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  4. FZR400 1988-1989
  5. Service Manual

Yamaha FZR400 1988-1989 Service Manual

Summary of FZR400 1988-1989

  • Page 1

    Yamaha fzr400 service manual 1988-1989 models.

  • Page 3: Contents

    Contents chapter 1. General information motorcycle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - l vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . L - l engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 4

    Chapter 3. Periodic inspection and adjustment introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 3-1 maintenance intervals chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance emission control system . . . . . . ....

  • Page 5

    Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 battery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 fuse inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 6

    Piston ring and piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 crankshaft and connecting rod . . . . . . . . . . . . . . . . . . . . . . . 4-37 1 2 starter clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 4 transmission . . . ....

  • Page 7

    Chapter 5. Cooling system 1 2 3 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 water pump and thermostatic valve. . . . . . . . . . . . . . . . . . . . . . . 5-6 7 9 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 8

    Front and rear brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 brake pad replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 caliper disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 master cylinder...

  • Page 9

    Chapter 8. Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 electrical components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 checking of switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 switc...

  • Page 10

    Yamaha exhaust variable valve system (for california only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83 circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83 troubleshooting . . . . . . . . . . . . . . . . . . ...

  • Page 11: Contents

    Contents general information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 motorcycle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . 1 engine serial number . ...

  • Page 12: General

    Motorcycle identification general information motorcycle identification vehicle identification number the vehicle identification number is stemped into the right side of the steering head. Starting serial number: (except for california): la012101 (for california): la003101 note: the vehicle identifi...

  • Page 13: Specifications

    General specifications specifications general specifications model model code number: vehicle identification number: engine starting number: basic weight: with oil and full fuel tank tire: size manufacture (type) l a 0 1 2 1 0 1 l a 0 0 3 1 0 1 188 kg (414 lb) 191 kg (421 lb) front rear tubeless tub...

  • Page 14

    Maintenance specifications maintenance specifications chassis model front suspension: front fork travel 130 mm (5.12 in) front spring free length 412 mm (16.2 in) 408 mm (16.1 in) collar length 160 mm (6.3 in) spring rate: 4.4 n/mm (0.5 kg/mm, 25.2 k2 6.6 n/mm (0.7 kg/mm, 37.5 stroke 0.0 90 mm (0.0 ...

  • Page 15

    Maintenance specifications tightening torque part to be tightened front axle and outer tube rear axle and nut handlebar crown and inner tube handlebar crown and steering stem brake caliper (front/rear) bleed screw and brake caliper brake hose and union bolt front master cylinder and master cylinder ...

  • Page 16

    General torque specifications general torque this chart specifies torque for standard fasteners with standard i.S.O. Pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid tighten fastener assemblies in a crisscross ...

  • Page 17: Periodic Inspections

    Drive chain slack adjustment periodic inspections and adjustments chassis drive chain slack adjustment note: before checking and/or adjusting the chain slack, rotate the rear wheel several revolutions. Check the chain slack several times to find the point where the chain is the tightest. Check and/o...

  • Page 18

    Drive chain slack adjustment clockwise slack is increased. Counterclockwise slack is decreased. Note: turn each adjuster exactly the same amount to maintain correct axle alignment. (there are marks on each side of swingarm; use them to check for proper alignment.) ?? Tighten the locknut. ?? Tighten ...

  • Page 19: Chassis

    Rear wheel chassis rear wheel @ c o l l a r oil seal bearing spacer clutch hub @ c o l l a r cotter pin tension bar wear limit: 1 .O mm (0.04 in) rim size: mt4.00 x 18 rim limit: radial: 2.0 mm (0.08 in) lateral: i.

  • Page 20

    Rear wheel removal 1. Place the motorcycle on a level place. Securely support the motorcycle so there is no danger of it falling over. 2. Elevate the rear wheel by placing a suitable stand under the swingarm. 3. Remove: ?? Bolts (brake caliper) note: do not depress the brake pedal while the caliper ...

  • Page 21

    Rear wheel inspection 1. Inspect: ?? Tire ?? Rear wheel axle ?? Wheel ?? Wheel bearings seals refer to the “front wheel inspec- tion”. 2. Measure: ?? Wheel refer to the “front wheel inspec- . Tion”. 3. Check: ?? Wheel balance refer to the “front wheel inspec- tion”. Installation reverse the “removal...

  • Page 22

    Rear wheel ?? Do not loosen the axle nut after torque tighten- ing. ?? If the axle nut groove is not aligned with the wheel shaft cotter pin hole, align groove with the hole by tightening up on the axle nut. 4. Install: pin ?? Always use a new cotter pin on the axle nut. ?? Make sure that the brake ...

  • Page 23

    Front and rear brake front and rear brake master cylinder cap brake caliper diaphragm pad spring master cylinder kit piston master cylinder piston seal brake hose dust seal union bolt @brake pad copper washer brake disc joint ? The arrow mark on the pad spring must pointing the disc rotating directi...

  • Page 24

    Front and rear brake reservoir tank cap bush @diaphragm reservoir tank reservoir hose master cylinder master cylinder kit brake hose brake pedal union bolt copper washer @brake caliper @ p i s t o n @piston seal dust seal brake pad pad shim pad spring @brake disc.

  • Page 25

    Front and rear brake disc brake components rarely require disassem- bly. Do not: ?? Disassembly components unless absolutely nec- essary. ?? Use solvents on internal brake component. ?? Use contaminated brake fluid for cleaning. Use only clean brake fluid. ?? Aiiow brake fluid to come in contact wit...

  • Page 26

    Front and rear brake 3. Remove: ?? Brake pads note: ?? Replace the pad spring if the pad replacement is required. ?? Replace the pads as a set if either is found to be worn to the wear limit. 0.5 mm (0.02 in) 4. Install: ?? Brake pads ?? Pad spring installation steps: a suitable hose tightly to the ...

  • Page 27

    Front and rear brake 6. Inspect: ?? Brake fluid level refer to the “brake fluid inspec- tion” section in the chapter 3. “lower” level line 7. Check: ?? Brake lever operation a softy or spongy filling bleed brake system. Refer to the “al bleeding” section in the chapter 3. 3. Remove: retaining bolts ...

  • Page 28

    Front and rear brake 4. Remove: ?? Brake pads (with shims) ?? Pad spring note : ?? Replace the pad spring if the pad replacement is required. ?? Replace the pads as a set if either is found to be worn to the wear limit. ?? Replace the pad shim if the pad replacement is required. 0.5 mm (0.02 in) 5. ...

  • Page 29

    Front and rear brake 6. Install: ?? Retaining bolts retaining bolts: 10 nm (1.0 kg, 7.2 7. Install: ?? Bolts (brake caliper) bolts (brake caliper): 35 nm (3.5 kg, 25 8. Inspect: ?? Brake fluid level refer to the “brake fluid inspec- tion” section in the chapter 3. “lower” level line 9. Check: ?? Bra...

  • Page 30

    Frontandrearbrake caliper disassembly note: before disassembling the front or rear brake master cylinders, drain the brake hose, master cylinder, brake caliper and reservoir tank of their brake fluid. Securely support the motorcycle so there is no danger of it falling over. Front brake 1. Remove: co...

  • Page 31

    Front and rear brake 4. Remove: ?? Pistons ?? Dust seals ?? Piston seals remove steps: *blow compressed air into the tube joint opening to force out the piston from the caliper body. ?? Never try to pry out the piston. ?? Cover the piston with a rag. Use care so that piston does not cause injury as ...

  • Page 32

    Front and rear brake remove steps: ?? Blow compressed air into the tube joint opening to force out the piston from the caliper body. ?? Never try to pry out the piston. ?? Cover the piston with a rag. Use care so that piston does not cause injury as it is expelled from the cylinder. Master cylinder ...

  • Page 33

    3. Remove: ?? Master cylinder front and rear brake 4. Remove: ?? Cap (master cylinder) ?? Diaphragm . Dust boot ?? Circlip ?? Master cylinder kit rear brake 1. Remove: seat ?? Side cover (right) 2. Remove: ?? Cotter pin ?? Washer 3. Disconnect: ?? Reservoir hose place the open hose end into a contai...

  • Page 34

    1 front and rear brake 7. Remove: ?? Reservoir tank (from flame) ?? Cap (reservoir tank) ?? Holder (diaphragm) ?? Diaphragm inspection and repair all internal parts should be cleaned in new brake fluid only. Do not use solvents will cause seals to swell and distort. 1. Inspect: @caliper pistons scra...

  • Page 35

    Front and rear brake 3. Inspect : ?? Master cylinder wear/scratches replace. ?? Master cylinder body cracks/damage replace. Delivery passage (master cylinder body) blow out with compressed air. F r o n t 4. Inspect: ?? Master cylinder kit scratches/wear/damage replace. ?? Front r e a r 5. Inspect: ?...

  • Page 36

    Front and rear brake 6. Inspect: ?? Brake hoses cracks/wear/damage replace. ?? Front r e a r 7. Measure: ?? Brake pads (thickness) out of specification replace. Wear limit: 0.5 mm (0.02 in) note: ?? Replace the pad spring as a set if pad replace- ment is required. ?? Replace the pads as a set if eit...

  • Page 37

    Front and rear brake assembly internal parts should be cleaned in new brake fluid only. ?? Internal parts should be lubricated with brake fluid when installed. ?? Replace the piston seal and dust seal whenever a caliper is disassembled. ?? Securely support the motorcycle so there is no danger of it ...

  • Page 38

    Front and rear brake 4. Install: ?? Copper washers ?? Brake hose bolt (onto brake caliper) union bolt: 26 nm (2.6 m kg, 19 lb) when installing the brake hose to the caliper lightly touch the brake pipe with the projec- tion on brake caliper. ?? Proper hose routing is essential to insure safe motorcy...

  • Page 39

    Front and rear brake 7. Install: ?? Brake hose ?? Copper washers ?? Union bolts 26 nm (2.6 m kg, 19 lb) *proper hose routing is essential to insure safe motorcycle operation. Refer to the “cable routing”. ?? Always use new copper washers. 8. Install: ?? Brake switch *spring lever note: apply lithium...

  • Page 40

    Front and rear brake 10. Install: ?? Diaphragm ?? Master cylinder cap screws (master cylinder cap): 2 nm (0.2 m kg, 1.4 11. Air bleed: @brake system refer to the “air bleeding” section in the chapter 3. 12. Inspect: ?? Brake fluid level fluid lever is under “lower” level line replenish. Refer to the...

  • Page 41

    Front and rear brake 3. Install: ?? Brake caliper bolts (brake caliper): 35 nm (3.5 m kg, 25 lb) 4. Install: ?? Master cylinder kit ?? Push rod circlip boot 5. Install: ?? Master cylinder assembly bolts (master cylinder assembly): 35 nm (3.5 m kg, 25 lb) 6. Install: @plain washer ?? Cotter pin alway...

  • Page 42

    Front and rear brake 8. Install: ?? Brake hose ?? Copper washers ?? Union bolts ?? Reservoir hose union bolts: 26 nm (2.6 kg, 19 i when installing the brake hose, lightly touch the brake pipe with the projections on the caliper and master cylinder. ?? Master cylinder brake caliper hose routing is es...

  • Page 43

    Front and rear brake ?? Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. ?? Refill with the same type of brake fluid; mixing fluids may result in a harmful chem- ical reaction and lead to poor performance. ?? Be car...

  • Page 44: Contents

    Contents chapter 1. General information motorcycle identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - l vehicle identification number . . . . . . . . . . . . . . . . . . . . . . . . . L - l engine serial number . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 45

    Chapter 3. Periodic inspection and adjustment introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . , 3-1 maintenance intervals chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance emission control system . . . . . . ....

  • Page 46

    Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 battery inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 fuse inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 47

    Piston ring and piston pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 crankshaft and connecting rod . . . . . . . . . . . . . . . . . . . . . . . 4-37 1 2 starter clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-43 4 transmission . . . ....

  • Page 48

    Chapter 5. Cooling system 1 2 3 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4 water pump and thermostatic valve. . . . . . . . . . . . . . . . . . . . . . . 5-6 7 9 installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 49

    Front and rear brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-10 brake pad replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-12 caliper disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-16 master cylinder...

  • Page 50

    Chapter 8. Electrical circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 electrical components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 checking of switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-5 switc...

  • Page 51

    Yamaha exhaust variable valve system (for california only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83 circuit diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-83 troubleshooting . . . . . . . . . . . . . . . . . . ...

  • Page 52: General

    Motorcycle identification i ” ‘ ” general motorcycle identification vehicle identification number the vehicle identification number is stemped into the right side of the steering head. (except for california): note: the vehicle identification number is used to identify your motorcycle and may be use...

  • Page 53

    Important information important information preparation for removal 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “special tool”. 3. When disassembling the machine, keep mated parts together. This includes gea...

  • Page 54

    Important information lock washers/plates and cotter pins 1. All lock washers/plates and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been pro- perly tightened. Bearings and oil seals 1. Install the bearing(s) ...

  • Page 55

    Special tools special tools the proper special tools are necessary for com- plete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or impro- vised techniques. For tune up 1. Inductive tachometer p/n w-08036 this tool is ne...

  • Page 56

    Special tools 5. Vacuum gauge p/n yu-08030 this gauge is needed for carburetor synchroniza- tion. For engine service 1. Cam chain cutter p/n y m-01 112 this tool is used when cutting the cam chain. 2. Piston pin puller p/n yu-01304 this tool is used to remove the piston pin. 3. Universal clutch hold...

  • Page 57

    Special tools 5. Universal rotor holder p/n yu-01235 this tool is used when loosening or tightening the a.C. Magneto securing bolt. 6. Heavy duty puller p/n y u-33270 this tool is used to remove the starter clutch. 7. Camshaft wrench p/n ym-04115 this tool is used to turn the camshaft. 8. Valve spri...

  • Page 58

    Special tools io. Valve guide installer p/n ym-041 i7 this tool is needed to install the valve guides properly. 1 i. Valve guide reamer (4.5 mm) p/n ym-041 this tool is used to rebore the new valve guide. 12. Valve seat cutter p/n ym-91043 this tool is needed to resurface the valve seat. 13. Set “gr...

  • Page 59

    Special tools 15. Piston base p/n y m-01 067 use 4 of these to hold the piston during cylinder installation. 16. Radiator cap tester p/n y u-24460-01 adaptor p/n y u-33984 this tester is needed for checking the cooling system. For chassis service t-handle p/n ym-01326 front fork cylinder holder p/n ...

  • Page 60

    Special tools for electrical components 1. Dynamic coil tester p/n y m-34487 this tester is necessary for checking the ignition system components. 2. Pocket tester p/n y u-031 12 this instrument is invaluable for checking the electrical system..

  • Page 61: Specifications

    General specifications specifications general specifications model model code number: vehicle identification number: engine starting number: dimensions: overall length overall width overall height seat height wheelbase minimum ground clearance basic weight: with oil and full fuel tank turning radius...

  • Page 62

    General specifications model tank capacity reserve amoun type x quantity manufacturer plug: type (manufacture) type: transmission: primary reduction system primary reduction ratio secondary reduction system secondary reduction ratio transmission type operation gear ratio 1 st 2nd 3rd 4th 5th 6th fra...

  • Page 63

    General specifications model brake: front brake type operation rear brake type operation suspension: front suspension rear suspension shock absorber: front shock absorber rear shock absorber wheel travel: front wheel travel rear wehel travel electrical: ignition system generator system battery type ...

  • Page 64

    Maintenance specifications maintenance specifications engine model cylinder head: warp limit* 0.03 mm (0.0012 in) , *lines indicate straightedge measurement cylinder: bore size 56.000 56.005 mm (2.2047 2.2049 ir drive method cam cap inside dia. Camshaft outside dia. Shaft-to-cap clearance limit > ca...

  • Page 65

    Maintenance specifications model “a” head dia. Face width “c” seat width “d” margin thickness stem outside diameter guide inside diameter stem-to-guide clearance stem limit i i n . 21.9 22.1 mm (0.8622 0.8701 in) ex. 18.9 19.1 mm (0.7441 0.7520 in) in. 1.6 2.4 mm (0.0630 0.0945 in) ex. 1.6 2.4 mm (0...

  • Page 66

    Maintenance specifications model piston size “d” 55.945 55.960 mm (2.2026 2.2031 in) measuring point 5 mm (0.197 in) (from bottom line of piston skirt) - - - - - - - - h d piston-to-cylinder clearance 0.04 0.06 mm (0.0016 0.0024 in) oversize: 2 n d 56.5 mm (2.22 in) 4 t h 57.0 mm (2.24 in) ring: sec...

  • Page 67

    Maintenance specifications model main journal oil clearance bearing size no. Color code clutch: friction plate thickness x quantity wear limit clutch plate thickness x quantity warp limit clutch spring free length x quantity clutch spring minimum length clutch housing thrust clearance clutch release...

  • Page 68

    Maintenance specifications model lubrication system: oil filter type oil pump type tip clearance side clearance bypass valve setting pressure relief valve operating pressure cooling system: radiator core size width height thickness radiator cap opening pressure reservoir tank capacity to full level ...

  • Page 69

    Maintenance specifications model lubrication chart: pressured feed splashed nozzle main journal bearing main journal bearing oil pan lightening sequence: crankcase (upper) crankcase (lower) 8 mm bolt: 24 nm (2.4 m-kg, 17 mm bolt: 12 nm (1.2 m-kg, 8.7 2-9.

  • Page 70

    Maintenance specifications torque part to be tightened camshaft cap cylinder head spark plug cylinder head cover blind plug (sand) blind plug (water) connecting rod cam chain sprocket cam chain tensioner cam chain guide (intake) cam chain tensioner end pipe stopper thermostat housing assembly thermo...

  • Page 71

    Maintenance specifications chassis steering system: steering bearing type taper roller bearing front suspension: front fork travel 130 mm (5.12 in) front spring free length 412 mm (16.2 in) 408 mm (16.1 in) collar length 160 mm (6.3 in) spring rate: k l 4.4 n/mm (0.5 kg/mm, 25.2 k2 6.6 n/mm (0.7 kg/...

  • Page 72

    Maintenance specifications model disc brake: dual disc outside diameter x thickness pad thickness inner 5.5 mm (0.22 in) 0.5 mm (0.02 in) pad thickness outer 5.5 mm (0.22 in) 0.5 mm (0.02 in) . . . . : master cylinder inside diameter caliper cylinder inside diameter: brake fluid type rear disc brake...

