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Yamaha FZS1000N Service Manual

Other manuals for FZS1000N: Owner's Manual

Summary of FZS1000N

  • Page 3

    Eas00001 fzs1000n (c) service manual 2001 by yamaha motor corporation, u.S.A. First edition, january 2001 all rights reserved. Any reproduction or unauthorized use without the written permission of yamaha motor corporation, u.S.A. Is expressly prohibited. Printed in u.S.A. P/ n lit-11616-14-48.

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

  • Page 8: Gen

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

  • Page 9: Gen

    Gen info.

  • Page 10: 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 11: 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 12: 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 13: 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: s lead 1 s coupler 2 s connector 3 2. Check: s lead s coupler s connector moisture ! Dry with an air blower. Rust / stai...

  • Page 14: 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 15: Gen

    1-6 special tools gen info tool no. Tool name / function illustration yu-38411 oil filter wrench this tool is needed to loosen or tighten the oil filter cartridge. Ym-01434 rod holder this tool is used to support the damper adjusting rod. Rod puller ym-01437 rod puller this tool is used to pull up t...

  • Page 16: Gen

    1-7 special tools gen info tool no. Tool name / function illustration ym-33277-a battery powered timing light this tool is used to check the ignition timing. Valve spring compressor ym-04019 adapter ym-4108 ym-4114 valve spring compressor set, quick release adapter these tools are used to remove or ...

  • Page 18: Spec

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

  • Page 19: Spec

    Spec.

  • Page 20: Spec

    2-1 general specifications spec specifications general specifications item standard limit model code 5lv5 (usa except for california) 5lv6 (cdn) 5lv7 (california) dimensions overall length overall width overall height seat height wheelbase minimum ground clearance minimum turning radius 2,125 mm (83...

  • Page 21: Spec

    2-2 engine specifications spec engine specifications item standard limit engine engine type displacement cylinder arrangement bore x 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...

  • Page 22: Spec

    2-3 engine specifications spec item standard limit oil filter oil filter type bypass valve opening pressure cartridge (paper) 180 x 220 kpa (1.8 x 2.2 kg / cm 2 , 25.6 x 31.3 psi) oil pump oil pump type inner-rotor-to-outer-rotor-tip clearance outer-rotor-to-oil-pump-housing clearance trochoidal 0.0...

  • Page 23: 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 24: Spec

    2-5 engine specifications spec head diameter face width seat width margin thickness item standard limit timing chain model / number of links tensioning system rh2015 / 130 automatic valves, valve seats, valve guides valve clearance (cold) intake 0.11 x 0.20 mm (0.0043 x 0.0079 in) 0 21 x 0 25 mm (0 ...

  • Page 25: Spec

    2-6 engine specifications spec item standard limit valve stem runout valve seat width intake exhaust 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) inta...

  • Page 26: Spec

    2-7 engine specifications spec item standard limit cylinders cylinder arrangement bore x stroke compression ratio bore max. Taper max. Out-of-round forward-inclined, parallel 4-cylinder 74 x 58 mm (2.91 x 2.28 in) 11.4 : 1 74.00 x 74.01 mm (2.9134 x 2.9138 in) 0.05 mm (0.0016 in) 0.05 mm (0.0016 in)...

  • Page 27: Spec

    2-8 engine specifications spec item standard limit 2nd ring ring type dimensions (b x t) end gap (installed) ring side clearance oil ring taper 0.8 x 2.8 mm (0.031 x 0.110 in) 0.43 x 0.58 mm (0.017 x 0.023 in) 0.020 x 0.055 mm (0.0008 x 0.0022 in) dimensions (b x t) end gap (installed) 1.5 x 2.6 mm ...

  • Page 28: Spec

    2-9 engine specifications spec item standard limit friction plates thickness plate quantity thickness plate quantity clutch plates thickness plate quantity max. Warpage clutch springs free length spring quantity 2.92 x 3.08 mm (0.115 x 0.121 in) 8 3.42 x 3.58 mm (0.135 x 0.141 in) 1 1.9 x 2.1 mm (0....

  • Page 29: Spec

    2-10 engine specifications spec item standard limit carburetors model (manufacturer) x 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) x 4 3 x 5 mm (0.12 x 0.20 in) 5lv5 40 carburetors 1 and 4: #1...

  • Page 30: Spec

    2-11 chassis specifications spec chassis specifications item standard limit frame frame type caster angle trail double cradle 26 _ 104 mm (4.09 in) 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 x mt3.50...

  • Page 31: Spec

    2-12 chassis specifications spec item standard limit rear tire tire type size model (manufacturer) tire pressure (cold) 0 x 90 kg 90 x 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 , 39 bar) 290 kpa (2.9 kg...

  • Page 32: 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 33: 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 34: Spec

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

  • Page 35: Spec

    2-16 electrical specifications spec item standard limit indicator light (voltage / wattage x 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 x 1 14 v 1.4 w x 1 14 v 1.4...

  • Page 36: 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 37: 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 ft lb 4.3 11 22 40 61 94 eas00030 general tightening torque specifications this chart specifies tightening...

  • Page 38: Spec

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

  • Page 39: Spec

    2-20 tightening torques spec note: item fastener thread size q’ty tightening torque remarks size y nm m s kg ft s lb 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-...

  • Page 40: Spec

    2-21 tightening torques spec crankcase tightening sequence:.

