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Yamaha 1999 YZF-R6 Service Manual

Manual is about: Motorcycle YZF-R6 99 5EB-AE1

Summary of 1999 YZF-R6

  • Page 2

    Eb000000 yzf-r6 service manual 1998 by yamaha motor co., ltd. First edition, august 1998 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 3: Notice

    Note: warning caution: eb001000 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintena...

  • Page 4: How To Use This Manual

    1 2 6 4 5 7 3 8 eb003000 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 check procedures are laid out with the individual steps in sequential order. 1 ...

  • Page 5: Gen

    22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 gen info spec eng carb elec chas cool chk adj trbl shtg eb004000 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 c...

  • Page 6: General Information

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

  • Page 7: Gen

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

  • Page 8: Gen

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

  • Page 9: Gen

    1-2 important information gen info eb102000 important information preparation for removal and dis- assembly 1. Before removal and disassembly, remove all dirt, mud, dust, and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “special tools”. 3. When disassembling, alway...

  • Page 10: Gen

    1-3 important information gen info caution: using a dynamometer the yzf-r6 has a carbon muffler that may change color when exposed to high tempera- tures. Therefore, when using a dynamometer always use a fan to cool the muffler. Eb102030 lock washers/ plates and cotter pins after removal, replace al...

  • Page 11: Gen

    1-4 checking the connections gen info 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 12: Gen

    1-5 features gen info former thermostat t emperature time new thermostat t emperature time features air intake system system diagram this system is designed to improve the power while riding a motorcycle at a high speed by increasing the air intake efficiency by means of pressurizing the air filter ...

  • Page 13: Gen

    1-6 features gen info 1) 2) 3) 4) 1 cdi unit 2 voltage converter 3 condenser 4 ignition coil 5 spark plug 6 ignition timing controller 7 pickup coil 8 t. P. S. 9 speed sensor 10 battery 11 rectifier / regulator 12 ac magneto 13 stator coil flow control operation 1) when valve is closed the lip 1 sea...

  • Page 14: Gen

    1-7 features gen info 2. Ignition coil compact and right weight design is provided since the plug top ignition coil is equipped in which the plug cap ignition coil are inte- grated. High tension cord was cut an end to use and ignition energy loss has become lower. 3. Spark plug the 2-pole spark plug...

  • Page 15: Gen

    1-8 special tools gen info 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 inappropri- ate tools or improvised techniques. When placing an ord...

  • Page 16: Gen

    1-9 special tools gen info tool no. Tool name / function illustration 90890-01426 oil filter wrench this tool is needed to loosen or tighten the oil filter cartridge. 90890-01434 rod holder this tool is used to support the damper ad- justing rod. Rod puller 90890-01437 rod puller attachment 90890-01...

  • Page 17: Gen

    1-10 special tools gen info tool no. Tool name / function illustration 90793-80009 engine tachometer this tool is used to check engine speed. 90890-03141 timing light this tool is used to check the ignition timing. Oil pressure gauge 90890-03153 adapter 90890-03139 oil pressure gauge adapter these t...

  • Page 18: Gen

    1-11 special tools gen info tool no. Tool name / function illustration 90890-04112 valve guide installer this tool is used to install the valve guides. 90890-04113 valve guide reamer this tool is used to rebore the new valve guides. 90890-06754 ignition checker this tool is used to check the ignitio...

  • Page 19: Spec

    Spec chapter 2. Specifications general specifications 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine specifications 2-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chassis specifications 2-11 . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 20: Spec

    2-1 general specifications spec specifications general specifications item standard limit dimensions overall length overall width overall height seat height wheelbase minimum ground clearance minimum turning radius 2025 mm (except for nor, swe, fin, aus nzl) 2075 mm (for nor, swe, fin, aus, nzl) 690...

  • Page 21: Spec

    2-2 engine specifications spec temp. Engine specifications item standard limit engine engine tipe displacement cylinder arrangement bore stroke compression ratio engine idling speed vacuum pressure at engine idling speed standard compression pressure (at sea level) liquid-cooled, 4-stroke, dohc 600 ...

  • Page 22: Spec

    2-3 engine specifications spec item standard limit oil filter oil filter type bypass valve opening pressure cartridge (paper) 80 120 kpa (0.8 1.2 kgf / cm 2 ) oil pump oil pump type inner-rotor-to-outer-rotor-tip clearance outer-rotor-to-oil-pump-housing clearance trochoidal 0.03 0.09 mm 0.03 0.08 m...

  • Page 23: Spec

    2-4 engine specifications spec item standard limit camshafts drive system camshaft cap inside diameter camshaft journal diameter camshaft-journal-to-camshaftcap clearance intake camshaft lobe dimensions measurement a measurement b measurement c exhaust camshaft lobe dimensions measurement a measurem...

  • Page 24: Spec

    2-5 engine specifications spec head diameter face width seat width margin thickness item standard limit timing chain model / number of links tensioning system rh2015 / 120 automatic valves, valve seats, valve guides valve clearance (cold) intake exhaust valve dimensions 0.11 0.20 mm 0.21 0.30 mm val...

  • Page 25: Spec

    2-6 engine specifications spec item standard limit valve springs free length intake (inner) (outer) exhaust installed length (valve closed) intake (inner) (outer) exhaust compressed spring force (installed) intake (inner) (outer) exhaust spring tilt intake (inner) (outer) exhaust winding direction (...

  • Page 26: Spec

    2-7 engine specifications spec item standard limit pistons piston-to-cylinder clearance diameter d height h piston pin bore (in the piston) diameter offset offset direction piston pins outside diameter piston-pin-to-piston-pin-bore clearance piston rings top ring ring type dimensions (b t) end gap (...

  • Page 27: Spec

    2-8 engine specifications spec item standard limit connecting rods crankshaft-pin-to-big-end-bearing clearance bearing color code 0.028 0.052 mm 1 = blue 2 = black 3 = brown 4 = green crankshaft width b max. Runout c big end side clearance d crankshaft-journal-to-crankshaft- journal-bearing clearanc...

  • Page 28: Spec

    2-9 engine specifications spec item standard limit transmission transmission type primary reduction system primary reduction ratio secondary reduction system secondary reduction ratio operation gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear max. Main axle runout max. Drive axle ru...

  • Page 29: Spec

    2-10 engine specifications spec item standard limit starter jet 1 starter jet 2 butterfly valve size fuel level (below the line on the float chamber) #50 0.6 #110 17.5 18.5 mm.

  • Page 30: Spec

    2-11 chassis specifications spec chassis specifications item standard limit frame frame type caster angle trail diamond 24 _ 81 mm sss sss sss front wheel wheel type rim size material wheel travel wheel runout max. Radial wheel runout max. Lateral wheel runout cast wheel 17 mt3.50 aluminum 130 mm ss...

  • Page 31: Spec

    2-12 chassis specifications spec item standard limit rear tire tire type size model (manufacturer) tire pressure (cold) 0 90 kg 90 197 kg high-speed riding min. Tire tread depth tubeless 180 / 55 zr17 (73 w) bridgeston bt56r . E dunlop d207 . N 250 kpa (2.5 kg / cm 2 , 2.5 bar) 290 kpa (2.9 kg / cm ...

  • Page 32: Spec

    2-13 chassis specification spec item standard limit front suspension suspension type front fork type front fork travel spring free length spacer length installed length spring rate (k1) spring stroke (k1) optional spring available fork oil recommended oil quantity (each front fork leg) level (from t...

  • Page 33: Spec

    2-14 chassis specifications spec item standard limit steering steering bearing type angular ball bearings rear suspension suspension type rear shock absorber assemblytype rear shock absorber assemblytravel spring free length installed length spring rate (k1) spring stroke (k1) optional spring availa...

  • Page 34: Spec

    2-15 electrical specifications spec electrical specifications item standard limit system voltage 12 v sss ignition system ignition system type ignition timing advanced timing advancer type pickup coil resistance / color transistorized coil ignition unit model (manufacturer) c.D.I. 10 _ btdc at 1700 ...

  • Page 35: Spec

    2-16 electrical specifications spec item standard limit license plate light meter light 12 v 5 w 2 12 v 1.4 w 2 electric starting system system type starter motor model (manufacturer) power output brushes overall length spring force commutator resistance commutator diameter mica undercut constant me...

  • Page 36: Spec

    2-17 electrical specifications spec item standard limit temperature sender model (manufacturer) resistance 11h (nippon seiki) 50.6 64.2 Ω at 80 _ c 16.1 17.3 Ω at 120 _ c sss sss fuses (amperage quantity) main fuse headlight fuse signaling system fuse ignition fuse radiator fan fuse backup fuse (odo...

  • Page 37: Spec

    2-18 conversion table/tightening torques spec eb202001 tightening torques general tightening torques this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tighten- ing torque specifications for special components or assemblies are provided for each chapter ...

  • Page 38: Spec

    2-19 tightening torques spec note: engine tightening torques item fastener thread size q’ty tightening torque remarks y nm n s kgf spark plugs cylinder head cylinder head camshaft caps cylinder head cover oil passage check bolt cylinder head (exhaust pipe) – bolt bolt bolt bolt bolt stud bolt m10 m1...

  • Page 39: Spec

    2-20 tightening torques spec item fastener thread size q’ty tightening torque remarks size y nm m kgf clutch cover pickup coil rotor cover shift shaft cover breather plate 2 starter clutch clutch boss clutch springs drive sprocket main axle bearing housing shift bar stopper shift shaft spring stoppe...

  • Page 40: Spec

    2-21 tightening torques spec crankcase tightening sequence:.

  • Page 41: Spec

    2-22 tightening torques spec note: chassis tightening torques item thread size tightening torque remarks nm m kgf upper bracket pinch bolts steering stem nut handlebar pinch bolts lower ring nut lower bracket pinch bolts brake fluid reservoir cap stopper front brake hose union bolts front brake mast...

  • Page 42: Spec

    2-23 lubrication points and lubricant types spec eb202000 lubrication points and lubricant types engine lubrication points and lubricant types lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts and nuts crankshaft journals cams...

  • Page 43: Spec

    2-24 lubrication points and lubricant types spec eb202010 chassis lubrication points and lubricant types lubrication lubricant steering bearings and bearing races (upper and lower) front wheel oil seal (right and left) rear wheel oil seal rear wheel drive hub oil seal rear wheel drive hub mating sur...

  • Page 44: Spec

    2-25 oil flow diagrams spec 1 intake camshaft 2 exhaust camshaft 3 crankshaft 4 oil pipe 5 oil strainer 6 oil pump oil flow diagrams.

  • Page 45: Spec

    2-26 oil flow diagrams spec 1 exhaust camshaft 2 intake camshaft 3 oil filter 4 oil cooler.

  • Page 46: Spec

    2-27 oil flow diagrams spec 1 cylinder head 2 crankshaft.

  • Page 47: Spec

    2-28 oil flow diagrams spec 1 main axle 2 oil delivery pipe 3 driveaxle.

  • Page 48: Spec

    2-29 1 radiator 2 radiator fan 3 oil cooler coolant flow diagrams spec coolant flow diagrams.

  • Page 49: Spec

    2-30 coolant flow diagrams spec 1 thermostat housing 2 thermostat 3 radiator 4 therm.

  • Page 50: Spec

    2-31 1 radiator cap 2 radiator 3 oil cooler 4 water jacket joint 5 water pump coolant flow diagrams spec.

  • Page 51: Spec

    2-32 1 radiator 2 radiator fan switch 3 radiator fan coolant flow diagrams spec.

  • Page 52: Spec

    2-33 cable routing spec 1 throttle cables 2 front brake hose 3 clutch cable 4 starter cable 5 left handlebar switch lead 6 main switch lead 7 right handlebar switch lead a install the headlight relays onto the headlight housing bridge. B route the headlight lead through the plastic guide. C route th...

  • Page 53: Spec

    2-34 cable routing spec g fasten the throttle cables and starter cable with a band. Locate the end of band to forward. H route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie. Cut the end of locking tie. And then, route the horn lead under the ...

  • Page 54: Spec

    2-35 1 fuel pump lead 2 pickup coil lead 3 clutch cable 4 rear brake switch lead a route the ignition coil lead over the heat protector plate. B position the face of steel clip up ward. C route the clutch cable through the guide on the frame. D route the coolant hose under the heat protector plate. ...

  • Page 55: Spec

    2-36 1 ac magneto lead 2 sidestand switch lead 3 oil lever switch lead 4 reservoir tank breather hose 5 fuel tank breather hose 6 fuel tank drain hose 7 speed sensor lead 8 neutral switch lead 9 fuel pump lead a route the throttle cable through inside of the radia- tor bracket and outside of the wir...

  • Page 56: Spec

    2-37 1 throttle cable 2 handlebar switch lead (right) 3 coolant reservoir breather hose 4 carburetor idle adjusting cable 5 pickup coil connector 6 neutral switch connector 7 rear brake switch connector 8 handlebar switch (right) connec- tors 9 main switch connectors 10 throttle position sensor conn...

  • Page 57: Spec

    2-38 c fasten the handlebar switch leads (left and right) and main switch lead with a band. D route the ignition coil lead and handlebar switch leads (left and right) over the heat protection plate. E route the reservoir tank hose, carburetor heater hoses under the heat protector plate. F fasten the...

  • Page 58: Spec

    2-39 p insert the projection of the band (wireharness) into the hole of the frame. Q 1: speed sensor connector 2: ac magneto connector 3: sidestand switch connector 4: oil level switch connector 5: meter ground lead r fasten the leads (above 1 – 5) and starter motor lead with a steel band on the eng...