  • Page 73

    Maintenance specifications part to be tightened thread size tightening torque n m kg lb front axle and outer tube 1.5 58 5.8 42 rear axle and nut 1.5 107 10.7 77 handlebar crown and inner tube x 1 . 2 5 2 6 2.6 1 9 handlebar crown and steering stem m22 x 1.0 1 1 0 11.0 brake caliper (front/rear) 1.2...

  • Page 74

    Maintenance specifications electrical model voltage: ignition system: ignition timing (b.T.D.C.) advanced timing (b.T.D.C.) advancer type 3bf: 0 1 2 3 4 5 6 7 8 9 1 0 11 1 2 1 3 1 4 15 engine speed t.C.I.: pickup coil resistance (color) t.C.I. Unit/manufacturer ignition coil: model/manufacturer mini...

  • Page 75

    Maintenance specifications model electrical starter system: constant mesh type starter motor: model/manufacturer sm-7/m output armature coil resistance at 20°c brush overall length 11 mm (0.43 in) 5 mm (0.20 in) spring force 540 660 g (19.05 23.28 commutator dia. 23 mm (0.91 in) wear limit 22 mm (0....

  • Page 76

    General torque specifications general torque this chart specifies torque for standard fasteners with standard i.S.O. Pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid tighten fastener assemblies in a crisscross ...

  • Page 77

    Lubrication point and grade of lubricant lubrication point and grade of lubricant engine lubrication point i symbol oil seal lip o-ring bearing piston surface piston pin cylinder head bolt crankshaft pin crankshaft journal connecting rod bolt/nut camshaft cam lobe/journal valve stem (in, valve stem ...

  • Page 78

    Lubrication point and grade of lubricant c h a s s i s lubrication point steering bearing (upper/lower) wheel bearing/axle front wheel oil seal (right/left) rear wheel oil seal , clutch hub oil seal clutch hub fitting area rear brake pedal shaft change pedal side stand sliding surface tube guide (th...

  • Page 79

    Lubrication diagram lubrication diagram oil filter oil strainer oil pump.

  • Page 80

    Coolant diagram radiator water pump thermostat housing @thermostatic valve radiator cap 5 2-20

  • Page 81

    Cable routing cable routing band throttle cables brake hose cable insert the clutch cable into the frame inner hole. 2-21.

  • Page 82

    Cable routing cable routing (2) brake hose clamp pass the handlebar switch lead (left) behind the inner tube •i to headlight unit to flasher light (left) to flasher light (right).

  • Page 83

    Cable routing cable routing (3).

  • Page 84

    Cable routing @speedometer assembly headlight unit @ h o r n @brake hose clamp @front brake caliper (left) speedometer cable @clutch cable @ignition coil lead (left) @starter cable switch @air vent hose @rectifier/regulator lead @ b a n d @canister (for california only) to handlebar switch (left) to...

  • Page 85

    Cable routing cable routing (4) 2-26.

  • Page 86

    Cable routing @brake hose (right) ?? To radiator cap assembly @ c l a m p ? Pass the spark lead and fan motor lead along the air ignition coil (right) guide groove. @spark lead (right) ? Pass the recovery tank hose on the fuel tank bracket. @air guide ? Pass on the inside of the water pipe the carbu...

  • Page 87

    Cable routing cable routing (5).

  • Page 88

    Cable routing fuel pump relay ignition coil (right) tarter motor @ c l a m p rear brake switch lead @breather hose (recovery tank) rear brake master cylinder @main fuse @recovery tank relay digital ignitor unit diode assembly @rectifier/regulator @ b a t t e r y @battery terminal @canister (for cali...

  • Page 89

    Introduction/maintenance intervals chart periodic inspections and adjustments introduction this chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longe...

  • Page 90

    Maintenance intervals chart j general maintenance/lubrication jo. 1 2 3” 4 5 ” 6 7 8 ” 9 0 odo 2 km 3 8,200 meter readir 19,000 krr 19 12,000 mi initial ,000 km 1 0 3 25,000 25 ? ? ? 1 7,000 km or 7 months 4,400 31,000 kn 31 19,600 mi 0 item oil or sae type “se” motor oil type “se” motor oil ethylen...

  • Page 91

    Initial odometer readings 1 2 3 j o . Item remarks 1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000 i or or or or or or 1 month 7 months 13 months 19 months 25 months 31 months (600 (4,400 (8,200 check operation yamaha chain and cable side stand and lube or sae 0 0 0 0 0 pivot lubricate. 1 mot...

  • Page 92

    Cowlings removal and installation cowling removal and installation removal 1. Remove: ?? Lower cowling (left) 2. Remove: ?? Lower cowling (right) 3. Remove: ?? Center cowling (left) 4. Remove: ?? Center cowling (right).

  • Page 93

    5. Remove: ?? Rear view mirrows (left and right) 9. Remove: upper cowling.

  • Page 94

    Cowlings removal and installation 10. Remove: ?? Seat note: to open the seat lock, insert the key in the lock and turn it clockwise. 11. Remove: ?? Top cover installation reverse the “removal” procedure. Note the following points. 1. Install: ?? Seat note: ?? Make sure that the seat is securely fitt...

  • Page 95

    Exup cable adjustment (for engine exup cable adjustment (for california 1. Remove: lower cowling (left) ?? Seat refer to the “cowlings removal and installation removal” section. 2. Remove: ?? Valve cover 3. Turn on the main switch. Note: if does not operate exup servo motor, refer to the “yamaha exh...

  • Page 96

    Valve clearance adjustment j 7. Install: valve cover i bolts (valve cover): 10 nm (1.0 m-kg, 7.2 valve clearance adjustment the engine must be cool before servicing the valve clearance. Note: measure and adjust valve clearance when piston is at tdc on compression stroke. Removal 1. Remove: ?? Lower ...

  • Page 97

    Valve clearance adjustment j 5. Remove: ?? Radiator cap 6. Drain: cooling system refer to the ‘“coolant replace. Ment” section. 7. Disconnect: ?? Fan motor coupler 8. Disconnect: ?? Hose (radiator inlet) ?? Hose (radiator 9. Remove: ?? Radiator 10. Remove: ?? Spark plug leads ?? Cylinder head cover ...

  • Page 98

    Valve clearance adjustment ex in , , uote: t.D.C. Can be found when the : a m l o b e s a r e a p a r t f r o m e a c h o t h e r , a s measure the valve clearance using thickness gauge . Out of specification+ adjust valve clearance. Intake valve (cold): 0.11 0.20 mm (0.004 0.008 in) exhaust valve (...

  • Page 99

    Valve clearance adjustment j refer to the “engine disassembly cam- shaft and cylinder head p r o c e d u r e in the chapter 4. Fasten the wire to the cam chain to prevent it from falling into the crankcase. 2. Remove: valve lifter ?? Pad use valve lapper record the installed pad number. Note: ?? Pla...

  • Page 100

    Valve clearance adjustment j example: installed pad number = 148 (1.48 mm) rounded off digit = 150 note: pads can only be selected in 0.05 mm (0.002 in) increments. ?? Locate the “rounded off pad number” on the chart, and then find the measured valve clearance. The point where these coordinates inte...

  • Page 101

    Valve clearance adjustment intake 235 240 220 225 225 230 235 valve clearance (cold): 0.11 0.20 mm (0.004 0.008 in) example: installed is 170 measured clearance is 0.24 mm (0.009 in) replace 170 pad with 180 pad exhaust 155 160 175 180 185 190 195~200~205~210~215 180118511901195 200 205 205 215 220 ...

  • Page 102

    Valve clearance adjustment note: ?? Refer to the “engine assembly and ad- j u s t m e n t c y l i n d e r h e a d a n d camshaft” section in the chapter 4. ?? Turn the carnkshaft counterclockwise several turns for the installed parts to settle into the correct position. 6. Measure: valve clearance v...

  • Page 103

    Carburetor synchronization i 3. Recheck: ?? Align the matching marks . 4. Install: ?? Chain guide (upper) ?? Chain guide (exhaust side) bolts (chain guide): 10 nm (1.0 m-kg, 7.2 i 5. Install: ?? Cylinder head cover bolts (cylinder head cover): 10 nm (1.0 m-kg, 7.2 ft-lb) 6. Fill: ?? Cooling system c...

  • Page 104

    Carburetor synchronization j 1. Remove: cowlings seat refer to the “cowling removal and installation removal” section. 2. Remove: ?? Fuel tank r e f e r t o t h e “ c a r b u r e t o r r e - moval” section in the chapter 6. 3. Remove: *vacuum plugs 4. Install: vacuum gauge ?? Sub tank vacuum gauge: ...

  • Page 105

    Idle speed adjustment j *racing the engine for less than a second, two or three times, and check the syn- chronization again. Vacuum pressure at idle speed: 21.33 0.6 (160 5 6.30 0.2 i vacuum synchronous difference: 1.33 (10 0.4 the above steps to synchronize carburetor no. 4 to carburetor no. 3 by ...

  • Page 106

    Throttle cable free play adjustment t h r o t t l e c a b l e f r e e p l a y a d j u s t - m e n t note: before adjusting the throttle cable free play, the engine idle speed should be adjusted. 1. Check: ?? Throttie cable free play out of specification adjust. Throttle cable free play (throttle gri...

  • Page 107

    Spark plug inspection throttle cable free play (throttle grip) : i 2 5 mm (0.08 0.20 in) ?? Tighten the locknut . I note: normally, once the throttle cable length adjuster (carburetor) is properly set; the only adjustment required is maintenance of free play at the throttle cable length adjuster (th...

  • Page 108

    Ignition timing checks j 4. Measure: *spark plug gap out of specification regap. Use a wire gauge. Spark plug gap: 0.7 0.8 mm (0.028 0.032 in) 5. Tighten: plug note: before installing a spark plug, clean the gasket surface and plug surface. Spark plug: 13 nm (1.3 9.4 note: if a torque wrench is not ...

  • Page 109

    Compression pressure measurement j 4. Warm up the engine and allow it to idle at the specified speed. Engine idle speed: 1,250 1,350 5. Check: ignition timing visually check the crankcase end is within the firing range on the magneto. Out of firing range check pickup as- sembly. Note: ignition timin...

  • Page 110

    Compression pressure measurement over the engine with the electric starter (be sure the battery is fully charged) with the throttle wide open until the compression reading on the gauge stabilizes. *check readings with specified levels (see chart). Compression gauge: yu-33223 compression pressure (at...

  • Page 111

    Engine oil level inspection/ engine oil replacement 0 5 10 15°c engine oil level inspection 1. Place the motorcycle on its centerstand and warm up the engine for several minutes. Note: position motorcycle straight up when checking oil level, a slight tilt to the side can produce false readings. 2. S...

  • Page 112

    Engine oil filter replacement 7. Fill: a caution: do not allow foreign material to enter the crankcase. Periodic oil change: 2.7 l (2.4 imp 2.9 us recommended engine oil: at 5°c (40” or higher: yamalube oil or sae type se motor oil at 15°c (60°f) or lower: sae type se motor oil 8. Install: oil fille...

  • Page 113

    Engine oil filter replacement 6. Remove: oil filter @spring 7. Check: o-ring cracks/damage replace. 8. Install: filter (new) ?? Shim spring to oil filter cover. Be sure the o-ring is positioned properly. 9. Install: oil filter cover bolt (oil filter cover): 15 nm (1.5 m-kg, 11 ft-lb) i note: m e s h...

  • Page 114

    Clutch adjustment j clutch adjustment 1. Check: ?? Clutch lever free play out of specification adjust. 2 3 mm (0.08 0.12 in) 2. Adjust: ?? Clutch lever free play adjustment steps: ?? Loosen the locknut , ?? Turn the adjuster in or out until the specified free play is obtained. Turn in free play is i...

  • Page 115

    Air filter cleaning/carburetor joint inspection/fuel line inspection j air cleaning 1. Remove: ?? Seat ?? Top cover r e f e r t o t h e “ c o w l i n g r e m o v a l a n d i n s t a l l a t i o n r e m o v a l ” section. 2. Remove: ?? Air filter case cover ?? Air filter element a the engine should n...

  • Page 116

    Crankcase ventilation hose inspection/ exhaust system inspection 2. Inspect: ?? Fuel pipes cracks/damage replace. ?? Fuel filter contamination/damage replace. Note: drain and flush the fuel tank if abrasive damage to any components is evident. Crankcase ventilation hose inspec- tion 1. Remove: seat ...

  • Page 117

    Coolant level inspection/coolant replacement 3. Tighten: nuts (exhaust pipe) : 10 nm (1.0 7.2 bolt (muffler/rear footrest) : 20 nm (2.0 m-kg, 14 bolt (muffler star) : (for california only) 20 nm (2.0 14 lb) coolant level inspection 1. Remove: seat cowling 2. Inspect: coolant level (reservoir tank lo...

  • Page 118

    Coolant replacement place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. 1. Remove: ...

  • Page 119

    Coolant replacement j coolant filling steps: the coolant into the radiator until the radiator is full. ?? Start the engine (coolant level decreases.) caution: always check coolant level, and check for coolant leakage before starting engine. ?? Add the coolant while engine is running. ?? Stop the eng...

  • Page 120

    Front brake adjustment/rear brake adjustment chassis front brake adjustment 1. Loosen: ?? Adjuster locknut 2. Adjust: ?? Free play turn the adjuster until the free play is within the specified limits. Turn in free play is decreased. Turn out free play is increased. Front brake lever free play: 2 5 m...

  • Page 121

    Brake fluid inspection/brake pad inspection rear brake light switch adjustment brake fluid inspection inspect: *brake fluid level fluid at lower level replenish. Front brake fluid lower level ?? Use only designated quality brake fluid to avoid poor brake performance. With same type and brand of brak...

  • Page 122

    Brake hose inspection/drive chain slack check/ air bleeding 2. Adjust: *rear brake light switch hold the switch body with your hand so it does not rotate and turn the adjuster note: proper adjustment is achieved when the brake light comes on just before the brake begins to take effect. Brake hose in...

  • Page 123

    Drive chain slack adjustment f r o n t r e a r place the other end of the tube into a con- tainer. Slowly apply the brake lever or pedal sever- al times. Pull the lever in or push down on the pedal. Hold the lever or pedal in position. Loosen the bleed screw and allow the lever or pedal to travel to...

  • Page 124

    Drive chain slack adjustment 3. Remove: *cotter pin 4. Loosen: ?? Nut (rear axle) ?? Locknut 5. Adjust: *chain slack turn the adjuster in or out. Turn in turn out chain slack is decreased. Chain slack is increased. Note: there are marks on each side of rear arm and on each chain puller; use them to ...

  • Page 125

    Drive chain lubrication/steering head inspection drive chain lubrication the chain consists of many parts which work against each other. If the chain is not maintained properly, it will wear out rapidly, therefore, form the habit of periodically servicing the chain. This service is especially necess...

  • Page 126

    Steering head inspection j 6. Remove: ?? Lock washer ring nut (upper) *washer 7. Remove: ?? Front fork refer to the “front fork val” section in the chapter 7 8. Tighten: ?? Ring nuts (lower and upper) ring nuts tightening steps: note: s e t t h e t o r q u e w r e n c h t o t h e r i n g n u t wrenc...

  • Page 127

    Steering head inspection if steering is loosen the ring nut so that there is no free play on bearing. If steering is loosened, repeat the adjustment steps. Install the washer . Install the ring nut (upper) . Note: the tapered side of ring nut must face down- ward. Finger tighten the ring nut then al...

  • Page 128

    Front fork inspection/ rear shock absorber adjustment front fork inspection securely support the motorcycle so there is no danger of it falling over. 1. Place the motorcycle on a level place. 2. Check: ?? Inner tube scratch/damage replace. ?? Oil seal excessive oil leakage replace. T h e m o t o r c...

  • Page 129

    Tire inspection tire inspection measure: ?? Tire pressure out of specification adjust. Tire inflation pressure should be checked and adjusted when the temperature of the tire euqals the ambient air temperature. Tire in- flation pressure must be adjusted according to total weight of cargo, rider, pas...

  • Page 130

    Wheel inspection ?? After extensive tests, the tires mentioned below have been approved by yamaha motor co., ltd. For this model. No guarantee for handling characteristics can be given if tire combinations other than what is approved are used on this motorcycle. The front and rear tires should be of...

  • Page 131

    Cable inspection/lubrication j cable inspection 1. Inspect: @throttle cables ?? Cable sheaths ?? Clutch cable ?? Starter cable check for damage to the cable insulation. Corrosion/damage replace. Obstruction reroute. Unsmoothness lubricate. Lubrication throttle cables/clutch cable/starter cable cable...

  • Page 132

    Battery inspection electrical battery inspection 1. Remove: seat refer to the “cowling removal an installation removal” section. J 2. Inspect: fluid level should be between upper and lower marks. Incorrect+ refill. Refill with water only; tap water con tains minerals harmful to a battery. 3. Connect...

  • Page 133

    Battery inspection replace the battery if: ?? Battery voltage will not rise to a specific value or bubbles fail to rise even after many hours of charging. ?? Sulfation of one or more cells occurs, as in- dicated by the plates turning white, or an ac- cumulation of material exists in the bottom of th...

  • Page 134

    Fuse inspection/headlight beam adjustment j fuse inspection the fuse panel is located under the seat. 1. Inspect: ?? Fuses defective+ replace. Blown fuse inspect circuit. Install new fuses of proper amperage. Spare fuses description amperage quantity main 30a 1 headlight 1 signal ignition 1 1 reserv...

  • Page 135

    Headlight bulb replacement j 2. Adjust: @vertical adjustment: to raise the beam, turn the adjusting screw clockwise. To lower the beam, turn the screw counterclockwise. Headlight bulb replacement 1. Remove: ?? Headlight cover 2. Disconnect: ?? Headlight bulb coupler 3. Remove: ?? Headlight bulb cove...

  • Page 136

    Tail/brake bulb replacement 7. Connect: ?? Headlight bulb coupler 8. Install: ?? Headlight cover. Tail/brake bulb replacement 1. Remove: seat cowling 2. Remove: ?? Bulb socket turn the bulb socket approximately counterclockwise. 3. Remove: ?? Defective bulb 4. Install: ?? Bulb socket seat cowling se...