  • Page 41: Spec

    2-22 tightening torques spec note: chassis tightening torques item thread size tightening remarks item thread size nm m kg ft lb 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 mast...

  • Page 42: 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 43: 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 44: Spec

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

  • Page 45: Spec

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

  • Page 46: Spec

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

  • Page 47: Spec

    2-28 cooling system diagrams spec 1 radiator.

  • Page 48: 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 49: 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 50: Spec

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

  • Page 51: Spec

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

  • Page 52: Spec

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

  • Page 53: Spec

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

  • Page 54: 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 55: 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 56: 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 57: 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 58: 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 59: 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 60: 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 61: 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 62: Chk

    Chk adj chapter 3 periodic checks and adjustments introduction 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Periodic maintenance chart for the emission control system 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Page 63: Chk

    Chk adj adjusting the front fork legs 3-43 . . . . . . . . . . . . . . . . . . . . . . . Adjusting the rear shock absorber assembly 3-45 . . . . . . Checking the tires 3-47 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking and lubricating the cables 3-50 . . . . . . ...

  • Page 64: Chk

    3-1 introduction periodic maintenance/lubrication intervals chk adj 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 reliable vehi...

  • Page 65: Chk

    3-2 periodic maintenance/lubrication intervals chk adj note: note: initial odometer readings no. Item routine 600 mi (1,000 km) or 1 month 4,000 mi (7,000 km) or 6 months 8,000 mi (13,000 km) or 12 months 12,000 mi (19,000 km) or 18 months 16,000 mi (25,000 km) or 24 months 20,000 mi (31,000 km) or ...

  • Page 66: 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 the parts in the order listed. Disconnect. For installation, reverse the remova...

  • Page 67: 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 68: 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. D valve clearance adjustment should be made on a cold engine, at room temperature. D when the valve clearance is to be measured or adjusted,...

  • Page 69: 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 70: 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 71: Chk

    3-8 adjusting the valve clearance chk adj 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 x 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 x 0.07 120 125 130 135 140 145 150 155 160 165 170 17...

  • Page 72: 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 oil to the valve pad and the valve lifter. The valve lifter must turn smoothly when ro- tated by hand. Install the valve lifter and the valve pad in the co...

  • Page 73: 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 74: 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 75: Chk

    3-12 adjusting the engine idling speed chk adj note: a b 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 en...

  • Page 76: Chk

    3-13 adjusting the engine idling speed/ adjusting the throttle cable free play chk adj note: 5. Adjust: throttle cable free play refer to “adjusting the throttle cable free play”. Throttle cable free play (at the flange of the throttle grip) 3 x 5 mm (0.12 x 0.20 in) eas00055 adjusting the throttle ...

  • Page 77: 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 78: 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 79: Chk

    3-16 checking the spark plugs/ checking the ignition timing chk adj 13 nm (1.3 m kg, 9.4 ft lb) 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 ignitio...

  • Page 80: 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 81: Chk

    3-18 measuring the compression pressure chk adj warning note: 13 nm (1.3 m kg, 9.4 ft lb) 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 affecte...

  • Page 82: Chk

    3-19 checking the engine oil level chk adj note: caution: note: note: eas00071 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. Check: engine oil level the engine oil level should be betwe...

  • Page 83: 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 84: Chk

    3-21 changing the engine oil chk adj 43 nm (4.3 m kg, 31 ft lb) c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 nm (1.7 m kg, 12 ft lb) 6. Check: engine oil drain bolt gasket damage replace. 7. Install: engine oil drain bolt 8. Fill: cran...

  • Page 85: 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 s kg, 7.2 ft s lb) eas00078 adjusting the clutch cable free play 1. Check: s clutch cable free play a out of specification ! Adjust. Clutch cable free play (at the end of the clutch...

  • Page 86: 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 87: 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 88: 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 89: Chk

    3-26 checking the canister/ adjusting the exup cables chk adj caution: checking the canister (for california only) 1. Remove: s seat s fuel tank 2. Check: s hose and canister cracks / damage ! Replace. S vent hose obstruction ! Clean. 3. Install: s fuel tank s seat eas00101 adjusting the exup cables...

  • Page 90: Chk

    3-27 adjusting the exup cables/ checking the coolant level chk adj 10 nm (1.0 m kg, 7.2 ft lb) note: 4. Check: exup cable free play a exup cable free play 1.5 mm (0.06 in) 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 p...

  • Page 91: 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 92: 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 93: 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 94: Chk

    3-31 changing the coolant chk adj 7 nm (0.7 m kg, 5.1 ft lb) 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 antifree...

  • Page 95: Chk

    3-32 changing the coolant chk adj caution: note: s 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. S use only distilled water. Soft water may be used i...

  • Page 96: 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 97: 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) ...

  • Page 98: 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 99: 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 t...

  • Page 100: 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 ! Ti...

  • Page 101: 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 102: 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 103: 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 104: 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 105: 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 spanner wrench 5 . Set the torque wrench at a right angle to the spanner wrench. Spanner wrench yu-33975 lower ring nut (initial tightening torque) 52 ...

  • Page 106: 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, 80 ft lb) upper bracket pinch bolt 30 nm (3.0 m kg, 22 ft lb) handlebar holder bolt 23 nm (2.3 m kg, 17 ft lb) eas00149 checking...

  • Page 107: Chk

    3-44 adjusting the front fork legs chk adj a b caution: a b 1. Adjust: s 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 minim...