  • Page 59: Chk

    Chk adj chapter 3. Periodic checks and adjustments introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance and lubrication intervals 3-1 . . . . . . Rider and passenger seats 3-3 . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 60: Chk

    Chk adj adjusting the rear brake light switch 3-42 . . . . . . . . . . . . . . . Checking the brake hoses 3-43 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bleeding the hydraulic brake system 3-43 . . . . . . . . . . . . . . . . Adjusting the shift pedal 3-45 . . . . . . . . . . . . . ....

  • Page 61: Chk

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

  • Page 62: 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) 15 * chassis fasteners make sure that all nuts, bolts and screws are properly tighten...

  • Page 63: Chk

    3-3 order job / part q’ty remarks 1 2 removing the rider and passenger seats passenger seat rider seat 1 1 remove the parts in the order listed. For installation, reverse the removal procedure. 7nm (0.7 m kg) rider and passenger seats chk adj eb302000 rider and passenger seats.

  • Page 64: Chk

    3-4 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the fuel tank rider seat bolt bolts fuel sender coupler fuel hose fuel tank overflow hose fuel tank breather hose fuel tank 1 2 1 1 1 1 1 remove the parts in the order listed refer to “seats”. Disconnect. Before disconnecting the fuel hose, se...

  • Page 65: Chk

    3-5 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the cowlings rider and passenger seats rear cowling bottom cowling (left) bottom cowling (right) front cowling inner panel (left) front cowling inner panel (right) side cowling inner panel (left) side cowling inner panel (right) 1 1 1 1 1 1 1 ...

  • Page 66: Chk

    3-6 order job / part q’ty remarks 8 9 10 11 12 left side cowling right side cowling windshield rear view mirror front cowling 1 1 1 2 1 for installation, reverse the removal procedure. 5 nm (0.5 m kg) 5 nm (0.5 m kg) cowlings chk adj cowlings.

  • Page 67: Chk

    3-7 cowlings chk adj note: note: removal 1. Remove: s rear cowling s side cowlings to remove the quick fastener, turn its center to 90 _ with a screwdriver, then pull the fastener out. Installation 1. Install: s side cowlings s rear cowling to install the quick fastener, push its pin so that it prot...

  • Page 68: Chk

    3-8 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 removing the air filter case and ignition coils rider seat and fuel tank front cowling inner panel (left) front cowling inner panel (right) crankcase breather hose air vent hose hoses drain cup air filter case balance hose clamp screw bolt...

  • Page 69: Chk

    3-9 air filter case and ignition coils chk adj order job / part q’ty remarks 13 14 15 heat protector plate ignition coil coupler ignition coil 1 4 4 for installation, reverse the removal procedure..

  • Page 70: Chk

    3-10 air filter case and ignition coil plate chk adj note: note: removal 1. Remove: heat protector plate to remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. Installation 1. Install: heat protector plate to install the quick fastener, push its pin so that ...

  • Page 71: Chk

    3-11 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 temperature. When the valve clearance is to be measured or adjusted, the piston mus...

  • Page 72: Chk

    3-12 adjusting the valve clearance chk adj note: note: 4. Measure: s valve clearance out of specification adjust valve clearance (cold) intake valve 0.11 0.20 mm exhaust valve 0.21 0.30 mm a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the tdc mark a...

  • Page 73: Chk

    3-13 adjusting the valve clearance chk adj note: note: note: 5. Remove: timing chain tensioner timing chain guide (exhaust side) camshaft cap timing chain (from the camshaft sprockets) intake camshaft exhaust camshaft refer to “camshafts” in chapter 4. When removing the timing chain from cam- shafts...

  • Page 74: Chk

    3-14 adjusting the valve clearance chk adj note: note: note: c. Round off the original valve pad number ac- cording to the following table. Last digit rounded value 0 or 2 0 5 5 8 10 example: original valve pad number = 148 (thickness = 1.48 mm) rounded value = 150 d. Locate the rounded number of th...

  • Page 75: Chk

    3-15 adjusting the valve clearance chk adj example: valve clearance (cold) 0.11 0.20 mm rounded value 150 measured valve clearance is 0.24 mm replace pad 150 with pad 160 pad no. 150 = 1.50 mm pad no. 160 = 1.60 mm always install the valve pad with the number facing down. Measured valve clearance b ...

  • Page 76: Chk

    3-16 adjusting the valve clearance/ synchronizing the carburetors chk adj note: note: note: g. Measure the valve clearance again. H. If the valve clearance is still out of specifica- tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained. 7. Install: all...

  • Page 77: Chk

    3-17 synchronizing the carburetors chk adj 3. Remove: hose 1 4. Install: vacuum gauge attachments (into the bolt holes) vacuum gauge 1 (onto the vacuum gauge attachments) engine tachometer 2 (onto the ignition coil of cylinder #1) vacuum gauge 90890-03094 vacuum gauge attachment 90890-03060 engine t...

  • Page 78: Chk

    3-18 synchronizing the carburetors/ adjusting the engine idling speed chk adj note: note: note: after each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. B. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw ...

  • Page 79: Chk

    3-19 adjusting the engine idling speed chk adj a b 2. Remove: air filter case quick fasteners 1 band 2 refer to “air filter case and ignition coils”. 3. Install: engine tachometer (onto the ignition coil of cylinder #1) engine tachometer 90793-80009 4. Install: air filter case refer to “air filter c...

  • Page 80: Chk

    3-20 adjusting the engine idling speed/ adjusting the throttle cable free play chk adj note: 7. Adjust: throttle cable free play refer to “adjusting the throttle cable free play”. Throttle cable free play (at the flange of the throttle grip) 6 8 mm eb303031 adjusting the throttle cable free play pri...

  • Page 81: Chk

    3-21 adjusting the throttle cable free play chk adj note: a b note: c d warning 3. Adjust: throttle cable free play when the throttle is opened, the accelerator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. B. Turn the adjusting nut 3 in direction a or b to tak...

  • Page 82: Chk

    3-22 checking the spark plugs chk adj note: caution: eb303040 checking the spark plugs the following procedure applies to all of the spark plugs. 1. Remove: rider seat fuel tank refer to “seats” and “fuel tank”. Air filter case heat protector plate refer to “air filter case and ignition coils”. 2. D...

  • Page 83: Chk

    3-23 checking the spark plugs/ checking the ignition timing chk adj 13 nm (1.3 m kg) note: note: 5. Check: electrodes 1 damage / wear replace the spark plug. Insulator 2 abnormal color replace the spark plug. Normal color is medium-to-light tan. 6. Clean: spark plug (with a spark plug cleaner or wir...

  • Page 84: Chk

    3-24 checking the ignition timing/ measuring the compression pressure chk adj note: note: 2. Install: timing light 1 engine tachometer (onto the ignition coil of cylinder #1) timing light 90890-03141 engine tachometer 90793-80009 3. Check: ignition timing a. Start the engine, warm it up for several ...

  • Page 85: Chk

    3-25 measuring the compression pressure chk adj caution: warning note: 4. Remove: spark plug before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: compression gauge 1 compression ga...

  • Page 86: Chk

    3-26 measuring the compression pressure/ checking the engine oil level chk adj 13 nm (1.3 m kg) note: c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. Carbon deposits eliminate. D. If the compression pre...

  • Page 87: Chk

    3-27 checking the engine oil level/ changing the engine oil chk adj caution: note: recommended oil refer to the chart for the engine oil grade which is best suited for cer- tain atmospheric temperatures. Api standard se or higher grade (non-friction modified) acea standard g4 or g5 engine oil also l...

  • Page 88: Chk

    3-28 changing the engine oil chk adj caution: 43 nm (4.3 m kg) 6. If the oil filter cartridge is also to be replaced, perform the following procedure. A. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01426 b. Lubricate the o-ring 3 of the new oil filter cart...

  • Page 89: Chk

    3-29 changing the engine oil/ measuring the engine oil pressure chk adj caution: warning 13. Check: s engine oil level refer to “checking the engine oil level”. 14. Install: s bottom cowling refer to “cowlings”. Eb303090 measuring the engine oil pressure 1. Check: s engine oil level below the minimu...

  • Page 90: Chk

    3-30 measuring the engine oil pressure/ adjusting the clutch cable free play chk adj note: 20 nm (2.0 m kg) a b note: c d regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity, the oil pressure may fluctuate when measuring. The following data should ...

  • Page 91: Chk

    3-31 cleaning the air filter element/ adjusting the clutch cable free play chk adj caution: note: eb303130 cleaning the air filter element 1. Remove: fuel tank refer to “fuel tank”. Air filter case cover 1 air filter element 2. Clean: air filter element use solvent to clean the air filter element. A...

  • Page 92: Chk

    3-32 checking the carburetor joints/ checking the fuel hoses and fuel filter/ chk adj note: eb303171 checking the carburetor joints the following procedure applies to all of the car- buretor joints and intake manifolds. 1. Remove: carburetor assembly refer to “carburetors” in chapter 6. 2. Check: ca...

  • Page 93: Chk

    3-33 checking the exhaust system/ cleaning the air intake system chk adj caution: eb303190 checking the crankcase breather hose 1. Remove: fuel tank refer to “fuel tank”. 2. Check: crankcase breather hose 1 cranks / damage replace. Loose connection connect properly. Make sure that the crankcase brea...

  • Page 94: Chk

    3-34 checking the crankcase breather hose/ checking the exhaust system chk adj caution: 2. Check: crankcase breather hose 1 cracks / damage replace. Loose connection connect properly. Make sure that the crankcase breather hose is routed correctly. 3. Install: fuel tank refer to “fuel tank”. Eb303200...

  • Page 95: Chk

    3-35 checking the coolant level/ checking the cooling system chk adj note: 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. Check: coolant level the coolant level shou...

  • Page 96: Chk

    3-36 changing the coolant chk adj note: warning eb303240 changing the coolant 1. Remove: bottom cowling left side cowling refer to “cowlings”. Reservoir hose clamps 1 2. Remove: coolant reservoir bolts 2 coolant reservoir cap 3 when draining the coolant from the coolant res- ervoir, be sure to tilt ...

  • Page 97: Chk

    3-37 changing the coolant chk adj 7 nm (0.7 m kg) warning 6. Remove: coolant drain bolt 1 (along with the copper washer) 7. Drain: coolant 8. Check: coper washer 1 coolant drain bolt 2 damage replace 9. Install: coolant drain bolt 10. Fill: cooling system (with the specified amount of the recom- men...

  • Page 98: Chk

    3-38 changing the coolant chk adj caution: note: adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. Use only distilled water. However, soft wa- ter may be...

  • Page 99: Chk

    3-39 adjusting the front brake/ adjusting the rear brake chk adj note: a a warning 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 lev...

  • Page 100: Chk

    3-40 adjusting the rear brake chk adj a b warning warning caution: 2. Adjust: brake pedal position a. Loosen the locknut 1 . B. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is ob- tained. Direction brake pedal is raised. Direction brake pedal is lowered. Aft...

  • Page 101: Chk

    3-41 checking the brake fluid level chk adj a note: warning caution: note: eb304020 checking the brake fluid level 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Check: brake fluid level below the minimum level mark ...

  • Page 102: Chk

    3-42 checking the brake pads/ adjusting the rear brake light switch chk adj a b note: a b eb304032 checking the brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: front brake pad rear brake pad brake pad wear limit a wear limit reached replace the br...

  • Page 103: Chk

    3-43 checking the brake hoses/ bleeding the hydraulic brake system chk adj warning note: eb304062 checking the brake hoses the following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: brake hose 1 cracks / damage / wear replace. 2. Check: brake hose clamp loose tighten ...

  • Page 104: Chk

    3-44 bleeding the hydraulic brake system chk adj a b note: warning 5. Bleed: hydraulic brake system a. Fill the brake fluid reservoir to the proper lev- el with the recommended brake fluid. B. Install the brake fluid reservoir diaphragm. C. Connect a clear plastic hose 1 tightly to the bleed screw 2...

  • Page 105: Chk

    3-45 adjusting the shift pedal/ adjusting the drive chain slack chk adj note: b c note: caution: warning note: eb304081 adjusting the shift pedal the shift pedal position is determined by the installed. 1. Measure: incorrect adjust. The top of sift pedal should be aligned with the lower part of the ...

  • Page 106: Chk

    3-46 adjusting the drive chain slack chk adj a b note: 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Measure: drive chain slack a out of specification adjust. Drive chain slack 40 50 mm 4. Adjust: drive chain slack a. Loosen the wheel axle nut 1 . ...

  • Page 107: Chk

    3-47 lubricating the drive chain/ checking and adjusting the steering head chk adj warning note: eb304100 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained prop- erly, it will wear out rapidly. Therefore, the drive chain should be se...

  • Page 108: Chk

    3-48 checking and adjusting the steering head chk adj note: 3. Remove: upper bracket bolts 1 front brake fluid reservoir bolt 2 4. Loosen: upper bracket pinch bolts 1 handlebar pinch bolts 2 washer 3 5. Remove: handlebars (from the upper bracket) 6. Remove: steering stem nut 1 washer 2 upper bracket...

  • Page 109: Chk

    3-49 checking and adjusting the steering head chk adj warning note: 115 nm (11.5 m kg) 13 nm (1.3 m kg) 13 nm (1.3 m kg) 23 nm (2.3 m kg) note: c. Loosen the lower ring nut completely, then tighten it to specification. Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 9...

  • Page 110: Chk

    3-50 checking and adjusting the steering head/ checking the front fork chk adj warning d. Hold the spring gauge at a 90 _ angle from the handlebar, pull the spring gauge, and re- cord the measurement when the handlebar starts to turn. Steering head tension 200 500 g e. Repeat the above procedure on ...

