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Yamaha FZS1000(N) 2001 Service Manual

Manual is about: FZS1000(N) 2001

Summary of FZS1000(N) 2001

  • Page 3

    Eas00000 fzs1000 (n) service manual 2000 by yamaha motor co.Ltd. First edition, december 2000 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited..

  • Page 4: Notice

    Note: caution: eas00003 notice this manual was produced by the yamaha motor company, ltd. Primarily for use by yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manu- al. Therefore, anyone who uses this book to perform maintenance and ...

  • Page 5: How To Use This Manual

    1 2 6 4 5 7 3 8 eas00007 how to use this manual this manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 ...

  • Page 6: Gen

    22 1 3 5 7 9 2 4 8 6 24 25 23 21 19 20 18 16 17 15 14 13 11 12 10 gen info spec eng carb elec cool chk adj trbl shtg chas eas00008 symbols the following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. 1 general information 2 specifications 3 periodic c...

  • Page 7: General Information

    General information specifications periodic checks and adjustments chassis engine cooling system carburetors electrical system troubleshooting gen info 1 spec 2 3 chas 4 eng 5 cool 6 carb 7 elec 8 trbl shtg 9 chk adj eas00012 table of contents.

  • Page 10: Gen

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

  • Page 11: Gen

    Gen info.

  • Page 12: Gen

    1-1 motorcycle identification gen info eas00014 general information motorcycle identification eas00017 vehicle identification number the vehicle identification number 1 is stamped into the right side of the steering head. Eas00018 model code the model code label 1 is affixed to the frame. This infor...

  • Page 13: Gen

    1-2 important information gen info spring lip oil grease lip eas00020 important information preparation for removal and dis- assembly 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “special tools” ...

  • Page 14: Gen

    1-3 important information gen info caution: eas00024 bearings and oil seals 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are vis- ible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips. Oil bearings liberally when insta...

  • Page 15: Gen

    1-4 checking the connections gen info note: note: note: eas00026 checking the connections check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: lead 1 coupler 2 connector 3 2. Check: lead coupler connector moisture dry with an air blower. Rust / stains connect and...

  • Page 16: Gen

    1-5 special tools gen info eas00027 special tools the following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part n...

  • Page 17: Gen

    1-6 special tools gen info tool no. Tool name / function illustration 90890-01426 oil filter wrench this tool is needed to loosen or tighten the oil filter cartridge. 90890-01434 rod holder this tool is used to support the damper ad- justing rod. Rod puller 90890-01437 rod puller attachment 90890-01...

  • Page 18: Gen

    1-7 special tools gen info tool no. Tool name / function illustration 90890-03141 timing light this tool is used to check the ignition tim- ing. 90890-03173 carburetor angle driver 2 this tool is used to turn the pilot screw when adjusting the engine idling speed. Valve spring com- pressor 90890-040...

  • Page 19: Gen

    1-8 special tools gen info tool no. Tool name / function illustration 90890-85505 yamaha bond no. 1215 this bond is used to seal two mating sur- faces (e.G., crankcase mating surfaces)..

  • Page 21: Spec

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

  • Page 22: Spec

    Spec.

  • Page 23: Spec

    2-1 general specifications spec specifications general specifications item standard limit model code 5vl1 (a) (b) (d) (dk) (e) (gb) (gr) (i) (n) (nl) (s) (sf) (ch) (p) 5lv2 (f) 5lv3 (d) 5lv4 (aus) dimensions overall length overall width overall height seat height wheelbase minimum ground clearance m...

  • Page 24: Spec

    2-2 engine specifications spec engine specifications item standard limit engine engine type displacement cylinder arrangement bore stroke compression ratio engine idling speed vacuum pressure at engine idling speed standard compression pressure (at sea level) liquid-cooled, 4-stroke, dohc 998 cm 3 f...

  • Page 25: Spec

    2-3 engine specifications spec item standard limit oil filter oil filter type bypass valve opening pressure cartridge (paper) 180 220 kpa (1.8 2.2 kg / cm 2 ) oil pump oil pump type inner-rotor-to-outer-rotor-tip clearance outer-rotor-to-oil-pump-housing clearance trochoid 0.09 0.15 mm 0.03 0.08 mm ...

  • Page 26: Spec

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

  • Page 27: Spec

    2-5 engine specifications spec head diameter face width seat width margin thickness item standard limit timing chain model / number of links tensioning system rh2015 / 130 automatic valves, valve seats, valve guides valve clearance (cold) intake exhaust valve dimensions 0.11 0.20 mm 0.21 0.25 mm val...

  • Page 28: Spec

    2-6 engine specifications spec item standard limit valve springs free length intake exhaust installed length (valve closed) intake exhaust compressed spring force (installed) intake exhaust spring tilt intake exhaust winding direction (top view) intake exhaust 38.9 mm 40.67 mm 34.5 mm 35 mm 82 96 n ...

  • Page 29: Spec

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

  • Page 30: Spec

    2-8 engine specifications spec item standard limit connecting rods crankshaft-pin-to-big-end-bearing clearance bearing color code 0.031 0.055 mm –1 = violet 0 = white 1 = blue 2 = black crankshaft width a width b max. Runout c big end side clearance d crankshaft-journal-to-crankshaft- journal-bearin...

  • Page 31: Spec

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

  • Page 32: Spec

    2-10 engine specifications spec item standard limit carburetors model (manufacturer) quantity throttle cable free play (at the flange of the throttle grip) id mark main jet main air jet jet needle needle jet pilot air jet bsr37 (mikuni) 4 3 5 mm 5lv1 00 carburetors 1 and 4: #132.5 carburetors 2 and ...

  • Page 33: Spec

    2-11 chassis specifications spec chassis specifications item standard limit frame frame type caster angle trail double cradle 26 _ 104 mm sss sss sss front wheel wheel type rim size material wheel travel wheel runout max. Radial wheel runout max. Lateral wheel runout cast wheel 17 mt3.50 aluminum 14...

  • Page 34: Spec

    2-12 chassis specifications spec item standard limit rear tire tire type size model (manufacturer) tire pressure (cold) 0 90 kg 90 201 kg high-speed riding min. Tire tread depth tubeless 180 / 55 zr17 (73w) mez4y (metzeler) bt020r u (bridgestone) 270 kpa (2.7 kgf / cm 2 , 2.7 bar) 290 kpa (2.9 kgf /...

  • Page 35: Spec

    2-13 chassis specifications spec item standard limit front suspension suspension type front fork type front fork travel spring free length spacer length installed length spring rate (k1) spring rate (k2) spring stroke (k1) spring stroke (k2) optional spring available fork oil recommended oil quantit...

  • Page 36: Spec

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

  • Page 37: Spec

    2-15 electrical specifications spec electrical specifications item standard limit system voltage 12 v sss ignition system ignition system type ignition timing advanced timing advancer type pickup coil resistance / color transistorized coil ignition unit model (manufacturer) transistorized coil ignit...

  • Page 38: Spec

    2-16 electrical specifications spec item standard limit indicator light (voltage / wattage quantity) neutral indicator light high beam indicator light oil level indicator light turn signal indicator light fuel indicator light water temperature indicator light 14 v 1.4 w 1 14 v 1.4 w 1 14 v 1.4 w 1 1...

  • Page 39: Spec

    2-17 electrical specifications spec item standard limit fuses (amperage quantity) main fuse headlight fuse signaling system fuse ignition fuse radiator fan fuse turn signal relay fuse backup fuse (odometer) reserve fuse 30 a 1 20 a 1 20 a 1 20 a 1 10 a 1 10 a 1 10 a 1 30 a 1 20 a 1 10 a 1.

  • Page 40: Spec

    2-18 tightening torques spec a (nut) 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm b (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm general tightening torques nm 6 15 30 55 85 130 m kg 0.6 1.5 3.0 5.5 8.5 13.0 eas00029 tightening torque general tightening torques this chart specifies tightening torques for stan- da...

  • Page 41: Spec

    2-19 tightening torques spec engine tightening torques item fastener thread size q’ty tightening torque remarks size y nm m s kgf spark plugs cylinder head cylinder head cylinder head camshaft caps cylinder head cover cylinder head (exhaust pipe) connecting rod caps generator rotor crankshaft sprock...

  • Page 42: Spec

    2-20 tightening torques spec note: item fastener thread size q’ty tightening torque remarks size y nm m s kgf ac magneto cover drive sprocker cover plate clutch cover timing chain cap bolt shift shaft cover breather plate timing mark accessing screw starter clutch idle gear shaft starter one-way clu...

  • Page 43: Spec

    2-21 tightening torques spec crankcase tightening sequence:.

  • Page 44: Spec

    2-22 tightening torques spec note: chassis tightening torques item thread size tightening remarks item thread size nm m kgf remarks upper bracket pinch bolt upper bracket cap nut upper bracket and handlebar holder handlebar holder lower bracket pinch bolt lower bracket ring nut front brake master cy...

  • Page 45: Spec

    2-23 lubrication points and lubricant types spec eas00031 lubrication points and lubricant types engine lubrication point lubricant oil seal lips o-rings bearings crankshaft pins piston surfaces piston pins connecting rod bolts and nuts crankshaft journals camshaft lobes camshaft journals valve stem...

  • Page 46: Spec

    2-24 lubrication points and lubricant types spec eas00032 chassis lubrication point lubricant steering bearings, steering seal lips and ball race cover lips pivot shaft swing arm pivoting points and connecting arm bearings connecting arm oil seal lips swing arm oil seal lips relay arm bearings relay...

  • Page 47: Spec

    2-25 cooling system diagrams spec 1 radiator cap 2 thermostat housing 3 radiator 4 water pump eas00033 cooling system diagrams.

  • Page 48: Spec

    2-26 cooling system diagrams spec 1 radiator cap 2 thermostat housing 3 radiator 4 oil cooler 5 water jacket joint.

  • Page 49: Spec

    2-27 cooling system diagrams spec 1 radiator cap 2 thermostat 3 thermo unit.

  • Page 50: Spec

    2-28 cooling system diagrams spec 1 radiator.

  • Page 51: Spec

    2-29 oil cooler exhaust camshaft intake camshaft main gallery oil filter main axle drive axle strainer relief valve engine oil lubrication chart spec engine oil lubrication chart.

  • Page 52: Spec

    2-30 1 oil cooler 2 oil filter cartridge 3 drain bolt 4 oil level switch 5 oil strainer 6 oil pump lubrication diagrams spec eas00034 lubrication diagrams.

  • Page 53: Spec

    2-31 lubrication diagrams spec 1 intake camshaft 2 exhaust camshaft 3 oil cooler 4 oil strainer 5 oil pump.

  • Page 54: Spec

    2-32 lubrication diagrams spec 1 intake camshaft 2 exhaust camsahft 3 oil filter cartridge 4 oil level switch.

  • Page 55: Spec

    2-33 lubrication diagrams spec 1 cylinder head 2 crankshaft.

  • Page 56: Spec

    2-34 lubrication diagrams spec 1 main axle 2 oil delivery pipe 3 drive axle.

  • Page 57: Spec

    2-35 cable routing spec f route the horn lead outside the motorcycle body, and fasten with the under bracket. Do not loose be- tween the horn and under bracket. G route the brake hose through the brake hose guide. H route the throttle cable 1 and 2 backward the brake hose, and left side the brake ho...

  • Page 58: Spec

    2-36 1 fuel pump lead 2 fuel pump 3 exup cable 4 handlebar switch lead (right) 5 throttle cable 1 6 throttle cable 2 7 water-carburetor hose 8 fan motor lead 9 coolant reservoir tank over flow hose 10 fuel tank drain hose 11 fuel tank breather hose 12 white paint mark 13 rear brake light switch lead...

  • Page 59: Spec

    2-37 q insert the all couplers into the rubber cover. R route the rear brake light switch lead inside the another leads. S route the neutral switch lead and speed sensor lead left side the coolant reservoir hose. T route the coolant reservoir hose left side the en- gine mounting bracket. U route the...

  • Page 60: Spec

    2-38 a fasten the main switch lead and handlebar switch lead with a plastic guide. B fasten the water-head hose and water-carburetor hose with a plastic band. C fasten the clutch cable with a plastic band. D fasten the clutch cable with a steel clamp. E fasten the wire harness with a plastic band. F...

  • Page 61: Spec

    2-39 cable routing spec and rectifier regulator lead. U route the water carburetor hose outside the coolant hose. V route the starter cable outside the coolant hose, and up- per the water-carburetor hose. W route the high tension cable (#2, 3) forward the exup cable and high tension cable (#4). X ro...

  • Page 62: Spec

    2-40 17 ignition coil lead 18 battery 19 emergency engine stop switch 20 flasher relay 21 fuse box 22 igniter unit 23 flasher light lead 24 taillight lead 25 alarm coupler (free) 26 starter relay 27 battery positive lead 28 fan motor lead 29 battery negative lead 30 starting circuit cutoff relay cab...

