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Yamaha 1998 FZS600 5DM1-AE1 Service Manual

Summary of 1998 FZS600 5DM1-AE1

  • Page 3

    Eb000000 fzs600 service manual 1997 by yamaha motor co., ltd. First edition, december 1997 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 4: Notice

    Note: caution: eb001000 notice this manual was produced by the yamaha motor company primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance a...

  • Page 5: How To Use This Manual

    7 2 1 4 3 8 6 5 yp002000 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal,disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order...

  • Page 6

    1 3 5 7 9 11 13 15 18 2 4 8 10 12 14 16 6 21 24 25 17 19 20 22 23 eb003000 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic inspection and adjustment 4 engine 5 cooling system 6 car...

  • Page 7: General Information

    General information specifications periodic inspections and adjustments engine cooling system carburetors chassis electrical system troubleshooting gen info 1 spec 2 chk adj 3 eng 4 cool 5 carb 6 chas 7 elec 8 trbl shtg 9 index.

  • Page 9: Gen

    Gen info 1.

  • Page 10: Gen

    Gen info chapter 1 general information motorcycle identification 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Vehicle identification number 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model code 1-1 . . . . . . . . . . . . . ...

  • Page 11: Gen

    Gen info.

  • Page 12: Gen

    1-1 gen info motorcycle identification 1 1 eb100000 general information motorcycle identification eb100010 vehicle identification number the vehicle identification number 1 is stamped into the right side of the steering head. Eb100020 model code the model code label 1 is affixed to the frame. This i...

  • Page 13: Gen

    1-2 spring lip oil grease lip gen info important information eb102000 important information preparation for removal and disassembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “special tools” se...

  • Page 14: Gen

    1-3 or gen info important information caution: eb102030 lock washers/ plates and cotter pins 1. After removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. Eb102040 bearings and oil...

  • Page 15: Gen

    1-4 gen info checking the connections note: note: note: eb103000 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead coupler connector 2. Check: lead coupler connector moisture dry with an air blower. Rust / stains connect and disco...

  • Page 16: Gen

    1-5 gen info special tools 1 2 1 2 1 2 1 eb104000 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When pl...

  • Page 17: Gen

    1-6 gen info special tools 1 tool no. Tool name / usage illustration 90890-01399 special thickness gauge this tool is used to measure the valve clearance. 90890-01401 spark plug wrench this tool is used for removing or installing the spark plug. 90890-01403 ring nut wrench this tool is used to tight...

  • Page 18: Gen

    1-7 gen info special tools 1 2 1 tool no. Tool name / usage illustration 90890-03141 timing light this tool is necessary for checking ignition timing. 90890-04044 piston ring compressor this tool is used to compress piston rings when installing the cylinder. 90890-03158 carburetor angle driver this ...

  • Page 19: Gen

    1-8 gen info special tools tool no. Tool name / usage illustration 90890-85505 yamaha bond no.1215 this sealant (bond) is used for crankcase mating surface, etc..

  • Page 20: Spec

    Spec 2.

  • Page 21: Spec

    Spec chapter 2 specifications general specifications 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance specifications 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 2-4 . . . . . . . . . . . . . ....

  • Page 22: Spec

    Spec.

  • Page 23: Spec

    2-1 general specifications spec specifications general specifications model fzs600 model code: 5dm1 dimensions: overall length overall width overall height seat height wheelbase minimum ground clearance minimum turning radius 2,080 mm 710 mm 1,170 mm 790 mm 1,415 mm 130 mm 2,900 mm basic weight: wit...

  • Page 24: Spec

    2-2 general specifications spec model fzs600 carburetor: type / quantity manufacturer bsr 33 / 4 mikuni spark plug: type manufacturer spark plug gap cr9e, cr8e / u27esr-nu24esr-n ngk/ denso 0.7 x 0.8 mm clutch type: wet, multiple-disc transmission: primary reduction system primary reduction ratio se...

  • Page 25: Spec

    2-3 general specifications spec model fzs600 brake: front brake type operation rear brake type operation dual disc brake right hand operation single disc brake right foot operation suspension: front suspension rear suspension telescopic fork swingarm (link suspension) shock absorber: front shock abs...

  • Page 26: Spec

    2-4 maintenance specifications spec face width seat width margin thickness maintenance specifications engine item standard limit cylinder head: warp limit 0.05 mm cylinder: bore size taper limit out of round limit 62.00 62.01 mm 62.1 mm 0.09 mm 0.07 mm camshaft: drive method cam cap inside dia. Cams...

  • Page 27: Spec

    2-5 maintenance specifications spec item standard limit stem-to-guide clearance in ex stem runout limit valve seat width in ex 0.010 0.037 mm 0.025 0.052 mm 0.9 1.1 mm 0.9 1.1 mm 0.08 mm 0.1 mm 0.04 mm 1.6 mm 1.6 mm valve spring: free length in / ex set length (valve closed) in / ex compressed press...

  • Page 28: Spec

    2-6 maintenance specifications spec item standard limit clutch: friction plate thickness quantity wear limit friction plate thickness quantity clutch plate thickness quantity warp limit clutch spring free length quantity minimum length clutch housing thrust clearance clutch housing radial clearance ...

  • Page 29: Spec

    2-7 maintenance specifications spec item standard limit lubrication system: oil filter type oil pump type tip clearance “a” or “b” side clearance bypass valve setting pressure relief valve operating pressure pressure check location paper type trochoid type 0.03 0.09 mm 0.03 0.08 mm 80 120 kpa (0.8 1...

  • Page 30: Spec

    2-8 maintenance specifications spec tightening torques engine part to be tightened part name thread size q’ty tightening torque remarks g size y nm m kg camshaft cap bolt m6 24 10 1.0 cylinder head nut m9 12 35 3.5 spark plug – m10 4 13 1.3 cylinder head cover bolt m6 8 10 1.0 cylinder head side cov...

  • Page 31: Spec

    2-9 maintenance specifications spec note: lower crankcase upper crankcase part to be tightened part name thread size q’ty tightening torque remarks g size y nm m kg starter cover bolt m6 7 12 1.2 oil gallery – m16 2 8 0.8 clutch cover bolt m6 10 12 1.2 clamp (a.C magneto cover) screw m6 1 7 0.7 star...

  • Page 32: Spec

    2-10 maintenance specifications spec chassis item standard limit steering system: steering bearing type angular bearing front suspension: front fork travel fork spring free length fitting length collar length spring rate (k1) (k2) stroke (k1) (k2) optional spring oil capacity oil level oil grade 120...

  • Page 33: Spec

    2-11 maintenance specifications spec item standard limit front disc brake: type disc outside dia. Thickness disc deflection limit pad thickness inner pad thickness outer master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type dual 298 4 mm 5.5 mm 5.5 mm 14 mm 30.2 mm 27 mm dot no.4...

  • Page 34: Spec

    2-12 maintenance specifications spec tightening torques chassis part to be tightened thread size tightening torque remarks g nm m kg upper bracket and inner tube m8 1.25 30 3.0 upper bracket and steering stem m22 1.0 110 11.0 handlebar under holder m10 1.25 40 4.0 handlebar upper holder m8 1.25 23 2...

  • Page 35: Spec

    2-13 maintenance specifications spec note: part to be tightened thread size tightening torque remarks g nm m kg side cover and frame m6 1.0 4 0.4 garb bar m8 1.25 19 1.9 front wheel axle m16 1.5 67 6.7 front wheel axle pinch bolt m8 1.0 20 2.0 front brake caliper m8 1.25 40 4.0 front brake disc m8 1...

  • Page 36: Spec

    2-14 maintenance specifications spec electrical item standard limit voltage 12 v ignition system: ignition timing (b.T.D.C.) advanced timing (b.T.D.C.) advance type 10 / 1,250 r / min 50 / 4,500 r / min tps and electrical type t.C.I.: pickup coil resistance t.C.I. Unit model / manufacturer 189 231 Ω...

  • Page 37: Spec

    2-15 maintenance specifications spec item standard limit starter motor: model / manufacturer i.D. Number output armature coil resistance brush overall length brush spring pressure commutator dia. Mica undercut (depth) sm-13 / mitsuba sm-13 0.7 kw 0.0015 0.0025 Ω at 20 c 10 mm 7.8 10.2 n (780 1.020 g...

  • Page 38: Spec

    2-16 maintenance specifications spec item standard limit amperage for individual circuit: main headlight signal ignition fan back up reserve 30 a 20 a 20 a 20 a 10 a 5 a 30 a 20 a 10 a 5 a.

  • Page 39: Spec

    2-17 general tightening torque specifications spec eb201000 general tightening torque specifications this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tight- ening torque specifications for special components or assemblies are provided for each chapter ...

  • Page 40: Spec

    2-18 lubrication point and lubrication types spec lubrication point and lubrication types engine lubrication point symbol oil seal lips bearing crankshaft journal connecting rod big end and small end piston, piston pin connecting rod bolt camshaft journal, profile valve stem (in, ex) valve stem end ...

  • Page 41: Spec

    2-19 lubrication point and lubrication types spec chassis lubrication point symbol steering bearing and bearing race (upper and lower) pivot shaft rear arm bearing rear arm oil seal rear arm cover oil seal lips relay arm bearing relay arm oil seal rear shock absorber (upper / lower) front wheel oil ...

  • Page 42: Spec

    2-20 10 3 2 4 1 1 3 6 5 5 6 7 8 9 8 radiator outlet hose 9 radiator 10 radiator inlet hose 1 engine outlet hose 2 engine outlet hose 3 carburetor inlet hose 4 carburetor outlet hose 5 water pump 6 coolant drain bolt 7 water pump outlet hose cooling system diagrams spec eb203000 cooling system diagra...

  • Page 43: Spec

    2-21 1 radiator 2 water pump outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 carburetor outlet hose cooling system diagrams spec.

  • Page 44: Spec

    2-22 1 2 3 4 7 6 5 4 1 oil nozzle (main nozzle) 2 oil nozzle (drive axle) 3 projection 4 oil filter 5 relief valve 6 oil strainer 7 oil pump lubrication diagrams spec eb204000 lubrication diagrams.

  • Page 45: Spec

    2-23 1 2 3 4 lubrication diagrams spec 1 main axle 2 drive axle 3 camshaft 4 oil delivery pipe.

  • Page 46: Spec

    2-24 1 2 lubrication diagrams spec 1 camshaft 2 crankshaft.

  • Page 47: Spec

    2-25 1 2 3 4 5 6 7 8 7 a b 9 handlebar switch (left) a use a plastic clamp to fasten together the handlebar switch lead (left), clutch cable and starter cable. B pass the brake hose out side of the speed sensor lead, then use a plastic clamp to fasten them. 1 throttle cable 2 clutch cable 3 handleba...

  • Page 48: Spec

    2-26 1 main switch lead 2 starter cable 3 handlebar switch lead (left) 4 clutch cable 5 rectifier / regulator 6 horn lead 7 box 8 air guide plate 9 starter cable 10 flasher leray cable routing spec 11 battery 12 starting circuit cut-off relay 13 battery positive (+) lead 14 seat lock cable 15 ac mag...

  • Page 49: Spec

    2-27 d use a steel holder to fasten together the ac magneto lead, sidestand lead and oil level / neutral switch lead. E use a plastic clamp to fasten the horn lead and air guide plate to the frame. A use a plastic clamp to fasten the handlebar switch lead (left), main switch lead, clutch cable and s...

  • Page 50: Spec

    2-28 1 battery negative (–) lead 2 rear brake switch lead 3 battery 4 reservoir tank hose 5 air filter 6 fuel tank breather hose 7 fuel tank drain hose 8 t.P.S. Lead 9 handlebar switch lead (right) cable routing spec 10 throttle cable 11 brake hose 12 headlight lead 13 speed sensor lead 14 main swit...

  • Page 51: Spec

    2-29 e pass the battery negative (–) lead inside of the reservoir hose. C pass the main switch lead under the throttle cables, headlight lead, handlebar switch lead (right) and speed sensor lead, then insert it right side of the box. D pass the reservoir tank over flow hose, fuel tank breather hose ...

  • Page 52: Spec

    2-30 21 starter relay 22 starting circuit cut-off relay 23 flasher relay 24 fuel pump lead coupler 25 ignition coil 26 clutch cable 27 ground lead 28 starter cable 29 fan motor lead 30 rectifier / regulator lead 11 battery negative (–) lead 12 battery 13 rear brake reservoir tank 14 rear brake switc...

