8

Use a lockwasher.

Use a lockwasher.

2-21


Crankcase tightening sequence:

2-22


NOTE:

CHASSIS TIGHTENING TORQUES

Item Thread sizeTightening

torque RemarksNm mkgf

Upper bracket pinch boltsSteering stem nutHandlebar pinch boltsLower ring nutLower bracket pinch boltsBrake fluid reservoir cap stopperFront brake hose union boltsFront brake master cylinderEngine mountingFront mounting bolts

Rear mounting boltsPinch bolts

Button head boltExhaust pipe bracketPivot shaft nutConnecting armsRelay arm and connecting armsRelay armRear shock absorber and relay armFuel cockFuel sender and fuel tankCoolant reservoir and radiatorRider footrest bracketPassenger footrest bracketRear master cylinderRear brake hose union boltsSidestandFront wheel axleRear wheel axle nutFront brake caliper and front forkRear brake caliper and bracketBrake disc and wheelRear wheel sprocket and rear wheel drive hubBrake caliper and bleed screwPinch bolt (front wheel axle)

M8M28M8

M30M8M4

M10M6

M12M12M10M8M6

M10M8

M18M10M10M10M10M6M6M6M8M8M8

M10M10M18M24M10M10M6

M10M8M8

25115339

23123013

555545241339209540404040775

282823306072

150402718696

23

2.511.53.30.92.31.23.01.3

5.55.54.52.41.33.92.09.54.04.04.04.00.70.70.52.82.82.33.06.07.2

15.04.02.71.86.90.62.3

See NOTE.

1. First, tighten the ring nut to approximately 17 Nm (1.7 mkg) with a torque wrench, then loosen the ring nut completely.

2. Retighten the ring nut to specification.

2-23

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EB202000

LUBRICATION POINTS AND LUBRICANT TYPESENGINE LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication point Lubricant

Oil seal lips

O-rings

Bearings

Crankshaft pins

Piston surfaces

Piston pins

Connecting rod bolts and nuts

Crankshaft journals

Camshaft lobes

Camshaft journals

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Water pump impeller shaft

Oil pump rotors (inner and outer)

Oil pump housing

Oil strainer

Starter clutch idle gear inner surface

Starter clutch assembly

Primary driven gear

Transmission gears (wheel and pinion)

Main axle and drive axle

Shift drum

Shift forks and shift fork guide bars

Shift shaft

Shift shaft boss

Engine mounting bolts (rear)

Cylinder head cover mating surface Yamaha bondNo.1215

Crankcase mating surface Yamaha bondNo.1215

Clutch cover (crankcase mating surface) Yamaha bondNo.1215

Generator rotor cover (crankcase mating surface) Yamaha bondNo.1215

Cylinder head cover Yamaha bondNo.1215

2-24

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EB202010

CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES

Lubrication 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

Throttle grip inner surface

Brake lever pivoting point and metal-to-metal moving parts

Clutch lever pivoting point and metal-to-metal moving parts

Rear shock absorber assembly oil seal

Rear shock absorber assembly bearing

Rear shock absorber assembly spacer

Pivot shaft

Connecting arm bearing (left and right)

Spacer (relay arm and connecting arm)

Oil seal (relay arm and connecting arm)

2-25

OIL FLOW DIAGRAMS SPEC

1 Intake camshaft2 Exhaust camshaft3 Crankshaft4 Oil pipe5 Oil strainer6 Oil pump

OIL FLOW DIAGRAMS

2-26


1 Exhaust camshaft2 Intake camshaft3 Oil filter4 Oil cooler

2-27


1 Cylinder head2 Crankshaft

2-28


1 Main axle2 Oil delivery pipe3 driveaxle

2-29

1 Radiator2 Radiator fan3 Oil cooler

COOLANT FLOW DIAGRAMS SPEC

COOLANT FLOW DIAGRAMS

2-30


1 Thermostat housing2 Thermostat3 Radiator4 Therm

2-31

1 Radiator cap2 Radiator3 Oil cooler4 Water jacket joint5 Water pump


2-32

1 Radiator2 Radiator fan switch3 Radiator fan


2-33

CABLE ROUTING SPEC

1 Throttle cables2 Front brake hose3 Clutch cable4 Starter cable5 Left handlebar switch lead6 Main switch lead7 Right handlebar switch lead

A Install the headlight relays onto the headlight housing bridge.B Route the headlight lead through the plastic guide.C Route the right handlebar switch lead in front of the front fork inner

tube.D Route the throttle cables between the brake hose and right handlebar

switch lead.E Route the wire harness through under the left handlebar switch lead

and starter cable.F Fasten the left handlebar switch lead to the front fork with a plastic

locking tie and cut the end of locking tie.

EB206000

CABLE ROUTING

2-34

CABLE ROUTING SPEC

G Fasten the throttle cables and starter cable with a band.Locate the end of band to forward.

H Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie. Cut the end of locking tie. And then, route the horn lead under the brake hose and clamp it to the under cover.

2-35

1 Fuel pump lead2 Pickup coil lead3 Clutch cable4 Rear brake switch lead

A Route the ignition coil lead over the heat protector plate.

B Position the face of steel clip up ward.C Route the clutch cable through the guide on the

frame.D Route the coolant hose under the heat protector

plate.

CABLE ROUTING SPEC

E Route the clutch cable through the guide on the ra-diator.

F Fasten the clutch cable to the coolant hose protec-tor with a plastic band.

G Fasten the rear brake switch lead to the footrest bracket with a plastic locking tie and cut the end of locking tie.

H Fasten the fuel pump lead and rear brake switch lead with a plastic band on the fuel pump bracket.

2-36

1 AC magneto lead2 Sidestand switch lead3 Oil lever switch lead4 Reservoir tank breather hose5 Fuel tank breather hose6 Fuel tank drain hose7 Speed sensor lead8 Neutral switch lead9 Fuel pump leadA Route the throttle cable through inside of the radia-

tor bracket and outside of the wireharness.B Fasten the wireharness, radiator hose and fan mo-

tor lead with a plastic band.

CABLE ROUTING SPEC

C Do not touch the wireharness with the throttle cablepully.Route the wireharness under the radiator hose.

D Route the wireharness through the slit of rear fender.E Route the rear turn signal light leads (left and right)

through the hole of rear fender.F Route the seat lock cable outside of the wirehar-

ness.G Fasten the sidestand switch lead and oil level sen-

sor lead with a band.H Route the fuel tank drain hose, fuel tank breather

hose, reservoir tank breather hose, oil level switch lead and sidestand switch lead through the guide on the frame.

I Route the starter cable between the main switch lead and left randlebar switch lead.

2-37

1 Throttle cable2 Handlebar switch lead (right)3 Coolant reservoir breather hose4 Carburetor idle adjusting cable5 Pickup coil connector6 Neutral switch connector7 Rear brake switch connector8 Handlebar switch (right) connec-

tors9 Main switch connectors10 Throttle position sensor connector11 Handlebar switch (left) connec-

tors12 Neutral switch lead13 Fuel pump connector14 Rear brake switch lead15 Starter motor lead

CABLE ROUTING SPEC

16 Battery negative (–) cable17 Fuel sender connector18 Coolant reservoir tank cap19 Crankcase breather hose20 Therm unit lead21 Fan motor lead connector22 Clutch cable23 Handlebar switch lead (left)24 Stater cable25 Main switch lead

A To headlight leadB Route the clutch cable through the guide.

2-38

C Fasten the handlebar switch leads (left and right) and main switch lead with a band.

D Route the ignition coil lead and handlebar switch leads (left and right) over the heat protection plate.

E Route the reservoir tank hose, carburetor heater hoses under the heat protector plate.

F Fasten the neutral switch lead, right handlebar switch lead, main switch lead, TPS lead, left han-dlebar switch lead, pickup coil lead and throttle stop screw cable with a band.

G Insert the projection of the band to the hole of the frame and fasten the wireharness, neutral switch lead, handlebar switch leads (left and right), main switch lead, throttle position sensor lead, rearbrake switch lead and pickup coil lead with them.

CABLE ROUTING SPEC

H Route the starter motor lead under the wirehar-ness.

I Fasten the starter motor to the rear fender with a band.

J Fasten the battery positive (+) cable and starter motor cable with a plastic band.

K Position the rear turn signal light connectors (left and right) and taillight connector between the rear fender and taillight bracket.

L Install the seat lock cable to the frame bracket with protector side.

M Fasten the wireharness, oil level sensor lead, ground lead and alarm leads (3 lines) with a band.

N Fasten the starter relay lead and battery negative (–) lead to the wireharness with a plastic band.

O Fasten the battery negative (–) lead and wirehar-ness with a plastic band.

2-39

P Insert the projection of the band (wireharness) into the hole of the frame.

Q 1: Speed sensor connector2: AC magneto connector3: Sidestand switch connector4: Oil level switch connector5: Meter ground lead

R Fasten the leads (above 1 – 5) and starter motor lead with a steel band on the engine.

S Route the fuel tank breather hose and fuel tank drain hose over the wireharness.

T Route the starter cable with slot of the heat protec-tion plate.

CABLE ROUTING SPEC

U Route the starter cable and wireharness through the guide of the heat protection plate.

V Route the fan motor lead under the throttle cable and then, fasten the fan motor lead and throttle cable with a band.

W To radiator fan motor

CHKADJ

CHAPTER 3.PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 3-1. . . . . .

RIDER AND PASSENGER SEATS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COWLINGS 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER CASE AND IGNITION COILS 3-8. . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 3-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE 3-11. . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE CARBURETORS 3-16. . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED 3-18. . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY 3-20. . . . . . . . . . . . . CHECKING THE SPARK PLUGS 3-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IGNITION TIMING 3-23. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE 3-24. . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL 3-26. . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL 3-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE 3-29. . . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY 3-30. . . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT 3-31. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR JOINTS 3-32. . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL HOSES AND FUEL FILTER 3-32. . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE 3-33. . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-33. . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE AIR INTAKE SYSTEM 3-34. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL 3-35. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM 3-35. . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT 3-36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHASSIS 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE 3-39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL 3-41. . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE PADS 3-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHKADJ

ADJUSTING THE REAR BRAKE LIGHT SWITCH 3-42. . . . . . . . . . . . . . . CHECKING THE BRAKE HOSES 3-43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM 3-43. . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL 3-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK 3-45. . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN 3-47. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD 3-47. . . . . . . . . . CHECKING THE FRONT FORK 3-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT FORK LEGS 3-51. . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 3-53. . . . . . CHECKING THE TIRES 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-58. . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-58. . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-58. . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-59. . . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS 3-66. . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS 3-67. . . . . . . . . . . . . . . . . . . . . . .

3-1

INTRODUCTION/PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

EB300000

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.EB301000

PERIODIC MAINTENANCE AND LUBRICATION INTERVALSEVERY

No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL

(1,000 km)

6,000 km or6 months

(whichevercomes first)

12,000 kmor

12 months(whichevercomes first)

1 * Fuel line Check fuel hoses for cracks or damage. Replace if necessary.

√ √

2 * Fuel filter Check condition. Replace if necessary.

√

3 Spark plugs Check condition. Clean, regap or replace if necessary.

√ √ √

4 * Valves Check valve clearance. Adjust if necessary.

Every 42,000 km or 42 months (which-ever comes first)

5 Air filter element Clean or replace if necessary. √ √

6 Clutch Check operation. Adjust or replace cable.

√ √ √

7 * Front brake

Check operation, fluid level and vehicle for fluid leak-age. (See NOTE on page 3-2.)

Correct accordingly. Replace brake pads if necessary.

√ √ √

8 * Rear brake

Check operation, fluid level and vehicle for fluid leak-age. (See NOTE on page 3-2.)

Correct accordingly. Replace brake pads if necessary.

√ √ √

9 * Wheels Check balance, runout and for damage. Rebalance or replace if necessary.

√ √

10 * Tires

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

√ √

11 * Wheel bearings Check bearing for looseness or damage. Replace if necessary.

√ √

12 * Swingarm

Check swingarm pivoting point for play. Correct if necessary. Lubricate with lithium soap base grease every 24,000

km or 24 months (whichever comes first).

√ √

13 Drive chain

Check chain slack. Adjust if necessary. Make sure that the rear wheel is

properly aligned. Clean and lubricate.

Every 1,000 km and after washing themotorcycle or riding in rain

14 * Steering bearings

Check bearing play and steering for roughness. Correct accordingly. Lubricate with lithium soap base grease every

24,000 km or 24 months (whichever comes first).

√ √

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSCHKADJ

NOTE:

EVERY

No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL

(1,000 km)

6,000 km or6 months

(whichevercomes first)

12,000 kmor

12 months(whichevercomes first)

15 * Chassis fasteners Make sure that all nuts, bolts and screws are properly

tightened. Tighten if necessary.

√ √

16 Sidestand Check operation. Lubricate and repair if necessary.

√ √

17 * Sidestand switch Check operation. Replace if necessary.

√ √ √

18 * Front fork Check operation and for oil leakage. Correct accordingly.

√ √

19 *Rear shock absorberassembly

Check operation and shock absorber for oil leakage. Replace shock absorber assembly if necessary.

√ √

20 *Rear suspension relayarm and connectingarm pivoting points

Check operation. Lubricate with lithium soap base grease every 24,000

km or 24 months (whichever comes first).√ √

21 * Carburetors Check engine idling speed, synchronization and

starter operation. Adjust if necessary.

√ √ √

22 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.)

√ √ √

23Engine oil filter car-tridge

Replace. √ √

24 * Cooling system

Check coolant level and vehicle for coolant leakage. Correct if necessary. Change coolant every 24,000 km or 24 months (which-

ever comes first).

√ √

* Since these items require special tools, data and technical skills, they should be serviced by aYamaha dealer.

The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake system.– Replace the brake fluid after disassembling the master cylinder or caliper cylinder.– Check the brake fluid level and add fluid as required.– Replace the master cylinder and caliper cylinder oil seals every two years.– Replace the brake hoses every four years, or if cracked or damaged.

3-3

Order Job/Part Q’ty Remarks

12

Removing the rider and passengerseatsPassenger seatRider seat

11

Remove the parts in the order listed.

For installation, reverse the removalprocedure.

7Nm (0.7 mkg)

RIDER AND PASSENGER SEATSCHKADJ

EB302000

RIDER AND PASSENGER SEATS

3-4


1234

567

Removing the fuel tankRider seatBoltBoltsFuel sender couplerFuel hose

Fuel tank overflow hoseFuel tank breather hoseFuel tank

1211

111

Remove the parts in the order listedRefer to “SEATS”.

Disconnect.

Before disconnecting the fuel hose, setthe fuel cock “OFF”.

For installation reverse the removalprocedure.

NOTE:

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

7 Nm (0.7 mkg)7 Nm (0.7 mkg)

FUEL TANKCHKADJ

FUEL TANK

3-5


1234567

Removing the cowlingsRider and passenger seatsRear cowlingBottom cowling (left)Bottom cowling (right)Front cowling inner panel (left)Front cowling inner panel (right)Side cowling inner panel (left)Side cowling inner panel (right)

1111111

Remove the parts in the order listedRefer to “SEATS”.

5 Nm (0.5 mkg)

5 Nm (0.5 mkg)

COWLINGSCHKADJ

COWLINGS

3-6


89

101112

Left side cowlingRight side cowlingWindshieldRear view mirrorFront cowling

11121


5 Nm (0.5 mkg)

5 Nm (0.5 mkg)

COWLINGSCHKADJ

COWLINGS

3-7

COWLINGSCHKADJ

NOTE:

NOTE:

REMOVAL1. Remove: rear cowlingside cowlings

To remove the quick fastener, turn its center to90 with a screwdriver, then pull the fastenerout.

INSTALLATION1. Install:side cowlings rear cowling

To install the quick fastener, push its pin so thatit protrudes from the fastener head, then insertthe fastener into the cowling and push the pin ain with a screwdriver. Make sure that the pin isflush with the fastener’s head.

3-8


123456789

101112

Removing the air filter case andignition coilsRider seat and fuel tankFront cowling inner panel (left)Front cowling inner panel (right)Crankcase breather hoseAir vent hoseHosesDrain cupAir filter case balance hoseClamp screwBoltSurge tank joint (left)Surge tank joint (right)Air filter caseClampQuick fastener

112124111122


Refer to “SEATS” and “FUEL TANK”.Refer to “COWLINGS”.

Loosen.

AIR FILTER CASE AND IGNITION COILSCHKADJ

AIR FILTER CASE AND IGNITION COILS

3-9

AIR FILTER CASE AND IGNITION COILSCHKADJ


131415

Heat protector plateIgnition coil couplerIgnition coil

144


3-10

AIR FILTER CASE AND IGNITION COIL PLATECHKADJ

NOTE:

NOTE:

REMOVAL1. Remove:heat protector plate

To remove the quick fastener, push its center inwith a screwdriver, then pull the fastener out.

INSTALLATION1. Install:heat protector plate

To install the quick fastener, push its pin so thatit protrudes from the fastener head, then insertthe fastener into the rubber baffle and push thepin a in with a screwdriver. Make sure that thepin is flush with the fastener’s head.

3-11

ADJUSTING THE VALVE CLEARANCECHKADJ

NOTE:

EB303001

ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.

Valve clearance adjustment should be madeon a cold engine, at room temperature.

When the valve clearance is to be measuredor adjusted, the piston must be at top deadcenter (TDC) on the compression stroke.

1. Remove: rider seat fuel tankRefer to “SEATS” and “FUEL TANK”.

air filter caseheat protector plateRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

bottom cowlingside cowlingsRefer to “COWLINGS”.

carburetor assemblyRefer to “CARBURETORS” in chapter 6.

radiator assemblyRefer to “RADIATOR” in chapter 5.

2. Remove: ignition coilsspark plugscylinder head cover 1cylinder head cover gasket

3. Remove:pickup coil rotor cover 1

3-12


NOTE:

NOTE:

4. Measure:valve clearanceOut of specification Adjust

Valve clearance (cold)Intake valve

0.11 0.20 mmExhaust valve

0.21 0.30 mm

a. Turn the crankshaft clockwise.b. When piston #1 is at TDC on the compres-

sion stroke, align the TDC mark a on thepickup coil rotor with the crankcase matingsurface b .

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

c. Measure the valve clearance with a thick-ness gauge 1 .

If the valve clearance is incorrect, record themeasured reading.

Measure the valve clearance in the followingsequence.

Valve clearance measuring sequenceCylinder #1 #2 #4 #3

A Frontd. To measure the valve clearances of the other

cylinders, starting with cylinder #1 at TDC,turn the crankshaft counterclockwise as spe-cified in the following table.

B Degrees that the crankshaft is turned counter-clockwise

C CylinderD Combustion cycle

Cylinder #2 180

Cylinder #4 360

Cylinder #3 540

3-13


NOTE:

NOTE:

NOTE:

5. Remove: timing chain tensioner timing chain guide (exhaust side)camshaft cap timing chain(from the camshaft sprockets)

intake camshaftexhaust camshaft

Refer to “CAMSHAFTS” in chapter 4.When removing the timing chain from cam-shafts, fasten the timing chain with a wire to re-trieve it if it falls into the crankcase.

6. Adjust:valve clearance

a. Remove the valve lifter 1 and the valve pad2 .

Cover the timing chain opening with a rag toprevent the valve pad from falling into thecrankcase.

Make a note of the position of each valve lifter1 and valve pad 2 so that they can beinstalled in the correct place.

b. Select the proper valve pad from the follow-ing table.

Valve pad thick-ness range

Available valvepads

Nos.120

240

1.20 2.40 mm

25 thicknesses in0.05 mm incre-

ments

The thickness a of each valve pad is markedin hundredths of millimeters on the side thattouches the valve lifter.

Since valve pads of various sizes are originallyinstalled, the valve pad number must berounded in order to reach the closest equiva-lent to the original.

3-14


NOTE:

NOTE:

NOTE:

c. Round off the original valve pad number ac-cording to the following table.

Last digit Rounded value

0 or 2 0

5 5

8 10

EXAMPLE:Original valve pad number = 148 (thickness =1.48 mm)Rounded value = 150d. Locate the rounded number of the original

valve pad and the measured valve clearancein the valve pad selection table. The pointwhere the column and row intersect is thenew valve pad number.

The new valve pad number is only an approxi-mation. The valve clearance must be measuredagain and the above steps should be repeated ifthe measurement is still incorrect.

e. Install the new valve pad 1 and the valve lift-er 2 .

Lubricate the valve pad with molybdenum dis-ulfide grease.

Lubricate the valve lifter with molybdenum dis-ulfide oil.

The valve lifter must turn smoothly when ro-tated by hand.

Install the valve lifter and the valve pad in thecorrect place.

f. Install the exhaust and intake camshafts,timing chain and camshaft caps.

Camshaft cap bolt10 Nm (1.0 mkg)

Refer to “CAMSHAFTS” in chapter 4.Lubricate the camshaft lobes and camshaftjournals.

First, install the exhaust camshaft.Align the camshaft marks with the camshaftcap marks.

Turn the crankshaft counterclockwise severalfull turns to seat the parts.

3-15


Example:Valve Clearance (cold)

0.11 0.20 mmRounded value 150

Measured valve clearance is 0.24 mmReplace pad 150 with pad 160

Pad No. 150 = 1.50 mmPad No. 160 = 1.60 mm

Always install the valve pad with thenumber facing down.

MEASURED

VALVE CLEARANCEB ORIGINAL VALVE PAD NUMBERA

Example:Valve Clearance (cold)

0.21 0.30 mmRounded value 175

Measured valve clearance is 0.35 mmReplace pad 150 with pad 185

Pad No. 175 = 1.75 mmPad No. 185 = 1.85 mm

Always install the valve pad with thenumber facing down.

MEASURED

VALVE CLEARANCEB ORIGINAL VALVE PAD NUMBERA

STANDARD CLEARANCE

STANDARD CLEARANCEC

C

VALVE PAD SELECTION TABLEINTAKE

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.08 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.11 0.200.21 0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.23 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.28 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.33 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73 0.77 180 185 190 195 200 205 210 215 220 225 230 235 2400.78 0.82 185 190 195 200 205 210 215 220 225 230 235 2400.83 0.87 190 195 200 205 210 215 220 225 230 235 2400.88 0.92 195 200 205 210 215 220 225 230 235 2400.93 0.97 200 205 210 215 220 225 230 235 2400.98 1.02 205 210 215 220 225 230 235 2401.03 1.07 210 215 220 225 230 235 2401.08 1.12 215 220 225 230 235 2401.13 1.17 220 225 230 235 2401.18 1.22 225 230 235 2401.23 1.27 230 235 2401.28 1.32 235 2401.33 1.37 240

EXHAUST

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 2150.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 2200.08 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.13 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.18 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2350.21 0.300.31 0.32 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.33 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.78 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.83 0.87 180 185 190 195 200 205 210 215 220 225 230 235 2400.88 0.92 185 190 195 200 205 210 215 220 225 230 235 2400.93 0.97 190 195 200 205 210 215 220 225 230 235 2400.98 1.02 195 200 205 210 215 220 225 230 235 2401.03 1.07 200 205 210 215 220 225 230 235 2401.08 1.12 205 210 215 220 225 230 235 2401.13 1.17 210 215 220 225 230 235 2401.18 1.22 215 220 225 230 235 2401.23 1.27 220 225 230 235 2401.28 1.32 225 230 235 2401.33 1.37 230 235 2401.38 1.42 235 2401.43 1.47 240

3-16

ADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE CARBURETORS

CHKADJ

NOTE:

NOTE:

NOTE:

g. Measure the valve clearance again.h. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust-ment steps until the specified clearance isobtained.

7. Install:all removed parts

For installation, reverse the removal procedure.Note the following points.

8. Install: timing chain guide (exhaust side) timing chain tensionerpickup coil rotor covercylinder head coverspark plugs ignition coilsRefer to “CAMSHAFTS” in chapter 4.

EB303010

SYNCHRONIZING THE CARBURETORS

Prior to synchronizing the carburetors, the valveclearance and the engine idling speed shouldbe properly adjusted and the ignition timingshould be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.


3-17

SYNCHRONIZING THE CARBURETORSCHKADJ

3. Remove:hose 1

4. Install:vacuum gauge attachments(into the bolt holes)

vacuum gauge 1(onto the vacuum gauge attachments)

engine tachometer 2(onto the ignition coil of cylinder #1)

Vacuum gauge90890-03094

Vacuum gauge attachment90890-03060

Engine tachometer90793-80009

5. Start the engine and let it warm up for severalminutes.

6. Measure:engine idling speedOut of specification Adjust.Refer to “ADJUSTING THE ENGINE ID-LING SPEED”.

Engine idling speed1,250 1,350 r/min

7. Adjust:carburetor synchronization

a. Synchronize carburetor #1 to carburetor #2by turning the synchronizing screw 1 in ei-ther direction until both gauges read thesame.

3-18

SYNCHRONIZING THE CARBURETORS/ADJUSTING THE ENGINE IDLING SPEED

CHKADJ

NOTE:

NOTE:

NOTE:

After each step, rev the engine two or threetimes, each time for less than a second, andcheck the synchronization again.

b. Synchronize carburetor #4 to carburetor #3by turning the synchronizing screw 2 in ei-ther direction until both gauges read thesame.

c. Synchronize carburetor #2 to carburetor #3by turning the synchronizing screw 3 in ei-ther direction until both gauges read thesame.

Vacuum pressure at engineidling speed

24.0 kPa (0.24 kg/cm 2)

The difference in vacuum pressure betweentwo carburetors should not exceed 1.33 kPa (10mm Hg).

8. Measure:engine idling speedOut of specification Adjust.

9. Stop the engine and remove the measuringequipment.

10. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.

Throttle cable free play(at the flange of the throttle grip)

6 8 mm

EB303020

ADJUSTING THE ENGINE IDLING SPEED

Prior to adjusting the engine idling speed, thecarburetor synchronization should be adjustedproperly, the air filter element should be clean,and the engine should have adequate com-pression.

1. Start the engine and let it warm up for severalminutes.

3-19

ADJUSTING THE ENGINE IDLING SPEEDCHKADJ

a

b

2. Remove:air filter casequick fasteners 1band 2Refer to “AIR FILTER CASE AND IGNITIONCOILS”.

3. Install:engine tachometer(onto the ignition coil of cylinder #1)


4. Install:air filter caseRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

5. Measure:engine idling speedOut of specification Adjust.


6. Adjust:engine idling speed

a. Turn the pilot screw 1 in until it is lightlyseated.

b. Turn the pilot screw out the specified numberof turns.

Carburetor angle driver90890-03158

Pilot screw setting2 turns out

c. Turn the throttle stop screw 2 in direction aor b until the specified engine idling speed isobtained.

Direction Engine idling speed isdecreased.

Direction Engine idling speed isincreased.

3-20

ADJUSTING THE ENGINE IDLING SPEED/ADJUSTING THE THROTTLE CABLE FREE PLAY

CHKADJ

NOTE:

7. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.


6 8 mm

EB303031

ADJUSTING THE THROTTLE CABLE FREEPLAY

Prior to adjusting the throttle cable free play, theengine idling speed and carburetor synchro-nization should be adjusted properly.

1. Measure: throttle cable free play aOut of specification Adjust.


6 8 mm



3-21

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

NOTE:

a

b

NOTE:

c

d

WARNING

3. Adjust: throttle cable free play

When the throttle is opened, the acceleratorcable 1 is pulled.

Carburetor sidea. Loosen the locknut 2 on the decelerator

cable.b. Turn the adjusting nut 3 in direction a or b

to take up any slack on the decelerator cable.c. Loosen the locknut 4 on the accelerator

cable.d. Turn the adjusting nut 5 in direction a or b

until the specified throttle cable free play isobtained.

Direction Throttle cable free playin increased.

Direction Throttle cable free playis decreased.

e. Tighten the locknuts.

If the specified throttle cable free play cannot beobtained on the carburetor side of the cable,use the adjusting nut on the handlebar side.

Handlebar sidea. Loosen the locknut 6 .b. Turn the adjusting nut 7 in direction c or d

until the specified throttle cable free play isobtained.

Direction Throttle cable free playis increased.

Direction Throttle cable free playis decreased.

d. Tighten the locknut.

After adjusting the throttle cable free play,start the engine and turn the handlebars tothe right and to the left to ensure that thisdoes not cause the engine idling speed tochange.

3-22

CHECKING THE SPARK PLUGSCHKADJ

NOTE:

CAUTION:

EB303040

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Remove: rider seat fuel tankRefer to “SEATS” and “FUEL TANK”.


2. Disconnect: Ignition coils

3. Remove:spark plug

a. Remove the coupler.b. Turn the coil counterdockwise. (5 to 6 turns

would be adequate.)c. Pull out the coil upward.

Never pry the coupler with a screw driver.d. Press the coil in the plug hole by hand as fa-

ras it will go.e. Turn the coil clockwise and screw it in, 5 to 6

turns would be adequate.f. Reins tall the coupler.

Do not strike on the coil with a hammer or thelike.

Before removing the spark plugs, blowaway any dirt accumulated in the spark plugwells with compressed air to prevent it fromfalling into the cylinders.

4. Check:spark plug typeIncorrect Change.

Spark plugstype (manufacturer)

CR10EK (NGK)

3-23

CHECKING THE SPARK PLUGS/CHECKING THE IGNITION TIMING

CHKADJ

13 Nm (1.3 mkg)

NOTE:

NOTE:

5. Check:electrodes 1Damage/wear Replace the spark plug.

insulator 2Abnormal 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. Measure:spark plug gap a(with a wire gauge)Out of specification Regap.

Spark plug gap0.6 0.7 mm

8. Install:spark plug

Before installing the spark plug, clean the sparkplug and gasket surface.

EB303050

CHECKING THE IGNITION TIMING

Prior to checking the ignition timing, check thewiring connections of the entire ignition system.Make sure that all connections are tight and freeof corrosion.

1. Remove:bottom cowlingRefer to “COWLINGS”.

rider seat fuel tankRefer to “SEATS” and “FUEL TANK”.

air filter caseRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

timing mark accessing screw 1

3-24

CHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSURE

CHKADJ

NOTE:

NOTE:

2. Install: timing light 1engine tachometer(onto the ignition coil of cylinder #1)

Timing light90890-03141


3. Check: ignition timing

a. Start the engine, warm it up for several min-utes, and then let it run at the specified en-gine idling speed.


b. Check that the mark a is within the requiredfiring range b on the pickup coil rotor.Incorrect firing range Check the ignitionsystem.

The ignition timing is not adjustable.

EB303060

MEASURING THE COMPRESSION PRES-SUREThe following procedure applies to all of the cyl-inders.

Insufficient compression pressure will result in aloss of performance.

1. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE”.

2. Start the engine, warm it up for several min-utes, and then stop it.


air filter caseheat protector plate ignition coilsRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

3-25

MEASURING THE COMPRESSION PRESSURECHKADJ

CAUTION:

WARNING

NOTE:

4. Remove:spark plug

Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders.

5. Install:compression gauge 1

Compression gauge90890-03081

Adapter90890-04136

6. Measure:compression pressureOut of specification Refer to steps (c) and(d).

Compression pressure (at sealevel)

Minimum1300 kPa (13.0 kg/cm 2,13.0 bar)

Standard1550 kPa (15.5 kg/cm 2,15.5 bar)

Maximum1600 kPa (16.0 kg/cm 2,16.0 bar)

a. Set the main switch to “ON”.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilizes.

To prevent sparking, ground all spark plugleads before cranking the engine.

The difference in compression pressure be-tween cylinders should not exceed 100 kPa (1kg/cm2, 1 bar).

3-26

MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL

CHKADJ

13 Nm (1.3 mkg)

NOTE:

c. If the compression pressure is above themaximum specification, check the cylinderhead, valve surfaces, and piston crown forcarbon deposits.Carbon deposits Eliminate.

d. If the compression pressure is below theminimum specification, squirt a few drops ofoil into the cylinder and measure again.

Refer to the following table.

Compression pressure(with oil applied into the cylinder)

Reading Diagnosis

Higher thanwithout oil

Piston wear ordamage Repair.

Same as withoutoil

Piston ring(-s),valve(-s), cylinderhead gasket orpiston possiblydefective Repair.

7. Install:spark plug

EB303070

CHECKING THE ENGINE OIL LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.Make sure that the motorcycle is upright.

2. Start the engine, let it idle for several min-utes, and then stop it.

3. Check:engine oil levelThe engine oil level should be between theminimum level mark a and maximum levelmark b .Below the minimum level mark Add therecommended engine oil to the proper level.

3-27

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

CHKADJ

CAUTION:

NOTE:

Recommended oilRefer to the chart for the engine oilgrade which is best suited for cer-tain atmospheric temperatures.API standard

SE or higher grade(Non-Friction modified)ACEA standard G4 or G5

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD c or higher and donot use oils labeled “ENERGY CONSERV-ING II” d or higher.

Do not allow foreign materials to enter thecrankcase.

4. Start the engine, warm it up for several min-utes, and then turn it off.

5. Check:engine oil level

Before checking the engine oil level, wait a fewminutes until the oil has settled.

EB303081

CHANGING THE ENGINE OIL1. Remove:bottom cowlingRefer to “COWLINGS”.


3. Place a container under the engine oil drainbolt.

4. Remove:engine oil filler cap 1engine oil drain bolt 2(along with the washer)

5. Drain:engine oil(completely from the crankcase)

3-28

CHANGING THE ENGINE OILCHKADJ

CAUTION:

43 Nm (4.3 mkg)

6. If the oil filter cartridge is also to be replaced,perform the following procedure.

a. Remove the oil filter cartridge 1 with an oilfilter wrench 2 .

Oil filter wrench90890-01426

b. Lubricate the O-ring 3 of the new oil filtercartridge with a thin coat of engine oil.

Make sure theat the O-ring 3 is positionedcorrectly in the groove of the oil filter car-tridge.

c. Tighten the new oil filter cartridge to specifi-cation with an oil filter wrench.