  • Page 63: Spec

    2-41 cable routing spec k fasten the fuel hose and air induction system hose with a plastic clamp. L route the coolant reservoir hose under the frame cross pipe. M fasten the fuel hose and frame with a plastic band. N put the fuel tank drain hose into the frontward nipple on the fuel tank. O put the...

  • Page 64: Spec

    2-42 aa put the seat lock cable into the groove on the rear fender. Ab fasten the battery positive lead with a plastic band. Cable routing spec t fasten the ignition coil lead and frame cross pipe with a plastic clamp. Do not fasten the red / black lead and orange lead. U fasten the handlebar switch...

  • Page 66: Chk

    Chk adj chapter 3 periodic checks and adjustments introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance / lubrication intervals 3-1 . . . . . . . . . . . Front cowling / seat / side cover / fuel tank 3-3 . . . . . . . . . ...

  • Page 67: Chk

    Chk adj checking and lubricating the cables 3-50 . . . . . . . . . . . . . . . . . Lubricating the levers and pedals 3-50 . . . . . . . . . . . . . . . . . . . Lubricating the sidestand 3-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubricating the rear suspension 3-50 . . . . . . . ...

  • Page 68: Chk

    3-1 introduction periodic maintenance/lubrication intervals chk adj note: eas00036 periodic checks and adjustments introduction this chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliabl...

  • Page 69: Chk

    3-2 periodic maintenance/lubrication intervals chk adj note: no item check or maintenance job odometer reading ( 1,000 km) annual no. Item check or maintenance job 1 10 20 30 40 check 16 * chassis fasteners (see page 2-22) make sure that all nuts, bolts and screws and properly tightened. √ √ √ √ √ 1...

  • Page 70: Chk

    3-3 front cowling chk adj order job / part q’ty remarks 1 2 3 4 5 6 removing the fron cowling inner panel headlight / meter coupler front cowling assembly back view mirror meter unit headlight unit 2 1 / 1 1 2 1 1 remove the4 parts in the order listed. Disconnect. For installation, reverse the remov...

  • Page 71: Chk

    3-4 seat, side cover and fuel tank chk adj order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the seat, side cover and fuel tank seat side cover (left and right) fuel sender coupler fuel tank fuel tank breather hose fuel tank drain hose fuel hose grab bar rear cowling 1 2 1 1 1 1 1 1 1 remove ...

  • Page 72: Chk

    3-5 adjusting the valve clearance chk adj note: note: note: eas00045 engine adjusting the valve clearance the following procedure applies to all of the valves. Valve clearance adjustment should be made on a cold engine, at room temperature. When the valve clearance is to be measured or adjusted, the...

  • Page 73: Chk

    3-6 adjusting the valve clearance chk adj note: a front d. For each cylinder, starting with cylinder #1 at tdc, turn the crankshaft clockwise as speci- fied in the following table. B degrees that the crankshaft is turned clockwise c cylinder d combustion cycle #2 cylinder 180 _ #4 cylinder 360 _ #3 ...

  • Page 74: Chk

    3-7 adjusting the valve clearance chk adj note: note: note: cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. B. Select the proper ...

  • Page 75: Chk

    3-8 adjusting the valve clearance chk adj measured clearance # exa ! Installed pad number example: valve clearance: 0.11 x 0.20 mm installed is 150 measured clearance is 0.25 mm replace 150 pad with 160 pad 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 2...

  • Page 76: Chk

    3-9 adjusting the valve clearance chk adj note: note: note: e. Install the new valve pad 1 and the valve lift- er 2 . Apply molybdenum disulfide to the valve pad. Lubricate the valve lifter with molybdenum dis- ulfide oil. The valve lifter must turn smoothly when ro- tated by hand. Install the valve...

  • Page 77: Chk

    3-10 synchronizing the carburetors chk adj note: note: eas00050 synchronizing the carburetors prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. Pla...

  • Page 78: Chk

    3-11 synchronizing the carburetors chk adj note: note: 6. Adjust: carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in ei- ther direction until both gauges read the same. After each step, rev the engine two or three times, each time for les...

  • Page 79: Chk

    3-12 adjusting the engine idling speed chk adj note: eas00052 adjusting the engine idling speed prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine...

  • Page 80: Chk

    3-13 adjusting the engine idling speed/ adjusting the throttle cable free play chk adj a b note: c. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained. Direction engine idling speed is in- creased. Direction engine idling speed is decreased. 5. Adj...

  • Page 81: Chk

    3-14 adjusting the throttle cable free play chk adj note: a b note: a b warning 3. Adjust: throttle cable free play when the motorcycle is accelerating, the accel- erator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. B. Turn the adjusting nut 3 in direction a o...

  • Page 82: Chk

    3-15 adjusting the throttle cable free play/ checking the spark plugs chk adj caution: 4. Install: fuel tank seat eas00059 checking the spark plugs the following procedure applies to all of the spark plugs. 1. Disconnect: spark plug cap 2. Remove: spark plug before removing the spark plugs, blow awa...

  • Page 83: Chk

    3-16 checking the spark plugs/ checking the ignition timing chk adj 13 nm (1.3 m kg) note: note: 7. Install: spark plug before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: spark plug cap eas00063 checking the ignition timing prior to checking the ignition timing, c...

  • Page 84: Chk

    3-17 checking the ignition timing/ measuring the compression pressure chk adj note: note: caution: b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range check the ignition system. The ignition timing is not adjustable. 4. Remove: timing light...

  • Page 85: Chk

    3-18 measuring the compression pressure chk adj warning note: 13 nm (1.3 m kg) 6. Measure: compression pressure above the maximum pressure inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure squirt a few drops of oil into the affected cylinder ...

  • Page 86: Chk

    3-19 checking the engine oil level chk adj note: caution: note: eas00069 checking the engine oil level 1. Stand the motorcycle on a level surface. Place the motorcycle on a suitable stand. Make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes. 3. Check: engine oil level ...

  • Page 87: Chk

    3-20 changing the engine oil chk adj caution: eas00073 changing the engine oil 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: engine oil filler cap 1 engine oil drain bolt 2 (along with the gasket) 4. Drai...

  • Page 88: Chk

    3-21 changing the engine oil chk adj 43 nm (4.3 m kg) c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 nm (1.7 m kg) 6. Check: engine oil drain bolt gasket damage replace. 7. Install: engine oil drain bolt 8. Fill: crankcase (with the spec...

  • Page 89: Chk

    3-22 changing the engine oil/ adjusting the clutch cable free play chk adj a b note: a b oil gallery bolt 10 nm (1.0 m kg) eas00078 adjusting the clutch cable free play 1. Check: clutch cable free play a out of specification adjust. Clutch cable free play (at the end of the clutch lever) 10 x 15 mm ...

  • Page 90: Chk

    3-23 cleaning the air filter element chk adj caution: eas00086 cleaning the air filter element 1. Remove: seat fuel tank side cover cover 1 2. Remove: air filter case cover 1 air filter element 3. Clean: air filter element apply compressed air to the outer surface of the air filter element. 4. Check...

  • Page 91: Chk

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

  • Page 92: Chk

    3-25 checking the fuel hoses and fuel filter / checking the crankcase breather hose / checking the exhaust system chk adj note: caution: drain and flush the fuel tank if abrasive dam- age to any components of the fuel line is evi- dent. The arrow mark a on the fuel filter should face to the side of ...

  • Page 93: Chk

    3-26 adjusting the exup cables chk adj caution: eas00101 adjusting the exup cables 1. Remove: seat fuel tank 2. Remove: exup valve pulley cover 1 3. Check: exup operation a. Disconnect the exup servomotor connector 1 . B. Connect the battery to the exup servomotor connector and check if the servomot...

  • Page 94: Chk

    3-27 adjusting the exup cables/ checking the coolant level chk adj 10 nm (1.0 m kg) note: 4. Check: exup cable free play a exup cable free play 1.5 mm max. 5. Adjust: exup cable free play a. Loosen both locknuts 1 . B. Insert a 4 mm long pin through the notch in the exup valve pulley and into the ho...

  • Page 95: Chk

    3-28 checking the coolant level chk adj caution: note: adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and correct the antifreeze concentration of the coolant. Use only distilled water. Soft water may be used if distilled water...

  • Page 96: Chk

    3-29 checking the cooling system chk adj eas00104 checking the cooling system 1. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3 oil cooler inlet hose 4 oil cooler outlet hose 5 water jacket inlet joint 6 water pump outlet joint 7 cracks / damage replace. Refer to “cooling system” in ...

  • Page 97: Chk

    3-30 changing the coolant chk adj warning eas00105 changing the coolant 1. Remove seat fuel tank front cowling rear suspension refer to “rear shock absorber as- sembly” in chapter 4. 2. Disconnect: coolant reservoir hose 1 3. Drain: coolant (from the coolant reservoir) 4. Remove: radiator cap 1 a ho...

  • Page 98: Chk

    3-31 changing the coolant chk adj 7 nm (0.7 m kg) warning 7. Check: copper washer 1 coolant drain bolt 2 damage replace. 8. Install: coolant drain bolt 9. Connect: coolant reservoir hose 10. Fill: cooling system (with the specified amount of the recom- mended coolant) recommended antifreeze high-qua...

  • Page 99: Chk

    3-32 changing the coolant chk adj caution: note: adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. Use only distilled water. Soft water may be used if di...

  • Page 100: Chk

    3-33 adjusting the front brake chk adj note: a a warning caution: eas00107 chassis adjusting the front brake 1. Adjust: brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desi...

  • Page 101: Chk

    3-34 adjusting the rear brake chk adj a b warning warning caution: eas00110 adjusting the rear brake 1. Check: brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) out of specification adjust. Brake pedal position (below the top of the rider footrest) 40...

  • Page 102: Chk

    3-35 adjusting the rear brake/ checking the brake fluid level chk adj a b note: warning caution: note: 3. Adjust: rear brake light switch refer to “adjusting the rear brake light switch”. Eas00115 checking the brake fluid level 1. Stand the motorcycle on a level surface. Place the motorcycle on a su...

  • Page 103: Chk

    3-36 a b checking the brake pads/ adjusting the rear brake light switch chk adj note: a b eas00122 checking the brake pads the following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: front brake pad rear brake pad wear indicator groove 1 almost disap- peared replace the...

  • Page 104: Chk

    3-37 checking the brake hoses/ bleeding the hydraulic brake system chk adj warning note: eas00131 checking the brake hoses the following procedure applies to all of the brake hoses and clamps. 1. Check: brake hose 1 cracks / damage / wear replace. 2. Check: brake hose clamp 2 loose connection tighte...

  • Page 105: Chk

    3-38 bleeding the hydraulic brake system / adjusting the shift pedal chk adj warning 2. Bleed: hydraulic brake system a. Add the recommended brake fluid to the proper level. B. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). C. Connect a clear plastic hose 1 tightly...

  • Page 106: Chk

    3-39 adjusting the shift pedal/ adjusting the drive chain slack chk adj a b note: caution: warning note: 2. Adjust: adjusting bolt length a. Loosen both locknuts 1 . B. Turn the adjusting bolt 2 in direction a or b to obtain the correct shift pedal position. Direction shift pedal is raised. Directio...

  • Page 107: Chk

    3-40 adjusting the drive chain slack chk adj a b note: 4. Adjust: drive chain slack a. Loosen the brake caliper bracket bolt. B. Loosen the wheel axle nut 1 . C. Loosen both locknuts 2 . D. Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is ob- tained. Direction ...

  • Page 108: Chk

    3-41 lubricating the drive chain/ checking and adjusting the steering head chk adj warning note: eas00142 lubricating the drive chain the drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out rapidly. Therefore, the drive chain should be se...

  • Page 109: Chk

    3-42 checking and adjusting the steering head chk adj note: warning note: b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . Set the torque wrench at a right angle to the ring nut wrench. Ring nut wrench 90890-01403 lower ring nut (initial tightening torqu...

  • Page 110: Chk

    3-43 checking and adjusting the steering head / checking the front fork / adjusting the front fork legs chk adj warning warning caution: steering stem nut 110 nm (11 m kg) upper bracket pinch bolt 30 nm (3.0 m kg) handlebar holder bolt 23 nm (2.3 m kg) eas00149 checking the front fork 1. Stand the m...

  • Page 111: Chk

    3-44 adjusting the front fork legs chk adj a b caution: a b 1. Adjust: spring preload a. Turn the adjusting bolt 1 in direction a or b . Direction spring preload is increased (suspension is harder). Direction spring preload is decreased (suspension is softer). Adjusting positions standard: 2 minimum...

  • Page 112: Chk

    3-45 adjusting the front fork legs/ adjusting the rear shock absorber assembly chk adj caution: warning caution: note: compression damping never go beyond the maximum or minimum adjustment positions. 1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or b . Direction compres...

  • Page 113: Chk

    3-46 adjusting the rear shock absorber assembly chk adj a b caution: a b a. Turn the adjusting ring 1 in direction a or b . B. Align the desired position on the adjusting ring with the stopper 2 . Direction spring preload is increased (s spension is direction increased (suspension is harder). Direct...