  • Page 53: Spec

    2-31 turn signal light lead and clamp it. D pass the reservoir hose left side of thermo stat housing. E do not fasten the high tension cord #4 with locking tie. F use a plastic band to fasten the high tension cord #3, #4. G pass the carburetor inlet hose under the high tension cord #2, #4. B pass th...

  • Page 54: Spec

    Spec.

  • Page 55: Chk

    Chk adj 3.

  • Page 56: Chk

    Chk adj chapter 3 periodic inspections and adjustments introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance / lubrication intervals 3-1 . . . . . . . . . . . . . . . . . . . . . . Front cowling / sea...

  • Page 57: Chk

    Chk adj.

  • Page 58: Chk

    3-1 introduction / periodic maintenance/lubrication intervals chk adj eb300000 periodic inspections and adjustments introduction this chapter includes all information necessary to perform recommended inspections and adjust- ments. If followed, these preventive maintenance procedures will ensure more...

  • Page 59: Chk

    3-2 periodic maintenance/lubrication intervals chk adj note: every no. Item checks and maintenance jobs initial (1,000 km) 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first) 17 * sidestand switch check operation. Replace if necessary. √ √ √ 18 * front fork ch...

  • Page 60: Chk

    3-3 remove the parts in the order listed. Disconnect the couplers. For installation, reverse the removal procedure. Note: order job name / part name q’ty remarks 1 2 3 4 5 6 7 removing the front cowling view mirror (left / right) inner panel (left / right) cowling stay (left / right) head light lead...

  • Page 61: Chk

    3-4 order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 removing the seat, side cover and fuel tank seat fuel tank fuel sender lead fuel tank breaser hose fuel tank drain hose fuel hose side cover (left / right) grab bar tail cover 1 1 1 1 1 1 1 / 1 1 1 remove the parts in the order listed. Di...

  • Page 62: Chk

    3-5 adjusting the valve clearance chk adj note: eb303001 engine adjusting the valve clearance the following procedure applies to all of the valves. Valve clearance adjustment should be made on a cold engine, at room tempera- ture. When the valve clearance is to be mea- sured or adjusted, the piston ...

  • Page 63: Chk

    3-6 adjusting the valve clearance chk adj b a 1 note: note: a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the com- pression stroke, align the tdc mark a on the generator rotor with the mark b on the crankcase. Tdc on the compression stroke can be found when the camshaft lob...

  • Page 64: Chk

    3-7 adjusting the valve clearance chk adj note: note: 7. Remove: timing chain tensioner bolt 1 timing chain tensioner assembly 2 8. Remove: timing chain guide 1 timing chain guide (upper) 2 camshaft cap 3 9. Remove: camshaft 1 refer to “disassembling the engine – camshaft and cylinder head” in chapt...

  • Page 65: Chk

    3-8 adjusting the valve clearance chk adj note: note: the thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. Since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest e...

  • Page 66: Chk

    3-9 adjusting the valve clearance chk adj measured clearance # exa ! Installed pad number example: valve clearance: 0.11 0.20 mm installed is 150 measured clearance is 0.25 mm replace 150 pad with 160 pad 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...

  • Page 67: Chk

    3-10 adjusting the valve clearance chk adj a note: note: caution: note: e. Install the new valve pad 1 and the valve lifter 2 . Apply molybdenum disulfide grease to the valve pad. Lubricate the valve lifter with molybdenum disulfide oil. The valve lifter must turn smoothly when rotated by hand. Inst...

  • Page 68: Chk

    3-11 adjusting the valve clearance/ synchronizing the carburetors chk adj note: note: 14. Install: cylinder head cover spark plugs bolt (cylinder head cover): 10 nm (1.0 m kg) spark plug: 13 nm (1.3 m kg) eb303010 synchronizing the carburetors prior to synchronizing the carburetors, the valve cleara...

  • Page 69: Chk

    3-12 synchronizing the carburetors chk adj note: note: 6. Adjust: carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same. After each step, rev the engine two or three times, each time for less ...

  • Page 70: Chk

    3-13 adjusting the engine idling speed chk adj 1 note: a b eb303020 adjusting the engine idling speed prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the ...

  • Page 71: Chk

    3-14 a b a b adjusting the throttle cable free play chk adj note: note: a b note: a b eb303032 adjusting the throttle cable free play prior to adjusting the throttle cable free play, the engine idling speed and carburetor syn- chronization should be adjusted properly. 1. Check: throttle cable free p...

  • Page 72: Chk

    3-15 adjusting the throttle cable free play/ checking the spark plugs chk adj caution: note: after adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. 4. Install: fuel pump ignition coil bracket...

  • Page 73: Chk

    3-16 checking the spark plugs/ checking the ignition timing chk adj note: note: 8. Connect: spark plug cap eb303053 checking the ignition timing prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of cor...

  • Page 74: Chk

    3-17 measuring the compression pressure chk adj note: caution: eb303060 measuring the compression pressure the following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Check: valve clearance out of specification adjust. Refer t...

  • Page 75: Chk

    3-18 measuring the compression pressure/ checking the engine oil level chk adj note: note: compression pressure (at sea level) standard 1,500 kpa (15.0 kg / cm 2 ) minimum 1,200 kpa (12.0 kg / cm 2 ) a. Turn the main switch to “on”. B. With the throttle wide open, crank the en- gine until the readin...

  • Page 76: Chk

    3-19 temp sae 10w-30 sae 10w-30 sae 10w-30 2 checking the engine oil level/ changing the engine oil chk adj caution: note: recommended engine oil refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. Api standard se or higher grade acea standard g4 or...

  • Page 77: Chk

    3-20 3 1 changing the engine oil chk adj caution: 43 nm (4.3 m kg) a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01469 b. Apply a thin coat of engine oil onto the o- ring 3 of the new oil filter cartridge. Make sure that the o-ring 3 is positioned correct...

  • Page 78: Chk

    3-21 2 measuring the engine oil pressure chk adj caution: eb303090 measuring the engine oil pressure 1. Check: engine oil level below the minimum level mark add the recommended engine oil to the proper lev- el. 2. Start the engine, warm it up for several min- utes, and then turn it off. When the eng...

  • Page 79: Chk

    3-22 measuring the engine oil pressure/ adjusting the clutch cable free play chk adj c d b a engine side handlebar side 8 nm (0.8 m kg) a b note: c d 6. Install: oil gallery bolt eb303100 adjusting the clutch cable free play 1. Check: clutch cable free play a out of specification adjust. Clutch cabl...

  • Page 80: Chk

    3-23 cleaning the air filter element chk adj caution: eb303130 cleaning the air filter element 1. Remove: seat fuel tank cover 1 2. Remove: air filter case cover 1 air filter element 2 3. Clean: air filter element apply compressed air to the outer surface of the air filter element. 4. Check: air fil...

  • Page 81: Chk

    3-24 cleaning the air filter element / checking the carburetor joints and in take manifolds / checking the fuel hoses and fuel filter chk adj note: note: when installing the air filter element into the air filter case cover, be sure their sealing sur- faces are aligned to prevent any air leaks. 6. I...

  • Page 82: Chk

    3-25 checking the crankcase breather hose/ checking the exhaust system chk adj 2 7 5 6 4 4 4 3 1 1 1 caution: eb303190 checking the crankcase breather hose 1. Remove: seat fuel tank carburetor 2. Check: crankcase breather hose 1 cracks / damage replace. Loose connection connect properly. Make sure t...

  • Page 83: Chk

    3-26 b a 7 6 checking the coolant level/ checking the cooling system chk adj caution: note: eb303220 checking the coolant level 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Remove: side cover (right) 3. Check: cool...

  • Page 84: Chk

    3-27 changing the coolant chk adj 10 nm (1.0 m kg) eb303240 changing the coolant 1. Remove: seat fuel tank 2. Disconnect: coolant reservoir hose 1 3. Drain: coolant (from the coolant reservoir) 4. Remove: radiator cap a hot radiator is under pressure. There- fore, do not remove the radiator cap when...

  • Page 85: Chk

    3-28 changing the coolant chk adj caution: 9. Coonect: coolant reservoir hose 10. Fill: cooling system (with the specified amount of the recom- mended coolant) recommended antifreeze high-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines mix ratio 50% antifr...

  • Page 86: Chk

    3-29 changing the coolant chk adj note: 12. Fill: coolant reservoir (with the recommended coolant to the maximum level mark a ) 13. Install: coolant reservoir cap 14. Start the engine, warm it up for several min- utes, and then turn if off. 15. Check: coolant level refer to “checking the coolant lev...

  • Page 87: Chk

    3-30 adjusting the front brake/ adjusting the rear brake chk adj c b a note: a a a b eb304001 chassis adjusting the front brake 1. Adjust: brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake l...

  • Page 88: Chk

    3-31 adjusting the rear brake/ checking the brake fluid level chk adj a b caution: note: after adjusting the brake pedal position, check that the end of the adjusting bolt 2 is visible through the hole c . C. Tighten the locknut 1 to specification. A soft or spongy feeling in the brake ped- al can i...

  • Page 89: Chk

    3-32 a b checking the brake fluid level / adjusting the rear brake light switch chk adj caution: note: note: a b use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance. Refill with the same type of brake fluid...

  • Page 90: Chk

    3-33 checking the brake hoses/ bleeding the hydraulic brake system chk adj note: eb304062 checking the brake hoses the following procedure applies to all of the brake hoses and clamps. 1. Check: brake hose cracks / damage / wear replace. 2. Check: brake hose clamp loose connection tighten. 3. Hold t...

  • Page 91: Chk

    3-34 rear front a b bleeding the hydraulic brake system/ adjusting the shift pedal chk adj a b 2. Bleed: hydraulic brake system a. Add the recommended brake fluid to the proper level. B. Install the diaphragm (brake master cylin- der reservoir or brake fluid reservoir). C. Connect a clear plastic ho...

  • Page 92: Chk

    3-35 adjusting the drive chain slack chk adj a b note: caution: note: a b note: eb304090 adjusting the drive chain slack the drive chain slack must be checked at the tightest point on the chain. A drive chain that is too tight will over- load the engine and other vital parts, and one that is too loo...

  • Page 93: Chk

    3-36 adjusting the drive chain slack /lubricating the drive chain /checking and adjusting the steering head chk adj note: c. Tighten the wheel axle nut to specifica- tion. Wheel axle nut 117 nm (11.7 m kg) locknut 16 nm (1.6 m kg) eb304100 lubricating the drive chain the drive chain consists of many...

  • Page 94: Chk

    3-37 1 2 3 4 8 7 6 a b checking and adjusting the steering head chk adj note: note: 4. Adjust: steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . B. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . Set the torque wr...

  • Page 95: Chk

    3-38 checking adjusting the steering head / checking the front fork / adjusting the rear shock absorber assembly chk adj caution: note: 5. Install: upper bracket handlebar steering stem nut 110 nm (11.0 m kg) upper bracket pinch bolt 30 nm (3.0 m kg) handlebar upper holder bolt 23 nm (2.3 m kg) eb30...

  • Page 96: Chk

    3-39 adjusting the rear shock absorber assembly/checking the tires chk adj a b adjusting position a b a. Turn the adjusting ring 1 in direction a or b . B. Align the desired position on the adjusting ring with the stopper. Direction spring preload is increased (suspension is harder). Direction sprin...

  • Page 97: Chk

    3-40 a b 3 2 1 checking the tires chk adj basic weight (with oil and a full fuel tank) 210 kg maximum load 187 kg cold tire pressure front tire rear tire up to 90 kg load* 225 kpa (2.25 kg / cm 2 ) 250 kpa (2.50 kg / cm 2 ) 90 kg maximum load* 225 kpa (2.25 kg / cm 2 ) 280 kpa (2.80 kg / cm 2 ) high...

  • Page 98: Chk

    3-41 checking the tires/ checking the wheels chk adj note: note: after extensive tests, the tires listed be- low have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufacturer and of the same de- sign. No guarantee concerning han- dlin...

  • Page 99: Chk

    3-42 checking and lubricating the cables / lubricating the levers and pedals / lubricating the sidestand / lubricating the center stand / lubricating the rear suspension chk adj note: eb304200 checking and lubricating the cables the following procedure applies to all of the cable sheaths and cables....

  • Page 100: Chk

    3-43 checking and charging the battery chk adj caution: eb305020 electrical system checking and charging the battery batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preven- tive measures: we...

  • Page 101: Chk

    3-44 checking and charging the battery chk adj note: caution: note: since mf batteries are sealed, it is not pos- sible to check the charge state of the battery by measuring the specific gravity of the elec- trolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at ...

