Yamaha FZS600 Fazer (2003) manual

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EB000000 FZS600 SERVICE MANUAL  1997 by Y amaha Motor Co., Ltd. First edition, December 1997 All rights reserved. Any reproduction or unauthorized use without the written permission of Y amaha Motor Co., Ltd. is expressly prohibited.[...]

NOTE: CAUTION: EB001000 NOTICE This manual was produced by the Y amaha Motor Company primarily for use by Y amaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Y amaha scooter has a basic unders[...]

7 2 1 4 3 8 6 5 YP002000 HOW T O USE THIS MANUAL This manual is intended as a handy , easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal,disassembly , assembly , repair and inspection procedures are laid out with the individual steps in sequential order . 1 The manual is divided into chapters. An a[...]

1 3 5 7 9 11 13 15 18 2 4 8 10 12 14 16 6 21 24 25 17 19 20 22 23 EB003000 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter . 1 General information 2 Specifications 3 Periodic inspection and adjustment 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis 8 Electrical system 9 T rou[...]

GENERAL INFORMA TION SPECIFICA TIONS PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE COOLING SYSTEM CARBURET ORS CHASSIS ELECTRICAL SYSTEM TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 ELEC 8 TRBL SHTG 9 INDEX[...]

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GEN INFO 1[...]

GEN INFO CHAPTER 1 GENERAL INFORMA TION MOTORCYCLE IDENTIFICA TION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICA TION NUMBER 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MODEL CODE 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

GEN INFO[...]

1-1 GEN INFO MOTORCYCLE IDENTIFICA TION 1 1 EB100000 GENERAL INFORMA TION MOTORCYCLE IDENTIFICA TION EB100010 VEHICLE IDENTIFICA TION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. EB100020 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts[...]

1-2 spring lip oil grease lip GEN INFO IMPORT ANT INFORMA TION EB102000 IMPORT ANT INFORMA TION PREP ARA TION FOR REMOV AL AND DISASSEMBL Y 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” section. 3. When disassembling, always [...]

1-3 OR GEN INFO IMPORT ANT INFORMA TION CAUTION: EB102030 LOCK W ASHERS / PLA TES AND COTTER PINS 1. After removal, replace all lock washers / plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EB102040 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so t[...]

1-4 GEN INFO CHECKING THE CONNECTIONS NOTE: NOTE: NOTE: EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect:  lead  coupler  connector 2. Check:  lead  coupler  connector Moisture  Dry with an air blower . Rust / stains  Connect and disconnect several tim[...]

1-5 GEN INFO SPECIAL TOOLS 1 2 1 2 1 2 1 EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly . Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order , refer to the list provided below[...]

1-6 GEN INFO SPECIAL TOOLS 1 T ool No. T ool name / Usage Illustration 90890-01399 Special thickness gauge This tool is used to measure the valve clearance. 90890-01401 Spark plug wrench This tool is used for removing or installing the spark plug. 90890-01403 Ring nut wrench This tool is used to tighten the steering ring nut. 90890-01469 Oil filter[...]

1-7 GEN INFO SPECIAL TOOLS 1 2 1 T ool No. T ool name / Usage Illustration 90890-03141 T iming light This tool is necessary for checking ignition timing. 90890-04044 Piston ring compressor This tool is used to compress piston rings when installing the cylinder . 90890-03158 Carburetor angle driver This tool is used to adjust the pilot screw . 90890[...]

1-8 GEN INFO SPECIAL TOOLS T ool No. T ool name / Usage Illustration 90890-85505 Y amaha bond No.1215 This sealant (bond) is used for crankcase mating surface, etc.[...]

SPEC 2[...]

SPEC CHAPTER 2 SPECIFICA TIONS GENERAL SPECIFICA TIONS 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE SPECIFICA TIONS 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE 2-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

SPEC[...]

2-1 GENERAL SPECIFICA TIONS SPEC SPECIFICA TIONS GENERAL SPECIFICA TIONS Model FZS600 Model code: 5DM1 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius 2,080 mm 710 mm 1,170 mm 790 mm 1,415 mm 130 mm 2,900 mm Basic weight: With oil and full fuel tank 210 kg Engine: Engine [...]