  • Page 114: Chk

    3-47 adjusting the rear shock absorber assembly/ checking the tires chk adj caution: a b warning compression damping never go beyond the maximum or minimum adjustment positions. 1. Adjust: compression damping a. Turn the adjusting screw 1 in direction a or b . Direction compression damping is increa...

  • Page 115: Chk

    3-48 checking the tires chk adj warning warning basic weight (with oil and a full fuel tank) 231 kg maximum load* 189 kg cold tire pressure front tire rear tire up to 90 kg load* 250 kpa (2.5 kgf/cm 2 ) 270 kpa (2.7 kgf/cm 2 ) 90 kg maximum load* 250 kpa (2.5 kgf/cm 2 ) 290 kpa (2.9 kgf/cm 2 ) high ...

  • Page 116: Chk

    3-49 checking the tires chk adj warning note: tube wheel tube tire only tubeless wheel tube or tubeless tire after extensive tests, the tires listed below have been approved by yamaha motor co., ltd. For this model. The front and rear tires should always be by the same manufactur- er and of the same...

  • Page 117: Chk

    3-50 checking and lubricating the cables / lubricating the levers and pedals / lubricating the sidestand / lubricating the rear suspension chk adj warning note: eas00170 checking and lubricating the cables the following procedure applies to all of the cable sheaths and cables. Damaged cable sheaths ...

  • Page 118: Chk

    3-51 checking and charging the battery chk adj warning caution: eas00178 electrical system checking and charging the battery batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive meas...

  • Page 119: Chk

    3-52 checking and charging the battery chk adj relationship between the open-circuit voltage and the charging time at 20 _ c open-circuit voltage (v) these values vary with the temperature, the condition of the battery plates, and the electrolyte level. 13.0 12.5 12.0 11.5 5 6.5 10 charging time (ho...

  • Page 120: Chk

    3-53 checking and charging the battery chk adj charging ambient temperature 20 _ c open-circuit voltage (v) check the open-circuit voltage. Time (minutes) ambient temperature 20 _ c open-circuit voltage (v) charging condition of the battery (%) warning caution: 5. Charge: s battery (refer to the app...

  • Page 121: Chk

    3-54 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charged and amp meter to the battery and start charging. Make sure that the current is higher than the standard charging current written on the battery. By turning the charging voltage adjust...

  • Page 122: Chk

    3-55 checking and charging the battery chk adj measure the open-circuit voltage prior to charging. Connect a charger and amp meter to the battery and start charging. Note: voltage should be measured 30 minutes after the machine is stopped. Make sure that the current is higher than the standard charg...

  • Page 123: Chk

    3-56 checking and charging the battery/ checking the fuses chk adj caution: caution: note: 6. Check: battery vent obstruction clean. Damage replace. 7. Install: battery 8. Connect: battery leads (to the battery terminals) first, connect the positive lead 1 , then the negative lead 2 . 9. Check: batt...

  • Page 124: Chk

    3-57 checking the fuses chk adj warning pocket tester 90890-03112 b. If the pocket tester indicates “ ∞ ”, replace the fuse. 3. Replace: blown fuse a. Turn off the ignition. B. Install a new fuse of the correct amperage rating. C. Turn on the switches to verify if the electrical circuit is operation...

  • Page 125: Chk

    3-58 replacing the headlight bulbs chk adj warning caution: eas00183 replacing the headlight bulbs the following procedure applies to both of the headlight bulbs. 1. Disconnect: headlight coupler 1 bulb cover 2 2. Remove: headlight bulb holder 1 3. Remove: headlight bulb 2 since the headlight bulb g...

  • Page 126: Chk

    3-59 adjusting the headlight beams/ adjusting the digital clock chk adj a b a b a b note: note: eas00185 adjusting the headlight beams the following procedure applies to both of the headlights. 1. Adjust: headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or b . Direction headl...

  • Page 129: Chas

    Chas chapter 4 chassis front wheel and brake discs 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front wheel 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front wheel 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 130: Chas

    Chas front fork 4-44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front fork legs 4-46 . . . . . . . . . . . . . . . . . . . . . . . . Disassembling the front fork legs 4-46 . . . . . . . . . . . . . . . . . . Checking the front fork ...

  • Page 131: Chas

    4-1 front wheel and brake discs chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the front wheel and brake discs brake hose holder (left and right) brake caliper (left and right) wheel axle pinch bolt front wheel axle front wheel collar (left and right) oil seal cover (left and right) bra...

  • Page 132: Chas

    4-2 front wheel and brake discs chas order job / part q’ty remarks disassembling the front wheel oil seal (left and right) wheel bearing (left and right) spacer 2 2 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 eas00518 front wheel.

  • Page 133: Chas

    4-3 front wheel and brake discs chas warning note: note: note: note: eas00521 removing the front wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the front wheel is elevat...

  • Page 134: Chas

    4-4 front wheel and brake discs chas warning note: eas00525 checking the front wheel 1. Check: wheel axle roll the wheel axle on a flat surface. Bends replace. Do not attempt to straighten a bent wheel axle. 2. Check: tire front wheel damage / wear replace. Refer to “checking the tires” and “checkin...

  • Page 135: Chas

    4-5 front wheel and brake discs chas caution: note: c. Remove the wheel bearings 3 with a gener- al bearing puller. D. Install the new wheel bearings and oil seals in the reverse order of disassembly. Do not contact the wheel bearing center race 1 or balls 2 . Contact should be made only with the ou...

  • Page 136: Chas

    4-6 front wheel and brake discs chas note: caution: note: 3. Measure: s brake disc thickness measure the brake disc thickness at a few different locations. Out of specification replace. Brake disc thickness limit (minimum) 4.5 mm 4. Adjust: s brake disc deflection a. Remove the brake disc. B. Rotate...

  • Page 137: Chas

    4-7 front wheel and brake discs chas 72 nm (7.2 m kg) 23 nm (2.3 m kg) caution: 40 nm (4.0 m kg) warning note: note: eas00544 installing the front wheel the following procedure applies to both brake discs. 1. Lubricate: wheel axle oil seal lips recommended lubricant lithium soap base grease 2. Tight...

  • Page 138: Chas

    4-8 front wheel and brake discs chas note: 2. Find: s front wheel’s heavy spot a. Spin the front wheel. B. When the front wheel stops, put an “x 1 ” mark at the bottom of the wheel. C. Turn the front wheel 90 _ so that the “x 1 ” mark is positioned as shown. D. Release the front wheel. E. When the w...

  • Page 139: Chas

    4-9 rear wheel and brake disc chas order job / part q’ty remarks 1 2 3 4 5 6 removing the rear wheel brake caliper brake torque rod nut washer wheel axle rear wheel assembly 1 1 1 1 1 1 remove the parts in the order listed. Place the motorcycle on a suitable stand so that the rear wheel is elevated....

  • Page 140: Chas

    4-10 order job / part q’ty remarks disassembling the rear wheel spacer bearing spacer oil seal circlip bearing 1 1 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 5 6 rear wheel and brake disc chas eas00560

  • Page 141: Chas

    4-11 rear wheel and brake disc chas order job / part q’ty remarks 1 2 3 4 5 6 7 removing the brake disc and rear wheel sprocket brake disc rear wheel sprocket collar (left and right) oil seal bearing rear wheel drive hub rear wheel drive hub damper 1 1 2 1 1 1 6 remove the parts in the order listed....

  • Page 142: Chas

    4-12 rear wheel and brake disc chas warning note: note: note: eas00561 removing the rear wheel 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Re...

  • Page 143: Chas

    4-13 rear wheel and brake disc chas eas00565 checking the rear wheel 1. Check: wheel axle rear wheel wheel bearings oil seals refer to “front wheel”. 2. Check: tire rear wheel damage / wear replace. Refer to “checking the tires” and “checking the wheels” in chapter 3. 3. Measure: rear wheel radial r...

  • Page 144: Chas

    4-14 rear wheel and brake disc chas note: rear wheel sprocket self-locking nut 69 nm (6.9 m kg) tighten the self-locking nuts in stages and in a crisscross pattern. Eas00531 checking the brake disc 1. Check: brake disc damage / galling replace. 2. Measure: brake disc deflection out of specification ...

  • Page 145: Chas

    4-15 rear wheel and brake disc chas note: 150 nm (15 m s kg) 40 nm (4.0 m s kg) note: 4. Adjust: s brake disc deflection a. Remove the brake disc. B. Rotate the brake disc by one bolt hole. C. Install the brake disc. Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt...

  • Page 146: Chas

    4-16 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 removing the front brake pads brake pad clip brake pad pin brake pad spring brake pad brake pad shim bleed scrw 2 1 1 2 2 1 remove the parts in the order listed. For installation, reverse the removal procedure. 40 nm (4.0 m kg...

  • Page 147: Chas

    4-17 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 removing the rear brake pads brake pad clip brake pad pin brake pad spring brake pad brake pad shim bleed screw 4 2 1 2 2 2 remove the parts in the order listed. For installation, reverse the removal procedure. 40 nm (4.0 m kg...

  • Page 148: Chas

    4-18 front and rear brakes chas caution: note: eas00579 disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: never disassemble brake components un- less absolutely necessary. If any connection on the hydraulic brake system is disconnected, the entir...

  • Page 149: Chas

    4-19 front and rear brakes chas note: 2. Remove: brake pad clips 1 brake pad pins 2 brake pad spring 3 3. Remove: brake pads 1 (along with the brake pad shims) 4. Measure: brake pad wear limit out of specification replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install: brake pad shi...

  • Page 150: Chas

    4-20 front and rear brakes chas note: 40 nm (4.0 m kg) note: d. Install new brake pad shims onto the new brake pads. E. Install new brake pads and a new brake pad spring. The arrow a on the brake pad spring must point in the direction of disc rotation. 6. Install: brake pad cover brake pad pins brak...

  • Page 151: Chas

    4-21 front and rear brakes chas note: 3. Measure: brake pad wear limit out of specification replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: brake pad shims (onto the brake pads) brake pads brake pad spring always install new brake pads, brake pad shims, brake pad pins, brake...

  • Page 152: Chas

    4-22 front and rear brakes chas 40 nm (4.0 m kg) 5. Install: brake pad cover brake pad pins brake pad clips brake caliper 6. Check: brake fluid level below the minimum level mark a add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 7. Check: ...

  • Page 153: Chas

    4-23 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 7 removing the front brake master cylinder brake fluid brake lever brake switch lead brake switch union bolt brake hose / copper washer master cylinder bracket master cylinder 1 2 1 1 1 / 2 1 1 remove the parts in the order li...

  • Page 154: Chas

    4-24 front and rear brakes chas order job / part q’ty remarks disassembling the front brake master cylinder master cylinder boot circlip master cylinder kit spring 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 eas00585.

  • Page 155: Chas

    4-25 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the rear brake master cylinder side cover (right) brake fluid master cylinder bolt union bolt brake hose / copper washer clip/hose cotter pin pin washer master cylinder 2 1 1 / 2 2 / 1 1 1 1 1 remove the parts in ...

  • Page 156: Chas

    4-26 front and rear brakes chas order job / part q’ty remarks disassembling the rear brake master cylinder master cylinder boot circlip master cylinder kit spring 1 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 eas00587.

  • Page 157: Chas

    4-27 front and rear brakes chas note: note: note: eas00588 disassembling the front brake mas- ter cylinder before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: brake switch coupler (from the brake switch) 2. Remove: union bolt 1 cop...

  • Page 158: Chas

    4-28 a b d c front and rear brakes chas eas00592 checking the front and rear brake master cylinders the following procedure applies to the both of the brake master cylinders. 1. Check: brake master cylinder damage / scratches / wear replace. Brake fluid delivery passages (brake master cylinder body)...

  • Page 159: Chas

    4-29 a front and rear brakes chas warning 10 nm (1.0 m kg) note: 30 nm (3.0 m kg) caution: warning note: eas00598 assembling and installing the front brake master cylinder before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never use s...

  • Page 160: Chas

    4-30 front and rear brakes chas warning caution: 3. Fill: brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and ...

  • Page 161: Chas

    4-31 front and rear brakes chas 30 nm (3.0 m kg) caution: warning warning caution: eas00608 assembling the rear brake master cylinder 1. Install: copper washers 1 new brake hose 2 union bolt 3 when installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the pr...

  • Page 162: Chas

    4-32 front and rear brakes chas 3. Bleed: brake system refer to “bleeding the hydraulic brake system” in chapter 3. 4. Check: brake fluid level below the minimum level mark a add the recommended brake fluid to the proper level. Refer to “checking the brake fluid level” in chapter 3. 5. Adjust: brake...

  • Page 163: Chas

    4-33 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 removing the front brake calipers brake fluid union bolt copper washer brake hose brake caliper 1 2 1 1 remove the parts in the order listed. Drain. For installation, reverse the removal procedure. 6 nm (0.6 m kg) 30 nm (3.0 m kg)...

  • Page 164: Chas

    4-34 front and rear brakes chas order job / part q’ty remarks disassembling the front brake calipers brake pad clip brake pad pin brake pad spring brake pad brake caliper piston brake caliper piston seal bleed screw 2 1 1 2 4 8 1 disassemble the parts in the order listed. The following procedure app...