  • Page 111: Chk

    3-51 adjusting the front fork legs chk adj warning caution: a b eb304153 adjusting the front fork legs the following procedure applies to both of the front fork legs. Always adjust both front fork legs evenly. Uneven adjustment can result in poor han- dling and loss of stability. Securely support th...

  • Page 112: Chk

    3-52 adjusting the front fork legs chk adj caution: a b caution: a b rebound damping never go beyond the maximum or minimum adjustment positions. 1. Adjust: rebound damping a. Turn the adjusting screw 1 in direction a or b . Direction rebound damping is increased (suspension is harder). Direction re...

  • Page 113: Chk

    3-53 adjusting the rear shock absorber assembly chk adj warning caution: note: a b eb304162 adjusting the rear shock absorb- er assembly securely support the motorcycle so that there is no danger of it falling over. Spring preload never go beyond the maximum or minimum adjustment positions. 1. Adjus...

  • Page 114: Chk

    3-54 adjusting the rear shock absorber assembly chk adj caution: a b caution: a b rebound damping never go beyond the maximum or minimum adjustment positions. 1. Adjust: rebound damping a. Turn the adjusting screw 1 in direction a or b . Direction rebound damping is increased (suspension is harder)....

  • Page 115: Chk

    3-55 checking the tires chk adj warning warning eb304170 checking the tires the following procedure applies to both of the tires. 1. Measure: tire pressure out of specification regulate. The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperatu...

  • Page 116: Chk

    3-56 checking the tires chk adj b a warning 2. Check: tire surfaces damage / wear replace the tire. Minimum tire tread depth 1.6 mm 1 tire tread depth 2 side wall 3 wear indicator do not use a tubeless tire on a wheel de- signed only for tube tires to avoid tire failure and personal injury from sudd...

  • Page 117: Chk

    3-57 checking the tires/checking the wheels chk adj warning note: warning note: rear tire manufacturer size model bridgestone 180 / 55 zr17 (73w) bt56r e dunlop 180 / 55 zr17 (73w) d207 n after mounting a new tire, ride conserva- tively for a while to become accustomed to the “feel” of the new tire ...

  • Page 118: Chk

    3-58 checking and lubricating the cables/ lubricating the levers and pedals/ lubricating the sidestand/lubricating the rear suspension chk adj warning note: eb304200 checking and lubricating the cables the following procedure applies to all of the cable sheaths and cables. Damaged cable sheaths may ...

  • Page 119: Chk

    3-59 checking and charging the battery chk adj warning 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 preventive measur...

  • Page 120: Chk

    3-60 relationship between the open-circuit voltage and the charging time at 20 _ c open-circuit voltage (v) these values vary with the temperature, the condition of the battery plates, and the electrolyte level. 13.0 12.5 12.0 11.5 5 6.5 10 charging time (hours) checking and charging the battery chk...

  • Page 121: Chk

    3-61 checking and charging the battery chk adj charging ambient temperature 20 _ c open-circuit voltage (v) check the open-circuit voltage. Time (minutes) ambient temperature 20 _ c open-circuit voltage (v) charging condition of the battery (%) warning caution: 5. Charge: s battery (refer to the app...

  • Page 122: Chk

    3-62 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charger and am- meter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery? Adjust the charging voltage to 20 25 v. Adjust the ...

  • Page 123: Chk

    3-63 checking and charging the battery chk adj caution: measure the open-circuit voltage prior to charging. Connect a charger and am- meter to the battery and start charging. Note: leave the battery unused for more than 30 minutes before measuring its open- circuit voltage. Is the amperage higher th...

  • Page 124: Chk

    3-64 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 125: Chk

    3-65 checking the fuses chk adj warning 3. Replace: blown fuse a. Set the main switch to “off”. B. Install a new fuse of the correct amperage. C. Set the main switch to “on” and verify if the electrical circuit is operational. D. If the fuse immediately blows again, check the electrical circuit. Ite...

  • Page 126: Chk

    3-66 replacing the headlight bulbs chk adj warning caution: eb305051 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Disconnect: headlight coupler 1 headlight bulb holder cover 2 2. Detach: headlight bulb holder 1 3. Remove: headlight bulb 2 since the...

  • Page 127: Chk

    3-67 adjusting the headlight beams chk adj a b a b a b eb305061 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Adjust: headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b . Direction headlight beams is raised. Direction headlight...

  • Page 128: Eng

    Eng clutch 4-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the clutch 4-48 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the friction plates 4-48 . . . . . . . . . . . . . . . . . . . . . . . . . . C...

  • Page 129: Eng

    4-1 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the drive sprocket reserve tank locknut shift rod shift arm drive sprocket cover nut lock washer drive sprocket 2 1 1 1 1 1 1 remove the parts in the order listed. Refer to “changing the coolant” for installation reverse the remove procedure. ...

  • Page 130: Eng

    4-2 engine eng order job / part q’ty remarks 1 2 3 removing the exhaust assembly bottom cowling and side cowlings coolant radiator assembly muffler exhaust pipe assembly exhaust pipe gasket 1 1 4 remove the parts in the order listed. Refer to “cowlings” in chapter 3 drain. Refer to “changing the coo...

  • Page 131: Eng

    4-3 engine eng order job / part q’ty remarks disconnecting the leads and hoses fuel tank air filter case carburetor assembly and joints engine oil and oil filter cartridge oil cooler disconnect the parts in the order listed. Refer to “fuel tank” in chapter 3. Refer to “air filter case and ignition c...

  • Page 132: Eng

    4-4 engine eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 battery negative lead battery positive lead startor coil assembly coupler pickup coil coupler engine earth clutch wire and holder crankcase breather hose separator 1 1 1 1 1 1 1 1 first, disconect the negative lead, then the positive lead....

  • Page 133: Eng

    4-5 engine eng 55 nm (5.5 m kg) 38 nm (3.8 m kg) 24 nm (2.4 m kg) order job / part q’ty remarks 1 2 3 4 5 6 7 removing the engine pinch bolts button head bolts collars front mounting bolts collars rear mounting bolts engine mounting adjust bolts 4 2 2 2 2 2 2 remove the parts in the order listed. Fo...

  • Page 134: Eng

    4-6 engine eng note: 47 nm (4.7m kg) 55 nm (5.5 m kg) 39 nm (3.9 m kg) 24 nm (2.4 m kg) 13 nm (1.3 m kg) note: 70nm (7.0 m kg) 10 nm (1.0 m kg) note: 10 nm (1.0 m kg) note: eas00192 installing the engine 1. Install: engine mounting adjust bolts 1 rear mounting bolts 2 self-locking nuts 3 collars 4 f...

  • Page 135: Eng

    4-7 camshafts eng order job / part q’ty remarks 1 2 3 4 removing the cylinder head cover carburetor assembly radiator assembly spark plugs cylinder head cover cylinder head cover gasket timing chain guide (top side) 4 1 1 1 remove the parts in the order listed. Refer to “carburetors” in chapter 6. R...

  • Page 136: Eng

    4-8 camshafts eng 24 nm (2.4 m kg) order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the camshafts pickup coil rotor cover timing chain tensioner timing chain tensioner gasket camshaft cap camshaft cap gasket dowel pin intake camshaft exahust camshaft timing chain guide (exhaust side) 1 1 1 4 2...

  • Page 137: Eng

    4-9 camshafts eng order job / part q’ty remarks 9 10 11 12 intake camshaft sproket exhaust camshaft sproket pin timing chain guide (intake side) 1 1 1 1 for installation reverse the removal procedure. Refer to “installing the camshafts”. 10 nm (1.0 m kg) 24 nm (2.4 m kg) 10 nm (1.0 m kg) 12 nm (1.2 ...

  • Page 138: Eng

    4-10 camshafts eng note: caution: note: eas00198 removing the camshafts 1. Align: tdc mark on the pickup coil rotor (with the crankcase mating surface) a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the mark a on the pickup coil rotor with the crankc...

  • Page 139: Eng

    4-11 camshafts eng eas00204 checking the camshafts 1. Check: camshaft lobes blue discoloration / pitting / scratches re- place the camshaft. 2. Measure: camshaft lobe dimensions a and b out of specification replace the cam- shaft. Camshaft lobe dimensions limit intake camshaft a 33.0 mm b 25.09 mm e...

  • Page 140: Eng

    4-12 camshafts eng note: tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. Do not turn the camshaft when measuring the camshaft-journal-to-camshaft-cap clearance with the plastigauge . Camshaft cap bolt 10 nm (1.0 m kg) d. Remove the camshaft caps...

  • Page 141: Eng

    4-13 camshafts eng note: 1. Check: camshaft sprocket more than 1 / 4 tooth wear a replace the camshaft sprockets and the timing chain as a set. A 1 / 4 tooth b correct 1 timing chain roller 2 camshaft sprocket 2. Check: timing chain guide (exhaust side) 1 timing chain guide (intake side) 2 timing ch...

  • Page 142: Eng

    4-14 camshafts eng 24 nm (2.4 m kg) 24 nm (2.4 m kg) note: note: caution: installing the camshafts 1. Install: timing chain guide (intake side) timing chain guide (exhaust side) 2. Install: intake camshaft sprocket exhaust camshaft sprocket cam sprocket timing mark is outside and align the cam sproc...

  • Page 143: Eng

    4-15 camshafts eng note: warning note: make sure that the camshaft sprocket timing marks c are aligned with the cylinder head edge d out of alignment reinstall. E. Remove the wire from the timing chain. 4. Install: timing chain tensioner a. Lightly press the timing chain tensioner rod into the timin...

  • Page 144: Eng

    4-16 camshafts eng note: 6. Check: tdc mark a make sure that the tdc mark is aligned with the crankcase mating surface b . Camshaft sprocket timing mark c make sure that the camshaft sprocket timing mark is aligned with the cylinder head edge d out of alignment adjust. Refer to the installation step...

  • Page 145: Eng

    4-17 cylinder head eng order job / part q’ty remarks 1 2 3 removing the cylinder head intake and exhaust camshafts water hose temp senser lead front mounting bolt cylinder head cylinder head gasket dowel pin 1 1 2 remove the parts in the order listed. Refer to “camshafts”. Disconnect disconnect refe...

  • Page 146: Eng

    4-18 cylinder head eng note: note: eas00223 removing the cylinder head 1. Remove: cylinder head bolts cylinder head loosen each bolt and nut 1 / 2 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts and nuts are fully loosened, remove them. Eas00229 checking the cylind...

  • Page 147: Eng

    4-19 cylinder head eng note: 51 nm (5.1 m kg) 10 nm (1.0 m kg) note: d. Place a 400 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. To ensure an even surface, rotate the cylinder head several times. Eas00223 installing the cylinder he...

  • Page 148: Eng

    4-20 valves and valve springs eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the valves and valve springs cylinder head intake valve lifter intake valve pad intake valve cotter intake valve upper spring seat intake valve spring outer intake valve spring inner intake valve oil seal i...

  • Page 149: Eng

    4-21 valves and valve springs eng order job / part q’ty remarks 11 12 13 14 15 16 17 18 19 exhaust valve lifter exhaust valve pad exhaust valve cotter exhaust valve upper spring seat exhaust valve spring exhaust valve oil seal exhaust valve lower spring seat exhaust valve exhaust valve guide 8 8 16 ...

  • Page 150: Eng

    4-22 valves and valve springs eng note: note: note: eas00237 removing the valves the following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure that the valves properly seal....

  • Page 151: Eng

    4-23 valves and valve springs eng note: note: 3. Remove: valve cotters 1 remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor 90890-04019 attachment 90890-04114 4. Remove: upper spring seat 1 valve spring outer 2 valve...

  • Page 152: Eng

    4-24 valves and valve springs eng note: note: 2. Replace: s valve guide to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 _ c (212 _ c) in an oven. A. Remove the valve guide with a valve guide remover 1 . B. Install the new valve guide with ...

  • Page 153: Eng

    4-25 valves and valve springs eng note: 5. Measure: valve margin thickness a out of specification replace the valve. Valve margin thickness 0.6 mm 0.8 mm : 0.5mm 6. Measure: valve stem runout out of specification replace the valve. When installing a new valve, always replace the valve guide. If the ...

  • Page 154: Eng

    4-26 valves and valve springs eng note: 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 impres- sion. D. Measure the valve seat width. W...

  • Page 155: Eng

    4-27 valves and valve springs eng e. Apply a fine lapping compound to the valve face and repeat the above steps. F. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. G. Apply mechanic’s blueing dye (dykem) b onto the valve face. H. In...

  • Page 156: Eng

    4-28 valves and valve springs eng 2. Measure: compressed spring force a out of specification replace the valve spring. B installed length compressed spring force (installed) intake valve spring inner 7.0 8.0 kg at 30.0 mm intake valve spring outer 11.6 13.4 kg at 32.5 mm exhaust valve spring 16.3 18...

  • Page 157: Eng

    4-29 valves and valve springs eng note: note: caution: 3. Install: lower spring seat 6 oil seal 5 new valve 4 valve spring inner (intake only) 3 valve spring outer 2 upper spring seat 1 (into the cylinder head) make sure that each valve is installed in its original place. Refer to the following em- ...

  • Page 158: Eng

    4-30 valves and valve springs eng note: 6. Lubricate: valve pad (with the recommended lubricant) recommended lubricant molybdenum disulfide oil 7. Install: valve pad valve lifter the valve lifter must move smoothly when ro- tated with a finger. Each valve lifter and valve pad must be rein- stalled i...