Oil filter cartridge17 Nm (1.7 mkg)

7. Check:engine oil drain bolt washerDamage Replace.

8. Install:engine oil drain bolt

9. Fill:crankcase(with the specified amount of the recom-mended engine oil)

QuantityTotal amount

3.5 LWithout oil filter cartridge re-placement

2.5 LWith oil filter cartridge replace-ment

2.7 L

10. Install:engine oil filler cap


12. Check:engine(for engine oil leaks)

3-29

CHANGING THE ENGINE OIL/MEASURING THE ENGINE OIL PRESSURE

CHKADJ

CAUTION:

WARNING

13. Check:engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL”.

14. Install:bottom cowlingRefer to “COWLINGS”.

EB303090

MEASURING THE ENGINE OIL PRESSURE1. Check:engine oil levelBelow the minimum level mark Add therecommended engine oil to the proper level.


When the engine is cold, the engine oil willhave a higher viscosity, causing the engineoil pressure to increase. Therefore, be sureto measure the engine oil pressure afterwarming up the engine.

3. Remove:oil gallery bolt 1

The engine, muffler and engine oil are ex-tremely hot.

4. Install:oil pressure gauge 1adapter 2

Oil pressure gauge90890-03153

Adapter90890-03139

5. Measure:engine oil pressure(at the following conditions)

Engine oil pressure240 kpa (2.4 kg/cm 2)

Engine speedApprox. 6000 r/min

Engine oil temperature96C

3-30

MEASURING THE ENGINE OIL PRESSURE/ADJUSTING THE CLUTCH CABLE FREE PLAY

CHKADJ

NOTE:

20 Nm (2.0 mkg)

a

b

NOTE:

c

d

Regarding the oil pressure as its own data mayfluctuate depending on the oil temperature andviscosity, the oil pressure may fluctuate whenmeasuring. The following data should be usedonly as a reference when measuring the engineoil pressure.

Out of specification Adjust.

Engine oil pressure Possible cause

Below specification

Faulty oil pumpClogged oil filterLeaking oil passapageBroken or damagedoil seal

Above specificationLeaking oil passageFaulty oil filterOil viscosity too high

6. Tighten the oil gallery bolt

EB303100

ADJUSTING THE CLUTCH CABLE FREEPLAY1. Measure:clutch cable free play aOut of specification Adjust.

Clutch cable free play (at the endof the clutch lever)

10 15 mm

2. Adjust:clutch cable free play

Handlebar sidea. Turn the adjusting bolt 1 in direction a or b

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play is in-creased.

Direction Clutch cable free play is de-creased.

If the specified clutch cable free play cannot beobtained on the handlebar side of the cable, usethe adjusting nut on the engine side.

Engine sidea. Loosen the locknut 2 .b. Turn the adjusting nut 3 in direction c or d

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play is in-creased.

Direction Clutch cable free play is de-creased.

c. Tighten the locknut.

3-31

CLEANING THE AIR FILTER ELEMENT/ADJUSTING THE CLUTCH CABLE FREE PLAY

CHKADJ

CAUTION:

NOTE:

EB303130

CLEANING THE AIR FILTER ELEMENT1. Remove: fuel tankRefer to “FUEL TANK”.

air filter case cover 1air filter element

2. Clean:air filter elementUse solvent to clean the air filter element. Af-ter cleaning the air filter element, remove thesolvent from the air filter element.

3. Apply the engine oil to the entire surface ofthe filter and remove the excess oil. The airfilter should be wet but not dripping.

4. Check:air filter elementDamage Replace.

5. Install:air filter elementair filter case cover

Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the air filter element will also affectthe carburetor tuning, leading to poor en-gine performance and possible overheat-ing.

When installing the air filter element into the airfilter case cover, make sure that their sealingsurfaces are aligned to prevent any air leaks.

6. Install: fuel tankRefer to “FUEL TANK”.

3-32

CHECKING THE CARBURETOR JOINTS/CHECKING THE FUEL HOSES AND FUEL FILTER/

CHKADJ

NOTE:

EB303171

CHECKING THE CARBURETOR JOINTSThe following procedure applies to all of the car-buretor joints and intake manifolds.1. Remove:carburetor assemblyRefer to “CARBURETORS” in chapter 6.

2. Check:carburetor joint 1Cracks/damage Replace.Refer to “CARBURETORS” in chapter 6.

3. Install:carburetor assemblyRefer to “CARBURETORS” in chapter 6.

EB303181

CHECKING THE FUEL HOSES AND FUELFILTERThe following procedure applies to all of the fuelhoses.1. Remove: fuel tankRefer to “FUEL TANK”.

2. Check: fuel hose 1Cracks/damage Replace.

fuel filter 2Contaminants/damage Replace.

Drain and flush the fuel tank if abrasive dam-age to any components of the fuel line is evi-dent.

The arrow mark on the fuel filter must point to-wards the fuel pump as shown.


3-33

CHECKING THE EXHAUST SYSTEM/CLEANING THE AIR INTAKE SYSTEM

CHKADJ

CAUTION:

EB303190

CHECKING THE CRANKCASE BREATHERHOSE1. Remove: fuel tankRefer to “FUEL TANK”.

2. Check:crankcase breather hose 1Cranks/damage Replace.Loose connection Connect properly.

Make sure that the crankcase breather hoseis routed correctly.


EAS00092

CLEANING THE AIR INTAKE SYSTEMThe following procedure applies to both air in-take system.1. Remove:side cowling inner coversside cowlings front cowling inner covers front cowling fuel tank

2. Loosen:clamps(on the inside of the front cowling)

3. Remove:air intake system air ducts 1

4. Clean:air intake system air ducts

a. Thoroughly flush out the air intake system airducts with clean water.

b. Hold the air intake system air ducts upsidedown to allow the water to drain out.

c. Repeat the flushing steps until the excesswater is clear and free of debris.

d. Place the air intake system air ducts in an up-right position to allow any remaining water todrain out of the lower drain tube.

e. Keep the air intake system air ducts uprightto allow it to dry sufficiently.

5. Install:air intake system air ducts fuel tank front cowling front cowling inner coversside cowlingsside cowlings inner covers

3-34

CHECKING THE CRANKCASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM

CHKADJ

CAUTION:

2. Check:crankcase breather hose 1Cracks/damage Replace.Loose connection Connect properly.

Make sure that the crankcase breather hoseis routed correctly.


EB303200

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes and gaskets.1. Remove: radiator assemblyRefer to “RADIATOR” in chapter 5.

2. Check:exhaust pipe 1muffler 2Cracks/damage Replace.

gasket 3Exhaust gas leaks Replace.

3. Measure: tightening torque

Exhaust pipe nut 420 Nm (2.0 mkg)

Muffler clamp bolt 520 Nm (2.0 mkg)

Exhaust pipe bolt 620 Nm (2.0 mkg)

Muffler bolt 738 Nm (3.8 mkg)

4. Install: radiator assemblyRefer to “RADIATOR” in chapter 5.

3-35

CHECKING THE COOLANT LEVEL/CHECKING THE COOLING SYSTEM

CHKADJ

NOTE:

CAUTION:

NOTE:

EB303220

CHECKING THE COOLANT LEVEL1. Stand the motorcycle on a level surface.


2. Check:coolant levelThe coolant level should be between themaximum level mark a and minimum levelmarks b .Below the minimum level mark Add therecommended coolant to the proper level.

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused instead of coolant, check and correctthe antifreeze concentration of the coolant.

Use only distilled water. Soft water may beused if distilled water is not available.


4. Check:coolant level

Before checking the coolant level, wait a fewminutes until it settles.

EB303230

CHECKING THE COOLING SYSTEM1. Remove:bottom cowlingside cowlingsRefer to “COWLINGS”.

2. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3oil cooler 4oil cooler inlet hose 5oil cooler outlet hose 6water pump outlet hose 7Cracks/damage Replace.Refer to “COOLING SYSTEM” in chapter 5.

3. Install:side cowlingsbottom cowlingRefer to “Cowlings”.

3-36

CHANGING THE COOLANTCHKADJ

NOTE:

WARNING

EB303240

CHANGING THE COOLANT1. Remove:bottom cowling left side cowlingRefer to “COWLINGS”.

reservoir hose clamps 12. Remove:coolant reservoir bolts 2coolant reservoir cap 3

When draining the coolant from the coolant res-ervoir, be sure to tilt the reservoir so that coolantcannot flow through the coolant reservoirbreather hose 4 .

3. Drain:coolant(from the coolant reservoir)

4. Install:coolant reservoir bolts reservoir cover

5. Remove: radiator cap 1

A hot radiator is under pressure. Therefore,do not remove the radiator cap when the en-gine is hot. Scalding hot fluid and steammay be blown out, which could cause seri-ous injury. When the engine has cooled,open the radiator cap as follows:Place a thick rag or a towel over the radiatorcap and slowly turn the radiator cap coun-terclockwise toward the detent to allow anyresidual pressure to escape. When the his-sing sound has stopped, turn the radiatorcap counterclockwise while pressing downon it and then remove it.

3-37


7 Nm (0.7 mkg)

WARNING

6. Remove:coolant drain bolt 1(along with the copper washer)

7. Drain:coolant

8. Check:coper washer 1coolant drain bolt 2Damage Replace

9. Install:coolant drain bolt

10. Fill:cooling system(with the specified amount of the recom-mended coolant)

Recommended antifreezeHigh-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Mixing ratio1:1 (antifreeze: water)

QuantityTotal amount

2.15 LCoolant reservoir capacity

0.44 L

Handling notes for coolantCoolant is potentially harmful and should behandled with special care.

If coolant splashes in your eyes, thorough-ly wash them with water and consult a doc-tor.

If coolant splashes on your clothes, quick-ly wash it away with water and then withsoap and water.

If coolant is swallowed, induce vomitingand get immediate medical attention.

3-38


CAUTION:

NOTE:

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused instead of coolant, check, and if nec-essary, correct the antifreeze concentra-tion of the coolant.

Use only distilled water. However, soft wa-ter may be used if distilled water is notavailable.

If coolant comes into contact with paintedsurfaces, immediately wash them with wa-ter.

Do not mix different types of antifreeze.

11. Install: radiator cap

12. Fill:coolant reservoir(with the recommended coolant to the maxi-mum level mark a )

13. Install:coolant reservoir cap


15. Check:coolant levelRefer to “CHECKING THE COOLANT LEV-EL”.

Before checking the coolant level, wait a fewminutes until the coolant has settled.

16. Install: left side cowlingbottom cowlingRefer to “COWLINGS”.

3-39

ADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR BRAKE

CHKADJ

NOTE:

a

a

WARNING

EB304001

CHASSISADJUSTING THE FRONT BRAKE1. Adjust:brake lever position(distance a from the throttle grip to thebrake lever)

a. While pushing the brake lever forward, turnthe adjusting dial 1 until the brake lever is inthe desired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the brake lever hold-er.

Position #1 Distance is the largest.

Position #5 Distance is the smallest.

After adjusting the brake lever position,make sure that the pin on the brake leverholder is firmly inserted in the hole in the ad-justing dial.

EB304010

ADJUSTING THE REAR BRAKE1. Measure:brake pedal position(distance a from the top of the brake pedalto the bottom of the rider footrest bracket boltcenter)Out of specification Adjust.

Brake pedal position (from the top of the brake pedal to the bottom of the rider footrest bracket bolt center)

4.3 9.3 mm

b : 11mm

3-40

ADJUSTING THE REAR BRAKECHKADJ

a

b

WARNING

WARNING

CAUTION:

2. Adjust:brake pedal position

a. Loosen the locknut 1 .b. Turn the adjusting bolt 2 in direction a or b

until the specified brake pedal position is ob-tained.

Direction Brake pedal is raised.

Direction Brake pedal is lowered.

After adjusting the brake pedal position,check that the end of the adjusting bolt c isvisible through the hole d .

c. Tighten the locknut 1 to specification.

Locknut16 Nm (1.6 mkg)

A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident.Therefore, check and, if necessary, bleedthe brake system.

After adjusting the brake pedal position,make sure that there is no brake drag.

3. Adjust: rear brake light switchRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”.

3-41

CHECKING THE BRAKE FLUID LEVELCHKADJ

A

NOTE:

WARNING

CAUTION:

NOTE:

EB304020

CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.


2. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.

Recommended brake fluidDOT 4

A Front brake

B Rear brake

Use only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing leakage andpoor brake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe brake fluid and could cause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

In order to ensure a correct reading of the brakefluid level, make sure that the top of the brakefluid reservoir is horizontal.

3-42

CHECKING THE BRAKE PADS/ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHKADJ

A

B

NOTE:

a

b

EB304032

CHECKING THE BRAKE PADSThe following procedure applies to all of thebrake pads.1. Operate the brake.2. Check: front brake pad rear brake padBrake pad wear limit aWear limit reached Replace the brakepads as a set.Refer to “FRONT AND REAR BRAKES” inchapter 7.

Brake pad wear limita 0.5 mm b 0.8 mm

A Front brake

B Rear brake

EB304050

ADJUSTING THE REAR BRAKE LIGHTSWITCH

The rear brake light switch is operated bymovement of the brake pedal.

The rear brake light switch is properly adjustedwhen the brake light comes on just before thebraking effect starts.

1. Check: rear brake light operation timingIncorrect Adjust.

2. Adjust: rear brake light operation timing

a. Hold the main body 1 of the rear brake lightswitch so that it does not rotate and turn theadjusting nut 2 in direction a or b until therear brake light comes on at the proper time.

Direction Brake light comes onsooner.

Direction Brake light comes onlater.

3-43

CHECKING THE BRAKE HOSES/BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHKADJ

WARNING

NOTE:

EB304062

CHECKING THE BRAKE HOSESThe following procedure applies to all of thebrake hoses and brake hose clamps.1. Check:brake hose 1Cracks/damage/wear Replace.

2. Check:brake hose clampLoose Tighten the clamp bolt.

3. Hold the motorcycle upright and apply thebrake several times.

4. Check:brake hoseBrake fluid leakage Replace the damagedhose.Refer to “FRONT AND REAR BRAKES” inchapter 7.

EB304072

BLEEDING THE HYDRAULIC BRAKE SYS-TEM

Bleed the hydraulic brake system whenev-er: the brake system was disassembled,a brake hose was loosened, disconnectedor replaced,

the brake fluid level is very low,brake operation is faulty.

Be careful not to spill any brake fluid or allowthe brake fluid reservoir to overflow.

When bleeding the hydraulic brake system,make sure that there is always enough brakefluid before applying the brake. Ignoring thisprecaution could allow air to enter the hydrau-lic brake system, considerably lengthening thebleeding procedure.

If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.

3-44

BLEEDING THE HYDRAULIC BRAKE SYSTEMCHKADJ

A

B

NOTE:

WARNING

5. Bleed:hydraulic brake system

a. Fill the brake fluid reservoir to the proper lev-el with the recommended brake fluid.

b. Install the brake fluid reservoir diaphragm.c. Connect a clear plastic hose 1 tightly to the

bleed screw 2 .

A Front brake

B Rear braked. Place the other end of the hose into a con-

tainer.e. Slowly apply the brake several times.f. Fully squeeze the brake lever or fully de-

press the brake pedal and hold it in position.g. Loosen the bleed screw.

Loosening the bleed screw will release thepressure and cause the brake lever to contactthe throttle grip or the brake pedal to fully ex-tend.

h. Tighten the bleed screw and then release thebrake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 mkg)

k. Fill the brake fluid reservoir to the proper lev-el with the recommended brake fluid.Refer to “CHECKING THE BRAKE FLUIDLEVEL”.

After bleeding the hydraulic brake system,check the brake operation.

3-45

ADJUSTING THE SHIFT PEDAL/ADJUSTING THE DRIVE CHAIN SLACK

CHKADJ

NOTE:

b

c

NOTE:

CAUTION:

WARNING

NOTE:

EB304081

ADJUSTING THE SHIFT PEDAL

The shift pedal position is determined by theinstalled.

1. Measure: incorrect Adjust.

The top of sift pedal should bealigned with the lower part of thebracket. (from the horizontal view)

2. Adjust: installed shift rod length

a. Loosen both locknuts 1 .b. Turn the shift rod 2 in direction b or c to

obtain the correct shift pedal position.

Direction Installed shift rod lengthincreases.

Direction Installed shift rod lengthdecreases.

c. Tighten both locknuts.d. Make sure that the installed shift rod length is

within specification.

EB304092

ADJUSTING THE DRIVE CHAIN SLACK

The drive chain slack must be checked at thetightest point on the chain.

A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip and damage the swin-garm or cause an accident. Therefore, keepthe drive chain slack within the specifiedlimits.

1. Stand the motorcycle on a level surface.

Securely support the motorcycle so thatthere is no danger of it falling over.

Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.

3-46

ADJUSTING THE DRIVE CHAIN SLACKCHKADJ

a

b

NOTE:

2. Rotate the rear wheel several times andcheck the drive chain to locate its tightestpoint.

3. Measure:drive chain slack aOut of specification Adjust.

Drive chain slack40 50 mm

4. Adjust:drive chain slack

a. Loosen the wheel axle nut 1 .b. Loosen both locknuts 2 .c. Turn both adjusting bolts 3 in direction a or

b until the specified drive chain slack is ob-tained.

Direction Drive chain slack isreduced.

Direction Drive chain slack isincreased.

To maintain the proper wheel alignment, adjustboth sides evenly.

d. Tighten both locknuts to specification.

Locknut16 Nm (1.6 mkg)

e. Tighten the wheel axle nut to specification.

Wheel axle nut150 Nm (15.0 mkg)

3-47

LUBRICATING THE DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEAD

CHKADJ

WARNING

NOTE:

EB304100

LUBRICATING THE DRIVE CHAINThe drive chain consists of many interactingparts. If the drive chain is not maintained prop-erly, it will wear out rapidly. Therefore, the drivechain should be serviced, especially when themotorcycle is used in dusty areas. This motor-cycle has a drive chain with small rubber O-rings between each side plate. Steam cleaning,high-pressure washing, certain solvents, andthe use of a coarse brush can damage these O-rings. Therefore, use only kerosine to clean thedrive chain. Wipe the drive chain dry and thor-oughly lubricate it with engine oil or chain lubri-cant that is suitable for O-ring chains. Do notuse any other lubricants on the drive chain sincethey may contain solvents that could damagethe O-rings.

Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains

EB304130

CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the motorcycle on a level surface.


Place the motorcycle on a suitable stand so thatthe front wheel is elevated.

2. Check:steering headGrasp the bottom of the front fork legs andgently rock the front fork.Looseness/binding Adjust the steeringhead.

3-48

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

NOTE:

3. Remove:upper bracket bolts 1 front brake fluid reservoir bolt 2

4. Loosen:upper bracket pinch bolts 1handlebar pinch bolts 2washer 3

5. Remove:handlebars(from the upper bracket)

6. Remove:steering stem nut 1washer 2upper bracket 3

7. Adjust:steering head

a. Remove the lock washer 1 , the upper ringnut 2 , and the washer 3 .

b. Loosen the lower ring nut 4 and then tightenit to specification with a ring nut wrench 5 .

Set the torque wrench at a right angle to thesteering nut wrench.

Steering nut wrench90890-01403

Lower ring nut (initial tightening torque)

17 Nm (1.7 mkg)

3-49

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

WARNING

NOTE:

115 Nm (11.5 mkg)

13 Nm (1.3 mkg)

13 Nm (1.3 mkg)

23 Nm (2.3 mkg)

NOTE:

c. Loosen the lower ring nut completely, thentighten it to specification.

Do not overtighten the lower ring nut.

Lower ring nut (final tightening torque)

9 Nm (0.9 mkg)

d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and check the upper andlower bearings.Refer to “STEERING HEAD” in chapter 7.

e. Install the washer 3 .f. Install the upper ring nut 2 .g. Finger tighten the upper ring nut 2 , then

align the slots of both ring nuts.If necessary, hold the lower ring nut andtighten the upper ring nut until their slots arealigned.

h. Install the lock washer 1 .

Make sure that the lock washer tabs a sit cor-rectly in the ring nut slots b .

8. Install:steering stem nut

upper bracket bolthandlebar pinch boltupper bracket pinch bolt

9. Measure:steering head tension(with the motorcycle still on the stand)

Make sure that all of the cables and wires areproperly routed.

a. Point the front wheel straight ahead.b. Install a plastic locking tie 1 loosely around

the end of the handlebar as shown.c. Hook a spring gauge 2 onto the plastic lock-

ing tie.

3-50

CHECKING AND ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK

CHKADJ

WARNING

d. Hold the spring gauge at a 90 angle fromthe handlebar, pull the spring gauge, and re-cord the measurement when the handlebarstarts to turn.

Steering head tension200 500 g

e. Repeat the above procedure on the oppositehandlebar.

f. If the steering head tension is out of specifi-cation (both handlebars should be withinspecification), remove the upper bracket andloosen or tighten the upper ring nut.

g. Reinstall the upper bracket and measure thesteering head tension again as describedabove.

h. Repeat the above procedure until the steer-ing head tension is within specification.

i. Grasp the bottom of the front fork legs andgently rock the front fork.Looseness or binding Adjust the steeringhead.

EB304141

CHECKING THE FRONT FORK1. Stand the motorcycle on a level surface.


2. Check: inner tube 1Damage/scratches Replace.

oil seal 2Oil leakage Replace.

3. Hold the motorcycle upright and apply thefront brake.

4. Check: front fork operationPush down hard on the handlebars severaltimes and check if the front fork reboundssmoothly.Rough movement Repair.Refer to “FRONT FORK” in chapter 7.

3-51

ADJUSTING THE FRONT FORK LEGSCHKADJ

WARNING

CAUTION:

a

b

EB304153

ADJUSTING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Always adjust both front fork legs evenly.Uneven adjustment can result in poor han-dling and loss of stability.


Spring preload

Grooves are provided to indicate the ad-justment position.

Never go beyond the maximum or mini-mum adjustment positions.

1. Adjust:spring preload

a. Turn the adjusting bolt 1 in direction a orb .

Direction Spring preload isincreased (suspension isharder).

Direction Spring preload isdecreased (suspension issofter).

HARD STD SOFT

1 2 3 4 5 6 7 8

3-52

ADJUSTING THE FRONT FORK LEGSCHKADJ

CAUTION:

a

b

CAUTION:

a

b

Rebound damping

Never go beyond the maximum or minimumadjustment positions.

1. Adjust: rebound damping

a. Turn the adjusting screw 1 in direction a orb .

DirectionRebound damping isincreased (suspension isharder).

DirectionRebound damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 12 clicks out*Standard: 6 clicks out*Maximum: 1 clicks out*

* from the fully turned-in position

Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 11 clicks out*Standard: 6 clicks out*Maximum: 1 clicks out*


3-53

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

WARNING

CAUTION:

NOTE:

a

b

EB304162

ADJUSTING THE REAR SHOCK ABSORB-ER ASSEMBLY


Spring preload


1. Adjust:spring preload

Adjust the spring preload with the specialwrench and extension bar included in the own-er’s tool kit.

a. Turn the adjusting ring 1 in direction a orb .

b. Align the desired position on the adjustingring with the position indicator 2 .

Direction Spring preload isincreased (suspension isharder).

Direction Spring preload isdecreased (suspension issofter).

Adjusting positionsMinimum: 1Standard: 4Maximum: 9

3-54

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

CAUTION:

a

b

CAUTION:

a

b

Rebound damping


1. Adjust: rebound damping


DirectionRebound damping isincreased (suspension isharder).

DirectionRebound damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 25 clicks out *

Standard: 9 clicks out *

Maximum: 1 click out *


Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 13 clicks out *

Standard: 7 clicks out *

Maximum: 1 click out *


3-55

CHECKING THE TIRESCHKADJ

WARNING

WARNING

EB304170

CHECKING THE TIRESThe following procedure applies to both of thetires.1. Measure: tire pressureOut of specification Regulate.

The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.

The tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated ridingspeed.

Operation of an overloaded motorcyclecould cause tire damage, an accident or aninjury.

NEVER OVERLOAD THE MOTORCYCLE.

Basic weight(with oiland a fullfuel tank)

188 kg

Maximumload* 187 kg

Cold tirepressure Front Rear

Up to 90 kgload*

250 kPa(2.5 kgf/cm 2,

2.5 bar)

250 kPa(2.5 kgf/cm 2,

2.5 bar)

90 kg max-imum load*

250 kPa(2.5 kgf/cm 2,

2.5 bar)

290 kPa(2.9 kgf/cm 2,

2.9 bar)

High-speedriding

250 kPa(2.5 kgf/cm 2,

2.5 bar)

250 kPa(2.5 kgf/cm 2,

2.5 bar)

* total of cargo, rider, passenger and accesso-ries

It is dangerous to ride with a worn-out tire.When the tire tread reaches the wear limit,replace the tire immediately.

3-56

CHECKING THE TIRESCHKADJ

BA

WARNING

2. Check: tire surfaces

Damage/wear Replace the tire.

Minimum tire tread depth1.6 mm

1 Tire tread depth2 Side wall3 Wear indicator

Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire failureand personal injury from sudden deflation.

When using a tube tire, be sure to install thecorrect tube.

Always replace a new tube tire and a newtube as a set.

To avoid pinching the tube, make sure thatthe wheel rim band and tube are centered inthe wheel groove.

Patching a punctured tube is not recom-mended. If it is absolutely necessary to do so,use great care and replace the tube as soonas possible with a good quality replacement.

A Tire B Wheel

Tube wheel Tube tire only

Tubeless wheel Tube or tubelesstire

After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. The front and rear tiresshould always be by the same manufacturerand of the same design. No guarantee con-cerning handling characteristics can be giv-en if a tire combination other than one ap-proved by Yamaha is used on thismotorcycle.

Front tire

Manufacturer Size Model

BRIDGESTONE 120/60 ZR17(55W) BT56FE

DUNLOP 120/60 ZR17(55W) D207FJ

3-57

CHECKING THE TIRES/CHECKING THE WHEELSCHKADJ

WARNING

NOTE:

WARNING

NOTE:

Rear tire

Manufacturer Size Model

BRIDGESTONE 180/55 ZR17(73W) BT56RE

DUNLOP 180/55 ZR17(73W) D207N

After mounting a new tire, ride conserva-tively for a while to become accustomed tothe “feel” of the new tire and to allow the tireto seat itself properly in the rim. Failure to doso could lead to an accident with possibleinjury to the rider or damage to the motor-cycle.

For tires with a direction of rotation mark 1 : Install the tire with the mark pointing in thedirection of wheel rotation.

Align the mark 2 with the valve installationpoint.

EB304180

CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Check:wheelDamage/out-of-round Replace.

Never attempt to make any repairs to thewheel.

After a tire or wheel has been changed or re-placed, always balance the wheel.

3-58

CHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/

LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSIONCHKADJ

WARNING

NOTE:

EB304200

CHECKING AND LUBRICATING THECABLESThe following procedure applies to all of thecable sheaths and cables.

Damaged cable sheaths may cause thecable to corrode and interfere with its move-ment. Replace damaged cable sheaths andcables as soon as possible.

1. Check:cable sheathDamage Replace.

2. Check:cable operationRough movement Lubricate.

Recommended lubricantEngine oil or a suitable cable lubricant

Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suit-able lubing device.

EB304210

LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.

Recommended lubricantLithium soap base grease

EB304220

LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.


EB304240

LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metalmoving parts of the rear suspension.


3-59

CHECKING AND CHARGING THE BATTERYCHKADJ

WARNING

CAUTION:

EB305020

ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY

Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures:Wear protective eye gear when handling orworking near batteries.

Charge batteries in a well-ventilated area.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes).

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.

FIRST AID IN CASE OF BODILY CONTACT:EXTERNALSkin – Wash with waterEyes – Flush with water for 15 minutes andget immediate medical attention.

INTERNALDrink large quantities of water or milk fol-lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medicalattention.

This is a sealed battery. Never remove thesealing caps because the balance betweencells will not be maintained and batteryperformance will deteriorate.

Charging time, charging amperage andcharging voltage for an MF battery are dif-ferent from those of conventional batter-ies. The MF battery should be charged asexplained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when charg-ing the battery.

3-60

Relationship between the open-circuit voltageand the charging time at 20C

Ope

n-ci

rcui

t vol

tage

(V

)

These values vary with the temperature, the condition ofthe battery plates, and the electrolyte level.

13.0

12.5

12.0

11.5

5 6.5 10Charging time (hours)


NOTE:

CAUTION:

NOTE:

Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the electrolyte.Therefore, the charge of the battery has to bechecked by measuring the voltage at the batteryterminals.

1. Remove: rider seatRefer to “SEATS”.

2. Disconnect:battery leads(from the battery terminals)

First, disconnect the negative lead 2 , thenthe positive lead 1 .

3. Remove:battery

4. Measure:battery charge

a. Connect a digital voltmeter to the battery ter-minals.

Tester positive probe battery positiveterminalTester negative probe battery nega-tive terminal

The charge state of an MF battery can bechecked by measuring its open-circuit voltage(i.e., the voltage when the positive terminal isdisconnected).

No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown inthe charts and the following example.

ExampleOpen-circuit voltage = 12.0 VCharging time = 6.5 hoursCharge of the battery = 20 30%

3-61


ChargingAmbient temperature 20C

Ope

n-ci

rcui

t vol

tage

(V

)

Check the open-circuitvoltage.

Time (minutes)

Ambienttemperature20C

Ope

n-ci

rcui

t vol

tage

(V

)

Charging condition of the battery (%)

WARNING

CAUTION:

5. Charge:battery(refer to the appropriate charging method il-lustration)

Do not quick charge a battery.

Never remove the MF battery sealing caps.Do not use a high-rate battery chargersince it forces a high-amperage currentinto the battery quickly and can cause bat-tery overheating and battery plate damage.

If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

When charging a battery, be sure to re-move it from the motorcycle. (If charginghas to be done with the battery mounted onthe motorcycle, disconnect the negativelead from the battery terminal.)

To reduce the chance of sparks, do notplug in the battery charger until the batterycharger leads are connected to the battery.

Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.

Make sure that the battery charger leadclips are in full contact with the battery ter-minal and that they are not shorted. A cor-roded battery charger lead clip may gener-ate heat in the contact area and a weak clipspring may cause sparks.

If the battery becomes hot to the touch atany time during the charging process, dis-connect the battery charger and let the bat-tery cool before reconnecting it. Hot batter-ies can explode!

As shown in the following illustration, theopen-circuit voltage of an MF battery stabi-lizes about 30 minutes after charging hasbeen completed. Therefore, wait 30 min-utes after charging is completed beforemeasuring the open-circuit voltage.

3-62


Measure the open-circuitvoltage prior to charging.

Connect a charger and am-meter to the battery andstart charging.

Is the amperage higherthan the standard chargingamperage written on thebattery?

Adjust the charging voltage to20 25 V.

Adjust the voltage to obtain thestandard charging amperage.

Monitor the amperage for 3 5 minutes. Is the standardcharging amperage exceed-ed?

Set the timer to the chargingtime determined by the open-circuit voltage.Refer to “CHECKING ANDCHARGING THE BATTERY”.

If the amperage does notexceed the standard charg-ing amperage after 5 min-utes, replace the battery.

If the required charging time exceeds 5 hours, it is advisable to checkthe charging amperage after 5 hours. If there is any change in the am-perage, readjust the voltage to obtain the standard charging amper-age.

Leave the battery unused for more than 30 minutes before measur-ing its open-circuit voltage.12.8 V Charging is complete.12.0 12.7 V Recharging is required.Under 12.0 V Replace the battery.

YES NO

YES

NO

NOTE:Leave the battery unused for more than30 minutes before measuring its open-circuit voltage.

NOTE:Set the charging voltage to 16 17 V.(If the charging voltage is lower, charg-ing will be insufficient, if it is higher, thebattery will be over-charged.)

ChargerAmmeter

Charging method using a variable-voltage charger

3-63


CAUTION:

Measure the open-circuitvoltage prior to charging.

Connect a charger and am-meter to the battery andstart charging.

NOTE:Leave the battery unused for more than30 minutes before measuring its open-circuit voltage.

Is the amperage higherthan the standard chargingamperage written on thebattery?

Charge the battery until the chargingvoltage reaches 15 V.

This type of battery charger cannotcharge an MF battery. A variable-voltage charger is recommended.

Leave the battery unused for morethan 30 minutes before measuring itsopen-circuit voltage.12.8 V Charging is complete.12.0 12.7 V Recharging is re-quired.Under 12.0 V Replace the battery.

NOTE:Set the charging time to a maximum of20 hours.

YES NO

Constant amperage chargers are notsuitable for charging MF batteries.

Voltmeter

Charger

Ammeter

Charging method using a constant-voltage charger

3-64

CHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES

CHKADJ

CAUTION:

CAUTION:

NOTE:

6. Install:battery

7. Connect:battery leads(to the battery terminals)

First, connect the positive lead 1 , then thenegative lead 2 .

8. Check:battery terminalsDirt Clean with a wire brush.Loose connection Connect properly.

9. Lubricate:battery terminals

Recommended lubricantDielectric grease

10. Install: rider seatRefer to “SEATS”.

EB305040

CHECKING THE FUSESThe following procedure applies to all of thefuses.

To avoid a short circuit, always set the mainswitch to “OFF” when checking or replacinga fuse.

1. Remove: rider seatRefer to “SEATS”.

2. Check:continuity

a. Connect the pocket tester to the fuse andcheck the continuity.

Set the pocket tester selector to “Ω 1”.


b. If the pocket tester indicates “∞”, replace thefuse.

3-65

CHECKING THE FUSESCHKADJ

WARNING

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 verify if the

electrical circuit is operational.d. If the fuse immediately blows again, check

the electrical circuit.