  • Page 102: Chk

    3-45 checking and charging the battery chk adj do not quick charge a battery. Make sure that the battery vent is free of obstructions. Never remove the mf battery sealing caps. Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery o...

  • Page 103: Chk

    3-46 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charged and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. By turning the charging voltage adjust...

  • Page 104: Chk

    3-47 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charger and amp meter to the battery and start charging. Note: voltage should be measured 30 minutes after the machine is stopped. Make sure that the current is higher than the standard charg...

  • Page 105: Chk

    3-48 checking and charging the battery/ checking the fuses chk adj caution: caution: note: 6. Install: battery 7. Connect: battery leads (to the battery terminals) first, connect the positive lead 1 , then the negative lead 2 . 8. Check: battery terminals dirt clean with a wire brush. Loose connecti...

  • Page 106: Chk

    3-49 checking the fuses/ replacing the headlight blubs chk adj 3. Replace: blown fuse a. Turn off the ignition. B. Install a new fuse of the correct amperage rating. C. Turn on the switches to verify if the electri- cal circuit is operational. D. If the fuse immediately blows again, check the electr...

  • Page 107: Chk

    3-50 replacing the headlight bulbs/ adjusting the headlight beams chk adj a a a a b b b b caution: a b 2. Remove: headlight bulb holder 1 3. Remove: headlight bulb 2 since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. In...

  • Page 108: Chk

    3-51 adjusting the headlight beams chk adj a b a b 2. Adjust: headlight beam (horizontally) a. Turn the adjusting knob 2 4 in direction a or b . Left headlight 2 direction headlight beam moves to the right. Direction headlight beam moves to the left. Right headlight 4 direction headlight beam moves ...

  • Page 109: Chk

    Chk adj.

  • Page 110: Eng

    Eng 4.

  • Page 111: Eng

    Eng chapter 4 overhauling the engine removing the engine 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive sprocket and exhaust pipe 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leads and hoses 4-3 . . . . . . . . . . ....

  • Page 112: Eng

    Eng ac magneto and starter clutch 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stator coil 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter clutch 4-42 . . . . . . . . . . . . . . . . . . . . . ...

  • Page 113: Eng

    4-1 70 nm (7.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 25 nm (2.5 m kg) 17 nm (1.7 m kg) order job name / part name q’ty remarks 1 2 3 removing the drive sprocket and exhaust pipe drain the coolant drain the engine oil front cowling fuel tank battery negative terminal radiator carbu...

  • Page 114: Eng

    4-2 25 nm (2.5 m kg) 70 nm (7.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 17 nm (1.7 m kg) order job name / part name q’ty remarks 4 5 6 7 8 9 shift arm drive sprocket cover drive chain sprocket gasket dowel pin lock washer drive sprocket / drive chain 1 1 1 2 1 1 / 1 refer to “instal...

  • Page 115: Eng

    4-3 12 nm (1.2 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 disconnecting the leads and hoses magneto / sidestand / neutral / engine oil level switch lead ground lead plug cap crankcase breather hose cover water pump outlet hose radiator outlet hose engine outlet hose engine outle...

  • Page 116: Eng

    4-4 33 nm (3.3 m kg) 55 nm (5.5 m kg) 33 nm (3.3 m kg) 55 nm (5.5 m kg) 33 nm (3.3 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 removing the engine bracket and engine engine mounting bolt (front left) engine mounting bolt (front right) engine bracket (front) engine mounting bolt (rear...

  • Page 117: Eng

    4-5 removing the engine eng note: note: eb400700 installing the engine 1. Install: bolt 1 bolt 2 bolt 3 bolt 4 engine bracket 5 engine bracket 6 do not fully tighten the bolts. 2. Tighten the bolts in the following order. Bolt 1 55 nm (5.5 m kg) bolt 2 55 nm (5.5 m kg) bolt 3 55 nm (5.5 m kg) bolt 4...

  • Page 118: Eng

    4-6 10 nm (1.0 m kg) 9 nm (0.9 m kg) order job name / part name q’ty remarks 1 2 3 removing the cylinder head cover front cowling seat and fuel tank drain the coolant radiator carburetor exhaust pipe plug cap cylinder head side cover cylinder head cover cylinder head cover gasket 4 1 1 remove the pa...

  • Page 119: Eng

    4-7 10 nm (1.0 m kg) 20 nm (2.0 m kg) 13 nm (1.3 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the camshafts spark plug magneto cover timing chain guide (upper) timing chain tensioner assembly timing chain guide (exhaust side) camshaft ...

  • Page 120: Eng

    4-8 camshaft eng 2 note: note: eb401102 removing the camshafts 1. Remove: magneto cover 2. Align: “t” mark on the magneto rotor (with the stationary pointer on the crank- case) a. Turn the crankshaft counterclockwise. B. When piston #1 is at tdc on the com- pression stroke, align the “t” mark a with...

  • Page 121: Eng

    4-9 1 3 2 camshaft eng caution: note: to prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the out- side in. 8. Remove: intake camshaft 1 exhaust camshaft 2 to prevent the timing chain from falling into ...

  • Page 122: Eng

    4-10 camshaft eng 1 note: 4. Measure: camshaft-journal-to-camshaft-cap clear- ance out of specification measure the cam- shaft journal diameter. Camshaft-journal-to- camshaft-cap clearance 0.08 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). B. Position ...

  • Page 123: Eng

    4-11 2 1 3 2 2 3 4 4 camshaft eng note: note: note: eb401430 checking the timing chain tensioner 1. Check: timing chain tensioner cracks / damage replace. 2. Check: one-way cam operation rough movement replace the timing chain tensioner housing. 3. Check: cap bolt 1 copper washer 2 ball 3 spring 4 b...

  • Page 124: Eng

    4-12 4 6 5 3 2 1 “e” “i” c c camshaft eng caution: note: caution: the camshaft cap bolts must be tight- ened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Camshaft cap bolt 10 nm (1.0 m kg) 4. Install: intake camshaft sprocket exhaust camshaft sprocket a. Turn the ...

  • Page 125: Eng

    4-13 camshaft eng c c d d caution: always use a new gasket. Timing chain tensioner bolt 10 nm (1.0 m kg) d. Install the springs 3 , washer 2 , and cap bolt 1 . Cap bolt 20 nm (2.0 m kg) 7. Turn: crankshaft (several full turns counterclockwise) 8. Check: “t” mark a make sure that the “t” mark on the ...

  • Page 126: Eng

    4-14 35 nm (3.5 m kg) 20 nm (2.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 removing the cylinder head camshaft union bolt copper washer oil delivery pipe cylinder head cylinder head gasket dowel pin 2 4 1 1 1 2 remove the parts in the order listed. Refer to “camshaft”section. Refer t...

  • Page 127: Eng

    4-15 cylinder head eng note: note: note: eb402101 removing the cylinder heads 1. Remove: cylinder head nuts loosen the nuts in the proper sequence as shown. Loosen each nut 1 / 2 of a turn at a time. After all of the nuts are fully loosened, re- move them. Eb402403 checking the cylinder heads the fo...

  • Page 128: Eng

    4-16 cylinder head eng note: note: eb402702 installing the cylinder head 1. Install: gasket (new) 1 dowel pins 2 the “up” mark a on the gasket must face up. 2. Install: cylinder head apply engine oil onto the threads of the cyl- inder head nuts. Tighten the cylinder head nuts in the prop- er tighten...

  • Page 129: Eng

    4-17 order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 removing the valves and valve springs camshaft cylinder head valve lifter adjusting pad valve cotters upper spring seat valve spring valve (intake) valve (exhaust) oil seal lower spring seat 4 4 8 4 4 2 2 4 4 remove the parts in the orde...

  • Page 130: Eng

    4-18 valves and valve springs eng 1 a note: note: note: note: eb403100 removing the valves the following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.G., valves, valve springs, valve seats), make sure that the valves proper...

  • Page 131: Eng

    4-19 a b valves and valve springs eng a b note: note: eb403400 checking the valves and valve guides the following procedure applies to all of the valves and valve guides. 1. Measure: s valve-stem-to-valve-guide clearance valve-stem-to-valve-guide clearance = valve guide inside diameter – valve stem ...

  • Page 132: Eng

    4-20 valves and valve springs eng a 4. Check: valve face pitting/ wear grind the valve face. Valve stem end mushroom shape of diameter larger than the body of the valve stem replace the valve. 5. Measure: valve margin thickness a out of specification replace the valve. Valve margin thickness 0.5 mm ...

  • Page 133: Eng

    4-21 valves and valve springs eng note: caution: note: a. Apply mechanic’s blueing dye (dykem) b onto the valve face. B. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear pattern. D. Measure the valve seat width. Where the va...

  • Page 134: Eng

    4-22 valves and valve springs eng a a eb403420 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: valve spring free length a out of specification replace the valve spring. Valve spring free length (intake and exhaust) spring 40.09 mm (limit 37.5 mm) 2...

  • Page 135: Eng

    4-23 valves and valve springs eng 2 1 2 2 1 5 4 3 2 a b large small note: note: eb403440 checking the camshaft cap 1. Check: camshaft case camshaft caps 1 cracks / damage replace th camshaft case and camshaft caps as a set, and check the camshafts (refer to “check- ing the camshafts”.). Camshaft bea...

  • Page 136: Eng

    4-24 valves and valve springs eng caution: note: valve spring compressor 90890-04019 attachment 90890-04114 5. To secure the valve cotters 1 onto the a valve stem, lightly tap the valve tip with a soft-face hammer. Hitting the valve tip with excessive force could damage the valve. 6. Install: valve ...

  • Page 137: Eng

    4-25 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the cylinder and pistons cylinder head water jacket joint o-ring cylinder cylinder gasket dowel pin o-ring piston pin circlip piston pin piston piston ring set 1 2 1 1 2 4 8 4 4 4 remove the parts in the orde...

  • Page 138: Eng

    4-26 1 2 4 cylinder and piston eng caution: note: note: note: eb404101 removing the cylinders and pistons the following procedure applies to all of the cyl- inders and pistons. 1. Remove: piston pin clip 1 piston pin 2 piston 3 do not use a hammer to drive the piston pin out. Before removing the pis...

  • Page 139: Eng

    4-27 cylinder and piston eng p a “c” = x + y 2 note: standard wear limit cylinder bore “c” 62.00 62.01 62.1 mm b. If out of specification, replace the cylin- der, piston and piston rings as a set. C. Measure piston skirt diameter “p” with the micrometer. A 5 mm from the bottom edge of the piston. Pi...

  • Page 140: Eng

    4-28 cylinder and piston eng a a note: note: 2. Install: piston ring 1 (into the cylinder) level the piston ring in the cylinder with the piston crown as shown. A 20 mm 3. Measure: piston ring end gap out of specification replace the piston ring. The oil ring expander spacer’s end gap can- not be me...

  • Page 141: Eng

    4-29 cylinder and piston eng b 1 2 4 5 3 a note: note: 3. Calculate: piston-pin-to-piston clearance out of specification replace the piston pin. Piston-pin-to-piston clearance = piston pin bore size b – piston pin outside diameter a piston-pin-to-piston clearance 0.011 0.013 mm : 0.023 mm eb404701 i...

  • Page 142: Eng

    4-30 1 2 2 d c e a b cylinder and piston eng note: 5. Offset: piston ring end gaps a top ring b lower oil ring rail c upper oil ring rail d 2nd ringe e oil ring expander 6. Install: cylinder 1 o-ring 2 first, install pistons #2 and #3. Pass the timing chain and timing chain guide (exhaust side) thro...

  • Page 143: Eng

    4-31 12 nm (1.2 m kg) 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 removing the clutch cover drain the engine oil clutch cover clutch cover gasket dowel pin drive sprocket cover clutch cable 1 1 2 1 1 remove the parts in the order listed. Refer to “changing the engine oil” sect...

  • Page 144: Eng

    4-32 8 nm (0.8 m kg) 70 nm (7.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 removing the clutch compression spring pressure plate short clutch push rod o-ring ball long clutch push rod friction plate clutch plate fricition plate (large) clutch spring plate nut 6 1 1 1 1 1 8...

  • Page 145: Eng

    4-33 8 nm (0.8 m kg) 70 nm (7.0 m kg) order job name / part name q’ty remarks 12 13 14 15 16 17 18 19 lock washer clutch boss thrust washer spacer bearing clutch housing thrust washer spacer 1 1 1 1 1 1 1 1 refer to “removing / installing the clutch” section. Refer to “installing the clutch” section...