  • Page 108: Chk

    3-45 adjusting the front fork legs/ adjusting the rear shock absorber assembly chk adj caution: a b 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 com...

  • Page 109: 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 110: 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 111: Chk

    3-48 checking the tires chk adj warning warning basic weight (with oil and a full fuel tank) 231 kg (509 lb) 232 kg (512 lb) (california) maximum load* 189 kg (417 lb) 188 kg (415 lb) (california) cold tire pressure front tire rear tire up to 90 kg load* 250 kpa (2.5 kgf/cm 2 , 36 psi) 270 kpa (2.7 ...

  • Page 112: 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 113: 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 114: 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 115: 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 116: 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 117: 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 118: 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. Make sure that the current is higher than the standard charging current written on the battery. Charge the battery until the battery’s...

  • Page 119: 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: ...

  • Page 120: Chk

    3-57 checking the fuses chk adj warning pocket tester measurement yu-03112-c 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 i...

  • Page 121: 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 122: 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 124: Chas

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

  • Page 125: Chas

    Chas front fork 4-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removing the front fork legs 4-48 . . . . . . . . . . . . . . . . . . . . . . . . Disassembling the front fork legs 4-48 . . . . . . . . . . . . . . . . . . Checking the front fork ...

  • Page 126: 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 127: 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 128: Chas

    4-3 front wheel and brake discs chas warning 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 elevated. 2....

  • Page 129: Chas

    4-4 front wheel and brake discs chas note: warning eas00523 disassembling the front wheel 1. Remove: oil seals wheel bearings a. Clean the outside of the front wheel hub. B. Remove the oil seals 1 with a flat-head screwdriver. To prevent damaging the wheel, place a rag 2 between the screwdriver and ...

  • Page 130: Chas

    4-5 front wheel and brake discs chas note: caution: note: 4. Check: wheel bearings front wheel turns roughly or is loose ! Re- place the wheel bearings. Oil seals damage / wear ! Replace. 5. Replace: wheel bearings new oil seals new a. Clean the outside of the front wheel hub. B. Remove the oil seal...

  • Page 131: Chas

    4-6 front wheel and brake discs chas note: 2. Measure: s brake disc deflection out of specification ! Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) 0.1 mm (0.004 in) a. Place the motorcycle on a suitable stand so that the wheel is elevated. B. Bef...

  • Page 132: Chas

    4-7 front wheel and brake discs chas caution: note: 72 nm (7.2 m kg, 52 ft lb) 23 nm (2.3 m kg, 17 ft lb) caution: 40 nm (4.0 m kg, 29 ft lb) warning eas00539 assembling the front wheel 1. Install: wheel bearings new oil seals new a. Install the new wheel bearings and oil seals in the reverse order ...

  • Page 133: Chas

    4-8 front wheel and brake discs chas note: note: note: eas00549 adjusting the front wheel static balance s after replacing the tire, wheel or both, the front wheel static balance should be adjusted. S adjust the front wheel static balance with the brake discs installed. 1. Remove: s balancing weight...

  • Page 134: Chas

    4-9 front wheel and brake discs chas b. Turn the front wheel 90 _ so that the heavy spot is positioned as shown. C. If the heavy spot does not stay in that posi- tion, install a heavier weight. D. Repeat steps (b) and (c) until the front wheel is balanced. 4. Check: s front wheel static balance a. T...

  • Page 135: Chas

    4-10 rear wheel and brake disc chas order job / part q’ty remarks 1 2 3 4 5 6 7 8 removing the rear wheel brake caliper brake torque rod lock nut adjusting nut wheel axle nut washer wheel axle rear wheel assembly 1 1 2 2 1 1 1 1 remove the parts in the order listed. Place the motorcycle on a suitabl...

  • Page 136: Chas

    4-11 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 137: Chas

    4-12 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 138: Chas

    4-13 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 139: Chas

    4-14 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” in chapter 3. 3. Measure: rear wheel radial runout rear wheel lateral...

  • Page 140: Chas

    4-15 rear wheel and brake disc chas note: note: rear wheel sprocket self-locking nut 69 nm (6.9 m kg, 50 ft lb) 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...

  • Page 141: Chas

    4-16 rear wheel and brake disc chas note: 150 nm (15 m s kg, 108 ft s lb) 40 nm (4.0 m s kg, 29 ft s lb) 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...

  • Page 142: Chas

    4-17 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 143: Chas

    4-18 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. 6 nm (0.6 m kg,...

  • Page 144: Chas

    4-19 front and rear brakes chas caution: note: eas00579 disc brake components rarely require disas- sembly. 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 145: Chas

    4-20 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 (0.02 in) 5. Install: b...

  • Page 146: Chas

    4-21 front and rear brakes chas note: 40 nm (4.0 m kg, 29 ft lb) 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 pins brake pad ...

  • Page 147: Chas

    4-22 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 (0.02 in) 4. Install: brake pad shims (onto the brake pads) brake pads brake pad spring always install new brake pads, brake pad shims, brake pad...

  • Page 148: Chas

    4-23 front and rear brakes chas 40 nm (4.0 m kg, 29 ft lb) 5. Install: 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: brak...

  • Page 149: Chas

    4-24 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 150: Chas

    4-25 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 151: Chas

    4-26 front and rear brakes chas 4 nm (0.4 m s kg, 2.9 ft s lb) 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 /...