Item Amperage Q’ty

Main fuse 30 A 1

Headlightfuse

20 A 1

Signalingsystem fuse

20 A 1

Ignitionfuse

15 A 1

Radiatorfan motor

fuse7.5 A 1

Backup fuse(odometer)

7.5 A 1

Never use a fuse with an amperage otherthan that specified. Improvising or using afuse with the wrong amperage rating maycause extensive damage to the electricalsystem, cause the lighting and ignition sys-tems to malfunction and could possiblycause a fire.

4. Install: rider seatRefer to “SEATS”.

3-66

REPLACING THE HEADLIGHT BULBSCHKADJ

WARNING

CAUTION:

EB305051

REPLACING THE HEADLIGHT BULBSThe following procedure applies to both of theheadlight bulbs.1. Disconnect:headlight coupler 1headlight bulb holder cover 2

2. Detach:headlight bulb holder 1

3. Remove:headlight bulb 2

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

4. Install:headlight bulb NewSecure the new headlight bulb with the head-light bulb holder.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

5. Attach:headlight bulb holder

6. Install:headlight bulb holder cover

7. Connect:headlight coupler

3-67

ADJUSTING THE HEADLIGHT BEAMSCHKADJ

a

b

a

b

a

b

EB305061

ADJUSTING THE HEADLIGHT BEAMSThe following procedure applies to both of theheadlights.1. Adjust:headlight beam (vertically)


Direction Headlight beams is raised.

Direction Headlight beams is low-ered.

2. Adjust:headlight beam (horizontally)

a. Turn the adjusting knob 1 in direction a orb .

Left headlight

Direction Headlight beam movesto the right.

Direction Headlight beams movesto the left.

Right headlight

Direction Headlight beam movesto the left.

Direction Headlight beam movesto the right.

ENG

CLUTCH 4-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CLUTCH 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRICTION PLATES 4-48. . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH PLATES 4-49. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH SPRINGS 4-49. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH HOUSING 4-49. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CLUTCH BOSS 4-50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PRESSURE PLATE 4-50. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PULL LEVER SHAFT AND PULL ROD 4-50. . . . . . . . . INSTALLING THE CLUTCH 4-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL PAN AND OIL PUMP 4-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE OIL PAN 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL PUMP 4-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELIEF VALVE 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 4-57. . . . . . . . . . . CHECKING THE OIL STRAINER 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL NOZZLES 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE OIL PUMP 4-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PUMP 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL STRAINER 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL PAN 4-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRANKCASE 4-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL BAFFLE PLATES AND OIL FILTER BOLT 4-61. . . . . . . . . . . . . . . . . . DISASSEMBLING THE CRANKCASE 4-62. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKCASE 4-63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BEARINGS AND OIL SEALS 4-63. . . . . . . . . . . . . . . . . CHECKING THE SPROCKETS AND CHAINS 4-63. . . . . . . . . . . . . . . . . . ASSEMBLING THE CRANKCASE 4-64. . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONNECTING RODS AND PISTONS 4-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CONNECTING RODS AND PISTONS 4-68. . . . . . . . . CHECKING THE CYLINDERS AND PISTONS 4-69. . . . . . . . . . . . . . . . . . CHECKING THE PISTON RINGS 4-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE PISTON PINS 4-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BIG END BEARINGS 4-72. . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE PISTONS AND CONNECTING RODS 4-74. . . . . . . .

CRANKSHAFT 4-78. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE CRANKSHAFT 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT 4-79. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CRANKSHAFT JOURNAL BEARINGS 4-79. . . . . . . . . INSTALLING THE CRANKSHAFT 4-82. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION 4-83. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE TRANSMISSION 4-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT FORKS 4-89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT DRUM ASSEMBLY 4-90. . . . . . . . . . . . . . . . . . . . CHECKING THE TRANSMISSION 4-90. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE TRANSMISSION 4-91. . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1


1234567

Removing the drive sprocket Reserve tankLocknutShift rodShift armDrive sprocket coverNutLock washerDrive sprocket

2111111

Remove the parts in the order listed.Refer to “CHANGING THE COOLANT”

For installation reverse the removeprocedure.

10 Nm (1.0 mkg)

70 Nm (7.0 mkg)

ENGINE ENG

EAS00190

OVERHAULING THE ENGINEENGINEDRIVE SPROCKET

4-2

ENGINE ENG


123

Removing the exhaust assemblyBottom cowling and side cowlingsCoolant

Radiator assemblyMufflerExhaust pipe assemblyExhaust pipe gasket

114

Remove the parts in the order listed.Refer to “COWLINGS” in chapter 3Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Refer to “RADIATOR” in chapter 5.


20 Nm (2.0 mkg)

20 Nm (2.0 mkg)

20 Nm (2.0 mkg)

38 Nm (3.8 mkg)

EXHAUST ASSEMBLY

4-3

ENGINE ENG


Disconnecting the leads and hosesFuel tankAir filter case

Carburetor assembly and jointsEngine oil and oil filter cartridge

Oil cooler

Disconnect the parts in the order listed.Refer to “FUEL TANK” in chapter 3.Refer to “AIR FILTER CASE AND IGNITION COILS” in chapter 3.Refer to “CARBURETORS” in chapter 6.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “OIL COOLER” in chapter 5.

LEADS AND HOSES

4-4

ENGINE ENG


12

345678

Battery negative leadBattery positive lead

Startor coil assembly couplerPickup coil couplerEngine earthClutch wire and holderCrankcase breather hoseSeparator

11

111111

First, disconect the negative lead, thenthe positive lead.

CAUTION:

For connecting reverse the discomectingprocedure.

4-5

ENGINE ENG

55 Nm (5.5 mkg)

38 Nm (3.8 mkg)

24 Nm (2.4 mkg)


1234567

Removing the engine

Pinch boltsButton head boltsCollarsFront mounting boltsCollarsRear mounting boltsEngine mounting adjust bolts

4222222

Remove The Parts In The Order Listed.

For Installation, Reverse The RemovalProcedure.

NOTE:

Use the point shaft wrench to loosen the engine mounting adjust bolt.

NOTE:

Place a suitable stand under the frame andengine.

Refer to “INSTALLING THE ENGINE”.

24 Nm (2.4 mkg)

45 Nm (4.5 mkg)

55 Nm (5.5 mkg)

7 Nm (0.7 mkg)

13 Nm (1.3 mkg)

ENGINE

4-6

ENGINE ENG

NOTE:

47 Nm (4.7mkg)

55 Nm (5.5 mkg)

39 Nm (3.9 mkg)

24 Nm (2.4 mkg)

13 Nm (1.3 mkg)

NOTE:

70Nm (7.0 mkg)

10 Nm (1.0 mkg)

NOTE:

10 Nm (1.0 mkg)

NOTE:

EAS00192

INSTALLING THE ENGINE1. Install:engine mounting adjust bolts 1 rear mounting bolts 2self-locking nuts 3collars 4 front mounting bolts 5collars 6button head bolts 7pinch bolts 8

Lubricate the rear mounting bolt threads withlithium soap base grease.

Do not fully tighten the nuts and bolts.

2. Tighten:self-locking nut front mounting boltsbutton head boltpinch bolt M8

M6engine adjusting bolts

Use the pivot shaft wrench 1 to tighten the en-gine mounting adjust bolt to finger tightness.

Pivot shaft wrench90890-01471

3. Install:drive sprocket

4. Install:drive sprocket cover

Refer to “CABLE ROUTING” in chapter 2.

5. Install:shift arm 1

Align the punch mark a in the shift shaft withthe slot in the shift arm.

4-7

CAMSHAFTS ENG


1234

Removing the cylinder head coverCarburetor assemblyRadiator assemblySpark plugsCylinder head coverCylinder head cover gasketTiming chain guide (top side)

4111

Remove the parts in the order listed.Refer to “CARBURETORS” in chapter 6.Refer to “RADIATOR” in chapter 5.


10 Nm (1.0 mkg)

13 Nm (1.3 mkg)

EAS00194

CAMSHAFTSCYLINDER HEAD COVER

4-8

CAMSHAFTS ENG

24 Nm (2.4 mkg)


12345

678

Removing the camshaftsPickup coil rotor cover

Timing chain tensionerTiming chain tensioner gasketCamshaft capCamshaft cap gasketDowel pin

Intake camshaftExahust camshaftTiming chain guide (exhaust side)

11142

111

Remove the parts in the order listed.Refer to “PICKUP COIL AND PICK UPCOIL COVER”.

During removal, the dowel pins may stillbe connected to the camshaft cap.

NOTE:

12 Nm (1.2 mkg)

10 Nm (1.0 mkg) 10 Nm (1.0 mkg)

Refer to “REMOVING/INSTALLINGTHE CAMSHAFTS”.

Refer to “REMOVING/INSTALLINGTHE CAMSHAFT”.

EAS00196

CAMSHAFTS

4-9

CAMSHAFTS ENG


9101112

Intake camshaft sproketExhaust camshaft sproketPinTiming chain guide (intake side)

1111


Refer to “INSTALLING THECAMSHAFTS”.

10 Nm (1.0 mkg)

24 Nm (2.4 mkg)

10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

4-10

CAMSHAFTS ENG

NOTE:

CAUTION:

NOTE:

EAS00198

REMOVING THE CAMSHAFTS1. Align:TDC mark on the pickup coil rotor (with thecrankcase mating surface)


sion stroke, align the mark a on the pickupcoil rotor with the crankcase mating surfaceb .

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

2. Remove: timing chain tensioner

3. Remove:camshaft capdowel pins

To prevent damage to the cylinder head,camshafts or camshaft cap, loosen the cam-shaft cap bolts in stages and in a crisscrosspattern, working from the outside in.

4. Remove: intake camshaft 1exhaust camshaft 2

To prevent the timing chain from falling into thecrankcase, fasten it with a wire 3 .

5. Remove: timing chain guide (exhaust side)

4-11

CAMSHAFTS ENG

EAS00204

CHECKING THE CAMSHAFTS1. Check:camshaft lobesBlue discoloration/pitting/scratches Re-place the camshaft.

2. Measure:camshaft lobe dimensions a and bOut of specification Replace the cam-shaft.

Camshaft lobe dimensions limitIntake camshaft a 33.0 mm b 25.09 mmExhaust camshaft a 32.50 mm b 25.02 mm

3. Measure:camshaft runoutOut of specification Replace.

Max. camshaft runout0.06 mm

4. Measure:camshaft-journal-to-camshaft-cap clear-anceOut of specification Measure the cam-shaft journal diameter.

Camshaft-journal-to-camshaftcapclearance

0.020 0.054 mm <Limit>: 0.08 mm

a. Install the camshaft into the cylinder head(without the dowel pins and camshaft caps).

b. Position a strip of Plastigauge 1 onto thecamshaft journal as shown.

c. Install the dowel pins and camshaft caps.

4-12

CAMSHAFTS ENG

NOTE:Tighten the camshaft cap bolts in stages and ina crisscross pattern, working from the innercaps out.

Do not turn the camshaft when measuring thecamshaft-journal-to-camshaft-cap clearancewith the Plastigauge .


d. Remove the camshaft caps and then mea-sure the width of the Plastigauge 1 .

5. Measure:camshaft journal diameter aOut of specification Replace the cam-shaft.Within specification Replace the cylinderhead and the camshaft caps as a set.

Camshaft journal diameter22.967 22.980 mm

EAS00208

CHECKING THE CAMSHAFT SPROCKETS,AND TIMING CHAIN GUIDESThe following procedure applies to all of thecamshaft sprockets and timing chain guides.

4-13

CAMSHAFTS ENG

NOTE:

1. Check:camshaft sprocketMore than 1/4 tooth wear a Replace thecamshaft sprockets and the timing chain as aset.

a 1/4 tooth

b Correct

1 Timing chain roller

2 Camshaft sprocket

2. Check: timing chain guide (exhaust side) 1 timing chain guide (intake side) 2 timing chain guide (top side) 3Damage/wear Replace the defectivepart(-s).

CHECKING THE TIMING CHAIN TENSIONER1. Check: timing chain tensionerCracks/damage/rough movement Re-place.

a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.

While pressing the timing chain tensioner rod,wind it clockwise with a thin screwdriver 1 untilit stops.

b. Remove the screwdriver and slowly releasethe timing chain tensioner rod.

c. Make sure that the timing chain tensioner rodcomes out of the timing chain tensionerhousing smoothly. If there is rough move-ment, replace the timing chain tensioner.

4-14

CAMSHAFTS ENG

24 Nm (2.4 mkg)

24 Nm (2.4 mkg)

NOTE:

NOTE:

CAUTION:

INSTALLING THE CAMSHAFTS1. Install: timing chain guide (intake side) timing chain guide (exhaust side)

2. Install: intake camshaft sprocket

exhaust camshaft sprocket

Cam sprocket timing mark is outside and alignthe cam sprocket hole to camshaft hole.

3. Install:exhaust camshaft 3 intake camshaft 2camshaft cap gasketcamshaft cap

The brim 1 of intake camshaft is not pro-cessed.The groove is processed around the brim 1 ofexhaust cameshaft as illustration.


sion stroke, align the a mark on the pickupcoil rotor with the crankcase mating surfaceb .

c. Install the timing chain onto both camshaftsprockets and then install the camshaftsprockets onto the camshafts.

Do not turn the crankshaft when installingthe camshaft to avoid damage or impropervalve timing.

d. Install the exhaust and intake camshaft cap.


4-15

CAMSHAFTS ENG

NOTE:

WARNING

NOTE:

Make sure that the camshaft sprocket timingmarks c are aligned with the cylinder headedge dOut of alignment Reinstall.

e. Remove the wire from the timing chain.

4. Install: timing chain tensioner

a. Lightly press the timing chain tensioner rodinto the timing chain tensioner housing byhand.

b. While pressing the timing chain tensionerrod, wind it clockwise with a thin screwdriver1 until if stops.

C. With the screwdriver still inserted into thetiming chain tensioner, install the timingchain tensioner 2 , gasket, and float cham-ber air vent hose holder 3 onto the cylinderblock. Then, tighten the timing chain tension-er bolts 4 to the specified torque.

Always use a new gasket.

The “UP” mark on the timing chain tensionershould face up.

Timing chain tensioner bolt12 Nm (1.2 mkg)

d. Remove the screwdriver, make sure that thetiming chain tensioner rod releases, andtighten the cap bolt to the specified torque.

Cap bolt10 Nm (1.0 mkg)

5. Turn:crankshaft (several turns counterclockwise)

4-16

CAMSHAFTS ENG

NOTE:

6. Check:TDC mark aMake sure that the TDC mark is aligned withthe crankcase mating surface b .

camshaft sprocket timing mark cMake sure that the camshaft sprocket timingmark is aligned with the cylinder head edgedOut of alignment Adjust.Refer to the installation steps above.

7. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE” in chapter 3.

8. Install:cylinder head cover gasketcylinder head cover

Apply bond TB1541 onto the mating surfacesof the cylinder head cover and cylinder headcover gasket.

Apply bond 1215B onto the mating surfaces ofthe cylinder head cover gasket and cylinderhead.

Tighten the cylinder head cover bolts in stagesand in a crisscross pattern.

4-17

CYLINDER HEAD ENG


1

23

Removing the cylinder headIntake and exhaust camshaftsWater hoseTemp senser leadFront mounting boltCylinder head

Cylinder head gasketDowel pin

1

12

Remove the parts in the order listed.Refer to “CAMSHAFTS”.DisconnectDisconnectRefer to “ENGINE”.Refer to “REMOVING/INSTALLING THECYLINDER HEAD”.


10 Nm (1.0 mkg)

51 Nm (5.1 mkg)

EAS00220

CYLINDER HEAD

4-18

CYLINDER HEAD ENG

NOTE:

NOTE:

EAS00223

REMOVING THE CYLINDER HEAD1. Remove:cylinder head boltscylinder head

Loosen each bolt and nut 1/2 of a turn at a time,in stages and in a crisscross pattern. After all ofthe bolts and nuts are fully loosened, removethem.

EAS00229

CHECKING THE CYLINDER HEAD1. Eliminate:combustion chamber carbon deposits (witha rounded scraper)

Do not use a sharp instrument to avoid damag-ing or scratching:spark plug bore threadsvalve seats

2. Check:cylinder headDamage/scratches Replace.

cylinder head water jacketMineral deposits/rust Eliminate.

3. Measure:cylinder head warpageOut of specification Resurface the cylin-der head.

Max. cylinder head warpage0.05 mm

a. Place a straightedge 1 and a thicknessgauge 2 across the cylinder head.

b. Measure the warpage.c. If the limited in exceeded, resurface the cyl-

inder head as follows.

4-19

CYLINDER HEAD ENG

NOTE:

51 Nm (5.1 mkg)

10 Nm (1.0 mkg)

NOTE:

d. Place a 400 600 grit wet sandpaper on thesurface plate and resurface the cylinderhead using a figure-eight sanding pattern.

To ensure an even surface, rotate the cylinderhead several times.

EAS00223

INSTALLING THE CYLINDER HEAD1. Install:cylinder head gasketcylinder headcylinder headbolt

(M10) (M6)

Lubricate the cylinder head nuts with engineoil.

Tighten the cylinder head nuts and bolts in twostages and in a crisscross pattern.

4-20

VALVES AND VALVE SPRINGS ENG


123456789

10

Removing the valves and valve springsCylinder headIntake valve lifterIntake valve padIntake valve cotterIntake valve upper spring seatIntake valve spring outerIntake valve spring innerIntake valve oil sealIntake valve lower spring seatIntake valveIntake valve guide

88

168888888


Refer to “CYLINDER HEAD”.

Refer to “REMOVING/INSTALLINGTHE VALVES”.

EAS00236

VALVES AND VALVE SPRINGS

4-21



111213141516171819

Exhaust valve lifterExhaust valve padExhaust valve cotterExhaust valve upper spring seatExhaust valve springExhaust valve oil sealExhaust valve lower spring seatExhaust valveExhaust valve guide

88

16888888


Refer to “REMOVING/INSTALLING THEVALVES”.

4-22


NOTE:

NOTE:

NOTE:

EAS00237

REMOVING THE VALVESThe following procedure applies to all of thevalves and related components.

Before removing the internal parts of the cylin-der head (e.g., valves, valve springs, valveseats), make sure that the valves properly seal.

1. Remove:valve lifter 1valve pad 2

Make a note of the position of each valve lifterand valve pad so that they can be reinstalled intheir original place.

2. Check:valve(for leakage)Leakage at the valve seat Check the valveface, valve seat, and valve seat width.Refer to “CHECKING THE VALVE SEATS”.

a. Pour a clean solvent a into the intake andexhaust ports.

b. Check that the valves properly seal.

There should be no leakage at the valve seat1 .

4-23


NOTE:

NOTE:

3. Remove:valve cotters 1

Remove the valve cotters by compressing thevalve spring with the valve spring compressor2 and attachment 3 .

Valve spring compressor90890-04019

Attachment90890-04114

4. Remove:upper spring seat 1valve spring outer 2valve spring inner (intake only) 3valve 4oil seal 5 lower spring seat 6

Identify the position of each part very carefullyso that it can be reinstalled in its original place.

EAS00239

CHECKING THE VALVES AND VALVEGUIDESThe following procedure applies to all of thevalves and valve guides.1. Measure:valve-stem-to-valve-guide clearance

Valve-stem-to-valve-guide clearance =Valve guide inside diameter a –Valve stem diameter b

Out of specification Replace the valveguide.

Valve-stem-to-valve-guide clea-rance

Intake 0.010 0.037 mm<Limit> : 0.08 mmExhaust 0.025 0.052 mm<Limit>: 0.1 mm

4-24


NOTE:

NOTE:

2. Replace:valve guide

To ease valve guide removal and installation,and to maintain the correct fit, heat the cylinderhead to 100C (212C) in an oven.

a. Remove the valve guide with a valve guideremover 1 .

b. Install the new valve guide with the valveguide installer 2 and valve guide remover1 .

c. After installing the valve guide, bore thevalve guide with a valve guide reamer 3 toobtain the proper valve-stem-to-valve-guideclearance.

After replacing the valve guide, reface the valveseat .

Valve guide remover Intake (4.0 mm),Exhaust (4.0 mm) 90890-04111

Valve guide installer Intake (4.0 mm),

Exhaust (4.0 mm) 90890-04112

Valve guide reamer Intake and Exhaust 90890-04113

3. Eliminate:carbon deposits(from the valve face and valve seat)

4. Check:valve facePitting/wear Grind the valve face.

valve stem endMushroom shape or diameter larger than thebody of the valve stem Replace the valve.

4-25


NOTE:

5. Measure:valve margin thickness aOut of specification Replace the valve.

Valve margin thickness0.6 mm 0.8 mm<LIMIT>: 0.5mm

6. Measure:valve stem runoutOut of specification Replace the valve.

When installing a new valve, always replacethe valve guide.

If the valve is removed or replaced, always re-place the oil seal.

Valve stem runout0.04 mm

EAS00240

CHECKING THE VALVE SEATSThe following procedure applies to all of thevalves and valve seats.1. Eliminate:carbon deposits(from the valve face and valve seat)

2. Check:valve seatPitting/wear Replace the cylinder head.

3. Measure:valve seat width aOut of specification Replace the cylinderhead.

Valve seat widthIntake: 0.9 1.1 mm<Limit>: 1.6 mm

4-26


NOTE:

NOTE:

CAUTION:

NOTE:

a. Apply Mechanic’s blueing dye (Dykem) bonto 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 impres-sion.

d. Measure the valve seat width.

Where the valve seat and valve face contactedone another, the blueing will have been re-moved.

4. Lap:valve facevalve seat

After replacing the cylinder head or replacingthe valve and valve guide, the valve seat andvalve face should be lapped.

a. Apply a coarse lapping compound a to thevalve face.

Do not let the lapping compound enter thegap between the valve stem and the valveguide.

b. Apply molybdenum disulfide oil onto thevalve stem.

c. Install the valve into the cylinder head.d. Turn the valve until the valve face and valve

seat are evenly polished, then clean off all ofthe lapping compound.

For the best lapping results, lightly tap the valveseat while rotating the valve back and forth be-tween your hand.

4-27


e. Apply a fine lapping compound to the valveface and repeat the above steps.

f. After every lapping procedure, be sure toclean off all of the lapping compound fromthe valve face and valve seat.

g. Apply Mechanic’s blueing dye (Dykem) bonto the valve face.

h. Install the valve into the cylinder head.i. Press the valve through the valve guide and

onto the valve seat to make a clear impres-sion.

j. Measure the valve seat width c again. If thevalve seat width is out of specification, refaceand lap the valve seat.

EAS00241

CHECKING THE VALVE SPRINGSThe following procedure applies to all of thevalve springs.1. Measure:valve spring free length aOut of specification Replace the valvespring.

Valve spring free lengthIntake valve spring (inner) 37.0 mm <Limit>: 35mmIntake valve spring (outer) 38.4 mm <Limit>: 36.5mmExhaust valve spring 41.7 mm <Limit>: 39.5mm

4-28


2. Measure:compressed spring force aOut of specification Replace the valvespring.

b Installed length

Compressed spring force(installed)

Intake valve spring inner 7.0 8.0 kg at 30.0 mmIntake valve spring outer 11.6 13.4 kg at 32.5 mmExhaust valve spring 16.3 18.7 kg at 36.1 mm

3. Measure:valve spring tilt aOut of specification Replace the valvespring.

Max. Spring tiltIntake valve spring inner 1.6 mmIntake valve spring outer 1.7 mmExhaust valve spring 1.8 mm

EAS00242

CHECKING THE VALVE LIFTERSThe following procedure applies to all of thevalve lifters.1. Check:valve lifterDamage/scratches Replace the valve lift-ers and cylinder head.

EAS00247

INSTALLING THE VALVESThe following procedure applies to all of thevalves and related components.1. Deburr:valve stem end(with an oil stone)

2. Lubricate:valve stem 1oil seal 2(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide oil

4-29


NOTE:

NOTE:

CAUTION:

3. Install: lower spring seat 6oil seal 5 Newvalve 4valve spring inner (intake only) 3valve spring outer 2upper spring seat 1(into the cylinder head)

Make sure that each valve is installed in itsoriginal place. Refer to the following em-bossed marks.

Install the valve spring with the larger pitch afacing up.

b Smaller pitch

4. Install:valve cotters 1

Install the valve cotters by compressing thevalve spring with the valve spring compressor2 and attachment 3 .

Valve spring compressor90890-04019

Attachment90890-04114

5. To secure the valve cotters 1 onto the valvestem, lightly tap the valve tip with a soft-facehammer.

Hitting the valve tip with excessive forcecould damage the valve.

4-30


NOTE:

6. Lubricate:valve pad(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide oil

7. Install:valve padvalve lifter

The valve lifter must move smoothly when ro-tated with a finger.

Each valve lifter and valve pad must be rein-stalled in its original position.

4-31

PICKUP COIL AND PICKUP COIL ROTOR ENG


Removing the pickup coil and pickup coil rotorRiders seat and fuel tank

Bottom cowling and right sidecowlingEngine oil

Generator cover


Refer to “SEATS” and “FUEL TANK” inchapter 3.Refer to “COWLINGS” in chapter 3.

Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Refer to “STARTER CLUTCH ANDGENERATOR”.

12 Nm (1.2 mkg)

15 Nm (1.5 mkg)

10 Nm (1.0 mkg)

35 Nm (3.5 mkg)

PICKUP COIL AND PICKUP COIL ROTOR

4-32

PICKUP COIL AND PICKUP COIL ROTOR ENG


12345678

Clutch cableClutch cable holderPickup coil couplerPickup coil coverPickup coil cover gasketDowel pinPickup coilPickup rotor

11111211

Disconnect


Refer to “REMOVING/INSTALLINGTHE PICKUP COIL ROTOR”.

12 Nm (1.2 mkg)

35 Nm (3.5 mkg)

15 Nm (1.5 mkg)

10 Nm (1.0 mkg)

4-33

PICKUP COIL AND PICKUP ROTOR ENG

NOTE:

NOTE:

NOTE:

REMOVING THE PICKUP COIL ROTOR1. Remove:clutch cable holder 1pickup coil cover 2

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern. After all ofthe bolts are fully loosened, remove them.

2. Remove:pickup coil rotor bolt 1plain washer 2pickup coil rotor 3

While holding the generator rotor 4 with the ro-tor holding tool 5 , loosen the pickup coil rotorbolt.

Sheave holder90890-01701

INSTALLING THE PICKUP COIL ROTOR1. Install:pickup coil rotor 1plain washerpickup coil rotor bolt

When installing the pickup coil rotor, align thepin 2 in the crankshaft sprocket with thegroove a in the pickup coil rotor.

4-34

PICKUP COIL AND PICKUP ROTOR ENG

35 Nm (3.5 mkg)

NOTE:

NOTE:

2. Tighten:pickup coil rotor bolt 1

While holding the generator rotor 2 with thesheave holder 3 , tighten the pickup coil rotorbolt.


3. Apply:sealant(onto the pickup coil lead grommet)

Yamaha bond No.121590890-85505

4. Install:pickup coil coverclutch cable holder

When installing the pickup coil cover, align thetiming chain guide (intake side) pin 1 of thewith the hole 2 in the pickup coil cover.

Tighten the pickup coil cover bolts in stagesand in a crisscross pattern.

4-35

STARTER CLUTCH AND GENERATOR ENG


12

3456

Removing the starter clutch and gener-atorRiders seat and fuel tank

Buttom and left side cowlingsEngine oil

Coolant treserver

Stator coil assembly couplerGenerator cover

Generator rotor cover gasketDowel pinStator coil assembly lead holderStator coil assembly

11

1211


Refer to “SEATS” and “FUEL TANK” inchapter 3.Refer to “COWLINGS” in chapter 3.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Disconnect.Refer to “REMOVING/INSTALLINGTHE GENERATOR”.

12 Nm (1.2 mkg) 10 Nm (1.0 mkg)

65 Nm (6.5 mkg)

EAS00341

STARTER CLUTCH AND GENERATOR

4-36



789

10111213

Generator rotor boltPlain washerGenerator rotorStarter one-way assyIdler gear shaftIdler hearStarter clutch gear

1111111

For installation reverse the removalproceduer.

Refer to “REMOVING/INSTALLINGTHE GENERATOR”.

12 Nm (1.2 mkg) 10 Nm (1.0 mkg)

65 Nm (6.5 mkg)

4-37


NOTE:

NOTE:

EAS00346

REMOVING THE GENERATOR1. Remove:generator rotor cover 1


2. Remove:generator rotor bolt 1Plain washer

While holding the generator rotor 2 with thesheave holder 3 , loosen the generator rotorbolt.Do not allow the sheave holder to touch the pro-jection on the generator rotor.


3. Remove:generator rotor 1(with the flywheel puller 2 and adapter 3 )

Flywheel puller90890-01362

Flywheel puller attachment90890-04089

4-38


EAS00345

REMOVING THE STARTER CLUTCH1. Remove:GeneratorStarter one-way assy 1 Idler gear shaft 2 Idler gear 3Starter clutch gear 4

EAS00351

CHECKING THE STARTER CLUTCH1. Check:Starter one-way assy Damage/wear Replace.

2. Check: Idler gear Idler gear shaftstarter clutch gear Pitting/Burrs/chips/roughness/wear Re-place the defective parts.

3. Check:Starter clutch operation

a. Install the starter clutch gear 1 onto thestarter clutch 2 and hold the starter clutch.

b. When turning the starter clutch drive gearclockwise A , the starter clutch and the start-er clutch gear should engage.If the starter clutch gear and starter clutch donot engage, the starter clutch is faulty andmust be replaced.

c. When turning the starter clutch drive gearcounterclockwise B , it should turn freely. Ifthe starter clutch drive gear does not turnfreely, the starter clutch is faulty and must bereplaced.

4-39


NOTE:

65 Nm (6.5 mkg)

NOTE:

NOTE:

EAS00355

INSTALLING THE STARTER CLUTCH1. Install:starter clutch gear 1 idler gear 2 idler gear shaft 3startor one-way assy 4

EAS00354

INSTALLING THE GENERATOR1. Install:generator rotor 1washer 2generator rotor bolt 3

Clean the tapered portion of the crankshaft andthe generator rotor hub with lacquer tinner.

2. Tighten:generator rotor bolt 3

While holding the generator rotor 2 with thesheave holder 3 , tighten the generator rotorbolt.Do not allow the sheave holder to touch the pro-jection on the generator rotor.


3. Apply:sealant(onto the stator coil assembly lead grommet)

Yamaha bond No.121590890-85505

4. Install:stator coil

5. Install:generator rotor cover

Tighten the generator rotor cover bolts in stagesand in a crisscross pattern.

4-40

SHIFT SHAFT ENG


12345

Removing the shift shaftCoolant reserver

Drive sprocket cover, sift rod and siftarm.Shift shaft coverShift shaft cover gasketDowel pinOil sealSift shaft

11211

Remove the parts in the order listed.Drain.Refer to “CHNGING THE COOLANT” inchapter 3.Refer to “ENGINE”.

Refer to “INSTALLING THE SHIFTSHAFT”.

22 Nm (2.2 mkg)

EAS00327

SHIFT SHAFT

4-41

SHIFT SHAFT ENG


6789

1011121314

Shift shaft springCollarStopper lever springCircripWasherStopper leverCollarWasherShift shaft spring stopper

111111111


Refer to “INSTALLING THE SHIFTSHAFT”.

22 Nm (2.2 mkg)

4-42

SHIFT SHAFT ENG

22 Nm (2.2 mkg)

NOTE:

NOTE:

EAS00329

CHECKING THE SHIFT SHAFT1. Check:shift shaft 1Bends/damage/wear Replace.

shift shaft spring 2Damage/wear Replace.

EAS00330

CHECKING THE STOPPER LEVER1. Check:stopper lever 1Bends/damage Replace.Roller turns roughly Replace the stopperlever.

EAS00334

INSTALLING THE SHIFT SHAFT1. Install:shift shaft spring stopper 1

stopper lever spring 2washerstopper lever 3

Apply LOCTITE to the threads of the shiftshaft spring stopper.

Hook the ends of the stopper lever spring ontothe stopper lever and the crankcase boss.

Mesh the stopper lever with the shift drum seg-ment assembly.

2. Install:shift shaft 1collor

Lubricate the oil seal lips with lithium soapbase grease.

Install the end of the shift shaft spring onto theshift shaft spring stopper 2

4-43

CLUTCH ENG


12

Removing the clutch coverBottom cowing and right side cowlingEngine oil

Coolant

Therm bypass hoseClutch cable

11

Remove the parts in the order listed.Refer to “COWLINGS” in chapter 3.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.

12 Nm (1.2 mkg)

12 Nm (1.2 mkg)

EB405000

CLUTCHCLUTCH COVER

4-44

CLUTCH ENG


3

45

Clutch cover

Clutch cover gasketDowel pin

1

12

Refer to “REMOVING/INSTALLINGTHE CLUTCH”.


12 Nm (1.2 mkg)

12 Nm (1.2 mkg)

4-45

CLUTCH ENG


Disassembling the clutch cover assemblyCirclipPlain washerPull leverPull lever springOil sealBearing

221112

Disassemble the parts in the order listed.

Refer to “INSTALLING THE CLUTCH”.

For assembly, reverse the disassemblyprocedure.

123456

4-46

CLUTCH ENG


123456789

10

Removing the clutchCompression splingPressure platePull rodBearingFriction plateClutch plateClutch plateClutch boss nutLook washerClutch boss

6111871111


Refer to“REMOVING/INSTALLINGTHE CLUTCH”.

Refer to “INSTALLING THE CLUTCH”.

70 Nm (7.0 mkg)

8 Nm (0.8 mkg)

CLUTCH

4-47

CLUTCH ENG


11 Thrust plate 1For installation, reverse the removalprocedure.

70 Nm (7.0 mkg)

8 Nm (0.8 mkg)

4-48

CLUTCH ENG

NOTE:

NOTE:

NOTE:

EAS00277

REMOVING THE CLUTCH1. Remove:clutch cover 1

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern.After all of the bolts are fully loosened, removethem.