  • Page 159: Eng

    4-31 pickup coil and pickup coil rotor eng order job / part q’ty remarks removing the pickup coil and pickup coil rotor riders seat and fuel tank bottom cowling and right side cowling engine oil generator cover remove the parts in the order listed. Refer to “seats” and “fuel tank” in chapter 3. Refe...

  • Page 160: Eng

    4-32 pickup coil and pickup coil rotor eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 clutch cable clutch cable holder pickup coil coupler pickup coil cover pickup coil cover gasket dowel pin pickup coil pickup rotor 1 1 1 1 1 2 1 1 disconnect for installation reverse the removal procedure. Refer...

  • Page 161: Eng

    4-33 pickup coil and pickup rotor eng note: note: note: removing the pickup coil rotor 1. Remove: clutch cable holder 1 pickup coil cover 2 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: pickup coi...

  • Page 162: Eng

    4-34 pickup coil and pickup rotor eng 35 nm (3.5 m kg) note: note: 2. Tighten: pickup coil rotor bolt 1 while holding the generator rotor 2 with the sheave holder 3 , tighten the pickup coil rotor bolt. Sheave holder 90890-01701 3. Apply: sealant (onto the pickup coil lead grommet) yamaha bond no.12...

  • Page 163: Eng

    4-35 starter clutch and generator eng order job / part q’ty remarks 1 2 3 4 5 6 removing the starter clutch and gener- ator riders seat and fuel tank buttom and left side cowlings engine oil coolant treserver stator coil assembly coupler generator cover generator rotor cover gasket dowel pin stator ...

  • Page 164: Eng

    4-36 starter clutch and generator eng order job / part q’ty remarks 7 8 9 10 11 12 13 generator rotor bolt plain washer generator rotor starter one-way assy idler gear shaft idler hear starter clutch gear 1 1 1 1 1 1 1 for installation reverse the removal proceduer. Refer to “removing / installing t...

  • Page 165: Eng

    4-37 starter clutch and generator eng note: note: eas00346 removing the generator 1. Remove: generator rotor 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: generator rotor bolt 1 plain wash...

  • Page 166: Eng

    4-38 starter clutch and generator eng eas00345 removing the starter clutch 1. Remove: generator starter one-way assy 1 idler gear shaft 2 idler gear 3 starter clutch gear 4 eas00351 checking the starter clutch 1. Check: starter one-way assy damage / wear replace. 2. Check: idler gear idler gear shaf...

  • Page 167: Eng

    4-39 starter clutch and generator eng note: 65 nm (6.5 m kg) note: note: eas00355 installing the starter clutch 1. Install: starter clutch gear 1 idler gear 2 idler gear shaft 3 startor one-way assy 4 eas00354 installing the generator 1. Install: generator rotor 1 washer 2 generator rotor bolt 3 cle...

  • Page 168: Eng

    4-40 shift shaft eng order job / part q’ty remarks 1 2 3 4 5 removing the shift shaft coolant reserver drive sprocket cover, sift rod and sift arm. Shift shaft cover shift shaft cover gasket dowel pin oil seal sift shaft 1 1 2 1 1 remove the parts in the order listed. Drain. Refer to “chnging the co...

  • Page 169: Eng

    4-41 shift shaft eng order job / part q’ty remarks 6 7 8 9 10 11 12 13 14 shift shaft spring collar stopper lever spring circrip washer stopper lever collar washer shift shaft spring stopper 1 1 1 1 1 1 1 1 1 for installation reverse the removal procedure. Refer to “installing the shift shaft”. 22 n...

  • Page 170: Eng

    4-42 shift shaft eng 22 nm (2.2 m kg) note: note: eas00329 checking the shift shaft 1. Check: shift shaft 1 bends / damage / wear replace. Shift shaft spring 2 damage / wear replace. Eas00330 checking the stopper lever 1. Check: stopper lever 1 bends / damage replace. Roller turns roughly replace th...

  • Page 171: Eng

    4-43 clutch eng order job / part q’ty remarks 1 2 removing the clutch cover bottom cowing and right side cowling engine oil coolant therm bypass hose clutch cable 1 1 remove the parts in the order listed. Refer to “cowlings” in chapter 3. Drain. Refer to “changing the engine oil” in chapter 3. Drain...

  • Page 172: Eng

    4-44 clutch eng order job / part q’ty remarks 3 4 5 clutch cover clutch cover gasket dowel pin 1 1 2 refer to “removing / installing the clutch”. For installation reverse the removal procedure. 12 nm (1.2 m kg) 12 nm (1.2 m kg).

  • Page 173: Eng

    4-45 clutch eng order job / part q’ty remarks disassembling the clutch cover assembly circlip plain washer pull lever pull lever spring oil seal bearing 2 2 1 1 1 2 disassemble the parts in the order listed. Refer to “installing the clutch”. For assembly, reverse the disassembly procedure. 1 2 3 4 5...

  • Page 174: Eng

    4-46 clutch eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the clutch compression spling pressure plate pull rod bearing friction plate clutch plate clutch plate clutch boss nut look washer clutch boss 6 1 1 1 8 7 1 1 1 1 remove the parts in the order listed. Refer to“removing / ins...

  • Page 175: Eng

    4-47 clutch eng order job / part q’ty remarks 11 thrust plate 1 for installation, reverse the removal procedure. 70 nm (7.0 m kg) 8 nm (0.8 m kg).

  • Page 176: Eng

    4-48 clutch eng note: note: note: eas00277 removing the clutch 1. Remove: 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. Pressure plate fricttion and clutch plates 2. Straighten the lock washer...

  • Page 177: Eng

    4-49 clutch eng note: eas00281 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: clutch plate damage replace the clutch plates as a set. 2. Measure: clutch plate warpage (with a surface plate and thickness gauge 1 ) out of specification replace the clu...

  • Page 178: Eng

    4-50 clutch eng note: eas00285 checking the clutch boss 1. Check: clutch boss splines damage / pitting / wear replace the clutch boss. Pitting on the clutch boss splines will cause er- ratic clutch operation. Eas00286 checking the pressure plate 1. Check: pressure plate 1 cracks / damage replace. Be...

  • Page 179: Eng

    4-51 clutch eng 70 nm (7.0 m kg) note: note: note: eas00296 installing the clutch 1. Install: thrust plate 1 clutch boss 2 2. Install: lock washer 3 new clutch boss nut 4 while holding the clutch boss 2 with the clutch holding tool 5 , tighten the clutch boss nut. Clutch holding tool 90890-04086 3. ...

  • Page 180: Eng

    4-52 clutch eng 8 nm (0.8 m kg) note: 12 nm (1.2 m kg) note: 7. Install: pressure plate clutch springs clutch spring bolts tighten the clutch spring bolts in stages and in a criss cross pattern. 8. Install: clutch cover when installing the clutch cover, push the pull lever and check that the punch m...

  • Page 181: Eng

    4-53 oil pan and oil pump eng order job / part q’ty remarks 1 2 removing the oil pan and oil pump engine oil coolant radiator assembly and water pump assembly exhaust pipe assembly oil level switch couplar oil level switch 1 1 remove the parts in the order listed. Drain. Refer to “changing the engin...

  • Page 182: Eng

    4-54 oil pan and oil pump eng order job / part q’ty remarks 3 4 5 6 7 8 9 10 11 12 13 oil level switch lead holder oil pan oil pan gasket dowel pin oil strainer oil pipe oil delivery pipe gear cover dowel pin oil pump assembly relief valve assembly 1 1 1 2 1 1 1 1 2 1 1 refer to “installing the oil ...

  • Page 183: Eng

    4-55 oil pan and oil pump eng order job / part q’ty remarks disassemblying the oil pump assembly oil pump rotor housing dowel pin oil pump inner rotor oil pump outer rotor dowel pin washer oil pump cover driver gear 1 2 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly reverse the ...

  • Page 184: Eng

    4-56 oil pan and oil pump eng note: eas00362 removing the oil pan 1. Remove: oil level switch 1 oil pan 2 oil pan 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. Eas00364 checking the oil pum...

  • Page 185: Eng

    4-57 oil pan and oil pump eng 3. Check: oil pump operation unsmooth repair or replace the defective part(-s). Eas00365 checking the relief valve 1. Check: relief valve body 1 relief valve 2 spring 3 o-ring 4 damage / wear replace the defective part(-s). Eas00367 checking the oil delivery pipe and oi...

  • Page 186: Eng

    4-58 oil pan and oil pump eng 12 nm (1.2 m kg) note: note: 12 nm (1.2 m kg) 10 nm (1.0 m kg) 43 nm (4.3m kg) note: eas00375 assembling the oil pump 1. Lubricate: inner rotor outer rotor impeller shaft (with the recommended lubricant) recommended lubricant engine oil 2. Check: oil pump operation refe...

  • Page 187: Eng

    4-59 crankcase eng order job / part q’ty remarks separating the crankcase engine cylinder head starter clutch and generator shift shaft pickup coil and pickup rotor clutch assembly water pump assembly oil pan and oil pump remove the parts in the order listed. Refer to “engine”. Refer to “cylinder he...

  • Page 188: Eng

    4-60 crankcase eng order job / part q’ty remarks 1 2 3 4 5 timing chain oil pump drive chain guide oil pump drive chain lower crankcase dowel pin 1 1 1 1 3 refer to “disassembly/assembly the crankcase”. For installation, reverse the removal procedure. 12 nm (1.2 m kg).

  • Page 189: Eng

    4-61 crankcase eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the oil baffle plates and oil filter bolt transmission oil baffle plate oil baffle plate oil delivery pipe bearing lower crankcase oil filter bolt upper crankcase 1 1 1 1 1 1 1 remove the parts in the order listed. Refer to “tra...

  • Page 190: Eng

    4-62 crankcase eng note: caution: eas00384 disassembling the crankcase 1. Place the engine upside down. 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 numerical or- der (refer t...

  • Page 191: Eng

    4-63 crankcase eng eas00399 checking the crankcase 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: upper crankcase lower crankcase cracks / damage replace. Oil delivery passages obstruction blow out with ...

  • Page 192: Eng

    4-64 crankcase eng note: caution: eas00415 assembling the crankcase 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) recommended lubricant engine oil 2. Apply: sealant (onto the crankcase mating surfaces and the groove a of the oil baffle plate) yamaha bond no. 1215 90890-8...

  • Page 193: Eng

    4-65 crankcase eng note: warning 6. Install: crankcase bolts lubricate the bolt threads with engine oil. Install a washer on bolts 1 x 10 . Install a gasket on bolt 21 . Not lubricate seal botts 18 12 tighten the bolts in the tightening sequence cast on the crankcase. M8 85 mm bolts: 1 x 7 , 10 m8 1...

  • Page 194: Eng

    4-66 connecting rods and pistons eng order job / part q’ty remarks 1 2 3 4 5 6 7 removing the connecting rods and pistons lower crankcase connecting rod cap big end lower bearing big end upper bearing piston pin clip piston pin piston connecting rod 4 4 4 8 4 4 4 remove the parts in the order listed...

  • Page 195: Eng

    4-67 connecting rods and pistons eng order job / part q’ty remarks 8 9 10 top ring 2nd ring oil ring 4 4 4 for installation, reverse the removal procedure. Refer to “removing/installing the connecting rods and pistons”. 15 nm (1.5 m s kg)+90 _.

  • Page 196: Eng

    4-68 connecting rods and pistons eng note: caution: note: note: eas00393 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: connecting rod cap 1 big end bearings identify the position of each big end bearing so that it can b...

  • Page 197: Eng

    4-69 connecting rods and pistons eng note: eas00262 checking the cylinder and pistons the following procedure applies to all of the cyl- inders and pistons. 1. Check: piston wall cylinder wall vertical scratches replace the crank- cases, and the piston and piston rings as a set. 2. Measure: piston-t...

  • Page 198: Eng

    4-70 connecting rods and pistons eng note: note: e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = cylinder bore “c” – piston skirt diameter “p” piston-to-cylinder clearance 0.025 0.045 mm : 0.07 mm f. If out of specification, replace the crank-...

  • Page 199: Eng

    4-71 connecting rods and pistons eng note: 3. Measure: piston ring end gap out of specification replace the piston ring. The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is exces- sive, replace all three piston rings. Piston ring end gap top ring 0.15 0.25 mm : 0...

  • Page 200: Eng

    4-72 connecting rods and pistons eng caution: note: 4. Calculate: piston-pin-to-piston-pin-bore clearance out of specification replace the piston pin. Piston-pin-to-piston-pin-bore clearance = piston pin bore diameter (in the piston) – piston pin outside diameter piston-pin-to-piston-pin-bore cleara...

  • Page 201: Eng

    4-73 connecting rods and pistons eng note: caution: c. Put a piece of plastigauge 1 on the crank- shaft pin. D. Assemble the connecting rod halves. S do not move the connecting rod or crankshaft until the clearance measurement has been completed. S lubricate the bolt threads and nut seats with molyb...

  • Page 202: Eng

    4-74 connecting rods and pistons eng note: note: 2. Select: big end bearings (“p 1 ” “p 4 ”) the numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. “p 1 ” “p 4 ” refer to the bearings shown in the crankshaft ill...

  • Page 203: Eng

    4-75 connecting rods and pistons eng note: 2. Install: piston 1 (onto the respective connecting rod 2 ) piston pin 3 piston pi clip 4 new apply engine oil onto the piston pin. Make sure that the “y” mark a on the connect- ing rod faces left when the arrow mark b on the piston is pointing up. Refer t...