  • Page 165: Chas

    4-35 front and rear brakes chas order job / part q’ty remarks 1 2 3 4 removing the rear brake caliper brake fluid union bolt copper washer brake hose brake caliper 1 2 1 1 remove the parts in the order listed. Drain. For installation, reverse the removal procedure. 40 nm (4.0 m kg) 30 nm (3.0 m kg) ...

  • Page 166: Chas

    4-36 front and rear brakes chas order job / part q’ty remarks disassembling the rear brake caliper brake pad clip brake pad pin brake pad spring brake pad brake caliper piston brake caliper piston seal bleed screw 4 2 1 2 2 4 2 disassemble the parts in the order listed. For assembly, reverse the dis...

  • Page 167: Chas

    4-37 front and rear brakes chas note: note: warning eas00625 disassembling the front brake cal- ipers the following procedure applies to both of the brake calipers. Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2...

  • Page 168: Chas

    4-38 front and rear brakes chas note: note: warning eas00628 disassembling the rear brake cal- iper before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: union bolt 1 copper washers 2 brake hose put the end of the brake hose into a container and pump ...

  • Page 169: Chas

    4-39 a b front and rear brakes chas warning eas00633 checking the front and rear brake calipers recommended brake component replacement schedule brake pads if necessary piston seals every two years brake hoses every two years brake fluid every two years and whenever the brake is disas- sembled. 1. C...

  • Page 170: Chas

    4-40 front and rear brakes chas warning 30 nm (3.0 m kg) warning caution: 6 nm (0.6 m kg) 40 nm (4.0 m kg) eas00638 assembling and installing the front brake calipers the following procedure applies to both of the brake calipers. Before installation, all internal brake com- ponents should be cleaned...

  • Page 171: Chas

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

  • Page 172: Chas

    4-42 front and rear brakes chas warning 30 nm (3.0 m kg) warning caution: 40 nm (4.0 m kg) eas00644 assembling and installing the rear brake caliper before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. Never use solevents on internal br...

  • Page 173: Chas

    4-43 front and rear brakes chas warning caution: use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a ...

  • Page 174: Chas

    4-44 front fork chas order job / part q’ty remarks 1 2 3 4 5 removing the front fork front wheel front fender bolt (upper bracket) cap bolt bolt (lower bracket) front fork assembly (left / right) 1 2 2 4 1 / 1 remove the parts in the order listed. Refer to “front wheel and brake discs”. Loosen. Loos...

  • Page 175: Chas

    4-45 front fork chas order job / part q’ty remarks disassembly the front fork cap bolt o-ring spacer spring seat fork spring damper adjusting rod dust seal oil seal clip damper rod bolt copper washer damper rod inner tube oil seal washer slide metal oil flow stopper 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 d...

  • Page 176: Chas

    4-46 front fork chas warning note: warning note: eas00649 removing the front fork legs the following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a ...

  • Page 177: Chas

    4-47 front fork chas caution: note: 2. Remove: spacer 1 spring seat 2 spring 3 damper adjusting rod 4 3. Drain: fork oil 4. Remove: oil seal clip 1 (with a flat-head screwdriver) do not scratch the inner tube. 5. Remove: damper rod bolt damper rod 1 while holding the damper rod with the damper rod h...

  • Page 178: Chas

    4-48 front fork chas caution: warning caution: excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. Eas00657 checking the front f...

  • Page 179: Chas

    4-49 front fork chas warning note: caution: note: 35 nm (3.5 m kg) note: eas00660 assembling the front fork legs the following procedure applies to both of the front fork legs. Make sure that the oil levels in both front fork legs are equal. Uneven oil levels can result in poor han- dling and a loss...

  • Page 180: Chas

    4-50 front fork chas caution: note: note: caution: note: 4. Install: oil seal 1 (with the fork seal driver weight 2 and fork seal driver attachemt 3 ) fork seal driver weight 90890-01367 fork seal driver attachment 90890-01374 make sure that the numbered side of the oil seal faces up. Before install...

  • Page 181: Chas

    4-51 front fork chas note: note: note: 7. Install: rod puller 1 rod puller attachment 2 (onto the damper rod 3 ) rod puller 90890-01437 rod puller attachment 90890-01436 8. After filling the front fork leg, slowly stroke the damper rod 1 up and down (at least ten times) to distribute the fork oil. B...

  • Page 182: Chas

    4-52 front fork chas note: note: caution: 12. Install: spring 1 spring seats 2 spacer 3 nut 4 damper adjusting rod 5 cap bolt 6 a. Install the fork spring, spring seats, and spacer. Install the fork spring with the larger pitch a fac- ing up. B smaller pitch b. Install the rod puller and the rod pul...

  • Page 183: Chas

    4-53 front fork chas note: 23 nm (2.3 m kg) 25 nm (2.5 m kg) 30 nm (3.0 m kg) warning eas00662 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: front fork leg temporarily tighten the upper and lower bracket pinch bolts. Make sure that the inn...

  • Page 184: Chas

    4-54 handlebar chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 removing the handlebar front brake master cylinder right handlebar switch throotle cable grip end (right) throttle grip grip end (left) left grip left handlebar switch starter cable clutch cable clutch lever handlebar ho...

  • Page 185: Chas

    4-55 handlebar chas warning note: warning warning eas00666 removing the handlebar 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: throttle cable housing 1 throttle grip 2 3. Remove: handlebar grip 1 blow compressed...

  • Page 186: Chas

    4-56 handlebar chas warning warning 23 nm (2.3 m kg) caution: note: note: 3.Install: handlebar grip a. Apply a light coat of rubber adhesive onto the left end of the handlebar. B. Slide the handlebar grip over the left end of the handlebar. C. Wipe off any excess rubber adhesive with a clean rag. Do...

  • Page 187: Chas

    4-57 handlebar chas note: note: 5. Install: left handlebar switch align the pins a on the right handlebar switch with the holes b in the handlebar. 6. Install: clutch lever holder align the slit in the clutch lever holder with the punch mark a in the left handlebar. 7. Install: brake master cylinder...

  • Page 188: Chas

    4-58 steering head chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 removing the steering head front wheel front fork handlebar front brake hose bracket horn / bracket brake hose joint upper bracket cap nut upper bracket lock washer upper ring nut rubber washer lower ring nut dust co...

  • Page 189: Chas

    4-59 steering head chas warning warning eas00677 removing the lower bracket 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: lower ring nut 1 (with the special tool 2 ) ring nut wrench 90890-01403 securely support t...

  • Page 190: Chas

    4-60 steering head chas caution: note: note: note: b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. C. Install a new rubber seal and new bearing races. If the bearing race is not installed properly, the steering head pipe could be damaged. Always replace the bear...

  • Page 191: Chas

    4-61 rear shock absorber assembly chas order job / part q’ty remarks 1 2 3 4 removing the rear shock absorber assembly rear wheel side cover (left / right) connecting arm relay arm rear shock absorber 1 / 1 1 1 1 remove the parts in the order listed. Refer to “rear wheel” for installation, reverse t...

  • Page 192: Chas

    4-62 rear shock absorber assembly chas warning warning eas00687 handling the rear shock absorber and gas cylinder this rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand the followi...

  • Page 193: Chas

    4-63 rear shock absorber assembly chas warning note: note: note: eas00694 removing the rear shock absorber assembly 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear whe...

  • Page 194: Chas

    4-64 rear shock absorber assembly chas note: eas00696 checking the rear shock absorber assembly 1. Check: rear shock absorber rod bends / damage replace the rear shock absorber assembly. Rear shock absorber gas leaks / oil leaks replace the rear shock absorber assembly. Spring damage / wear replace ...

  • Page 195: Chas

    4-65 swingarm and drive chain chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the swing arm and drive chain rear wheel rear shock absorber assembly rear brake caliper brake hose holder side protector (left / right) pivot shaft swing arm drive chain case drive chain guard dust cover oil...

  • Page 196: Chas

    4-66 swingarm and drive chain chas order job / part q’ty remarks 10 11 12 13 14 15 16 bearing spacer shoft pedal assembly drive sprocket cover drive chain guide drive sprocket drive chain 2 1 1 1 1 1 1 for installation, reverse the removal procedure. 125 nm (12.5 m kg) 23 nm (2.3 m kg) 85 nm (8.5 m ...

  • Page 197: Chas

    4-67 swingarm and drive chain chas warning note: note: eas00703 removing the swingarm 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: con...

  • Page 198: Chas

    4-68 swingarm and drive chain chas warning note: warning eas00704 removing the drive chain 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove...

  • Page 199: Chas

    4-69 swingarm and drive chain chas note: 4. Check: dust covers 1 spacer 2 oil seals 3 damage / wear replace. Bearings 4 damage / pitting replace. 5. Check: connecting arms 1 relay arm 2 damage / wear replace. Bearings 3 oil seals 4 damage / pitting replace. Spacers 5 damage / scratches replace. Eas0...

  • Page 200: Chas

    4-70 swingarm and drive chain chas caution: 3. Clean: drive chain a. Wipe the drive chain with a clean cloth. B. Put the drive chain in kerosine and remove any remaining dirt. C. Remove the drive chain from the kerosine and completely dry it. This motorcycle has a drive chain with small rubber o-rin...

  • Page 201: Chas

    4-71 swingarm and drive chain chas 85 nm (8.5 m kg) note: 48 nm (4.8 m kg) 48 nm (4.8 m kg) eas00713 installing the drive chain 1. Lubricate: drive chain recommended lubricant engine oil or chain lubricant suitable for o-ring chains 2. Install: drive chain 1 drive sprocket 2 washer 3 new drive sproc...

  • Page 202: Chas

    4-72 swingarm and drive chain chas note: caution: install the connecting arm front bolt 1 from the right. 3. Install: rear shock absorber assembly rear wheel refer to “installing the rear shock absorber assembly” and ”rear wheel”. 4. Adjust: drive chain slack refer to “adjusting the drive chain slac...

  • Page 204: Eng

    Eng chapter 5 overhauling the engine engine 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive sprocket and exhaust pipe 5-1 . . . . . . . . . . . . . . . . . . . . . Leads and hoses 5-2 . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 205: Eng

    Eng clutch 5-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch cover 5-36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clutch 5-38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 206: Eng

    Eng transmission 5-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transmission, shift drum assembly and shift forks 5-78 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the transmission 5-83 . . . . . . . ...

  • Page 207: Eng

    Eng.

  • Page 208: Eng

    5-1 order job / part q’ty remarks 1 2 3 4 5 6 7 removing the drive sprocket and exhaust pipe carburetor plug code ignition coil radiator water hose air iduction system side cover (left) stator coil coupler / oil level switch shit rod drive sprocket cover drive sprocket water outlet hose exhaust pipe...

  • Page 209: Eng

    5-2 order job / part q’ty remarks 1 2 3 4 5 removing the leads and hoses cover clutch cable nuetral switch / speed sensor / pickup coil lead water head pipe coolant outlet hose 1 1 1/1/1 1 1 remove the parts in the order listed. Disconnect. For installation, reverse the removal pro- cedure. Engine e...

  • Page 210: Eng

    5-3 order job / part q’ty remarks 1 2 3 4 5 6 removing the engine down tube engine mounting bolt (front) engine bracket engine mounting bolt (rear upper) engine mounting bolt (rear lower) engine 1 2 1 1 1 1 remove the parts in the order listed. For installation, reverse the removal procedure. 55 nm ...

  • Page 211: Eng

    5-4 engine eng note: 10 nm (10 m kg) note: eas00192 installing the engine 1. Install: engine mount bolt 1 engine mount bolt 2 engine mount bolt 3 engine bracket 4 engine mount bolt 5 down tube 6 do not fully tighten the bolts. 2. Tighten the bolts in the following order. Engine mount bolt 1 55 nm (5...

  • Page 212: Eng

    5-5 camshaft eng order job / part q’ty remarks 1 2 3 4 removing the cylinder head cover carburetor assembly radiator assembly and thermostat assembly spark plug cylinder head cover cylinder head cover gasket timing chain guide (top side) 4 1 1 1 remove the parts in the order listed. Refer to “carbur...

  • Page 213: Eng

    5-6 order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the camshafts pickup coil rotor cover float chamber air vent hose holder timing chain tensioner timing chain tensioner gasket timing chain guide (exhaust side) intake camshaft cap dowel pin exhaust camshaft cap dowel pin intake camshaft...

  • Page 214: Eng

    5-7 camshaft eng order job / part q’ty remarks 11 12 13 14 intake camshaft sprocket exhaust camshaft sprocket pin timing chain guide (intake side) 1 1 1 1 for installation, reverse the removal procedure. 10 nm (1.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 24 nm (2.4 m kg) 10 nm (1.0 m kg).

  • Page 215: Eng

    5-8 camshaft eng note: note: eas00198 removing the camshafts 1. Remove: pickup rotor coil cover 2. Align: “t” mark on the pickup coil rotor a (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. B. When piston #1 is at tdc on the compres- sion stroke, align the “t” mark a with th...