Pressure plateFricttion and clutch plates

2. Straighten the lock washer tab.3. Loosen:clutch boss nut 1

While holding the clutch boss 2 with the clutchholding tool 3 , loosen the clutch boss nut.

Clutch holding tool90890-04086

4. Remove:clutch boss nut 1 lock washer 2clutch boss 3 thrust plate 4

EAS00280

CHECKING THE FRICTION PLATESThe following procedure applies to all of the fric-tion plates.1. Check: friction plateDamage/wear Replace the friction platesas a set.

2. Measure: friction plate thicknessOut of specification Replace the frictionplates as a set.

Measure the friction plate at four places.

Friction plate thickness2.9 3.1 mm<Limit>: 2.8 mm

4-49

CLUTCH ENG

NOTE:

EAS00281

CHECKING THE CLUTCH PLATESThe following procedure applies to all of theclutch plates.1. Check:clutch plateDamage Replace the clutch plates as aset.

2. Measure:clutch plate warpage(with a surface plate and thickness gauge1 )Out of specification Replace the clutchplates as a set.

Max. clutch plate warpage0.1 mm

EAS00282

CHECKING THE CLUTCH SPRINGSThe following procedure applies to all of theclutch springs.1. Check:

clutch springDamage Replace the clutch springs as aset.

2. Measure:clutch spring free length aOut of specification Replace the clutchsprings as a set.Clutch spring free length

Clutch spring free length55 mm <Limit>: 54 mm

EAS00284

CHECKING THE CLUTCH HOUSING1. Check:clutch housing dogsDamage/pitting/wear Deburr the clutchhousing dogs or replace the clutch housing.

Pitting on the clutch housing dogs will cause er-ratic clutch operation.

2. Check:bearingDamage/wear Replace the clutch hous-ing.

4-50

CLUTCH ENG

NOTE:

EAS00285

CHECKING THE CLUTCH BOSS1. Check:clutch boss splinesDamage/pitting/wear Replace the clutchboss.

Pitting on the clutch boss splines will cause er-ratic clutch operation.

EAS00286

CHECKING THE PRESSURE PLATE1. Check:pressure plate 1Cracks/damage Replace.

bearing 2Damage/wear Replace.

EAS00287

CHECKING THE PULL LEVER SHAFT ANDPULL ROD1. Check:pull lever shaft pinion gear teeth apull rod teeth bDamage/wear Replace the pull rod andpull lever shaft as a set.

2. Check:pull rod bearingDamage/wear Replace.

4-51

CLUTCH ENG

70 Nm (7.0 mkg)

NOTE:

NOTE:

NOTE:

EAS00296

INSTALLING THE CLUTCH1. Install: thrust plate 1clutch boss 2

2. Install: lock washer 3 Newclutch boss nut 4

While holding the clutch boss 2 with the clutchholding tool 5 , tighten the clutch boss nut.

Clutch holding tool90890-04086

3. Bend the lock washer tab along a flat side ofthe nut.

4. Lubricate: friction platesclutch plates(with the recommended lubricant)

Recommended lubricantEngine oil

5. Install: friction platesclutch plates

First, install a friction plate and then alternatebetween a clutch plate and a friction plate.

6. Install:washerbearing 1pull rod 2

Install the pull rod so that the teeth a face to-wards the rear of the motorcycle. Then, installthe clutch cover.Tighten the clutch cover bolts in stages and in acrisscross pattern.Apply oil onto the bearing.Apply molybdenum disulfide grease onto thepull rod.

4-52

CLUTCH ENG

8 Nm (0.8 mkg)

NOTE:

12 Nm (1.2 mkg)

NOTE:

7. Install:pressure plateclutch springsclutch spring bolts

Tighten the clutch spring bolts in stages and in acriss cross pattern.

8. Install:clutch cover

When installing the clutch cover, push the pulllever and check that the punch mark a on thepull lever aligns with the mark b on the clutchcover. Make sure that the pull rod teeth andpull lever shaft pinion gear are engaged.

Tighten the clutch cover bolts in stages and ina crisscross pattern.

4-53

OIL PAN AND OIL PUMP ENG


12

Removing the oil pan and oil pumpEngine oil

Coolant

Radiator assembly and water pumpassemblyExhaust pipe assemblyOil level switch couplarOil level switch

11

Remove the parts in the order listed.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Refer to “RADIATOR” and “WATERPUMP” in chapter 5.Refer to “ENGINE”.Disconnect.

43 Nm (4.3 mkg)

10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

EAS00356

OIL PAN AND OIL PUMP

4-54



34567

89

10111213

Oil level switch lead holderOil panOil pan gasketDowel pinOil strainer

Oil pipeOil delivery pipeGear coverDowel pinOil pump assemblyRelief valve assembly

11121

111211

Refer to “INSTALLING THE OIL STRAINER”.

Refer to “INSTALLING THE OIL PUMP”.


Refer to “REMOVEING/INSTALLINGTHE OIL PAN.

43 Nm (4.3 mkg)

10 Nm (1.0 mkg)

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

4-55



Disassemblying the oil pumpassemblyOil pump rotor housingDowel pinOil pump inner rotorOil pump outer rotorDowel pinWasherOil pump coverDriver gear

12111111


For assembly reverse the disassemblyprocedure.

12345678

12 Nm (1.2 mkg)

EB411010

OIL PUMP

4-56


NOTE:

EAS00362

REMOVING THE OIL PAN1. Remove:oil level switch 1oil pan 2oil pan gasketdowel pins

Loosen each bolt 1/4 of a turn at a time, instages and in a crisscross pattern.After all of the bolts are fully loosened, removethem.

EAS00364

CHECKING THE OIL PUMP1. Check:oil /pump driven gear 1 rotor housing 2Cracks/damage/wear Replace the defec-tive part(-s).

2. Measure: inner-rotor-to-outer-rotor-tip clearance aouter-rotor-to-oil-pump-cover clearance bOut of specification Replace the oil pump.

1 Inner rotor

2 Outer rotor

3 Oil pump cover

Inner-rotor-to-outer-rotor-tipclearance

0.03 0.09 mm <Limit>: 0.15 mm

Outer-rotor-to-oil-pump-coverclearance

0.03 0.08 mm <Limit>: 0.15 mm

4-57


3. Check:oil pump operationUnsmooth Repair or replace the defectivepart(-s).

EAS00365

CHECKING THE RELIEF VALVE1. Check: relief valve body 1 relief valve 2spring 3O-ring 4Damage/wear Replace the defectivepart(-s).

EAS00367

CHECKING THE OIL DELIVERY PIPE ANDOIL PIPE1. Check:oil delivery pipe 1oil pipe 2Damage Replace.Obstruction Wash and blow out with com-pressed air.

EAS00368

CHECKING THE OIL STRAINER1. Check:oil strainer 1Damage Replace.Contaminants Clean with engine oil.

EAS00373

CHECKING THE OIL NOZZLESThe following procedure applies to all of the oilnozzles.1. Check:oil nozzle 1O-ring 2Damage/wear Replace the oil nozzle.oil nozzle passageObstruction Blow out with compressed air.

4-58


12 Nm (1.2 mkg)

NOTE:

NOTE:

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

43 Nm (4.3mkg)

NOTE:

EAS00375

ASSEMBLING THE OIL PUMP1. Lubricate: inner rotorouter rotor impeller shaft(with the recommended lubricant)


2. Check:oil pump operationRefer to “CHECKING THE OIL PUMP”.

EAS00376

INSTALLING THE OIL PUMP1. Install:oil pump 1

Install the oil pump assembly drive chain ontothe oil pump assembly driven sprocket.

EAS00378

INSTALLING THE OIL STRAINER1. Install:oil strainer 1

The arrow a on the oil strainer housing mustpoint towards the front of the engine.

EAS00380

INSTALLING THE OIL PAN1. Install:dowel pinsoil pan gasket Newoil pan 1oil level switch 2engine oil drain bolt 3

Tighten the oil pan bolts in stages and in acrisscross pattern.

Lubricate the oil level switch O-ring with lithiumsoap base grease.

4-59

CRANKCASE ENG


Separating the crankcaseEngineCylinder headStarter clutch and generator

Shift shaftPickup coil and pickup rotor

Clutch assemblyWater pump assemblyOil pan and oil pump

Remove the parts in the order listed.Refer to “ENGINE”.Refer to “CYLINDER HEAD”.Refer to “STARTER CLUTCH ANDGENERATOR”.Refer to “SHIFT SHAFT”.Refer to “PICKUP COIL AND PICKUP ROTOR”.Refer to ‘‘CLUTCH’’.Refer to “WATER PUMP” in chapter 5.Refer to “OIL PAN AND OIL PUMP”.

12 Nm (1.2 mkg)

CRANKCASE

4-60

CRANKCASE ENG


1234

5

Timing chainOil pump drive chain guideOil pump drive chainLower crankcase

Dowel pin

1111

3

Refer to “DISASSEMBLY/ASSEMBLY THE CRANKCASE”.


12 Nm (1.2 mkg)

4-61

CRANKCASE ENG


1234567

Removing the oil baffle plates and oil filter boltTransmissionOil baffle plateOil baffle plateOil delivery pipeBearingLower crankcaseOil filter boltUpper crankcase

1111111


Refer to “TRANSMISSION”.

For instalation, reverse the removalprocedure.

80 Nm (8.0 mkg)

12 Nm (1.2 mkg)

12 Nm (1.2 mkg)

OIL BAFFLE PLATES AND OIL FILTER BOLT

4-62

CRANKCASE ENG

NOTE:

CAUTION:

EAS00384

DISASSEMBLING THE CRANKCASE1. Place the engine upside down.


Loosen the bolts in decreasing numerical or-der (refer to the numbers in the illustration).

The numbers embossed on the crankcase in-dicate the crankcase tightening sequence.

2. Remove:crankcase bolts

3. Remove: lower crankcase

Tap on one side of the crankcase with a soft-face hammer. Tap only on reinforced por-tions of the crankcase, not on the crankcasemating surfaces. Work slowly and carefullyand make sure that the crankcase halvesseparate evenly.

M8 85 mm bolts: 1 7 , 10M8 115 mm bolts: 8 , 9M8 65 mm bolts: 11 , 12M6 65 mm bolts: 13 , 14 , 17 , 27M6 55 mm bolts: 15 , 22 26M6 45 mm bolts: 16 , 19 21M6 75 mm bolt: 18

4. Remove:dowel pins

4-63

CRANKCASE ENG

EAS00399

CHECKING THE CRANKCASE1. 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 crankcaseCracks/damage Replace.

oil delivery passagesObstruction Blow out with compressed air.

EAS00401

CHECKING THE BEARINGS AND OILSEALS1. Check:bearingsClean and lubricate the bearings, then rotatethe inner race with your finger.Rough movement Replace.

2. Check:oil sealsDamage/wear Replace.

CHECKING THE SPROCKETS AND CHAINS1. Check:crankshaft sprocket 1oil /water pump assembly drive sprocket 2Cracks/damage/wear Replace the de-fective part(-s).

2. Check: timing chain 1Damage/stiffness Replace the timingchain and crankshaft sprocket as a set.

oil /water pump assembly drive chain 2Damage/stiffness Replace the oil /waterpump assembly drive chain and oil /waterpump assembly drive sprocket as a set.

4-64

CRANKCASE ENG

NOTE:

CAUTION:

EAS00415

ASSEMBLING THE CRANKCASE1. Lubricate:crankshaft journal bearings(with the recommended lubricant)


2. Apply:sealant(onto the crankcase mating surfaces and thegroove a of the oil baffle plate)

Yamaha bond No. 121590890-85505

Do not allow any sealant to come into contactwith the oil gallery or crankshaft journal bear-ings. Do not apply sealant to within 2 3 mm ofthe crankshaft journal bearings.

3. Install:dowel pin

4. Set the shift drum assembly and transmis-sion gears in the neutral position.

5. Install: lower crankcase 1(onto the upper crankcase 2 )

Before tightening the crankcase bolts, makesure that the transmission gears shift cor-rectly when the shift drum assembly isturned by hand.

4-65

CRANKCASE ENG

NOTE:

WARNING

6. Install:crankcase bolts

Lubricate the bolt threads with engine oil. Install a washer on bolts 1 10 . Install a gasket on bolt 21 .Not lubricate seal botts 18 12

Tighten the bolts in the tightening sequencecast on the crankcase.

M8 85 mm bolts: 1 7 , 10M8 115 mm bolts: 8 , 9M8 65 mm bolts: 11 , 12M6 65 mm bolts: 13 , 14 , 17 , 27M6 55 mm bolts: 15 , 22 26M6 45 mm bolts: 16 , 19 21M6 75 mm bolt: 18

Bolt 15 27

12 Nm (1.2 mkg)Bolt 13 14

14 Nm (1.4 mkg)Bolt 1 12

24 Nm (2.4 mkg)

Always use new copper washers.

4-66

CONNECTING RODS AND PISTONS ENG


1234567

Removing the connecting rods and pistonsLower crankcase

Connecting rod capBig end lower bearingBig end upper bearingPiston pin clipPiston pinPistonConnecting rod

4448444


Separate.Refer to “CRANKCASE”.

Refer to “REMOVING/INSTALLING THECONNECTING RODS AND PISTONS”.

15 Nm (1.5 mkg)+90

EAS00252

CONNECTING RODS AND PISTONS

4-67



89

10

Top ring2nd ringOil ring

444


Refer to “REMOVING/INSTALLING THECONNECTING RODS AND PISTONS”.

15 Nm (1.5 mkg)+90

4-68


NOTE:

CAUTION:

NOTE:

NOTE:

EAS00393

REMOVING THE CONNECTING RODS ANDPISTONSThe following procedure applies to all of theconnecting rods and pistons.1. Remove:connecting rod cap 1big end bearings

Identify the position of each big end bearing sothat it can be reinstalled in its original place.

2. Remove:piston pin clips 1piston pin 2piston 3connecting rod

Do not use a hammer to drive the piston pinout.

For reference during installation, put identifi-cation marks on the piston crown.

Before removing the piston pin, deburr the pis-ton pin clip groove and the piston pin bore areain the piston. If both areas are deburred andthe piston pin is still difficult to remove, removeit with the piston pin puller 4 .

Piston pin puller90890-01304

3. Remove: top ring2nd ringoil ring

To remove a piston ring, open the end gap withyour fingers and lift the other side of the ringover the piston crown.

4-69


NOTE:

EAS00262

CHECKING THE CYLINDER AND PISTONSThe following procedure applies to all of the cyl-inders and pistons.1. Check:piston wallcylinder wallVertical scratches Replace the crank-cases, and the piston and piston rings as aset.

2. Measure:piston-to-cylinder clearance

a. Measure cylinder bore “C” with the cylinderbore gauge.

Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of thecylinder. Then, find the average of the measure-ments.

Cylinder bore gauge90890-03017

Cylinder bore “C” 65.50 65.51 mm

Max. taper “T” 0.05 mm

Out of round “R” 0.05 mm

b. If out of specification, replace the crank-cases, and the piston and piston rings as aset.

c. Measure piston skirt diameter “P” with themicrometer.

Micrometer90890-03008

a 4 mm from the bottom edge of the piston

Piston size “P”

Standard 65.460 65.475 mm

d. If out of specification, replace the piston andpiston rings as a set.

4-70


NOTE:

NOTE:

e. Calculate the piston-to-cylinder clearancewith the following formula.

Piston-to-cylinder clearance =Cylinder bore “C” –Piston skirt diameter “P”

Piston-to-cylinder clearance0.025 0.045 mm<Limit>: 0.07 mm

f. If out of specification, replace the crank-cases, and the pistons and piston rings as aset.

EAS00263

CHECKING THE PISTON RINGS1. Measure:piston ring side clearanceOut of specification Replace the pistonand piston rings as a set.

Before measuring the piston ring side clear-ance, eliminate any carbon deposits from thepiston ring grooves and piston rings.

Piston ring side clearanceTop ring

0.030 0.065 mm<Limit>: 0.115 mm

2nd ring0.020 0.055 mm<Limit>: 0.115 mm

2. Install:piston ring(into the cylinder)

Level the piston ring in the cylinder with the pis-ton crown.

a 5 mm

4-71


NOTE:

3. Measure:piston ring end gapOut of specification Replace the pistonring.

The oil ring expander spacer’s end gap cannotbe measured. If the oil ring rail’s gap is exces-sive, replace all three piston rings.

Piston ring end gapTop ring

0.15 0.25 mm<Limit>: 0.50 mm

2nd ring0.40 0.50 mm<Limit>: 0.85 mm

Oil ring0.10 0.35 mm

ABS00266

CHECKING THE PISTON PINSThe following procedure applies to all of the pis-ton pins.1. Check:piston pinBlue discoloration/grooves Replace thepiston pin and then check the lubrication sys-tem.

2. Measure:piston pin outside diameter aOut of specification Replace the pistonpin.

Piston pin outside diameter15.991 16.000 mm

3. Measure:piston pin bore diameter (in the piston)Out of specification Replace the pistonpin.

Piston pin bore diameter(in the piston)

16.002 16.013 mm

4-72


CAUTION:

NOTE:

4. Calculate:piston-pin-to-piston-pin-bore clearanceOut of specification Replace the pistonpin.

Piston-pin-to-piston-pin-bore clearance =Piston pin bore diameter (in the piston) –Piston pin outside diameter

Piston-pin-to-piston-pin-boreclearance

0.002 0.022 mm<Limit>: 0.072 mm

CHECKING THE BIG END BEARINGS1. Measure:crankshaft-pin-to-big-end-bearing clearanceOut of specification Replace the big endbearings.

Crankshaft-pin-to-big-end-bearing clearance

0.028 0.052 mm

The following procedure applies to all of theconnecting rods.

Do not interchange the big end bearings andconnecting rods. To obtain the correctcrankshaft-pin-to-big-end-bearing clearanceand prevent engine damage, the big endbearings must be installed in their originalpositions.

a. Clean the big end bearings, crankshaft pins,and bearing portions of the connecting rods.

b. Install the big end upper bearing into the con-necting rod and the big end lower bearinginto the connecting rod cap.

Align the projections a on the big end bearingswith the notches b in the connecting rod andconnecting rod cap.

4-73


NOTE:

CAUTION:

c. Put a piece of Plastigauge 1 on the crank-shaft pin.

d. Assemble the connecting rod halves.

Do not move the connecting rod or crankshaftuntil the clearance measurement has beencompleted.

Lubricate the bolt threads and nut seats withmolybdenum disulfide grease.

Make sure that the “Y” mark c on the connect-ing rod faces towards the left side of the crank-shaft.

Make sure that the characters d on both theconnecting rod and connecting rod cap arealigned.

e. Tighten the connecting rod nuts.

When tightening the connecting rod nuts,be sure to use an F-type torque wrench.

After tightening the connecting rod nut tothe specified torque, turn the connectingrod nut another+90 .

Refer to “INSTALLING THE PISTONS ANDCONNECTING RODS”.

Connecting rod nut15 Nm (1.5 mkg) + 90

f. Remove the connecting rod and big endbearings.Refer to “REMOVING THE CONNECTINGRODS AND PISTONS”.

g. Measure the compressed Plastigauge width e on the crankshaft pin.If the crankshaft-pin-to-big-end-bearing clearance is out of specification, select re-placement big end bearings.

4-74


NOTE:

NOTE:

2. Select:big end bearings (“P1” “P4”)

The numbers stamped into the crankshaft weband the numbers on the connecting rods areused to determine the replacement big endbearing sizes.

“P1” “P4” refer to the bearings shown in thecrankshaft illustration.

For example, if the connecting rod “P1” andthe crankshaft web “P1” numbers are “5” and“1” respectively, then the bearing size for“P1” is:

“P 1” (connecting rod) – “P 1” (crank-shaft) =5 – 1 = 4

BIG END BEARING COLOR CODE

1 blue

2 black

3 brown

4 green

EAS00271

INSTALLING THE PISTONS AND CONNECT-ING RODSThe following procedure applies to all of the pis-tons and cylinders.1. Install: top ring2nd ringoil ring

Be sure to install the piston rings so that themanufacturer’s marks or numbers face up.

4-75


NOTE:

2. Install:piston 1(onto the respective connecting rod 2 )

piston pin 3piston pi clip 4 New

Apply engine oil onto the piston pin.Make sure that the “Y” mark a on the connect-ing rod faces left when the arrow mark b onthe piston is pointing up. Refer to the illustra-tion.

Reinstall each piston into its original cylinder(numbering order starting from the left: #1 to#4).

3. Offset:piston ring end gaps

a Top ring

b Lower oil ring rail

c Upper oil ring rail

d 2nd ring

A Intake side

4. Lubricate:pistonpiston ringscylinder(with the recommended lubricant)


5. Lubricate:bolt threadsnut seats(with the recommended lubricant)

Recommended lubricantMolybdenum disulfide grease

4-76


NOTE:

15 Nm (1.5 mkg)+90

CAUTION:

6. Lubricate:crankshaft pinsbig end bearingsconnecting rod big end inner surface(with the recommended lubricant)


7. Install:big end bearingsconnecting rod assembly(into the cylinder and onto the crankshaftpin).

connecting rod cap(onto the connecting rod)

Align the projections on the big end bearingswith the notches in the connecting rods andconnecting rod caps.

Be sure to reinstall each big end bearing in itsoriginal place.

While compressing the piston rings with onehand, install the connecting rod assembly intothe cylinder with the other hand.

Make sure that the “Y” marks a on the con-necting rods face towards the left side of thecrankshaft.

Make sure that the characters b on both theconnecting rod and connecting rod cap arealigned.

8. Align:bolt heads(with the connecting rod caps)

9. Tighten:connecting rod nuts

a. Replace the connecting rod bolts and nutswith new ones.

Tighten the connecting rod bolts using theplastic-region tightening angle method.Always install new bolts and nuts.

4-77


WARNING

CAUTION:

NOTE:

b. Clean the connecting rod bolts and nuts.c. Tighten the connecting rod nuts.d. Put a mark 1 on the corner of the connecting

rod nut 2 and the connecting rod 3 .

e. Tighten the nut further to reach the specifiedangle (90).

When the nut is tightened more than thespecified angle, do not loosen the nut andthen retighten it.Replace the bolt with a new one and performthe procedure again.

Do not use a torque wrench to tighten thenut to the specified angle.

Tighten the nut until it is at the specifiedangles.

When using a hexagonal nut, note that theangle from one corner to another is 60.

4-78

CRANKSHAFT ENG


123

Removing the crankshaftCrankcase lower

Connecting rods and pistons

CrankshaftCrankshaft journal lower bearingCrankshaft journal upper bearing

155

Remove the parts in the order listed.Separate.Refer to “CRANKCASE”.Refer to “CONNECTING RODS ANDPISTONS”.


Refer to “REMOVING/INSTALLINGTHE CRANKSHAFT”.

EAS00381

CRANKSHAFT

4-79

CRANKSHAFT ENG

NOTE:

CAUTION:

EAS00387

REMOVING THE CRANKSHAFT1. Remove:crankshaft 1crankshaft journal upper bearings(from the upper / lower crankcase)

Identify the position of each crankshaft journalupper bearing so that it can be reinstalled in itsoriginal place.

EAS00397

CHECKING THE CRANKSHAFT1. Measure:crankshaft runoutOut of specification Replace the crank-shaft.

Max. crankshaft runout0.03 mm

2. Check:crankshaft journal surfacescrankshaft pin surfacesbearing surfacesScratches/wear Replace the crankshaft.

CHECKING THE CRANKSHAFT JOURNALBEARINGS1. Measure:crankshaft-journal-to-crankshaft-journal-bearing clearanceOut of specification Replace the crank-shaft journal bearings.

Crankshaft-journal-to-crankshaft-journal-bearing clearance

0.034 0.058 mm

Do not interchange the crankshaft journalbearings. To obtain the correct crankshaft-journal-to-crankshaft-journal-bearingclearance and prevent engine damage, thecrankshaft journal bearings must beinstalled in their original positions.

4-80

CRANKSHAFT ENG

NOTE:

NOTE:

NOTE:

NOTE:

a. Clean the crankshaft journal bearings,crankshaft journals, and bearing portions ofthe crankcase.

b. Place the upper crankcase upside down on abench.

c. Install the crankshaft journal upper bearings1 and the crankshaft into the upper crank-case.

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in theupper crankcase.

d. Put a piece of Plastigauge 2 on eachcrankshaft journal.

Do not put the Plastigauge over the oil hole inthe crankshaft journal.

e. Install the crankshaft journal lower bearingsinto the lower crankcase and assemble thecrankcase.

Align the projections a on the crankshaft jour-nal lower bearings with the notches b in thelower crankcase.

Do not move the crankshaft until the clearancemeasurement has been completed.

f. Tighten the bolts to specification in the tight-ening sequence cast on the crankcase.

Bolt 15 27

12 Nm (1.2 mkg)Bolt 13 14

14 Nm (1.4 mkg)Bolt 1 12

24 Nm (2.4 mkg)

Lubricate the crankcase bolt threads with en-gine oil.

4-81

CRANKSHAFT ENG

J1 J2 J3 J4 J5

NOTE:

NOTE:

g. Remove the lower crankcase and the crank-shaft journal lower bearings.

h. Measure the compressed Plastigauge width c each crankshaft journal.If the clearance is out of specification, selectreplacement crankshaft journal bearings.

2. Select:crankshaft journal bearings (J1 J5)

The numbers stamped into the crankshaft weband the numbers stamped into the lowercrankcase are used to determine the replace-ment crankshaft journal bearing sizes.

“J1” “J5” refer to the bearings shown in thecrankshaft illustration.

If “J1” “J5” are the same, use the same sizefor all of the bearings.

For example, if the crankcase “J1” and crank-shaft web “J1” numbers are “6” and “2” respec-tively, then the bearing size for “J1” is:

Bearing size for J 1:“J 1” (crankcase) – “J 1” (crankshaft web) – 1=6 – 2 – 1 = 3

CRANKSHAFT JOURNAL BEARINGCOLOR CODE

0 White

1 Blue

2 Black

3 Brown

4 Green

If the size is the same for all “J1 to J5”, one digitfor that size is indicated. (crankcase side only)

4-82

CRANKSHAFT ENG

NOTE:

EAS00407

INSTALLING THE CRANKSHAFT1. Install:crankshaft journal upper bearings(into the upper / lower crankcase)

Align the projections a on the crankshaft jour-nal upper bearings with the notches b in theupper crankcase.

Be sure to install each crankshaft journal up-per bearing in its original place.

4-83

TRANSMISSION ENG


123456

Removing the transmissionCrankcase lower

Shift shaft and stopper leverDrive axle assemblyCirclipOil sealBearingShift bar stopperShift fork guide bar

111112

Remove the parts in the order listed.Separate.Refer to “CRANKCASE”.Refer to “SHIFT SHAFT”.

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

EAS00419

TRANSMISSION

4-84

TRANSMISSION ENG


789

101112

SpringShift fork “L”Shift fork “R”Shift drum assemblyShift fork “C”Main axle assembly

411111


Refer to “INSTALLING THETRANSMISSION”.Refer to “REMOVING THETRANSMISSION”.

12 Nm (1.2 mkg)

10 Nm (1.0 mkg)

4-85

TRANSMISSION ENG


Disassembling the main axleassemblyBearing2nd pinion gearToothed lock washerToothed lock washer retainer6th pinion gearCollarWasherCirclip3rd pinion gearCirclip

1111111111


12345678910

4-86

TRANSMISSION ENG


Washer5th pinion gearCollarMain axleBearing housingBearing

111111


111213141516

4-87

TRANSMISSION ENG


Disassembling the drive axleassemblyWasher1st wheel gearCollar5th wheel gearCirclipWasher3rd wheel gearCollarToothed lock washerToothed lock washer retainer4th wheel gear

11111111111


1234567891011

4-88

TRANSMISSION ENG


CollarWasherCircrip6th wheel gearCircripwasher2nd wheel gearCollarCollarOil sealBearingCircripDrive axle

1111111111111


12131415161718192021222324

4-89

TRANSMISSION ENG

WARNING

EAS00420

REMOVING THE TRANSMISSION1. Remove:drive axle assembly

2. Remove:main axle assembly 1(with the Torx wrench T30)

a. Insert two bolts 2 of the proper size, asshown in the illustration, into the main axleassembly bearing housing.

b. Tighten the bolts until they contact the crank-case surface.

c. Continue tightening the bolts until the mainaxle assembly comes free from the uppercrankcase.

EAS00421

CHECKING THE SHIFT FORKSThe following procedure applies to all of the shiftforks.1. Check:shift fork cam follower 1shift fork pawl 2Bends/damage/scoring/wear Replace the shift fork.

2. Check:shift fork guide barRoll the shift fork guide bar on a flat surface.Bends Replace.

Do not attempt to straighten a bent shift forkguide bar.

4-90

TRANSMISSION ENG

3. Check:shift fork movement(along the shift fork guide bar)Rough movement Replace the shiftfork(-s) and shift fork guide bar as a set.

EAS00422

CHECKING THE SHIFT DRUM ASSEMBLY1. Check:shift drum groovesDamage/scratches/wear Replace theshift drum assembly.

shift drum segment 1Damage/wear Replace the shift drum as-sembly.

shift drum bearing 2Damage/pitting Replace the shift drumassembly.

EAS00425

CHECKING THE TRANSMISSION1. Measure:main axle runout(with a centering device and dial gauge 1 )Out of specification Replace the mainaxle.

Max. main axle runout0.02 mm

2. Measure:drive axle runout(with a centering device and dial gauge 1 )Out of specification Replace the driveaxle.

Max. drive axle runout0.02 mm

3. Check: transmission gearsBlue discoloration/pitting/wear Replace the defective gear(-s).

transmission gear dogsCracks/damage/rounded edges Replace the defective gear(-s).

4-91

TRANSMISSION ENG

NOTE:

NOTE:

4. Check: transmission gear engagement(each pinion gear to its respective wheelgear)Incorrect Reassemble the transmissionaxle assemblies.

5. Check: transmission gear movementRough movement Replace the defectivepart(-s).

6. Check:circlipsBends/damage/looseness Replace.

INSTALLING THE TRANSMISSION1. Install:main axle assemblyshift fork “C”shift drum assemblyshift fork “R”shift fork “L”springsshift fork guide barsdrive axle assembly

Carefully position the shift forks so that theyare installed correctly into the transmissiongears.

Install shift fork “C” into the groove in the 3rdand 4th pinion gear on the main axle.

Install shift fork “L” into the groove in the 6thwheel gear and shift fork “R” into the groove inthe 5th wheel gear on the drive axle.

Make sure that the drive axle bearing circlip isinserted into the grooves in the upper crank-case.

2. Check: transmissionRough movement Repair.

Oil each gear, shaft, and bearing thoroughly.

COOL

CHAPTER 5.COOLING SYSTEM

RADIATOR 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIATOR 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE RADIATOR 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OIL COOLER 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE OIL COOLER 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE OIL COOLER 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THERMOSTAT 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE THERMOSTAT 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE THERMOSTAT 5-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER PUMP 5-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE WATER PUMP 5-15. . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WATER PUMP 5-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE WATER PUMP 5-16. . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1

RADIATOR COOL


123

Removeing the radiatorRider seat and fuel tank

Air filter case and heat protector plate

Bottom cowling and side cowlingsCoolantCoolant reserver hoseBreather hoseRadiator outlet hose

121

Remove the parts in the order listed.Refer to “SEATS” and “FUEL TANK” inchapter 3.Refer to “AIRFILTER CASE AND IGNI-TION COILS” in chapter 3.Refer to “COWLINGS” in chapter 3.Drain.

Disconnect.

9 Nm (0.9 mkg)

28 Nm (2.8 mkg)

7 Nm (0.7 mkg)

COOLING SYSTEMRADIATOR

5-2

RADIATOR COOL


456789

Radiator inlet hoseOil cooler outlet hoseThermo switch couplerRadiator fan motor couplerRadiatorRadiator fan

111111

Disconnect.

Disconnect.Disconnect.

For installation reverse the removal procedure.

28 Nm (2.8 mkg)

9 Nm (0.9 mkg)

7 Nm (0.7 mkg)

5-3

RADIATOR COOL

NOTE:

EAS00455

CHECKING THE RADIATOR1. Check: radiator finsObstruction Clean.Apply compressed air to the rear of the radia-tor.Damage Repair or replace.

Straighten any flattened fins with a thin, flat-head screwdriver.

2. Check: radiator hosesCracks/damage Replace.

3. Measure: radiator cap opening pressureBelow the specified pressure Replace theradiator cap.

Radiator cap opening pressure110 140 kPa(1.1 1.4 kg/cm 2, 1.1 1.4 bar)

a. Install the radiator cap tester 1 and adapter2 onto the radiator cap 3 .

Radiator cap tester90890-01325

Adapter90890-01352

b. Apply the specified pressure for ten secondsand make sure that there is no drop in pres-sure.

4. Check: radiator fanDamage Replace.Malfunction Check and repair.Refer to “COOLING SYSTEM” in chapter 8.

5-4

RADIATOR COOL

EAS00456

INSTALLING THE RADIATOR1. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.

2. Check:cooling systemLeaks Repair or replace any faulty part.

3. Measure: radiator cap opening pressureBelow the specified pressure Replace theradiator cap.Refer to “CHECKING THE RADIATOR”.

5-5

OIL COOLER COOL


1234

Removing the oil coolerRadiator assemblyExaust pipe assemblyEngine oil

Oil cooler outlet hoseBoltWasherOil cooler

1111

Remove the parts in the order listed.Refer to “RADIATOR”.Refer to “ENGINE” in chapter 4.Drain.Refer to “CHANGING THE ENGINE OIL”in chapter 3.

Refer to “INSTALLING THE OILCOOLER”.