  • Page 204: Eng

    4-76 connecting rods and pistons eng note: 15 nm (1.5 m s kg)+90 _ caution: 6. Lubricate: s crankshaft pins s big end bearings s connecting rod big end inner surface (with the recommended lubricant) recommended lubricant engine oil 7. Install: s big end bearings s connecting rod assembly (into the c...

  • Page 205: Eng

    4-77 connecting rods and pistons eng warning caution: note: b. Clean the connecting rod bolts and nuts. C. Tighten the connecting rod nuts. D. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod 3 . E. Tighten the nut further to reach the specified angle (90 _ ). When the n...

  • Page 206: Eng

    4-78 crankshaft eng order job / part q’ty remarks 1 2 3 removing the crankshaft crankcase lower connecting rods and pistons crankshaft crankshaft journal lower bearing crankshaft journal upper bearing 1 5 5 remove the parts in the order listed. Separate. Refer to “crankcase”. Refer to “connecting ro...

  • Page 207: Eng

    4-79 crankshaft eng note: caution: eas00387 removing the crankshaft 1. Remove: crankshaft 1 crankshaft journal upper bearings (from the upper / lower crankcase) identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. Eas00397 checking the c...

  • Page 208: Eng

    4-80 crankshaft eng note: note: note: note: a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. B. Place the upper crankcase upside down on a bench. C. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. Ali...

  • Page 209: Eng

    4-81 crankshaft eng j 1 j 2 j 3 j 4 j 5 note: note: g. Remove the lower crankcase and the crank- shaft journal lower bearings. H. Measure the compressed plastigauge width c each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings. 2. Select: c...

  • Page 210: Eng

    4-82 crankshaft eng note: eas00407 installing the crankshaft 1. Install: crankshaft journal upper bearings (into the upper / lower crankcase) align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. Be sure to install each crankshaft journal up- p...

  • Page 211: Eng

    4-83 transmission eng order job / part q’ty remarks 1 2 3 4 5 6 removing the transmission crankcase lower shift shaft and stopper lever drive axle assembly circlip oil seal bearing shift bar stopper shift fork guide bar 1 1 1 1 1 2 remove the parts in the order listed. Separate. Refer to “crankcase”...

  • Page 212: Eng

    4-84 transmission eng order job / part q’ty remarks 7 8 9 10 11 12 spring shift fork “l” shift fork “r” shift drum assembly shift fork “c” main axle assembly 4 1 1 1 1 1 for installation, reverse the removal procedure. Refer to “installing the transmission”. Refer to “removing the transmission”. 12 ...

  • Page 213: Eng

    4-85 transmission eng order job / part q’ty remarks disassembling the main axle assembly bearing 2nd pinion gear toothed lock washer toothed lock washer retainer 6th pinion gear collar washer circlip 3rd pinion gear circlip 1 1 1 1 1 1 1 1 1 1 remove the parts in the order listed. 1 2 3 4 5 6 7 8 9 ...

  • Page 214: Eng

    4-86 transmission eng order job / part q’ty remarks washer 5th pinion gear collar main axle bearing housing bearing 1 1 1 1 1 1 for installation, reverse the removal procedure. 11 12 13 14 15 16.

  • Page 215: Eng

    4-87 transmission eng order job / part q’ty remarks disassembling the drive axle assembly washer 1st wheel gear collar 5th wheel gear circlip washer 3rd wheel gear collar toothed lock washer toothed lock washer retainer 4th wheel gear 1 1 1 1 1 1 1 1 1 1 1 remove the parts in the order listed. 1 2 3...

  • Page 216: Eng

    4-88 transmission eng order job / part q’ty remarks collar washer circrip 6th wheel gear circrip washer 2nd wheel gear collar collar oil seal bearing circrip drive axle 1 1 1 1 1 1 1 1 1 1 1 1 1 for installation, reverse the removal procedure. 12 13 14 15 16 17 18 19 20 21 22 23 24.

  • Page 217: Eng

    4-89 transmission eng warning eas00420 removing the transmission 1. Remove: drive axle assembly 2. Remove: main axle assembly 1 (with the torx wrench t30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. B. Tighten the bolts until t...

  • Page 218: Eng

    4-90 transmission eng 3. Check: shift fork movement (along the shift fork guide bar) rough movement replace the shift fork(-s) and shift fork guide bar as a set. Eas00422 checking the shift drum assembly 1. Check: shift drum grooves damage / scratches / wear replace the shift drum assembly. Shift dr...

  • Page 219: Eng

    4-91 transmission eng note: note: 4. Check: transmission gear engagement (each pinion gear to its respective wheel gear) incorrect reassemble the transmission axle assemblies. 5. Check: transmission gear movement rough movement replace the defective part(-s). 6. Check: circlips bends / damage / loos...

  • Page 220: Cool

    Cool chapter 5. Cooling system radiator 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the radiator 5-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the radiator 5-4 . . . . . . . . . . . . . . . . ...

  • Page 221: Cool

    5-1 radiator cool order job / part q’ty remarks 1 2 3 removeing the radiator rider seat and fuel tank air filter case and heat protector plate bottom cowling and side cowlings coolant coolant reserver hose breather hose radiator outlet hose 1 2 1 remove the parts in the order listed. Refer to “seats...

  • Page 222: Cool

    5-2 radiator cool order job / part q’ty remarks 4 5 6 7 8 9 radiator inlet hose oil cooler outlet hose thermo switch coupler radiator fan motor coupler radiator radiator fan 1 1 1 1 1 1 disconnect. Disconnect. Disconnect. For installation reverse the removal procedure. 28 nm (2.8 m kg) 9 nm (0.9 m k...

  • Page 223: Cool

    5-3 radiator cool note: eas00455 checking the radiator 1. Check: radiator fins obstruction clean. Apply compressed air to the rear of the radia- tor. Damage repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: radiator hoses cracks / damage replace. 3. Meas...

  • Page 224: Cool

    5-4 radiator cool eas00456 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. 3. Measure: radiator cap opening pressure below the spec...

  • Page 225: Cool

    5-5 oil cooler cool order job / part q’ty remarks 1 2 3 4 removing the oil cooler radiator assembly exaust pipe assembly engine oil oil cooler outlet hose bolt washer oil cooler 1 1 1 1 remove the parts in the order listed. Refer to “radiator”. Refer to “engine” in chapter 4. Drain. Refer to “changi...

  • Page 226: Cool

    5-6 oil cooler cool order job / part q’ty remarks 5 6 7 8 9 10 oil cooler inlet hose water jacket joint water jacket joint hose water pump outlet pipe water pump outlet hose water pump inlet hose 1 1 1 1 1 1 for installation, reverse the removal procedure. 63 nm (6.3 m kg).

  • Page 227: Cool

    5-7 oil cooler cool 63 nm (6.3 m kg) note: eas00458 checking the oil cooler 1. Check: oil cooler cracks / damage replace. 2. Check: oil cooler inlet hose oil cooler outlet hose cracks / damage / wear replace. 3. Check: water jacket joint water jacket joint inlet hose water pump outlet hose cracks / ...

  • Page 228: Cool

    5-8 oil cooler cool 4. Fill: cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. Crankcase (with the specified amount of the recom- mended engine oil) refer to “changing the engine oil” in chapter 3. 5. Check: cooling system leaks rep...

  • Page 229: Cool

    5-9 thermostat cool order job / part q’ty remarks removing the termostat rider seat and fuel tank coolant air filter case carburetor assembly remove the parts in the order listed. Refer to “seat” and “fuel tank” in chapter 3. Drain. Refer to “changing the coolant” in chapter 3. Refer to “airfilter c...

  • Page 230: Cool

    5-10 thermostat cool order job / part q’ty remarks 1 2 3 4 radiator inlet hose carburator outlet hose thermostat cover thermostat 1 1 1 1 for installation, revers the removal procedure. Refer to “installing the thermostat.

  • Page 231: Cool

    5-11 thermostat cool opening (mm) temperature 84 note: note: 10 nm (1.0 m s kg) note: eas00462 checking the thermostat 1. Check: s thermostat 1 does not open at 71 84 _ c replace. A. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the wate...

  • Page 232: Cool

    5-12 thermostat cool 3. Fill: coolling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 4. Check: cooling system leaks repair or replace any faulty part. 5. Measure: radiator cap opening pressure below the specified pressure replace the ra...

  • Page 233: Cool

    5-13 water pump cool order job / part q’ty remarks 1 2 3 4 5 removing the water pump assembly coolant water pump inlet hose water pump outlet hose water pump hose clutch wire and holder water pump 1 1 1 1 1 remove the parts in the order listed. Drain. Refer to “changing the coolant” in chapter 3. Fo...

  • Page 234: Cool

    5-14 water pump cool order job / part q’ty remarks disassembling the water pump assembly water pump cover o-ring impeller shaft (along with the impeller) water pump seal oil seal bearing circlip 1 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure....

  • Page 235: Cool

    5-15 water pump cool note: note: note: eas00470 disassembling the water pump 1. Remove: water pump seal 1 tap out the water pump seal from the inside of the water pump housing. 2 water pump housing 2. Remove: oil seal 1 circlip bearing 2 tap out the bearing and oil seal from the outside of the water...

  • Page 236: Cool

    5-16 water pump cool note: caution: note: note: eas00475 assembling the water pump 1. Install: bearing oil seal 1 new (into the water pump housing 2 ) before installing the oil seal, apply tap water or coolant onto its outer surface. Install the oil seal with a socket that matches its outside diamet...

  • Page 237: Cool

    5-17 water pump cool caution: 4. Measure: impeller shaft tilt out of specification repeat steps (3) and (4). Make sure that the rubber damper and rub- ber damper holder are flush with the impel- ler. Max. Impeller shaft tilt 0.15 mm 1 straightedge 2 impeller.

  • Page 238: Carb

    Carb chapter 6. Carburetors carburetors 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the carburetors 6-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembling the carburetors 6-9 . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 239: Carb

    6-1 carburetors carb order job / part q’ty remarks 1 2 3 4 removing the carburetors rider seat and fuel tank air filter case and heat protector plate starter cable fuel hose throttle position sensor coupler throttle stop screw 1 1 1 1 remove the parts in the order listed. Refer to “seats” and “fuel ...

  • Page 240: Carb

    6-2 carburetors carb order job / part q’ty remarks 5 6 7 8 9 10 therm bypass hose carburetor joint clamp screw throttle cable carburetor assembly carburetor joint side cover 2 4 2 1 4 2 for installation, reverse the removal procedure..

  • Page 241: Carb

    6-3 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 separating the carburetors starter plunger link connecting bolt connecting bolt hose joint spring fuel feed pipe fuel feed pipe pipe throttle stop screw throttle position sensor water pipe 1 1 1 2 2 2 1 2 1 1 2 remove the parts in the order l...

  • Page 242: Carb

    6-4 order job / part q’ty remarks 12 13 14 15 balance pipe balance pipe bracket throttle cable bracket carburetor 2 1 1 4 for installation, reverse the removal procedure carburetors carb.

  • Page 243: Carb

    6-5 carburetors carb order job / part q’ty remarks disassembling the carburetor starter plunger air funnel vacuum chamber cover piston valve spring jet needle holder jet needle kit piston valve pilot screw fuel drain bolt float chamber float pivot pin 1 1 1 1 1 1 1 1 1 1 1 disassemble the parts in t...

  • Page 244: Carb

    6-6 carburetors carb order job / part q’ty remarks float needle valve main jet main jet holder pilot jet 1 1 1 1 1 for assembly, reverse the disassembly procedure. 12 13 14 15 16.

  • Page 245: Carb

    6-7 carburetors carb eas00486 checking the carburetors the following procedure applies to all of the car- buretors. 1. Check: carburetor body float chamber cracks / damage replace. 2. Check: fuel passages obstruction clean. A. Wash the carburetor in a petroleum-based solvent. Do not use any caustic ...

  • Page 246: Carb

    6-8 carburetors carb 7. Check: piston valve 1 damage / scratches / wear replace. Piston valve diaphragm 2 cracks / tears replace. 8. Check: vacuum chamber cover 1 piston valve spring 2 jet needle holder 3 cracks / damage replace. 9. Check: jet needle kit 1 main jet 2 main jet holder 3 pilot jet 4 pi...

  • Page 247: Carb

    6-9 carburetors carb caution: note: 12. Check: fuel hoses cracks / damage / wear replace. Obstruction clean. Blow out the hoses with compressed air. Eas00490 assembling the carburetors the following procedure applies to all of the car- buretors. Before assembling the carburetors, wash all of the par...

  • Page 248: Carb

    6-10 carburetors carb note: note: 7 nm (0.7 m kg) note: note: 3. Install: pipes fuel feed pipes vacuum chamber pipe vacuum chamber air vent hose springs float chamber air vent hoses hose joint spacers copper washer connecting bolts do not tighten the connecting bolts yet. Install the throttle valve ...

  • Page 249: Carb

    6-11 carburetors carb eas00493 installing the carburetors 1. Adjust: carburetor synchronization refer to “synchronizing the carbu- retors” in chapter 3. 2. Adjust: engine idling speed engine idling speed 1250 1350 r / min refer to “adjusting the engine id- ling speed” in chapter 3. 3. Adjust: thrott...

  • Page 250: Carb

    6-12 carburetors carb note: eas00497 measuring and adjusting the fuel level 1. Measure: fuel level a out of specification adjust. Fuel level (below the mark on the body) 17.5 18.5 mm a. Stand the motorcycle on a level surface. B. Place the motorcycle on a suitable stand to ensure that the motorcycle...

  • Page 251: Carb

    6-13 carburetors carb note: note: eas00502 checking and adjusting the throttle position sensor before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: s throttle position sensor (installed on the carburetor) a. Disconnect the throttle position ...