  • Page 137: Engine Overhaul

    Engine removal engine overhaul engine removal note: it is not necessary to remove the engine in order to remove the following components: ?? Cylinder head ?? Cylinder piston . Clutch water pump ?? A.C. Magneto lower cowling, center cowling, upper cowling and top cover 1. Remove: ?? Lower cowlings (l...

  • Page 138

    Engine removal radiator 1. Disconnect: ?? Hose (radiator inlet) ?? Hose (radiator outlet) 2. Disconnect: ?? Fan motor coupler 3. Remove: ?? Radiator assembly cover the cylinder head cover and the fender with rugs to prevent a scratching. 4. Disconnect: ?? Pipes (left and right) 5. Remove: ?? Pipes (...

  • Page 139

    Engine disassembly muffler assembly (for california only) 1. Remove: ?? Nuts (exhaust pipe) ?? Cowling stays ?? Bolt (muffler bracket) 2. Remove: ?? Bolt (muffler stay) 3. Loosen: ?? Lock nut ?? Adjuster 4. Remove: cover ?? Clips 5. Remove: ?? Bracket ?? Housing ?? Gasket (left side) ?? Shaft arm 4-...

  • Page 140

    Engine removal clutch cable and drive chain 1. Remove: ?? Shift arm ?? Crankcase cover (left) 2. Remove: ?? Clutch cable 3. Straighten: ?? Lock washer tab 4. Remove: ?? Drive sprocket leads 1. Straighten: clamp 2. Disconnect: ?? Battery leads note: disconnect the negative lead first..

  • Page 141

    Engine removal 3. Disconnect: ?? Lead (starter motor) 4. Remove: cover 5. Disconnect: ?? Coupler (oil level neutral switch) ?? Coupler (a.C. Generator) ?? Coupler (sidestand switch) 6. Remove: ?? Spark plug leads engine removal 1. Remove: lever 2. Place a suitable stand under the engine. 3. Remove: ...

  • Page 142

    Engine removal 4. Remove: ?? Bolt (engine-mounting lower) ?? Bolt (engine-mounting upper) ?? Collars 5. Remove: ?? E n g i n e a s s e m b l y . From right side. 4-6.

  • Page 143

    Engine disassembly engine disassembly cylinder head cover, camshaft and cylinder head note: with the engine mounted, the cylinder head cover, camshaft and cylinder head can be maintained by removing the following parts. ?? Lower cowlings (left and right) ?? Center cowlings (left and right) ?? Seat ?...

  • Page 144

    Engine disassembly 5. Remove: ?? Cam chain tensioner ?? Gasket (cam chain tensioner) 6. Remove: ?? Union bolts ?? Oil delivery pipe 7. Remove: ?? Cam chain guide (upper) ?? Cam chain guide (exhaust side) note: ?? Select either of the two procedures explained in this manual, as follows: ?? Procedure ...

  • Page 145: Eng

    Engine disassembly eng procedure disconnect: ?? Cam chain use the cam chain cutter . Cam chain cutter: p/n ym-01112 2. Remove: ?? Rubbers (camshaft cap) 3. Remove: ?? Nuts (cylinder head) use the hexagon wrench 6 mm (0.24 4. Remove: ?? Cylinder head ?? Gasket (cylinder head) dowel pins 5. Go to “cyl...

  • Page 146

    Engine disassembly 3. Remove: ?? Nuts (cylinder head) use the hexagon wrench 6 mm (0.24 in)@. Note: ?? Loosen the nuts in their proper loosening sequence. ?? Follow numerical order shown in photo. Start by loosening each nut turn until all are loose. 4. Remove: ?? Cylinder head note: remove the cyli...

  • Page 147

    Engine disassembly 1. Remove: water pipe o-rings ?? Cylinder 2. Remove: ?? Gasket (cylinder) ?? Dowel pins 3. Mark: pistons with the piston number designations as shown. 4. Remove: ?? Circlips (piston pin) note: before removing the piston pin circlip, cover the crankcase with a clean rag to prevent ...

  • Page 148

    Engine disassembly starter clutch note: with the engine mounted, the starter clutch can be maintained by removing the following parts. ?? Lower cowling (right) ?? Starter clutch cover 1. Remove: clutch cover ?? Gasket (starter clutch cover) ?? Dowel pens. 2. Remove: ?? Bolt (starter clutch) ?? Washe...

  • Page 149

    Engine disassembly clutch note: with the engine mounted, the starter clutch can be maintained by removing the following parts. ?? Lower cowling (right) ?? Crankcase cover (right) 1. Remove: ?? Crankcase cover (right) ?? Gasket (crankcase cover) ?? Dowel pins note: working in a crisscross pattern, lo...

  • Page 150

    Engine disassembly 6. Remove: (clutch boss) ?? Lock washer boss washer 7. Remove: ?? Spacer ?? Bearing note: install the 5 mm (0.2 in) screw on the spacer then remove the spacer with pulling out screw. Remove: housing 9. Remove: ?? Thrust washer *collar a.C. Magneto note: with the engine mounted, th...

  • Page 151

    Engine disassembly 1. Remove: (magneto) ?? Washer note: hold the magneto to loosen the nut by the universal rotor holder universal rotor holder: p/n yu-01235 i 2. Attach: rotor puller p/n ym-01080 3. Remove: 4. Remove: ?? Starter coil assembly ?? Pickup coil key water pump note: with the engine moun...

  • Page 152

    Engine disassembly oil pump and shift shaft note: with the engine mounted, the oil pump and shift shaft can be maintained by removing the following parts. ?? Lower cowling (right) ?? Crankcase cover (right) ?? Clutch housing 1. Remove: pump assembly 2. Remove: (oil pump assembly) ?? Dowel pin 4-16.

  • Page 153

    Engine disassembly 3. Remove: ?? Shift shaft assembly oil pan and oil strainer note: with the engine mounted, the oil pan and oil strainer can be maintained by removing the following parts. ?? Lower cowlings (left and right) ?? Muffler assembly stay 1. Disconnect: ?? 0il level switch lead ?? Neutral...

  • Page 154

    Engine disassembly 4. Remove: oil strainer cover ?? Relief valve 5. Remove: ?? Oil strainer assembly starter motor note: with the engine mounted, the starter motor, can be maintained by removing the following parts. Seat ?? Top cover ?? Fuel tank 1. Remove: ?? Starter motor ?? Crankcase ventilation ...

  • Page 155

    Engine disassembly a 3. Remove: ?? Bolts (crankcase) note: ?? Remove the bolts starting with the highest numbered one. E m b o s s e d n u m b e r s i n t h e c r a n k c a s e designate the crankcase tightening sequence. 4. Place the engine upside down. 5. Remove: ?? Crankcase (lower) use a soft ha...

  • Page 156

    Engine disassembly 4. Remove: ?? Shift cam crankshaft 1. Remove: ?? Crankshaft assembly 2. Remove: ?? Main journal bearing note: identify each main journal bearing position very carefully so that it can be reinstalled in its original place. 4. Remove: ?? Neutral switch 4 - 2 0

  • Page 157

    Engine disassembly 5. Remove: ?? Breather hose baffle plate valve pad and valve note: with the engine mounted, the valve pad and valve can be maintained by removing the following parts. ?? Lower cowlings (left and right) @center cowlings (left and right) ?? Fuel tank ?? Carburetor ?? Radiator @gener...

  • Page 158

    Engine disassembly 2. Check: valve sealing leakage at valve seat inspect the valve face, valve seat and valve seat width. Refer to the “inspection and repair valve seat” section. Note: before removing the internal parts (valve, valve spring, spring seat, etc.) of the cylinder head, the valve sealing...

  • Page 159

    Engine disassembly connecting rod 1. Remove: ?? Connecting rod ?? Connecting rod bearing inner rotor (oil pump) 1. Remove: ?? Pump housing 2. Remove: rotor inner rotor ?? Washer pump cover ?? Pump shaft.

  • Page 160

    Inspection and repair inspection and repair cylinder head 1. Eliminate: ?? Carbon deposit (from combustion chamber) use rounded scraper. Note: do not use a sharp instrument and avoid - - ing or scratching: ?? Spark plug threads ?? Va ive seat 2. Inspect: ?? Cylinder head scratches/damage replace. 3....

  • Page 161

    Inspection and repair valve 1. Inspect: valve face end wear/pitting reface. Out of specification replace. Face width : 1.6 2.4 mm (0.0630 0.0945 in) seat width : 0.9 1.1 mm (0.0354 0.0433 in) 1.6 mm (0.063 in) margin thickness : 0.6 0.8 mm (0.0236 0.0315 in) 0.4 mm (0.0157 in) 2. Measure: valve stem...

  • Page 162

    Inspection and repair 302-019 302-020 4. Measure: valve stem out of specification replace. Maximum 0.02 mm (0.0008 in) valve guide note: ?? Always replace the valve guide if the valve is replaced. ?? Always replace the oil seal if the valve is removed. Inspect: ?? Valve guide wear/oil leakage into c...

  • Page 163

    Inspection and repair 302 027 302 017 valve seat 1. Clean: ?? Valve face ?? Valve seat remove carbon deposit. 2. Inspect: ?? Valve seat pitting/wear reface valve seat. 3. Measure: ?? Valve seat width out of specification reface valve seat. Valve seat width intake 0.9 1.1 m m (0.035 0.043 in) exhaust...

  • Page 164

    Inspection and repair a remove just enough material to achieve satis- factory seat. When twisting cutter, keep and even downward pressure to prevent chatter marks. Cut sections as follows i section i cutter i b 45” c 60” valve seat refacing steps: valve face indicates that valve seat is centered on ...

  • Page 165

    Inspection and repair 302 017 302 024 302 017 5. Lap: valve face valve seat note: after refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Valve lapping steps: ?? Apply a coarse lapping compound to the valve face. A caution: be sure no com...

  • Page 166

    Inspection and repair 302 006 ?? Press the valve through the valve guide and onto the valve seat to make a clear pattern. The valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. Valve spring 1. Measure: ?? Valve spring free length out of specificat...

  • Page 167

    Inspection and repair valve lifter 1. I nspect: valve lifters scratches/damage replace both lifters and camshaft case. Camshaft, c a m c h a i n , a n d c a m sprocket camshaft 1. I nspect : lobes pitting/scratches/blue discoloration replace. 2. Measure: lobes use the micrometer. Out of specificatio...

  • Page 168

    Inspection and repair 3. Install: ?? Dowel pins ?? Camshaft caps 4. Tighten: ?? Camshaft cap bolts bolts (camshaft cap) : 10 nm (1.0 7.2 note: ?? Tighten the camshaft caps in a crisscross pattern from innermost to outer caps. ?? Do not turn the camshaft when measuring clearance with the 5. Remove: ?...

  • Page 169

    Inspection and repair cam chain 1. Inspect: chain chain stretch/cracks replace. Cam sprockets 1. Inspect: *cam sprockets wear/damage replace. Cam chain guide 1. I ?? Cam chain guide (upper) ?? Cam chain guide (exhaust side) ?? Cam chain guide (intake side) wear replace. Cam chain tensioner 1. Check:...

  • Page 170

    Inspection and repair 4-34 piston-to-cylinder clearance measurement steps: first step: measure the cylinder bore “c” with a cylinder bore gauge. Note: measure the-cylinder bore “c” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements. Standard wear limit c...

  • Page 171

    Inspection and repair 2 0 m m ?? If out of specification, rebore or replace cylinder, and replace piston and piston rings as a set. Piston-to-cylinder clearance: limit: 0.15 mm (0.006 in) piston ring and piston pin piston ring 1. Measure: ?? Side clearance use the feeler gauge out of specification r...

  • Page 172

    Inspection and repair end gap (installed) : standard t o p ring 0.15 0.30 mm (0.0059 0.0118 in) 2nd ring 0.15 0.30 mm (0.0059 0.0118 in) oil control 0.2 0.8 mm (rails) (0.0079 0.0315 in) piston ring oversize and 2nd piston ring oversize top and middle ring size is stamped on the top of ring. I overs...

  • Page 173

    Inspection and repair 5. Check: ?? Free play when the pin is in place in the piston. Free play replace the piston pin and/or piston. Crankshaft and connecting rod crankshaft measure: ?? Use the v-blocks and dial gauge. Out of specification replace. Out of specification replace. Limit: 0.03 mm (0.001...

  • Page 174

    Inspection and repair 1 5. Install: *bearings into the lower crankcase. ?? Crankcase (lower) 6. Tighten: tighten to full torque in torque sequence cast on the crankcase. Bolt : 24 nm (2.4 17 bolt : 12 nm (1.2 8.7 7. Remove: reverse assembly procedure. ?? Crankcase (lower) use care in removing. 8. Me...

  • Page 175

    Inspection and repair connecting rod oil clearance 1. Clean all parts thoroughly. 2. Install: ?? Connecting rod bearings into the connecting rod and cap. 3. Attach: onto the crank pin. 4. Install: ?? Connecting rod ?? Connecting rod cap note: ?? Be sure the “y” marks on the connecting rods face towa...

  • Page 176

    Inspection and repair j2 j4 j6 p2 p4 7. Remove: ?? Connecting rod cap use care in removing. 8. Measure: ?? Width of out of specification replace the bearings and/or replace the crankshaft if necessary. Connecting rod oil clearance: 0.043 0.0066 mm (0.0017 0.0026 in) crankshaft main journal and conne...

  • Page 177

    Inspection and repair example 1: selection of the main journal bearings: the crankcase and crankshaft sizes are no. 4 and no. 1, respectively, the bearing size no. Is: bearing size no. R crankcase no. Crankshaft no. 4 1 = 3 (brown) bearing color code no. 1 b l u e example 2: selection of the connect...

  • Page 178

    Inspection and repair 2. Lubricate: inner rotors outer rotors oil seal ?? Pump shaft sae motor oil 3. Install: reverse removal procedure. A l i g h n t h e p i n s i n t h e p u m p s h a f t a n d t h e groove on the inner rotors dualing assembly. 4. Check: oil pump operation with a finger. Unsmoot...

  • Page 179

    Inspection and repair starter clutch 1. Check: ?? Roller operation push the roller to arrow direction. Unsmooth operation replace starter clutch. 2. Inspect: idle gear teeth drive gear teeth burrs/chips/roughness/wear replace. 3. Inspect: ?? Contacting surfaces pitting/wear/damage replace. 4. Check ...

  • Page 180

    Inspection and repair clutch clutch housing 1 . Inspect : ?? Dogs on the housing cracks/wear/damage deburr or replace. ?? Clutch housing bearing chafing/wear/damage replace. Note: wear on the friction plate dogs of the clutch housing will cause an erratic operation. Clutch boss 1 . Inspect : ?? Clut...

  • Page 181

    Inspection and repair 2. Inspect: ?? Pressure plate damage replace. Push rod 1. I nspect : r o d 1 @push rod 2 wear/cracks/damage replace. Push lever assembly and boll screw housing 1. I nspect : ?? Push lever assembly unsmooth replace. 2. Measure: ?? Push rod use the v-blocks and dial gauge. Out of...

  • Page 182

    Inspection and repair transmission shift fork 1. Inspect: ?? Shift fork cam follower ?? Shift fork wear/chafing/bends/damage replace. 2. Check: ?? Shift fork movement on its guide bar . Unsmooth operation replace the fork and/guide bar. Shift cam 1. Inspect: ?? Shift cam grooves wear/damage/scratche...

  • Page 183

    Inspection and repair relief valve and pipe 1. Check: ?? Relief valve body ?? Cover *spring ?? O-ring damage/wear replace. 2. Check: ?? Oii pipe damage replace. C o m t a m i n a t i o n w a s h a n d b l o w o u t the passage. 3. Check: ?? Water pipe ?? Water jacket joint ?? O-rings damage replace....

  • Page 184

    Inspection and repair yamaha exhaust variable (for california only) 1. I : ?? Shaft arm wear/cracks/damage replace. 2. Inspect: wear replace..

  • Page 185

    Engine assembly and adjustment m a engine assembly and adjustment inner rotor (oil pump) 1. Install: ?? Pump shaft pump cover inner rotor *pin ?? Outer rotor note: insert the inner rotor into the outer rotor then with the pump shaft dowel pin in the inner rotor slit. 2. Install: ?? Pump housing conn...

  • Page 186

    Engine assembly and adjustment crankshaft @crankshaft ournal bearing @connecting rod assembly @connecting rod bolt @connecting rod bearing @ n u t.

  • Page 187

    Engine assembly and adjustment 5. Install: @connecting rods rod caps note: stamped “y” mark on the connecting rods should face towards the left side of the crankcase. ?? Be sure the letter on both components align to form a perfect character. 6. Install: @connecting rod bolts align the bolt head and...

  • Page 188

    Engine assembly and adjustment 2. Install: valve spring seat ?? Oil seal 3. Install: valve note: apply molybdenum disulfide oil. 4. Install: valve spring note: install springs with wider-gapped coils facing upwards, as shown. Larger @smaller pitch 5. Attach: ?? Valve spring compressor ?? Attachment ...

  • Page 189

    Engine assembly and adjustment 8. Install: pads note: apply molybdnum disulfide oil. 9. Install: lifters crankshaft 1. Install: ?? Oil baffle plate ?? Breather hose oil baffle plate bolts: 10 nm (1.0 m-kg, 7.2 2. Install: ?? Neutral switch assembly 3. Install: ?? Cam chain guide (intake side) ?? O-r...

  • Page 190

    Engine assembly and adjustment crankcase @crankcase assembly level window @crankcase ventilation hose mm bolt o-ring 8 mm bolt mm bolt mm bolt mm bolt mm bolt mm bolt 12 nm (1.2 m-kg, 8.7 24 nm (2.4 m-kg, 17.

  • Page 191

    Engine assembly and adjustment transmission main axle 5th pinion gear circlip 3rd pinion gear 6th pinion gear 2nd pinion gear bearing circlip @drive axle wheel gear wheel gear wheel gear wheel gear wheel gear 1st wheel gear @ w a s h e r c use new one.

  • Page 192

    Engine assembly and adjustment 4. Install: ?? Main journal bearing to crankcase (lower) note: apply molybedenum disulfide oil. 5. Install: ?? Cam onto the crankshaft ?? Crankshaft assembly note: stepped crankshaft end should face to the left. *pass the cam chain through the cam chain cavity. Be sure...