  • Page 216: Eng

    5-9 camshaft eng caution: 7. Remove timing chain guide (exhaust side) 1 camshaft caps dowel pins to prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 8. Remove: intake camshaft 1 exhaus...

  • Page 217: Eng

    5-10 camshaft eng note: 3. Measure: s camshaft runout out of specification replace. Camshaft runout less than 0.03 mm 4. Measure: s camshaft-journal-to-camshaft-cap clear- ance out of specification ³ measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 x 0.062 mm ...

  • Page 218: Eng

    5-11 camshaft eng eas00208 checking the timing chain, camshaft sprockets, and timing chain guides the following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: timing chain 1 damage / stiffness replace the timing chain and camshaft sprockets as a set. 2. Check: ...

  • Page 219: Eng

    5-12 camshaft eng note: note: note: 2. Check: one-way cam operation rough movement replace the timing chain tensioner housing. A. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. While pressing the timing chain tensioner rod, wind it clockwise with a thin...

  • Page 220: Eng

    5-13 camshaft eng 10 nm (1.0 m kg) note: caution: note: caution: 3. Install: camshaft cap bolts tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and ...

  • Page 221: Eng

    5-14 camshaft eng warning d. Turn both camshafts opposite each other so that the punch marks c in the camshaft are aligned with the arrow marks d in the cam- shaft caps as shown. E. While holding the camshafts, temporarily tighten the camshaft sprocket bolts. 5. Install: timing chain tensioner a. Wh...

  • Page 222: Eng

    5-15 camshaft eng 15 nm (15 m kg) 7. Check: “t” mark a make sure that the “t” mark a on the pickup coil rotor is aligned with the crankcase mat- ing surface b . Camshaft punch marks c make sure that the marks c on the camshaft are aligned with the arrow marks d in the comshaft caps. Out of alignment...

  • Page 223: Eng

    5-16 cylinder head eng order job / part q’ty remarks 1 2 3 removing the cylinder head engine intake and exhaust camshafts cylinder head cylinder head gasket dowel pin 1 1 2 remove the parts in the order listed. Refer to “engine”. Refer to “camshafts”. For installation, reverse the removal procedure....

  • Page 224: Eng

    5-17 cylinder head eng note: note: note: eas00223 removing the cylinder heads 1. Remove: cylinder head nuts cylinder head cap nuts cylinder head bolts loosen the nuts in the proper sequence as shown. Loosen each nut 1 / 2 of a turn at a time. After all of the nuts are fully loosened, remove them. Ea...

  • Page 225: Eng

    5-18 cylinder head eng note: 20 nm (2.0 m kg) 50 nm (5.0 m kg) note: note: eas00233 installing the cylinder head 1. Install: gasket new 1 dowel pins 2 2. Install: cylinder head pass the timing chain through the timing chain cavity. 3. Tighten: cylinder head nuts 1 x 10 1st 2nd cylinder head bolt 11 ...

  • Page 226: Eng

    5-19 valves and valve springs eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the valves and valve springs cylinder head intake valve lifter intake valve pad intake valve cotter intake valve upper spring seat intake valve spring intake valve oil seal intake valve lower spring seat intak...

  • Page 227: Eng

    5-20 order job / part q’ty remarks 10 11 12 13 14 15 16 17 18 exhaust valve lifter exhaust valve pad exhaust valve cotter exhaust valve upper spring seat exhaust valve spring exhaust valve oil seal exhaust valve lower spring seat exhaust valve exhaust valve guide 8 8 16 8 8 8 8 8 8 for installation,...

  • Page 228: Eng

    5-21 valves and valve springs eng note: note: note: note: eas00237 removing the valves the following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.G., valves, valve springs, valve seats), make sure that the valves properly...

  • Page 229: Eng

    5-22 note: valves and valve springs eng 4. Remove: upper spring seat 1 valve spring 2 oil seal 3 lower spring seat 4 valve 5 identify the position of each part very carefully so that it can be reinstalled in its original place. Eas00239 checking the valves and valve guides the following procedure ap...

  • Page 230: Eng

    5-23 valves and valve springs eng note: note: 2. Replace: s valve guide to ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 _ c in an oven. A. Remove the valve guide with a valve guide remover 1 . B. Install the new valve guide with a valve gu...

  • Page 231: Eng

    5-24 valves and valve springs eng note: 3. Eliminate: carbon deposits (from the valve face and valve seat) 4. Check: valve face pitting/ wear grind the valve face. Valve stem end mushroom shape or diameter larger than the body of the valve stem replace the valve. 5. Measure: valve margin thickness a...

  • Page 232: Eng

    5-25 valves and valve springs eng note: note: caution: note: a. Apply mechanic’s blueing dye (dykem) 1 onto the valve face. B. Install the valve into the cylinder head. C. Press the valve through the valve guide and onto the valve seat to make a clear pattern. D. Measure the valve seat width. Where ...

  • Page 233: Eng

    5-26 valves and valve springs eng eas00241 checking the valve springs the following procedure applies to all of the valve springs. 1. Measure: valve spring free length a out of specification replace the valve spring. Valve spring free length intake spring 38.9 mm exhaust spring 40.67 mm 2. Measure: ...

  • Page 234: Eng

    5-27 valves and valve springs eng note: note: eas00242 checking the valve lifters the following procedure applies to all of the valve lifters. 1. Check: valve lifter damage / scratches replace the valve lift- ers and cylinder head. Eas00245 installing the valves the following procedure applies to al...

  • Page 235: Eng

    5-28 valves and valve springs eng note: caution: note: 4. Install: valve cotters 1 install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor 90890-04019 attachment intake valve 90890-04114 exhaust valve 90890-04108 5. To s...

  • Page 236: Eng

    5-29 order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the stator coil assembly rider seat and fuel tank bottom cowling engine oil generator rotor cover generator rotor cover gasket dowel pin generator rotor bolt generator rotor stator coil assembly coupler stator coil assembly lead holder stat...

  • Page 237: Eng

    5-30 generator eng note: note: warning caution: removing the generator 1. Remove: generator rotor cover 1 loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: generator rotor bolt 1 washer while holding ...

  • Page 238: Eng

    5-31 generator eng 65 nm (6.5 m s kg) + 60 _ note: note: 3. Tighten: s generator rotor bolt 1 new s while holding the generator rotor 2 with the rotor holding tool 3 , tighten the generator ro- tor bolt. S after tightening to 65 nm (6.5 m s kg), tighten another 60 _ . Rotor holding tool 90890-01235 ...

  • Page 239: Eng

    5-32 order job / part q’ty remarks 1 2 3 4 removing the pickup coil and pickup coil rotor rider seat and fuel tank bottom cowling and right side cowling engine oil generator rotor cover pickup coil lead holder pickup coil rotor cover pickup coil rotor cover gasket dowel pin 1 1 1 2 remove the parts ...

  • Page 240: Eng

    5-33 pickup coil eng order job / part q’ty remarks 5 6 7 pickup coil coupler pickup coil pickup coil rotor 1 1 1 disconnect. For installation, reverse the removal procedure. 12 nm (1.2 m kg) 15 nm (1.5 m kg) 60 nm (6.0 m kg) 10 nm (1.0 m kg).

  • Page 241: Eng

    5-34 pickup coil eng note: note: note: removing the pickup coil rotor 1. Remove: pickup coil lead holder 1 pickup coil rotor cover 2 loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: pickup coil rotor...

  • Page 242: Eng

    5-35 pickup coil eng 60 nm (6.0 m kg) note: note: 2. Tighten: pickup coil rotor bolt 1 while holding the generator rotor 2 with the ro- tor holding tool 3 , tighten the pickup coil rotor bolt. Rotor holding tool 90890-01235 3. Apply: sealant (onto the pickup coil lead grommet) yamaha bond no. 1215 9...

  • Page 243: Eng

    5-36 clutch eng order job / part q’ty remarks 1 2 3 4 removing the clutch cover engine oil clutch cable clutch cover clutch cover gasket dowel pin 1 1 1 2 remove the parts in the order listed. Drain. Refer to “changing the engine oil” in chapter 3. For installation, reverse the removal procedure. 12...

  • Page 244: Eng

    5-37 order job / part q’ty remarks 1 2 3 4 5 6 removing the pull lever shaft circlip pull lever pull lever spring pull lever shaft oil seal bearing 2 1 1 1 1 2 remove the parts in the order listed. For installation, reverse the removal procedure. Clutch eng eb405010

  • Page 245: Eng

    5-38 clutch eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the clutch clutch cover pull rod friction plate clutch plate friction plate clutch plate friction plate friction plate clutch damper spring clutch damper spring seat 1 1 1 2 4 6 3 1 1 1 remove the parts in the order listed. ...

  • Page 246: Eng

    5-39 clutch eng 12 nm (1.2 m kg) 70 nm (7.0 m kg) 8 nm (0.8 m kg) order job / part q’ty remarks 11 12 13 14 15 16 17 18 19 20 21 clutch boss nut lock washer clutch boss thrust washer clutch housing bearing starter clutch gear bearing starter clutch assembly circlip starter clutch idle gear 1 1 1 1 1...

  • Page 247: Eng

    5-40 clutch eng note: eas00277 removing the clutch 1. Straighten the lock washer tab. 2. Loosen: clutch boss nut 1 while holding the clutch boss 2 with the univer- sal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder 90890-04086 3. Remove: clutch boss nut 1 lock washer 2 clutch ...

  • Page 248: Eng

    5-41 clutch eng note: note: 2. Measure: friction plate thickness out of specification replace the friction plates as a set. Measure the friction plate at four places. Friction plate thickness friction plate a 3.42 3.58 mm : 3.32 mm friction plate b 2.92 3.08 mm : 2.82 mm 3. Measure: assembly width a...

  • Page 249: Eng

    5-42 clutch eng eas00281 checking the clutch plates the following procedure applies to all of the clutch plates. 1. Check: clutch plate damage replace the clutch plates as a set. 2. Measure: clutch plate warpage (with a surface plate and thickness gauge 1 ) out of specification replace the clutch pl...

  • Page 250: Eng

    5-43 clutch eng note: note: eas00284 checking the clutch housing 1. Check: clutch housing dogs damage / pitting / wear deburr the clutch housing dogs or replace the clutch housing. Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: bearing damage / wear replace the c...

  • Page 251: Eng

    5-44 clutch eng 2. Check: pull rod bearing damage / wear replace. Eas00351 checking the starter clutch 1. Check: starter clutch rollers damage / wear replace. 2. Check: starter clutch idle gear starter clutch drive gear starter clutch gear burrs / chips / roughness / wear replace the defective part(...

  • Page 252: Eng

    5-45 clutch eng note: 90 nm (9.0 m kg) note: 4. Check: starter clutch operation a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. B. When turning the starter clutch drive gear clockwise a , the starter clutch and the start- er clutch drive gear should ...

  • Page 253: Eng

    5-46 clutch eng note: 3. Bend the lock washer tab along a flat side of the nut. 4. Lubricate: friction plates clutch plates (with the recommended lubricant) recommended lubricant engine oil 5. Install: friction plates clutch plates first, install a friction plate and then alternate between a clutch ...

  • Page 254: Eng

    5-47 clutch eng note: 8 nm (0.8 m kg) note: note: 12 nm (1.2 m kg) note: 7. Install: pressure plate 1 align the punch mark b in the pressure plate with the punch mark a in the clutch boss. 8. Install: clutch springs clutch spring bolts tighten the clutch spring bolts in stages and in a crisscross pa...

  • Page 255: Eng

    5-48 shift shaft eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the shift shaft and stopper lever drive sprocket cover shift shaft cover shift shaft cover gasket dowel pin shift shaft shift shaft spring spacer stopper lever spring stopper lever collar shift shaft spring stopper 1 1 ...

  • Page 256: Eng

    5-49 shift shaft eng 22 nm (2.2 m kg) note: note: eas00328 checking the shift shaft 1. Check: shift shaft 1 bends / damage / wear replace. Shift shaft spring 3 damage / wear replace. Eas00330 checking the stopper lever 1. Check: stopper lever 1 bends / damage replace. Roller turns roughly replace th...

  • Page 257: Eng

    5-50 oil pan and oil pump eng order job / part q’ty remarks 1 2 3 4 5 6 removing the oil pan and oil pump engine oil coolant radiator assembly and water pump outlet pipe exhaust pipe assembly oil level switch connector oil level switch oil level switch lead holder oil pan oil pan gasket dowel pin 1 ...

  • Page 258: Eng

    5-51 10 nm (1.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 10 nm (1.0 m kg) 43 nm (4.3 m kg) order job / part q’ty remarks 7 8 9 10 11 12 13 14 drain pipe oil strainer oil pipe oil delivery pipe oil/ water pump assembly drive sprocket cover dowel pin oil/ water pump as...