  • Page 252: Carb

    6-14 carburetors carb note: 2. Check: s throttle position sensor (removed from the carburetor) a. Disconnect the throttle position sensor cou- pler. B. Remove the throttle position sensor from the carburetor. C. Connect the pocket tester ( Ω 1k) to the throttle position sensor. Tester positive probe...

  • Page 253: Carb

    6-15 carburetors carb note: note: 2 a b note: 3. Adjust: throttle position sensor angle a. Set the main switch to “on”. B. Disconnect the throttle position sensor cou- pler. C. Reconnect the throttle position sensor cou- pler. After reconnecting the throttle position sensor coupler, the tachometer s...

  • Page 254: Carb

    6-16 carburetors carb eas00504 checking the fuel pump 1. Check: fuel pump 1 a. Remove the fuel tank. Refer to “fuel tank” in chapter 3. B. Disconnect the fuel-pump-to-carburetor fuel hose 2 from the carburetor. C. Connect the fuel-tank-to-fuel-pump fuel hose to the fuel tank and then set the fuel co...

  • Page 255: Carb

    6-17 carburetors carb note: eas00505 checking the fuel cock 1. Remove fuel tank fuel filter 1 fuel cock 2 2. Check: fuel cock cracks / damage / wear replace. 3. Check: fuel cock strainer 1 (with compressed air) dirt / obstruction clean. Damage replace. 4. Install fuel cock fuel filter fuel tank eas0...

  • Page 256: Chas

    Chas chapter 7. Chassis front wheel and brake discs 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front wheel 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the front wheel 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the bra...

  • Page 257: Chas

    Chas front fork 7-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front fork legs 7-45 . . . . . . . . . . . . . . . . . . . . . . . . Disassembling the front fork legs 7-45 . . . . . . . . . . . . . . . . . . Checking the front fork ...

  • Page 258: Chas

    7-1 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the front wheel and brake discs brake hose holders (left and right) brake calipers (left and right) wheel axle pinch bolt front wheel axle front wheel collars (left and right) brake discs (left and right) 2 2 1 1 1 2 2 remove the parts in the ...

  • Page 259: Chas

    7-2 order job / part q’ty remarks disassembling the front wheel oil seals (left and right) wheel bearings (left and right) spacer 2 2 1 remove the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 front wheel and brake discs chas eas00518.

  • Page 260: Chas

    7-3 front wheel and brake discs chas warning note: note: note: warning eas00521 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 elev...

  • Page 261: Chas

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

  • Page 262: Chas

    7-5 front wheel and brake discs chas note: eas00533 checking the brake discs the following procedure applies to both of the brake discs. 1. Check: brake disc damage / galling replace. 2. Measure: brake disc deflection out of specification correct the brake disc deflection or replace the brake disc. ...

  • Page 263: Chas

    7-6 front wheel and brake discs chas 72 nm (7.2 m kg) 20 nm (2,0 m kg) caution: 40 nm (4.0 m kg) warning note: brake disc bolt 18 nm (1,8 m kg) loctite d. Measure the brake disc deflection. E. If out of specification, repeat the adjustment steps until the brake disc deflection is within specificatio...

  • Page 264: Chas

    7-7 front wheel and brake discs chas note: 1. Remove: s balancing weight(-s) 2. Find: s front wheel’s heavy spot a. Place the front wheel on a suitable balancing stand. B. Spin the front wheel. C. When the front wheel stops, put an “x 1 ” mark at the bottom of the wheel. D. Turn the front wheel 90 _...

  • Page 265: Chas

    7-8 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 removing the rear wheel brake caliper locknuts (left and right) adjusting bolts (left and right) wheel axle nut washer rear wheel axle left adjusting block right adjusting block rear wheel brake caliper bracket bolt brake caliper bracket 1 2 ...

  • Page 266: Chas

    7-9 order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the brake disc and rear wheel sprocket brake disc rear wheel sprocket spacers (left and right) oil seal bearing rear wheel drive hub rear wheel drive hub dampers rear wheel 1 1 2 1 1 1 5 1 remove the parts in the order listed. For installati...

  • Page 267: Chas

    7-10 order job / part q’ty remarks disassembling the rear wheel spacer bearing spacer oil seal circlip bearing 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 rear wheel, brake disc, and rear wheel sprocket chas.

  • Page 268: Chas

    7-11 rear wheel, brake disc, and rear wheel sprocket chas warning note: note: note: eas00561 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 269: Chas

    7-12 rear wheel, brake disc, and rear wheel sprocket chas note: 3. Measure: radial wheel runout lateral wheel runout refer to “front wheel”. Over the specified limits replace. Max. Radial wheel runout 1.0 mm max. Lateral wheel runout 0.5 mm eas00567 checking the rear wheel drive hub 1. Check: rear w...

  • Page 270: Chas

    7-13 rear wheel, brake disc, and rear wheel sprocket chas 150 nm (15.0 m kg) 27 nm (2.7 m kg) warning note: eas00571 installing the rear wheel 1. Lubricate: wheel axle wheel bearings oil seal lips recommended lubricant lithium soap base grease 2. Install: rear wheel brake caliper bracket adjusting b...

  • Page 271: Chas

    7-14 order job / part q’ty remarks 1 2 3 4 5 6 removing the front brake pads brake pad clips brake pad pin brake pad spring brake pads brake pad shims bleed screw 2 1 1 2 2 1 remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Refer to “replacin...

  • Page 272: Chas

    7-15 order job / part q’ty remarks 1 2 3 4 removing the rear brake pads brake caliper bolts brake pads brake pad shims bleed screw 2 2 4 1 remove the parts in the order listed. Refer to “replacing the rear brake pads”. 27 nm (2.7 m kg) 6 nm (0.6 m kg) 40 nm (4.0 m kg) for installation, reverse the r...

  • Page 273: Chas

    7-16 front and rear brakes chas caution: note: eas00579 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: never disassemble brake components un- less absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entir...

  • Page 274: Chas

    7-17 front and rear brakes chas note: note: 2. Remove: brake pad clips 1 brake pad pins 2 brake pad spring 3 brake pads (along with the brake pad shims) 3. Measure: brake pad wear limit a out of specification replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: brake pad shims (o...

  • Page 275: Chas

    7-18 front and rear brakes chas 40 nm (4.0 m kg) 6 nm (0.6 m kg) note: 5. Install: brake pad pins brake pad clips brake caliper bolts brake hose holder bolt 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 fl...

  • Page 276: Chas

    7-19 front and rear brakes chas note: 3. Measure: brake pad wear limit a out of specification replace the brake pads as a set. Brake pad wear limit 0.8 mm 4. Install: brake pad shims (onto the brake pads) brake pads always install new brake pads, brake pad shims, and a brake pad spring as a set. A. ...

  • Page 277: Chas

    7-20 front and rear brakes chas 40 nm (4.0 m kg) 5. Install: brake caliper bolts 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 feel...

  • Page 278: Chas

    7-21 order job / part q’ty remarks 1 2 34 5 6 7 8 9 10 11 12 13 removing the front brake master cylinder and brake fluid reservoir brake fluidbrake fluid reservoir cap stopper brake fluid reservoir cap brake fluid reservoir diaphragm holder brake fluid reservoir diaphragm brake fluid reservoir brake...

  • Page 279: Chas

    7-22 order job / part q’ty remarks 14 15 16 17 brake hose brake master cylinder holder brake master cylinder front brake switch 2 1 1 1 for installation, reverse the removal procedure. Refer to “installing the front brake master sylinder”. 1 2 3 4 5 6 8 7 9 10 11 12 13 14 13 14 13 15 16 17 30 nm (3....

  • Page 280: Chas

    7-23 order job / part q’ty remarks disassembling the front brake master cylinder dust boot circlip brake master cylinder kit brake master cylinder 1 1 1 1 remove the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 front and rear brakes chas eas00585.

  • Page 281: Chas

    7-24 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the rear brake master cylinder and brake fluid reservoir brake fluid brake fluid reservoir cap brake fluid reservoir diaphragm holder brake fluid reservoir diaphragm brake fluid reservoir brake fluid reservoir hose hose joint union bol...

  • Page 282: Chas

    7-25 order job / part q’ty remarks disassembling the rear brake master cylinder brake master cylinder kit brake master cylinder 1 1 remove the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 16 nm (1.6 m kg) front and rear brakes chas eas00587.

  • Page 283: Chas

    7-26 a b front and rear brakes chas note: note: note: eas00588 removing the front brake master cylinder before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hoses 3 master cylinder holder 4 to collect...

  • Page 284: Chas

    7-27 a b a b front and rear brakes chas warning 2. Check: brake master cylinder kit damage / scratches / wear replace. A front b rear 3. Check: brake fluid reservoir 1 cracks / damage replace. Brake fluid reservoir diaphragm 2 cracks / damage replace. 4. Check: brake hoses cracks / damage / wear rep...

  • Page 285: Chas

    7-28 front and rear brakes chas 13 nm (1.3 m kg) note: 30 nm (3.0 m kg) warning note: warning 1. Install: brake master cylinder 1 brake master cylinder holder install the brake master cylinder holder with the “up” mark facing up. Align the end of the brake master cylinder holder with the punch mark ...

  • Page 286: Chas

    7-29 front and rear brakes chas caution: 30 nm (3.0 m kg) warning caution: brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: brake system refer to “bleeding the hydraulic brake system” in chapter 3. 5. Check: brake flui...

  • Page 287: Chas

    7-30 front and rear brakes chas warning caution: 2. Fill: brake fluid reservoir recommended brake fluid dot 4 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 i...

  • Page 288: Chas

    7-31 order job / part q’ty remarks 1 2 3 4 removing the front brake calipers brake fluidunion bolt union bolt copper washer brake hose brake caliper 1 2 1 1 remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Drain. Refer to “installing the fron...

  • Page 289: Chas

    7-32 order job / part q’ty remarks disassembling the front brake calipers brake pad clip brake pad pin brake pad spring brake pad brake caliper piston brake caliper piston seal bleed screw 2 1 1 2 4 8 1 disassemble the parts in the order listed. The following procedure applies to both of the front b...

  • Page 290: Chas

    7-33 order job / part q’ty remarks 1 2 3 4 removing the rear brake caliper brake fluid union bolt copper washer brake hose brake caliper 1 2 1 1 remove the parts in the order listed. Drain. Refer to “installing the rear brake calipers”. 30 nm (3.0 m kg) 27 nm (2.7 m kg) for installation, reverse the...

  • Page 291: Chas

    7-34 order job / part q’ty remarks disassembling the rear brake caliper brake pad brake caliper piston brake caliper piston seal bleed screw 2 2 4 1 disassemble the parts in the order listed. Refer to “removing the rear brake calipers”. 1 2 3 4 for assembly, reverse the disassembly procedure. 6 nm (...

  • Page 292: Chas

    7-35 front and rear brakes chas note: note: warning eas00625 removing the front brake calipers the following procedure applies to both of the brake calipers. Before removing either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hose ...

  • Page 293: Chas

    7-36 front and rear brakes chas note: note: warning eas00628 removing the rear brake caliper before removing 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 container and pump out the br...

  • Page 294: Chas

    7-37 a b front and rear brakes chas warning eas00633 checking the front and rear brake calipers recommended brake component replacement schedule brake pads if necessary piston seals every two years brake hoses every four years brake fluid every two years and whenever the brake is disassembled 1. Che...

  • Page 295: Chas

    7-38 front and rear brakes chas warning new 30 nm (3.0 m kg) warning caution: 40 nm (4.0 m kg) 7 nm (0.7 m kg) eas00640 installing the front brake calipers the following procedure applies to both of the brake calipers. Before installation, all internal brake com- ponents should be cleaned and lubric...

  • Page 296: Chas

    7-39 front and rear brakes chas warning caution: 4. Fill: brake fluid reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake...

  • Page 297: Chas

    7-40 front and rear brakes chas warning 30 nm (3.0 m kg) warning caution: eas00642 installing the rear brake caliper before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never use solvents on internal brake com- ponents as they will cau...

  • Page 298: Chas

    7-41 front and rear brakes chas warning caution: 2. Fill: brake fluid reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake...

  • Page 299: Chas

    7-42 front fork chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the front fork legs front brake calipers front wheel front cowling inner panel front fender handlebar pinch bolt upper bracket bolt handlebar (left) handlebar (right) upper bracket pinch bolts cap bolts lower bracket pinch...

  • Page 300: Chas

    7-43 front fork chas order job / part q’ty remarks disassembling the front fork legs cap bolt o-ring nut washer spacer washer fork spring copper washer damper rod assembly bolt damper rod assembly 1 1 1 1 1 1 1 1 1 1 remove the parts in the order listed. The following procedure applies to both of th...

  • Page 301: Chas

    7-44 front fork chas order job / part q’ty remarks dust seal oil seal clip oil seal washer outer tube bushing inner tube oil lock piece 1 1 1 1 1 1 1 for assembly, reverse the disassembly procedure. Refer to “disassembling / assembling the front fork legs”. 23 nm (2.3 m kg) 40 nm (4.0 m kg) 11 12 13...

  • Page 302: Chas

    7-45 front fork chas warning note: warning eas00649 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 suitab...

  • Page 303: Chas

    7-46 front fork chas note: warning note: note: use the side of the rod holder that is marked “b”. C. Loosen the nut. D. Remove the cap bolt. E. Remove the rod holder and fork spring com- pressor. The fork spring is compressed. F. Remove the spacer and nut. G. Remove the fork spring. 2. Drain: fork o...