  • Page 152: Chas

    4-27 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 153: Chas

    4-28 front and rear brakes chas note: note: note: eas00588 removing and disassembling the front brake master 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...

  • Page 154: Chas

    4-29 a b d c front and rear brakes chas 3. Remove: clip hose cotter pin pin washer 4. Remove: master cylinder 5. Remove: master cylinder boot circlip 6. Remove: master cylinder kit spring eas00592 checking the front and rear brake master cylinders the following procedure applies to the both of the b...

  • Page 155: Chas

    4-30 front and rear brakes chas warning 4. Check: front brake master cylinder reservoir 1 cracks / damage ! Replace. Front brake master cylinder reservoir dia- phragm 2 damage / wear ! Replace. 5. Check: brake hoses cracks / damage / wear ! Replace. Eas00598 assembling and installing the front brake...

  • Page 156: Chas

    4-31 a front and rear brakes chas 10 nm (1.0 m s kg, 7.2 ft s lb) note: 30 nm (3.0 m s kg, 22 ft s lb) caution: warning note: 3. Install: s brake master cylinder 1 s install the brake master cylinder holder with the “up” mark facing up. S align the end of the brake master cylinder hold- er with the ...

  • Page 157: Chas

    4-32 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 158: Chas

    4-33 front and rear brakes chas 30 nm (3.0 m kg, 22 ft lb) caution: warning eas00608 assembling the rear brake master cylinder 1. Install: spring master cylinder kit 2. Install: circlip master cylinder boot 3. Install: master cylinder 4. Install: washer pin cotter pin hose clip 5. Install: copper wa...

  • Page 159: Chas

    4-34 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 160: Chas

    4-35 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, 4.3 ft lb) 30 nm...

  • Page 161: Chas

    4-36 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 162: Chas

    4-37 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. 30 nm (3.0 m kg, 22 ft lb) 40 nm (...

  • Page 163: Chas

    4-38 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 164: Chas

    4-39 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: s union bolt 1 s copper washe...

  • Page 165: Chas

    4-40 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: s union bolt 1 s copper washers 2 s brake hose put the end of the brake hose into a container and...

  • Page 166: Chas

    4-41 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 167: Chas

    4-42 front and rear brakes chas warning 30 nm (3.0 m s kg, 22 ft s lb) warning caution: 6 nm (0.6 m s kg, 4.3 ft s lb) 40 nm (4.0 m s kg, 29 ft s lb) eas00638 assembling and installing the front brake calipers the following procedure applies to both of the brake calipers. S before installation, all ...

  • Page 168: Chas

    4-43 front and rear brakes chas warning caution: 4. Fill: s brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) recommended brake fluid dot 4 s use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage ...

  • Page 169: Chas

    4-44 front and rear brakes chas warning 30 nm (3.0 m s kg, 22 ft s lb) warning caution: 40 nm (4.0 m s kg, 29 ft s lb) eas00644 assembling and installing the rear brake caliper s before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S ne...

  • Page 170: Chas

    4-45 front and rear brakes chas warning caution: s use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result i...

  • Page 171: Chas

    4-46 front fork chas order job / part q’ty remarks 1 2 3 4 5 removing the front fork front wheel front fender upper bracket pinch bolt cap bolt lower bracket pinch bolt 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”. Loos...

  • Page 172: Chas

    4-47 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 173: Chas

    4-48 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 174: Chas

    4-49 front fork chas caution: note: 2. Remove: s spacer 1 s spring seat 2 s spring 3 s damper adjusting rod 4 3. Drain: s fork oil 4. Remove: s oil seal clip 1 (with a flat-head screwdriver) do not scratch the inner tube. 5. Remove: s damper rod bolt s damper rod 1 while holding the damper rod with ...

  • Page 175: Chas

    4-50 front fork chas caution: warning caution: s excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. S avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. Eas00657 checking the fro...

  • Page 176: Chas

    4-51 front fork chas warning note: caution: note: 35 nm (3.5 m s kg, 25 ft s lb) note: eas00660 assembling the front fork legs the following procedure applies to both of the front fork legs. S make sure that the oil levels in both front fork legs are equal. S uneven oil levels can result in poor han...

  • Page 177: Chas

    4-52 front fork chas caution: note: note: caution: note: 4. Install: s oil seal 1 (with the driver 2 and 43 mm adapter 3 ) driver ym-33963 43 mm adapters ym-8020-a make sure that the numbered side of the oil seal faces up. S before installing the oil seal, apply lithium soap base grease onto its lip...

  • Page 178: Chas

    4-53 front fork chas note: note: note: 7. Install: s rod puller 1 (onto the damper rod 2 ) rod puller ym-01437 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. Be sure to stroke the damper rod slowly be- cause the fork o...

  • Page 179: Chas

    4-54 front fork chas note: note: caution: 12. Install: s spring 1 s spring seats 2 s spacer 3 s nut 4 s damper adjusting rod 5 s 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 ont...

  • Page 180: Chas

    4-55 front fork chas note: 23 nm (2.3 m s kg, 17 ft s lb) 25 nm (2.5 m s kg, 18 ft s lb) 30 nm (3.0 m s kg, 22 ft s lb) warning eas00662 installing the front fork legs the following procedure applies to both of the front fork legs. 1. Install: s front fork leg temporarily tighten the upper and lower...