63 Nm (6.3 mkg)

EAS00457

OIL COOLER

5-6

OIL COOLER COOL


56789

10

Oil cooler inlet hoseWater jacket jointWater jacket joint hoseWater pump outlet pipeWater pump outlet hoseWater pump inlet hose

111111


63 Nm (6.3 mkg)

5-7

OIL COOLER COOL

63 Nm (6.3 mkg)

NOTE:

EAS00458

CHECKING THE OIL COOLER1. Check:oil coolerCracks/damage Replace.

2. Check:oil cooler inlet hoseoil cooler outlet hoseCracks/damage/wear Replace.

3. Check:water jacket jointwater jacket joint inlet hosewater pump outlet hoseCracks/damage Replace.

EBS00459

INSTALLING THE OIL COOLER1. Clean:mating surfaces of the oil cooler and thecrankcase(with a cloth dampened with lacquer thinner)

2. Install:O-ring Newoil cooler 1washer 2 Newbolt 3

Before installing the oil cooler, lubricate the oilcooler bolt and O-ring with a thin coat of engineoil.

Make sure that the O-ring is positioned proper-ly.

Align the projection a on the oil cooler with theslot b in the crankcase.

3. Bend the lock washer tab along a flat side ofthe bolt.

5-8

OIL COOLER COOL

4. Fill:cooling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.

crankcase(with the specified amount of the recom-mended engine oil)Refer to “CHANGING THE ENGINE OIL” inchapter 3.



5-9

THERMOSTAT COOL


Removing the termostatRider seat and fuel tank

Coolant

Air filter case

Carburetor assembly

Remove the parts in the order listed.Refer to “SEAT” and “FUEL TANK” inchapter 3.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.Refer to “AIRFILTER CASE ANDIGNITION COILS” in chapter 3.Refer to “CARBURETORS” in chapter 6.

THERMOSTAT

5-10

THERMOSTAT COOL


1234

Radiator inlet hoseCarburator outlet hoseThermostat coverThermostat

1111

For installation, revers the removalprocedure.

Refer to “INSTALLING THETHERMOSTAT

5-11

THERMOSTAT COOLO

peni

ng (

mm

)

Temperature

84

NOTE:

NOTE:

10 Nm (1.0 mkg)

NOTE:

EAS00462

CHECKING THE THERMOSTAT1. Check: thermostat 1Does not open at 71 84C Replace.

a. Suspend the thermostat in a container filledwith water.

b. Slowly heat the water.c. Place a thermometer in the water.d. While stirring the water, observe the thermo-

stat and thermometer’s indicated tempera-ture.

1 Thermostat

2 Thermometer

3 Water

4 Container

A Fully closed

B Fully opens

If the accuracy of the thermostat is in doubt, re-place it. A faulty thermostat could cause seriousoverheating or overcooling.

2. Check: thermostat housing cover thermostat housingCracks/damage Replace.

EB00467

INSTALLING THE THERMOSTAT1. Install:

Install the thermostat with its breather hole afacing up.

2. Install thermostat cover

Befor installing the thermostat cover to the cyl-inder head, lubricate the O-ring with a thin coatof litium soap base grease.

5-12

THERMOSTAT COOL

3. Fill:coolling system(with the specified amount of the recom-mended coolant)Refer to “CHANGING THE COOLANT” inchapter 3.



5-13

WATER PUMP COOL


12345

Removing the water pump assemblyCoolant

Water pump inlet hoseWater pump outlet hoseWater pump hoseClutch wire and holderWater pump

11111

Remove the parts in the order listed.Drain.Refer to “CHANGING THE COOLANT” inchapter 3.


12 Nm (1.2 mkg)

WATER PUMP

5-14

WATER PUMP COOL


Disassembling the water pumpassemblyWater pump coverO-ringImpeller shaft (along with the impeller)Water pump sealOil sealBearingCirclip

1111111



Refer to “DISASSEMBLING/ASSEMBLING THE WATER PUMP”.

1234567

10 Nm (1.0 mkg)

5-15

WATER PUMP COOL

NOTE:

NOTE:

NOTE:

EAS00470

DISASSEMBLING THE WATER PUMP1. Remove:water pump seal 1

Tap out the water pump seal from the inside ofthe water pump housing.

2 Water pump housing

2. Remove:oil seal 1circlipbearing 2

Tap out the bearing and oil seal from the outsideof the water pump housing.

3 Water pump housing

3. Remove: rubber damper holder 1 rubber damper 2(from the impeller, with a thin, flat-headscrewdriver)

Do not scratch the impeller shaft.

EAS00474

CHECKING THE WATER PUMP1. Check:water pump housing cover 1water pump housing 2 impeller 3 rubber damper 4 rubber damper holder 5Cracks/damage/wear Replace.

2. Check:water pump sealoil sealCracks/damage/wear Replace.

bearingRough movement Replace.

5-16

WATER PUMP COOL

NOTE:

CAUTION:

NOTE:

NOTE:

EAS00475

ASSEMBLING THE WATER PUMP1. Install:bearingoil seal 1 New(into the water pump housing 2 )

Before installing the oil seal, apply tap water orcoolant onto its outer surface.

Install the oil seal with a socket that matchesits outside diameter.

2. Install:water pump seal 1 New

Never lubricate the water pump seal surfacewith oil or grease.

Install the water pump seal with the specialtools.

Before installing the water pump seal, applyYamaha bond No.1215 2 to the water pumphousing 3 .

Mechanical seal installer90890-04078 4

Middle driven shaft bearingdriver 5

90890-04058 5Yamaha bond No. 1215

90890-85505

A Push down.

3. Install: rubber damper 1 New rubber damper holder 2 New

Before installing the rubber damper, apply tapwater or coolant onto its outer surface.

5-17

WATER PUMP COOL

CAUTION:

4. Measure: impeller shaft tiltOut of specification Repeat steps (3) and(4).

Make sure that the rubber damper and rub-ber damper holder are flush with the impel-ler.

Max. impeller shaft tilt0.15 mm

1 Straightedge

2 Impeller

CARB

CHAPTER 6.CARBURETORS

CARBURETORS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETORS 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETORS 6-9. . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE CARBURETORS 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING AND ADJUSTING THE FUEL LEVEL 6-12. . . . . . . . . . . . . CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR 6-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 6-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL COCK 6-17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL COCK OPERATION 6-17. . . . . . . . . . . . . . . . . . .

6-1

CARBURETORS CARB


1234

Removing the carburetorsRider seat and fuel tank

Air filter case and heat protector plate

Starter cableFuel hoseThrottle position sensor couplerThrottle stop screw

1111

Remove the parts in the order listed.Refer to “Seats” and “FUEL TANK” inchapter 3.Refer to “AIR FILTER CASE ANDIGNITION COILS” in chapter 3.

Disconnect

EAS00481

CARBURETORSCARBURETORS

6-2

CARBURETORS CARB


56789

10

Therm bypass hoseCarburetor joint clamp screwThrottle cableCarburetor assemblyCarburetor jointSide cover

242142


6-3


12345

6789

1011

Separating the carburetorsStarter plunger linkConnecting boltConnecting boltHose jointSpring

Fuel feed pipeFuel feed pipePipeThrottle stop screwThrottle position sensorWater pipe

11122

212112


Refer to “ASSEMBLING THECARBURETORS”

Refer to “ASSEMBLING THECARBURETORS”

CARBURETORS CARB

6-4


12131415

Balance pipeBalance pipe bracketThrottle cable bracketCarburetor

2114

For installation, reverse the removalprocedure

CARBURETORS CARB

6-5

CARBURETORS CARB


Disassembling the carburetor

Starter plungerAir funnelVacuum chamber coverPiston valve springJet needle holderJet needle kitPiston valvePilot screwFuel drain boltFloat chamberFloat pivot pin

11111111111


The following procedure applies to all ofthe carburetors.

NOTE:

Refer to “ASSEMBLING THECARBURETORS.”

1234567891011

6-6

CARBURETORS CARB


FloatNeedle valveMain jetMain jet holderPilot jet

11111


1213141516

6-7

CARBURETORS CARB

EAS00486

CHECKING THE CARBURETORSThe following procedure applies to all of the car-buretors.1. Check:carburetor body float chamberCracks/damage Replace.

2. Check: fuel passagesObstruction Clean.

a. Wash the carburetor in a petroleum-basedsolvent. Do not use any caustic carburetorcleaning solution.

b. Blow out all of the passages and jets withcompressed air.

3. Check: float chamber bodyDirt Clean.

4. Check: float chamber rubber gasket 1Cracks/damage/wear Replace.

5. Check: floatDamage Replace.

6. Check:needle valve 1Damage/obstruction/wear Replace theneedle valve, needle valve seat and O-ringas a set.

6-8

CARBURETORS CARB

7. Check:piston valve 1Damage/scratches/wear Replace.

piston valve diaphragm 2Cracks/tears Replace.

8. Check:vacuum chamber cover 1piston valve spring 2 jet needle holder 3Cracks/damage Replace.

9. Check: jet needle kit 1main jet 2main jet holder 3pilot jet 4pilot screw 5starter plunger 6Bends/damage/wear Replace.Obstruction Clean.Blow out the jets with compressed air.

10. Check:piston valve movementInsert the piston valve into the carburetorbody and move it up and down.Tightness Replace the piston valve.

11. Check: fuel feed pipes 1pipes 2hose joint 3Cracks/damage Replace.Obstruction Clean.Blow out the pipes with compressed air.

6-9

CARBURETORS CARB

CAUTION:

NOTE:

12. Check: fuel hosesCracks/damage/wear Replace.Obstruction Clean.Blow out the hoses with compressed air.

EAS00490

ASSEMBLING THE CARBURETORSThe following procedure applies to all of the car-buretors.

Before assembling the carburetors, washall of the parts in a petroleumbased sol-vent.

Always use a new gasket.

1. Install:pilot screw kit 1

Pilot screw setting2 turns out

2. Install:piston valve 1 jet needle jet needle holderpiston valve springvacuum chamber cover

Install the end of the piston valve spring ontothe spring guide on the vacuum chamber cov-er.

Align the tab a on the piston valve diaphragmwith the recess b in the carburetor body.

6-10

CARBURETORS CARB

NOTE:

NOTE:

7 Nm (0.7 mkg)

NOTE:

NOTE:

3. Install:pipes fuel feed pipesvacuum chamber pipevacuum chamber air vent hosesprings float chamber air vent hoseshose jointspacerscopper washerconnecting bolts

Do not tighten the connecting bolts yet. Install the throttle valve lever 1 onto carbure-tors #2, #3, and #4 between the spring 2 andsynchronizing screw 3 .

4. Install:starter plunger link 1

Install the starter plunger link 1 onto each start-er plunger.

5. Tighten:connecting bolts

Place the carburetor assembly on a surfaceplate with the intake manifold side down.Then, tighten the connecting bolts while push-ing down the carburetor assembly with aneven force.

After tightening the connecting bolts, checkthat the throttle valve lever and starter plungerlink operate smoothly.

6. Install:starter cable 1

Install the starter cable holder 2 onto the start-er cable.

6-11

CARBURETORS CARB

EAS00493

INSTALLING THE CARBURETORS1. Adjust:carburetor synchronizationRefer to “SYNCHRONIZING THE CARBU-RETORS” in chapter 3.

2. Adjust:engine idling speed

Engine idling speed1250 1350 r/min

Refer to “ADJUSTING THE ENGINE ID-LING SPEED” in chapter 3.

3. Adjust: throttle cable free play

Throttle cable free play (at the flange of the throttle grip)

6 8 mm

Refer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.

6-12

CARBURETORS CARB

NOTE:

EAS00497

MEASURING AND ADJUSTING THE FUELLEVEL1. Measure: fuel level aOut of specification Adjust.

Fuel level (below the mark onthe body)

17.5 18.5 mm

a. Stand the motorcycle on a level surface.b. Place the motorcycle on a suitable stand to

ensure that the motorcycle is standingstraight up.

c. Install the fuel level gauge 1 onto the fueldrain pipe 2 .

Fuel level gauge90890-01312

d. Loosen the fuel drain bolt 3 .e. Hold the fuel level gauge vertically next to the

line 4 on the float chamber.f. Measure the fuel level a .

Fuel level readings should be equal on bothsides of the carburetor assembly.

2. Adjust: fuel level

a. Remove the carburetor assembly.b. Check the needle valve seat and needle

valve.c. If either is worn, replace them as a set.d. If both are fine, adjust the float level by slight-

ly bending the float tang 1 .e. Install the carburetor assembly.f. Measure the fuel level again.g. Repeat steps (a) to (f) until the fuel level is

within specification.

6-13

CARBURETORS CARB

NOTE:

NOTE:

EAS00502

CHECKING AND ADJUSTING THE THROTTLEPOSITION SENSOR

Before adjusting the throttle position sensor, theengine idling speed should be properly ad-justed.

1. Check: throttle position sensor(installed on the carburetor)

a. Disconnect the throttle position sensor cou-pler.

b. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Tester positive probe blue 1Tester negative probe black/blue 2

c. Measure the throttle position sensor maxi-mum resistance.Out of specification Replace the throttleposition sensor.

Throttle position sensor maximumresistance

4.0 6.0 kΩ at 20C(blue – black/blue)

d. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Tester positive probe yellow 3Tester negative probe black/blue 2

e. While slowly opening the throttle, check thatthe throttle position sensor resistance iswithin the specified range.

Check mainly that the resistance changes grad-ually when turning the throttle, since the read-ings (from closed to wide-open throttle) may dif-fer slightly from those specified.

Out of specification or the resistance changesabruptly Go to step (2).

Throttle position sensor resistance0 5 ± 1.0 kΩ at 20C(yellow – black/blue)

6-14

CARBURETORS CARB

NOTE:

2. Check: throttle position sensor(removed from the carburetor)

a. Disconnect the throttle position sensor cou-pler.

b. Remove the throttle position sensor from thecarburetor.

c. Connect the pocket tester (Ω 1k) to thethrottle position sensor.

Tester positive probe blue 1Tester negative probe black/blue 2

d. Measure the throttle position sensor maxi-mum resistance.Out of specification Replace the throttleposition sensor.

Throttle position sensor maxi-mum resistance

4.0 6.0 kΩ at 20C(blue – black/blue)

e. Connect the pocket tester (Ω 1k) to thethrottle position sensor coupler.

Tester positive probe yellow 3Tester negative probe black/blue 2

f. While slowly opening the throttle, check thatthe throttle position sensor resistance iswithin the specified range.

The resistance does not change or it changesabruptly Replace the throttle position sensor.The slot is worn or broken Replace thethrottle position sensor.

Check mainly that the resistance changes grad-ually when turning the throttle, since the read-ings (from closed to wide-open throttle) may dif-fer slightly from those specified.

Throttle position sensor resistance0 5 ± 1.0 kΩ at 20C(yellow – black/blue)

6-15

CARBURETORS CARB

NOTE:

NOTE:

2

a

b

NOTE:

3. Adjust: throttle position sensor angle

a. Set the main switch to “ON”.b. Disconnect the throttle position sensor cou-

pler.c. Reconnect the throttle position sensor cou-

pler.

After reconnecting the throttle position sensorcoupler, the tachometer switches to the throttleposition sensor adjustment mode.

d. Loosen the throttle position sensor screws1 .

e. Adjust the throttle position sensor angle ac-cording to the following table.

The angle of the throttle position sensor is indi-cated by the r/min which are displayed on thetachometer.

TachometerReading

Throttle posi-tion sensor

angle

Adjustmentdirection

5000 rpm Correct –

0 rpm Incorrect

10000 rpm Incorrect

f. After adjusting the throttle position sensorangle, tighten the throttle position sensorscrews.

To exit the throttle position sensor adjustmentmode, start the engine or set the main switch to“OFF”.

6-16

CARBURETORS CARB

EAS00504

CHECKING THE FUEL PUMP1. Check: fuel pump 1

a. Remove the fuel tank.Refer to “FUEL TANK” in chapter 3.

b. Disconnect the fuel-pump-to-carburetor fuelhose 2 from the carburetor.

c. Connect the fuel-tank-to-fuel-pump fuelhose to the fuel tank and then set the fuelcock to “ON”.

d. Place a container under the end of the fuelhose 2 .

e. Start the engine and check if fuel flows fromthe fuel hose 2 .

Fuel flows. Fuel pump is OK.

Fuel does not Replace the fuelflow.

ppump.

f. Stop the engine and check if the fuel stopsflowing from the fuel hose 2 .

Fuel stops flowing. Fuel pump is OK.

F el flows Replace the fuelFuel flows . ppump.

6-17

CARBURETORS CARB

NOTE:

EAS00505

CHECKING THE FUEL COCK1. Remove fuel tank fuel filter 1 fuel cock 2

2. Check: fuel cockCracks/damage/wear Replace.

3. Check: fuel cock strainer 1(with compressed air)Dirt /obstruction Clean.Damage Replace.

4. Install fuel cock fuel filter fuel tank

EAS00506

CHECKING THE FUEL COCK OPERATION

After installing the fuel cock, check its opera-tion.

1. Check that the fuel cock lever is turned to“ON” or “OFF”.

2. Place a container under the end of the fuelhose.

3. Check: fuel cock operation

a. Suck on the end of the vacuum hose.Fuel flows.Fuel cock is OK.Fuel does not flow.Replace the fuel cock.

CHAS

CHAPTER 7.CHASSIS

FRONT WHEEL AND BRAKE DISCS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS 7-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL 7-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT WHEEL STATIC BALANCE 7-6. . . . . . . . . .

REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET 7-8. . . . REAR WHEEL 7-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BRAKE DISC AND REAR WHEEL SPROCKET 7-9. . . . . . . . . . . . . . . . . REMOVING THE REAR WHEEL 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL 7-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REAR WHEEL DRIVE HUB 7-12. . . . . . . . . . . . . . . . . . CHECKING AND REPLACING THE REAR WHEEL SPROCKET 7-12. INSTALLING THE REAR WHEEL 7-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR WHEEL STATIC BALANCE 7-13. . . . . . . . . . . .

FRONT AND REAR BRAKES 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE PADS 7-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE PADS 7-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE FRONT BRAKE PADS 7-16. . . . . . . . . . . . . . . . . . . . . . REPLACING THE REAR BRAKE PADS 7-18. . . . . . . . . . . . . . . . . . . . . . . FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID

RESERVOIR 7-21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE MASTER CYLINDER AND BRAKE FLUID

RESERVOIR 7-24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT BRAKE MASTER CYLINDER 7-26. . . . . . . . . REMOVING THE REAR BRAKE MASTER CYLINDER 7-26. . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE MASTER

CYLINDERS 7-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT BRAKE MASTER CYLINDER 7-27. . . . . . . . INSTALLING THE REAR BRAKE MASTER CYLINDER 7-29. . . . . . . . . . FRONT BRAKE CALIPERS 7-31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REAR BRAKE CALIPER 7-33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT BRAKE CALIPERS 7-35. . . . . . . . . . . . . . . . . . REMOVING THE REAR BRAKE CALIPER 7-36. . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT AND REAR BRAKE CALIPERS 7-37. . . . . . . . INSTALLING THE FRONT BRAKE CALIPERS 7-38. . . . . . . . . . . . . . . . . INSTALLING THE REAR BRAKE CALIPER 7-40. . . . . . . . . . . . . . . . . . . .

CHAS

FRONT FORK 7-42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT FORK LEGS 7-45. . . . . . . . . . . . . . . . . . . . . . . . DISASSEMBLING THE FRONT FORK LEGS 7-45. . . . . . . . . . . . . . . . . . CHECKING THE FRONT FORK LEGS 7-47. . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE FRONT FORK LEGS 7-48. . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT FORK LEGS 7-53. . . . . . . . . . . . . . . . . . . . . . .

HANDLEBARS 7-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBARS 7-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBARS 7-56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBARS 7-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STEERING HEAD 7-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER BRACKET 7-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET 7-61. . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STEERING HEAD 7-61. . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE STEERING HEAD 7-62. . . . . . . . . . . . . . . . . . . . . . . . . .

REAR SHOCK ABSORBER ASSEMBLY 7-64. . . . . . . . . . . . . . . . . . . . . . . . . HANDLING THE REAR SHOCK ABSORBER AND

GAS CYLINDER 7-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DISPOSING OF A REAR SHOCK ABSORBER AND

GAS CYLINDER 7-65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 7-66. . . . . . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND

GAS CYLINDER 7-66. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RELAY ARM AND CONNECTING ARM 7-67. . . . . . . . INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 7-67. . . . . .

SWINGARM AND DRIVE CHAIN 7-68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SWINGARM 7-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE DRIVE CHAIN 7-70. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE SWINGARM 7-71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE DRIVE CHAIN 7-73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE SWINGARM 7-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE DRIVE CHAIN 7-75. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1


1234567

Removing the front wheel and brakediscs

Brake hose holders (left and right)Brake calipers (left and right)Wheel axle pinch boltFront wheel axleFront wheelCollars (left and right)Brake discs (left and right)

2211122


Place the motorcycle on a suitable standso that the front wheel is elevated.

Loosen

NOTE:

Refer to “INSTALLING THE FRONTWHEEL”.

72 Nm (7.2 mkg) 6 Nm (0.6 mkg)

40 Nm (4.0 mkg)

18 Nm (1.8 mkg)

20 Nm (2.0 mkg)

Refer to “REMOVING/INSTALLING THEFRONT WHEEL”.


FRONT WHEEL AND BRAKE DISCS CHAS

EAS00514

CHASSISFRONT WHEEL AND BRAKE DISCS

7-2


Disassembling the front wheelOil seals (left and right)Wheel bearings (left and right)Spacer

221



123


EAS00518

7-3


WARNING

NOTE:

NOTE:

NOTE:

WARNING

EAS00521

REMOVING THE FRONT WHEEL1. Stand the motorcycle on a level surface.



2. Remove:Brake hose holders left brake caliper right brake caliperwheel axle

Do not squeeze the brake lever when removingthe brake calipers.

3. Elevate: front wheel


EAS00525

CHECKING THE FRONT WHEEL1. Check:wheel axleRoll the wheel axle on a flat surface.Bends Replace.

Do not attempt to straighten a bent wheelaxle.

2. Check: tire front wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.

7-4


NOTE:

CAUTION:

NOTE:

3. Measure: radial wheel runout 1 lateral wheel runout 2Over the specified limits Replace.

Front radial wheel runout1.0 mm

Front lateral wheel runout0.5 mm

4. Check:wheel bearingsFront wheel turns roughly or is loose Re-place the wheel bearings.

oil sealsDamage/wear Replace.

5. Replace:wheel bearings Newoil seals New

a. Clean the outside of the front wheel hub.b. Remove the oil seals 1 with a flat-head

screwdriver.

To prevent damaging the wheel, place a rag 2between the screwdriver and the wheel surface.

c. Remove the wheel bearings 3 with a gener-al bearing puller.

d. Install the new wheel bearings and oil sealsin the reverse order of disassembly.

Do not contact the wheel bearing centerrace 4 or balls 5 . Contact should be madeonly with the outer race 6

Use a socket 7 that matches the diameter ofthe wheel bearing outer race and oil seal.

7-5


NOTE:

EAS00533

CHECKING THE BRAKE DISCSThe following procedure applies to both of thebrake discs.1. Check:brake discDamage/galling Replace.

2. Measure:brake disc deflectionOut of specification Correct the brake discdeflection or replace the brake disc.

Max. brake disc deflectionFront: 0.1 mmRear: 0.1 mm

a. Place the motorcycle on a suitable stand sothat the wheel is elevated.

b. Before measuring the front brake discdeflection, turn the handlebars to the left orright to ensure that the front wheel is station-ary.

c. Remove the brake caliper.d. Hold the dial gauge at a right angle against

the brake disc surface.e. Measure the deflection 1.5 mm below the

edge of the brake disc.

3. Measure:brake disc thicknessMeasure the brake disc thickness at a fewdifferent locations.Out of specification Replace.

Min. brake disc thicknessFront: 4.5 mmRear: 4.5 mm

4. Adjust:brake disc deflection

a. Remove the brake disc.b. Rotate the brake disc by one bolt hole.c. Install the brake disc.

Tighten the brake disc bolts in stages and in acrisscross pattern.

7-6


72 Nm (7.2 mkg)

20 Nm (2,0 mkg)

CAUTION:

40 Nm (4.0 mkg)

WARNING

NOTE:

Brake disc bolt18 Nm (1,8 mkg)LOCTITE

d. Measure the brake disc deflection.e. If out of specification, repeat the adjustment

steps until the brake disc deflection is withinspecification.

f. If the brake disc deflection cannot be broughtwithin specification, replace the brake disc.

EAS00545

INSTALLING THE FRONT WHEEL1. Lubricate:wheel axleoil seal lips


2. Tighten:wheel axle 1wheel axle pinch bolt 2

Before tightening the wheel axle nut, pushdown hard on the handlebars several timesand check if the front fork reboundssmoothly.

3. Install:brake calipersbrake hose holders

Make sure that the brake hose is routedproperly.

EAS00549

ADJUSTING THE FRONT WHEEL STATICBALANCE

After replacing the tire, wheel or both, the frontwheel static balance should be adjusted.

Adjust the front wheel static balance with thebrake discs installed.

7-7


NOTE:

1. Remove:balancing weight(-s)

2. Find: front wheel’s heavy spot

a. Place the front wheel on a suitable balancingstand.

b. Spin the front wheel.c. When the front wheel stops, put an “X1” mark

at the bottom of the wheel.d. Turn the front wheel 90 so that the “X1” mark

is positioned as shown.e. Release the front wheel.f. When the front wheel stops, put an “X2” mark

at the bottom of the wheel.g. Repeat steps (a) through (d) several times

until all the marks come to rest at the samespot.

h. The spot where all the marks come to rest isthe front wheel’s heavy spot “X”.

3. Adjust: front wheel static balance

a. Install a balancing weight 1 onto the rim ex-actly opposite the heavy spot “X”.

Start with the lightest weight.

b. Turn the front wheel 90 so that the heavyspot is positioned as shown.

c. If the heavy spot does not stay in that posi-tion, install a heavier weight.

d. Repeat steps (b) and (c) until the front wheelis balanced.

4. Check: front wheel static balance

a. Turn the front wheel and make sure that itstays at each position shown.

b. If the front wheel does not remain stationaryat all of the positions, rebalance it.

7-8


123456789

1011

Removing the rear wheel

Brake caliperLocknuts (left and right)Adjusting bolts (left and right)Wheel axle nutWasherRear wheel axleLeft adjusting blockRight adjusting blockRear wheelBrake caliper bracket boltBrake caliper bracket

12211111111


Place the motorcycle on a suitable standso that the rear wheel is elevated.

Loosen.Loosen.

Make sure that the tapered side of the rightadjusting block faces the wheel.


NOTE:

NOTE:

150 Nm (15 mkg)

40 Nm (4.0 mkg)

REAR WHEEL, BRAKE DISC, AND REAR WHEELSPROCKET CHAS

EAS00550

REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKETREAR WHEEL

7-9


12345678

Removing the brake disc and rearwheel sprocketBrake discRear wheel sprocketSpacers (left and right)Oil sealBearingRear wheel drive hubRear wheel drive hub dampersRear wheel

11211151



18 Nm (1.8 mkg)

69 Nm (6.9 mkg)


EAS00556

BRAKE DISC AND REAR WHEEL SPROCKET

7-10


Disassembling the rear wheelSpacerBearingSpacerOil sealCirclipBearing

111111



123456


7-11


WARNING

NOTE:

NOTE:

NOTE:

EAS00561

REMOVING THE REAR WHEEL1. Stand the motorcycle on a level surface.



2. Remove:brake caliper

Do not depress the brake pedal when removingthe brake caliper.

3. Remove:wheel axle nutwasherwheel axleadjusting blocksbrake caliper bracket. rear wheel

Push the rear wheel forward and remove thedrive chain from the rear wheel sprocket.

EAS00565

CHECKING THE REAR WHEEL1. Check:wheel axle rear wheelwheel bearingsoil sealsbrake discRefer to “BRAKE DISC AND REAR WHEELSPROKET”.

2. Check: tire rear wheelDamage/wear Replace.Refer to “CHECKING THE TIRES” and“CHECKING THE WHEELS” in chapter 3.

7-12


NOTE:

3. Measure: radial wheel runout lateral wheel runoutRefer to “FRONT WHEEL”.Over the specified limits Replace.

Max. radial wheel runout1.0 mm

Max. lateral wheel runout0.5 mm

EAS00567

CHECKING THE REAR WHEEL DRIVE HUB1. Check: rear wheel drive hub 1Cracks/damage Replace.

rear wheel drive hub dampers 2Damage/wear Replace.

EAS00568

CHECKING AND REPLACING THE REARWHEEL SPROCKET1. Check: rear wheel sprocketMore than 1/4 tooth a wear Replace therear wheel sprocket.Bent teeth Replace the rear wheel sprock-et.

b Correct1 Drive chain roller2 Rear wheel sprocket2. Replace: rear wheel sprocket

a. Remove the self-locking nuts and the rearwheel sprocket.

b. Clean the rear wheel drive hub with a cleancloth, especially the surfaces that contact thesprocket.

c. Install the new rear wheel sprocket.

Rear wheel sprocket self-lockingnut

69 Nm (6.9 mkg)

Tighten the self-locking nuts in stages and in acrisscross pattern.

7-13


150 Nm (15.0 mkg)

27 Nm (2.7 mkg)

WARNING

NOTE:

EAS00571

INSTALLING THE REAR WHEEL1. Lubricate:wheel axlewheel bearingsoil seal lips


2. Install: rear wheelbrake caliper bracketadjusting blockswheel axlewasherwheel axle nutbrake caliper

3. Adjust:drive chain slack a


Refer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.

4. Tighten:wheel axle nutbrake caliper bolts

Make sure that the brake hose is routedproperly.

EAS00575

ADJUSTING THE REAR WHEEL STATICBALANCE

After replacing the tire, wheel or both, the rearwheel static balance should be adjusted.

Adjust the rear wheel static balance with thebrake disc and rear wheel drive hub installed.

1. Adjust: rear wheel static balanceRefer to “FRONT WHEEL”.

7-14


123456

Removing the front brake pads

Brake pad clipsBrake pad pinBrake pad springBrake padsBrake pad shimsBleed screw

211221

Remove the parts in the order listed.The following procedure applies to bothof the front brake calipers.

Refer to “REPLACING THE FRONTBRAKE PADS”.

40 Nm (4.0 mkg) 6 Nm (0.6 mkg)


FRONT AND REAR BRAKES CHAS

EAS00577

FRONT AND REAR BRAKESFRONT BRAKE PADS

7-15


1234

Removing the rear brake padsBrake caliper boltsBrake padsBrake pad shimsBleed screw

2241


Refer to “REPLACING THE REARBRAKE PADS”.

27 Nm (2.7 mkg)

6 Nm (0.6 mkg)

40 Nm (4.0 mkg)



EAS00578

REAR BRAKE PADS

7-16


CAUTION:

NOTE:

EAS00579

Disc brake components rarely require dis-assembly.Therefore, always follow these preventivemeasures:Never disassemble brake components un-less absolutely necessary.

If any connection on the hydraulic brakesystem is disconnected, the entire brakesystem must be disassembled, drained,cleaned, properly filled, and bled afterreassembly.

Never use solvents on internal brake com-ponents.

Use only clean or new brake fluid for clean-ing brake components.


Avoid brake fluid coming into contact withthe eyes as it can cause serious injury.

First aid for brake fluid entering the eyes:Flush with water for 15 minutes and get im-mediate medical attention.

EAS00582

REPLACING THE FRONT BRAKE PADSThe following procedure applies to both brakecalipers.

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:brake hose holder bolt 1brake caliper 2

7-17


NOTE:

NOTE:

2. Remove:brake pad clips 1brake pad pins 2brake pad spring 3brake pads(along with the brake pad shims)

3. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.

Brake pad wear limit0.5 mm

4. Install:brake pad shims(onto the brake pads)

brake padsbrake pad spring

Always install new brake pads, brake padshims, and a brake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


d. Install a new brake pad shim onto each newbrake pads.

e. Install new brake pads and a new brake padspring.

The arrow a on the brake pad spring mustpoint in the direction of disc rotation.

7-18


40 Nm (4.0 mkg)

6 Nm (0.6 mkg)

NOTE:

5. Install:brake pad pinsbrake pad clipsbrake caliper boltsbrake hose holder bolt

6. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.Refer to “CHECKING THE BRAKE FLUIDLEVEL” in chapter 3.

7. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

EAS00583

REPLACING THE REAR BRAKE PADS

When replacing the brake pads, it is not neces-sary to disconnect the brake hose or disas-semble the brake caliper.

1. Remove:brake caliper 1

2. Remove:brake pads(along with the brake pad shims)

7-19


NOTE:

3. Measure:brake pad wear limit aOut of specification Replace the brakepads as a set.

Brake pad wear limit0.8 mm

4. Install:brake pad shims(onto the brake pads)

brake pads

Always install new brake pads, brake padshims, and a brake pad spring as a set.

a. Connect a clear plastic hose 1 tightly to thebleed screw 2 . Put the other end of the hoseinto an open container.

b. Loosen the bleed screw and push the brakecaliper pistons into the brake caliper withyour finger.

c. Tighten the bleed screw.


d. Install a new brake pa shim onto each newbrake pad.

7-20


40 Nm (4.0 mkg)5. Install:brake caliper bolts


7. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

7-21


12

3456789

10111213

Removing the front brake mastercylinder and brake fluid reservoirBrake fluidBrake fluid reservoircap stopperBrake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoirBrake fluid reservoir hoseCirclipDust coverHose jointBrake leverFront brake switch connectorUnion boltCopper washer

1111111111213


Drain.

Disconnect.Refer to “INSTALLING THE FRONTBRAKE MASTER CYLINDER”.