  • Page 304: Chas

    7-47 front fork chas warning caution: eas00657 checking the front fork legs the following procedure applies to both of the front fork legs. 1. Check: inner tube 1 outer tube 2 bends / damage / scratches replace. Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Mea...

  • Page 305: Chas

    7-48 front fork chas warning note: warning caution: 4. Check: cap bolt o-ring damage / wear replace. Eas00661 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 result i...

  • Page 306: Chas

    7-49 front fork chas 1 40 nm (4.0 m kg) note: caution: note: note: 3. Tighten: damper rod assembly bolt while holding the damper rod with the damper rod holder 2 , tighten the damper rod assembly bolt. Damper rod holder 90890-01425 4. Install: outer tube bushing 1 washer 2 oil seal 3 oil seal clip 4...

  • Page 307: Chas

    7-50 front fork chas caution: note: 7. Install: dust seal 1 (with the fork seal driver 2 ) 8. Install: rod puller 1 adapter 2 (onto the damper rod 3 ) rod puller 90890-01437 adapter 90890-01436 9. Fully compress the front fork leg. 10. Fill: front fork leg (with the specified amount of the recom- me...

  • Page 308: Chas

    7-51 front fork chas note: note: 12. Slowly stroke the inner tube 1 up and down to distribute the fork oil once more (1 stroke = about 100 mm). Be careful not to stroke the inner tube over 100 mm as this will cause air to enter. If the inner tube is stroked more than 100 mm, repeat steps (12) and (1...

  • Page 309: Chas

    7-52 front fork chas note: warning c. Install the rod puller and adapter onto the damper rod. Rod puller 90890-01437 adapter 90890-01436 d. Install the fork spring, washers and spacer. E. Press down on the spacer with the fork spring compressor 8 . F. Pull up the rod puller and install the rod hold-...

  • Page 310: Chas

    7-53 front fork chas note: note: 23 nm (2.3 m kg) 33 nm (3.3 m kg) 23 nm (2.3 m kg) 26 nm (2.6 m kg) warning 16. Install: cap bolt (onto the inner tube) temporarily tighten the cap bolt. Eas00662 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Instal...

  • Page 311: Chas

    7-54 handlebars chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 removing the handlebars left grip end handlebar grip clutch switch connector left handlebar switch starter cable starter lever clutch cable clutch lever holder right grip end throttle cable throttle grip 1 1 2 1 1 1 1 1 1 2 1...

  • Page 312: Chas

    7-55 handlebars chas order job / part q’ty remarks 12 13 14 15 16 17 18 19 20 21 22 front brake switch connector right handlebar switch brake master cylinder holder brake master cylinder handlebar pinch bolt upper bracket bolt upper bracket pinch bolt steering stem nut left handlebar right handlebar...

  • Page 313: Chas

    7-56 handlebars chas warning note: warning eas00667 removing the handlebars 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: grip end handlebar grip left handlebar switch clutch lever holder blow compressed air betw...

  • Page 314: Chas

    7-57 handlebars chas caution: note: note: note: eas00674 installing the handlebars 1. Install: brake master cylinder holder 1 install the brake master cylinder holder with the “up” mark facing up. First, tighten the upper bolt, then the lower bolt. Align the mating surfaces of the brake master cylin...

  • Page 315: Chas

    7-58 handlebars chas note: warning 4. Install: left handlebar switch 1 align the projection a on the left handlebar switch with the hole b in the left handlebar. 5. Install: handlebar grip grip end a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. B. Slide the handlebar gri...

  • Page 316: Chas

    7-59 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 removing the lower bracket front wheel front fork legs main switch coupler upper bracket bolt left handlebar assembly right handlebar assembly steering stem nut washer upper bracket lower bracket panel brake hose holder bolt lock washer u...

  • Page 317: Chas

    7-60 steering head chas order job / part q’ty remarks 13 14 15 16 17 18 19 20 lower ring nut lower bracket bearing cover bearing inner race upper bearing lower bearing dust seal bearing outer race 1 1 1 2 1 1 1 2 refer to “check and adjusting the steering head” in chapter 3. For installation, revers...

  • Page 318: Chas

    7-61 steering head chas warning warning eas00677 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: front fork legs steering stem nut upper bracket ring nuts 1 (with the special tool 2 ) rin...

  • Page 319: Chas

    7-62 steering head chas caution: 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 properly, the steering head pipe could be damaged. Always replace the bearing balls and be...

  • Page 320: Chas

    7-63 steering head chas note: note: 115 nm (11.5 m kg) 23 nm (2.3 m kg) 23 nm (2.3 m kg) 13 nm (1.3 m kg) 13 nm (1.3 m kg) 3. Install: upper bracket steering stem nut temporarily tighten the steering stem nut. 4. Install: front fork legs refer to “front fork”. Temporarily tighten the upper and lower...

  • Page 321: Chas

    7-64 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 removing the rear shock absorber assembly rear wheel self-locking nut / bolt self-locking nut / bolt self-locking nut / bolt / coller self-locking nut / bolt pin/ clip / washer rear shock absorber assembly coller / oil seal / bearing relay a...

  • Page 322: Chas

    7-65 rear shock absorber assembly chas warning warning eas00687 handling the rear shock absorber and gas cylinder this rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand the followi...

  • Page 323: Chas

    7-66 rear shock absorber assembly chas warning note: note: note: eas00694 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 rear whe...

  • Page 324: Chas

    7-67 rear shock absorber assembly chas note: 40 nm (4.0 m kg) 40 nm (4.0 m kg) 40 nm (4.0 m kg) 40 nm (4.0 m kg) checking the relay arm and con- necting arm 1. Check: relay arm 1 connecting arm 2 damage / wear replace. Bearings oil seals damage / pitting replace. Spacers damage / scratches replace. ...

  • Page 325: Chas

    7-68 swingarm and drive chain chas order job / part q’ty remarks 1 2 3 4 5 6 7 removing the swingarm and drive chain drive sprocket rear wheel rear shock absorber assembly adjusting bolt / locknut drive chain guard rear fender flap pivot shaft nut / washer pivot shaft swingarm 2 / 2 1 1 1 1 / 1 1 1 ...

  • Page 326: Chas

    7-69 swingarm and drive chain chas order job / part q’ty remarks 8 9 10 11 12 13 14 15 16 17 pivot shaft adjust bolt drive chain dust cover oil seal bush shim drive chain guide bush left bearing right bearing 2 1 1 1 1 1 1 1 1 1 refer to “removing / installing the swingarm”. For installation, revers...

  • Page 327: Chas

    7-70 swingarm and drive chain chas note: note: note: note: before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a tenlink section of the drive chain. Ec573000 removing the swingarm 1. Remove: bolt (connecting rod) 1 connecting rod 2 remove ...

  • Page 328: Chas

    7-71 swingarm and drive chain chas warning note: note: eas00703 checking the swingarm 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 wheel is elevated. 2. Measure: sw...

  • Page 329: Chas

    7-72 swingarm and drive chain chas warning 4. Check: pivot shaft roll the pivot shaft on a flat surface. Bends replace. Do not attempt to straighten a bent pivot shaft. 5. Wash: pivot shaft pivot shaft adjust bolt dust covers spacer bearings recommended cleaning solvent kerosine 6. Check: dust cover...

  • Page 330: Chas

    7-73 swingarm and drive chain chas note: eas00709 checking the drive chain 1. Measure: ten-link section a of the drive chain out of specification replace the drive chain. Max. Ten-link drive chain section 149 mm while measuring the ten-link section, push down on the drive chain to increase its tensi...

  • Page 331: Chas

    7-74 swingarm and drive chain chas caution: c. Remove the drive chain from the kerosine and completely dry it. This motorcycle has a drive chain with small rubber o-rings 1 between the drive chain side plates. Never use high-pressure water or air, steam, gasoline, certain solvents (e.G., benzine), o...

  • Page 332: Chas

    7-75 swingarm and drive chain chas 95 nm (9.5 m kg) note: eas00711 installing the swingarm 1. Lubricate: bearings spacers dust covers pivot shaft recommended lubricant lithium soap base grease 2. Install: swingarm pivot shaft washer pivot shaft adjust bolt 1 pivot shaft nut use the pivot shaft wrenc...

  • Page 333: Elec

    Elec chapter 8. Electrical electrical components 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument functions 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicator lights 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 334: Elec

    Elec signaling system 8-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circuit diagram 8-35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8-37 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 335: Elec

    8-1 electrical components elec 1 wire harness 2 main switch 3 front brake light switch 4 plug top ignition coils 5 clutch switch 6 starting circuit cutoff relay 7 fuse box 8 flasher relay 9 cdi unit 10 starter relay 11 main fuse 12 oil level relay 13 battery 14 rectifier / regulator 15 rear brake li...

  • Page 336: Elec

    8-2 neutral indicator light “ ” high beam indicator light “ ” turn indicator light “ ” fuel indicator light “ ” 1 2 3 4 oil level / coolant temperature warning light “ ” oil level symbol “ ” coolant temperature symbol “ ” 1 2 3 instrument functions elec caution: note: instrument functions indicator ...

  • Page 337: Elec

    8-3 instrument functions elec speedometer clock, odometer “select” button “reset” button 1 2 3 4 coolant temperature display conditions what to do 0 _ c 40 _ c symbol is on and “lo” is displayed. Go ahead with riding. 41 _ c 117 _ c symbol is on and temperature is dis- played. Go ahead with riding. ...

  • Page 338: Elec

    8-4 instrument functions elec note: when the fuel level indicator light comes on the odometer display will automatically change to the fuel reserve trip meter mode “trip f” and start counting the distance traveled from that point. Push the “select” button to change be- tween the fuel odometer, trip ...

  • Page 339: Elec

    8-5 switches elec caution: note: note: eb801000 switches checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the cou- pler te...

  • Page 340: Elec

    8-6 checking the switches elec eb801010 checking the switches check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “checking switch continuity”. Damage / wear repair or replace the switch. Improperly connected properly connect. Incorrect...

  • Page 341: Elec

    8-7 checking the switches elec 1 main switch 2 pass switch 3 dimmer switch 4 turn signal switch 5 horn switch 6 clutch switch 7 light switch (for europe) 8 engine stop switch 9 start switch 10 front brake light switch 11 rear brake light switch 12 neutral switch 13 fuse 14 sidestand switch 15 oil le...

  • Page 342: Elec

    8-8 checking the bulbs and bulb sockets elec eb801020 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage / wear repair or replace the bulb, bulb socket or both. Improperly connected prope...

  • Page 343: Elec

    8-9 checking the bulbs and bulb sockets elec warning caution: note: since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be ...

  • Page 344: Elec

    8-10 checking the bulbs and bulb sockets elec note: warning checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: bulb socket (for continuity) (with the pocket tester) no continuity replace. Pocket tester 90890-03112 check each bulb socket f...

  • Page 345: Elec

    8-11 1 main switch 5 battery 6 main fuse 9 starting circuit cutoff relay 11 sidestand switch 14 cdi unit 15 ignition coil #1 16 ignition coil #2 17 ignition coil #3 18 ignition coil #4 19 spark plugs 20 pick up coil 21 neutral switch 56 ignition fuse 63 engine stop switch 66 diode 2 ignition system ...

  • Page 346: Elec

    8-12 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Min. Open-circuit voltage 12.8 v or more at 20 _ c s is the battery ok? Yes s clean the battery terminals. S recharge or re- place the battery. No 3. Spark plugs the following procedure a...

  • Page 347: Elec

    8-13 ignition system elec tester positive probe ignition coil terminal tester negative probe ignition coil terminal tester positive probe ignition coil terminal tester positive probe spark plug terminal 4. Ignition spark gap the following procedure applies to all of the spark plugs. S disconnect the...

  • Page 348: Elec

    8-14 eb802410 7. Pickup coil resistance s disconnect the pickup coil coupler from the wire harness. S connect the pocket tester ( Ω 100) to the pickup coil terminal. Pickup coil resistance 248 x 372 Ω at 20 _ c (between gray and black) s is the pickup coil ok? Yes replace the pickup coil. No tester ...

  • Page 349: Elec

    8-15 12. Starting circuit cutoff relay remove the relay unit from the wire harness. Connect the pocket tester ( Ω 1) to the relay terminals as shown. Check the starting circuit cutoff relay for con- tinuity. Yes replace the starting circuit cutoff relay. No tester positive probe sky blue tester nega...

  • Page 350: Elec

    8-16 1 main switch 5 battery 6 main fuse 7 starter relay 8 starter motor 9 starting circuit cutoff relay 11 sidestand switch 21 neutral switch 38 clutch switch 56 ignition fuse 63 engine stop switch 64 start switch 65 diode 1 electric starting system elec eb803000 electric starting system circuit di...

  • Page 351: Elec

    8-17 electric starting system elec eb803010 starting circuit cutoff system op- eration if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: the transmission is in ...

  • Page 352: Elec

    8-18 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Open-circuit voltage 12.8 v or more at 20 _ c s is the battery ok? Yes s clean the battery terminals. S recharge or replace the battery. No 3. Starter motor s connect the battery positive...

  • Page 353: Elec

    8-19 4. Starting circuit cutoff relay disconnect the relay from the coupler. Connect the pocket tester ( Ω 1) and bat- tery (12 v) to the relay terminals as shown. Yes replace the starting circuit cutoff relay no battery positive terminal red / black battery negative terminal black / yellow 1 2 test...

  • Page 354: Elec

    8-20 electric starting system elec check the diode for continuty. Disconnect the diode from the coupler. Connect the pocket tester ( Ω 1) to the diode terminals as a shown. Measur the diode for continuity as follows. 6. Starter relay disconnect the starter relay from the coupler. Connect the pocket ...