  • Page 146: Eng

    4-34 clutch eng 3 2 1 note: note: note: eb405100 removing the clutch 1. Straighten the lock washer tab. 2. Loosen: clutch boss nut 1 while holding the clutch boss 2 with the uni- versal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder 3 90890-04086 3. Remove: spacer 1 bearing 2 ...

  • Page 147: Eng

    4-35 clutch eng 2 a note: eb405420 checking the clutch springs the following procedure applies to all of the clutch springs. 1. Check: clutch spring damage replace the clutch springs as a set. 2. Measure: clutch spring free length a out of specification replace the clutch springs as a set. Clutch sp...

  • Page 148: Eng

    4-36 clutch eng 1 1 2 note: note: eb405450 checking the clutch boss 1. Check: clutch boss splines 1 damage / pitting / wear replace the clutch boss. Pitting on the clutch boss splines will cause erratic clutch operation. Eb405450 checking the pressure plate 1. Check: pressure plate 1 cracks / damage...

  • Page 149: Eng

    4-37 clutch eng 1 2 2 1 3 70 nm (7.0 m kg) note: 8.0 nm (0.8 m kg) note: 2. Tighten: clutch boss nut 1 while holding the clutch boss with the uni- versal clutch holder 2 , tighten the clutch boss nut. Universal clutch holder 90890-04086 3. Bend the lock washer 3 tab along a flat side of the nut. 4. ...

  • Page 150: Eng

    4-38 clutch eng 12 nm (1.2 m kg) note: 9. Install: clutch cover 1 tighten the clutch cover bolts in stages and in a crisscross pattern..

  • Page 151: Eng

    4-39 order job name / part name q’ty remarks 1 2 3 4 5 removing the shift shaft oil pump drive sprocket cover collar shift shaft shift lever spring stopper lever shift lever spring 1 1 1 1 1 remove the parts in the order listed. Refer to “oil pump” section. Refer to “removing the engine” section. Re...

  • Page 152: Eng

    4-40 1 2 4 2 1 2 3 shift shaft eng note: note: eb408400 checking the shift shaft 1. Check: shift shaft 1 shift lever 2 bends / damage / wear replace. Shift lever spring 3 stopper lever spring 4 damage / wear replace. Eb408700 installing the shift shaft 1. Install: stopper lever 1 stopper lever sprin...

  • Page 153: Eng

    4-41 5 nm (0.5 m kg) 10 nm (1.0 m kg) 12 nm (1.2 m kg) order job name / part name q’ty remarks 1 2 3 4 5 removing the stator coil seat fuel tank stator / pickup coil lead cover generator cover dowel pin stator coil 1 / 1 1 1 2 1 remove the parts in the order listed. Refer to “front cowling / seat / ...

  • Page 154: Eng

    4-42 12 nm (1.2 m kg) 80 nm (8.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 removing the starter clutch generator cover starter clutch cover dowel pin gasket starter clutch assembly wood ruff key starter wheel gear shaft (primary) starter idle gear (primary) shaft (seconda...

  • Page 155: Eng

    4-43 130 nm (13.0 m kg) order job name / part name q’ty remarks 1 2 3 removing the generator roter bolt/ washer rotor woodruff key 1 / 1 1 1 remove the parts in the order listed. Refer to “removing / installing the ac magneto” section. For installation, reverse the removal procedure. Ac magneto and ...

  • Page 156: Eng

    4-44 ac magneto and starter clutch eng note: note: note: eb410100 removing the starter clutch 1. Remove: starter clutch cover 1 loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: starter clutch bolt 1 ...

  • Page 157: Eng

    4-45 2 1 3 ac magneto and starter clutch eng note: 2. Remove: ac magneto rotor 1 woodruff key use a flywheel puller 2 to remove the ac magneto rotor 1 . Flywheel puller: 90890-01362 eb410401 checking the starter clutch 1. Check: starter clutch idle gear 1 starter clutch drive gear 2 starter clutch g...

  • Page 158: Eng

    4-46 ac magneto and starter clutch eng note: note: note: installing the ac magneto 1. Install: woodruff key 1 ac magneto rotor 2 bolt (ac magneto rotor) clean the tapered portion of the crankshaft and the ac magneto rotor. When installing the ac magneto rotor, make sure that the woodruff key is prop...

  • Page 159: Eng

    4-47 63 nm (6.3 m kg) 10 nm (1.0 m kg) 12 nm (1.2 m kg) 43 nm (4.3 m kg) 7 nm (0.7 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 removing the oil strainer engine oil level warning switch / o-ring oil pan dowel pin oil pan gasket relief valve / o-ring oil strainer oil strainer housi...

  • Page 160: Eng

    4-48 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 removing the oil pump clutch oil pump assembly oil pump gasket dowel pin 1 1 1 remove the parts in the order listed. Refer to “clutch” section. Refer to “installing the oil pump” section. For installation, reverse the removal proced...

  • Page 161: Eng

    4-49 order job name / part name q’ty remarks 1 2 3 4 5 6 7 disassembling the oil pump oil pump rotor housing dowel pin inner rotor / outer rotor dowel pin oil pump shaft assembly oil pump cover washer 1 2 1 / 1 1 1 1 1 disassembly the parts in the order listed. Refer to “assembling the oil pump” sec...

  • Page 162: Eng

    4-50 oil pan and oil strainer eng note: eb411100 removing the oil pan 1. Remove: oil level switch 1 oil pan 2 gasket dowel pins loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eb411401 checking the oil pump 1....

  • Page 163: Eng

    4-51 oil pan and oil strainer eng b a 4 6 5 7 6 7.0 nm (0.7 m kg) note: eb411430 checking the oil strainer 1. Check: oil strainer 1 damage replace. Contaminants clean with engine oil. Eb411470 checking the oil nozzle 1. Check: oil nozzle 1 check ball 2 damage / wear replace the oil nozzle. O-ring 3 ...

  • Page 164: Eng

    4-52 oil pan and oil strainer eng d c b 10 nm (1.0 m kg) caution: note: note: 10 nm (10 m kg) note: note: eb411710 installing the oil pump install: oil pump 1 after tightening the bolts, make sure that the oil pump turns smoothly. Align the projection a on the oil pump shaft with the slot b on the w...

  • Page 165: Eng

    4-53 oil pan and oil strainer eng note: tighten the oil pan bolts in stages and in a crisscross pattern. Lubricate the oil level switch’s o-ring with engine oil. Oil pan bolt 12 nm (1.2 m kg) oil level switch bolt 7 nm (0.7 m kg).

  • Page 166: Eng

    4-54 10 nm (1.0 m kg) 24 nm (2.4 m kg) 24 nm (2.4 m kg) 12 nm (1.2 m kg) order job name / part name q’ty remarks 1 2 3 disassembling the crankcase engine camshaft cylinder head cylinder, piston clutch oil pump shift shaft magneto rotor starter clutch oil strainer water pump oil seal stopper plate ne...

  • Page 167: Eng

    4-55 10 nm (1.0 m kg) 24 nm (2.4 m kg) 24 nm (2.4 m kg) 12 nm (1.2 m kg) order job name / part name q’ty remarks 4 5 6 7 8 9 o-ring upper crankcase dowel pin oil seal oil jet o-ring 1 1 1 1 1 1 refer to “disassembling / assembling the crankcase” section. For assembly, reverse the disassembly procedu...

  • Page 168: Eng

    4-56 a b crankcase eng note: caution: note: eb412100 disassembling the crankcase 1. Remove: crankcase bolts 1 15 a upper crankcase loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decreasing...

  • Page 169: Eng

    4-57 crankcase eng 2 b a note: note: caution: eb412742 assembling the crankcase 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) recommended lubricant engine oil 2. Apply: sealant (onto the crankcase mating surfaces) yamaha bond no. 1215 90890-85505 do not allow any sealant...

  • Page 170: Eng

    4-58 crankcase eng a b note: 7. Install: upper crankcase bolts lower crankcase bolts lubricate the bolt threads with engine oil. Tighten the bolts in increasing numerical order. Install washers on bolts 1 12 . Install the cable holder on bolt #35. A upper crankcase b lower crankcase m8 bolt 24 nm (2...

  • Page 171: Eng

    4-59 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 removing the crankshaft disassembly the crankcase timing chain guide (intake side) crankshaft assembly oil seal timing chain crankshaft journal bearing 1 1 1 1 12 remove the parts in the order listed. Refer to “crankcase” sectio...

  • Page 172: Eng

    4-60 15 nm (1.5 m s kg) + 90 _ order job name / part name q’ty remarks 1 2 3 4 5 removing the connecting rod nut connecting rod bolt connecting rod connecting rod cap connecting rod big end bearing 8 8 4 4 8 remove the parts in the order listed. Refer to “installing the connecting rods” section. Ref...

  • Page 173: Eng

    4-61 1 2 1 2 crankshaft eng note: note: eb412110 removing the crankshaft assembly 1. Remove: crankshaft assembly 1 crankshaft journal upper bearing 2 (from the upper crankcase) timing chain guide (intake side) identify the position of each crankshaft jour- nal upper bearing so that it can be reinsta...

  • Page 174: Eng

    4-62 crankshaft eng 2 b a b a caution: note: note: note: crankshaft-journal-to-crank- shaft-journal-bearing clearance 0.025 0.043 mm limit 0.08 mm do not interchange the crankshaft jour- nal bearings. To obtain the correct crank- shaft journal-to-crankshaft-journal-bear- ing clearance and prevent en...

  • Page 175: Eng

    4-63 crankshaft eng a b c note: note: f. Tighten the bolts to specification in the tightening sequence cast on the crank- case. Crankcase bolt m8: 24 nm (2.4 m kg) m6: 12 nm (1.2 m kg) a upper crankcase b lower crankcase lubricate the crankcase bolt threads (m8) and (m6) with engine oil. G. Remove t...

  • Page 176: Eng

    4-64 crankshaft eng a 1 1 b a 1 1 caution: note: for example, if the crankcase “j 1 ” and crankshaft web “j1” numbers are “6” and “2” respectively, then the bearing size for “j1” is: bearing size for j1: j 1 (crankcase) – j1 (crankshaft web) + 1 = 6 – 2 + 1 = 5 (yellow) crankshaft journal bearing co...

  • Page 177: Eng

    4-65 c e a crankshaft eng note: note: s do not move the connecting rod or crank- shaft until the clearance measurement has been completed. S apply molybdenum disulfide grease onto the bolts, threads, and nut seats. S make sure that the “y” mark c on the con- necting rod faces towards the left side o...

  • Page 178: Eng

    4-66 crankshaft eng 2 2 3 2 2 note: for example, if the connecting rod “p 1 ” and the crankshaft web “p1” numbers are “4” and “1” respectively, then the bearing size for “p 1 ” is: bearing size for p 1 : p 1 (connecting rod) – p1 (crankshaft- web) = 4 – 1 = 3 (brown) big end bearing color code 1 2 3...

  • Page 179: Eng

    4-67 crankshaft eng caution: caution: note: 4. Align: s bolt heads 1 (with the connecting rod caps) 5. Tighten: s nuts (connecting rod) nut (connecting rod): 15 nm (1.5 m s kg) + (turn the nut another 90 _ ) a. Replace the connecting rod bolts and nuts with new ones. Tighten the connecting rod bolts...

  • Page 180: Eng

    4-68 crankshaft eng b a note: note: 10 nm (1.0 m kg) eb412720 installing the crankshaft 1. Install: crankshaft journal upper bearings 1 (into the upper crankcase) align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase. Be sure to install each crankshaft ...

  • Page 181: Eng

    4-69 order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 removing the transmission disassembly the crankcase main axle assembly circlip bearing bearing drive axle assembly circlip nozzle bearing plate washer oil seal / collar bearing 1 1 1 1 1 1 1 1 1 1 / 1 1 remove the parts in the orde...

  • Page 182: Eng

    4-70 order job name / part name q’ty remarks disassembling the transmission 1st wheel gear 5th wheel gear circlip washer 4th wheel gear 3rd wheel gear 6th wheel gear 2nd wheel gear washer circlip drive axle 2nd pinion gear 6th pinion gear 1 1 1 1 1 1 1 1 1 1 1 1 1 disassembly the parts in the order ...

  • Page 183: Eng

    4-71 order job name / part name q’ty remarks 3rd / 4th pinion gear circlip washer 5th main axle 1 1 1 1 1 for assembly, reverse the disassembly procedure. 14 15 16 17 18 transmission eng.