  • Page 259: Eng

    5-52 oil pan and oil pump eng order job / part q’ty remarks disassembling the oil pump oil/ water pump assembly driven sprocket washer oil pump housing bearing pin oil pump outer rotor oil pump inner rotor pin 1 1 1 1 2 1 1 1 disassemble the parts in the order listed. For assembly, reverse the disas...

  • Page 260: Eng

    5-53 oil pan and oil pump eng note: eas00362 removing the oil pan 1. Remove: oil level switch 1 oil pan 2 engine oil drain bolt 3 gasket dowel pins loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Eas00364 chec...

  • Page 261: Eng

    5-54 oil pan and oil pump eng eas00365 checking the relief valve 1. Check: relief valve body 1 relief valve 2 spring 3 o-ring 4 damage / wear replace the defective part(-s). Eas00366 checking the oil delivery pipe 1. Check: oil delivery pipe 1 oil pipe 2 damage replace. Obstruction wash and blow out...

  • Page 262: Eng

    5-55 oil pan and oil pump eng note: 12 nm (1.2 m kg) note: 10 nm (1.0 m kg) note: 2. Install: pin 1 inner rotor 2 outer rotor 3 oil pump housing 4 oil pump housing screw 10 nm (1.0 m kg) when installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the in- ner rotor 2 ....

  • Page 263: Eng

    5-56 oil pan and oil pump eng 10 nm (10 m kg) 10 nm (10 m kg) 43 nm (4.3 m kg) warning note: eas00380 installing the oil pan 1. Install: dowel pins gasket new oil pan 1 oil level switch 2 engine oil drain bolt 3 always use new copper washers. Tighten the oil pan bolts in stages and in a crisscross p...

  • Page 264: Eng

    5-57 crankcase eng order job / part q’ty remarks 1 2 3 4 5 removing the crankcase engine cylinder head pickup coil and pickup coil rotor stator coil assembly clutch housing and starter clutch idle gear oil/ water pump assembly timing chain crankshaft sprocket pin oil/ water pump assembly drive chain...

  • Page 265: Eng

    5-58 order job / part q’ty remarks 6 7 8 9 10 oil/ water pump assembly drive sprocket washer plate lower crankcase dowel pin 1 1 1 1 3 for installation, reverse the removal procedure. 10 nm (1.0 m kg) 10 nm (1.0 m kg) crankcase eng.

  • Page 266: Eng

    5-59 crankcase eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 removing the connecting rods and pistons connecting rod cap big end lower bearing piston pin clip piston pin piston connecting rod big end upper bearing top ring 2nd ring oil ring 4 4 8 4 4 4 4 4 4 4 remove the parts in the order ...

  • Page 267: Eng

    5-60 crankcase eng order job / part q’ty remarks 1 2 3 removing the crankshaft assembly crankcase connecting rod caps crankshaft crankshaft journal lower bearing crankshaft journal upper bearing 1 5 5 remove the parts in the order listed. Separate. Refer to “crankcase”. Refer to “connecting rods and...

  • Page 268: Eng

    5-61 crankcase eng note: caution: note: eas00384 disassembling the crankcase 1. Place the engine upside down. 2. Remove: crankcase bolts loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Loosen the bolts in decr...

  • Page 269: Eng

    5-62 crankcase eng note: caution: note: eas00393 removing the connecting rods and pistons the following procedure applies to all of the connecting rods and pistons. 1. Remove: connecting rod cap 1 big end bearings identify the position of each big end bearing so that it can be reinstalled in its ori...

  • Page 270: Eng

    5-63 crankcase eng note: note: 3. Remove: top ring 2nd ring oil ring when removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. Eas00387 removing the crankshaft assembly 1. Remove: crankshaft assembly 1 crankshaft journal upper bearings...

  • Page 271: Eng

    5-64 crankcase eng note: eas00256 checking the cylinders and pistons the following procedure applies to all of the cyl- inders and pistons. 1. Check: piston wall cylinder wall vertical scratches rebore or replace the cylinder, and replace the piston and piston rings as a set. 2. Measure: piston-to-c...

  • Page 272: Eng

    5-65 crankcase eng note: c. Measure piston skirt diameter “p” with the micrometer. A 0.5 mm from the bottom edge of the piston. Piston size “p” 73.955 73.970 mm d. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinder clearance with the following ...

  • Page 273: Eng

    5-66 crankcase eng note: note: 2. Install: piston ring (into the cylinder) level the piston ring in the cylinder with the pis- ton crown as shown. A 5 mm 3. Measure: piston ring end gap out of specification replace the piston ring. The oil ring expander spacer’s end gap cannot be measured. If the oi...

  • Page 274: Eng

    5-67 crankcase eng 3. Measure: piston pin bore inside diameter out of specification → replace the piston. Piston pin bore inside diameter 17.002 17.013 mm 4. Calculate: piston-pin-to-piston clearance out of specification replace the piston pin and piston as a set. Piston-pin-to-piston clearance = pi...

  • Page 275: Eng

    5-68 crankcase eng caution: note: note: note: do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crank- shaft journal bearings must be installed in their original positions. A. Clean t...

  • Page 276: Eng

    5-69 crankcase eng note: note: f. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase. Crankcase bolt bolt 1 10 1st: 15 nm (1.5 m s kg) 2nd: 15 nm (1.5 m s kg) + 45 50 _ bolt 11 15 , 17 20 , 23 , 25 28 12 nm (1.2 m s kg) bolt 16 , 24 14 nm (1.4 m s kg) bolt 21 22 24...

  • Page 277: Eng

    5-70 crankcase eng caution: note: crankshaft journal bearing color code –1 pink / violet 0 pink / white 1 pink / blue 2 pink / black 3 pink / brown 5. Measure: crankshaft-pin-to-big-end-bearing clear- ance out of specification replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance...

  • Page 278: Eng

    5-71 crankcase eng note: caution: c. Put a piece of plastigauge 1 on the crank- shaft pin. D. Assemble the connecting rod halves. Do not move the connecting rod or crankshaft until the clearance measurement has been completed. Apply molybdenum disulfide grease onto the bolts, threads, and nut seats....

  • Page 279: Eng

    5-72 crankcase eng note: 6. Select: big end bearings (p 1 p 4 ) the numbers a stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. “p1” “p5” refer to the bearings shown in the crankshaft illustration. For example, if th...

  • Page 280: Eng

    5-73 crankcase eng note: checking the sprockets and chains 1. Check: crankshaft sprocket 1 oil / water pump assembly drive sprocket 2 cracks / damage / wear replace the de- fective part(-s). 2. Check: timing chain 1 damage / stiffness replace the timing chain and crankshaft sprocket as a set. Oil / ...

  • Page 281: Eng

    5-74 crankcase eng note: note: eas00268 installing the connecting rod and piston the following procedure applies to all of the connecting rods and pistons. 1. Install: top ring 1 2nd ring 2 upper oil ring rail 3 oil ring expander 4 lower oil ring rail 5 be sure to install the piston rings so that th...

  • Page 282: Eng

    5-75 crankcase eng note: 36 nm (3.6 m kg) caution: 5. Lubricate: crankshaft pins big end bearings connecting rod big end inner surface (with the recommended lubricant) recommended lubricant engine oil 6. Install: big end bearings connecting rod assembly (into the cylinder and onto the crankshaft pin...

  • Page 283: Eng

    5-76 crankcase eng note: note: eas00414 assembling the crankcase 1. Lubricate: crankshaft journal bearings (with the recommended lubricant) recommended lubricant engine oil 2. Apply: sealant (onto the crankcase mating surfaces) yamaha bond no. 1215 90890-85505 do not allow any sealant to come into c...

  • Page 284: Eng

    5-77 crankcase eng caution: note: 6. Install: s upper crankcase 1 (onto the lower crankcase 2 ) before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 7. Install: s crankcase bolts s lubricate the bolt threads wi...

  • Page 285: Eng

    5-78 transmission eng order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 removing the transmission, shift drum assembly, and shift forks crankcase stopper lever drive axle assembly circlip oil seal bearing shift drum retainer shift fork guide bar spring shift fork “l” shift fork “r” 1 1 1 1 1 2 4 1 1 r...

  • Page 286: Eng

    5-79 order job / part q’ty remarks disassembling the main axle assembly 2nd pinion gear toothed lock washer toothed lock washer retainer 6th pinion gear toothed spacer toothed washer circlip 3rd / 4th pinion gears 5th pinion gear collar 1 1 1 1 1 2 2 1 1 1 disassembly the parts in the order listed. ...

  • Page 287: Eng

    5-80 order job / part q’ty remarks main axle / 1st pinion gear bearing main axle bearing housing 1 1 1 for assembly, reverse the disassembly procedure. 11 13 12 transmission eng.

  • Page 288: Eng

    5-81 order job / part q’ty remarks disassembling the drive axle assembly washer 1st wheel gear spacer 5th wheel gear circlip washer 3rd wheel gear toothed spacer toothed lock washer toothed lock washer retainer 1 1 1 1 3 3 1 2 1 1 disassembly the parts in the order listed. 1 10 2 3 4 5 6 7 8 9 trans...

  • Page 289: Eng

    5-82 order job / part q’ty remarks 4th wheel gear 6th wheel gear 2nd wheel gear spacer drive axle bearing spacer 1 1 1 1 1 1 1 for assembly, reverse the disassembly procedure. 11 13 12 14 15 16 17 transmission eng.

  • Page 290: Eng

    5-83 transmission eng warning eas00420 removing the transmission 1. Remove: main axle assembly 1 (with the torx wrench t30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. B. Tighten the bolts until they contact the crank- case sur...

  • Page 291: Eng

    5-84 transmission eng eas00422 checking the shift drum assembly 1. Check: shift drum grooves damage / scratches / wear replace the shift drum. Shift drum segment 1 damage / wear replace. Shift drum bearing 2 damage / pitting replace. Eas00425 checking the transmission 1. Measure: main axle runout (w...

  • Page 292: Eng

    5-85 transmission eng note: note: eas00428 installing the transmission main axle assembly shift fork “c” shift drum assembly shift fork “r” shift fork “l” springs shift fork guide bars drive axle assembly carefully position the shift forks so that they are installed correctly into the transmission g...

  • Page 295: Cool

    Cool chapter 6 cooling system radiator 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the radiator 6-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installing the radiator 6-3 . . . . . . . . . . . . . . . . ....

  • Page 296: Cool

    Cool.

  • Page 297: Cool

    6-1 radiator cool order job / part q’ty remarks 1 2 3 4 5 6 removing the radiator coolant water inlet hose carburetor hose oil cooler hose water outlet hose radiator fan motor 1 1 1 1 1 1 remove the parts in the order listed. Drain. For installation, reverse the removal procedure. Eas00454 cooling s...

  • Page 298: Cool

    6-2 radiator cool note: eas00455 checking the radiator 1. Check: radiator fins obstruction clean. Apply compressed air to the rear of the radia- tor. Damage repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver. 2. Check: radiator hoses radiator pipes cracks / damage r...

  • Page 299: Cool

    6-3 radiator cool eas00456 installing the radiator 1. Fill: cooling system (with the specified amount of the recom- mended coolant) refer to “changing the coolant” in chapter 3. 2. Check: cooling system leaks repair or replace any faulty part. A. Attach the radiator cap tester 1 to the radia- tor. R...

  • Page 300: Cool

    6-4 thermostat cool order job / part q’ty remarks 1 2 3 4 removing the thermostat front cowling coolant reservoir hose water inlet hose water outlet hose thermostat housing 1 1 1 1 remove the parts in the order listed. Refer to “front cowling” in chapter 3. For installation, reverse the removal proc...

  • Page 301: Cool

    6-5 thermostat cool order job / part q’ty remarks disassembling the thermostat housing thermostat housing cover thermostat / o-ring thermostat housing thermo unit 1 1/1 1 1 disassemble the parts in the order listed. For assembly, reverse the disassembly procedure. 1 2 3 4 15 nm (1.5 m kg) eas00461.

  • Page 302: Cool

    6-6 thermostat cool note: note: eas00462 checking the thermostat 1. Check: s thermostat does not open at 71 85 _ c replace. A. Suspend the thermostat in a container filled with water. B. Slowly heat the water. C. Place a thermometer in the water. D. While stirring the water, observe the ther- momete...

  • Page 303: Cool

    6-7 thermostat cool 15 nm (1.5 m kg) caution: 2. Install: thermo unit 1 use extreme care when handling the thermo unit. Replace any part that was dropped or subjected to a strong impact. Eas00466 installing the thermostat 1. Fill: cooling system (with the specified amount of the recom- mended coolan...

  • Page 304: Cool

    6-8 water pump cool order job / part q’ty remarks disassembling the water pump oil/ water pump assembly and oil pump rotor water pump cover o-ring pin impeller shaft (along with the impeller) 1 1 2 1 disassemble the parts in the order listed. The water pump and oil pump are combined into one unit (o...

  • Page 305: Cool

    6-9 water pump cool order job / part q’ty remarks water pump seal oil seal bearing 1 1 1 for assembly, reverse the disassembly procedure. 10 nm (1.0 m kg) 5 6 7.