  • Page 181: Chas

    4-56 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 182: Chas

    4-57 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: s throttle cable housing 1 s throttle grip 2 3. Remove: s handlebar grip 1 blow comp...

  • Page 183: Chas

    4-58 handlebar chas warning warning 23 nm (2.3 m s kg, 17 ft s lb) caution: note: note: 3.Install: s 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...

  • Page 184: Chas

    4-59 handlebar chas note: note: 5. Install: s left handlebar switch align the pins a on the right handlebar switch with the holes b in the handlebar. 6. Install: s clutch lever holder align the slit in the clutch lever holder with the punch mark a in the left handlebar. 7. Install: s brake master cy...

  • Page 185: Chas

    4-60 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 186: Chas

    4-61 steering head chas warning warning eas00677 removing the lower bracket 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: s lower ring nut 1 (with the special tool 2 ) steering nut wrench yu-1268 securely support...

  • Page 187: Chas

    4-62 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. S always replace the be...

  • Page 188: Chas

    4-63 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 189: Chas

    4-64 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 190: Chas

    4-65 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 191: Chas

    4-66 rear shock absorber assembly chas note: eas00696 checking the rear shock absorber assembly 1. Check: s rear shock absorber rod bends / damage ! Replace the rear shock absorber assembly. S rear shock absorber gas leaks / oil leaks ! Replace the rear shock absorber assembly. S spring damage / wea...

  • Page 192: Chas

    4-67 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 193: Chas

    4-68 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. 85 nm (8.5 m s kg, 61 ft s lb) 125 nm (12.5 m s k...

  • Page 194: Chas

    4-69 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: s c...

  • Page 195: Chas

    4-70 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 196: Chas

    4-71 swingarm and drive chain chas note: 4. Check: s dust covers 1 s spacer 2 s oil seals 3 damage / wear ! Replace. S bearings 4 damage / pitting ! Replace. 5. Check: s connecting arms 1 s relay arm 2 damage / wear ! Replace. S bearings 3 s oil seals 4 damage / pitting ! Replace. S spacers 5 damage...

  • Page 197: Chas

    4-72 swingarm and drive chain chas caution: 3. Clean: s 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-r...

  • Page 198: Chas

    4-73 swingarm and drive chain chas 85 nm (8.5 m s kg, 61 ft s lb) note: 48 nm (4.8 m s kg, 35 ft s lb) 48 nm (4.8 m s kg, 35 ft s lb) eas00713 installing the drive chain 1. Lubricate: s drive chain recommended lubricant engine oil or chain lubricant suitable for o-ring chains 2. Install: s drive cha...

  • Page 199: Chas

    4-74 swingarm and drive chain chas note: caution: install the connecting arm front bolt 1 from the right. 3. Install: s rear shock absorber assembly s rear wheel refer to “installing the rear shock absorber assembly” and ”rear wheel”. 4. Adjust: s drive chain slack refer to “adjusting the drive chai...

  • Page 200: Eng

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

  • Page 201: Eng

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

  • Page 202: Eng

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

  • Page 203: Eng

    Eng.

  • Page 204: Eng

    5-1 85 nm (8.5 m kg, 61 ft lb) 20 nm (2.0 m kg, 14 ft lb) 20 nm (2.0 m kg, 14 ft lb) 10 nm (1.0 m kg, 7.2 ft lb) 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) stato...

  • Page 205: 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 206: Eng

    5-3 24 nm (2.4 m kg, 17 ft lb) 33 nm (3.3 m kg, 24 ft lb) 55 nm (5.5 m kg, 40 ft lb) 24 nm (2.4 m kg, 17 ft lb) 55 nm (5.5 m kg, 40 ft lb) 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 moun...

  • Page 207: Eng

    5-4 engine eng note: 10 nm (10 m kg, 7.2 ft lb) note: eas00192 installing the engine 1. Install: engine mount bolt 1 engine mount bolt 2 engine mount bolts 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 bol...

  • Page 208: Eng

    5-5 camshaft eng 13 nm (1.3 m kg, 9.4 ft lb) 12 nm (1.2 m kg, 8.7 ft lb) 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 ...

  • Page 209: Eng

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

  • Page 210: Eng

    5-7 camshaft eng order job / part q’ty remarks 10 11 12 13 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, 7.2 ft lb) 24 nm (2.4 m kg, 17 ft lb) 10 nm (1.0 m kg, 7.2 ft lb) 10 nm (1.0 m ...

  • Page 211: 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 212: 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 213: Eng

    5-10 camshaft eng note: 3. Measure: s camshaft runout out of specification ! Replace. Camshaft runout less than 0.03 mm (0.0012 in) 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 0.0...

  • Page 214: 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: r timing chain 1 damage / stiffness ! Replace the timing chain and camshaft sprockets as a set. 2. Che...

  • Page 215: Eng

    5-12 camshaft eng note: note: note: 2. Check: r 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 ...

  • Page 216: Eng

    5-13 camshaft eng 10 nm (1.0 m r kg, 7.2 ft r lb) note: caution: note: caution: 3. Install: r 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-...

  • Page 217: 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: r timing chain tensioner a. ...

  • Page 218: Eng

    5-15 camshaft eng 15 nm (15 m r kg, 11 ft r lb) 7. Check: r “t” mark a make sure that the “t” mark a on the pickup coil rotor is aligned with the crankcase mat- ing surface b . R camshaft punch marks c make sure that the marks c on the camshaft are aligned with the arrow marks d in the comshaft caps...