  • Page 184: Eng

    4-72 transmission eng eb413422 checking the transmission 1. Measure: main axle runout (with a centering device and dial gauge 1 ) out of specification replace the main axle. Main axle runout limit 0.02 mm 2. Measure: drive axle runout (with a centering device and dial gauge 1 ) out of specification ...

  • Page 185: Eng

    4-73 transmission eng note: note: note: eb413710 installing the transmission 1. Install: oil baffle plate 1 crankcase breather hose 2 insert the metal clamp 3 on the crankcase breather hose into the slots 4 in the crank- case. 2. Install: main axle assembly 1 drive axle assembly 2 oil seals circlips...

  • Page 186: Eng

    4-74 10 nm (1.0 m kg) 10 nm (1.0 m kg) remove the parts in the order listed. Refer to “crankcase” section. Refer to “transmission” section. Refer to “installing the shift forks and shift drum” section. For installation, reverse the removal procedure. Order job name / part name q’ty remarks 1 2 3 4 5...

  • Page 187: Eng

    4-75 shift drum and shift forks eng 1 2 1 2 eb413400 checking the shift forks the following procedure applies to all of the shift forks and related components. 1. Check: shift fork cam follower 1 shift fork pawl 2 bends / damage / scoring / wear replace the shift fork. 2. Check: shift fork guide bar...

  • Page 188: Eng

    4-76 shift drum and shift forks eng 1 1 2 3 note: 10 nm (1.0 m s kg) 10 nm (1.0 m s kg)r 2. Install: s shift fork guide bars 1 s shift fork “l” 2 s shift fork “c” 3 s shift fork “r” 4 s the embossed marks on the shift forks should face towards the left side of the en- gine and be in the following se...

  • Page 189: Cool

    Cool 5.

  • Page 190: Cool

    Cool chapter 5 cooling system radiator 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the radiator 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the ra...

  • Page 191: Cool

    Cool.

  • Page 192: Cool

    5-1 7 nm (0.7 m kg) order job name / part name q’ty remarks 1 2 3 4 5 removing the radiator seat fuel tank drain the coolant fan motor leads radiator outlet hose radiator inlet hose radiator fan 1 1 1 1 1 remove the parts in the order listed. Refer to “front cowling / seat / side cover/ fuel tank” s...

  • Page 193: Cool

    5-2 radiator cool note: eb500010 checking the radiator 1. Check: radiator fins obstruction clean. Apply compressed air to the rear of the ra- diator. Damage repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: radiator hoses radiator pipes cracks / damage r...

  • Page 194: Cool

    5-3 radiator cool eb500020 installing the radiator 1. Fill: cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: cooling system leaks repair or replace any faulty part. A. Attach the radiator cap tester 1 to the radiator. Rad...

  • Page 195: Cool

    5-4 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 removing the thermostat seat fuel tank drain the coolant thermo switch lead (engine temperature) thermo switch lead (fan motor) reservoir tank hose carburetor inlet hose engine outlet hose engine outlet hose radiator inle...

  • Page 196: Cool

    5-5 23 nm (2.3 m kg) 8 nm (0.8 m kg) 10 nm (1.0 m kg) order job name / part name q’ty remarks disassembling the thermostat thermo switch (fan motor) thermo switch (engine temperature) thermostat housing cover o-ring thermostat thermostat housing 1 1 1 1 1 1 disassembly the parts in the order listed....

  • Page 197: Cool

    5-6 thermostat cool 1 1 3 4 2 80.5 _ 83.5 _ 95 _ c 8 mm note: eb502021 checking the thermostat 1. Check: s thermostat 1 does not open at 80.5 83.5 _ c replace. A. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the water. D. While stirring...

  • Page 198: Cool

    5-7 thermostat cool note: 23 nm (2.3 m kg) 8 nm (0.8 m kg) caution: eb502030 assembling the thermostat 1. Install: thermostat housing 1 thermostat 2 o-ring (new) 3 thermostat housing cover 4 install the thermostat with its breather hole a facing up. 2. Install: thermo switch (fan motor) 1 thermo swi...

  • Page 199: Cool

    5-8 10 nm (1.0 m kg) 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 removing the water pump drain the coolant shift arm, drive chain cover radiator outlet hose water pump outlet hose water pump outlet pipe water pump housing cover o-ring water pump assembly o-ring 1 1 1 1 1 1...

  • Page 200: Cool

    5-9 water pump cool 1 2 note: eb503020 removing the water pump 1. Remove: water pump housing 1 tap out the water pump seal from the inside of the water pump housing. Eb503032 checking the water pump 1. Check: water pump housing cover water pump housing 1 impeller 2 2. Check: water pump seal 1 oil se...

  • Page 201: Cool

    5-10 water pump cool a b note: note: 10 nm (1.0 m kg) 10 nm (1.0 m kg) note: align the slot a on the impeller shaft with the projection b on the oil pump shaft. Before installing the water pump housing, apply a thin coat of lithium soap base grease onto the o-ring. 2. Install: water pump housing cov...

  • Page 202: Carb

    Carb 6.

  • Page 203: Carb

    Carb chapter 6 carburetors carburetors 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air filter case 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetors 6-2 ....

  • Page 204: Carb

    Carb.

  • Page 205: Carb

    6-1 order job name / part name q’ty remarks 1 2 3 4 5 removing the air filter case seat, fueltank and sidecovers drain the coolant air filter case (left / right) battery negative lead battery positive lead battery stay 1 / 1 1 1 1 1 remove the parts in the order listed. Refer to “front cowling / sea...

  • Page 206: Carb

    6-2 carburetors carb order job name / part name q’ty remarks 1 2 3 4 5 6 removing the carburetors throttle position sensor lead air filter joint screw carburetors joint screw carburetor inlet / outlet hose carburetors assembly starter cable throttle cable 4 4 1 / 1 1 1 2 remove the parts in the orde...

  • Page 207: Carb

    6-3 carburetors carb order job name / part name q’ty remarks disassembling the carburetors starter plunger link carburetors assembly vacuum chamber cover piston valve spring piston valve needle kit float chamber float chamber gasket float pin float needle valve assembly main jet 1 4 1 1 1 1 1 1 1 1 ...

  • Page 208: Carb

    6-4 carburetors carb order job name / part name q’ty remarks main jet holder needle jet pilot jet pilot screw set starter plunger kit 1 1 1 1 1 refer to “assembling the carburetors” section. For assembly, reverse the disassembly procedure. 13 14 15 16 17.

  • Page 209: Carb

    6-5 carburetors carb eb600031 checking the carburetors the following procedure applies to all of the car- buretors. 1. Check: carburetor body float chamber main jet holder cracks / damage replace. 2. Check: fuel passages obstruction clean. A. Wash the carburetor in a petroleumbased solvent. Do not u...

  • Page 210: Carb

    6-6 carburetors carb 8. Check: piston valve 1 damage / scratches / wear replace. Rubber diaphragm 2 cracks / tears replace. 9. Check: vacuum chamber cover 1 piston valve spring 2 jet needle holder 3 cracks / damage replace. 10. Check: jet needle kit 1 needle jet 2 main jet 3 pilot jet 4 pilot screw ...

  • Page 211: Carb

    6-7 carburetors carb caution: note: eb600041 assembling the carburetors the following procedure applies to all of the car- buretors. Before assembling the carburetors, wash all of the parts in a petroleum- based solvent. Always use a new gasket. 1. Install: o-ring (new) washer pilot screw spring pil...

  • Page 212: Carb

    6-8 carburetors carb note: 4. Install: fuel feed joints 1 hose joints 2 spacer 3 connecting bolt 4 starter plunger link 5 throttle cable holder 6 spacer 7 connecting bolt 8 do not tighten the connecting bolts yet. Install the throttle arm 9 onto carburetors #1, #2, and #4 between the spring 10 and s...

  • Page 213: Carb

    6-9 carburetors carb 2 3 note: eb600062 measuring and adjusting the fuel level 1. Measure: fuel level a out of specification adjust fuel level (above the float chamber mating surface) 4.5 mm a. Stand the motorcycle on a level surface. B. Place the motorcycle on a suitable stand to ensure that the mo...

  • Page 214: Carb

    6-10 carburetors carb note: 1 2 3 2 eb600070 checking and adjusting the throttle position sensor s before adjusting the throttle position sen- sor, the engine idling speed should be properly adjusted. S when installing the throttle position sen- sor, adjust its angle according to the rpm which is di...

  • Page 215: Carb

    6-11 carburetors carb 2 3 note: note: 1 2 3 a b note: b. Disconnect the throttle position sensor coupler. C. Reconnect the throttle position sensor coupler. After reconnecting the throttle position sen- sor coupler, the tachometer switches to the throttle position sensor adjustment mode. D. Loosen t...

  • Page 216: Carb

    6-12 carb.

  • Page 217: Chas

    Chas 7.

  • Page 218: Chas

    Chas chapter 7 chassis front wheel and brake discs 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wheel 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front wheel 7-3 . . . . . . ...

  • Page 219: Chas

    Chas steering head 7-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lower bracket 7-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the lower bracket 7-55 . . . . ....

  • Page 220: Chas

    7-1 23 nm(2.3 m kg) 40 nm(4.0 m kg) 67 nm (6.7 m kg) 20 nm (2.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 removing the flont wheel and brake discs wheel axle pinch bolt brake hose horder (left / right) brake caliper (left / right) wheel axle front wheel assembly speed sensor unit...

  • Page 221: Chas

    7-2 order job name / part name q’ty remarks disassembling the front wheel oil seal bearing spacer bearing 1 1 1 1 disassembly the parts in the order listed. For assembly, reverse the disassembly prodedure. 1 2 3 4 front wheel and brake disc chas front wheel.

  • Page 222: Chas

    7-3 front wheel and brake disc chas note: note: caution: note: eb700102 removing the front wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the front wheel is elevated. 2....

  • Page 223: Chas

    7-4 front wheel and brake disc chas 2 1 note: caution: note: 3. Measure: front wheel radial runout 1 front wheel lateral runout 2 over the specified limits replace. Front wheel radial runout limit 1.0 mm front wheel lateral runout limit 0.5 mm 4. Check: wheel bearings front wheel turns roughly or is...

  • Page 224: Chas

    7-5 front wheel and brake disc chas note: eb700414 checking the brake discs the following procedure applies to all of the brake discs. 1. Check: s brake disc damage / galling replace. 2. Measure: s brake disc deflection a out of specification correct the brake disc deflection or replace the brake di...

  • Page 225: Chas

    7-6 front wheel and brake disc chas note: note: caution: eb700722 installing the front wheel 1. Lubricate: wheel axle wheel bearings oil seal lips recommended lubricant lithium soap base grease 2. Install: speed sensor unit make sure that the speed sensor unit and the wheel hud are installed with th...

  • Page 226: Chas

    7-7 front wheel and brake disc chas a b c d x 1 x note: note: note: eb700901 adjusting the front wheel static balance s after replacing the tire. Wheel or both, the front wheel static balance should be ad- justed. S adjust the front wheel static balance with the brake discs installed. 1. Remove: s b...

  • Page 227: Chas

    7-8 117 nm (11.7 m kg) 40 nm (4.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 removing the rear wheel brake caliper nut washer wheel axle washer drive chain puller (left) drive chain puller (right) rear wheel assembly 1 1 1 1 1 1 1 1 remove the parts in the order listed. Refer to “...

  • Page 228: Chas

    7-9 23 nm (2.3 m kg) 60 nm (6.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 removing the brake disk and rear wheel sprocket collar (left / right) brake disc rear wheel sprocket collar drive hub damper rear wheel drive hub oil seal bearing 1 / 1 1 1 1 6 1 1 1 remove the parts in the...

  • Page 229: Chas

    7-10 order job name / part name q’ty remarks disassembling the rear wheel oil seal bearing collar bearing 1 1 1 1 disassembly the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 rear wheel, brake disc and rear wheel sprocket chas diassembly the rear wheel.

  • Page 230: Chas

    7-11 1 1 2 3 rear wheel, brake disc and rear wheel sprocket chas note: note: note: eb701100 removing the rear wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so. That there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wh...

  • Page 231: Chas

    7-12 rear wheel, brake disc and rear wheel sprocket chas note: 3. Measure: rear wheel radial runout rear wheel lateral runout refer to “front wheel and brake disc”. Eb701440 checking and replacing the rear wheel sprocket 1. Check: rear wheel sprocket more than 1 / 4 tooth a wear replace the rear whe...