  • Page 306: Cool

    6-10 water pump cool note: note: note: eas00470 disassembling the water pump 1. Remove: water pump seal 1 tap out the water pump seal from the inside of the water pump housing. 2 water pump housing 2. Remove: oil sesal 1 bearing 2 tap out the bearing and oil seal from the outside of the water pump h...

  • Page 307: Cool

    6-11 water pump cool note: caution: note: eas00475 assembling the water pump 1. Install: oil seal new 1 (to the water pump housing 2 ) install the oil seal with a socket that matches its outside diameter. Before installing the oil seal, apply tap water or coolant onto its outer surface. 2. Install: ...

  • Page 308: Cool

    6-12 water pump cool note: caution: 3. Install: rubber damper new 1 rubber damper holder new 2 before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: tilt out of specification repeat steps (3) and (4). Make sure that the rubber damper and rub- ber damper ...

  • Page 310: Carb

    Carb chapter 7 carburetors carburetors 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air filter case 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the carburetors 7-6 . . . . . . . . . . . . . . . ...

  • Page 311: Carb

    Carb.

  • Page 312: Carb

    7-1 carburetors carb order job / part q’ty remarks 1 2 3 4 5 removing the air filter case seat, fueltank and sidecovers drain the coolant air filter case panel (left / right) battery negative lead battery positive lead battery stay 1 / 1 1 1 1 1 remove the parts in the order listed. Refer to “front ...

  • Page 313: Carb

    7-2 carburetors carb order job / part q’ty remarks 1 2 3 4 5 6 removing the carburetors throttle position sensor lead air filter joint screw carburetors joint screw carburetor inlet / outlet hose carburetors assembly starter cable throttle cable 4 4 1 / 1 1 1 2 remove the parts in the order listed. ...

  • Page 314: Carb

    7-3 carburetors carb order job / part q’ty remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 separating the carburetor throttle stop screw coolant hose starter plunger link connecting bolt spacer connecting bolt spacer fuel inlet pipe fuel feed pipe spring vacuum chamber air vent hose float chamber air ve...

  • Page 315: Carb

    7-4 carburetors carb order job / part q’ty remarks disassembling the carburetor starter plunger pilot air jet vacuum chamber cover piston valve spring piston valve jet needle holder jet needle kit pilot screw fuel drain bolt float pin 1 1 1 1 1 1 1 1 1 1 disassemble the parts in the order listed. Th...

  • Page 316: Carb

    7-5 carburetors carb order job / part q’ty remarks float needle valve needle valve seat main jet main jet holder pilot jet needle jet 1 1 1 1 1 1 1 for assembly, reverse the disassembly procedure. 11 12 13 14 15 16 17.

  • Page 317: Carb

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

  • Page 318: Carb

    7-7 carburetors carb 8. Check: piston valve 1 damage / scratches / wear replace. Rubber diaphragm 2 cracks / tears replace. 9. Check: vacuum chamber cover 1 piston valve spring 2 jet needle holder 3 cracks / damage replace. 10. Check: jet needle kit 1 needle jet 2 main jet 3 main jet holder 4 pilot ...

  • Page 319: Carb

    7-8 carburetors carb caution: note: eas00489 assembling the carburetors the following procedure applies to both of the carburetors. Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent. Always use a new gasket. 1. Install: jet needle kit 2. Install: needle jet 1 pi...

  • Page 320: Carb

    7-9 carburetors carb note: note: d. If either the needle valve seat or needle valve is worn, replace them both. E. If both the needle valve seat and needle valve are fine, adjust the float height by bend- ing the float tang 1 . F. Check the float height again. 4. Install: piston valve piston valve s...

  • Page 321: Carb

    7-10 carburetors carb note: eas00495 measuring and adjusting the fuel level 1. Measure: fuel level a out of specification adjust. Fuel level (below the line on the float chamber) 3.0 4.0 mm a. Stand the motorcycle on a level surface. B. Place the motorcycle on a suitable stand to ensure that the mot...

  • Page 322: Carb

    7-11 carburetors carb note: eas00500 checking and adjusting the throttle position sensor s before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. S when installing the throttle position sensor, adjust its angle according to the rpm which is displayed on...

  • Page 323: Carb

    7-12 carburetors carb note: note: 1 2 3 note: 2. Adjust: throttle position sensor angle a. Turn the main switch to “on”. B. Disconnect the throttle position sensor cou- pler. C. Reconnect the throttle position sensor cou- pler. After reconnecting the throttle position sensor coupler, the tachometer ...

  • Page 324: Carb

    7-13 carburetors carb eas00504 checking the fuel pump 1. Check: fuel pump 1 a. Place a container under the end of the fuel hose. B. Start the engine and check if fuel flows from the fuel hose 2 . Fuel flows. Fuel pump is ok. Fuel does not flow. Replace the fuel pump. C. Stop the engine and check if ...

  • Page 325: Carb

    7-14 view 1. (no flow) view 2. (flow) air induction system carb eas00507 air induction system air injection the air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at ...

  • Page 326: Carb

    7-15 air induction system carb eas00509 air induction system diagrams 1 reed valve 2 air cleaner 3 air cutoff valve 4 carburetor joint (cylinder #4) a to the air cutoff valve b to cylinder #1 c to cylinder #2 d to cylinder #3 e to cylinder #4.

  • Page 327: Carb

    7-16 air induction system carb eas00510 checking the air induction system 1. Check: hoses loose connection connect properly. Cracks / damage replace. Pipes cracks / damage replace. 2. Check: fibre reed 1 fibre reed stopper reed valve seat cracks / damage replace the reed valve. 3. Measure: fibre ree...

  • Page 329: Elec

    Elec chapter 8 electrical electrical components 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Arrangement of the electrical components and couplers 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Instrument fuenctions 8-6 . . . ...

  • Page 330: Elec

    Elec exup system 8-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Circut diagram 8-51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting 8-52 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 331: Elec

    8-1 electrical components elec 1 main switch 2 fuel sender 3 rear brake switch 4 battery 5 ignitor unit 6 starter relay 7 starting circuit cutoff relay 8 flasher relay 9 speed sensor 10 sidestand switch 11 neutral switch 12 oil level gauge 13 ignition coil 14 rectifier / regulator 15 thermo unit 16 ...

  • Page 332: Elec

    8-2 1 thermo unit 2 t.P.S. 3 starter motor 4 pickup rotor 5 pickup coil arrangement of the electrical components and couplers elec arrangement of the electrical components and couplers.

  • Page 333: Elec

    8-3 arrangement of the electrical components and couplers elec 1 ignitor unit 2 fuse box 3 battery 4 fuel pump 5 fuel pump coupler 6 brake light switch coupler 7 newtral switch coupler 8 pickup coil coupler 9 speed sensor coupler.

  • Page 334: Elec

    8-4 arrangement of the electrical components and couplers elec 1 ignition coil #2.3 2 ignition coil #1.4 3 rectifier / regulator 4 stator coil.

  • Page 335: Elec

    8-5 arrangement of the electrical components and couplers elec 1 emargency stop switch 2 flasher relay 3 starter relay 4 fan motor relay 5 starting circuit cutoff relay 6 stator coil coupler 7 sidestand switch coupler 8 fuel sender coupler 9 oil level switch coupler.

  • Page 336: Elec

    8-6 instrument functions elec oil level warning light “ ” coolant temperature warning light “ ” fuel level warning light “ ” turn indicator light (left) “ ” turn indicator light (right) “ ” neutral indicator light “ ” high beam indicator light “ ” 1 2 3 4 1 2 3 caution: note: instrument functions in...

  • Page 337: Elec

    8-7 instrument functions elec “select” button “reset” button 1 2 note: digital clock clock to set the clock: 1. Push both the “select” 1 and “reset” 2 buttons for at least two seconds. 2. When the hour digits start flashing, push the “reset” button 2 to set the hours. 3. Push the “select” button 1 t...

  • Page 338: Elec

    8-8 checking switch continuity elec caution: note: note: eas00730 checking switch continuity check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. Never insert the tester probes into the cou...

  • Page 339: Elec

    8-9 1 main switch 2 pass switch 3 dimmer switch 4 horn switch 5 clutch switch 6 hazard switch 7 turn signal switch 8 front brake switch 9 light switch 10 engine stop switch 11 start switch 12 rear brake switch 13 fuse 14 side stand switch 15 neutral switch 16 oil level switch checking the switches e...

  • Page 340: Elec

    8-10 checking the bulbs and bulb sockets elec eas00732 checking the bulbs and bulb sockets check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage / wear repair or replace the bulb, bulb socket or both. Improperly connected prop...

  • Page 341: Elec

    8-11 checking the bulbs and bulb sockets elec warning caution: note: checking the condition of the bulbs the following procedure applies to all of the bulbs. 1. Remove: bulb since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled dow...

  • Page 342: Elec

    8-12 checking the bulbs and bulb sockets elec note: warning checking the condition of the bulb sockets the following procedure applies to all of the bulb sockets. 1. Check: bulb socket (for continuity) (with the pocket tester) no continuity replace. Pocket tester 90890-03112 check each bulb socket f...

  • Page 343: Elec

    8-13 1 main switch 5 battery 7 fuse (main) 15 ignitor 16 ignition coil 17 spark plug 18 pickup coil 41 engine stop switch 58 fuse (ignition) ignition system elec eas00735 ignition system circuit diagram.

  • Page 344: Elec

    8-14 yes no yes no eas00739 eas00741 2. Battery s check the condition of the battery. Refer to “checking the battery” in chapter 3. Minimum open-circuit voltage 12.8 v or more at 20 _ c s is the battery ok? S clean the battery terminals. S recharge or replace the battery. 3. Spark plugs the followin...

  • Page 345: Elec

    8-15 ignition system elec no yes eas00745 yes no eas00747 1 a 2 4. Ignition spark gap the following procedure applies to all of the spark plugs. S disconnect the spark plug cap from the spark plug. S connect the ignition checker as shown. Spark plug cap s set the main switch to “on”. S measure the i...

  • Page 346: Elec

    8-16 1 2 9. Pickup coil resistance s disconnect the pickup coil coupler from the wire harness. S connect the pocket tester ( Ω 100) to the pickup coil terminal as shown. Positive tester probe gray negative tester probe black yes no no eas00749 yes s measure the pickup coil resistance. Pickup coil re...

  • Page 347: Elec

    8-17 1 main switch 5 battery 6 fuse (main) 7 starter relay 8 starter motor 9 starting circuit cutoff relay 10 side stand switch 19 neutral switch 41 engine stop switch 42 start switch 48 clutch switch 58 fuse (ignition) 59 alarm electric starting system elec eas00755 electric starting system circuit...

  • Page 348: Elec

    8-18 electric starting system elec eas00756 starting circuit cutoff system op- eration if the engine stop switch is set to “ ” and the main switch is set to “on” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: the transmission is in ...

  • Page 349: Elec

    8-19 s a wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn. S this check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity. S does the starter motor turn? Warning no yes ...

  • Page 350: Elec

    8-20 positive tester probe red negative tester probe red 1 2 positive battery lead blue / white negative battery lead red / white 5. Starter relay disconnect the starter relay coupler from the wireharness. Connect the pocket tester ( Ω 1) and bat- tery (12 v) to the starter relay coupler as shown. 3...

  • Page 351: Elec

    8-21 no eas00764 yes 11. Start switch check the start switch for continuity. Refer to “checking the switches”. Replace the right handlebar switch. Eas00766 no yes 12. Wiring check the entire starting system’s wiring. Refer to “circuit diagram”. The starting system circuit is ok? Properly connect or ...

  • Page 352: Elec

    8-22 order job / part q’ty remarks 1 2 removing the starter motor carburetor starter motor lead starter motor / o-ring 1 1 / 1 remove the parts in the order listed. Refer to “carburetor” in chapter 7. For installation, reverse the removal procedure. Electric starting system elec eas00767 starter mot...

  • Page 353: Elec

    8-23 electric starting system elec order job / part q’ty remarks disassembling the starter motor starter motor front cover lock washer oil seal bearing washer set starter motor rear cover washer set brush seat (along with the brushes) armature assembly brush holder (along with the brushes) o-ring st...

  • Page 354: Elec

    8-24 electric starting system elec note: eas00769 checking the starter motor 1. Check: s commutator dirt clean with 600-grit sandpaper. 2. Measure: s commutator diameter a out of specification replace the starter motor. Commutator wear limit 27 mm 3. Measure: s mica undercut a out of specification s...

  • Page 355: Elec

    8-25 electric starting system elec note: b. If any resistance is out of specification, re- place the starter motor. 5. Measure: brush length a out of specification replace the brushes as a set. Brush length wear limit 4 mm 6. Measure: brush spring force out of specification replace the brush springs...

  • Page 356: Elec

    8-26 electric starting system elec note: 2. Install: starter motor front cover 1 starter motor rear cover 2 o-ring 3 new align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers..

  • Page 357: Elec

    8-27 2 rectifire / reguretor 3 ac magneto 5 battery 7 fuse (main) charging system elec eas00773 charging system circuit diagram.