  • Page 219: Eng

    5-16 cylinder head eng 12 nm (1.2 m s kg, 8.7 ft s lb) 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...

  • Page 220: Eng

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

  • Page 221: Eng

    5-18 cylinder head eng note: 20 nm (2.0 m r kg, 14 ft r lb) 50 nm (5.0 m r kg, 36 ft r lb) 12 nm (1.2 m r kg, 8.7 ft r lb) note: note: eas00233 installing the cylinder head 1. Install: r gasket new 1 r dowel pins 2 2. Install: r cylinder head pass the timing chain through the timing chain cavity. 3....

  • Page 222: 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 223: 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 224: 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 225: Eng

    5-22 note: valves and valve springs eng 4. Remove: r upper spring seat 1 r valve spring 2 r oil seal 3 r lower spring seat 4 r 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 pr...

  • Page 226: 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 227: Eng

    5-24 valves and valve springs eng note: 3. Eliminate: r carbon deposits (from the valve face and valve seat) 4. Check: r valve face pitting/ wear ! Grind the valve face. R valve stem end mushroom shape or diameter larger than the body of the valve stem ! Replace the valve. 5. Measure: r valve margin...

  • Page 228: 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 229: 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: r valve spring free length a out of specification ! Replace the valve spring. Valve spring free length intake spring 38.9 mm (1.53 in) exhaust spring 40.67 m...

  • Page 230: 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: r valve lifter damage / scratches ! Replace the valve lift- ers and cylinder head. Eas00245 installing the valves the following procedure applies t...

  • Page 231: Eng

    5-28 valves and valve springs eng note: caution: note: 4. Install: r valve cotters 1 install the valve cotters by compressing the valve spring with the valve spring compressor 2 and adapter 3 . Valve spring compressor set, quick release ym-04019 adapter intake valve ym-4114 exhaust valve ym-4108 5. ...

  • Page 232: Eng

    5-29 14 nm (1.4 m s kg, 10 ft s lb) 65 nm (6.5 m s kg, 47 ft s lb) + 60 _ 12 nm (1.2 m s kg, 8.7 ft s lb) 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 ge...

  • Page 233: Eng

    5-30 generator eng note: note: warning caution: removing the generator 1. Remove: r 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: r generator rotor bolt 1 r washer while ho...

  • Page 234: Eng

    5-31 generator eng 65 nm (6.5 m s kg, 47 ft s lb) + 60 _ note: note: 3. Tighten: s generator rotor bolt 1 new s while holding the generator rotor 2 with the universal magneto & rotor holder 3 , tighten the generator rotor bolt. S after tightening to 65 nm (6.5 m s kg, 47 ft s lb), tighten another 60...

  • Page 235: Eng

    5-32 12 nm (1.2 m r kg, 8.7 ft r lb) 15 nm (1.5 m r kg, 11 ft r lb) 60 nm (6.0 m r kg, 43 ft r lb) 10 nm (1.0 m r kg, 7.2 ft r lb) 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 ...

  • Page 236: 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 r kg, 8.7 ft r lb) 15 nm (1.5 m r kg, 11 ft r lb) 60 nm (6.0 m r kg, 43 ft r lb) 10 nm (1.0 m r kg, 7.2 ft r lb).

  • Page 237: Eng

    5-34 pickup coil eng note: note: note: removing the pickup coil rotor 1. Remove: r pickup coil lead holder 1 r 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: r pickup coil...

  • Page 238: Eng

    5-35 pickup coil eng 60 nm (6.0 m r kg, 43 ft r lb) note: note: 2. Tighten: r pickup coil rotor bolt 1 while holding the generator rotor 2 with the universal magneto & rotor holder 3 , tighten the pickup coil rotor bolt. Universal magneto & rotor holder yu-01235 3. Apply: r sealant (onto the pickup ...

  • Page 239: Eng

    5-36 clutch eng 12 nm (1.2 m s kg, 8.7 ft s lb) 12 nm (1.2 m s kg, 8.7 ft s lb) 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” i...

  • Page 240: 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 241: Eng

    5-38 clutch eng 8 nm (0.8 m s kg, 5.8 ft s lb) 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 ...

  • Page 242: Eng

    5-39 clutch eng 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 1 1 1 1 1 1 for installation, reverse the removal...

  • Page 243: Eng

    5-40 clutch eng note: eas00277 removing the clutch 1. Straighten the lock washer tab. 2. Loosen: r 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 ym-91042 3. Remove: r clutch boss nut 1 r lock washer 2 r cl...

  • Page 244: Eng

    5-41 clutch eng note: note: 2. Measure: s 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 x 3.58 mm (0.135 x 0.141 in) : 3.32 mm (0.131 in) friction plate b 2.92 x 3.08 mm ...

  • Page 245: Eng

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

  • Page 246: Eng

    5-43 clutch eng note: note: eas00284 checking the clutch housing 1. Check: r 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: r bearing damage / wear ! Repla...

  • Page 247: Eng

    5-44 clutch eng 2. Check: r pull rod bearing damage / wear ! Replace. Eas00351 checking the starter clutch 1. Check: r starter clutch rollers damage / wear ! Replace. 2. Check: r starter clutch idle gear r starter clutch drive gear r starter clutch gear burrs / chips / roughness / wear ! Replace the...