  • Page 193: Eng

    Engine assembly and adjustment eng 2. Install: ?? Stopper plate (shift cam) ?? Stopper lever bolts (stopper plate) : 10 nm (1.0 7.2 use bolt (stopper lever) : 10 nm (1.0 7.2 use 3. Install: ?? Circlip to crankcase lower) note: be sure the circlips are inserted into the lower crankcase positioning gr...

  • Page 194

    Engine assembly and adjustment before tightening the crankcase bolts, check the following points: *be sure the gear shifts correctly while turning the shift cam. 2. Tighten: lower crankcase bolt ?? Upper crankcase bolt (follow the proper tightening sequence.) 24 nm (2.4 17 6mmbolt : 12 nm (1.2 8.7 n...

  • Page 195

    I engine assembly and adjustment starter motor 1. Check: (starter motor) damage replace. 2. Install: motor bolt (starter motor) : 10 nm (1.0 m-kg, 7.2 oil pan and oil strainer 1. Install: ?? Oil strainer assembly bolts (oil strainer assembly): 10 nm (1.0 m-kg, 7.2 lb) i 2. Install: ?? Oil strainer c...

  • Page 196

    Engine assembly and adjustment oil pump and shift shaft 1. Install: ?? Shift shaft note: insert the stopper between spring ends. 2. Install: pin *gasket (new) 3. Install: pump assembly note: align the oil pump arrow mark with crank- case arrow mark water pump 1. Install: pump housing bolts (water pu...

  • Page 197

    Engine assembly and adjustment a.C. Magneto magneto coil assembly pickup coil 10 nm (1.0 7.2 st 0.44 at (white -white) pickup coil resistance: 85 at 20°c (68°f) (white/red -white/black) 80 nm (8.0 58 4-61.

  • Page 198

    Engine assembly and adjustment a.C. Magneto 1. Install: ?? Coil assembly ?? Pickup coil *woodruff key bolts coil assembly): 10 nm (1.0 7.2 use screws (pickup coil): 5 nm (0.5 kg, 3.6 note: the tapered portions of the crankshaft and magneto. ?? When installing the magneto, make sure the woodruff key ...

  • Page 199

    Engine assembly and adjustment clutch @primary driven gear @thrust washer clutch boss friction plate @clutch plate pressure plate @clutch spring push rod # 1 @ o - r i n g lock washer @ b o l l @oil seal @push rod @push lever assembly screw housing 1 0 ar thrust washer spacer bearing spring free len...

  • Page 200

    Engine assembly and adjustment clutch 1. Install: *collar washer housing ?? Bearing *spacer ?? Thrust washer boss ?? Lock washer (new) (clutch boss) note: install the bearing and spacer @after installa- tion of the clutch housing . 2. Tighten: (clutch boss) use the universal clutch holder . Note: ho...

  • Page 201

    Engine assembly and adjustment 4. Install: pressure plate be sure the match mark on the clutch boss is aligned with the match mark @on the pressure plate. 5. Install: springs ?? Bolts (clutch spring) bolts (clutch spring) : 6 nm (0.6 m-kg, 4.3 lb) i 6. Install: ?? Dowel pins ?? Gasket (crankcase cov...

  • Page 202

    Engine assembly and adjustment starter clutch starter drive gear i d l e g e a r i d l e g e a r shaft starter clutch assembly starter clutch gear w o o d r u f f k e y w a s h e r 4 - 6 6.

  • Page 203

    Engine assembly and adjustment piston and cylinder @ t o p r i n g @ d o w e l p i n @oil ring (lower) @ c y l i n d e r @ o i l r i n g ( u p p e r ) o-ring @second ring @ g a s k e t ( c y l i n d e r ) @piston pin piston ring @ p i s t o n s i d e c l e a r a n c e top: 0.10 mm (0.004 in) 2 n d :...

  • Page 204

    Engine assembly and adjustment 3. Install: ?? Dowel pins @gasket clutch cover) (new) ?? Stater clutch cover bolts (stater clutch cover): 10 nm (1.0 m-kg, 7.2 i piston and cylinder 1. Install: rings note: be sure to install rings so that manufacturer’s marks or numbers are located on the top side of ...

  • Page 205

    Engine assembly and adjustment 3. Install: ?? Gasket (cylinder) ?? Dowel pins 4. Lubricate: pistons piston rings ?? Cylinder note: apply a liberal coating of engine oil. 5. Position: offset the piston ring end gaps. Ring end ?? Oil ring end (lower) ring end (upper) ?? 2nd ring end 6. Install: ?? Cyl...

  • Page 206

    Engine assembly and adjustment cylinder head and camshaft cylinder head @ w a s h e r rubber washer gasket (cylinder head cover) @ w a s h e r guide circlip @gasket (cylinder head) head cover @cylinder head assembly 10 nm m-kg, 25 (2.5 nm (1.0 m-kg, 7.2 c use new 4-70

  • Page 207

    Engine assembly and adjustment camshaft @camshaft (intake) @cam chain sprocket valve lifter valve pad valve retainer @spring seat valve spring spring seat oil seal intake valve exhaust valve cam chain tensioner @gasket (cam chain tensioner) @cam chain guide (intake side) @camshaft (exhaust) chain gu...

  • Page 208

    Engine assembly and adjustment cylinder head and camshaft 1. Install: @gasket (cylinder head) (new) ?? Dowel pins note: the gasket “head” mark should face upward. Note: either of the two procedures explained in this manual, as follows: ?? Procedure 1. The cam chain is disconnected connect. @procedur...

  • Page 209

    Engine assembly and adjustment 4. Connect: ?? Cam chain with the chain joint (new). Use the cam chain cutter . Cam chain cutter: p/n ym-01112 note: keep the cam chain as tense as possible on exhaust side. 5. Go to “cam chain tensioner”. Procedure 2. 1. Install: ?? Camshaft case and cylinder head ass...

  • Page 210

    Engine assembly and adjustment ?? Lubricate the camshaft bearing surfaces, cam lobes and cam journals. Molybdeum disulfide oil install the exhaust camshaft first, then install the intake camshaft . ?? Be sure the timing marks on the camshaft face upward. Keep the cam chain as tense as possible on th...

  • Page 211

    Engine assembly and adjustment cam chain tensioner 1. Position: ?? Cam chain exhaust side tense. Intake side slack. 2. Install: ?? Cam chain tensioner cam chain tensioner installation steps: ?? Remove the tensioner end cap bolt and spring. ?? Release the cam chain tensioner one-way cam and push the ...

  • Page 212

    Engine assembly and adjustment 6 . I n s t a l l : ?? Washers (new) ?? Oil delivery pipe ?? Union bolts 7. Install: ?? Dowel pins ?? Generator cover bolts (generator cover): 10 nm (1.0 7.2 i remounting engine when remounting the engine, reverse the removal procedure. Note the following points. 1. In...

  • Page 213

    Engine assembly and adjustment 3. Install: *starter lever bolt (starter lever) : 8 nm (0.8 kg, 5.8 4. Install: ?? Drive chain ?? Drive sprocket ?? Lock washer (new) ?? Nut (drive sprocket) nut (drive sprocket) : 70 nm (7.0 kg, 50 note: adjust the drive chain slack if necessary. 5. Install: *cover (c...

  • Page 214

    Engine assembly and adjustment yamaha exhaust variable valve (for california only) exhaust pipe assembly bracket gasket (exhaust pipe) cables bush @ w a s h e r o i l s e a l pulley gasket valve cover shaft arm gasket (muffler) housing muffler assembly 20 nm (2.0 m-kg, 14 a u s e n e w o n e 1.0 7.2...

  • Page 215

    Engine assembly and adjustment 9. Install (for california only): ?? Shaft arm * g a s k e t io. Install (for california only): ?? Washer ?? Bracket bolts (bracket): 10 nm (1.0 7.2 11. Install (for california only): @cables 12. Adjust (for california only): ?? Cable refer to the “exup cable adjust- m...

  • Page 216

    Engine assembly and adjustment 14. Adjust: cable clutch cable free play: 2 3 mm (0.08 0.12 in) refer to the “clutch section in the chapter 3. 15. Fill: ?? Coolant total amount: 1.0 l (0.9 imp qt, 1.1 us qt) refertothe”coolant replaceme section in the chapter 3. 16. Fill: ?? Engine oil total amount: ...

  • Page 217

    R a d i a t o r cooling system radiator radiator assembly fan motor assembly radiator cap assembly radiator cap radiator cover hose (radiator outlet) @outlet pipe @ o - r i n g @hose (radiator inlet) radiator cap opening pressure: a (0.75 1.05 10.7 14.9 psi) coolant capacity: b 19 l (1.7 imp qt, 2.0...

  • Page 218

    Radiator removal 1. Remove: ?? Lower cowlings (left and right) ?? Side cowlings (left and right) refer to the “cowling removal anc i n s t a l l a t i o n r e m o v a l ” in the chapter 3. 2. Drain: cooling system refer to the”coolant replacement section in the chapter 3. 3. Remove: ?? Muffler assem...

  • Page 219

    6. Remove: ?? Fan motor assembly inspection 1. Inspect: ?? Radiator core obstruction blow out with compressed air through rear of the radiator. Flattened fin repair/replace. 2. Inspect: ?? Hose (radiator inlet) cracks/damage replace. ?? Hose (radiator outlet) cracks/damage replace. Outlet pipe crack...

  • Page 220

    Measurement steps: the cooling system tester and adapter to the radiator cap . Cooling system tester: y u-24460-0 1 adapter: y u-33984 ?? Apply the specified pressure for 10 seconds, and make sure there is no pressure drop. Installation reverse the “removal” procedure. Note the following points. 1. ...

  • Page 221

    Inspection steps: @attach the cooling system tester to the radiator. Cooling system tester: y u-24460-0 1 ?? Apply 100 (1 .O 14 psi) pressure . @measure the indicated pressure with the gauge..

  • Page 222

    Water pump and thermostatic valve water pump and thermostatic valve hose 3 ermostatic cover thermostatic thermostatic housing hose 1 hose 2 pipe 2 @pipe 1 @water jacket joint @water pipe @ o - r i n g @water pump cover @ o - r i n g pump housing o-ring thermostatic valve opening use new one b u s e ...

  • Page 223

    Water pump and thermostatic valve removal 1. Remove: ?? Lower cowlings (left and right) ?? Center cowlings (left and right) seat ?? Top cover refer to the “cowling removal and installation removal” section in the chapter 3. 2. Drain: cooling system refer to replacement” section in the chapter 3. 3. ...

  • Page 224

    Water pump and thermostatic valve 7. Disconnect: ?? Thermo unit lead ?? Thermo switch lead 8. Remove: ?? Thermostatic housing 9. Remove: ?? Thermostatic cover ?? Thermostatic 10. Remove: ?? Shift arm ?? Crankcase cover 11. Remove: ?? Water pipe 5 - 8.

  • Page 225

    Water and thermostatic 12. Remove: pipe water pump cover 13. Remove: ?? Water pump housing @ o - r i n g inspection 1. Inspect: ?? Thermostatic valve valve does not open at 80 84°c (176 183” f) replace. Inspection steps: *suspend thermostatic valve in a vessel ?? Place reliable thermometer in a wate...

  • Page 226

    Water pump and thermostatic valve 2. Inspect: impeller cracks/wear/damage replace. Installation reverse the “removal” procedure. Note the following points. 1. Install: water pump cover pipe ?? Crankcase cover (left) shift arm ?? Thermostatic cover bolts (water pump 10 nm (1.0 kg, 7.2 bolts (pipe) : ...

  • Page 227: Carburetor

    Carburetor carburetor carburetor upper bracket throttle stop screw fuel overflow hose lower bracket ncronizing screw float float pin float chamber needle jet fuel drain screw valve seat assembly pilot jet main jet starter plunger assembly pilot screw piston valve assembly jet needle set starter leve...

  • Page 228

    Carburetor section view a @starter air bleed @main air jet @pilot outlet the pilot screw settings are adjusted starter air bleed pipe air jet 1 screw @ a i r v e n t inlet @main jet maximum performance at the factory. Air inlet @float needle valve @main bleed pipe any attempt to change these setting...

  • Page 229

    Carburetor removal 1. Remove: seat top cover refer to the “cowling removal and installation removal” section in the chapter 3. 2. Turn the fuel cock to “off” position. 3. Remove: ?? Fuel cock lever 4. Disconnect: ?? Fuel hose 5. Remove: ?? Fuel pump gasoline is highly flammable. Avoid spilling fuel ...

  • Page 230

    C a r b u r e t o r 8. Disconnect: ?? Crankcase ventilation hose ?? Air vent hose 9. Remove: ?? Air filter case 10. Loosen : screw (starter cable clamp) 11. Disconnect: ?? Starter cable 12. Disconnect: ?? Fuel hose 13. Loosen : *screws (carburetor joint clamp 14. Remove: ?? Carburetor assembly 15. D...

  • Page 231

    Carburetor disassembly note: the following parts can be cleaned and in- spected without carburetor separation. ?? Throttle valve piston valve starter plunger ?? Float chamber components 1. Remove: *bracket (upper) (lower) lever shaft 2. Remove: ?????? Plunger 3. Remove: ?? Vacuum chamber cover ?? Sp...

  • Page 232

    Carburetor 5. Remove: pilot screw 6. Remove: ?? Float chamber cover *gasket *float pin *float seat screw seat assembly 7. Remove: ?? Main jet ?? Holder (main jet) ?? Washer pilot jet ?? Needle jet ?? Pilot air jet inspection 1. Inspect: ?? Carburetor body ?? Float chamber ?? Fuel passage contaminati...

  • Page 233

    Carburetor 3. Inspect: *float needle valve valve seat ?? O-ring as a set. 4. Inspect: *throttle valve *rubber diaphragm tears+ replace. 5. Inspect: ?? Needle jet ?? Main jet ?? Holder pilot jet ?? Pilot adjust screw pilot air jet bends/wear/damage replace. Contamination blow out jets with a compress...

  • Page 234

    Carburetor assembly to assemble the carburetor, reverse the disassem- bly procedures. Note the following points. ?? Before reassembling, wash all parts in clean gasoline. ?? Always use a new gasket. 1. Install: ?? Valve assembly note: note position of tab on diaphragm. This tab must be placed in the...

  • Page 235

    Carburetor 5. Installer: bracket bracket screw (upper bracket): 3 nm (0.3 m-kg, 2.2 screw (lower bracket): 5 nm (0.5 m-kg, 3.6 installation reverse the “removal” procedure. Note the following points. 1. Install: ?? Fuel tank bolts (fuel tank): 14 nm (1.4 kg, 10.2 2. Install: ?? Fuel tank bracket bol...

  • Page 236

    Carburetor adjustment note: before adjusting the fuel level, the float heigl should be the pilot screw settings are adjusted f maximum performance at the factory. A attempt to change these settings decrease enaine performance. Fuel level adjustment 1. Measure: level out of it by the ing adjustment s...

  • Page 237

    Carburetor 2. Adjust: ?? Fuel level fuel level adjustment steps: *remove the carburetor assembly. Refer to “removal” section. *remove the float, valve seat and the needle valve. ?? Inspect the valve seat and the needle valve. If either is worn, replace as a set. *if both are fine, adjust the float h...

  • Page 238: Chassis

    Front wheel front wheel gear unit assembly bearing oil seal spacer meter clutch collar clutch retainer wheel axle chassis load is the total weight of cargo, rider, passenger,anc accessories. 1 1 wear limit: i 1.0 mm (0.04 in) r i m s i z e : i mt3.00 x 17 i d rim limit:.

  • Page 239

    Front wheel i removal 1. Place the motorcycle on a level place. Securely support the motorcycle so there is no danger of it falling over. 2, remove: ?? Speedometer cable 3. Remove: ?? Brake calipers (right/left) 4. Loosen: ?? Pinch bolt (front axle) ?? Axle (front) 5. Elevate the front wheel by plac...

  • Page 240

    Front wheel 3. Inspect: ?? Wheel replace. 4. Measure: ?? Wheel over specified limit repalce. Rim limits: radial : 2.0 mm (0.08 in) lateral : 2.0 mm (0.08 in) mounting a tire, ride conservatively to allow proper tire to rim seating. Failure to do so may cause an accident resulting in motor- cycle dam...

  • Page 241

    Front wheel note: use a socket that matches the outside diameter of the race of the bearing. A caution: do not strike the center race or balls of the bearing. Contact should be made only with the outer race. 6. Inspect: ?? Brake disc wear/over specified limit replace. Maximum deflection: (front and ...

  • Page 242

    Front wheel 3. Install: ?? Front wheel note: b e s u r e t h a t t h e p r o j e c t i n g p o r t i o n ( t o r q u e stopper) of the gear unit housing is position- ed correctly. 4. Tighten: ?? Front axle ?? Pinch bolt (front axle) ?? Brake calipers (right/left) ?? Speedometer cable front axle: 58 ...

  • Page 243

    Front wheel 2. Set the wheel on a suitable stand. 3. Find: ?? Heavy spot procedure: a. Spin the wheel and wait for it to rest. B. Put an “x i ” mark on the wheel bottom spot. C. Turn the wheel so that the mark is up. D. Let the wheel fall and wait for it to rest. Put an mark on the wheel bottom spot...

  • Page 244

    Rear wheel rear wheel collar oil seal e a r i n g spacer clutch hub collar cotter pin bar brake hose holder i t i r e s i z e : 1 .O mm (0.04 in) rim limit: r a d i a l : d 2.0 mm (0.08 in) l a t e r a l : 2.0 mm (0.08 in) 28 nm (2.8 m kg.

  • Page 245

    Rear wheel removal 1. Place the motorcycle on a level place. Securely support the motorcycle so there is nc danger of it falling over. 2. Elevate the rear wheel by placing a stand under the swing arm. 3. Remove: ?? Brake caliper note: do not depress the brake pedal while the is off the disc. 4. Loos...

  • Page 246

    Rear wheel installation when installing the rear wheel, reverse the re- moval procedure. Note the following points. 1. Lubricate: ?? Bearings oil seals spacer lithium soap base grease 2. Adjust: ?? Drive chain slack drive chain slack: 10 20 mm (0.4 0.8 refer to the “drive chain adjust- ment” section...

  • Page 247

    Front and rear brake front and rear brake master cylinder cap rubber seal master cylinder kit master cylinder brake hose union bolt copper washer joint brake caliper spring piston seal dust seal brake pad brake disc ? The arrow mark on the pad spring must pointing the disc rotating direction. . Brak...