2-2 GENERAL SPECIFICA TIONS SPEC Model FZS600 Carburetor: T ype / quantity Manufacturer BSR 33 / 4 MIKUNI Spark plug: T ype Manufacturer Spark plug gap CR9E, CR8E / U27ESR-NU24ESR-N NGK / DENSO 0.7 X 0.8 mm Clutch type: Wet, multiple-disc T ransmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction [...]

2-3 GENERAL SPECIFICA TIONS SPEC Model FZS600 Brake: Front brake type operation Rear brake type operation Dual disc brake Right hand operation Single disc brake Right foot operation Suspension: Front suspension Rear suspension T elescopic fork Swingarm (link suspension) Shock absorber: Front shock absorber Rear shock absorber Coil spring / Oil damp[...]

2-4 MAINTENANCE SPECIFICA TIONS SPEC Face Width Seat Width Margin Thickness MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit  0.05 mm Cylinder: Bore size T aper limit Out of round limit 62.00  62.01 mm   62.1 mm 0.09 mm 0.07 mm Camshaft: Drive method Cam cap inside dia. Camshaft out sid[...]

2-5 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Stem-to-guide clearance IN EX Stem runout limit V alve seat width IN EX 0.010  0.037 mm 0.025  0.052 mm  0.9  1.1 mm 0.9  1.1 mm 0.08 mm 0.1 mm 0.04 mm 1.6 mm 1.6 mm V alve spring: Free length IN / EX Set length (valve closed) IN / EX Compressed pressure IN / EX T ilt lim[...]

2-6 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Clutch: Friction plate thickness Quantity Wear limit Friction plate thickness Quantity Clutch plate thickness Quantity W arp limit Clutch spring free length Quantity Minimum length Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Push rod bending limit 2.9[...]

2-7 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Lubrication system: Oil filter type Oil pump type T ip clearance “A” or “B” Side clearance Bypass valve setting pressure Relief valve operating pressure Pressure check location Paper type T rochoid type 0.03  0.09 mm 0.03  0.08 mm 80  120 kPa (0.8  1.2 kg / cm 2 ) 450  [...]

2-8 MAINTENANCE SPECIFICA TIONS SPEC TIGHTENING TORQUES ENGINE Part to be ti g htened Part name Thread size Q’t y T ightening torque Remarks g size y Nm m  kg Camshaft cap Bolt M6 24 10 1.0 Cylinder head Nut M9 12 35 3.5 Spark plug – M10 4 13 1.3 Cylinder head cover Bolt M6 8 10 1.0 Cylinder head side cover Bolt M5 8 9 0.9 Connecting rod cap[...]

2-9 MAINTENANCE SPECIFICA TIONS SPEC NOTE: Lower crankcase Upper crankcase Part to be ti g htened Part name Thread size Q’t y T ightening torque Remarks g size y Nm m  kg Starter cover Bolt M6 7 12 1.2 Oil gallery – M16 2 8 0.8 Clutch cover Bolt M6 10 12 1.2 Clamp (A.C magneto cover) Screw M6 1 7 0.7 Starter clutch assembly Bolt M10 1 80 8.0[...]

2-10 MAINTENANCE SPECIFICA TIONS SPEC CHASSIS Item Standard Limit Steering system: Steering bearing type Angular bearing  Front suspension: Front fork travel Fork spring free length Fitting length Collar length Spring Rate (K1) (K2) Stroke (K1) (K2) Optional spring Oil capacity Oil level Oil grade 120 mm 323 mm 315.9 mm 200 mm 7.5 N / mm ([...]

2-1 1 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Front disc brake: T ype Disc outside dia.  thickness Disc deflection limit Pad thickness Inner Pad thickness Outer Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type Dual 298  4 mm  5.5 mm 5.5 mm 14 mm 30.2 mm 27 mm DOT No.4   0.2 mm 0[...]

2-12 MAINTENANCE SPECIFICA TIONS SPEC TIGHTENING TORQUES CHASSIS Part to be ti g htened Thread size T ightening torque Remarks g Nm m  kg Upper bracket and inner tube M8  1.25 30 3.0 Upper bracket and steering stem M22  1.0 11 0 1 1.0 Handlebar under holder M10  1.25 40 4.0 Handlebar upper holder M8  1.25 23 2.3 Under bracket and inn[...]