1

3

4

5

6 8

7

9

1011

1213

1413

1413

15

16

17

30 Nm (3.0 mkg)

13 Nm (1.3 mkg)

New

2


EAS00584

FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR

7-22


14151617

Brake hoseBrake master cylinder holderBrake master cylinderFront brake switch

2111


Refer to “INSTALLING THE FRONTBRAKE MASTER SYLINDER”.

1

2

3

4

5

6 8

7

9

1011

1213

1413

1413

15

16

17

30 Nm (3.0 mkg)

13 Nm (1.3 mkg)

New


7-23


Disassembling the front brakemaster cylinderDust bootCirclipBrake master cylinder kitBrake master cylinder

1111



1234


EAS00585

7-24


123456789

10

Removing the rear brake mastercylinder and brake fluid reservoirBrake fluidBrake fluid reservoir capBrake fluid reservoir diaphragm holderBrake fluid reservoir diaphragmBrake fluid reservoirBrake fluid reservoir hoseHose jointUnion boltCopper washerBrake hoseBrake master cylinder

1111111211


Drain.

Refer to “INSTALLING THE REARBRAKE MASTER SYLINDER”.

5 Nm (0.5 mkg)

23 Nm (2.3 mkg)

30 Nm (3.0mkg)



EAS00586

REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR

7-25


Disassembling the rear brakemaster cylinderBrake master cylinder kitBrake master cylinder

11



12

16 Nm (1.6 mkg)


EAS00587

7-26

A

B


NOTE:

NOTE:

NOTE:

EAS00588

REMOVING THE FRONT BRAKE MASTERCYLINDER

Before disassembling the front brake mastercylinder, drain the brake fluid from the entirebrake system.

1. Remove:union bolt 1copper washers 2brake hoses 3master cylinder holder 4

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

EAS00589

REMOVING THE REAR BRAKE MASTERCYLINDER1. Remove:union bolt 1copper washers 2brake hose 3button head bolts 4

To collect any remaining brake fluid, place acontainer under the master cylinder and the endof the brake hose.

EAS00593

CHECKING THE FRONT AND REAR BRAKEMASTER CYLINDERSThe following procedure applies to both of thebrake master cylinders.1. Check:brake master cylinderDamage/scratches/wear Replace.

brake fluid delivery passages(brake master cylinder body)Obstruction Blow out with compressed air.

A Front

B Rear

7-27

A

B

A B


WARNING

2. Check:brake master cylinder kitDamage/scratches/wear Replace.

A Front

B Rear

3. Check:brake fluid reservoir 1Cracks/damage Replace.

brake fluid reservoir diaphragm 2Cracks/damage Replace.

4. Check:brake hosesCracks/damage/wear Replace.

EAS00607

INSTALLING THE FRONT BRAKE MASTERCYLINDER

Before installation, all internal brake com-ponents should be cleaned and lubricatedwith clean or new brake fluid.

Never use solvents on internal brake com-ponents.


7-28


13 Nm (1.3 mkg)

NOTE:

30 Nm (3.0 mkg)

WARNING

NOTE:

WARNING

1. Install:brake master cylinder 1

brake master cylinder holder

Install the brake master cylinder holder withthe “UP” mark facing up.

Align the end of the brake master cylinderholder with the punch mark a in the right han-dlebar.

First, tighten the upper bolt, then the lowerbolt.

2. Install:copper washers Newbrake hoseunion bolt

Proper brake hose routing is essential to in-sure safe motorcycle operation. Refer to“CABLE ROUTING”.

While holding the brake hose, tighten theunion bolt as shown.

Turn the handlebars to the left and to the rightto make sure that the brake hose does nottouch other parts (e.g., wire harness, cables,leads). Correct if necessary.

3. Fill:brake fluid reservoir(with the specified amount of the recom-mended brake fluid)


Use only the designated brake fluid. Otherbrake fluids may cause the rubber seals todeteriorate, causing leakage and poorbrake performance.



7-29


CAUTION:

30 Nm (3.0 mkg)

WARNING

CAUTION:


4. Bleed:brake systemRefer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.


6. Check:brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

EAS00608

INSTALLING THE REAR BRAKE MASTERCYLINDER1. Install:copper washers Newbrake hosesunion boltbutton head bolts


When installing the brake hose onto thebrake master cylinder, make sure that thebrake pipe touches the projection a asshown.

7-30


WARNING

CAUTION:

2. Fill:brake fluid reservoir




When refilling, be careful that water doesnot enter the reservoir. Water will signifi-cantly lower the boiling point of the brakefluid and could cause vapor lock.




5. Adjust:brake pedal positionRefer to “ADJUSTING THE REAR BRAKE”in chapter 3.

Brake pedal position (from thetop of the brake pedal to the bot-tom of the rider footrest bracketbolt center)

4.3 9.3 mm

6. Adjust: rear brake light operation timingRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH” in chapter 3.

7-31


1234

Removing the front brake calipers

Brake fluidUnion boltUnion boltCopper washerBrake hoseBrake caliper

1211

Remove the parts in the order listed.The following procedure applies to bothof the front brake calipers.Drain.

Refer to “INSTALLING THE FRONTBRAKE CALIPERS”.

6 Nm (0.6 mkg)

30 Nm (3.0 mkg)

40 Nm (4.0 mkg)



EAS00613

FRONT BRAKE CALIPERS

7-32


Disassembling the front brakecalipers

Brake pad clipBrake pad pinBrake pad springBrake padBrake caliper pistonBrake caliper piston sealBleed screw

2112481


The following procedure applies to bothof the front brake calipers.

Refer to “REMOVING THE FRONTBRAKE CALIPERS”.

6 Nm (0.6 mkg)

1234567



EAS00615

7-33


1234

Removing the rear brake caliperBrake fluidUnion boltCopper washerBrake hoseBrake caliper

1211

Remove the parts in the order listed.Drain.

Refer to “INSTALLING THE REARBRAKE CALIPERS”.

30 Nm (3.0 mkg)

27 Nm (2.7 mkg)



EAS00616

REAR BRAKE CALIPER

7-34


Disassembling the rear brake caliperBrake padBrake caliper pistonBrake caliper piston sealBleed screw

2241


Refer to “REMOVING THE REARBRAKE CALIPERS”.

1234


6 Nm (0.6 mkg)


EAS00617

7-35


NOTE:

NOTE:

WARNING

EAS00625

REMOVING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.

Before removing either brake caliper, drain thebrake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose 3brake caliper 4

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Secure the right side brake caliper pistonswith a piece of wood a .

b. Blow compressed air into the brake hosejoint opening b to force out the pistons fromthe brake caliper.

Never try to pry out the brake caliper pis-tons.

Do not loosen the bolts 3 .

c. Remove the brake caliper piston seals.d. Repeat the previous steps to force out the

right side pistons from the brake caliper.

7-36


NOTE:

NOTE:

WARNING

EAS00628

REMOVING THE REAR BRAKE CALIPER

Before removing the brake caliper, drain thebrake fluid from the entire brake system.

1. Remove:union bolt 1copper washers 2brake hose 3

Put the end of the brake hose into a containerand pump out the brake fluid carefully.

2. Remove:brake caliper pistons 1brake caliper piston seals 2

a. Blow compressed air into the brake hosejoint opening a to force out the pistons fromthe brake caliper.Be careful not to get injured when the pistonsare expelled from the brake caliper..

Cover the brake caliper piston with a rag.Never try to pry out the brake caliper pis-tons.

b. Remove the brake caliper piston seals.

7-37

A

B


WARNING

EAS00633

CHECKING THE FRONT AND REAR BRAKECALIPERS

Recommended brake componentreplacement schedule

Brake pads If necessary

Piston seals Every two years

Brake hoses Every four years

Brake fluidEvery two years andwhenever the brakeis disassembled

1. Check:brake caliper pistons 1Rust/scratches/wear Replace the brakecaliper.

brake caliper cylinders 2Scratches/wear Replace the brake cali-per.

brake calipers 3Cracks/damage Replace.

brake fluid delivery passages(brake caliper body)Obstruction Blow out with compressed air.

Whenever a brake caliper is disassembled,replace the brake caliper piston seals.

A Front

B Rear

2. Check: rear brake caliper bracket 1Cracks/damage Replace.

7-38


WARNING

New

30 Nm (3.0 mkg)

WARNING

CAUTION:

40 Nm (4.0 mkg)

7 Nm (0.7 mkg)

EAS00640

INSTALLING THE FRONT BRAKE CALIPERSThe following procedure applies to both of thebrake calipers.


Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.



1. Install:brake caliper 1(temporarily)

copper washers brake hose 2union bolt 3


When installing the brake hose onto thebrake caliper 1 , make sure that the brakepipe a touches the projection b on thebrake caliper.

2. Remove:brake caliper

3. Install:brake padsbrake pad springbrake caliperbrake hose holderRefer to “REPLACING THE FRONT BRAKEPADS”.

7-39


WARNING

CAUTION:









7. Check;brake lever operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

7-40


WARNING

30 Nm (3.0 mkg)

WARNING

CAUTION:

EAS00642

INSTALLING THE REAR BRAKE CALIPER


Never use solvents on internal brake com-ponents as they will cause the piston sealsto swell and distort.



1. Install:brake padsbrake caliper 1copper washers Newbrake hose 2union bolt 3


When installing the brake hose onto thebrake caliper 1 , make sure that the brakepipe a touches the projection b on thebrake caliper.

7-41


WARNING

CAUTION:



Use only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing leakage andpoor brake performance.






5. Check:brake pedal operationSoft or spongy feeling Bleed the brakesystem.Refer to “BLEEDING THE HYDRAULICBRAKE SYSTEM” in chapter 3.

7-42

FRONT FORK CHAS


123456789

Removing the front fork legsFront brake calipers

Front wheel

Front cowling inner panelFront fenderHandlebar pinch boltUpper bracket boltHandlebar (left)Handlebar (right)Upper bracket pinch boltsCap boltsLower bracket pinch boltsFront fork legs

122112242

Remove the parts in the order listed.The following procedure applies to bothof the front fork legs.Refer to ”FRONT WHEEL AND BRAKEDISCS”.Refer to ”COWLINGS” in chapter 3.

Loosen

LoosenLoosenLoosen


23 Nm (2.3 mkg)

6 Nm (0.6mkg)

6 Nm (0.6mkg)

13 Nm (2.3 mkg)

23 Nm (2.3 mkg)

23 Nm (2.3 mkg)

FRONT FORKEAS00647

7-43

FRONT FORK CHAS


Disassembling the front fork legs

Cap boltO-ringNutWasherSpacerWasherFork springCopper washerDamper rod assembly boltDamper rod assembly

1111111111

Remove the parts in the order listed.The following procedure applies to both of the front fork legs.

Refer to “DISASSEMBLING/ASSEMBLING THE FRONT FORKLEGS”.

23 Nm (2.3 mkg)

40 Nm (4.0 mkg)

12345678910

EB703002

7-44

FRONT FORK CHAS


Dust sealOil seal clipOil sealWasherOuter tube bushingInner tubeOil lock piece

1111111


Refer to “DISASSEMBLING/ASSEMBLING THE FRONT FORKLEGS”.

23 Nm (2.3 mkg)

40 Nm (4.0 mkg)

11121314151617

7-45

FRONT FORK CHAS

WARNING

NOTE:

WARNING

EAS00649

REMOVING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Stand the motorcycle on a level surface.



2. Loosen:upper bracket pinch bolt 3cap bolt 2handlebar pinch bolt 1 lower bracket pinch boltupper bracket bolt 4handlebar 5

Before loosening the upper and lowerbracket pinch bolts and handlebar pinchbolt, support the front fork leg.

3. Remove: front fork leg

EAS00655

DISASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Remove:cap bolt 1(from the damper adjusting rod)

spacer 2nut 3

a. Press down on the spacer with the forkspring compressor 4 .

b. Install the rod holder 5 between the nut 3and the spacer 2 .

Fork spring compressor90890-01441

Rod holder90890-01434

7-46

FRONT FORK CHAS

NOTE:

WARNING

NOTE:

NOTE:

Use the side of the rod holder that is marked “B”.

c. Loosen the nut.d. Remove the cap bolt.e. Remove the rod holder and fork spring com-

pressor.

The fork spring is compressed.

f. Remove the spacer and nut.g. Remove the fork spring.

2. Drain: fork oil

Stroke the damper rod 1 several times whiledraining the fork oil.

3. Remove:dust sealoil seal clip 1oil sealwasher(with a flat-head screwdriver)

Slide metal

4. Remove:damper rod assembly boltcopper washer

While holding the damper rod with the damperrod holder 1 , loosen the damper rod assemblybolt.

Damper rod holder90890-01425

7-47

FRONT FORK CHAS

WARNING

CAUTION:

EAS00657

CHECKING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Check: inner tube 1outer tube 2Bends/damage/scratches Replace.

Do not attempt to straighten a bent innertube as this may dangerously weaken it.

2. Measure:spring free length aOut of specification Replace.

Spring free length limit251.8 mm<Limit>: 246 mm

3. Check:damper rod 1Damage/wear Replace.Obstruction Blow out all of the oil pas-sages with compressed air.

The front fork leg has a built-in damper ad-justing rod and a very sophisticated inter-nal construction, which are particularlysensitive to foreign material.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

7-48

FRONT FORK CHAS

WARNING

NOTE:

WARNING

CAUTION:

4. Check:cap bolt O-ringDamage/wear Replace.

EAS00661

ASSEMBLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Make sure that the oil levels in both frontfork legs are equal.

Uneven oil levels can result in poor han-dling and a loss of stability.

When assembling the front fork leg, be sure toreplace the following parts:- inner tube bushing- outer tube bushing- oil seal- dust seal

Before assembling the front fork leg, makesure that all of the components are clean.

1. Install:oil lock piece inner tube 2damper rod assembly 1

Always use new copper washers.

Allow the damper rod assembly to slideslowly down the inner tube 2 until it pro-trudes from the bottom of the inner tube. Becareful not to damage the inner tube.

2. Lubricate: inner tube’s outer surface

Recommended lubricantYamaha fork and suspension oil01 or equivalent

7-49

FRONT FORK CHAS

140 Nm (4.0 mkg)

NOTE:

CAUTION:

NOTE:

NOTE:

3. Tighten:damper rod assembly bolt

While holding the damper rod with the damperrod holder 2 , tighten the damper rod assemblybolt.

Damper rod holder90890-01425

4. Install:outer tube bushing 1washer 2oil seal 3oil seal clip 4dust seal 5

Make sure that the numbered side of the oilseal faces up.

Before installing the oil seal, lubricate its lipswith lithium soap base grease.

Lubricate the outer surface of the inner tubewith fork oil.

Before installing the oil seal, cover the top ofthe front fork leg with a plastic bag 6 to protectthe oil seal during installation.

5. Install:washeroil seal 1(with the fork seal driver 2 )

Fork seal driver weight90890-01367

Fork seal driver attachment90890-01374

6. Install:oil seal clip 1

Adjust the oil seal clip so that it fits into the outertube’s groove.

7-50

FRONT FORK CHAS

CAUTION:

NOTE:

7. Install:dust seal 1(with the fork seal driver 2 )

8. Install: rod puller 1adapter 2(onto the damper rod 3 )

Rod puller90890-01437

Adapter90890-01436

9. Fully compress the front fork leg.10. Fill: front fork leg(with the specified amount of the recom-mended fork oil)

Quantity (each front fork leg)476 cm3

Recommended oilYamaha fork and suspensionoil 01or equivalent

Be sure to use the recommended fork oil.Other oils may have an adverse effect onfront fork performance.

When disassembling and assembling thefront fork leg, do not allow any foreign ma-terial to enter the front fork.

11. After filling the front fork leg, slowly strokethe damper rod 1 up and down (at least tentimes) to distribute the fork oil.

Be sure to stroke the damper rod slowly be-cause the fork oil may spurt out.

7-51

FRONT FORK CHAS

NOTE:

NOTE:

12. Slowly stroke the inner tube 1 up and downto distribute the fork oil once more (1 stroke= about 100 mm).

Be careful not to stroke the inner tube over 100mm as this will cause air to enter. If the innertube is stroked more than 100 mm, repeat steps(12) and (13).

13. Before measuring the fork oil level, wait tenminutes until the oil has settled and the airbubbles have dispersed.

Be sure to bleed the front fork leg of any residualair.

14. Measure: front fork leg oil level aOut of specification Correct.

Front fork leg oil level (from thetop of the inner tube, with theinner tube fully compressed, and without the spring)

107 mm

15. Install:nut 1 fork spring 2washer 3spacer 4washer 5damper adjusting rod 6cap bolt 7

a. Remove the rod puller and adapter.b. Install the nut.

7-52

FRONT FORK CHAS

NOTE:

WARNING

c. Install the rod puller and adapter onto thedamper rod.

Rod puller90890-01437

Adapter90890-01436

d. Install the fork spring, washers and spacer.e. Press down on the spacer with the fork

spring compressor 8 .f. Pull up the rod puller and install the rod hold-

er 9 between the nut 1 and the spacer 4 .

Use the side of the rod holder that is marked “B”.

Fork spring compressor90890-01441

Rod holder90890-01434

g. Remove the rod puller and adapter.h. Install the nut 1 and position it as specified

b .

Distance b11 mm

i. Install the damper adjusting rod and cap bolt,and then finger tighten the cap bolt.

j. Hold the cap bolt and tighten the nut to speci-fication.

Nut:15 Nm (1.5 mkg)

k. Remove the rod holder and fork spring com-pressor.

The fork spring is compressed.Always use a new cap bolt O-ring.

7-53

FRONT FORK CHAS

NOTE:

NOTE:

23 Nm (2.3 mkg)

33 Nm (3.3 mkg)

23 Nm (2.3 mkg)

26 Nm (2.6 mkg)

WARNING

16. Install:cap bolt(onto the inner tube)

Temporarily tighten the cap bolt.

EAS00662

INSTALLING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.1. Install: front fork legTemporarily tighten the upper and lowerbracket pinch bolts.

Make sure that the inner fork tube is flush withthe top of the handlebar.

2. Tighten: lower bracket pinch bolt

handlebar pinch bolt 1

cap bolt 2upper bracket pinch bolt 3

Make sure that the brake hoses are routedproperly.

3. Adjust:spring preload rebound dampingcompression dampingRefer to “ADJUSTING THE FRONT FORKLEGS” in chapter 3.

7-54

HANDLEBARS CHAS


1234

56789

1011

Removing the handlebarsLeft grip endHandlebar gripClutch switch connectorLeft handlebar switch

Starter cableStarter leverClutch cableClutch lever holderRight grip endThrottle cableThrottle grip

1121

1111121


Disconnect.Refer to “INSTALLING THEHANDLEBARS”.Disconnect.

Disconnect.

Refer to “INSTALLING THEHANDLEBARS”.

Refer to “REMOVING/INSTALLING THEHANDLEBARS”.

13 Nm (1.3 mkg)

115 Nm (11.5 mkg)

13 Nm (1.3 mkg)

13 Nm (1.3 mkg)

13 Nm (1.3 mkg)

23 Nm (2.3 mkg)

18

EAS00665

HANDLEBARS

7-55

HANDLEBARS CHAS


1213141516171819202122

Front brake switch connectorRight handlebar switchBrake master cylinder holderBrake master cylinderHandlebar pinch boltUpper bracket boltUpper bracket pinch boltSteering stem nutLeft handlebarRight handlebarUpper bracket

21112221111

Disconnect.

Refer tp “INSTALLING THEHANDLEBARS”.


13 Nm (1.3 mkg)

115 Nm (11.5 mkg)

13 Nm (1.3 mkg)

13 Nm (1.3 mkg)

13 Nm (1.3 mkg)

23 Nm (2.3 mkg)

18

7-56

HANDLEBARS CHAS

WARNING

NOTE:

WARNING

EAS00667

REMOVING THE HANDLEBARS1. Stand the motorcycle on a level surface.


2. Remove:grip endhandlebar grip left handlebar switchclutch lever holder

Blow compressed air between the left handle-bar and the handlebar grip, and gradually pushthe grip off the handlebar.

3. Remove:grip end right handle switch 1 throttle grip 2 right handlebar switchbrake master cylinder holder

EAS00669

CHECKING THE HANDLEBARS1. Check: left handlebar right handlebarBends/cracks/damage Replace.

Do not attempt to straighten bent handle-bars as this may dangerously weaken them.

7-57

HANDLEBARS CHAS

CAUTION:

NOTE:

NOTE:

NOTE:

EAS00674

INSTALLING THE HANDLEBARS1. Install:brake master cylinder holder 1

Install the brake master cylinder holderwith the “UP” mark facing up.

First, tighten the upper bolt, then the lowerbolt.

Align the mating surfaces of the brake mastercylinder holder with the punch mark a in theright handlebar.

There should be 2 mm of clearance betweenthe right handlebar switch and the brake mas-ter cylinder holder.

2. Install: right handlebar switch 1 throttle cablesgrip end

Align the projection a on the throttle cablehousing with the hole b in the right handlebar.

3. Install:clutch lever holder 1

Align the slit in the clutch lever holder with thepunch mark a in the left handlebar.

7-58

HANDLEBARS CHAS

NOTE:

WARNING

4. Install: left handlebar switch 1

Align the projection a on the left handlebarswitch with the hole b in the left handlebar.

5. Install:handlebar gripgrip end

a. Apply a thin coat of rubber adhesive onto theend of the left handlebar.

b. Slide the handlebar grip over the end of theleft handlebar.

c. Wipe off any excess rubber adhesive with aclean rag.

Do not touch the handlebar grip until therubber adhesive has fully dried.

6. Adjust:clutch cable free playRefer to “ADJUSTING THE CLUTCHCABLE FREE PLAY” in chapter 3.

Clutch cable free play (at the end of the clutch lever)

10 15 mm

7. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY” in chapter 3.

Throttle cable free play (at theflange of the throttle grip)

6 8 mm

7-59


123456789

101112

Removing the lower bracketFront wheel

Front fork legsMain switch couplerUpper bracket boltLeft handlebar assemblyRight handlebar assemblySteering stem nutWasherUpper bracketLower bracket panelBrake hose holder boltLock washerUpper ring nutRubber washer

221111112111

Remove the parts in the order listed.Refer to “FRONT WHEEL AND BRAKEDISCS”.Refer to “FRONT FORK”.Disconnect.

Refer to ”CHECK AND ADJUSTING THESTEERING HEAD” in chapter 3.

23 Nm (2.3 mkg)

13 Nm (1.3 mkg) 115 Nm (11.5 mkg)

13 Nm (1.3 mkg)

23 Nm (2.3 mkg)

17 Nm (1.7 mkg)9 Nm (0.9 mkg)

1st.2nd.

STEERING HEAD CHAS

EAS00676

STEERING HEADLOWER BRACKET

7-60

STEERING HEAD CHAS


13

14151617181920

Lower ring nut

Lower bracketBearing coverBearing inner raceUpper bearingLower bearingDust sealBearing outer race

1

1121112

Refer to “CHECK AND ADJUSTING THESTEERING HEAD” in chapter 3.


23 Nm (2.3 mkg)

13 Nm (1.3 mkg) 115 Nm (11.5 mkg)

13 Nm (1.3 mkg)

23 Nm (2.3 mkg)

17 Nm (1.7 mkg)9 Nm (0.9 mkg)

1st.2nd.

7-61

STEERING HEAD CHAS

WARNING

WARNING

EAS00677

REMOVING THE LOWER BRACKET1. Stand the motorcycle on a level surface.


2. Remove: front fork legssteering stem nutupper bracket ring nuts 1(with the special tool 2 )

Ring nut wrench90890-01403

Securely support the lower bracket so thatthere is no danger of it falling.

EAS00682

CHECKING THE STEERING HEAD1. Wash:bearing ballsbearing races

Recommended cleaning solventKerosine

2. Check:bearing balls 1bearing races 2Damage/pitting Replace.

3. Replace:bearing ballsbearing races

a. Remove the bearing races from the steeringhead pipe with a long rod 1 and hammer.

7-62

STEERING HEAD CHAS

CAUTION:

NOTE:

b. Remove the bearing race from the lowerbracket with a floor chisel 2 and hammer.

c. Install a new dust seal and new bearingraces.

If the bearing race is not installed properly,the steering head pipe could be damaged.

Always replace the bearing balls and bearingraces as a set.

Whenever the steering head is disassembled,replace the dust seal.

4. Check:upper bracket lower bracket(along with the steering stem)Bends/cracks/damage Replace.

EAS00683

INSTALLING THE STEERING HEAD1. Lubricate:upper bearing lower bearingbearing races


2. Install:bearingbearing cover lower ring nut 1 rubber washer 2upper ring nut 3 lock washer 4Refer to “CHECKING AND ADJUSTINGTHE STEERING HEAD” in chapter 3.

7-63

STEERING HEAD CHAS

NOTE:

NOTE:

115 Nm (11.5 mkg)

23 Nm (2.3 mkg)

23 Nm (2.3 mkg)

13 Nm (1.3 mkg)

13 Nm (1.3 mkg)

3. Install:upper bracketsteering stem nut

Temporarily tighten the steering stem nut.

4. Install: front fork legsRefer to “FRONT FORK”.

Temporarily tighten the upper and lower bracketpinch bolts, and handlebar pinch bolts.

5. Tighten:steering stem nut lower bracket pinch bolt

upper bracket pinch bolt

upper bracket bolthandlebar pinch bolt

7-64


123456789

1011

Removing the rear shock absorberassemblyRear wheelSelf-locking nut/boltSelf-locking nut/boltSelf-locking nut/bolt /collerSelf-locking nut/boltPin/clip/washerRear shock absorber assemblyColler/oil seal/bearingRelay armColler/oil seal/bearingConnecting armColler/oil seal/bearing

1/11/1

1/1/11/1

1/1/11

1/2/12

1/2/11

1/2/1


Refer to “REMOVING THE REAR WHEEL”.

Refer to “REMOVING THE REARSHOCK ABSORBER ASSEMBLY”.


40 Nm (4.0 mkg)

40 Nm (4.0 mkg)

40 Nm (4.0 mkg)

REAR SHOCK ABSORBER ASSEMBLY CHAS

EAS00685

REAR SHOCK ABSORBER ASSEMBLY

7-65


WARNING

WARNING

EAS00687

HANDLING THE REAR SHOCK ABSORBERAND GAS CYLINDER

This rear shock absorber and gas cylindercontain highly compressed nitrogen gas.Before handling the rear shock absorber orgas cylinder, read and make sure you under-stand the following information. Themanufacturer cannot be held responsiblefor property damage or personal injury thatmay result from improper handling of therear shock absorber and gas cylinder.Do not tamper or attempt to open the rearshock absorber or gas cylinder.

Do not subject the rear shock absorber orgas cylinder to an open flame or any othersource of high heat. High heat can causean explosion due to excessive gas pres-sure.

Do not deform or damage the rear shockabsorber or gas cylinder in any way. If therear shock absorber, gas cylinder or bothare damaged, damping performance willsuffer.

EAS00689

DISPOSING OF A REAR SHOCK ABSORB-ER AND GAS CYLINDERGas pressure must be released before dispos-ing of a rear shock absorber and gas cylinder.To release the gas pressure, press on the gasvalve needle with a suitable tool as shown, untilall of the gas is released (the hissing hasstopped).

Wear eye protection to prevent eye damagefrom released gas or metal chips.

7-66


WARNING

NOTE:

NOTE:

NOTE:

EAS00694

REMOVING THE REAR SHOCK ABSORBERASSEMBLY1. Stand the motorcycle on a level surface.



2. Remove: rear wheel rear shock absorber assembly lower bolt 1 relay-arm-to-swingarm bolt 2

While removing the rear shock absorber as-sembly lower bolt, hold the swingarm so that itdoes not drop down.

3. Remove: rear shock absorber assembly upper bin 1 rear shock absorber assembly

Raise the swingarm and then remove the rearshock absorber assembly from between theswingarm.

EAS00696

CHECKING THE REAR SHOCK ABSORBERASSEMBLY AND GAS CYLINDER1. Check: rear shock absorber rodBends/damage Replace the rear shockabsorber assembly.

rear shock absorberGas leaks/oil leaks Replace the rearshock absorber assembly.

springDamage/wear Replace the rear shockabsorber assembly.

gas cylinderDamage/gas leaks Replace.

bushingsDamage/wear Replace.

dust sealsDamage/wear Replace.

boltsBends/damage/wear Replace.

7-67


NOTE:

40 Nm (4.0 mkg)

40 Nm (4.0 mkg)

40 Nm (4.0 mkg)

40 Nm (4.0 mkg)

CHECKING THE RELAY ARM AND CON-NECTING ARM1. Check: relay arm 1connecting arm 2Damage/wear Replace.

bearingsoil sealsDamage/pitting Replace.

spacersDamage/scratches Replace.

EAS00698

INSTALLING THE REAR SHOCK ABSORB-ER ASSEMBLY1. Lubricate:bearingsoil sealsspacers


2. Install:connecting arm relay arm rear shock absorber assembly

When installing the rear shock absorber assem-bly, lift up the swingarm.

3. Tighten:connecting-arm-to-frame nut

relay-arm-to-connecting-arm nut

relay-arm-to-swingarm nut

rear shock absorber assembly lower nut

7-68

SWINGARM AND DRIVE CHAIN CHAS


1234567

Removing the swingarm and drive chainDrive sprocketRear wheel

Rear shock absorber assembly

Adjusting bolt / locknutDrive chain guardRear fenderFlapPivot shaft nut/washerPivot shaftSwingarm

2/2111

1/111


Refer to “ENGINE” in chapter 4.Refer to “REAR WHEEL, BRAKE DISC,AND REAR WHEEL SPROCKET”.Refer to “REAR SHOCK ABSORBER ASSEMBLY”.

95 Nm (9.5 mkg)

6 Nm (0.6 mkg)

6 Nm (0.6 mkg)

EAS00700

SWINGARM AND DRIVE CHAIN

7-69



8

91011121314151617

Pivot shaft adjust bolt

Drive chainDust coverOil sealBushShimDrive chain guideBushLeft bearingRight bearing

2

111111111

Refer to “REMOVING/INSTALLING THESWINGARM”.


95 Nm (9.5 mkg)

6 Nm (0.6 mkg)

6 Nm (0.6 mkg)

7-70


NOTE:

NOTE:

NOTE:

NOTE:

Before removing the drive sprocket, drive chain,and rear wheel, measure the drive chain slackand the length of a tenlink section of the drivechain.

EC573000

REMOVING THE SWINGARM1. Remove:Bolt (connecting rod) 1Connecting rod 2

Remove the bolt while holding the swingarm.

2. Loosen:Pivot shaft adjust bolt 1

Loosen the pivot shaft adjust bolt using a pivotshaft wrench 2

Pivot shaft wrench:90890-01471

3. Remove:Pivot shaft 1Swingarm

EAS00704

REMOVING THE DRIVE CHAIN1. Remove:drive chain

Only cut the drive chain if or the swingarm is tobe replaced.

7-71


WARNING

NOTE:

NOTE:

EAS00703

CHECKING THE SWINGARM1. Stand the motorcycle on a level surface.



2. Measure:swingarm side playswingarm vertical movement

a. Measure the tightening torque of the pivotshaft nut.

Pivot shaft nut95 Nm (9.5mkg)

b. Measure the swingarm side play A by mov-ing the swingarm from side to side.

c. If the swingarm side play is out of specifica-tion, check the spacers, bearings, washers,and dust covers.

Swingarm side play (at the endof the swingarm)

1.0mm

d. Check the swingarm vertical movement Bby moving the swingarm up and down.

If swingarm vertical movement is not smooth orif there is binding, check the spacers, bearings,washers, and bust covers.

3. Check:swingarmBends/cracks/damage Replace.

If the swingarm must be replaced, the drivechain must be cut with a drive chain cutter.

7-72


WARNING

4. Check:pivot shaftRoll the pivot shaft on a flat surface.Bends Replace.

Do not attempt to straighten a bent pivotshaft.

5. Wash:pivot shaftpivot shaft adjust boltdust coversspacerbearings

Recommended cleaning solventKerosine

6. Check:dust coversspaceroil sealsDamage/wear Replace.

bearingsDamage/pitting Replace.

7-73


NOTE:

EAS00709

CHECKING THE DRIVE CHAIN1. Measure: ten-link section a of the drive chainOut of specification Replace the drivechain.

Max. ten-link drive chain section149 mm

While measuring the ten-link section, pushdown on the drive chain to increase its tension.

Measure the length between drive chain roller1 and 11 as shown.

Perform this measurement at two or three dif-ferent places.

2. Check:drive chainStiffness Clean and lubricate or replace.

3. Clean:drive chain

a. Wipe the drive chain with a clean cloth.b. Put the drive chain in kerosine and remove

any remaining dirt.

7-74


CAUTION:

c. Remove the drive chain from the kerosineand completely dry it.

This motorcycle has a drive chain with smallrubber O-rings 1 between the drive chainside plates. Never use high-pressure wateror air, steam, gasoline, certain solvents(e.g., benzine), or a coarse brush to cleanthe drive chain.High-pressure methods could force dirt orwater into the drive chain’s internals, andsolvents will deteriorate the O-rings. Acoarse brush can also damage the O-rings.Therefore, use only kerosine to clean thedrive chain.Don’t soak drive drain in kerosine morethem ten minutes. O-ring is damage by kero-sine.

4. Check:O-rings 1Damage Replace the drive chain.

drive chain rollers 2Damage/wear Replace the drive chain.

drive chain side plates 3Cracks/damage/wear Replace the drivechain.

5. Lubricate:drive chain

Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains

6 Check:drive sprocket rear wheel sprocketMore than 1/4 tooth a wear Replace thedrive chain sprockets as a set.Bent teeth Replace the drive chainsprockets as a set.

b Correct

1 Drive chain roller

2 Drive chain sprocket

7-75


95 Nm (9.5 mkg)

NOTE:

EAS00711

INSTALLING THE SWINGARM1. Lubricate:bearingsspacersdust coverspivot shaft


2. Install:swingarmpivot shaftwasherpivot shaft adjust bolt 1pivot shaft nut

Use the pivot shaft wrench 2 to tighten the piv-ot adjust bolt to finger tightness.