  • Page 248: Eng

    5-45 clutch eng note: 90 nm (9.0 m kg, 65 ft lb) 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 ge...

  • Page 249: Eng

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

  • Page 250: Eng

    5-47 clutch eng note: 8 nm (0.8 m kg, 5.8 ft lb) note: note: 12 nm (1.2 m kg, 8.7 ft lb) 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 ...

  • Page 251: Eng

    5-48 shift shaft eng 12 nm (1.2 m kg, 8.7 ft lb) 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 shi...

  • Page 252: Eng

    5-49 shift shaft eng 22 nm (2.2 m kg, 16 ft lb) 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 ro...

  • Page 253: 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 254: Eng

    5-51 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 assembly relief valve assembly 1 1 1 1 1 1 1 1 for installation, reverse the removal pro- cedure. 10 nm (1.0 m kg, 7.2 ft...

  • Page 255: Eng

    5-52 oil pan and oil pump eng 10 nm (1.0 m kg, 7.2 ft lb) 15 nm (1.5 m kg, 11 ft lb) 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 par...

  • Page 256: 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 257: 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 bl...

  • Page 258: Eng

    5-55 oil pan and oil pump eng note: 12 nm (1.2 m kg, 8,7 ft lb) note: 10 nm (1.0 m kg, 7.2 ft lb) 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, 7.2 ft lb) when installing the inner rotor, align the pin 1 in the oil pump shaft with the ...

  • Page 259: Eng

    5-56 oil pan and oil pump eng 10 nm (10 m kg, 7.2 ft lb) 10 nm (10 m kg, 7.2 ft lb) 43 nm (4.3 m kg, 31 ft lb) 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...

  • Page 260: 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 261: 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, 7.2 ft lb) 10 nm (1.0 m kg, 7.2 ft lb) crankcase eng.

  • Page 262: 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 263: 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 264: 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 265: 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 266: 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 267: 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...

  • Page 268: Eng

    5-65 crankcase eng note: c. Measure piston skirt diameter “p” with the micrometer. A 5 mm (0.20 in) from the bottom edge of the piston. Piston size “p” 73.955 x 73.970 mm (2.9118 x 2.9122 in) d. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinde...

  • Page 269: 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 (0.20 in) 3. Measure: piston ring end gap out of specification ! Replace the piston ring. The oil ring expander spacer’s end gap cannot be measure...

  • Page 270: 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 x 17.013 mm (0.6694 x 0.6698 in) 4. Calculate: piston-pin-to-piston clearance out of specification ! Replace the piston pin and piston as a set. Piston-pin...

  • Page 271: 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 272: 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 x 10 1st: 15 nm (1.5 m s kg, 11 ft s lb) 2nd: 15 nm (1.5 m s kg, 11 ft s lb) + 45 x 50 _ bolt 11 x 15 , 17 x 20 , 23 , 25 x 28 12 nm (1.2 m s kg, 8.7 ft s lb...

  • Page 273: 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 clearan...

  • Page 274: 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 275: Eng

    5-72 crankcase eng note: 6. Select: big end bearings (p 1 x 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” x “p5” refer to the bearings shown in the crankshaft illustration. For example, i...

  • Page 276: 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. Oi...

  • Page 277: 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 278: Eng

    5-75 crankcase eng note: 36 nm (3.6 m kg, 25 ft lb) 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 cran...

  • Page 279: 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 acc-11001-05-01 do not allow any sealant to come in...

  • Page 280: 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 281: 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 282: 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 283: 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 284: 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 285: 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 286: 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 287: 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 run...

  • Page 288: 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 290: Cool

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

  • Page 291: Cool

    Cool.

  • Page 292: 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 293: Cool

    6-2 radiator cool note: eas00455 checking the radiator 1. Check: s 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: s radiator hoses s radiator pipes cracks ...

  • Page 294: Cool

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

  • Page 295: 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 296: 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 s kg, 11 ft s ...

  • Page 297: Cool

    6-6 thermostat cool note: note: eas00462 checking the thermostat 1. Check: s thermostat does not open at 71 x 85 _ c (160 x 185 _ f) ! 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, obse...

  • Page 298: Cool

    6-7 thermostat cool 15 nm (1.5 m kg, 11 ft lb) 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- men...

  • Page 299: 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 300: 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. 5 6 7 10 nm (1.0 m kg, 7.2 ft lb).

  • Page 301: 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 302: 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 303: 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 dampe...

  • Page 304: Carb

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

  • Page 305: Carb

    Carb.

  • Page 306: 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 307: 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 308: 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 309: 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 fuel drain bolt float pin 1 1 1 1 1 1 1 1 1 disassemble the parts in the order listed. The following pr...

  • Page 310: 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. 10 11 12 13 14 15 16.

  • Page 311: Carb

    7-6 carburetors carb eas00486 checking the carburetors the following procedure applies to all of the car- buretors. 1. Check: s carburetor body s float chamber s jet housing cracks / damage ! Replace. 2. Check: s fuel passages obstruction ! Clean. A. Wash the carburetor in a petroleum-based solvent....

  • Page 312: Carb

    7-7 carburetors carb 8. Check: s piston valve 1 damage / scratches / wear ! Replace. S rubber diaphragm 2 cracks / tears ! Replace. 9. Check: s vacuum chamber cover 1 s piston valve spring 2 s jet needle holder 3 cracks / damage ! Replace. 10. Check: s jet needle kit 1 s needle jet 2 s main jet 3 s ...