2-13 MAINTENANCE SPECIFICA TIONS SPEC NOTE: Part to be ti g htened Thread size T ightening torque Remarks g Nm m  kg Side cover and frame M6  1.0 4 0.4 Garb bar M8  1.25 19 1.9 Front wheel axle M16  1.5 67 6.7 Front wheel axle pinch bolt M8  1.0 20 2.0 Front brake caliper M8  1.25 40 4.0 Front brake disc M8  1.25 23 2.3 Front b[...]

2-14 MAINTENANCE SPECIFICA TIONS SPEC ELECTRICAL Item Standard Limit V oltage 12 V  Ignition system: Ignition timing (B.T .D.C.) Advanced timing (B.T .D.C.) Advance type 10  / 1,250 r / min 50  / 4,500 r / min TPS and electrical type    T .C.I.: Pickup coil resistance T .C.I. unit model / manufacturer 189 ?[...]

2-15 MAINTENANCE SPECIFICA TIONS SPEC Item Standard Limit Starter motor: Model / manufacturer I.D. number Output Armature coil resistance Brush overall length Brush spring pressure Commutator dia. Mica undercut (depth) SM-13 / MITSUBA SM-13 0.7 kW 0.0015  0.0025 Ω at 20  C 10 mm 7.8  10.2 N (780  1.020 gf) 28 mm 0.7 mm  ?[...]

2-16 MAINTENANCE SPECIFICA TIONS SPEC Item Standard limit Amperage for individual circuit: Main Headlight Signal Ignition Fan Back up Reserve 30 A 20 A 20 A 20 A 10 A 5 A 30 A 20 A 10 A 5 A          [...]

2-17 GENERAL TIGHTENING TORQUE SPECIFICA TIONS SPEC EB201000 GENERAL TIGHTENING TORQUE SPECIFICA TIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. T ight- ening torque specifications for special components or assemblies are provided for each chapter of this manual. T o avoid warpage, tighten mult[...]

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2-19 LUBRICA TION POINT AND LUBRICA TION TYPES SPEC CHASSIS Lubrication Point Symbol Steering bearing and bearing race (upper and lower) Pivot shaft Rear arm bearing Rear arm oil seal Rear arm cover oil seal lips Relay arm bearing Relay arm oil seal Rear shock absorber (upper / lower) Front wheel oil seal Speed sensor oil seal Rear wheel oil seal C[...]

2-20 10 3 2 4 1 1 3 6 5 5 6 7 8 9 8 Radiator outlet hose 9 Radiator 10 Radiator inlet hose 1 Engine outlet hose 2 Engine outlet hose 3 Carburetor inlet hose 4 Carburetor outlet hose 5 W ater pump 6 Coolant drain bolt 7 W ater pump outlet hose COOLING SYSTEM DIAGRAMS SPEC EB203000 COOLING SYSTEM DIAGRAMS[...]

2-21 1 Radiator 2 W ater pump outlet hose 3 Oil cooler inlet hose 4 Oil cooler outlet hose 5 Carburetor outlet hose COOLING SYSTEM DIAGRAMS SPEC[...]

2-22 1 2 3 4 7 6 5 4 1 Oil nozzle (main nozzle) 2 Oil nozzle (drive axle) 3 Projection 4 Oil filter 5 Relief valve 6 Oil strainer 7 Oil pump LUBRICA TION DIAGRAMS SPEC EB204000 LUBRICA TION DIAGRAMS[...]

2-23 1 2 3 4 LUBRICA TION DIAGRAMS SPEC 1 Main axle 2 Drive axle 3 Camshaft 4 Oil delivery pipe[...]

2-24 1 2 LUBRICA TION DIAGRAMS SPEC 1 Camshaft 2 Crankshaft[...]

2-25 1 2 3 4 5 6 7 8 7 A B 9 Handlebar switch (left) A Use a plastic clamp to fasten together the handlebar switch lead (left), clutch cable and starter cable. B Pass the brake hose out side of the speed sensor lead, then use a plastic clamp to fasten them. 1 Throttle cable 2 Clutch cable 3 Handlebar switch (right) 4 Starter cable 5 Main switch 6 B[...]