  • Page 248

    Front and rear brake reservoir tank cap bush diaphragm reservoir tank reservoir hose master cylinder master cylinder kit brake hose brake pedal union bolt copper @brake caliper @ p i s t o n piston seal dust seal @brake pad pad spring @brake disc brake fluid type: if dot is not available, m kg, 4.3 ...

  • Page 249

    Brake pad replacement note: to.

  • Page 250

    Front and rear brake.

  • Page 251

    Front and rear brake 8 . T h e “ brake chapter 3.

  • Page 252

    Front and rear brake screw: (0.6 4.3.

  • Page 253

    Front and rear brake caliper disassembly before disassembling the front brake caliper or rear brake caliper, drain the brake system of its brake fluid. Front brake 1. Remove: cover retaining clips retaining pins ?? Pad spring refer to the “brake pad replace ment” section. 2. Remove: ?? Brake hose pl...

  • Page 254

    Front and rear brake remove steps: ?? Blow compressed air into the tube joint opening to force out the piston from the caliper body. ?? Never try to pry out the piston. ?? Cover the piston with a rag. Use care so that piston does not cause injury as it is expelled from the cylinder. Rear brake 1. Re...

  • Page 255

    Front and rear brake removal steps: *blow compressed air into the tube joint opening to force out the piston from the caliper body. ?? Never try to pry out the piston. ?? Cover the piston with a rag. Use care so that piston does not cause injury as it is expelled from the cylinder. Master cylinder d...

  • Page 256

    Front and rear brake 3. Remove: (master cylinder cap) ?? Master cylinder cap ?? Rubber seal ?? Union bolt ?? Copper washer ?? Bolt (master cylinder bracket) ?? Master cylinder bracket ?? Master cylinder ?? Dust boot ?? Circlip ?? Master cylinder kit rear brake remove: *cotter pin ?? Plain washer ?? ...

  • Page 257

    Front and rear brake 1 i 2. Measure: ?? Brake pad thickness out of specification replace. Pad wear limit: 0.5 mm (0.02 in) note: replace the pads as a set if either is found to be worn to the wear limit. 3. Inspect: ?? Brake hose cracks/damage replace. 4. Inspect: ?? Master cylinder body scratches/w...

  • Page 258

    Front and rear brake assembly ?? All internal parts should be cleaned in new brake fluid only. ?? Internal parts should be lubricated with brake fluid when installed. Brake fluid: dot if dot is not available, can be used. ?? Replace the piston seals whenever a caliper is disassembled. Front brake 1....

  • Page 259

    Front and rear brake 4. Install: ?? Master cylinder kit circlip . Dust boot 5. Install: ?? Master cylinder note: tighten first the upper bolt, then the lower bolt. Bolts (master cylinder bracket): 9 nm (0.9 kg, 6.5 lb) i 6. Install: ?? Brake hose ?? Copper washers ?? Union bolts union bolts: 26 nm (...

  • Page 260

    Front and rear brake 8. Fill: ?? Brake fluid recommended brake fluid: if dot # 4 is not available, # 3 can be used. Caution: brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. ?? Use only the designated quality brake fluid. Otherwise, the rubber seals...

  • Page 261

    Front and rear brake il. Inspect: ?? Brake fluid level fluid level is under “lower” level line replenish. Refer to the “brake fluid inspec- tion” section in the chapter 3. Rear brake 1. Install: piston seal ?? Dust seal piston 2. Install: ?? Brake caliper bolts (brake caliper): 35 nm (3.5 m kg, 25 3...

  • Page 262

    Front and rear brake 4. Install: ?? Master cylinder kit ?? Adjusting rod ?? Master cylinder *bolt (master cylinder) ?? Plain washer cotter pin bolt (master cylinder): 20 nm (2.0 kg, 14 i always use new cotter pin. 5. Install: ?? Reservoir tank 6. Install: ?? Master cylinder assembly bolts (master cy...

  • Page 263

    Front and rear brake 8. Install: ?? Brake hose ?? Copper washers ?? Union bolts union bolts: 26 nm (2.6 kg, 19 ?? Master cylinder ?? Brake caliper a when installing the brake hose , lightly touch the brake pipe with the p o n the caliper and master cylinder. Always use new copper washers. 9. Fill: ?...

  • Page 264

    Front and rear brake ?? Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance. ?? Refill with the same type of brake fluid; mixing fluids may result in a harmful chem- ical reaction and lead to poor performance. ?? Be car...

  • Page 265

    Front fork front fork cap bolt damper rod o-ring oil lock piece collar inner tube spring seat dust seal fork spring retaining clip rebound spring oil seal seal spacer guide bushing @outer tube @gasket drain screw @gasket a f o r k o i l ( e a c h ) : capacity: 4 4 4 (15.6 imp oz, 15.0 us oil level: ...

  • Page 266

    Front fork removal securely support the motorcycle so there is no danger of it falling over. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove: ?? Front wheel refer to the “front wheel remo- val” section. 3. Remove: ?? Front brake caliper ?? Front fender ?? Bolts (br...

  • Page 267

    Front fork 7. Loosen: ?? Pinch bolt (handlebar crown) ?? Pinch bolt (steering stem) support the fork before loosening the pinch bolts. 8. Remove: ?? Front fork disassembly 1. Remove: *cap bolt *collar spring seat ?? Fork spring drain the fork oil 2. Remove: ?? Dust seal retaining clip use a thin fla...

  • Page 268

    Front fork 4. Remove: ?? Damper rod ?? Rebound spring 5. Remove: ?? Inner tube inner tube removal steps: ?? Hold fork leg horizontally. The caliper mounting boss of the outer tube securely in a vise with soft jaws. ?? Pull out the inner tube from the outer tube by forcefully, but carefully, with dra...

  • Page 269

    Front fork 2. Inspect: ?? Outer tube scratches/bends/damage replace. 3. Measure: ?? Fork spring over specified limit replace. Fork spring free length (limit) : 408 mm (16.1 in) 1 4. I : ?? Damper rod wear/damage replace. Contamination blow out all oil passages with compressed air. ?? 0il lock piece ...

  • Page 270

    Front fork j 2. Tighten: ?? Bolt (damper rod) use the damper rod holder and t-handle to lock the damper rod. Bolt (damper rod): 40 nm (4.0 m kg, 29 lb) apply 3. Install: ?? Guide bushing (new) into the outer tube . Spacer on the top of guide bushing seal use the fork seal driver weight adopter . And...

  • Page 271

    Front fork each fork: 444 (15.6 imp oz, 15.0 us fork oil or equivalent after filling, slowly pump the fork up and down to distribute oil. Oil level : 92 mm (3.62 in) from the top of inner fork tube fully compressed without spring. Inner tube fork oil 5. Install: ?? Fork spring with the smaller pitch...

  • Page 272

    Front fork ?? Pinch bolt (handlebar crown) ?? Pinch bolt (steering stem) 3. Install: ?? Handlebar boss note: insert the pin on the spacer into the correspond- ing hole on the handlebar. Bolts (handlebar boss) : 23 nm (2.3 m-kg, 17 i 4. Install: ?? Front fender bolt (front fender): 7 nm (0.7 m-kg, 5....

  • Page 273

    Steering head and handlebar steering head and handlebar handlebar throttle guide tube locknut handlebar (right) adjuster handlebar boss (right) clutch cable handlebar boss (left) throttle cable 1 handlebar (left) throttle cable 2 grip rubber starter cable handlebar grip end starter lever assembly 23...

  • Page 274

    Steering head and handlebar steering head steering stem nut handle crown lock washer ring nut (upper) washer ring nut (lower) @bearing cover @bearing (upper) bearing (lower) @steering stem (11 26 nm (2.6 19 52 nm (5.2 m-kg, 37 2 n d : a loosen it completely 3 r d : 3 nm (0.3 m-kg, 2.2 7-37.

  • Page 275

    Steering head and handlebar removal securely support the motorcycle so there is no danger of it falling over. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove: ?? Front wheel refer to the “front wheel r e - moval” section. 3. Remove: ?? Bracket (master cylinder) 4. ...

  • Page 276

    Steering head and handlebar 6. Remove: ?? Throttle cable ?? Handlebar grip (right) 7. Remove: ?? Handlebar switch (left) 8. Remove: ?? Handlebar grip end (left) ?? Handlebar grip (left) ?? Clutch lever holder 9. Remove: ?? Handlebar (right) ?? Handlebar bosses (left and right) with handlebar (left)....

  • Page 277

    Steering head and handlebar 13. Remove: ?? Horn ?? Joint (brake hose) remove: ?? Handlebar crown 15. Remove: ?? Lock washer ?? Ring nut (upper) use ring nut wrench ring nut wrench: p/n y u-33975 16. Remove: ?? Washer ?? Ring nut (lower) ?? Bearing cover support the steering shaft so that it may not ...

  • Page 278

    Steering head and handlebar inspection 1. Wash the bearing in a solvent. 2. Inspect: ?? Bearings ?? Bearing race pitting/damage replace. Bearing race remplacement steps: ?? Remove the bearing races using long rod and the hammer as shown. ?? Remove the bearing race on the steering stem using the floo...

  • Page 279

    Steering head and handlebar installation reverse the removal procedure. Note the following points. 1. Lubricate: bearings (upper/lower) ?? Bearing races lithium-soap base 2. Install: ?? Bearing (lower) onto the steering stem. Steering stem caution: hold the steering stem until it is secured. (upper)...

  • Page 280

    Steering head and handlebar ?? Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steer- ing bearings ?? Install the washer . ?? Install the ring nut (upper) note: the tapered side of ring nut must face down- ward. Tighten t...

  • Page 281

    Steering head and handlebar 8. Install: ?? Handlebar bosses note: insert the pin on the handlebar bosses into the corresponding hole on the handlebar crown. 9. Install: ?? Handlebars pinch bolts (handlebar): 23 nm (2.3 17 i 10. Install: *clutch lever holder ?? Handlebar switch (left) ?? Handlebar gr...

  • Page 282

    ?? Install the handlebar grip end (left) 11. Install: ?? Handlebar grip (right) ?? Throttle cable ?? Handlebar switch (right) note: before installing the handlebar grip (right), apply a light coat of lithium soap base grease onto the handlebar end. 12. Install: ?? Front brake master cylinder note: i...

  • Page 283

    Steering head and handlebar 14. Install: ?? Front fender bolt (front fender) : 7 nm (0.7 m-kg, 5.1 ft-lb) i 15. Install: ?? Front wheel refer to the “front wheel insta- llation” section. Wheel axle: 58 nm (5.8 m-kg, 42 lb) bolt (brake caliper): 35 nm (3.5 m kg, 25 lb) pinch bolt (front fork): 20 nm ...

  • Page 284

    Rear shock absorber and rear shock absorber and rear shock absorber shock absorber collar washer collar oil seal bearing.

  • Page 285

    Rear shock absorber and guard seal bearing arm (left) thrust washer arm (right) thrust cover oil seal bush collar pivot shaft relay arm note: coat the bearings, bushings, thrust covers, oil seals, and collars with a liberal amount of light weight lithiun-soap base grease before installing. After ins...

  • Page 286

    Rear shock absorber and 2 5 30 mm 1.2 in) handling notes this shock absorber contains highly compressed nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result f...

  • Page 287

    Rear shock absorber and 2. Remove: ?? Lower cowlings (left and right) refer to the “cowling removal and installation removal” section in the chapter 3. Securely support the motorcycle so there is no danger of it falling down. 3. Remove: ?? Bolt (arms bottom) 4. Remove: ?? Bolt (swingarm) ?? Bolt (re...

  • Page 288

    Rear shock absorber and 1. Remove: ?? Rear wheel refer to the “ r e a r w h e e l r e - moval” section. ?? Rear shock absorber 2. Remove: ?? Chain case 3. Check: (side play) side play replace the bearings and collar. Move the from side to side. There should be no noticeable side play. Side play (at ...

  • Page 289

    Rear shock absorber and 6. Remove: ?? Guard seal 7. Remove: ?? Tension bar 8. Remove: ?? Arms (left and right) 9. Remove: ?? Thrust covers washer i nspection rear shock absorber 1. Inspect: ?? Rear shock absorber oil leaks/damage replace. 7-52.

  • Page 290

    Rear shock absorber and ,, wash the bearings in a 2. Inspect: ?? Bearings (race/rollers) pitting/damage replace. ?? Trust washers ?? Trust covers damage replace. ?? Collar ?? Pivot shaft damage replace. 3. Inspect: ?? Arm (left) * a r m ( r i g h t ) ?? Relay arm damage replace. ?? Bearings pitting/...

  • Page 291

    Rear shock absorber and installation reverse the removal procedure. Note the following points. 1. Lubricate: ?? Bearings oil seals collars lithium-soap base grease 1. Install: seal @tension bar screw (guard seal): 8 nm (0.8 m kg, 5.8 bolt (tension bar): 15‘nm (1.5 kg, 11 lb) 2. Install: (left and ri...

  • Page 292

    Rear shock absorber and 2. Install: ?? Relay arm rear arm frame: 40 nm (4.0 kg, 29 lb) relay arm rear shock absorber: 40 nm (4.0 m kg, 29 3. Install: ?? Arms (left and right) relay arm arms: 40 nm (4.0 m kg, 29 lb) 4. Install: ?? Rear wheel refer to the “rear wheel instal- lation” section. Nut (rear...

  • Page 293

    Drive chain and sprocket drive chain and sprocket removal p l a c e t h e m o t o r c y c l e o n a l e v e l place. Securely support the motorcycle so there is no danger of it falling over. 2. Remove: arm ?? Crankcase cover (left) ?? Nut (drive sprocket) ?? Lock washer ?? Drive sprocket r e f e r t...

  • Page 294

    Drive chain and sprocket 2. Check: ?? Drive chain stiffness clean and oil the chain and hold as illus- trated. Stiff replace drive chain. 3. Clean: ?? Drive chain drive chain cleaner: kerosene a do not use steam cleaning, high-pressure and certain solvent of o-ring damage may occur. 4. Inspect: ?? D...

  • Page 295

    Drive chain and sprocket 2. Lubricate: ?? Bearings oil seals ?? Collars lithium-soap base grease 3. Install: ?? Drive chain ?? Rear wheel refer to the “rear shock absorber a n d i n s t a l l a t i o n ” a n d “ r e a r w h e e l i n s t a l l a - tion”. 4. Install: ?? Drive sprocket ?? Lock washer ...

  • Page 296: Electrical

    Circuit diagram electrical circuit diagram b i l b ch b b 8-l.

  • Page 297

    Circuit diagram main switch rectifier/regulator a.C. Generator “start” switch starter motor starter relay f u s e “ m a i n ” battery f u s e “ i g n i t i o n ” “engine stop” switch diode block clutch switch sidestand switch ignition circuit cut-off relay digital ignitor unit ignition coil and cyli...

  • Page 298

    Electrical components electrical components (1) switch ermo unit relay assembly fuel pump relay @ h o r n level switch neutral switch sidestand switch sidestand relay exup control unit (for california only) exup (for california only) 8-3.

  • Page 299

    Electrical components electrical components wireharness rear brake switch diode block @ f u s e “ m a i n ” @main switch @ignition coil @plug @ b a t t e r y @starter relay @rectifier/regulator ignitor unit b-4.

  • Page 300

    Checking of switches i checking of switches check the switches for the continuity between the terminals to determine correct connection. Read the following for switch inspection. Switch connection as shown in manual the manual contains a connection chart as shown left showing the terminal connection...

  • Page 301

    Checking of switches 1. Disconnect the main switch coupler from the wireharness. Never disconnect the main switch coupler by pulling the leads. Otherwise, leads may be pulled off the terminals inside the coupler. 2. Inspect whether any lead is off the terminal inside the coupler. If it is, repair it...

  • Page 302

    Checking of switches note: use thin probes for checking the continuity. Otherwise, the probes may contact other inside the coupler. *check the continuity between “r” and at the respective switch positions of “on” “off” “lock” and “p” there must be continuity (the tester ing “0”) at the “on” switch p...

  • Page 303

    Checking of bulbs checking of bulbs (for headlight, tail/brake light, flasher light, meter light, etc.) check the bulb terminal continuity for the condi- tion of the bulb. Kinds of bulbs the bulbs used in the motorcycle are classified as shown left by the shape of the bulb socket. And are mainly use...

  • Page 304

    Checking of bulbs 2. Check the bulb terminals for continuity. Checking steps: the pocket tester selector to the x 1”. *connect the tester leads to the respective bulb terminals. Take for example a 3-terminal bulb as shown left. First check the continuity be- tween the and terminals by connect- ing t...

  • Page 305

    Ignition system ignition system circuit diagram 8-11.

  • Page 306

    Ignition system aforementioned circuit diagram shows the ignition circuit in the wiring diagram. Note: for the color codes, see page 8-2. Main switch fuse “main” battery fuse “ignition” “engine stop” switch @diode block sidestand switch sidestand relay digital ignitor unit ignition coil and cylinder...

  • Page 307

    Ignition system digital ignition control system description the electronic ignition that sparks the engine is computer controlled and operated by the digital microprocessor. It has a pre-programed ignition advance curve. This programed advance curve closely matches the spark timing to the engine’s i...

  • Page 308

    Ignition system troubleshooting if ignition system should become inoperative (no spark or intermittent spark) procedure check; 1. Fuse “main” 8. “engine stop” switch 2. Battery 9. Neutral switch 3. Spark plug 10. Sidestand switch 4. Ignition spark gap 11. Sidestand relay 5. Spark plug cap resistance...

  • Page 309

    Ignition system 3. Spark plug the spark plug condition. ?? Check the spark type. @check the spark plug gap. Refer to the “spark plug inspection” section in the chapter 3. Standard spark plug: (n.D.) spark plug gap: 0.7 0.8 mm (0.028 0.032 in) correct 4. Ignition spark gap *disconnect the spark plug ...

  • Page 310

    Ignition system 5. Spark plug cap resistance ?? Remove the spark plug cap. ?? Connect the pocket tester x 1 to the spark plug cap. The spark plug cap for specificated resistance. Spark plug cap resistance: 9 11 at 20°c (68°f) meets specification 6. Ignition coil resistance @disconnect the ignition c...

  • Page 311

    Ignition system the pocket tester x lk) to the ignition coil. Tester lead spark plug lead tester lead spark plug lead ?? Check the secondary coil for specificated resistance. Secondary coil resistance: c l 9.6 14.4 at 20°c (68” (spark plug lead spark plug) a both meet specifications 7. Main switch *...