Pivot shaft wrench:90890-1471

3. Install: rear shock absorber assembly rear wheelRefer to “REAR SHOCK ABSORBER AS-SEMBLY” and “REAR WHEEL”.

4. Adjust:drive chain slackRefer to “ADJUSTING THE DRIVE CHAINSLACK” in chapter 3.


EAS00713

INSTALLING THE DRIVE CHAIN1. Lubricate:drive chain

2. Install:drive chain(with the drive chain riveter)

ELEC

CHAPTER 8.ELECTRICAL

ELECTRICAL COMPONENTS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTRUMENT FUNCTIONS 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INDICATOR LIGHTS 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT 8-2. . . . . . COMBINATION METER 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SWITCHES 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCH CONTINUITY 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE SWITCHES 8-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE BULBS AND BULB SOCKETS 8-8. . . . . . . . . . . . . . . . . . TYPES OF BULBS 8-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULBS 8-8. . . . . . . . . . . . . . . . . CHECKING THE CONDITION OF THE BULB SOCKETS 8-10. . . . . . . . CHECKING THE LEDs 8-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IGNITION SYSTEM 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRIC STARTING SYSTEM 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STARTING CIRCUIT CUTOFF SYSTEM OPERATION 8-17. . . . . . . . . . . TROUBLESHOOTING 8-18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STARTER MOTOR 8-22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE STARTER MOTOR 8-24. . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE STARTER MOTOR 8-25. . . . . . . . . . . . . . . . . . . . . . . .

CHARGING SYSTEM 8-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

LIGHTING SYSTEM 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE LIGHTING SYSTEM 8-31. . . . . . . . . . . . . . . . . . . . . . . . .

ELEC

SIGNALING SYSTEM 8-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SIGNALING SYSTEM 8-38. . . . . . . . . . . . . . . . . . . . . . .

COOLING SYSTEM 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL PUMP SYSTEM 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL PUMP CIRCUIT OPERATION 8-50. . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL PUMP 8-53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SELF-DIAGNOSIS 8-54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TROUBLESHOOTING 8-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8-1

ELECTRICAL COMPONENTS ELEC

1 Wire harness2 Main switch3 Front brake light switch4 Plug top ignition coils5 Clutch switch6 Starting circuit cutoff relay7 Fuse box8 Flasher relay9 CDI unit

10 Starter relay11 Main fuse12 Oil level relay13 Battery14 Rectifier / regulator15 Rear brake light switch16 Neutral switch17 Speed sensor18 Sidestand switch19 Stator coil assembly

20 Oil level switch21 Pickup coil22 Radiator fan23 Horn24 Thermo unit25 Thermo switch26 Headlight relay (HI, LO)

EB800000

ELECTRICALELECTRICAL COMPONENTS

8-2

Neutral indicator light “ ”High beam indicator light “ ”Turn indicator light “ ”Fuel indicator light “ ”

1

2

3

4

Oil level /coolant temperature warning light “ ”Oil level symbol “ ”Coolant temperature symbol “ ”

1

2

3

INSTRUMENT FUNCTIONS ELEC

CAUTION:

NOTE:

INSTRUMENT FUNCTIONSINDICATOR LIGHTS

Turn indicator light “ ”This indicator flashes when the turn switch ismoved to the left or right.

Neutral indicator light “ ”This indicator comes on when the transmis-sion is in neutral.

High beam indicator light “ ”This indicator comes on when the headlighthigh beam is used.

Fuel indicator light “ ”When the fuel level drops below approxi-mately 3.7 L, this light will come on.When this light comes on, fill the fuel tank atthe first opportunity.

OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT

This warning light has two functions.The light will come on and symbol “ ” willflash if the engine oil level is low. If this sym-bol flashes, stop the engine immediatelyand fill it with oil to the specified level.

The light will come on and symbol “ ” willflash if the coolant temperature is too high.The following chart shows the conditions ofthe indicator light, symbol and temperaturedisplay in accordance with the coolant tem-perature.

Do not run the motorcycle until you know ithas sufficient engine oil.

Do not run the motorcycle if the engine isoverheated.

Even if the oil is filled to the specified level, thewarning light may flicker when riding on a slopeor during sudden acceleration or deceleration,but this is normal.

8-3


SpeedometerClock, odometer“SELECT” button“RESET” button

1

2

3

4

Coolanttemperature

Display Conditions What to do

0C 40C Symbol is on and“LO” is displayed.

Go ahead with riding.

41C 117CSymbol is on andtemperature is dis-played.

Go ahead with riding.

118C 140C

Symbol and tem-perature flashesand indicator lightcomes on.

Stop the motorcycle andallow it to idle until thecoolant temperature goesdown. If the temperature doesnot go down, stop the en-gine. Refer to “OVER-HEATING” in chapter 9.

141 C

Symbol flashes,“HI” is displayedand flashes, andthe indicator lightcomes on.

Stop the engine and allowit to cool. Refer to “OVERHEATING”in chapter 9.

COMBINATION METERThis combination meter is equipped with the fol-lowing.A speedometerAn odometerTwo trip odometersA fuel reserve tripmeterA clockFor GB and USA models only:To change the speedometer display from kilo-meters to miles, press the “SELECT” button forat least two seconds.

Odometer and trip metersUse the trip meters to estimate how far you canride on a tank of fuel.Use the fuel reserve trip meter to see the dis-tance traveled from when the fuel level droppedto the reserve level.

Push the “SELECT” button to change betweenthe odometer mode “ODO” and the trip odome-ter modes “TRIP 1”and “TRIP 2” in the followingorder:“ODO” “TRIP 1” “TRIP 2” “ODO”

8-4


NOTE:

When the fuel level indicator light comes on theodometer display will automatically change tothe fuel reserve trip meter mode “TRIP F” andstart counting the distance traveled from thatpoint. Push the “SELECT” button to change be-tween the fuel odometer, trip odometer andodometer modes in the following order:“TRIP F” “TRIP 1” “TRIP 2” “ODO” “TRIP F”

To reset a trip odometer to 0.0, select it by push-ing the “SELECT” button and push the “RESET”button for at least one second. To reset the fuelreserve trip meter, select it by pushing the “SE-LECT” button and push the “RESET” button forat least one second.The display will return to “TRIP 1”. If you do notreset the fuel reserve trip meter manually, it willautomatically reset and return to “TRIP 1” afterrefueling and the motorcycle has traveled both5 km and for approximately 3 minutes.ClockTo change the display to the clock mode, pushboth the “SELECT” and “RESET” buttons.To set the clock:1. Push both the “SELECT” and “RESET” but-

tons for at least two seconds.2. When the hour digits start flashing, push the

“RESET” button to set the hours.3. Push the “SELECT” button to change the

minutes.4. When the minute digits start flashing, push

the “RESET” button to set the minutes.5. Push the “SELECT” button to start the clock.

After setting the clock, be sure to push the “SE-LECT” button before turning the main switch to“OFF”, otherwise the clock will not be set.

8-5

SWITCHES ELEC

CAUTION:

NOTE:

NOTE:

EB801000

SWITCHESCHECKING SWITCH CONTINUITYCheck each switch for continuity with the pockettester. If the continuity reading is incorrect,check the wiring connections and if necessary,replace the switch.

Never insert the tester probes into the cou-pler terminal slots 1 . Always insert theprobes from the opposite end of the coupler,taking care not to loosen or damage theleads.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

When checking for continuity, switch back andforth between the switch positions a few times.

The terminal connections for switches (e.g.,main switch, engine stop switch) are shown inan illustration similar to the one on the left.The switch positions a are shown in the far leftcolumn and the switch lead colors b are shownin the top row in the switch illustration.

“ ” indicates a continuity of electricitybetween switch terminals (i.e., a closed circuitat the respective switch position).

The example illustration on the left showsthat:There is continuity between blue/red and redwhen the switch is set to “ ”.There is continuity between blue/red and blue,between brown/blue and red, and betweenblue/yellow and blue/black when the switch isset to “ON”.

8-6

CHECKING THE SWITCHES ELEC

EB801010

CHECKING THE SWITCHESCheck each switch for damage or wear, proper connections, and also for continuity between the termi-nals. Refer to “CHECKING SWITCH CONTINUITY”.

Damage/wear Repair or replace the switch.Improperly connected Properly connect.Incorrect continuity reading Replace the switch.

8-7

CHECKING THE SWITCHES ELEC

1 Main switch2 Pass switch3 Dimmer switch4 Turn signal switch5 Horn switch6 Clutch switch7 Light switch (for Europe)8 Engine stop switch

9 Start switch10 Front brake light switch11 Rear brake light switch12 Neutral switch13 Fuse14 Sidestand switch15 Oil level switch*: for AUS

8-8

CHECKING THE BULBS AND BULB SOCKETS ELEC

EB801020

CHECKING THE BULBS ANDBULB SOCKETSCheck each bulb and bulb socket for damage orwear, proper connections, and also for continu-ity between the terminals.Damage/wear Repair or replace the bulb,bulb socket or both.Improperly connected Properly connect.Incorrect continuity reading Repair or re-place the bulb, bulb socket or both.

TYPES OF BULBSThe bulbs used on this motorcycle are shown inthe illustration on the left.Bulbs A and B are used for headlights andusually use a bulb holder which must be de-tached before removing the bulb. The majorityof these bulbs can be removed from their re-spective socket by turning them counterclock-wise.

Bulb C is used for turn signal and tail /brakelights and can be removed from the socket bypushing and turning the bulb counterclock-wise.

Bulbs D and E are used for meter and indica-tor lights and can be removed from their re-spective socket by carefully pulling them out.

CHECKING THE CONDITION OF THE BULBSThe following procedure applies to all of thebulbs.1. Remove:bulb

8-9


WARNING

CAUTION:

NOTE:

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

Be sure to hold the socket firmly when re-moving the bulb. Never pull the lead, other-wise it may be pulled out of the terminal inthe coupler.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverse-ly affected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

2. Check:bulb (for continuity)(with the pocket tester)No continuity Replace.


Before checking for continuity, set the pockettester to “0” and to the “Ω 1” range.

a. Connect the tester positive probe to terminal1 and the tester negative probe to terminal3 , and check the continuity.

b. Connect the tester positive probe to terminal2 and the tester negative probe to terminal3 , and check the continuity.

c. If either of the readings indicate no continu-ity, replace the bulb.

8-10


NOTE:

WARNING

CHECKING THE CONDITION OF THE BULBSOCKETSThe following procedure applies to all of thebulb sockets.1. Check:bulb socket (for continuity)(with the pocket tester)No continuity Replace.


Check each bulb socket for continuity in thesame manner as described in the bulb section;however, note the following.

a. Install a good bulb into the bulb socket.b. Connect the pocket tester probes to the re-

spective leads of the bulb socket.c. Check the bulb socket for continuity.

If any of the readings indicate no continuity,replace the bulb socket.

CHECKING THE LEDsThe following procedure applies to all of theLEDs.1. Check:

LED (for proper operation)

a. Disconnect the meter assembly coupler(meter assembly side).

b. Connect two jumper leads 1 from the bat-tery terminals to the respective coupler ter-minals as shown.

A wire that is used as a jumper lead musthave at least the same capacity of the bat-tery lead, otherwise the jumper lead mayburn.

This check is likely to produce sparks,therefore make sure that no flammable gasor fluid is in the vicinity.

c. When the jumper leads are connected to theterminals the respective LED should illumi-nate.Does not light Replace the meter assem-bly.

8-11

1 Main switch5 Battery6 Main fuse9 Starting circuit cutoff relay11 Sidestand switch14 CDI unit15 Ignition coil #116 Ignition coil #217 Ignition coil #318 Ignition coil #419 Spark plugs20 Pick up coil21 Neutral switch56 Ignition fuse63 Engine stop switch66 Diode 2

IGNITION SYSTEM ELEC

EB802001

IGNITION SYSTEMCIRCUIT DIAGRAM

8-12

2. Battery

Check the condition of the battery.Refer to “CHECKING AND CHARGING THEBATTERY” in chapter 3.

Min. open-circuit voltage12.8 V or more at 20 C

Is the battery OK?

YES

Clean the batteryterminals.

Recharge or re-place the battery.

NO

3. Spark plugs

The following procedure applies to all of thespark plugs.Check the condition of the spark plug.Check the spark plug type.Measure the spark plug gap.Refer to “CHECKING THE SPARK PLUGS”in chapter 3.

Standard spark plugCR10EK (NGK)

Spark plug gap0.6 0.7 mm

Is the spark plug in good condition, is it of thecorrect type, and its gap within specification?

YES

Re-gap or replace thespark plug.

NO

EB802401

EB802403


NOTE:

YES NO

Replace the fuse(-s).

1. Main and ignition fuses

Check the main and ignition fuses for conti-nuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main and ignition fuses OK?

EB802011

TROUBLESHOOTING

The ignition system fails to operate (nospark or intermittent spark).

Check:1. main and ignition fuses2. battery3. spark plugs4. ignition spark gap5. spark plug cap resistance6. ignition coil resistance7. pickup coil resistance8. main switch9. engine stop switch

10. neutral switch11. sidestand switch12. starting circuit cutoff relay13. wiring

(of the entire ignition system)

Before troubleshooting, remove the followingpart(-s):

1) rider seat2) fuel tank3) air filter case4) heat protector plate5) front cowling inner panel (right)6) side cowling inner panel (right)7) side cowling (right)Troubleshoot with the following special tool(-s).

Ignition checker90890-06754


EB802400

8-13


Tester positive probe ignition coil terminal

Tester negative probe ignition coil terminal

Tester positive probe

ignition coil terminalTester positive probe

spark plug terminal

4. Ignition spark gap

The following procedure applies to all of thespark plugs.Disconnect the spark plug cap from the sparkplug.

Connect the ignition checker as shown. Spark plug capSet the main switch to “ON”.Measure the ignition spark gap .Crank the engine by pushing the start switchand gradually increase the spark gap until amisfire occurs.

Min. ignition spark gap6 mm

Is there a spark and is the spark gap withinspecification?

NO

The ignition system isOK.

YES

EB802409

6. Ignition coil resistance

The following procedure applies to all of theignition coils.Disconnect the ignition coil connectors fromthe ignition coil terminals.

Connect the pocket tester (Ω 1) to the igni-tion coil as shown.

Primary coil resistance0.238 0.322 Ω at 20C

Connect the pocket tester (Ω 1k) to theignition coil as shown.

Measure the secondary coil resistance.

Measure the primary coil resistance.

1

1

2

a

2

Secondary coil resistance8.16 11.04 kΩ at 20C

Is the ignition coil OK?

YES

Replace the ignitioncoil.

NO

EB802405

8-14

EB802410

7. Pickup coil resistance

Disconnect the pickup coil coupler from thewire harness.

Connect the pocket tester (Ω 100) to thepickup coil terminal.

Pickup coil resistance248 372 Ω at 20C(between gray and black)

Is the pickup coil OK?

YES

Replace the pickupcoil.

NO

Tester positive probe gray Tester negative probe black

12

Measure the pickup coil resistance.

EB802411

Check the main switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the main switch OK?

YES

Replace the mainswitch.

NO

8. Main switch

EB802412

Check the engine stop switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the engine stop switch OK?

YES

Replace the righthandlebar switch.

NO

9. Engine stop switch

EB802413

Check the neutral switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the neutral switch OK?

YES

Replace the neutralswitch.

NO

10. Neutral switch

EB802414

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES

Replace the side-stand switch.

NO

11. Sidestand switch


8-15

12. Starting circuit cutoff relay

Remove the relay unit from the wire harness.Connect the pocket tester (Ω 1) to the relayterminals as shown.

Check the starting circuit cutoff relay for con-tinuity.

YES

Replace the startingcircuit cutoff relay.

NO


sky blueTester negative probe

blue/yellow

1

2


blue/yellowTester negative probe

sky blue

2

1

Continuity

No continuity

NOTE:When you switch the “–” and “” leads of thedigital pocket tester, the readings in the abovechart will be reversed.

Are the tester readings correct?

EB802416

Check the entire ignition system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the ignition system’s wiring properly con-nected and without defects?

NO

Replace the ignitorunit.

YES

13. Wiring

Properly connect orrepair the ignitionsystem’s wiring.


EB802415

8-16

1 Main switch5 Battery6 Main fuse7 Starter relay8 Starter motor9 Starting circuit cutoff relay11 Sidestand switch21 Neutral switch38 Clutch switch56 Ignition fuse63 Engine stop switch64 Start switch65 Diode 1

ELECTRIC STARTING SYSTEM ELEC

EB803000

ELECTRIC STARTING SYSTEMCIRCUIT DIAGRAM

8-17


EB803010

STARTING CIRCUIT CUTOFF SYSTEM OP-ERATIONIf the engine stop switch is set to “ ” and themain switch is set to “ON” (both switches areclosed), the starter motor can only operate if atleast one of the following conditions is met:

The transmission is in neutral (the neutralswitch is closed).

The clutch lever is pulled to the handlebar (theclutch switch is closed) and the sidestand is up(the sidestand switch is closed).

The starting circuit cutoff relay prevents thestarter motor from operating when neither ofthese conditions has been met. In this instance,the starting circuit cutoff relay is open so currentcannot reach the starter motor. When at leastone of the above conditions has been met thestarting circuit cutoff relay is closed and the en-gine can be started by pressing the start switch.

WHEN THE TRANSMISSION IS INNEUTRALWHEN THE SIDESTAND IS UP ANDTHE CLUTCH LEVER IS PULLED TOTHE HANDLEBAR

1 Battery

2 Main fuse

3 Main switch

4 Ignition fuse

5 Engine stop switch

6 Starting circuit cutoff relay

7 Diode

8 Clutch switch

9 Sidestand switch

10 Neutral switch

11 Start switch

12 Starter relay

13 Starter motor

8-18

2. Battery


Open-circuit voltage12.8 V or more at 20 C

Is the battery OK?

YES


Recharge or replace the battery.

NO

3. Starter motor

Connect the battery positive terminal andstarter motor lead with a jumper lead .

YES

Repair or replace thestarter motor.

NO

EB803400

132

WARNINGA wire that is used as a jumper lead musthave at least the same capacity of thebattery lead, otherwise the jumper leadmay burn.

This check is likely to produce sparks,therefore make sure that no flammablegas or fluid is in the vicinity.

Does the starter motor turn?

EB802401


NOTE:

YES NO





EB803020

TROUBLESHOOTING

The starter motor fails to turn.

Check:1. main and ignition fuses2. battery3. starter motor4. starting circuit cutoff relay5. Diode6. starter relay7. main switch8. engine stop switch9. neutral switch

10. sidestand switch11. clutch switch12. start switch13. wiring

(of the entire starting system)

Before, troubleshooting, remove the followingpart(-s):

1) rider seat2) fuel tank3) air filter case4) front cowling inner panels5) Side cowling inner panels6) Side cowlingsTroubleshoot with the following special tool(-s).


EB802400

8-19


Disconnect the relay from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay terminals as shown.

YES

Replace the startingcircuit cutoff relay

NO

Battery positive terminal red/blackBattery negative terminal

black/yellow

1

2

Tester positive probe blue/whiteTester negative probe black

34

Does the starting circuit cutoff relay havecontinuity between black and blue/white?

5. DIODE

Disconnect the relay from the coupler.Connect the pocket tester (Ω 1) to the relayterminals as shown.

Measure the starting circuit cutoff relay forcontinuity as follows.

YES

Replace the startingcircuit cutoff relay

NO



black/yellow

1

2



blue/yellow

1

3

Continuity

NOTE:When you switch the “–” and “” leads of thedigital pocket tester, the readings in the abovechart will be reversed.

Are the tester readings correct?

EB803403


black/yellowTester negative probe

sky blue

2

1



sky blue

3

1

Nocontinuity


EB803402

8-20


Check the diode for continuty.Disconnect the diode from the coupler.Connect the pocket tester (Ω1) to the diodeterminals as a shown.

Measur the diode for continuity as follows.

6. Starter relay

Disconnect the starter relay from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the starter relay coupler asshown.

YES

Replace the starter relay.

NO

Battery positive terminal red/whiteBattery negative terminal

blue/white 2

EB802412



YES


NO


EB802413



YES

Replace the diode.

NO

9. Neutral switch

10. Diode

1

Tester positive probe red Tester negative probe black

34

Does the starter relay have continuity be-tween red and black?

EB802411



YES


NO

7. Main switch

YES NO



blue/black

1

2


blue/blackTester negative probe

blue/yellow

2

1

Nocontinuity

Continuity


Is the diode ok?

EB803404

8-21

EB803408

Check the entire starting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the starting system’s wiring properly con-nected and without defects?

NO

The starting systemcircuit is OK.

YES

14. Wiring

Check the start switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the start switch OK?

YES


NO

13. Start switch

Properly connect orrepair the startingsystem’s wiring.

EB803406

Check the sidestand switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the sidestand switch OK?

YES

Replace the sidestand switch.

NO

11. Sidestand switch

EB803405

Check the clutch switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the clutch switch OK?

YES

Replace the clutchswitch.

NO

12. Clutch switch


EB8022414

8-22


123

Removing the starter motorRider seatFuel tankCarburetorsCoolant

ThermostatStarter motor leadStarter motor assemblyThrottle stop screw

111

Remove the parts in the order listed.Refer to “SEATS” in chapter 3.Refer to “FUEL TANK” in chapter 3.Refer to “CARBURETORS” in chapter 6.DrainRefer to “CHANGING THE COOLANT”in chapter 3.Refer to “THERMOSTAT” in chapter 5.


5Nm (0.5mkg)

STARTER MOTOR ELEC

EAS00767

STARTER MOTOR

8-23


12345678910111213

Disassembling the starter motorO-ringStarter motor front coverLock washerOil sealBearingWasher setStarter motor rear coverWasher setO-ringBrush holder setO-ringArmature assemblyStarter motor yoke

1111111121111



5Nm (0.5mkg)

10 Nm (1.0mkg)

STARTER MOTOR ELEC

8-24

STARTER MOTOR ELEC

NOTE:

EB803511

CHECKING THE STARTER MOTOR1. Check:commutatorDirt Clean with 600 grit sandpaper.

2. Measure:commutator diameter aOut of specification Replace the startermotor.

Min. commutator diameter27 mm

3. Measure:mica undercut aOut of specification Scrape the mica to theproper measurement with a hacksaw bladewhich has been grounded to fit the commuta-tor.

Mica undercut0.7 mm

The mica must be undercut to ensure properoperation of the commutator.

4. Measure:armature assembly resistances (commuta-tor and insulation)Out of specification Replace the startermotor.

a. Measure the armature assembly resis-tances with the pocket tester.


Armature assemblyCommutator resistance 10.012 0.022 Ω at 20C

Insulation resistance 2Above 1 M Ω at 20C

b. If any resistance is out of specification, re-place the starter motor.

8-25

STARTER MOTOR ELEC

NOTE:

5 Nm (0.5 mkg)

NOTE:

5. Measure:brush length aOut of specification Replace the brushesas a set.

Min. brush length3.5 mm

6. Measure:brush spring forceOut of specification Replace the brushsprings as a set.

Brush spring force7.16 9.52 N (7.16 9.52 gf)

7. Check:gear teethDamage/wear Replace the gear.

8. Check:bearingoil sealDamage/wear Replace the defectivepart(-s).

EB803701

ASSEMBLING THE STARTER MOTOR1. Install:brush seat 1

Align the tab a on the starter motor rear coverwith the slot b in the yoke.

2. Install:starter motor yoke 1O-rings 2 Newstarter motor front cover 3starter motor rear cover 4bolts

Align the match marks a on the starter motoryoke with the match marks b on the front andrear covers.

8-26

CHARGING SYSTEM ELEC

3 Rectifier / regulator4 AC magneto5 Battery6 Main fuse

EB804000

CHARGING SYSTEMCIRCUIT DIAGRAM

8-27


2. Battery



Is the battery OK?

YES



NO

EB804400

3. Charging voltage

Connect the engine tachometer to the sparkplug lead of cylinder #1.

Connect the pocket tester (DC 20 V) to thebattery as shown.

Charging voltage14 V at 5,000 r/min


battery positive terminalTester negative probe

battery negative terminal

Start the engine and let it run at approximate-ly 5,000 r/min.

Measure the charging voltage.

NOTE:

YES NO

Replace the fuse.

1. Main fuse

Check the main fuse for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Is the main fuse OK?

EB804010 EB802401

TROUBLESHOOTING

The battery is not being charged.

Check:1. main fuse2. battery3. charging voltage4. stator coil assembly resistance5. wiring

(of the entire charging system)


1) rider seat2) fuel tankTroubleshoot with the following specialtool(-s).



EB802400

8-28


NO

The charging circuitis OK.

YES

NOTE:Make sure that the battery is fully charged.

Is the charging voltage within specification?

EB804404

Check the wiring connections of the entirecharging system.Refer to “CIRCUIT DIAGRAM”.

Is the charging system’s wiring properly con-nected and without defects?

NO

Replace the rectifier/regulator.

YES

5. Wiring

Properly connect orrepair the chargingsystem’s wiring.

EB804401

4. Stator coil assembly resistances

Remove the generator cover.Connect the pocket tester (Ω 1) to the sta-tor coil assembly coupler as shown.

Stator coil resistance0.27 0.33 Ω at 20C

Is the stator coil assembly OK?

YES

Replace the stator coil assembly.

NO

Tester positive probe white Tester negative probe white

12

Measure the stator coil assembly resis-tances.

Tester positive probe white Tester negative probe white

13

8-29

1 Main switch5 Battery6 Main fuse30 High beam indicator light32 Illumination light34 Pass switch35 Dimmer switch45 Headlight

46 Auxiliary light47 Headlight relay (Hi)48 Headlight relay (LO)49 Tail /brake light53 Headlight fuse54 Signaling system fuse62 Light switch

LIGHTING SYSTEM ELEC

EB805000

LIGHTING SYSTEMCIRCUIT DIAGRAM

8-30


2. Battery



Is the battery OK?

YES



NO

EB802411



YES


NO

3. Main switch

EB805400

Check the lights switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the lights switch OK?

YES

The lights switch isfaulty. Replace theright handlebarswitch.

NO

4. Lights switch (for Europe)

NOTE:

YES NO


1. Main, signaling system, and headlightfuses

Check the main, signaling system, andheadlight fuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, signaling system, and head-light fuses OK?

EB805010 EB802401

TROUBLESHOOTING

Any of the following fail to light: head-light, high beam indicator light, taillight,auxiliary light or meter light.

Check:1. main, signaling system, and headlight fuses2. battery3. main switch4. lights switch5. dimmer switch6. pass switch7. wiring

(of the entire charging system)


1) seats2) fuel tank3) air filter case4) front cowling inner panels5) front cowling6) rear cowlingTroubleshoot with the following specialtool(-s).


EB802400

8-31

Check the dimmer switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the dimmer switch OK?

YES

The dimmer switch isfaulty. Replace theleft handlebar switch.

NO

5. Dimmer switch

EB805403

Check the pass switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the pass switch OK?

YES

The pass switch isfaulty. Replace theleft handlebar switch.

NO

6. Pass switch

EB805404

Check the entire lighting system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the lighting system’s wiring properly con-nected and without defects?

YES

Properly connect orrepair the lightingsystem’s wiring.

NO

7. Wiring

Check the conditionof each of the lightingsystem’s circuits.Refer to “CHECKINGTHE LIGHTINGSYSTEM”.

Check the headlight bulb and socket for con-tinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the headlight bulb and socket OK?

YES

Replace the head-light bulb, socket orboth.

NO

1. Headlight bulb and socket

Check the LED of the high beam indicatorlight.Refer to “CHECKING THE LEDs”.

Is the high beam indicator light LED OK?

YES

Replace the meterassembly.

NO

2. High beam indicator light LED

3. Voltage

Connect the pocket tester (DC 20 V) to theheadlight and high beam indicator light cou-plers as shown.

When the dimmer switch is set to “ ”When the dimmer switch is set to “ ”

AB

Headlight coupler (wire harness side)

EB805410

CHECKING THE LIGHTING SYSTEM1. The headlight and the high beam indicator

light fail to come on.


EB805401

8-32

Battery positive terminal white/yellow (white/green)

Battery negative terminal black

HeadlightTester positive probe

yellow or green Tester negative probe black

High beam indicator lightTester positive probe yellowTester negative probe black/blue

Meter assembly coupler (wire harness side)

Set the main switch to “ON”.Set the light switch to “ ”.Set the dimmer switch to “ ” or “ ”.Measure the voltage (12 V) of yellow (green)

on the headlight coupler (headlight side). Is the voltage within specification?

1 23

14

2

YES

Replace the meterlight bulb, socket orboth.

NO

4. Headlight relay (Hi or LO)

Disconnect the headlight relay from the cou-pler.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the headlight relay terminals asshown.


yellow (green) Tester negative probe red/yellow

12

43

YES

Replace the head-light relay.

NO

Does the headlight relay have continuity be-tween yellow (green) and red/yellow?

This circuit is OK.

EB805411

2. Illumination fails to come on.

1. Meter light bulb and socket.

Check the meter light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the meter light bulb and socket OK?

The wiring circuitfrom the main switchto the headlight cou-pler is faulty and mustbe repaired.

NO

YES

2. Voltage

Connect the pocket tester (20 V) to the meterassembly coupler (wire harness side) asshown.

Tester positive probe blue Tester negative probe black/blue

12


8-33

Replace the tail /brake light bulb, sock-et or both.

NO

YES

The wiring circuitfrom the main switchto the meter assem-bly coupler is faultyand must be re-paired.

NO

This circuit is OK.

EB805412

3. A tail /brake light fails to come on.

1. Tail /brake light bulb and socket

Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the tail /brake light bulb and socket OK?

YES

2. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side) asshown.

Tester positive probe blue/red Tester negative probe black

12

Set the main switch to “ON”.Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue on themeter assembly coupler (wire harness side).

Is the voltage within specification?

1

YES

The wiring circuitfrom the main switchto the tail /brake lightcoupler is faulty andmust be repaired.

NO

This circuit is OK.

Set the main switch to “ON”.Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue/red onthe tail /brake light coupler (wire harnessside).


1

Replace the auxiliarylight bulb, socket orboth.

NO

EB805413

4. The auxiliary light fails to come on.(for Europe)

1. Auxiliary light bulb and socket

Check the auxiliary light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the auxiliary light bulb and socket OK?

YES

2. Voltage

Connect the pocket tester (DC 20 V) to theauxiliary light couplers (wire harness side) asshown.

Tester positive probe blue/red Tester negative probe black

12


8-34


YES

The wiring circuitfrom the main switchto the auxiliary lightconnectors is faultyand must be re-paired.

NO

This circuit is OK.

Set the main switch to “ON”.Set the light switch to “ ” or “ ”.Measure the voltage (12 V) of blue/red onthe auxiliary light couplers (wire harnessside).


1

8-35

SIGNALING SYSTEM ELEC

EB806000

SIGNALING SYSTEMCIRCUIT DIAGRAM

8-36


1 Main switch5 Battery6 Main fuse9 Starting circuit cutoff relay12 Fuel sender21 Neutral switch22 Speed sensor25 Fuel level indicator light26 Oil level /coolant temperature

warning light27 Neutral indicator light28 Tachometer29 Combination meter31 Turn signal indicator light36 Horn switch37 Horn39 Turn signal switch40 Flasher relay41 Front turn signal light (L)42 Front turn signal light (R)43 Rear turn signal light (L)44 Rear turn signal light (R)49 Tail /brake light54 Signaling system fuse57 Oil level relay58 Oil level switch59 Rear brake light switch61 Front brake light switch

8-37


YES


NO

YES



NO


NO

EB802411

3. Main switch



YES

1. Main and signaling system fuses

Check the main and signaling system fusesfor continuity.Refer to “CHECKING AND CHARGINGTHE FUSES” in chapter 3.

Are the main and signaling system fusesOK?

2. Battery

Check the condition of the battery.Refer to “CHECKING THE BATTERY” inchapter 3.

Is the battery OK?

NO

EB806400

4. Wiring

Check the entire signaling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the signaling system’s wiring properly con-nected and without defects?

YES

Properly connect orrepair the signalingsystem’s wiring.

Check the conditionof each of the signal-ing system’s circuits.Refer to “CHECKINGTHE SIGNALINGSYSTEM”.


NOTE:

EB806010 EB802401

TROUBLESHOOTING

Any of the following fail to light: turn sig-nal light, brake light or an indicator light.

The horn fails to sound.

Check:1. main and signaling system fuses2. battery3. main switch4. wiring

(of the entire signaling system)


1) seats2) fuel tank3) air filter case4) front cowling inner panels5) bottom cowling6) side cowling inner panels7) side cowlings8) windshield9) rear cowlingTroubleshoot with the following special tool(-s).


EB802400

8-38

Replace the left han-dlebar switch.

NO

1. Horn switch

Check the horn switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the horn switch OK?

YES

2. Voltage

Connect the pocket tester (DC 20 V) to thehorn connector at the horn terminal asshown.

Tester positive probe pink Tester negative probe ground

1

The horn is OK.

YES

3. Horn

Disconnect the black connector at the hornterminal.

Connect a jumper lead to the horn terminaland ground the jumper lead.

Set the main switch to “ON”.Push the horn switch.Does the horn sound?

NO

4. Voltage

Connect the pocket tester (DC 20 V) to thehorn connector at the black terminal asshown.

Tester positive probe black Tester negative probe ground

1

Set the main switch to “ON”.Push the horn switch.Measure the voltage (12 V) of Pink at the hornterminal.


The wiring circuitfrom the main switchto the horn connectoris faulty and must berepaired.

NOYES

Set the main switch to “ON”.Measure the voltage (12 V) of black at thehorn terminal.