  • Page 232: Chas

    7-13 rear wheel, brake disc and rear wheel sprocket chas note: eb701900 adjusting the rear wheel static balance after replacing the tire, wheel or both, the rear wheel static balance should be ad- justed. Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1....

  • Page 233: Chas

    7-14 40 nm (4.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 removing the front brake pads brake caliper brake pads clip brake pad pin brake pad spring brake pad 1 2 1 1 2 remove the parts in the order listed. Refer to “replacing the front brake pads” section. For installation, reverse th...

  • Page 234: Chas

    7-15 40 nm (4.0 m kg) 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 removing the rear brake pads caliper brake pad pin brake pad / shim brake pad spring 1 2 2 / 2 1 remove the parts in the order listed. Refer to “replacing the rear brake pads” section. For instalation, reverse the...

  • Page 235: Chas

    7-16 front and rear brakes chas caution: note: eb702100 disc brake componets rarely require dis- assembly. Tehrefore, always follow these preven- tive measures: never disassemble brake components unless absolutely necessary. If any connection on the hydraulic brake system is disconnected, the en- ti...

  • Page 236: Chas

    7-17 front and rear brakes chas note: 6 nm (0.6 m kg) 40 nm (4.0 m kg) note: 3. Remove: brake pads 1 (along with the brake pad shims) 4. Measure: brake pad wear limit a out of specification replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install: brake pad shims (onto the brake pads)...

  • Page 237: Chas

    7-18 front and rear brakes chas note: note: 6 nm (6 m kg) eb702113 replacing the rear brake pads when replacing the brake pads, it is not nec- essary to disconnect the brake hose or dis- assemble the brake caliper. 1. Remove: brake caliper 1 2. Remove: brake pad pins 1 3. Remove: brake pads 2 (along...

  • Page 238: Chas

    7-19 front and rear brakes chas 10 nm (1.0 m kg) 40 nm (4.0 m kg) 6. Install: brake pad pins 1 brake caliper 7. Check: brake fluid level below the minimum level mark a add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 8. Check: brake lever o...

  • Page 239: Chas

    7-20 10 nm(1.0 m kg) 30 nm(3.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 removing the front brake master cylinder drain the brake fluid brake lever brake switch lead brake switch union bolt copper washer / brake hose master cylinder bracket master cylinder 1 2 1 1 2 / 1 1 1 remove ...

  • Page 240: Chas

    7-21 order job name / part name q’ty remarks disassembling the front brake master cylinder master cylinder boot circlip master cylinder kit spring 1 1 1 1 disassembly the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 front and rear brakes chas.

  • Page 241: Chas

    7-22 30 nm(3.0 m kg) 4 nm(0.4 m kg) 23 nm(2.3 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 removing the rear brake master cylinder side cover (right) drain the brake fluid master cylinder bolt union bolt copper washer / brake hose clip/ hose cotter pin pin washer master cylinder 2 1...

  • Page 242: Chas

    7-23 order job name / part name q’ty remarks 1 2 3 4 disassembling the rear brake master cylinder master cylinder boot circlip master cylinder kit spring 1 1 1 1 disassembly the parts in the order listed. For assembly, reverse the disassembly procedure. Front and rear brakes chas.

  • Page 243: Chas

    7-24 front and rear brakes chas note: note: note: eb702210 removing the front brake master cylinder befor disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: brake switch coupler 1 (from the brake switch) 2. Remove: union bolt 2 copper wa...

  • Page 244: Chas

    7-25 front and rear brakes chas d a b c eb702242 checking the front and rear brake master cylinders the following procedure applies to the both of the brake master cylinders. 1. Check: brake master cylinder damage / scratches / wea replace. Brake fluid delivery passages (brake master cylinder body) ...

  • Page 245: Chas

    7-26 a front and rear brakes chas 30 nm (3.0 m kg) caution: note: eb702270 assembling and installing the front brake master cylinder before installation, all internal brake components should be cleaned and lu- bricated with clean or new brake fluid. Never use solvents on internal brake components. R...

  • Page 246: Chas

    7-27 front and rear brakes chas caution: 30 nm (3.0 m kg) caution: brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: brake system refer to “bleeding the hydraulic brake system” in chapter 3. 4. Check: brake fluid level ...

  • Page 247: Chas

    7-28 front and rear brakes chas caution: use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful ...

  • Page 248: Chas

    7-29 30 nm(3.0 m kg) 40 nm(4.0 m kg) order job name / part name q’ty remarks 1 2 3 4 removing the front brake calipers drain the brake fluid union bolt copper washer brake hose brake caliper assembly 1 2 1 1 remove the parts in the order listed. Refer to “assembling and installing the front brake ca...

  • Page 249: Chas

    7-30 order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 disassembling the front brake calipers clip pad pin brake pad spring brake pad bleed screw kit brake caliper piston dust seal piston seal 2 1 1 2 1 4 4 4 disassembly the parts in the order listed. Refer to “replacing the front brake pads” ...

  • Page 250: Chas

    7-31 order job name / part name q’ty remarks 1 2 3 4 removing the rear brake caliper drain the brake fluid union bolt copper washer brake hose rear brake caliper 1 2 1 1 remove the parts in the order listed. Refer to “assembling and installing the rear brake caliper” section. For installation, rever...

  • Page 251: Chas

    7-32 10 nm (1.0 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 disassembling the rear brake caliper pad pin pad spring brake pad assembly / shim bleed screw kit brake caliper piston dust seal piston seal 2 1 2 / 2 2 2 2 2 disassembly the parts in the order listed. Refer to “replacing th...

  • Page 252: Chas

    7-33 front and rear brakes chas note: note: eb702317 disassembling the front brake calipers the following procedure applies to both of the brake calipers. Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hos...

  • Page 253: Chas

    7-34 front and rear brakes chas note: note: eb702322 disassembling the rear brake caliper before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hose 3 put the end of the brake hose into a contain- er and pump out th...

  • Page 254: Chas

    7-35 front and rear brakes chas a b 30 nm (30 m kg) 1. Check: brake caliper pistons 1 rust / scratches / wear replace the brake caliper. Brake caliper cylinders 2 scratches / wear replace the brake cali- per. Brake calipers 3 cracks / damage replace. Brake fluid delivery passages (brake caliper body...

  • Page 255: Chas

    7-36 front and rear brakes chas caution: caution: when installing the brake hose onto the brake caliper, make sure that the brake pipe a touches the projection a on the brake caliper. 2. Remove: brake caliper 3. Install: brake pads brake spring brake caliper pins brake caliper clips brake caliper br...

  • Page 256: Chas

    7-37 1 3 2 front and rear brakes chas 30 nm (3.0 m kg) caution: 5. Bleed: brake system refer to “bleeding the hydraulic brake system” in chapter 3. 6. Check: brake fluid level below the minimum level mark a add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level...

  • Page 257: Chas

    7-38 front and rear brakes chas caution: 2. Remove: brake caliper 3. Install: brake pad spring brake pads brake pad pins brake caliper brake hose holder refer to “replacing the brake pads”. Brake caliper pad pin 10 nm (1.0 m kg) brake caliper bolt 40 nm (4.0 m kg) 4. Fill: brake fluid reservoir (wit...

  • Page 258: Chas

    7-39 front and rear brakes chas 6. Check: brake fluid level below the minimum level mark a add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 7. Check: brake pedal operation soft or spongy feeling bleed the brake system. Refer to “bleeding th...

  • Page 259: Chas

    7-40 30 nm (3.0 m kg) 30 nm (3.0 m kg) 7 nm (0.7 m kg) order job name / part name q’ty remarks 1 2 3 4 5 removing the front fork front wheel front brake calipers front fender bolt (upper bracket) cap bolt bolt (lower bracket) front fork assembly (left / right) 1 2 2 2 1 / 1 remove the parts in the o...

  • Page 260: Chas

    7-41 10 23 nm (2.3 m kg) 30 nm (3.0 m kg) 6 7 9 8 11 14 13 12 15 order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 disassembling the front fork cap bolt o-ring spacer washer front fork spring dust seal oil seal clip bolt gasket damper rod / rebound spring inner tube / inner tube ...

  • Page 261: Chas

    7-42 10 23 nm (2.3 m kg) 30 nm (3.0 m kg) 7 9 8 11 14 13 12 15 order job name / part name q’ty remarks 14 15 outer tube bushing oil flow stopper 1 1 / 1 refer to “assembling the front fork legs” section. For assembly, reverse the disassembly procedure. 6 front fork chas.

  • Page 262: Chas

    7-43 front fork chas note: caution: note: eb703100 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitabl...

  • Page 263: Chas

    7-44 front fork chas caution: caution: 3. Remove: inner tube a. Hold the front fork leg horizontally. B. Securely clamp the brake caliper bracket in a vise with soft jaws. C. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully. Excessive force will damage t...

  • Page 264: Chas

    7-45 front fork chas 1 note: caution: 30 nm (3.0 m kg) note: 4. Check: cap bolt o-ring damage / wear replace. Eb703700 assembling the front fork legs the following procedure applies to both of the front fork legs. Make sure that the oil levels in both front fork legs are equal. Uneven oil levels can...

  • Page 265: Chas

    7-46 front fork chas caution: note: note: 4. Install: outer tube bushing 1 (with the fork seal driver weight 2 and adapter 3 ) fork seal driver weight 2 90890-01367 adapter 3 90890-01381 5. Install: washer oil seal 1 (with the fork seal driver weight 2 and adapter 3 ) fork seal driver weight 2 90890...

  • Page 266: Chas

    7-47 front fork chas note: note: note: while filling the front fork leg, keep it up- right. After filling, slowly pump the front fork leg up and down to distribute the fork oil. 9. Install: spring 1 spring seat 2 spacer 3 cap bolt install the spring with the smaller pitch fac- ing up. Before install...

  • Page 267: Chas

    7-48 7 nm (0.7 m kg) 10 nm (1.0 m kg) 23 nm (2.3 m kg) 7 nm (0.7 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 removing the handle bar master cylinder bracket master cylinder assembly throttle cable housing cover handle bar switch (right) throttle cable housing throttle...

  • Page 268: Chas

    7-49 7 nm (0.7 m kg) 10 nm (1.0 m kg) 23 nm (2.3 m kg) 7 nm (0.7 m kg) order job name / part name q’ty remarks 14 15 16 17 grip (left) clutch lever holder upper handlebar holder handle bar 1 1 2 1 refer to “removing the handlebar” section. Refer to “installing the handlebar” section. For installatio...

  • Page 269: Chas

    7-50 handlebar chas 1 1 note: note: eb704100 removing the handlebar 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: throttle cable housing 1 throttle grip 2 while removing the throttle cable housing, pull back the ...

  • Page 270: Chas

    7-51 handlebar chas b 23 nm (2.3 m kg) caution: note: note: note: note: eb704701 installing the handlebar 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Install: handlebar 1 upper handlebar holders 2 first, tighten the bo...

  • Page 271: Chas

    7-52 handlebar chas note: note: note: 6. Install: throttle grip 1 throttle cable housing 2 throttle cables 3 apply a thin coat of lithium soap base grease onto the inside of the throttle grip and install it onto the handlebar. Align the projection a on the throttle cable housing with the hole b in t...

  • Page 272: Chas

    7-53 110 nm (11.0 m kg) 52 nm (5.2 m kg) 1st 18 nm (1.8 m kg) 2nd order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 removing the lower bracket front cowling fuel tank front wheel front fork handle bar main switch lead coupler brake hose joint / cover steering stem nut upper bracket lock washer...

  • Page 273: Chas

    7-54 110 nm (11.0 m kg) 52 nm (5.2 m kg) 1st 18 nm (1.8 m kg) 2nd order job name / part name q’ty remarks 9 10 11 12 13 lower bracket ball race cover ball bearing rubber washer 1 ball bearing 1 1 1 1 1 refer to “installing the steering head” section. For installation, reverse the removal procedure. ...

  • Page 274: Chas

    7-55 steering head chas note: eb705102 removing the lower bracket 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: upper ring nut lower ring nut 1 hold the lower ring nut with the exhaust and steering nut wrench 2 ,...

  • Page 275: Chas

    7-56 steering head chas 4 3 2 1 caution: note: note: note: b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. C. Install a new dust seal and new bearing races. If the bearing race is not installed proper- ly, the steering head pipe could be dam- aged. Always replace ...

  • Page 276: Chas

    7-57 40 nm (4.0 m kg) 48 nm (4.8 m kg) 40 nm (4.0 m kg) 48 nm (4.8 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 removing the rear shock absorber assembly and relay arm side covers rear wheel self-locking nut / washer bolt self-locking nut / washer bolt self-locking nut / bolt rear sho...