  • Page 312

    Ignition system 8. “engine stop” switch disconnect the “engine stop” switch coupler from the wire harness. The switch component for the conti- nuity between “red/white and red/- white refer to the “checking of switches” section. A correct 9. Neutral switch ?? Disconnect the neutral switch coupler fr...

  • Page 313

    Ignition system 10. Sidestand switch disconnect the sidestand switch coupler from the wire harness. ?? Check the switch component for the conti- nuity between “blue/yellow and black r e f e r t o t h e “ c h e c k i n g o f switches” section. Correct il. Sidestand relay disconnect the sidestand rela...

  • Page 314

    Ignition system a pickup coil resistance ?? Disconnect the a.C. Magneto coupler the wire harness. ?? Connect the pocket tester x to the pickup coil terminal. Tester (+) lead white/red @terminal tester (-) lead white/black terminal the pickup coil for specificated resistance. Pickup coil resistance: ...

  • Page 315

    Electric starting system electric starting system circuit diagram 8-21.

  • Page 316

    Electric starting system a forementioned circuit diagram shows the electric starting circuit in the wiring diagram. Note: for the color codes, see page 8-2. @main switch “start” switch @starter motor @starter relay fuse “main” battery @ f u s e “ i g n i t i o n ” “engine stop” switch diode block @c...

  • Page 317

    Electric starting system m 1 starting circuit operation the starting circuit on this model consist of the starter motor, starter relay, and the relay unit (starting circuit cut-off relay). If the engine stop switch and the main switch are both closed, the starter motor can operate only if: the trans...

  • Page 318

    Electric starting system troubleshooting starter motor does not operate. 1 procedure check; 1. Fuse “main” 2. Battery 3. Starter motor 4. Starter relay 5. Starting circuit cut-off relay 6. Main switch 7. “engine stop” switch 8. Neutral switch 9. Sidestand switch 10. Clutch switch 11. “start” switch ...

  • Page 319

    Electric starting system 3. Starter motor t h e b a t t e r y p o s i t i v e t e r m i n a l and starter motor cable using the jumper lead as shown. The starter motor operation. Operative 4. Starter relay ?? Disconnect the starter relay lead. ?? Ground the starter relay lead to the frame using the ...

  • Page 320

    Electric starting system tester (+) lead red/white terminal tester (-) lead+ black/yellow terminal tester (+) lead blue/white terminal tester (-) blue/white terminal ?? Check the starting circuit cut-off relay for continuity. Continuity 6. Main switch i no continuity replace relay assembly. ?? Disco...

  • Page 321

    Electric starting system incorrect replace handlebar switch (right). Correct 8. Neutral switch ?? Disconnect the neutral switch coupler from the wire harness. ?? Check the switch component for the conti- nuity between “sky blue and ground”. Refer to the “checking of switches” section. A correct 9. S...

  • Page 322

    Electric starting system 10. Clutch switch ?? Disconnect the clutch switch coupler from w i r e h a r n e s s . The switch component for the conti- nuity between “blue/yellow and black/- yellow refer to the “checking of switches” section. “start” switch @ d i s c o n n e c t t h e “ s t a r t ” s w ...

  • Page 323

    Electric starting system a diode block is faulty. Replace the diode block..

  • Page 324

    Electric starting system starter motor @brush @ a r m a t u r e o-ring.

  • Page 325

    Electric starting system 1 or more removal 1. Remove: ?? Starter motor refer to the “engine overhaul e n g i n e r e m o v a l ” s e c t i o n i n t h e chapter 4. Inspection and repair 1. Inspect: commutator dirty clean it with grit sandpaper. 2. Measure: ?? Commutator diameter out of specification...

  • Page 326

    Electric starting system armature coil resistance: continuity check : at 20°c (68” insulation check : more than at 20°c (68°f) ?? If the resistance is incorrect, replace the starter motor. 5. Measure: ?? Brush length out of specification replace. Brush length limit: 5.0 mm (0.20 in) 6. Measure: ?? B...

  • Page 327

    Charging system charging system circuit diagram 8 - 3 3.

  • Page 328

    Charging system aforementioned circuit diagram show the charging circuit in the wiring diagram. Note: for the color codes, see page 8-2. Rectifier/regulator generator fuse “ma in” @ b a t t e r y 8-34.

  • Page 329

    Charging system troubleshooting i the battery is not charged. Procedure check; 1. Fuse “main” 2. Battery 3. Charge voltage 4. Coil resistance 5. Wiring connection (entire charging system) note: ?? Remove the following parts before troubleshooting. 1) seat 4) fuel tank 2) seat 5) lower cowling 3) top...

  • Page 330

    Charging system 3. Charge voltage ?? Connect the inductive tachometer to spark plug lead. The pocket tester to the battery tester lead battery terminal tester lead battery terminal the engine and accelerate to about, 3,000 r/min. ?? Check charging voltage. Charging voltage: 14.3 at 3,000 out of spec...

  • Page 331

    Charging system 1 w 2 w w 3 ?? Check the coil for specificated resis- tance. Coil resistance: white -white 0.44 at 20°c (68” white -white 0.44 at 20°c (68” out of specification replace coil. Check the entire charging system for refer to the “wiring diagram” section. Poor i n correct replace rectifie...

  • Page 332

    Lighting system lighting system circuit diagram w/b 1 i i br ch p - t - @ 8-39.

  • Page 333

    Lighting system a f o r e m e n t i o n e d c i r c u i t d i a g r a m s h o w s t h e l i g h t i n g c i r c u i t i n t h e w i r i n g d i a g r a m . Note: for the color codes, see page 8-2. Main switch “start” switch fuse “main” battery front position light (left) front position light (right)...

  • Page 334

    Lighting system troubleshooting headlight, “high beam” indicator light, taillight, license light meter light, and position light do not come on. I procedure check; 1. Fuse “main” 2. Battery 3. Main switch 4. “lights” (dimmer) switch 5. Wiring connection (entire lighting system) note: ?? Remove the f...

  • Page 335

    Lighting system 3. Main switch disconnect the main switch couplers from the wire harness. The switch component for the conti- nuity between “red and brown and “red and blue refer to the ‘checking of switches” section. 4. “lights” (dimmer) switch disconnect the handlebar switch (left) coupler from th...

  • Page 336

    Lighting system 5. “start” switch . Disconnect the “start” switch coupler from wire harness. Check the “start” switch component for the continuity between “red/yellow and blue/black refer to the “checking of switches” section. Incorrect replace handlebar switch (right). I refer to the “wi ring diagr...

  • Page 337

    Lighting system lighting system check headlight and “high beam” indicator light do not come on. 1. Fuse “head” ?? Remove the fuse “head”. ?? Connect the pocket tester x 1) to the fuse “head”. ?? Check the fuse “head” for continuity. Continuity no continuity replace fuse “head”. 2. Bulb and bulb sock...

  • Page 338

    Lighting system check the entire lighting system for connec- tions. Refer to the “wi ring diagram” section. 2. Meter light does not come on. 1. Fuse “head” no continuity ?? Remove the fuse “head”. ?? Connect the pocket tester x to the fuse “head”. ?? Check the fuse “head” for continuity. A continuit...

  • Page 339

    Lighting system ?? Turn the main switch to “on”. ?? Check for voltage on the “black/ out of specification white” lead at the bulb socket connector. Light does not come on. 4. Wiring connection check the entire lighting system for connections. Refer to the “wiring diagram” section. ?? Check the bulb ...

  • Page 340

    Lighting system 4. Taillight does not come on. 2. Voltage the pocket tester to the bulb socket connector. Tester lead blue terminal tester lead black terminal turn the main switch to “on”. The “lights” switch to “on”. For voltage on the “blue” lead at the bulb socket connector. N meets specification...

  • Page 341

    Lighting system 4. Taillight does not come on. *check the bulb and bulb socket for a continuity 2. Voltage connect the pocket tester to the bulb socket connector. Tester lead blue terminal tester lead black terminal turn the main switch to “on”. The “lights” switch to “on”. For voltage on the “blue”...

  • Page 342

    Signal system signal system circuit diagram - \ n - i l/w 1 i l b l i i 8-49.

  • Page 343

    Signal system aforementioned circuit diagram shows the signal circuit in the wiring diagram. Note: for the color codes, see page 8-2. @main switch “start” switch fuse “main” battery diode block digital ignitor unit fuse “signal” @front brake switch rear brake switch @“neutral” indicator light neutra...

  • Page 344

    Signal system troubleshooting ?? Flasher light, brake light and/or indicator light do not come on. . Horn does not sound. ?? Tachometer does not operate. Procedure check; 1. Fuse “main” 2. Battery 3. Main switch 4. Wiring connection (entire signal system) note: ?? Remove the following parts before t...

  • Page 345

    Signal system 3. Main switch @disconnect the main switch coupler from the wire harness. ?? Check the switch component for the conti- n u i t y b e t w e e n “ r e d a n d b r o w n refer to the “checking of switches” section. Correct c o n n e c t i o n check the entire signal system for refer to th...

  • Page 346

    Signal system signal system check 1. Horn does not sound. 1. “horn” switch ?? Disconnect the handlebar switch coupler from the wire harness. ?? Check the switch component for the conti- n u i t y b e t w e e n “ p i n k a n d b l a c k refer to the “checking of switches” section. Off (free) on (push...

  • Page 347

    Signal system 3. Horn ?? Disconnect the “pink” lead at the horn terminal. ?? Correct a jumper lead to the horn termi- nal and ground the jumper lead. ?? Turn the mainswitch to “on”. Horn is not sounded 4. Voltage ?? Connect the pocket tester to the horn at the pink terminal. Tester lead pink lead te...

  • Page 348

    2. Brake light does not come on. Signal system ?? Check the bulb and bulb socket for replace bulb and/or bulb socket. Continuity 2. Brake switch ?? Disconnect the brake switch coupler from the wire harness. ?? Check the switch component for the conti- nuity between “brown and green/- yellow or “brow...

  • Page 349

    Signal system - - ) turn the main switch to “on”. Brake lever is pulled in or brake pedal is stepped down. For voltage o n t h e “ y e l l o w ” lead at the bulb socket connector. J out of specification specification this circuit is good. 4. Wiring connection 1 check the entire signal system for con...

  • Page 350

    Signal system out of specification ?? Turn the main switch to “on”. ?? Lhe brake lever is pulled in or brake pedal ?? Check for voltage on the lead at the bulb socket connector. A meets specification this circuit is good. 1 4. Wiring connection check the entire signal system for connections. Refer t...

  • Page 351

    Signal system 3. Voltage the pocket tester to the relay assembly connector. Tester lead brown terminal tester (--) lead black terminal the main switch to “on”. For voltage o n t h e “ b r o w n ” lead at the flasher relay terminal. M e e t s 4. Voltage the pocket tester to the relay assembly connect...

  • Page 352

    Signal system 5. Voltage the pocket tester to the bulb socket connector. At flasher light (left): tester lead chocolate lead tester lead frame ground at flasher light (right): tester lead dark yreen lead tester lead frame ground the main switch to “on”. The “turn” switch to “l” or check for voltage ...

  • Page 353

    Signal system correct 2. Reed switch ?? Disconnect reed switch coupler from the wire harness. ?? Connect the pocket tester x to the reed switch terminal. Tester (+) lead white/green terminal tester lead ground ?? Check the reed switch for specificated resis- tance. C l reed switch resistance: about ...

  • Page 354

    Signal system replace relay assembly. 4. “neutral” indicator light does not come on. 1. Bulb and bulb socket i the bulb and bulb socket for conti- n u i t y . R e f e r t o t h e “ c h e c k i n g o f bulbs” section. C o n t i n u i t y 2. Neutral switch ?? Disconnect the neutral switch coupler from...

  • Page 355

    Signal system br turn the main switch to “on”. Check for voltage o n t h e “ b r o w n ” lead at bulb socket connector. Out of specification 6. Wirinq connection i r check the entire signal system for i meets specification this circuit is good. 5. L” indicator light does not come on when push “start...

  • Page 356

    Signal system 3. Diode disconnect the diode unit coupler from the wire harness. Connect the pocket tester x to the diode leads. Tester lead blue/white @lead tester lead green lead ?? Check the diode for continuity. Continuity 4. Voltage ?? Connect the pocket tester to the bulb socket connector. Test...

  • Page 357

    Signal system ?? Check for voltage on the brown 1 a meets 5. Wiring connection specification check the entire signal system for this circuit is good. 6. L” indicator light does not come on, when oil tank is empty. The bulb and bulb socket for replace bulb and/or bulb socket. Continuity 2. Resister t...

  • Page 358

    Signal system 3. Oil level switch ?? Remove the oil level switch from the oil tank. @connect the pocket tester x 1) to the oil level gauge. Tester lead black/red @terminal tester lead oil level switch body the oil level switch for continuity. Switch good position condition bad condition upright posi...

  • Page 359

    Signal system *turn the main switch to “on”. For voltage on the “brown” lead at bulb socket connector. Meets out of specification 5. Wiring connection specification check the entire signal system for i connections. This circuit is good. Refer to the “wiring diagram” section. 7. When engine is hot, t...

  • Page 360

    Signal system 2. Unit ?? Remove the unit. ?? Immerse the unit in coolant ?? Measure the resistance at each temperature as tabulated. Meter coolant temoerature i resistance 50°c (122” 80°c 47 100°c (212” 26 120°c measuring the unit, install the unit. Handle the unit with special care. Never subject i...

  • Page 361

    Signal system meets specifications 5. Voltage ‘connect the pocket tester to the temperature gauge leads. Tester lead brown terminal tester lead black terminal turn the main switch to “on”. For voltage on the “brown” lead the temperature gauge connector. 6. Wiring connection out of specification meet...

  • Page 362

    Cooling system cooling system circuit diagram l br ! I - g -.

  • Page 363

    Cooling system a forementioned circuit diagram shows the cooling circuit in the circuit diagram. Note: for the color codes, see page 8-2. @main switch @fuse “main” attery @ f u s e “ f a n ” switch @fan motor 8-70

  • Page 364

    Cooling system troubleshooting i procedure check; 1. Fuse “main/fan” 2. Battery 3. Fan motor (test 1) 4. Fan motor (test 2) fan motor does not turn. 5. Switch 6. Wiring connection (entire cooling system) note: ?? Remove the following before troubleshooting. 1) seat 2) top cover 3) air filter case ??...

  • Page 365

    3. Fan motor (test 1) ?? Disconnect the fan motor coupler. ?? Connect the battery voltage as shown. Battery lead blue terminal battery lead black terminal 1, ?? Check the fan motor for operation. Operative 4. Fan motor (test ?? Disconnect the switch coupler. ?? Connect the terminal with the jumper l...

  • Page 366

    Cooling system 5. Switch ?? Remove the s w i t c h f r o m t h e thermostat housing. *connect the pocket tester x to the switch . ?? Immerse the switch in the water ?? Check the switch for continuity. Note temperatures while heating the water with the temperature gauge . Test step water temperature ...

  • Page 367

    Cooling system (221 good condition therm0 switch “on”, fan “on” coolant temperature bad condition switch. I ?? Check the entire cooling system for refer to the “wiring diagram” section. Fan motor inspection the following problems may require repair or replacement of components component condition fa...

  • Page 368

    Fuel system fuel system circuit diagram.

  • Page 369

    Fuel system a forementioned circuit diagram shows the fuel circuit in the circuit diagram. For the color codes, see page 8-2. @main switch @ f u s e “ m a i n ” @ b a t t e r y @ f u s e “ i g n i t i o n ” switch digital ignitor unit @fuel pump relay @fuel pump 8-76.

  • Page 370

    Fuel pump circuit operation the fuel pump circuit consists of the fuel pump relay, fuel pump, “engine stop” switch and digital ignition unit. The digital ignition unit includes the control unit for the fuel pump. The fuel pump starts and stops as indicated in the chart below. To main fuse and batter...

  • Page 371

    Troubleshooting i - fuel pump fails to operate. I procedure 1 . Fuse “main/ignition” 2 . Battery 3 . Main switch 4. “engine stop” switch 5 . Fuel pump relay 6 . Fuel pump 7 . Wiring connection (entire fuel system) note: ?? Remove the following before troubleshooting. 1) seat 2) fuel tank ?? Use the ...

  • Page 372

    Fuel system 3. Main switch ?? Disconnect the main switch coupler and lead from the wire harness. ?? Check the switch component for the conti- nuity between “red and brown refer to the “checking of switches” section. A correct 4. “engine stop” switch disconnect the “engine stop” switch coupler from t...

  • Page 373

    Fuel system 5. Fuel ?? Disconnect the fuel pump relay coupler from the wire harness. ?? Connect the pocket tester x 1) and battery v o l t a g e t o t h e f u e l p u m p relay coupler terminals. Tester lead blue/black terminal tester lead+ red/white terminal battery lead red/white terminal battery ...

  • Page 374

    Fuel system . . Check the fuel system for refer to the “wi ring diagram” section. Correct correct. Replace digital ignitor unit. 8-81.

  • Page 375

    Fuel system fuel pump test operation the diaphragm is pulled in by the plunger allow- ing fuel to be sucked into the fuel chamber. Fuel is pushed out from the pump until float chamber is filled with fuel, and then the cut-off switch cuts off the circuit. When the spring pushes the diaphragm further ...

  • Page 376

    Yamaha exhaust variable valve system yamaha exhaust variable valve system (for california only) circuit diagram . I - - - r / w - - - - - 4 ! I i i i i i i 8 - 8 3.

  • Page 377

    Yamaha exhaust variable valve system a forementioned circuit diagram shows the cooling circuit in the circuit diagram. Note: for the color codes, see page 8-2. @main switch @ f u s e “ m a i n ” @ b a t t e r y f u s e “ i g n i t i o n ” @ “ e n g i n e s t o p ” s w i t c h @digital ignition unit ...

  • Page 378

    Yamaha exhaust variable valve system troubleshooting when main switch is turned to “on”, exup servomotor does not operate one cycle. Procedure (1) check; 1. Voltage 2. Exup servomotor operation 3. Exup servomotor operation 4. Wiring connection (entire exup system) procedure (2) check; 1. Fuse “main/...