1

NOYES

Replace the horn.Repair or replace thehorn.

1


EB806410

CHECKING THE SIGNALING SYSTEM1. The horn fails to sound.

8-39

Replace the tail /brake light bulb, sock-et or both.

NO

1. Tail /brake light bulb and socket

Check the tail /brake light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the tail /brake light bulb and socket OK?

YES

3. Voltage

Connect the pocket tester (DC 20 V) to thetail /brake light coupler (wire harness side) asshown.

Tester positive probe yellow Tester negative probe black

1

Replace the brakelight switch.

NO

2. Brake light switches

Check the brake light switches for continuity.Refer to “CHECKING THE SWITCHES”.

Is the brake light switch OK?

YES

2

YES

The wiring circuitfrom the main switchto the tail /brake lightcoupler is faulty andmust be repaired.

NO

This circuit is OK.

Set the main switch to “ON”.Pull in the brake lever or push down on thebrake pedal.

Measure the voltage (12 V) of yellow at thetail /brake light coupler (wire harness side).


Replace the turn sig-nal light bulb, socketor both.

NO

EB806413

3. A turn signal light, turn signal indicator lightor both fail to blink.

1. Turn signal light bulb and socket

Check the turn signal light bulb and socket forcontinuity.Refer to “CHECKING THE BULBS ANDBULB SOCKETS”.

Are the turn signal light bulb and socket OK?

YES


NO

2. Turn signal indicator light LED

Check the LED of the turn signal indicatorlight.Refer to “CHECKING THE LEDs”.

Is the turn signal indicator light LED OK?

YES


EB806411

2. A tail /brake light fails to come on.

8-40

Replace the left han-dlebar switch.

NO

3. Turn signal switch

Check the turn signal switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the turn signal switch OK?

YES

The wiring circuitfrom the main switchto the turn signal relaycoupler (turn signalrelay side) is faultyand must be repaired.

NO

4. Voltage

Connect the pocket tester (DC 20 V) to therelay coupler (wire harness side) as shown.

YES

Tester positive probe brown Tester negative probe ground

1

Set the main switch to “ON”.Measure the voltage (12 V) of brown at theturn signal relay coupler (wire harness side).


1

5. Voltage

Connect the pocket tester (DC 20 V) to theturn signal relay coupler (wire harness side)as shown.

The turn signal relayis faulty and must bereplaced.

NOYES

1

Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) or brown/white atthe turn signal relay coupler (wire harnessside).


Tester positive probe brown/white Tester negative probe ground

6. Voltage

Connect the pocket tester (DC 20 V) to theturn signal light connectors or the meter as-sembly coupler (wire harness side) asshown.

Turn signal lightTurn signal indicator light

AB

Left turn signal lightTester positive probe chocolate Tester negative probe ground

Right turn signal lightTester positive probe dark green Tester negative probe ground

1

2

A B


8-41



NO

YES

The wiring circuitfrom the turn signalswitch to the turn sig-nal light connector isfaulty and must be re-paired.

NO

This circuit is OK.

EB806414

4. The neutral indicator light fails to come on.

1. Neutral indicator light LED

Check the LED of the neutral indicator light.Refer to “CHECKING THE LEDs”.

Is the neutral indicator light LED OK?

YES

Set the main switch to “ON”.Set the turn signal switch to “ ” or “ ”.Measure the voltage (12 V) of chocolate ordark green at the turn signal light connec-tor (wire harness side).


3. Voltage

Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harness side)as shown.

Tester positive probe brown Tester negative probe sky blue

12

12


NO

2. Neutral switch



YES

Set the main switch to “ON”.Measure the voltage (12 V) of brown andsky blue at the meter assembly coupler.


12

YES

The wiring circuitfrom the main switchto the meter light bulbcoupler is faulty andmust be repaired.

NO

This circuit is OK.


NO

EB806416

5. The oil level warning light fails to come on.

1. Oil level warning light LED

Check the LED of the oil level warning light.Refer to “CHECKING THE LEDs”.

Is the oil level warning light LED OK?

YES

8-42

Replace the oil levelswitch.

NO

2. Oil level switch

Drain the engine oil and remove the oil levelswitch from the oil pan.

Check the oil level switch for continuity.Refer to “CHECKING THE SWITCHES”.

Is the oil level switch OK?

YES

Replace the oil levelrelay.

NO

3. Oil level relay

Disconnect the oil level relay from the cou-pler.

Connect the pocket tester (Ω 1) and bat-tery (12 V) to the oil level relay terminals asshown.

YES

Battery positive terminal brown Battery negative terminal white

Does the oil level relay have continuity be-tween red/blue and black?

Tester positive probe red/blue Tester negative probe black

12

34

4. Voltage

Connect the pocket tester (DC 20 V) to themeter assembly coupler (wire harness side)as shown.

Tester positive probe brown Tester negative probe red/blue

12

Set the main switch to “ON”.Measure the voltage (12 V) of brown andred/blue at the meter assembly coupler.


YES

The wiring circuitfrom the main switchto the meter assem-bly coupler is faultyand must be re-paired.

NO

This circuit is OK.


NO

EB806417

6. The fuel level indicator light fails to comeon.

1. Fuel level indicator light LED

Check the LED of the fuel level indicator light.Refer to “CHECKING THE LEDs”.

Is the fuel level indicator light LED OK?

YES

1


8-43

Replace the fuelsender.

NO

2. Fuel sender

Disconnect the fuel sender coupler from thewire harness.

Drain the fuel from the fuel tank and removethe fuel sender from the fuel tank.

Check the fuel sender for continuity.

YES

Tester positive probe green Tester negative probe black

1

Is the fuel sender OK?

2

3. Voltage

Connect the pocket tester (DC 20 V) to the me-ter assembly coupler (wire harness side) asshown.

Tester positive probe green/white Tester negative probe black/blue

12

YES

The wiring circuit fromthe main switch to themeter assembly cou-pler is faulty and mustbe repaired.

NO

This circuit OK.

Set the main switch to “ON”.Measure the voltage (12 V). Is the voltage within specification?

NO

EAS00805

7.The clock fails to come on.

1. Voltage

Connect the pocket tester (20 V DC) to theclock coupler (clock side) as shown.

YES

Tester positive probe green/yellow Tester negative probe ground

1

Set the main switch to “ON”.Measure the voltage (12 V).Is the voltage within specification?

The wiring circuit from the mainswitch to the clock coupler(clock side) is faulty and must berepaired.

2. Clock

Check that the clock is operating properly.When setting the clock after its power sourcehas been disconnected (e.g., when the batteryis removed), first set the clock to 1:00 AM andthen to the correct time.Is the clock operating properly?

YES

Replace the clock.

NO

This circuit is OK.


8-44

Does the startup display appear first and thenafter approximately three seconds the normaldisplay appears?

First, connect the battery to the green/yellow and black/blue coupler terminals, then

connect the battery positive lead to thered/green terminal.When connecting the battery, check whetherthe startup display 3 appears first and then af-ter approximately three seconds the normaldisplay appears 4.

Battery positive lead green/yellow Battery negative lead black/blue Battery positive lead red

12

1. Speedometer bulb socket

Check the speedometer bulb socket for con-tinuity.

Is the speedometer bulb socket OK?

NOYES

Replace the speedometer bulbsocket.

2. Voltage

Connect the pocket tester (20 V DC) to thespeedometer coupler (wire harness side) asshown.

3

NOTE:

1 2

3

NOYES

Replace the speedometer.

Tester positive probe blue Tester negative probe blue/black

12

3. Voltage

Connect the pocket tester (20 V DC) to thespeedometer bulb socket coupler (wire har-ness side) as shown.

NOYES

Set the main switch to “ON”.Measure the voltage (12 V) of blue on thespeedometer bulb socket coupler (wire har-ness side).


The wiring circuit from the mainswitch to the speedometer bulbsocket coupler (wire harnessside) is faulty, repair it.

1

4. Speedometer sensor

Connect the pocket tester (20 V DC) to thespeedometer coupler (wire harness side) asshown.

Tester positive probe blue/yellow Tester negative probe black/blue

1

Set the main switch to “ON”.Elevate the rear wheel and slowly rotate it.Measure the voltage (5 V) of blue/yellow andblack/blue. With each full rotation of the rearwheel, the voltage reading should cycle from0 V to 5 V to 0 V to 5 V.

Does the voltage reading cycle correctly?

YES

Replace the speedom-eter sensor.

NO

This circuit is OK.

2


EAS00806

The speedometer fails to come on.

8-45

1 Main switch5 Battery6 Main fuse23 Thermo unit26 Oil level /coolant temperature

warning light29 Combination meter50 Radiator fan motor51 Thermo switch52 Radiator fan motor fuse54 Signaling system fuse

COOLING SYSTEM ELEC

EB807000

COOLING SYSTEMCIRCUIT DIAGRAM

8-46


NO

1. Main, signal system and radiator fanmotor fuses

Check the main, signal system, and radiatorfan motor fuses for continuity.Refer to “CHECKING THE FUSES” in chap-ter 3.

Are the main, signal system, and radiator fanmotor fuses OK?

YES

YES



NO

Is the battery OK?

2. Battery

Check the condition of the battery.Refer to “CHECKING AND CHARGINGTHE BATTERY” in chapter 3.


NO

EB802411

3. Main switch



YES

NO

EB807400

4. Radiator fan motor (test 1)

Disconnect the radiator fan motor couplerfrom the wire harness.

Connect the battery (12 V) as shown.

YES

The radiator fan mo-tor is faulty and mustbe replaced.

Battery positive lead blue Battery negative lead black

12

Does the radiator fan motor turn?


COOLING SYSTEM ELEC

NOTE:

EB807010

TROUBLESHOOTING

The radiator fan motor fails to turn.The coolant temperature display and/orwarning light fails to indicate when theengine is warm.

Check:1. main, signal system, and radiator fan motor

fuses2. battery3. main switch4. radiator fan motor5. thermo switch6. thermo unit7. wiring

(the entire cooling system)


1) rider seat2) bottom cowling3) front cowling inner panels4) side cowling inner panels5) side cowlings6) windshieldTroubleshoot with the following special tool(-s).


EB802400

EB802401

8-47

The wiring circuitfrom the main switchto the radiator fan mo-tor coupler is faultyand must be repaired.

NO

5. Radiator fan motor (test 2)

Disconnect the thermo switch coupler.Set the main switch to “ON”.Connect the brown and blue terminalswith a jumper lead as shown.

YES

Does the radiator fan motor turn?

13

2

Remove the thermo switch from the radiator.Connect the pocket tester (Ω 1) to the ther-mo switch as shown.

Immerse the thermo switch in a containerfilled with coolant .

Make sure that the thermo switch terminalsdo not get wet.

Place a thermometer in the coolant.Slowly heat the coolant, then let it cool to thespecified temperature as indicated in thetable.

Check the thermo switch for continuity at thetemperatures indicated in the table.

6. Thermo switch

NOTE:

Teststep

Coolant temperatureThermo switch

Continuity

*1**2**3**4*

0 105 ± 3C

More than 105 ± 3C

105 ± 3C to 100 ± 3C

Less than 100 ± 3C

NO

YES

YES

NO

Test steps 1 & 2: Heating phaseTest steps 3* & 4*: Cooling phase

Handle the thermo switch with specialcare.

Never subject the thermo switch tostrong shocks. If the thermo switch isdropped, replace it.

WARNING

Thermo switch28 Nm (2.8 mkg)Three bond sealock 10

The thermo switch circuit is open and the ra-diator fan is off.The thermo switch circuit is closed and theradiator fan is on.

A

B

1

2

3

COOLING SYSTEM ELEC

EB807400

8-48

Replace the thermoswitch.

NOYES

Does the thermo switch operate properly asdescribed above?

Remove the temperature sender from thecylinder head.

Connect the pocket tester (Ω 10) to thethermo unit as shown.

Immerse the thermo unit in a container filledwith coolant .

Place a thermometer in the coolant.Slowly heat the water, then let it cool down tothe specified temperature.

Check the thermo unit for continuity at thetemperatures indicated below.

7. Thermo unit

Handle the temperature sender with spe-cial care.Never subject the temperature sender tostrong shocks. If the temperature senderis dropped, replace it.

WARNING

Temperature sender15 Nm (1.5 mkg)Three bond sealock 10

Thermo unit resistance50.6 64.2 Ω at 80C17.3 16.1 Ω at 120C

Replace the tempera-ture sender.

NOYES

Properly connect orrepair the coolingsystem’s wiring.

NO

EB807403

8. Wiring

Check the entire cooling system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the cooling system’s wiring properly con-nected and without defects?

YES

Replace the com-bination meter.

1

23

105 ± 3 C100 ± 3 C

COOLING SYSTEM ELEC

8-49

1 Main switch5 Battery6 Main fuse9 Starting circuit cutoff relay10 Fuel pump14 CDI unit54 Signaling system fuse56 Ignition fuse63 Engine stop switch

FUEL PUMP SYSTEM ELEC

EB808000

FUEL PUMP SYSTEMCIRCUIT DIAGRAM

8-50


1 Battery2 Main fuse3 Main switch4 Ignition fuse5 Engine stop switch6 CDI unit7 Starting circuit cutoff relay8 Fuel pump

EB808010

FUEL PUMP CIRCUIT OPERATIONThe CDI unit includes the control unit for the fuel pump.

8-51



NO




YES


YES



NO


NO

EB802411

3. Main switch



YES

2. Battery


Is the battery OK?

NO

EB802412




YES


NOTE:

EB808020 EB802401

TROUBLESHOOTING

The fuel pump fails to operate.

Check:1. main and ignition fuses2. battery3. main switch4. engine stop switch5. starting circuit cutoff relay6. fuel pump7. wiring

(the entire fuel pump system)


1) rider seat2) fuel tank3) air filter case4) front cowling inner panel (left)Troubleshoot with the following specialtool(-s).


EB802400

8-52

Replace the startingcircuit cutoff relay.

NO


Disconnect the relay from the coupler.Connect the pocket tester (Ω 1) and bat-tery (12 V) to the relay terminals as shown.

YES

Battery positive terminal redBattery negative terminal blue/red

1

Does the fuel pump relay have continuity be-tween red/black and blue/black?

2

6. Fuel pump resistance

Disconnect the fuel pump coupler from thewire harness.

Connect the pocket tester (Ω 1) to the fuelpump coupler (fuel pump side) as shown.

Tester positive probe blue/black Tester negative probe black

12

Tester positive probe redTester negative probe blue/black

13

EB808400

Fuel pump resistance4 30 Ω at 20C

YES

Replace the fuelpump.

NO

Replace the CDI unit.

NO

EB808401

7. Wiring

Check the entire fuel pump system’s wiring.Refer to “CIRCUIT DIAGRAM”.

Is the fuel pump system’s wiring properlyconnected and without defects?

YES

Is the fuel pump OK?

Measure the fuel pump resistance.

Properly connect orrepair the fuel pumpsystem’s wiring.


8-53


WARNING

EB808410

CHECKING THE FUEL PUMP

Gasoline is extremely flammable and undercertain circumstances there can be a dan-ger of an explosion or fire. Be extremelycareful and note the following points:Stop the engine before refuelling.Do not smoke and keep away from openflames, sparks or any other source of fire.

If you do accidentally spill gasoline, wipe itup immediately with dry rags.

If gasoline touches the engine when it ishot, a fire may occur. Therefore, make surethat the engine is completely cool beforeperforming the following test.

1. Check: fuel pump operation

a. Fill the fuel tank.b. Put the end of the fuel hose into an open con-

tainer.c. Connect the battery (12 V) to the fuel pump

coupler as shown.

Battery positive lead blue/black 1Battery negative lead black 2

d. If fuel flows out of the fuel hose, the fuelpump is OK. If fuel does not flow, replace thefuel pump.

8-54

SELF-DIAGNOSIS ELEC

Revolution( 103 r /min)

Tachometer display

Time (seconds)

Engine speed

0 r /min ... 3 secondsCondition code ... 2.5 secondsEngine speed ... 3 seconds

123

EB812000

SELF-DIAGNOSISThe YZF-R6 features a self-diagnosing system for the following circuit(-s): throttle position sensor fuel level indicator light

If any of these circuits are defective, their respective condition codes will be displayed on the tachome-ter when the main switch is set to “ON” (irrespective of whether the engine is running or not)

Circuit Defect(-s) System response Condition code

Throttle posi-tion sensor

DisconnectedShort-circuitLocked

The ignitor unit stays set to thewide-open throttle ignition timing.The motorcycle can be ridden.

The tachometer displays thecondition code.

3,000 r/min

Fuel level indi-cator light

Improper connec-tion

The tachometer displays thecondition code.

8,000 r/min

Tachometer display sequence

When more than one item is being monitored, the tachometer needle displays the condition codes inascending order, cycling through the sequence repeatedly.If the engine is stopped, the engine speed 3 is 0 r/min.

8-55

Repair or replace thewire harness.

NO

1. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES

NO

2. Throttle position sensor

Check the throttle position sensor for conti-nuity.Refer to “CHECKING AND ADJUSTINGTHE THROTTLE POSITION SENSOR” inchapter 6.

Is the throttle position sensor OK?

YES

Replace the throttleposition sensor.


EB812401

SELF-DIAGNOSIS ELEC

NOTE:

13 Throttle position sensor14 CDI unit

EB812010

TROUBLESHOOTING

The tachometer starts to display the self-diagnosis sequence.

Check:1. throttle position sensor2. fuel level indicator light


1) rider seat2) fuel tank3) air filter case4) right side cowling inner panel5) right side cowlingTroubleshoot with the following specialtool(-s).


EB812020

1. Throttle position sensorCIRCUIT DIAGRAM

8-56

Repair the fuel levelindicator light LED.

NO

1. Fuel level indicator light LED

Check the LED of the fuel level indicator light.Refer to “CHECKING THE LEDs”.

Is the fuel level indicator light LED OK?

YES

Replace the fuelsender.

NO

2. Fuel sender

Disconnect the fuel sender coupler from thewire harness.

Connect the pocket tester (W 1) to the fuelsender coupler as shown.

YES

Tester positive probe green Tester negative probe black

1

Check the fuel sender for continuity. Is the fuel sender OK?

2

EB812404

SELF-DIAGNOSIS ELEC

12 Fuel sender14 CDI unit25 Fuel level indicator light29 Combination meter

EB812040 EB812403

2. Fuel level indicator lightCIRCUIT DIAGRAM

8-57

Replace or replacethe wire harness.

NO

3. Wire harness

Check the wire harness for continuity.Refer to “CIRCUIT DIAGRAM”.

Is the wire harness OK?

YES


SELF-DIAGNOSIS ELEC

EB812405

TRBLSHTG

CHAPTER 9.TROUBLESHOOTING

STARTING PROBLEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INCORRECT ENGINE IDLING SPEED 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE 9-2. . . . . . . . . . . . . ENGINE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY GEAR SHIFTING 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFTING IS DIFFICULT 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SHIFT PEDAL DOES NOT MOVE 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . JUMPS OUT OF GEAR 9-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY CLUTCH 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH SLIPS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CLUTCH DRAGS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERHEATING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OVERCOOLING 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COOLING SYSTEM 9-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POOR BRAKING PERFORMANCE 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY FRONT FORK LEGS 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEAKING OIL 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MALFUNCTION 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRBLSHTG

UNSTABLE HANDLING 9-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAULTY LIGHTING AND SIGNALING SYSTEMS 9-5. . . . . . . . . . . . . . . . . . HEADLIGHT DOES NOT LIGHT 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HEADLIGHT BULB BURNT OUT 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT DOES NOT LIGHT 9-5. . . . . . . . . . . . . . . . . . . . . . . TAIL/BRAKE LIGHT BULB BURNT OUT 9-5. . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL DOES NOT LIGHT 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS SLOWLY 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL REMAINS LIT 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURN SIGNAL BLINKS QUICKLY 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . HORN DOES NOT SOUND 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9-1

STARTING PROBLEMSTRBLSHTG

NOTE:

FUEL SYSTEMFuel tankEmpty fuel tankClogged fuel filterClogged fuel tank breather hoseDeteriorated or contaminated fuelFuel pumpFaulty fuel pumpFaulty fuel pump relayFuel cockClogged or damaged fuel hoseCarburetorsDeteriorated or contaminated fuelClogged pilot jetClogged pilot air passageSucked-in airDamaged floatWorn needle valve Incorrectly installed needle valve seat Incorrect fuel level Incorrectly installed pilot jetClogged starter jetFaulty starter plunger Incorrectly adjusted starter cable

Ignition systemFaulty CDI unitFaulty pickup coilSwitches and wiringFaulty main switchFaulty engine stop switchBroken or shorted wiringFaulty neutral switchFaulty start switchFaulty sidestand switchFaulty clutch switch Incorrectly grounded circuitLoose connectionsStarting systemFaulty starter motorFaulty starter relayFaulty starting circuit cutoff relayFaulty starter clutch

EB900000

TROUBLESHOOTING

The following guide for troubleshooting does not cover all the possible causes of trouble. It should behelpful, however, as a guide to basic troubleshooting. Refer to the relative procedure is this manual forchecks, adjustments, and replacement of parts.

STARTING PROBLEMSENGINECylinders and cylinder head(-s)Loose spark plugLoose cylinder headDamaged cylinder head gasketWorn or damaged cylinder Incorrect valve clearance Incorrectly sealed valve Incorrect valve-to-valve-seat contact Incorrect valve timingFaulty valve springSeized valvePistons and piston rings Incorrectly installed piston ringDamaged, worn or fatigued piston ringSeized piston ringSeized or damaged pistonAir filter Incorrectly installed air filterClogged air filter elementCrankcase and crankshaft Incorrectly assembled crankcaseSeized crankshaft

ELECTRICAL SYSTEMSBatteryFaulty batteryDischarged batteryFusesBlown, damaged or incorrect fuse Incorrectly installed fuseSpark plugs Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug capIgnition coilsDamaged ignition coilBroken or shorted primary or secondary coils

9-2

INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING

TRBLSHTG

ELECTRICAL SYSTEMSBatteryFaulty batteryDischarged batterySpark plugs Incorrect spark plug gap Incorrect spark plug heat rangeFouled spark plugWorn or damaged electrodeWorn or damaged insulatorFaulty spark plug capIgnition coilsBroken or shorted primary or secondary coilsFaulty spark plug leadDamaged ignition coilIgnition systemFaulty ignition unitFaulty pickup coil

FUEL SYSTEMCarburetorsFaulty diaphragm Incorrect fuel levelLoose or clogged main jetFuel pumpFaulty fuel pump

JUMPS OUT OF GEARShift shaft Incorrect shift pedal position Incorrectly returned stopper leverShift forksWorn shift forkShift drum Incorrect axial playWorn shift drum grooveTransmissionWorn gear dog

EB901000

INCORRECT ENGINE IDLING SPEEDENGINECylinders and cylinder head Incorrect valve clearanceDamaged valve train componentsAir filterClogged air filter element

FUEL SYSTEMCarburetorsFaulty starter plungerLoose or clogged pilot jetLoose or clogged pilot air jetDamaged or loose carburetor joint Incorrectly synchronized carburetors Incorrectly adjusted engine idling speed(throttle stop screw)

Incorrect throttle cable free playFlooded carburetor

EB902000

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCERefer to “STARTING PROBLEMS”.ENGINEAir filterClogged air filter elementAir intake systemClogged air ducts

EB903000

FAULTY GEAR SHIFTINGSHIFTING IS DIFFICULTRefer to “CLUTCH DRAGS”.SHIFT PEDAL DOES NOT MOVEShift shaft Incorrectly adjusted shift rodBent shift shaftShift drum and shift forksForeign object in a shift drum grooveSeized shift forkBent shift fork guide barTransmissionSeized transmission gearForeign object between transmission gears Incorrectly assembled transmission

9-3

FAULTY CLUTCH/OVERHEATING/OVERCOOLINGTRBLSHTG

CLUTCH DRAGSClutchUnevenly tensioned clutch spring plateWarped pressure plateBent clutch plateSwollen friction plateBent clutch pull rodDamaged clutch bossBurnt primary driven gear bushingMatch marks not alignedEngine oil Incorrect oil level Incorrect oil viscosity (high)Deteriorated oil

FUEL SYSTEMCarburetors Incorrect main jet setting Incorrect fuel levelDamaged or loose carburetor jointAir filterClogged air filter element

CHASSISBrakesDragging brake

ELECTRICAL SYSTEMSSpark plugs Incorrect spark plug gap Incorrect spark plug heat rangeIgnition systemFaulty CDI unit

EB904000

FAULTY CLUTCHCLUTCH SLIPSClutch Incorrectly assembled clutch Incorrectly adjusted clutch cableLoose or fatigued clutch springWorn friction plateWorn clutch plateEngine oil Incorrect oil level Incorrect oil viscosity (low)Deteriorated oil

EB905001

OVERHEATINGENGINEClogged coolant passagesCylinder head(-s) and piston(-s)Heavy carbon buildupEngine oil Incorrect oil level Incorrect oil viscosity Inferior oil quality

COOLING SYSTEMCoolantLow coolant levelRadiatorDamaged or leaking radiatorFaulty radiator capBent or damaged radiator finWater pumpDamaged or faulty water pumpThermostatThermostat stays closedOil coolerClogged or damaged oil coolerHoses and pipesDamaged hose Incorrectly connected hoseDamaged pipe Incorrectly connected pipe

EB906000

OVERCOOLINGCOOLING SYSTEMThermostatThermostat stays open

9-4

POOR BRAKING PERFORMANCE/FAULTY FRONT FORKLEGS/UNSTABLE HANDLING

TRBLSHTG

Loose union boltDamaged brake hoseOil or grease on the brake discOil or grease on the brake pad Incorrect brake fluid level

MALFUNCTIONBent or damaged inner tubeBent or damaged outer tubeDamaged fork springWorn or damaged outer tube busingBent or damaged damper rod Incorrect oil viscosity Incorrect oil level

SwingarmWorn bearing or bushingBent or damaged swingarmRear shock absorber assemblyFaulty rear shock absorber springLeaking oil or gasTiresUneven tire pressures (front and rear) Incorrect tire pressureUneven tire wearWheels Incorrect wheel balanceDeformed cast wheelDamaged wheel bearingBent or loose wheel axleExcessive wheel runoutFrameBent frameDamaged steering head pipe Incorrectly installed bearing race

EB907000

POOR BRAKING PERFORMANCEWorn brake padWorn brake discAir in hydraulic brake systemLeaking brake fluidFaulty brake caliper piston seal

EB908001

FAULTY FRONT FORK LEGSLEAKING OILBent, damaged or rusty inner tubeDamaged outer tube Incorrectly installed oil sealDamaged oil seal lip Incorrect oil level (high)Loose damper rod assembly boltDamaged damper rod assembly bolt copperwasher

Damaged cap bolt O-ring

EB909001

UNSTABLE HANDLINGHandlebarsBent or incorrectly installed right handlebarBent or incorrectly installed left handlebarSteering head components Incorrectly installed upper bracket Incorrectly installed lower bracket(incorrectly tightened ring nut)

Bent steering stemDamaged ball bearing or bearing raceFront fork legsUnevenoil levels (both front fork legs)Unevenly tensioned fork spring (both front forklegs)

Damaged fork springBent or damaged inner tubeBent or damaged outer tube

9-5

FAULTY LIGHTING AND SIGNALING SYSTEMSTRBLSHTG

TURN SIGNAL DOES NOT LIGHTFaulty turn signal switchFaulty turn signal relayBurnt-out turn signal bulb Incorrect connectionDamaged or faulty wire harness Incorrectly grounded circuitFaulty batteryBlown, damaged or incorrect fuse

TURN SIGNAL BLINKS SLOWLYFaulty flasher relayFaulty main switchFaulty turn signal switchWrong turn signal bulb

TURN SIGNAL REMAINS LITFaulty flasher relayBurnt-out-turn signal bulb

TURN SIGNAL BLINKS QUICKLY Incorrect turn signal bulbFaulty flasher relayBurnt-out turn signal bulb

HORN DOES NOT SOUND Incorrectly adjusted hornDamaged or faulty hornFaulty main switchFaulty horn switchFaulty batteryBlown, damaged or incorrect fuseFaulty wire harness

EB910000

FAULTY LIGHTING AND SIGNALING SYSTEMSHEADLIGHT DOES NOT LIGHTWrong headlight bulbToo many electrical accessoriesHard charging Incorrect connection Incorrectly grounded circuitPoor contacts (main or light switch)Burnt-out headlight bulb

HEADLIGHT BULB BURNT OUTWrong headlight bulbFaulty batteryFaulty rectifier/regulator Incorrectly grounded circuitFaulty main switchFaulty light switchHeadlight bulb life expired

TAIL/BRAKE LIGHT DOES NOT LIGHTWrong tail /brake light bulbToo may electrical accessories Incorrect connectionBurnt-out tail /brake light bulb

TAIL/BRAKE LIGHT BULB BURNT OUTWrong tail /brake light bulbFaulty battery Incorrectly adjusted rear brake light switchTail /brake light bulb life expired

1 Main switch2 Fuse (backup)3 Rectifier / regulator4 AC magneto5 Battery6 Fuse (main)7 Starter relay8 Starter motor9 Starting circuit cutoff relay10 Fuel pump11 Sidestand switch12 Fuel sender13 Throttle position sensor14 CDI unit15 lgnition coil #116 lgnition coil #217 lgnition coil #318 lgnition coil #419 Spark plug20 Pickup coil21 Neutral switch22 Speed sensor 23 Thermo unit24 Meter assembly25 Fuel level indicator light26 Oil level / coolant temperature

warning light27 Neutral indicator light28 Tachometer29 Combination meter30 High beam indicator light31 Turn signal indicator light32 lllumination light33 Handlebar switch (left)34 Pass switch35 Dimmer switch36 Horn switch37 Horn38 Clutch switch39 Turn signal switch40 Flasher relay41 Front turn signal light (L)42 Front turn signal light (R)43 Rear turn signal light (L)44 Rear turn signal light (R)45 Headlight46 Auxiliary light47 Headlight relay (Hi)48 Headlight relay (Lo)49 Tail /brake light50 Radiator fan motor51 Thermo switch52 Fuse (radiator fan motor)53 Fuse (headlight)54 Fuse (signaling system)55 Alarm56 Fuse (ignition)57 Oil level relay58 Oil level switch59 Rear brake light switch60 Handlebar switch (right)61 Front brake light switch62 Light switch63 Engine stop switch64 Start switch65 Diode 166 Diode 2

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . .

L Blue. . . . . O Orange. . . . P Pink. . . . . R Red. . . . . Sb Sky blue. . . . W White. . . .

Y Yellow. . . . . B /L Black /Blue. . . B /Y Black /Yellow. . . Br /B Brown/Black. . Br /L Brown/Blue. . Br /R Brown/Red. .

Br /W Brown/White. . G /R Green/Red. . G /W Green/White. . G /Y Green/Yellow. . . Gy /B Gray /Black. . L /B Blue/Black. . .

L /R Blue/Red. . . L /W Blue/White. . L /Y Blue/Yellow. . . O /B Orange/Black. . . R /B Red/Black. . . R /L Red/Blue. . .

R /W Red/White. . R /Y Red/Yellow. . . W/G White /Green. . W/R White /Red. . W/Y White /Yellow. . Y /B Yellow/Blcak. . .

YZF-R6 ’99 WIRING DIAGRAM (for Europe)

1 Main switch2 Fuse (backup)3 Rectifier / regulator4 AC magneto5 Battery6 Fuse (main)7 Starter relay8 Starter motor9 Starting circuit cutoff relay10 Fuel pump11 Sidestand switch12 Fuel sender13 Throttle position sensor14 CDI unit15 lgnition coil #116 lgnition coil #217 lgnition coil #318 lgnition coil #419 Spark plug20 Pickup coil21 Neutral switch22 Speed sensor23 Thermo unit24 Meter assembly25 Fuel level indicator light26 Oil level / coolant temperature

warning light27 Neutral indicator light28 Tachometer29 Combination meter30 High beam indicator light31 Turn signal indicator light32 lllumination light33 Handlebar switch (left)34 Pass switch35 Dimmer switch36 Horn switch37 Horn38 Clutch switch39 Turn signal switch40 Flasher relay41 Front turn signal light (L)42 Front turn signal light (R)43 Rear turn signal light (L)44 Rear turn signal light (R)45 Headlight47 Headlight relay (Hi)48 Headlight relay (Lo)49 Tail /brake light50 Radiator fan motor51 Thermo switch52 Fuse (radiator fan motor)53 Fuse (headlight)54 Fuse (signaling system)56 Fuse (ignition)57 Oil level relay58 Oil level switch59 Rear brake light switch60 Handlebar switch (right)61 Front brake light switch63 Engine stop switch64 Start switch65 Diode 166 Diode 2

COLOR CODEB Black. . . . . Br Brown. . . . Ch Chocolate. . . Dg Dark green. . . G Green. . . . Gy Gray. . .

L Blue. . . . . O Orange. . . . P Pink. . . . . R Red. . . . . Sb Sky blue. . . . W White. . . .

Y Yellow. . . . . B /L Black /Blue. . . B /Y Black /Yellow. . . Br /B Brown/Black. . Br /L Brown/Blue. . Br /R Brown/Red. .

Br /W Brown/White. . G /R Green/Red. . G /W Green/White. . G /Y Green/Yellow. . . Gy /B Gray /Black. . L /B Blue/Black. . .

L /R Blue/Red. . . L /W Blue/White. . L /Y Blue/Yellow. . . O /B Orange/Black. . . R /B Red/Black. . . R /L Red/Blue. . .

R /W Red/White. . R /Y Red/Yellow. . . W/G White /Green. . W/R White /Red. . W/Y White /Yellow. . Y /B Yellow/Blcak. . .

YZF-R6 ’99 WIRING DIAGRAM (for AUS)

Documents

99-02 R6 Service Manual