  • Page 313: Carb

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

  • Page 314: 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: s piston valve s piston val...

  • Page 315: Carb

    7-10 carburetors carb note: eas00495 measuring and adjusting the fuel level 1. Measure: s fuel level a out of specification ! Adjust. Fuel level (below the line on the float chamber) 3.0 x 4.0 mm (0.118 x 0.157 in) a. Stand the motorcycle on a level surface. B. Place the motorcycle on a suitable sta...

  • Page 316: 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 317: 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 318: 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 319: 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 320: 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 321: 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. ...

  • Page 322: Elec

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

  • Page 323: Elec

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

  • Page 324: 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 325: 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 326: 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 327: 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 328: 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 329: 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 330: 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 331: 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 332: Elec

    8-9 1 main switch 2 dimmer switch 3 horn switch 4 clutch switch 5 hazard switch 6 turn signal switch 7 front brake switch 8 engine stop switch 9 start switch 10 rear brake switch 11 fuse 12 side stand switch 13 neutral switch 14 oil level switch checking the switches elec eas00731 checking the switc...

  • Page 333: 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 ! ...

  • Page 334: 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 335: 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 measurement yu-03112-c check each ...

  • Page 336: Elec

    8-13 1 main switch 5 battery 7 fuse (main) 15 ignitor 16 ignition coil 17 spark plug 18 pickup coil 40 engine stop switch 54 fuse (ignition) ignition system elec eas00735 ignition system circuit diagram.

  • Page 337: 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 (68 _ f) s is the battery ok? S clean the battery terminals. S recharge or replace the battery. 3. Spark plugs the...

  • Page 338: Elec

    8-15 ignition system elec no yes eas00745 yes no eas00747 1 a 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 dynamic spark tester as shown. S set the main switch to “on”. S measure the ignition spark...

  • Page 339: 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 coi...

  • Page 340: Elec

    8-17 1 main switch 5 battery 6 starter relay 7 fuse (main) 8 starter motor 9 starting circuit cutoff relay 10 side stand switch 19 neutral switch 40 engine stop switch 41 start switch 46 clutch switch 54 fuse (ignition) electric starting system elec eas00755 electric starting system circuit diagram.

  • Page 341: 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 342: 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 343: 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 x 1) and bat- tery (12 v) to the starter relay coupler a...

  • Page 344: 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 345: 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 346: 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 347: 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 (1.06 in) 3. Measure: s mica undercut a out of s...

  • Page 348: 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 (0.16 in) 6. Measure: brush spring force out of specification ! Replace the...

  • Page 349: 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 350: Elec

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

  • Page 351: Elec

    8-28 s check the condition of the battery. Refer to “checking the battery” in chapter 3. 3. Charging voltage s connect the inductive self-powered 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 ...

  • Page 352: Elec

    8-29 s measure the stator coil resistances. Stator coil resistance 0.27 x 0.33 Ω at 20 _ c (68 _ f) 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...

  • Page 353: Elec

    8-30 49 front turn signal light (right) 52 headlight 53 tail / brake light 54 fuse (ignition) 56 fuse (headlight) 61 headlight relay (dimmer) 1 main switch 5 battery 7 fuse (main) 31 hi-beam indicator light 34 meter light 44 dimmer switch 48 front turn signal light (left) lighting system elec eas007...

  • Page 354: Elec

    8-31 eas00749 yes no 3. Main switch s check the main switch for continuity. Refer to “checking the switches”. S is the main switch ok? Replace the main switch. Yes no 4. Dimmer switch s check the dimmer switch for continuity. Refer to “checking the switches”. The dimmer switch is faulty. Replace the...

  • Page 355: Elec

    8-32 does the headlight rrelay (dimmer) have continuity? No yes replace the head- light relay (dimmer). 1 2 hi-beam positive battery lead ! Yellow negative battery lead ! Black positive tester probe ! Red / yellow negative tester probe ! Black / yellow 3 4 5. Headlight relay (dimmer) disconnect the ...

  • Page 356: 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 har...

  • Page 357: 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 ...

  • Page 358: Elec

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

  • Page 359: 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 360: 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 361: 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 362: 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...

  • Page 363: 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 r...

  • Page 364: 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 365: 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 resistanc...

  • Page 366: 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 57 fues (fan) 58 fan motor relay 59 fan motor eas00807 cooling system circuit diagram.

  • Page 367: 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 368: Elec

    8-45 cooling system elec thermo unit 15 nm (1.5 m s kg, 11 ft s lb) 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 pr...

  • Page 369: Elec

    8-46 1 main switch 5 battery 7 fuse (main) 9 starting circuit cutoff relay 11 fuel pump 15 ignitor 40 engine stop switch 54 fuse (ignition) fuel pump system elec eas00814 fuel pump system circuit diagram.

  • Page 370: 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 371: 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 372: 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 373: 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 374: Elec

    8-51 1 main switch 5 battery 7 fuse (main) 12 exup servomotor 15 ignitor 54 fuse (ignition) exup system elec eas00827 exup system circuit diagram.

  • Page 375: 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 376: 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 377: 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 378: 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 379: 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 380: 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 381: 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 382: 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 383: 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 384: Trbl

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

  • Page 385: 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 386: Trbl

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

  • Page 387: Trbl

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

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

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

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

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

  • Page 392: Trbl

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

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