  • Page 379

    Yamaha exhaust variable valve system the main switch to “on” and check for the voltage between “black and red/- white”. Voltage (red/white black): 14v meets specification 2. Exup servomotor operation ?? Disconnect the exup cables from the pulley. ?? Turn the main switch to “on” and check the exup se...

  • Page 380

    Yamaha exhaust variable valve system check the entire exup system for connec- tions. Refer to the “wiring diagram” exup control unit. I procedure 1. Fuse “main/ignition” nocontinuity ?? Remove the fuse “main” and “ignition”. *connect the pocket tester x 1) to the fuse “main” and “ignition”. ?? Check...

  • Page 381

    Yamaha exhaust variable valve system correct 4. “engine stop” switch disconnect the “engine stop” switch coupler from the wire harness. The switch component for the con- tinuity between “red/white and red/ white refer to the “checking of switches” section. O f f i incorrect replace main switch. I in...

  • Page 382

    Meter assembly meter assembly @speedometer @tachometer tempmeter indicator lights unit @ d a m p e r @meter bracket bulb bulb socket leads speedometer cable nm (0.6 m-kg, 4.3 8-89.

  • Page 383

    Meter assembly removal 1. Remove: ?? Upper cowling refer to the “cowling removal and installation removal” section in the chapter 3. 2. Disconnect: ?? Bulb socket coupler ?? Speedometer cable 3. Remove: ?? Speedometer assembly 4. Remove: ?? Damper 5. Remove: indicator light unit ?? Meter bracket 6. ...

  • Page 384

    Meter assembly ‘w/g” installation reverse the “removal” procedure. Note the following points. 1. Install the meter lights and leads as shown. 2. Install the indicator lights as shown..

  • Page 385: Troubleshooting

    Troubleshooting the following troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. Starting failure/hard starting fuel stem ...

  • Page 386

    Starting failure/hard starting elect cal system spark plug improper plug cap ?? Worn electrodes ?? Wire between terminals broken ?? Improper heat range ?? Faulty spark plug cap ?? Broken or shorted primary/secondary plug lead -full-transistor system ?? Faulty igniter unit ?? Faulty pickup coil -swit...

  • Page 387

    Poor idle speed performance and piston rings ? Improperly installed piston ring ? Worn, fatigued or broken piston ring ? Seized piston ring ? Seized or damaged piston and crankshaft ?? Improperly seated crankcase ?? Damaged crankshaft oil seal lip ?? Improperly sealed valve ?? Improperly contacted v...

  • Page 388

    Poor medium and high speed performance/ faulty gear shifting poor medium and speed performance poor medium and high speed performance refer to “starting failure/hard starting.” (fuel system, electrical system, system and valve train) probable cause ? Improper jet needle clip position ? Diaphragm mal...

  • Page 389

    Clutch slipping/dragging clutch slipping/dragging clutch slipping probable cause t ?? Worn friction plate/clutch plate engine low oil level improper quality/viscosity clutc dragging warped pressure plate ?? Unevenly tensioned clutch springs ?? Match marks not aligned ?? Bent push rod ?? Loose push r...

  • Page 390

    Overheating or over-cooling ? Overheating or over-cooling overheating -ignition system ? Improper spark plug gap ? Improper spark plug heat range ? Faulty ignitor unit ?? Improper carburetor main jet (setting) clogged air cleaner element ?? Improperly adjusted fuel level -compression system ?? Heavy...

  • Page 391

    Faulty brake/ front fork oil leakage/malfunction faulty brake poor braking effect ?? Worn brake pads ?? Worn disc ?? Air in brake fluid ?? Leaking brake fluid ?? Faulty cylinder kit cup ?? Faulty caliper kit seal ?? Loose union bolt ?? Broken brake hose ?? Oily or greasy disc/brake pads improper bra...

  • Page 392

    Instable handling instable handling handlebars ?? Improperly installed or bent ?? Improperly installed handle crown ?? Uneven oil levels on both sides unevenly worn tires incorrect tire pressure ? Uneven tire pressures on both sides ? Loose bearing ? Bent or loose wheel axle ? Excessive wheel run-ou...

  • Page 393

    Faulty signals and lights faulty signals and lights headlight dark ?? Improper bulb ?? Too many electrical accessories ?? Hard charging (broken coil wire, faulty rectifier with regulator) ? Incorrectly connected coupler/connector/ wire harness ? Improperly grounded ? Poor contacts (main or light swi...

  • Page 394

    Faulty signals and lights flasher winks slower ? Faulty flasher relay ? Insufficient battery capacity (nearly discharged) ? Improper bulb ? Faulty switch (main or flasher switch) flasher winks quicker ?? Improper bulb ?? Faulty flasher relay horn is inoperative ? Faulty battery ? Faulty switch (main...

  • Page 395

    J i i i.

  • Page 397: Fox Racing Shox

    Fox racing shox setup manual motorcycle.

  • Page 398

    2 introduction thank you for choosing fox racing shox for your motorcycle. In doing so, you have chosen the number one shock absorber in the industry! All fox racing shox products are designed, manufactured and assembled by the finest professionals in the industry. You need to be aware of the import...

  • Page 399

    3 fox racing shox history back in the mid-70’s bob fox, an avid motocross racer, came to the conclusion that the quality and performance of the shock absorbers available for motocross racing were not up to the extreme demands of the sport. As a mechanical engineer, he saw an opportunity to design an...

  • Page 400

    4 valving warranty fox racing shox guarantees satisfaction with your shock’s internal valving. If you are dissatisfied with the internal valving of your shock, fox racing shox will modify the valving at no charge within one year of the purchase of the shock. Optional springs fox racing shox wants yo...

  • Page 401

    5 international orders all international orders must be paid in full prior to shipment. We suggest wire transfer, visa or mastercard for pre-payments. Freight, any applicable duties or taxes must be pre-paid unless prior arrangements have been made. Our most frequent method of shipping is ups, but w...

  • Page 402

    6 2) have a friend hold the front end of the bike. Sit on the bike in your normal riding position. It is also a good idea to have your normal riding gear on including your helmet. If you normally carry luggage on your motorcycle, leave it on the motorcycle for this measurement. Push down on the rear...

  • Page 403

    7 damping adjustment (if equipped) your fox shock has up to two external damping adjustments – rebound damping and compression damping. Rebound damping controls how quickly the shock extends after hitting a bump – more rebound damping means slower extension. Compression damping controls how quickly ...

  • Page 404

    8 the main reasons to adjust ride height are to change the steering geometry of the motorcycle or to change the ground clearance of the motorcycle. Raising the rear ride height steepens the steering head angle; lowering the rear ride height slackens the steering head angle. If the cornering clearanc...

  • Page 405

    9 damping perfect damping control is as important as fine tuning your engine. Whether it comes to cutting precious seconds off of your lap times or just obtaining a comfortable ride on a sunday afternoon, fox shocks were especially designed to help achieve riding harmony. The range of damping adjust...

  • Page 406

    10 summary of damp in g solutions a d jus tm ent be st for t es ting t oo m u ch da m p ing w h en … t oo little da m p ing w h en … "p er fe ct " w h en ... L o w s p eed r ebou nd da m p ing (blue k nob) • sm all bum ps • sweep er t u rn s • ri p p le d su rf aces e x cess d a m p in g keep s t h ...

  • Page 407

    11 maintenance checklist periodically inspect your fox shock: • inspect the chrome shaft surface for damage or wear. • inspect the shaft seals for damage or wear. Oil should not normally be visible on the shock absorber shaft. • inspect the hose and hose fittings for damage or leakage. Make sure tha...

  • Page 411: Yamaha Fzr400 1988-90

    Retail price list effective 2/1/01 prices subject to change without notice bodywork: sharkskinz rear sets: cfm 54-0400 $212.95 part # for race upper 59-4006 $145.00 relocator kit s&c 54-401 $54.95 bodywork right mid 59-4007 $65.00 protek n/a left mid 59-4008 $65.00 vortex n/a lower 1pc 59-4094 $215....

  • Page 412

    Fzr400u a1.

  • Page 413: Cylinder Head

    1 1wg-11101-00-00 cylinder head assembly . 1 2 1wg-11133-10-00 . Guide, intake valve . . . . . 16 3 93440-10153-00 . Circlip . . . . . . . . . . . . . . . . . 16 4 99510-08016-00 . Pin, dowel . . . . . . . . . . . . . 12 5 90105-06384-00 . Bolt, washer based . . . . 23 6 90338-08174-00 . Plug . . . ...

  • Page 414: Cylinder

    1 1wg-11310-00-00 cylinder . . . . . . . . . . . . . . . . 1 2 93210-60737-00 o-ring . . . . . . . . . . . . . . . . . . 4 3 99510-12016-00 pin, dowel . . . . . . . . . . . . . . 2 4 3tj-11351-00-00 gasket, cylinder . . . . . . . . 1 5 90153-06045-00 screw, hexagon . . . . . . . . . 2 6 90430-06014-...

  • Page 415: Crankshaft-Piston

    1 99999-01963-00 crankshaft . . . . . . . . . . . . . 1 2 93101-26156-00 oil seal . . . . . . . . . . . . . . . . . 1 3 1wg-11416-00-00 plane bearing, crankshaft 1 . . . . . . . . . . . 12 ur blue 1wg-11416-10-00 plane bearing, crankshaft 1 . . . . . . . . . . . 12 ur black 1wg-11416-20-00 plane bea...

  • Page 416: Camshaft-Chain

    1 3bf-12171-00-00 camshaft 1 . . . . . . . . . . . . . . 1 2 3bf-12181-00-00 camshaft 2 . . . . . . . . . . . . . . 1 3 1wg-12176-00-00 sprocket, cam chain . . . . . 2 4 90105-07385-00 bolt, washer based . . . . . 4 5 94590-95112-00 chain bf04ma . . . . . . . . . . . . 1 6 94690-95021-00 . Master li...

  • Page 417: Valve

    1 1wg-12111-00-00 valve, intake . . . . . . . . . . . . 8 2 1wg-12121-00-00 valve, exhaust . . . . . . . . . . 8 3 1wg-12116-00-00 seat, valve spring . . . . . . . 16 4 1wg-12113-01-00 spring, valve inner . . . . . . 16 5 1wg-12117-00-00 retainer, valve spring . . 16 6 1wg-12118-00-00 cotter, valve ...

  • Page 418: Valve

    9 1hx-12169-90-00 pad, adjusting 2 (2.10) . . . . 16 ur 1hx-12169-e0-00 pad, adjusting 2 (2.15) . . . . 16 ur 1hx-12169-g0-00 pad, adjusting 2 (2.20) . . . . 16 ur 1hx-12169-j0-00 pad, adjusting 2 (2.25) . . . . 16 ur 1hx-12169-l0-00 pad, adjusting 2 (2.30) . . . . 16 ur 1hx-12169-n0-00 pad, adjusti...

  • Page 419: Water Pump

    1 1wg-12420-00-00 water pump assembly . . . 1 2 1wg-12439-00-00 . O-ring . . . . . . . . . . . . . . . . . 1 3 93210-33133-00 o-ring . . . . . . . . . . . . . . . . . . 1 4 91316-06025-00 bolt . . . . . . . . . . . . . . . . . . . . 2 5 91316-06035-00 bolt . . . . . . . . . . . . . . . . . . . . 2 6...

  • Page 420: Radiator-Hose

    1 1wg-12461-00-00 radiator assembly . . . . . . 1 2 1wg-12405-00-00 blower assembly . . . . . . . 1 3 1aa-12630-00-00 . Motor assembly . . . . . . . 1 4 1uf-12611-00-00 . Fan . . . . . . . . . . . . . . . . . . . . 1 5 98580-05010-00 . Screw, pan head . . . . . . . 3 6 92901-05600-00 . Washer, plate...

  • Page 421: Radiator-Hose

    30 93210-21190-00 o-ring . . . . . . . . . . . . . . . . . . 1 31 91316-06012-00 bolt, socket head . . . . . . . 1 32 90110-06142-00 bolt, hexagon socket head . . . . . . . . . . . . . . . . . . . . 1 radiator-hose ref. Part no. Number description qty remarks a10 fzr400u.

  • Page 422: Oil Pump

    1 1wg-13330-01-00 pump shaft assembly . . . . 1 2 1wg-13316-00-00 cover, pump . . . . . . . . . . . . . 1 3 90201-113k2-00 washer, plate . . . . . . . . . . . 1 4 93603-17070-00 pin, dowel . . . . . . . . . . . . . . 1 5 1wg-13310-00-00 rotor assembly 1 . . . . . . . 1 6 93603-09106-00 pin, dowel . ...

  • Page 423: Oil Filter

    1 4h7-13447-00-00 cover, oil element . . . . . . 1 2 1l9-13340-01-00 by-pass valve assembly . 1 3 93210-16629-00 . O-ring . . . . . . . . . . . . . . . . . 1 4 93210-87723-00 o-ring . . . . . . . . . . . . . . . . . . 1 5 90501-20422-00 spring, compression . . . . . 1 6 90201-21608-00 washer, plate ...

  • Page 424: Air Filter

    1 1wg-13586-00-00 joint, carburetor 1 . . . . . 2 2 2 1wg-13596-00-00 joint, carburetor 2 . . . . . 2 4 3 1wg-13597-00-00 joint, carb 3 . . . . . . . . . . . . 4 4 93210-32738-00 o-ring . . . . . . . . . . . . . . . . . . 4 5 16g-13569-00-00 plug, blind . . . . . . . . . . . . . . 4 6 90467-10039-00...

  • Page 425: Carburetor

    1 3fh-14901-00-00 carburetor assembly 1 . 1 2 3bf-14902-00-00 carburetor assembly 2 . 1 3 3bf-14903-00-00 carburetor assembly 3 . 1 4 3bf-14904-00-00 carburetor assembly 4 . 1 5 1wg-14940-00-00 . Diaphragm assembly . . . 1 6 3bf-1490j-00-00 . Needle set . . . . . . . . . . . . . 1 7 1wg-14141-90-00 ...

  • Page 426: Carburetor

    30 830-14231-26-00 . Jet, pilot air #1 0 . . . . . . . 1 31 3f9-14118-00-00 . Cap . . . . . . . . . . . . . . . . . . . . 1 32 1wg-1490l-00-00 starter levr set, 1 . . . . . . 1 33 1wg-1490k-10-00 stop screw set . . . . . . . . . 3 34 98580-05010-00 screw, pan head . . . . . . . . 16 35 1wg-14251-00-...

  • Page 427: Exhaust

    1 3bf-14710-00-00 muffler assembly l . . . . . 1 2 90101-06576-00 . Bolt . . . . . . . . . . . . . . . . . . . 1 3 92906-06600-00 . Washer . . . . . . . . . . . . . . . . 1 4 90179-06500-00 nut . . . . . . . . . . . . . . . . . . . . . 8 5 3yf-14613-01-00 gasket, exhaust pipe . . . . 4 6 95816-08020...

  • Page 428: Crankcase

    1 1wg-15100-01-00 crankcase assembly . . . . 1 2 11h-15138-00-00 . Nozzle 1 . . . . . . . . . . . . . . . 4 3 99510-12016-00 . Pin, dowel . . . . . . . . . . . . . 3 4 1hx-15138-00-00 . Nozzle 1 . . . . . . . . . . . . . . . 1 5 93210-12152-00 . O-ring . . . . . . . . . . . . . . . . . 1 6 371-11167...

  • Page 429: Crankcase

    30 90467-14015-00 clip . . . . . . . . . . . . . . . . . . . . 2 31 90445-116e9-00 hose . . . . . . . . . . . . . . . . . . . . 1 32 90465-06289-00 clamp . . . . . . . . . . . . . . . . . . 1 33 90467-10038-00 clip . . . . . . . . . . . . . . . . . . . . 1 34 1wg-15381-00-00 plate, bearing cover . ....

  • Page 430: Crankcase Cover

    1 1wg-15411-00-00 cover, crankcase l . . . . . 1 2 1l9-15417-00-00 cover, cap . . . . . . . . . . . . . . 1 3 1wg-15316-00-00 damper, engine mount 1 . . 1 4 1wg-15427-00-00 cover, cap 2 . . . . . . . . . . . . 1 5 98901-05008-00 screw, bind . . . . . . . . . . . . . 4 6 3he-15451-10-00 gasket, crank...

  • Page 431: Crankcase Cover

    26 93210-27778-00 o-ring . . . . . . . . . . . . . . . . . . 1 27 1wg-15410-00-00 crcs cover assembly lassembly 1 . . . . . . . . . . . . . 1 28 1wg-15416-00-00 . Cover, oil pump . . . . . . . . 1 29 1wg-15449-00-00 . Ring, rubber . . . . . . . . . . . 1 30 1jk-15486-00-00 . Grommet . . . . . . . . ...

  • Page 432: Generator

    1 3fh-81450-10-00 rotor assembly . . . . . . . . . 1 2 3fh-81410-10-00 stator assembly . . . . . . . . 1 3 90110-06138-00 bolt, hex skt head . . . . . . 3 4 98580-05016-00 screw, pan head . . . . . . . . 2 5 92990-05100-00 washer, spring . . . . . . . . . . 2 6 92901-05600-00 washer, plate . . . . ....

  • Page 433: Starting Motor

    1 1wg-81800-61-00 starting motor assemblyassy . . . . . . . . . . . 1 2 1hx-81815-00-00 . Cord, starter motor . . . 1 3 25g-81826-00-00 . Bolt . . . . . . . . . . . . . . . . . . . 1 4 1wg-81820-01-00 . Rear bracket assembly. 1 5 5h0-81844-01-00 . Gasket . . . . . . . . . . . . . . . . 2 6 5h0-81847...

  • Page 434: Starter Clutch

    1 1wg-15521-00-00 shaft 1 . . . . . . . . . . . . . . . . . 1 2 1wg-15512-00-00 gear, idler 1 . . . . . . . . . . . . 1 3 1wg-15517-00-00 gear, idler 2 . . . . . . . . . . . . 1 4 4h7-15521-00-00 shaft 1 . . . . . . . . . . . . . . . . . 2 5 1wg-15570-00-00 starter clutch assemblyassy . . . . . . . ...

  • Page 435: Clutch

    1 1wg-16150-01-00 pri drvn geargear comp . 1 2 1wg-16154-00-00 plate, thrust 1 . . . . . . . . . . 1 3 1wg-16371-01-00 boss, clutch . . . . . . . . . . . . 1 4 21v-16321-00-00 plate, friction . . . . . . . . . . 8 5 131-16324-00-00 plate, clutch 1 . . . . . . . . . . 7 6 37f-16351-00-00 plate, press...