  • Page 358: Elec

    8-28 s check the condition of the battery. Refer to “checking the battery” in chapter 3. 3. Charging voltage s connect the engine tachometer to the spark plug lead of cylinder #1. S connect the pocket tester (dc 20 v) to the battery as shown. Positive tester probe positive battery terminal negative ...

  • Page 359: Elec

    8-29 s measure the stator coil resistances. Stator coil resistance 0.27 x 0.33 Ω at 20 _ c s is the stator coil ok? No yes replace the stator coil assembly. Positive tester probe white negative tester probe white 1 2 3 1 eas00776 4. Stator coil resistance s remove the generator cover. S connect the ...

  • Page 360: Elec

    8-30 46 dimmer switch 55 headlight 56 tail / brake light 60 fuse (alarm) 61 fuse (headlight) 66 headlight relay (on / off) 67 headlight relay (dimmer) 1 main switch 5 battery 7 fuse (main) 31 hi-beam indicator light 34 meter light 40 headlight switch 45 pass switch lighting system elec eas00780 ligh...

  • Page 361: Elec

    8-31 yes no 4. Headlight switch s check the headlight switch for continuity refer to “checking the switches”. The headlight switch is faulty. Replace the right handlebar switch. Eas00783 eas00749 yes no 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the...

  • Page 362: Elec

    8-32 yes no 6. Pass switch check the pass switch for continuity. Refer to “checking the switches”. The pass switch is faulty. Replace the left han- dlebar switch. Eas00786 is the pass switch ok? Does the headlight relay (on / off) have conti- nuity between red / yellow and black / blue? No yes repla...

  • Page 363: Elec

    8-33 lighting system elec headlight positive tester probe black / yellow or black / green negative tester probe black high beam indicator light positive tester probe black / yellow negative tester probe black 2. Vollage connect the pocket tester (dc 20 v) to the meter light coupler (wire harness sid...

  • Page 364: Elec

    8-34 1 2 2. Voltage connect the pocket tester (dc 20 v) to the tail / brake light coupler (wire harness side) as shown. Positive tester probe blue/red negative tester probe black eas00790 3. The tail / brake light fails to come on. Chek the tail / brake light bulb and socket for continuity. Yes no r...

  • Page 365: Elec

    8-35 signal system elec eas00793 signal system circuit diagram.

  • Page 366: Elec

    8-36 signal system elec 1 main switch 5 battery 7 fuse (main) 9 starting circuit cutoff relay 19 neutral switch 23 fuel level warning light 24 oil level warning light 25 neutral indicator light 27 combination meter 29 fuel gauge 32 turn signal indicator light (left) 33 turn signal indicator light (r...

  • Page 367: Elec

    8-37 eas00749 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Yes no replace the main switch. Yes no yes no 4. Wiring s check the entire signal system’s wiring. Refer to “circuit diagram”. Properly connect or repair the signaling syst...

  • Page 368: Elec

    8-38 yes no the wiring circuit from the main switch to the horn connector is faulty and must be repaired. Set the main switch to “on”. Push the horn switch. Measure the voltage (12 v) of pink at the horn terminal. 3. Horn disconnect the black connector at the horn terminal. Connect a jumper lead to ...

  • Page 369: Elec

    8-39 positive tester probe yellow negative tester probe black no yes set the main switch to “on”. Pull in the brake lever or push down on the brake pedal. Measure the voltage (12 v) of yellow on the tail/brake light coupler (wire harness side). The wiring circuit from the main switch to the tail/bra...

  • Page 370: Elec

    8-40 left turn signal light positive tester probe chocolate negative tester probe ground right turn signal light positive tester probe dark green negative tester probe ground 1. Neutral indicator light bulb and socket check the neutral indicator light bulb and socket for continuity. No yes replace t...

  • Page 371: Elec

    8-41 eas00802 5. The oil level warning light fails to come on. 1. Oil level warning light bulb and socket check the oil level warning light bulb and socket for continuity. No yes replace the oil level warning light bulb, socket or both. Yes no drain the engine oil and remove the engine oil level swi...

  • Page 372: Elec

    8-42 1. Fuel sender s remove the fuel sender from the fuel tank. S connect the pocket tester to the fuel sender coupler (wire harness side) as shown. Eas00804 5. The fuel level gauge fails to operate. Positive tester probe green negative tester probe black 1 2 s measure the fuel sender resistances. ...

  • Page 373: Elec

    8-43 cooling system elec 1 main switch 5 battery 7 fuse (main) 21 thermo unit 27 combination meter 28 water temp warning light 62 fues (fan) 63 fan motor relay 64 fan motor eas00807 cooling system circuit diagram.

  • Page 374: Elec

    8-44 s check the main switch for continuity. Refer to “checking the switches”. 3. Main switch yes no replace the main switch. Yes no s clean the battery terminals. S recharge or re- place the battery. Eas00749 s is the main switch ok? Eas00809 yes no 4. Radiator fan motor s disconnect the rediator f...

  • Page 375: Elec

    8-45 cooling system elec thermo unit 15 nm (1.5 m s kg) three bond sealock 10 yes no 7. Wiring s check the entire cooling system’s wiring. Refer to “circuit diagram”. Properly connect or repair the cooling system’s wiring. Yes no replace the thermo unit. S does the thetmo unit operate properly? Eas0...

  • Page 376: Elec

    8-46 1 main switch 5 battery 7 fuse (main) 9 starting circuit cutoff relay 11 fuel pump 15 ignitor 41 engine stop switch 51 fuse (ignition) fuel pump system elec eas00814 fuel pump system circuit diagram.

  • Page 377: Elec

    8-47 fuel pump system elec eas00815 fuel pump circuit operation the ignitor unit includes the control unit for the fuel pump. 1 battery 2 main fuse 3 main switch 4 ignition fuse 5 engine stop switch 6 ignitor unit 7 fuel pump relay 8 fuel pump.

  • Page 378: Elec

    8-48 eas00749 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Yes no replace the main switch. Eas00750 4. Engine stop switch s check the engine stop switch for continuity. Refer to “checking the switches”. S is the engine stop switch ...

  • Page 379: Elec

    8-49 fuel pump system elec yes no 6. Fuel pump resistance s disconnect the fuel pump coupler from the wire harness. S connect the pocket tester ( Ω 1) to the fuel pump coupler as shown. Positive tester probe black / blue negative tester probe black replace the fuel pump. S measure the fuel pump resi...

  • Page 380: Elec

    8-50 fuel pump system elec b / l warning positive battery lead black / blue negative battery lead black 1 2 eas00819 checking the fuel pump gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following point...

  • Page 381: Elec

    8-51 1 main switch 5 battery 7 fuse (main) 12 exup servomotor 15 ignitor 58 fuse (ignition) exup system elec eas00827 exup system circuit diagram.

  • Page 382: Elec

    8-52 exup system elec yes no check that the exup cables are properly installed. If the connections are correct, check the exup valve and cables. Refer to “ex- haust system” in chapter 5. Eas00830 connect the pocket tester (dc 20 v) to the exup servomotor coupler as shown. 2. Voltage positive tester ...

  • Page 383: Elec

    8-53 exup system elec yes no replace the exup servomotor. Eas00832 disconnect the exup servomotor coupler from the wire harness. Connect the pocket tester ( Ω 1 k) to the exup servomotor coupler. 4. Exup servomotor resistance (potentiometer resistance) positive tester probe blue negative tester prob...

  • Page 384: Elec

    8-54 exup system elec procedure 2 eas00738 s check the main and ignition fuses for conti- nuity. Refer to “checking the fuses” in chap- ter 3. 1. Main and ignition fuses s are the main and ignition fuses ok? Yes no replace the fuse(s). Eas00833 s check the entire exup system’s wiring. Refer to “circ...

  • Page 385: Elec

    8-55 self-diagnosis elec self-diagnosis the fzs1000 features a self-diagnosing system for the following circuit(-s): throttle position sensor exup speed sensor emargency stop switch if any of these circuits are defective, their respective condition codes will be displayed on the tachome- ter when th...

  • Page 386: Elec

    8-56 self-diagnosis elec revolution ( 10 3 r / min) tachometer display time (seconds) engine speed 0 r / min ... 3 seconds condition code ... 2.5 seconds engine speed ... 3 seconds 1 2 3 tachometer display sequence when more than one item is being monitored, the tachometer needle displays the condit...

  • Page 387: Elec

    8-57 self-diagnosis elec repair or replace the wire harness. No 1. Wire harness check the wire harness for continuity. Refer to “circuit diagram”. Is the wire harness ok? Yes no 2. Throttle position sensor check the throttle position sensor for conti- nuity. Refer to “checking and adjusting the thro...

  • Page 388: Elec

    8-58 self-diagnosis elec replace the exup servomotor. No 2. Exup servomotor check the exup servomotor for continuity. Refer to “exup system”. Is the exup servomotor ok? Yes repair or replace the wire harness. No 1. Wire harness check the wire harness for continuity. Refer to “circuit diagram”. Is th...

  • Page 389: Elec

    8-59 check the wire harness for continuity. Refer to “circuit diagram”. 1. Wire harness is the wire harness ok? Yes no replace the speed sensor. Bad repair or replace the wire harness. Replace the ignitor unit. Self-diagnosis elec 15 lgnitor unit 20 speed sensor 3. Speed sensor circuit diagram.

  • Page 390: Elec

    8-60 check the wire harness for continuity. Refer to “circuit diagram”. 1. Wire harness is the wire harness ok? Yes no replace the emar- gency stop switch. Bad repair or replace the wire harness. Replace the ignitor unit. Self-diagnosis elec 14 emargency stop switch 15 lgnitor unit 4. Emargency stop...

  • Page 392: Trbl

    Trbl shtg chapter 9 troubleshooting starting problems engine 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel system 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical systems 9-2 . . ...

  • Page 393: Trbl

    Trbl shtg faulty lighting or signaling system headlight does not light 9-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight bulb burnt out 9-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail/ brake light does not light 9-7 . . . . . . . . . . . . . . . . . . . . ....

  • Page 394: Trbl

    9-1 troubleshooting trbl shtg note: piston(s) and piston ring(s) improperly installed piston ring damaged, worn or fatigued piston ring seized piston ring seized or damaged piston air filter improperly installed air filter clogged air filter element crankcase and crankshaft improperly assembled cran...

  • Page 395: Trbl

    9-2 troubleshooting trbl shtg ignition system faulty ignitor unit faulty pickup coil broken generator rotor woodruff key switches and wiring faulty main switch faulty engine stop switch broken or shorted wiring faulty neutral switch faulty start switch faulty sidestand switch faulty clutch switch im...

  • Page 396: Trbl

    9-3 troubleshooting trbl shtg fuel system carburetor(s) faulty diaphragm incorrect fuel level loose or clogged main jet fuel pump faulty fuel pump jumps out of gear shift shaft incorrect shift pedal position improperly returned stopper lever shift forks worn shift fork shift drum incorrect axial pla...

  • Page 397: Trbl

    9-4 troubleshooting trbl shtg clutch drags clutch unevenly tensioned clutch springs warped pressure plate bent clutch plate swollen friction plate bent clutch push rod broken clutch boss burnt primary driven gear bushing match marks not aligned engine oil incorrect oil level incorrect oil viscosity ...

  • Page 398: Trbl

    9-5 troubleshooting trbl shtg malfunction bent or damaged inner tube bent or damaged outer tube damaged fork spring worn or damaged outer tube bushing bent or damaged damper rod incorrect oil viscosity incorrect oil level eas00856 overcooling cooling system thermostat thermostat stays open eas00857 ...

  • Page 399: Trbl

    9-6 troubleshooting trbl shtg rear shock absorber assembly(-ies) faulty rear shock absorber spring leaking oil or gas tire(s) uneven tire pressures (front and rear) incorrect tire pressure uneven tire wear wheel(s) incorrect wheel balance deformed cast wheel damaged wheel bearing bent or loose wheel...

  • Page 400: Trbl

    9-7 troubleshooting trbl shtg turn signal does not light faulty turn signal switch faulty turn signal relay burnt-out turn signal bulb incorrect connection damaged or faulty wire harness improperly grounded circuit faulty battery blown, damaged or incorrect fuse turn signal blinks slowly faulty turn...

  • Page 402

    1 main switch 2 rectifier / regulator 3 ac magneto 4 fuse (back up) 5 battery 6 starter relay 7 fuse (main) 8 starter motor 9 starting circuit cutoff relay 10 sidestand switch 11 fuel pump 12 exup servo motor 13 t.P.S. 14 emargency stop switch 15 igniter 16 ignition coil 17 spark plug 18 pickup coil...

  • Page 403

    1 main switch 2 rectifier / regulator 3 ac magneto 4 fuse (back up) 5 battery 6 starter relay 7 fuse (main) 8 starter motor 9 starting circuit cutoff relay 10 sidestand switch 11 fuel pump 12 exup servo motor 13 t.P.S. 14 emargency stop switch 15 igniter 16 ignition coil 17 spark plug 18 pickup coil...