  • Page 277: Chas

    7-58 40 nm (4.0 m kg) 48 nm (4.8 m kg) 40 nm (4.0 m kg) 48 nm (4.8 m kg) order job name / part name q’ty remarks 8 9 10 11 12 13 14 15 16 17 18 19 bolt relay arm self-locking nut / washer bolt connecting plate spacer spacer spacer oil seal bearing bearing bearing 1 1 1 / 1 1 2 1 2 1 2 2 1 1 = 80 mm ...

  • Page 278: Chas

    7-59 rear shock absorber and relay arm chas eb706101 handling the rear shock absorber this rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for...

  • Page 279: Chas

    7-60 rear shock absorber and relay arm chas note: caution: note: note: eb706204 removing the rear shock absorber assembly 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the re...

  • Page 280: Chas

    7-61 rear shock absorber and relay arm chas note: caution: eb706401 checking the rear shock absorber assembly 1. Check: rear shock absorber rod bends / damage replace the rear shock absorber assembly. Rear shock absorber oil leaks replace the rear shock absorb- er assembly. Spring damage / wear repl...

  • Page 281: Chas

    7-62 115 nm (11.5 m kg) 23 nm (2.3 m kg) 7 nm (0.7 m kg) order job name / part name q’ty remarks 1 2 3 4 5 6 7 8 9 removing the swingarm and drive chain rear wheel rear shock absorber assembly relay arm rear wheel sprocket drive chain guard brake hose holder caliper bracket compression bar drive cha...

  • Page 282: Chas

    7-63 115 nm (11.5 m kg) 23 nm (2.3 m kg) 7 nm (0.7 m kg) order job name / part name q’ty remarks 10 11 12 spacer bearing washer 1 2 2 for installation, reverse the removal procedure. Swingarm and drive chain chas.

  • Page 283: Chas

    7-64 a b swingarm and drive chain chas note: note: note: eb707100 before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a ten-link sec- tion of the drive chain. Eb707111 removing the swingarm 1. Stand the motorcycle on a level surface. Secur...

  • Page 284: Chas

    7-65 swingarm and drive chain chas eb707400 checking the swingarm 1. Check: swingarm bends / cracks / damage replace. 2. Check: pivot shaft roll the pivot shaft on a flat surface. Bends replace. Do not attempt to straighten a bent pivot shaft. 3. Wash: pivot shaft dust covers spacer washers bearings...

  • Page 285: Chas

    7-66 swingarm and drive chain chas note: caution: eb707410 checking the drive chain 1. Measure: ten-link section a of the drive chain out of specification replace the drive chain. Ten-link drive chain section limit (maximum) 150 mm while measuring the ten-link section, push down on the drive chain t...

  • Page 286: Chas

    7-67 swingarm and drive chain chas note: 5. Lubricate: drive chain recommended lubricant engine oil or chain lubricant suitable for o-ring chains 6. Check: drive sprocket rear wheel sprocket more than 1 / 4 tooth a wear replace the drive chain sprockets as a set. Bent teeth replace the drive chain s...

  • Page 287: Chas

    7-68 swingarm and drive chain chas 70 nm (7.0 m kg) note: caution: caution: 4. Adjust: drive chain slack refer to “adjusting the drive chain slack” in chapter 3. Drive chain slack 30 45 mm eb707710 installing the drive chain 1. Lubricate: drive chain recommended lubricant engine oil or chain lubrica...

  • Page 288: Elec

    Elec 8 – +.

  • Page 289: Elec

    Elec chapter 8 electrical electrical components 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit diagram 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking switches 8-4 . . . ...

  • Page 290: Elec

    Elec.

  • Page 291: Elec

    8-1 electrical components elec 13 rectifier / regulator 14 thermo switch (warning light) 15 thermo switch (fan motor) 16 horn 17 diode 7 starting circuit cut-off relay 8 flasher relay 9 sidestand switch 10 neutral switch 11 oil level gauge 12 ignition coil 1 main switch 2 fuel sender 3 rear brake sw...

  • Page 292: Elec

    8-2 circuit diagram elec circuit diagram.

  • Page 293: Elec

    8-3 1 a.C. Magneto 2 rectifier regulator 3 main switch 4 battery 5 fuse (back up) 6 fuse (main) 7 starter relay 8 starter motor 9 starting circuit cut-off relay 10 fuel pump relay 11 ignitor unit 12 ignition coil 13 spark plug 14 pickup coil 15 throttle position sensor 16 neutral switch 17 speed sen...

  • Page 294: Elec

    8-4 checking switches elec note: yp-n checking switches checking steps using pocket tester, check switches for continu- ity between their terminals to determine whether they are correctly connected. Replace the switch component if any of the com- binations does not produce the correct reading. Pocke...

  • Page 295: Elec

    8-5 before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault repair or replace. * indicates coupler positions. Checking switches ele...

  • Page 296: Elec

    8-6 fuse (main) 3 4 6 22 11 12 13 14 16 56 54 main switch battery sidestand switch ignitor unit ignition coil spark plug pickup coil neutral switch fuse (ignition) engine stop switch ignition system elec eb802000 ignition system circuit diagram.

  • Page 297: Elec

    8-7 ignition system elec note: eb802011 1. Fuses (main and ignition) s remove the fuses. S connect the pocket tester ( Ω 1) to the fuses. S check the fuses for continuity. Replace the fuses. Continuity no continuity open-circuit voltage: 12.8 v or more at 20 _ c eb802012 : 2. Battery s check the bat...

  • Page 298: Elec

    8-8 eb802013 3. Spark plugs s check the spark plug condition. S check the spark plug type. S check the spark plug gap. Refer to “spark lug inspection” in chapter 3. Standard spark plug: cr9e, cr8e / u27esr-n, u24esr-n ngk/ nippondenso spark plug gap: 0.7 x 0.8 mm correct incorrect eb802014 4. Igniti...

  • Page 299: Elec

    8-9 eb802015 5. Spark plug cap resistance s remove the spark plug cap. S connect the pocket tester ( Ω 1k) to the spark plug cap. S check if the spark plug cap has the speci- fied resistance. Replace the spark plug cap. Spark plug cap resistance: 10 k Ω at 20 _ c out of specification 6. Ignition coi...

  • Page 300: Elec

    8-10 eb802017 7. Main switch s disconnect the main switch couplers from the wire harness. S check for continuity as follows: red – brown / blue replace the main switch. Continuity no continuity 1 : eb802018 8. Engine stop switch s disconnect the right handlebar switch cou- pler from the wire harness...

  • Page 301: Elec

    8-11 replace the main switch. Continuity no continuity eb80201a 10. Sidestand switch disconnect the sidestand switch coupler from the wire harness. Check for continuity as follows: black – black replace the sidestand switch. No continuity 1 2 continuity 11. Diode (starting circuit cut-off relay unit...

  • Page 302: Elec

    8-12 tester lead ! Blue / yellow tester lead ! Light green replace the relay unit. Correct incorrect 1 tester (+) lead ! Yellow terminal tester (–) lead ! Blue terminal eb80201c 12. Pickup coil resistance s disconnect the pickup coil coupler from the wire harness. S connect the pocket tester ( Ω 100...

  • Page 303: Elec

    8-13 54 16 22 33 55 56 engine stop switch starter motor starting circuit cut-of f relay neutral switch sidestand switch clutch switch start switch fuse (ignition) 8 9 fuse (main) 3 4 6 main switch battery starter relay 7 electric starting system elec eb803000 electric starting system circuit diagram.

  • Page 304: Elec

    8-14 electric starting system elec eb803010 starting circuit operation the starting circuit on this model consists of the starter motor, starter relay, and the starting cir- cuit cut-off relay. If the engine stop switch is on “run” and the main switch is on “on” (both switches are closed), the start...

  • Page 305: Elec

    8-15 electric starting system elec note: eb802011 1. Fuses (main and ignition) s remove the fuses. S connect the pocket tester ( Ω 1) to the fuses. S check the fuses for continuity. Replace the fuses. Continuity no continuity open-circuit voltage: 12.8 v or more at 20 _ c eb802012 : 2. Battery s che...

  • Page 306: Elec

    8-16 : : s a wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. S this check is likely to reduce sparks, so be sure that no flammable gas or fluid is in the vicinity. Eb803021 3. Starter motor s connect the ba...

  • Page 307: Elec

    8-17 eb803024 5. Starter relay s disconnect the relay unit coupler from the wire harness. S connect the pocket tester ( Ω 1) and bat- tery (12 v) to the relay unit coupler termi- nals. Replace the starter relay. No continuity : continuity eb802017 6. Main switch s disconnect the main switch couplers...

  • Page 308: Elec

    8-18 eb802018 7.Engine stop switch s disconnect the right handlebar switch cou- pler from the wire harness. S check for continuity as follows: red / white – red / white replace the right handlebar switch. Continuity no continuity 1 : eb802019 8. Neutral switch s disconnect the neutral switch / lead ...

  • Page 309: Elec

    8-19 eb80201a 9. Sidestand switch s disconnect the sidestand switch coupler from the wire harness. S check for continuity as follows: black – black replace the sidestand switch. Continuity no continuity 1 : eb803025 10. Clutch switch s disconnect the clutch switch coupler from the wire harness. S ch...

  • Page 310: Elec

    8-20 eb803027 11. Start switch s disconnect the right handlebar switch cou- pler from the wire harness. S check for continuity as follows: blue/ white – black replace the right handlebar switch. Continuity no continuity 1 : eb803026 12. Diode (starting circuit cut-off relay) s remove the relay unit ...

  • Page 311: Elec

    8-21 eb803028 13. Wiring connection s check the connections of the entire starting system. Refer to “circuit diagram”. Properly connect the starting system. Poor connection : electric starting system elec.

  • Page 312: Elec

    8-22 order job name / part name q’ty remarks 1 2 starter motor removal starter motor starter motor lead starter motor disassembly front bracket washers rear bracket shims brush holder / brush armature ass’y 1 1 1 1 2 1 1 / 1 1 remove the parts in order. Reverse the removal procedure for installation...

  • Page 313: Elec

    8-23 electric starting system elec checking the starter motor 1. Measure: s brush length a out of specification replace. Brush length wear limit: 4 mm 2. Measure: s brush spring force fatigue / out of specification replace as a set. Brush spring force: 780 x 1,020 g 3. Inspect: s commutator dirty cl...

  • Page 314: Elec

    8-24 electric starting system elec note: 5. Measure: commutator diameter a out of specification replace the starter motor. Commutator wear limit: 27 mm 6. Measure: mica undercut a out of specification scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the ...

  • Page 315: Elec

    8-25 battery 1 2 4 ac magneto rectifier/regulator fuse (main) 6 charging system elec eb804000 charging system circuit diagram.

  • Page 316: Elec

    8-26 charging system elec note: eb802011 1. Fuses (main) s remove the fuses. S connect the pocket tester ( Ω 1) to the fuses. S check the fuses for continuity. Replace the fuses. Continuity no continuity open-circuit voltage: 12.8 v or more at 20 _ c eb802012 : 2. Battery s check the battery conditi...

  • Page 317: Elec

    8-27 stator coil resistance: 0.36 x 0.44 Ω at 20 _ c eb804011 3. Charging voltage s connect the engine tachometer to the spark plug lead. S connect the pocket tester (dc 20 v) to the battery. The charging circuit is not faulty. Charging voltage = measured voltage-terminal voltage: 0.2 x 2.5 v up out...

  • Page 318: Elec

    8-28 charging system elec eb804015 5. Wiring connections s check the connections of the entire charg- ing system. Refer to “circuit diagram”. Properly connect the charging system. Poor connection : replace the rectifier / regulator. Correct.

  • Page 319: Elec

    8-29 3 4 38 30 32 37 43 44 main switch battery dimmer switch high beam indicator light meter light pass switch headlight t ail/brake light 49 45 53 fuse (head) auxiliary light lights switch 6 fuse (main) lighting system elec eb805000 lighting system circuit diagram.

  • Page 320: Elec

    8-30 lighting system elec note: eb802011 1. Fuses (main and head) s remove the fuses. S connect the pocket tester ( Ω 1) to the fuses. S check the fuses for continuity. Replace the fuses. Continuity no continuity open-circuit voltage: 12.8 v or more at 20 _ c eb802012 : 2. Battery s check the batter...