  • Page 436: Transmission

    1 1wg-17411-00-00 axle, main . . . . . . . . . . . . . . . 1 2 1wg-17151-00-00 gear, 5th pinion . . . . . . . . . 1 3 90209-18208-00 washer . . . . . . . . . . . . . . . . . 1 4 93410-22039-00 circlip . . . . . . . . . . . . . . . . . . 1 5 3en-17131-00-00 gear, 3rd pinion (21t/23t) . 1 6 1wg-17161-...

  • Page 437: Transmission

    30 93311-42045-00 bearing (20ng3315ne) . . . . . 1 31 278-17424-01-00 circlip 1 . . . . . . . . . . . . . . . . 1 32 278-17425-00-00 circlip 2 . . . . . . . . . . . . . . . . 1 33 4g0-17433-01-00 nozzle . . . . . . . . . . . . . . . . . . 1 transmission ref. Part no. Number description qty remarks c...

  • Page 438: Shift Cam-Fork

    1 1wg-18540-01-00 shift cam assembly . . . . . . 1 2 90501-06022-00 . Spring, compression . . . . 1 3 278-18542-00-00 . Point, neutral . . . . . . . . . 1 4 278-18566-00-00 . Plate, side 2 . . . . . . . . . . . . 1 5 98701-05012-00 . Screw, flat head . . . . . . . 1 6 1wg-18531-01-00 bar, shift fork...

  • Page 439: Shift Shaft

    1 3en-18101-01-00 shift shaft assembly . . . . 1 2 90508-32682-00 . Spring, torsion . . . . . . . . 1 3 93102-12321-00 oil seal, sd-type . . . . . . . . 1 4 90560-12211-00 spacer . . . . . . . . . . . . . . . . . 1 5 93109-12053-00 oil seal (sdo 12/18/4-1) . . . . 2 6 3he-18110-00-00 shift pedal ass...

  • Page 440: Frame

    1 3fh-21110-00-00 frame . . . . . . . . . . . . . . . . . . 1 2 1wg-21277-00-00 sheet 3 . . . . . . . . . . . . . . . . . 1 3 1wg-21268-00-00 seal . . . . . . . . . . . . . . . . . . . . 1 4 1wg-2143a-00-00 cap . . . . . . . . . . . . . . . . . . . . . 2 5 1wg-21190-00-35 frame, rear . . . . . . . ....

  • Page 441: Frame

    30 91012-06016-00 bolt, flange (1wg) . . . . . . . 4 31 90480-18171-00 grommet . . . . . . . . . . . . . . . . 1 32 1wg-2137y-00-00 guide, air . . . . . . . . . . . . . . . 1 33 1wg-2139r-00-00 cover 2 . . . . . . . . . . . . . . . . . 1 34 90183-05003-00 nut, spring . . . . . . . . . . . . . . 5 35...

  • Page 442: Fender

    1 3fh-21510-00-ge fender, front . . . . . . . . . . . 1 silky white 2 1kh-21717-00-00 . Damper, side cover (4n0-24181-00-00) . . . . . . . . . 2 3 46x-2313a-00-00 brace, fork . . . . . . . . . . . . . 1 4 90105-06456-00 bolt, washer based . . . . . 4 5 1a8-21518-00-00 holder, cable . . . . . . . . ....

  • Page 443: Side Cover

    1 1wg-y2171-00-ge cover side 1 . . . . . . . . . . . . . 1 silky white 2 36y-28346-00-00 . Mold 2 . . . . . . . . . . . . . . . . . 1 3 90480-18495-00 . Grommet . . . . . . . . . . . . . . . 2 4 1wg-21781-00-00 . Emblem 1 . . . . . . . . . . . . . . . 2 5 1wg-2173e-01-00 . Graphic . . . . . . . . . ...

  • Page 444: Side Cover

    29 1aa-21874-00-00 gasket . . . . . . . . . . . . . . . . . 1 30 3gm-21816-00-00 pipe 1 . . . . . . . . . . . . . . . . . . . 1 31 90159-06056-00 screw, with washer . . . . . 2 32 34x-21691-00-00 flap . . . . . . . . . . . . . . . . . . . . 1 33 3bf-21683-80-00 plate, spec . . . . . . . . . . . . . ...

  • Page 445: Swing Arm

    1 3fh-22110-00-00 rear arm . . . . . . . . . . . . . . . 1 2 33m-22184-00-00 bush . . . . . . . . . . . . . . . . . . . . 1 3 93320-32403-00 bearing . . . . . . . . . . . . . . . . . 2 4 47x-22129-00-00 cover, thrust 2 . . . . . . . . . 2 5 90201-161j2-00 washer, plate . . . . . . . . . . . 2 6 9331...

  • Page 446: Swing Arm

    30 90201-10774-00 washer, plate . . . . . . . . . . . 1 31 90201-101j1-00 washer, plate . . . . . . . . . . . 3 32 95611-10100-00 nut, u . . . . . . . . . . . . . . . . . . . 4 33 2gh-25875-50-00 holder, brke hose 1 . . . . . 1 34 98580-06020-00 screw . . . . . . . . . . . . . . . . . . 1 35 92995-0...

  • Page 447: Rear Shocks

    1 3fh-22210-00-00 shk/abs assembly, rearassembly, rear . . . . . 1 2 90387-124t2-00 collar . . . . . . . . . . . . . . . . . 1 3 90109-10554-00 bolt . . . . . . . . . . . . . . . . . . . . 1 4 90201-101j1-00 washer, plate . . . . . . . . . . . 1 5 95601-10100-00 nut, u (95602-10100-00) . . . . . 1 r...

  • Page 448: Front Fork

    1 1wg-23102-00-00 front fork assembly l (l.H) . . . . . . . . . . . . . . . . . . . . 1 2 1wg-23126-00-00 . Tube, outer 1 . . . . . . . . . . . 1 3 122-23129-00-00 . . Gasket, drain plug . . . . 1 4 4h7-23119-00-00 . . Plug, drain - (122-23119-01) . . . . . . . . . . . . 1 5 3r4-23153-00-00 . Ring, ...

  • Page 449: Front Fork

    26 2yk-23125-00-00 . Metal, slide 1 . . . . . . . . . . 1 27 3en-23144-00-00 . Seal, dust . . . . . . . . . . . . . 1 28 4v2-23146-l0-00 . Washer, oil seal . . . . . . . 1 29 3bf-23110-50-00 . Inner tube comp. 1 . . . . . . 1 30 1wg-23170-00-00 . Cylinder, frtfrkfront fork . . . . . . . . . . . . . ...

  • Page 450: Steering

    1 93332-00008-00 bearing . . . . . . . . . . . . . . . . . 1 2 3en-23415-00-00 cover, ball race 1 . . . . . . 1 3 90179-25033-00 nut . . . . . . . . . . . . . . . . . . . . . 2 4 90202-26142-00 washer, plate . . . . . . . . . . . 1 5 26h-23418-01-00 washer, special . . . . . . . . . 1 6 90176-22050-...

  • Page 451: Fuel Tank

    1 1wg-24110-01-00 fuel tank . . . . . . . . . . . . . . . 1 2 1hx-24181-00-00 damper, locating 1 . . . . . . 2 3 90387-06380-00 collar . . . . . . . . . . . . . . . . . 1 4 95811-06080-00 bolt, flange . . . . . . . . . . . . 1 5 (1wg-21346-00-00) bracket, tank ftng . . . . . . 2 6 95811-06016-00 bol...

  • Page 452: Fuel Tank

    30 90387-07391-00 collar . . . . . . . . . . . . . . . . . 1 31 90179-06500-00 nut . . . . . . . . . . . . . . . . . . . . . 1 32 90480-11454-00 grommet . . . . . . . . . . . . . . . . 1 33 1wg-24311-00-00 pipe, fuel 1 . . . . . . . . . . . . . . 1 34 1wg-24312-00-00 pipe 2 . . . . . . . . . . . . ....

  • Page 453: Fuel Tank

    56 90201-06067-00 washer, plate . . . . . . . . . . . 3 57 95380-06600-00 nut . . . . . . . . . . . . . . . . . . . . . 3 58 90110-06132-00 bolt, hex skt headsocket head . . . . . . . . . . . . . . . . . . . . 2 59 1wg-2414a-00-00 cover, filler . . . . . . . . . . . . 1 60 1wg-24622-00-00 washer, ri...

  • Page 454: Seat

    2 1wg-24711-00-00 . Cover, single seat . . . . . 1 3 116-24741-00-00 . Pad, seat . . . . . . . . . . . . . . 1 4 1t4-24741-00-00 . Pad, seat . . . . . . . . . . . . . . 1 5 1wg-24750-00-00 tandem seat assembly . . . 1 6 1wg-24751-00-00 cover, tandem seat . . . . . 1 7 1wg-24723-00-00 . Damper, seat ...

  • Page 455: Front Wheel

    1 1wg-25168-00-ua wheel, cast front . . . . . . . 1 cast wheel white 2 90560-15314-00 spacer . . . . . . . . . . . . . . . . . 1 3 93306-30202-00 bearing . . . . . . . . . . . . . . . . . 2 4 93102-22014-00 oil seal . . . . . . . . . . . . . . . . . 1 5 341-25149-00-00 clutch, meter . . . . . . . . ...

  • Page 456: Front Brake Caliper

    1 1wg-25830-02-00 disc brake assembly. . . . . 2 2 90109-08718-00 bolt . . . . . . . . . . . . . . . . . . . . 12 3 1wg-25810-01-00 caliper assembly right . . 1 4 31a-w0057-00-00 . Piston assembly, caliper 2 5 31a-w0047-00-00 . . Caliper seal kit . . . . . . . 1 6 26h-w0045-11-00 . Brake pad kit . ....

  • Page 457: Rear Wheel

    1 1wg-25338-00-ua wheel, cast rear . . . . . . . . 1 cast wheel white 2 93306-30309-00 bearing . . . . . . . . . . . . . . . . . 1 3 93306-20310-00 bearing . . . . . . . . . . . . . . . . . 1 4 93102-25044-00 oil seal . . . . . . . . . . . . . . . . . 1 5 90387-173m5-00 collar . . . . . . . . . . . ...

  • Page 458: Rear Wheel

    27 90105-08321-00 bolt, washer based . . . . . 2 28 95701-08500-00 nut, flange . . . . . . . . . . . . . 2 29 91490-20020-00 pin, cotter . . . . . . . . . . . . . . 2 30 3fh-25381-00-00 axle, wheel . . . . . . . . . . . . . 1 31 90201-177k7-00 washer, plate . . . . . . . . . . . 2 32 90387-172r7-00 ...

  • Page 459: Rear Brake Caliper

    1 1wg-25831-50-00 disc, brake . . . . . . . . . . . . . 1 2 90109-08718-00 bolt . . . . . . . . . . . . . . . . . . . . 3 3 1wg-25810-51-00 caliper assembly . . . . . . . 1 4 51l-w0057-00-00 . Piston assembly, caliper 1 5 51l-w0047-11-00 . . Caliper seal kit . . . . . . . 1 6 51l-25919-00-00 . Suppo...

  • Page 460: Handlebar-Cable

    1 2tk-26121-00-00 handlebar lh . . . . . . . . . . . 1 2 2tk-26122-00-00 handlebar rh . . . . . . . . . . . 1 3 91316-08030-00 bolt, socket head . . . . . . . 2 4 91316-08025-00 bolt, socket head . . . . . . . 2 5 341-23469-00-00 cap, bolt . . . . . . . . . . . . . . . 4 6 1wg-26111-00-00 handlebar ...

  • Page 461: Front Master Cylinder

    1 36y-25850-01-00 master cylinder assembly . . . . . . . . . . . . . . . 1 2 36y-25852-01-00 . Cap, reservoir . . . . . . . . . 1 3 98706-04012-00 . Screw, flat head . . . . . . . 2 4 36y-25854-00-00 . Diaphragm, reservoir . . 1 5 36y-w0041-00-00 . Cylinder kit, master . . . . 1 6 36y-25867-00-00 br...

  • Page 462: Stand-Footrest

    1 2kt-27311-00-00 stand, side . . . . . . . . . . . . . . 1 2 90109-10474-00 bolt . . . . . . . . . . . . . . . . . . . . 1 3 90185-10037-00 nut, self-locking . . . . . . . . 1 4 90506-18224-00 spring, tension . . . . . . . . . . 1 5 90506-26225-00 spring, tension . . . . . . . . . . 1 6 1tx-27351-0...

  • Page 463: Stand-Footrest

    28 93501-04011-00 ball . . . . . . . . . . . . . . . . . . . . 2 29 1hx-27437-00-00 washer, special . . . . . . . . . 2 30 91701-06040-00 pin, clevis . . . . . . . . . . . . . . . 2 31 91490-20020-00 pin, cotter . . . . . . . . . . . . . . 2 32 90387-064h8-00 collar . . . . . . . . . . . . . . . . ....

  • Page 464: Rear Master Cylinder

    1 1wg-27200-00-00 pedal, brake . . . . . . . . . . . . 1 2 90506-20377-00 spring, tension . . . . . . . . . . 1 3 1wg-25850-50-00 master cylinder assembly . . . . . . . . . . . . . . . 1 4 1wg-w0042-50-00 . Cylinder kit, master . . . . 1 5 36y-2582a-50-00 . Joint . . . . . . . . . . . . . . . . . . ...

  • Page 465: Fairing-Cowling

    1 2ax-28381-00-00 windshield . . . . . . . . . . . . . . 1 2 90150-05020-00 screw, round head . . . . . . 6 3 95706-05500-00 nut, flange . . . . . . . . . . . . . 6 4 46x-28376-01-00 trim . . . . . . . . . . . . . . . . . . . . 1 5 3fh-2835g-00-ge body, front upper 1 . . . . . 1 silky white 6 3fh-28...

  • Page 466: Fairing-Cowling

    29 1kt-26280-00-00 mirror assembly (white)assembly (l) . . . . . . 1 ur white 30 1kt-26290-00-00 mirror assembly (white)assembly (r) . . . . . . 1 ur white 31 1kt-28371-00-00 damper . . . . . . . . . . . . . . . . . 2 32 1kt-28372-00-00 damper . . . . . . . . . . . . . . . . . 2 33 92906-06100-00 wa...

  • Page 467: Fairing-Cowling

    56 90183-05024-00 nut, spring . . . . . . . . . . . . . . 6 57 90179-05523-00 nut . . . . . . . . . . . . . . . . . . . . . 2 58 1wg-2836a-00-00 bracket 1 . . . . . . . . . . . . . . . 2 59 1wg-2836e-00-00 bracket 2 . . . . . . . . . . . . . . . 1 60 91026-06010-00 bolt . . . . . . . . . . . . . . ....

  • Page 468: Meter

    1 3fh-83570-00-00 speedometer assembly . . 1 2 3fh-83540-00-00 tachometer assembly . . . 1 3 1wg-83590-00-00 water temp meterassembly . . . . . . . . . 1 4 47x-83530-00-00 pilot light assembly . . . . 1 5 1wg-83513-00-00 damper . . . . . . . . . . . . . . . . . 1 6 1wg-83519-00-00 bracket, meter . ....

  • Page 469: Headlight

    1 3bf-84310-00-00 headlight unit assemblyassy . . . . . . . . . . . 1 2 2ax-84330-00-00 . Body assembly. . . . . . . . . 1 3 93210-06632-00 . O-ring . . . . . . . . . . . . . . . . . 2 4 3bf-84320-00-00 . Lens assembly. . . . . . . . . . 1 5 3bf-8432a-00-00 . Lens assembly. . . . . . . . . . 1 6 3ma...

  • Page 470: Taillight

    1 1uj-84710-a0-00 taillight unit assembly . . 1 2 1fn-84721-e0-00 . Lens, taillight . . . . . . . . . 1 3 47x-84723-00-00 . Gasket, tail lens . . . . . . . 1 4 1a2-84718-40-00 . Grommet . . . . . . . . . . . . . . . 1 5 256-84714-61-00 . Bulb (12v-27/8w) . . . . . . . . . 1 6 1uj-84735-a0-00 . Cord ...

  • Page 471: Turnsignal

    1 1uf-83310-00-00 front flasher light assembly 1 . . . . . . . . . . . . . . 1 2 51l-83332-01-00 . Lens, flasher . . . . . . . . . . 1 3 256-84714-61-00 . Bulb (12v-27/8w) . . . . . . . . . 1 4 97706-40620-00 . Screw, tapping . . . . . . . . . 1 5 1uf-83320-00-00 front flasher light assembly 2 . . ....

  • Page 472: Electrical 1

    1 1wg-82310-10-00 ignition coil assembly . . . 1 4 2 1wg-82320-10-00 ignition coil assembly . . . 1 3 3 97011-06025-00 bolt (97001-06025) . . . . . . . . 4 4 92995-06100-00 washer, spring . . . . . . . . . . 4 5 1wg-82370-00-00 plug cap assembly . . . . . . 4 6 3bf-82305-00-00 ignitor unit assembly ...

  • Page 473: Electrical 1

    25 3fh-82501-10-00 main swch strg lcksteering lock . . . . . . . 1 26 90149-06228-00 screw . . . . . . . . . . . . . . . . . . 2 electrical 1 ref. Part no. Number description qty remarks f2 fzr400u.

  • Page 474: Electrical 2

    1 1ae-82540-00-00 neutral switch assembly 1 2 93210-29196-00 o-ring . . . . . . . . . . . . . . . . . . 1 3 98503-06014-00 screw, pan head (92502-06016) . . . . . . . . . . . . . 2 4 11h-83591-00-00 thermo unit . . . . . . . . . . . . . 1 5 1wg-85720-00-00 oil level gauge assembly 1 6 95026-06016-00...

  • Page 475: Handle Switch-Lever

    1 3fh-83973-00-00 switch, handle 3 . . . . . . . . 1 2 98506-05035-00 . Screw, pan head . . . . . . . 2 3 3fh-83975-00-00 switch, handle 2 . . . . . . . . 1 4 98506-05040-00 . Screw, pan head . . . . . . . 1 5 98506-05045-00 . Screw, pan head . . . . . . . 1 6 29l-82911-01-00 holder, lever 1 . . . ....

  • Page 476

    Fzr400u k1.

  • Page 477

    Fzr400u k2.