  • Page 355: Elec

    8-21 eb803408 check the entire starting system’s wiring. Refer to “circuit diagram”. Is the starting system’s wiring properly con- nected and without defects? No the starting system circuit is ok. Yes 14. Wiring check the start switch for continuity. Refer to “checking the switches”. Is the start sw...

  • Page 356: Elec

    8-22 order job / part q’ty remarks 1 2 3 removing the starter motor rider seat fuel tank carburetors coolant thermostat starter motor lead starter motor assembly throttle stop screw 1 1 1 remove the parts in the order listed. Refer to “seats” in chapter 3. Refer to “fuel tank” in chapter 3. Refer to...

  • Page 357: Elec

    8-23 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 disassembling the starter motor o-ring starter motor front cover lock washer oil seal bearing washer set starter motor rear cover washer set o-ring brush holder set o-ring armature assembly starter motor yoke 1 1 1 1 1 1 1 1 2 1 1 1 1 ...

  • Page 358: Elec

    8-24 starter motor elec note: eb803511 checking the starter motor 1. Check: s commutator dirt clean with 600 grit sandpaper. 2. Measure: s commutator diameter a out of specification replace the starter motor. Min. Commutator diameter 27 mm 3. Measure: s mica undercut a out of specification scrape th...

  • Page 359: Elec

    8-25 starter motor elec note: 5 nm (0.5 m kg) note: 5. Measure: brush length a out of specification replace the brushes as a set. Min. Brush length 3.5 mm 6. Measure: brush spring force out of specification replace the brush springs as a set. Brush spring force 7.16 9.52 n (7.16 9.52 gf) 7. Check: g...

  • Page 360: Elec

    8-26 charging system elec 3 rectifier / regulator 4 ac magneto 5 battery 6 main fuse eb804000 charging system circuit diagram.

  • Page 361: Elec

    8-27 charging system elec 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Open-circuit voltage 12.8 v or more at 20 _ c s is the battery ok? Yes s clean the battery terminals. S recharge or replace the battery. No eb804400 3. Charging volta...

  • Page 362: Elec

    8-28 charging system elec no the charging circuit is ok. Yes note: make sure that the battery is fully charged. S is the charging voltage within specification? Eb804404 s check the wiring connections of the entire charging system. Refer to “circuit diagram”. S is the charging system’s wiring properl...

  • Page 363: Elec

    8-29 1 main switch 5 battery 6 main fuse 30 high beam indicator light 32 illumination light 34 pass switch 35 dimmer switch 45 headlight 46 auxiliary light 47 headlight relay (hi) 48 headlight relay (lo) 49 tail / brake light 53 headlight fuse 54 signaling system fuse 62 light switch lighting system...

  • Page 364: Elec

    8-30 lighting system elec 2. Battery s check the condition of the battery. Refer to “checking and charging the battery” in chapter 3. Open-circuit voltage 12.8 v or more at 20 _ c s is the battery ok? Yes s clean the battery terminals. S recharge or replace the battery. No eb802411 s check the main ...

  • Page 365: Elec

    8-31 check the dimmer switch for continuity. Refer to “checking the switches”. Is the dimmer switch ok? Yes the dimmer switch is faulty. Replace the left handlebar switch. No 5. Dimmer switch eb805403 check the pass switch for continuity. Refer to “checking the switches”. Is the pass switch ok? Yes ...

  • Page 366: Elec

    8-32 battery positive terminal white / yellow (white /green) battery negative terminal black headlight tester positive probe yellow or green tester negative probe black high beam indicator light tester positive probe yellow tester negative probe black / blue meter assembly coupler (wire harness side...

  • Page 367: Elec

    8-33 replace the tail / brake light bulb, sock- et or both. No yes the wiring circuit from the main switch to the meter assem- bly coupler is faulty and must be re- paired. No this circuit is ok. Eb805412 3. A tail / brake light fails to come on. 1. Tail / brake light bulb and socket check the tail ...

  • Page 368: Elec

    8-34 lighting system elec yes the wiring circuit from the main switch to the auxiliary light connectors is faulty and must be re- paired. No this circuit is ok. Set the main switch to “on”. Set the light switch to “ ” or “ ”. Measure the voltage (12 v) of blue / red on the auxiliary light couplers (...

  • Page 369: Elec

    8-35 signaling system elec eb806000 signaling system circuit diagram.

  • Page 370: Elec

    8-36 signaling system elec 1 main switch 5 battery 6 main fuse 9 starting circuit cutoff relay 12 fuel sender 21 neutral switch 22 speed sensor 25 fuel level indicator light 26 oil level / coolant temperature warning light 27 neutral indicator light 28 tachometer 29 combination meter 31 turn signal ...

  • Page 371: Elec

    8-37 open-circuit voltage 12.8 v or more at 20 _ c yes replace the fuse(-s). No yes s clean the battery terminals. S recharge or re- place the battery. No replace the main switch. No eb802411 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switc...

  • Page 372: Elec

    8-38 replace the left han- dlebar switch. No 1. Horn switch check the horn switch for continuity. Refer to “checking the switches”. Is the horn switch ok? Yes 2. Voltage connect the pocket tester (dc 20 v) to the horn connector at the horn terminal as shown. Tester positive probe pink tester negativ...

  • Page 373: Elec

    8-39 replace the tail / brake light bulb, sock- et or both. No 1. Tail / brake light bulb and socket check the tail / brake light bulb and socket for continuity. Refer to “checking the bulbs and bulb sockets”. Are the tail / brake light bulb and socket ok? Yes 3. Voltage connect the pocket tester (d...

  • Page 374: Elec

    8-40 replace the left han- dlebar switch. No 3. Turn signal switch check the turn signal switch for continuity. Refer to “checking the switches”. Is the turn signal switch ok? Yes the wiring circuit from the main switch to the turn signal relay coupler (turn signal relay side) is faulty and must be ...

  • Page 375: Elec

    8-41 signaling system elec replace the meter assembly. No yes the wiring circuit from the turn signal switch to the turn sig- nal light connector is faulty and must be re- paired. No this circuit is ok. Eb806414 4. The neutral indicator light fails to come on. 1. Neutral indicator light led check th...

  • Page 376: Elec

    8-42 replace the oil level switch. No 2. Oil level switch drain the engine oil and remove the oil level switch from the oil pan. Check the oil level switch for continuity. Refer to “checking the switches”. Is the oil level switch ok? Yes replace the oil level relay. No 3. Oil level relay disconnect ...

  • Page 377: Elec

    8-43 replace the fuel sender. No 2. Fuel sender disconnect the fuel sender coupler from the wire harness. Drain the fuel from the fuel tank and remove the fuel sender from the fuel tank. Check the fuel sender for continuity. Yes tester positive probe green tester negative probe black 1 is the fuel s...

  • Page 378: Elec

    8-44 does the startup display appear first and then after approximately three seconds the normal display appears? First, connect the battery to the green / yellow and black / blue coupler terminals, then connect the battery positive lead to the red / green terminal. When connecting the battery, chec...

  • Page 379: Elec

    8-45 1 main switch 5 battery 6 main fuse 23 thermo unit 26 oil level / coolant temperature warning light 29 combination meter 50 radiator fan motor 51 thermo switch 52 radiator fan motor fuse 54 signaling system fuse cooling system elec eb807000 cooling system circuit diagram.

  • Page 380: Elec

    8-46 replace the fuse(-s). No 1. Main, signal system and radiator fan motor fuses s check the main, signal system, and radiator fan motor fuses for continuity. Refer to “checking the fuses” in chap- ter 3. S are the main, signal system, and radiator fan motor fuses ok? Yes yes s clean the battery te...

  • Page 381: Elec

    8-47 the wiring circuit from the main switch to the radiator fan mo- tor coupler is faulty and must be repaired. No 5. Radiator fan motor (test 2) s disconnect the thermo switch coupler. S set the main switch to “on”. S connect the brown and blue terminals with a jumper lead as shown. Yes s does the...

  • Page 382: Elec

    8-48 replace the thermo switch. No yes s does the thermo switch operate properly as described above? S remove the temperature sender from the cylinder head. S connect the pocket tester ( Ω 10) to the thermo unit as shown. S immerse the thermo unit in a container filled with coolant . S place a therm...

  • Page 383: Elec

    8-49 1 main switch 5 battery 6 main fuse 9 starting circuit cutoff relay 10 fuel pump 14 cdi unit 54 signaling system fuse 56 ignition fuse 63 engine stop switch fuel pump system elec eb808000 fuel pump system circuit diagram.

  • Page 384: Elec

    8-50 fuel pump system elec 1 battery 2 main fuse 3 main switch 4 ignition fuse 5 engine stop switch 6 cdi unit 7 starting circuit cutoff relay 8 fuel pump eb808010 fuel pump circuit operation the cdi unit includes the control unit for the fuel pump..

  • Page 385: Elec

    8-51 fuel pump system elec replace the fuse(-s). No 1. Main and ignition fuses s check the main and ignition fuses for conti- nuity. Refer to “checking the fuses” in chap- ter 3. S are the main and ignition fuses ok? Yes open-circuit voltage 12.8 v or more at 20 _ c yes s clean the battery terminals...

  • Page 386: Elec

    8-52 replace the starting circuit cutoff relay. No 5. Starting circuit cutoff relay s disconnect the relay from the coupler. S connect the pocket tester ( Ω 1) and bat- tery (12 v) to the relay terminals as shown. Yes battery positive terminal red battery negative terminal blue / red 1 s does the fu...

  • Page 387: Elec

    8-53 fuel pump system elec warning eb808410 checking the fuel pump gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: stop the engine before refuelling. Do not smoke and keep away from o...

  • Page 388: Elec

    8-54 self-diagnosis elec revolution ( 10 3 r / min) tachometer display time (seconds) engine speed 0 r / min ... 3 seconds condition code ... 2.5 seconds engine speed ... 3 seconds 1 2 3 eb812000 self-diagnosis the yzf-r6 features a self-diagnosing system for the following circuit(-s): throttle posi...

  • Page 389: Elec

    8-55 repair or replace the wire harness. No 1. Wire harness check the wire harness for continuity. Refer to “circuit diagram”. Is the wire harness ok? Yes no 2. Throttle position sensor check the throttle position sensor for conti- nuity. Refer to “checking and adjusting the throttle position sensor...

  • Page 390: Elec

    8-56 repair the fuel level indicator light led. No 1. Fuel level indicator light led check the led of the fuel level indicator light. Refer to “checking the leds”. Is the fuel level indicator light led ok? Yes replace the fuel sender. No 2. Fuel sender disconnect the fuel sender coupler from the wir...

  • Page 391: Elec

    8-57 replace or replace the wire harness. No 3. Wire harness check the wire harness for continuity. Refer to “circuit diagram”. Is the wire harness ok? Yes replace the cdi unit. Self-diagnosis elec eb812405.

  • Page 392: Trbl

    Trbl shtg chapter 9. Troubleshooting starting problems 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system 9-1 . . . . . . . . . . . . . . . . ...

  • Page 393: Trbl

    Trbl shtg unstable handling 9-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Faulty lighting and signaling systems 9-5 . . . . . . . . . . . . . . . . . . Headlight does not light 9-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight bulb burnt ...

  • Page 394: Trbl

    9-1 starting problems trbl shtg note: fuel system fuel tank empty fuel tank clogged fuel filter clogged fuel tank breather hose deteriorated or contaminated fuel fuel pump faulty fuel pump faulty fuel pump relay fuel cock clogged or damaged fuel hose carburetors deteriorated or contaminated fuel clo...

  • Page 395: Trbl

    9-2 incorrect engine idling speed/poor medium-and- high-speed performance/faulty gear shifting trbl shtg electrical systems battery faulty battery discharged battery spark plugs incorrect spark plug gap incorrect spark plug heat range fouled spark plug worn or damaged electrode worn or damaged insul...

  • Page 396: Trbl

    9-3 faulty clutch/overheating/overcooling trbl shtg clutch drags clutch unevenly tensioned clutch spring plate warped pressure plate bent clutch plate swollen friction plate bent clutch pull rod damaged clutch boss burnt primary driven gear bushing match marks not aligned engine oil incorrect oil le...

  • Page 397: Trbl

    9-4 poor braking performance/faulty front fork legs/unstable handling trbl shtg loose union bolt damaged brake hose oil or grease on the brake disc oil or grease on the brake pad incorrect brake fluid level malfunction bent or damaged inner tube bent or damaged outer tube damaged fork spring worn or...

  • Page 398: Trbl

    9-5 faulty lighting and signaling systems trbl shtg turn signal does not light faulty turn signal switch faulty turn signal relay burnt-out turn signal bulb incorrect connection damaged or faulty wire harness incorrectly grounded circuit faulty battery blown, damaged or incorrect fuse turn signal bl...

  • Page 399

    1 main switch 2 fuse (backup) 3 rectifier / regulator 4 ac magneto 5 battery 6 fuse (main) 7 starter relay 8 starter motor 9 starting circuit cutoff relay 10 fuel pump 11 sidestand switch 12 fuel sender 13 throttle position sensor 14 cdi unit 15 lgnition coil #1 16 lgnition coil #2 17 lgnition coil ...

  • Page 400

    1 main switch 2 fuse (backup) 3 rectifier / regulator 4 ac magneto 5 battery 6 fuse (main) 7 starter relay 8 starter motor 9 starting circuit cutoff relay 10 fuel pump 11 sidestand switch 12 fuel sender 13 throttle position sensor 14 cdi unit 15 lgnition coil #1 16 lgnition coil #2 17 lgnition coil ...