  • Page 321: Elec

    8-31 disconnect the right handlebar switch cou- pler from the wire harness. Turn the lights switch to “on” or “po”. Check for continuity as follows: red / yellow – blue turn the lights switch to “on”. Check for continuity as follows: red / yellow – blue red / yellow – blue / black 1 1 2 1 2 1 2 2 1 ...

  • Page 322: Elec

    8-32 5. Dimmer switch disconnect the left handlebar switch cou- plers from the wire harness. Turn the dimmer switch to “hi”. Check for continuity as follows: blue/ black – yellow the dimmer switch is faulty. Replace the left handlebar switch. Continuity no continuity 1 eb805012 6. Pass switch discon...

  • Page 323: Elec

    8-33 lighting system elec b 1. Bulb and bulb socket. Check the bulb and bulb socket for continu- ity. Replace the bulb and / or bulb socket. Continuity no continuity when the dimmer switch is on “lo”. When the dimmer switch is on “hi”. 2. Voltage connect the pocket tester (dc 20 v) to the headlight ...

  • Page 324: Elec

    8-34 lighting system elec 1 1. Bulb and bulb socket check the bulb and bulb socket for continu- ity. Replace the bulb and / or bulb socket. Continuity no continuity tester (+) lead blue terminal tester (–) lead black terminal 2. Voltage connect the pocket tester (20 v) to the bulb socket coupler. Tu...

  • Page 325: Elec

    8-35 lighting system elec turn the main switch to “on”. Turn the lights switch to “on” or “po”. Check the voltage (12 v) of the “blue” lead on the bulb socket connector. The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. Meets specification out of specificatio...

  • Page 326: Elec

    8-36 signal system elec eb806000 signal system circuit diagram.

  • Page 327: Elec

    8-37 3 main switch 4 battery 6 fuse (main) 16 neutral switch 18 fuel sender 20 diode 25 fuel meter 26 fuel level warning light 28 neutral indicator light 29 oil level warning light 31 turn indicator light 34 oil level switch 35 flasher relay 36 horn 39 horn switch 40 turn switch 41 front turn signal...

  • Page 328: Elec

    8-38 signal system elec note: eb802011 1. Fuses (main and signal) s remove the fuses. S connect the pocket tester ( Ω 1) to the fuses. S check the fuses for continuity. Replace the fuses. Continuity no continuity open-circuit voltage: 12.8 v or more at 20 _ c eb802012 : 2. Battery s check the batter...

  • Page 329: Elec

    8-39 eb802017 3. Main switch disconnect the main switch coupler from the wire harness. Check for continuity as follows: red – brown / blue replace the main switch. Continuity no continuity 2 eb806011 4. Wiring connections check the connections of the entire signal system. Refer to “circuit diagram”....

  • Page 330: Elec

    8-40 signal system elec 1 disconnect the left handlebar switch cou- pler from the wire harness. Disconnect the “black / white” lead at the horn terminal. Check for continuity as follows: pink – black replace the left handlebar switch. Continuity no continuity tester (+) lead brown lead tester (–) le...

  • Page 331: Elec

    8-41 1 the horn is not faulty. Horn does not sound horn sounds tester (+) lead brown lead tester (–) lead pink 4. Voltage connect the pocket tester (dc 20 v) to the horn at the “pink” terminal. Turn the main switch to “on”. Check the voltage (12 v) of the “pink” lead at the horn terminal. Replace th...

  • Page 332: Elec

    8-42 b a 1 replace the brake switch. Continuity no continuity tester (+) lead yellow terminal tester (–) lead black terminal 3. Voltage connect the pocket tester (dc 20 v) to the bulb socket connector. Turn the main switch to “on”. The brake lever is pulled in or the brake ped- al is pressed down. C...

  • Page 333: Elec

    8-43 signal system elec tester (+) lead brown terminal tester (–) lead frame ground 1 1. Bulb and bulb socket check the bulb and bulb socket for continu- ity. Replace the bulb and / or bulb socket. Continuity no continuity 3. Voltage connect the pocket tester (dc 20 v) to the flasher relay coupler. ...

  • Page 334: Elec

    8-44 a b turn the main switch to “on”. Turn the turn switch to “l” or “r”. Check the voltage (12 v) on the “brown / white” lead at the flasher relay terminal. The flasher relay is faulty, replace it. Meets specification out of specification at the flasher light (left): tester (+) lead chocolate lead...

  • Page 335: Elec

    8-45 signal system elec 1 2 1 1. Bulb and bulb socket check the bulb and bulb socket for continu- ity. Replace the bulb and / or bulb socket. Continuity no continuity 3. Diode remove the diode from the wire harness. Check for continuity as follows: sky blue – light green replace the diode. Correct i...

  • Page 336: Elec

    8-46 tester (+) lead brown terminal tester (–) lead frame ground 4. Voltage s connect the pocket tester (dc 20 v) to the bulb socket coupler. S turn the main switch to “on”. S check the voltage (12 v). The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. Meets s...

  • Page 337: Elec

    8-47 tester (+) lead black / red terminal tester (–) lead frame ground 3. Oil level switch drain the engine oil and remove the oil level switch from the oil pan. Connect the pocket tester ( Ω 1) to the oil level switch. Check the oil level switch for continuity. Replace the oil level switch. No cont...

  • Page 338: Elec

    8-48 2 tester (+) lead brown lead tester (–) lead black / red lead 6. Voltage connect the pocket tester (dc 20 v) to the bulb socket connector. Turn the main switch to “on”. Check the voltage (12 v). The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. Meets spe...

  • Page 339: Elec

    8-49 signal system elec fuel sender resistance : 4 x 10 Ω at 20 _ c : 90 x 100 Ω at 20 _ c tester (+) lead green / red terminal tester (–) lead black terminal 1. Bulb and bulb socket s check the bulb and bulb socket for continu- ity. Replace the bulb and / or bulb socket. Continuity no continuity 2....

  • Page 340: Elec

    8-50 2 tester (+) lead brown terminal tester (–) lead green / red terminal 3. Voltage connect the pocket tester (dc 20 v) to the bulb socket connector. Drain the fuel. Turn the main switch to “on”. Check the voltage (12 v). The wiring circuit from the main switch to the bulb socket connector is faul...

  • Page 341: Elec

    8-51 fuse (main) 3 4 6 19 main switch battery thermo switch (warning light) 27 46 47 48 fan motor fuse (fan) 51 fuse (signal) thermo switch (fan) engine temperature warning light cooling system elec eb807000 cooling system circuit diagram.

  • Page 342: Elec

    8-52 cooling system elec note: eb802011 1. Fuses (main, signal and fan) s remove the fuses. S connect the pocket tester ( Ω 1) to the fuses. S check the fuses for continuity. Replace the fuse(s). Continuity no continuity open-circuit voltage: 12.8 v or more at 20 _ c eb802012 : 2. Battery s check th...

  • Page 343: Elec

    8-53 disconnect the main switch coupler from the wire harness. Check for continuity as follows: red – brown / blue disconnect the fan motor coupler. Connect the battery (12 v) as shown. 2 eb802017 3. Main switch replace the main switch. Continuity no continuity eb807011 the fan motor is faulty, repl...

  • Page 344: Elec

    8-54 les than 98 _ c f 3* 105 to 98 _ c s remove the thermo switch from the thermo- static valve housing. S connect the pocket tester ( Ω 1) to the thermo switch . S immerse the thermo switch in coolant . S check the thermo switch for continuity. While heating the coolant use a thermome- ter to reco...

  • Page 345: Elec

    8-55 tester (+) lead brown lead tester (–) lead green / white lead 7. Voltage connect the pocket tester (dc 20 v) to the bulb socket connector. Turn the main switch to “on”. Check the voltage (12 v). The wiring circuit from the main switch to the bulb socket connector is faulty, repair it. Meets spe...

  • Page 346: Elec

    8-56 fuse (main) 3 4 6 10 11 21 54 56 main switch battery fuel pump relay ignitor unit fuel pump engine stop switch fuse (ignition) fuel pump system elec eb808000 fuel pump system circuit diagram.

  • Page 347: Elec

    8-57 fuel pump system elec 1 battery 2 fuse (main) 3 main switch 4 fuse (ignition) 5 engine stop switch 6 ignitor unit 7 fuel pump relay 8 fuel pump eb808010 fuel pump circuit operation the fuel pump circuit consists of the fuel pump relay, fuel pump, engine stop switch and ignitor unit. The ignitor...

  • Page 348: Elec

    8-58 cooling system elec note: eb802011 1. Fuses (main and ignition) s remove the fuses. S connect the pocket tester ( Ω 1) to the fuses. S check the fuses for continuity. Replace the fuse(s). Continuity no continuity open-circuit voltage: 12.8 v or more at 20 _ c eb802012 : 2. Battery s check the b...

  • Page 349: Elec

    8-59 disconnect the right handlebar switch cou- pler from the wire harness. Check for continuity as follows: red / white – red / white 1 2 2 1 eb802017 3. Main switch disconnect the main switch coupler from the wire harness. Check for continuity as follows: red – brown / blue replace the main switch...

  • Page 350: Elec

    8-60 battery (+) terminal red / black terminal battery (–) terminal blue / red terminal 6. Fuel pump resistance s disconnect the fuel pump coupler from the wire harness. S connect the pocket tester ( Ω 1) to the fuel pump coupler terminals. S check if the fuel pump has the specified re- sistance. Re...

  • Page 351: Elec

    8-61 fuel pump system elec 2 1 eb808030 fuel pump test gasoline is extremely flammable and un- der certain circumstances there can be danger of an explosion or combustion. Be extremely careful and note the follow- ing points: stop the engine before refuelling. Do not smoke and keep away from open fl...

  • Page 352: Elec

    8-62 tachometer display engine speed engine speed tachometer display revolusion revolusion second second self-diagnosis elec self-diagnosis the yzf600r features self-diagnosis. When the main switch is turned to “on”, the following items are monitored and the condition codes are displayed on the tach...

  • Page 353: Elec

    8-63 self-diagnosis elec note: 11 15 ignitor unit throttle position sensor (tps) 1. Wire harness check the wire harness for continuity. Refer to “circuit diagram”. Repair or replace the wire harness. Continuity no continuity 2. Tps check the tps for continuity. Refer to “throttle position sensor (tp...

  • Page 354: Elec

    8-64 self-diagnosis elec 11 ignitor unit 17 speed sensor 1. Wire harness check the wire harness for continuity. Refer to “circuit diagram”. Repair or replace the wire harness. Continuity no continuity replace the speed sensor. 2. Speed sensor circuit diagram.

  • Page 355: Trbl

    Trbl shtg 9.

  • Page 356: Trbl

    Trbl shtg chapter 9. Troubleshooting starting failure/ hard starting 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical system 9-1 . ....

  • Page 357: Trbl

    Trbl shtg.

  • Page 358: Trbl

    9-1 starting failure/hard starting trbl shtg note: eb900000 troubleshooting the following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustm...

  • Page 359: Trbl

    9-2 starting failure/ hard starting / poor engine idle speed performance/ poor medium-and high-speed performance trbl shtg compression system cylinder and cylinder head loose spark plug loose cylinder head or cylinder faulty cylinder head gasket worn, damaged or seized cylinder improperly sealed val...

  • Page 360: Trbl

    9-3 faulty gear shifting/ faulty clutch performance trbl shtg eb903000 faulty gear shifting hard shifting refer to “clutch dragging”. Shift pedal does not move shift shaft improperly adjusted shift pedal link bent shift shaft shift cam, shift fork groove jammed with impurities seized shift fork bent...

  • Page 361: Trbl

    9-4 overheating/overcooling/ poor braking/faulty front fork legs trbl shtg eb905000 overheating overheating ignition system improper spark plug gap improper spark plug heat range faulty ignitor unit fuel system improper carburetor main jet setting improper fuel level clogged air filter element cooli...

  • Page 362: Trbl

    9-5 unstable handling/ faulty lighting and signal systems trbl shtg eb908000 unstable handling unstable handling handlebar improperly installed or bent steering improperly installed handlebar crown bent steering stem improperly installed steering shaft (improperly tightened ring nut) damaged ball be...

  • Page 363: Trbl

    Trbl shtg.

  • Page 364

    1 a.C. Magneto 2 rectifier / regulator 3 main switch 4 battery 5 fuse (back up) 6 fuse (main) 7 starter relay 8 starter motor 9 starting circuit cut-off relay 10 fuel pump relay 11 ignitor unit 12 ignition coil 13 spark plug 14 pick up coil 15 throttle position sensor 16 neutral switch 17 speed sens...