2-26 1 Main switch lead 2 Starter cable 3 Handlebar switch lead (left) 4 Clutch cable 5 Rectifier / regulator 6 Horn lead 7 Box 8 Air guide plate 9 Starter cable 10 Flasher leray CABLE ROUTING SPEC 11 Battery 12 Starting circuit cut-off relay 13 Battery positive (+) lead 14 Seat lock cable 15 AC magneto lead 16 Starter motor lead 17 Air filter drai[...]

2-27 D Use a steel holder to fasten together the AC magneto lead, sidestand lead and oil level / neutral switch lead. E Use a plastic clamp to fasten the horn lead and air guide plate to the frame. A Use a plastic clamp to fasten the handlebar switch lead (left), main switch lead, clutch cable and starter cable to the frame. B Use a plastic band to[...]

2-28 1 Battery negative (–) lead 2 Rear brake switch lead 3 Battery 4 Reservoir tank hose 5 Air filter 6 Fuel tank breather hose 7 Fuel tank drain hose 8 T .P .S. lead 9 Handlebar switch lead (right) CABLE ROUTING SPEC 10 Throttle cable 11 Brake hose 12 Headlight lead 13 Speed sensor lead 14 Main switch lead 15 Reservoir tank 16 Cross tube 17 Res[...]

2-29 E Pass the battery negative (–) lead inside of the reservoir hose. C Pass the main switch lead under the throttle cables, headlight lead, handlebar switch lead (right) and speed sensor lead, then insert it right side of the box. D Pass the reservoir tank over flow hose, fuel tank breather hose and fuel tank drain hose through the cable holde[...]

2-30 21 Starter relay 22 Starting circuit cut-off relay 23 Flasher relay 24 Fuel pump lead coupler 25 Ignition coil 26 Clutch cable 27 Ground lead 28 Starter cable 29 Fan motor lead 30 Rectifier / regulator lead 11 Battery negative (–) lead 12 Battery 13 Rear brake reservoir tank 14 Rear brake switch lead 15 Seat lock cable 16 Ignitor 17 Rear tur[...]

2-31 turn signal light lead and clamp it. D Pass the reservoir hose left side of thermo stat housing. E Do not fasten the high tension cord #4 with locking tie. F Use a plastic band to fasten the high tension cord #3, #4. G Pass the carburetor inlet hose under the high tension cord #2, #4. B Pass the rectifier / regulator lead, fan motor lead, hand[...]

SPEC[...]

CHK ADJ 3[...]

CHK ADJ CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PERIODIC MAINTENANCE / LUBRICA TION INTERV ALS 3-1 . . . . . . . . . . . . . . . . . . . . . . FRONT COWLING / SEA T / SIDE COVER / FUEL T ANK 3-3 . . . . . . . .[...]

CHK ADJ[...]

3-1 INTRODUCTION / PERIODIC MAINTENANCE / LUBRICA TION INTERV ALS CHK ADJ EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. If followed, these preventive maintenance procedures will ensure more reliable vehicle opera- tion, a longer servic[...]

3-2 PERIODIC MAINTENANCE / LUBRICA TION INTERV ALS CHK ADJ NOTE: EVER Y NO. ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first) 17 * Sidestand switch  Check operation.  Replace if necessary . √ √ √ 18 * Front fork  Check operation and for oil [...]

3-3 Remove the parts in the order listed. Disconnect the couplers. For installation, reverse the removal procedure. NOTE: Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Removing the front cowling View mirror (left / right) Inner panel (left / right) Cowling stay (left / right) Head light lead Front flasher light lead (left / right) Front c[...]

3-4 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the seat, side cover and fuel tank Seat Fuel tank Fuel sender lead Fuel tank breaser hose Fuel tank drain hose Fuel hose Side cover (left / right) Grab bar T ail cover 1 1 1 1 1 1 1/1 1 1 Remove the parts in the order listed. Disconnect the couplers. For installation, reverse [...]

3-5 ADJUSTING THE V AL VE CLEARANCE CHK ADJ NOTE: EB303001 ENGINE ADJUSTING THE V AL VE CLEARANCE The following procedure applies to all of the valves.  V alve clearance adjustment should be made on a cold engine, at room tempera- ture.  When the valve clearance is to be mea- sured or adjusted, the piston must be at top dead center (TDC) on t[...]

3-6 ADJUSTING THE V AL VE CLEARANCE CHK ADJ b a 1 NOTE: NOTE: a. T urn the crankshaft counterclockwise. b. When piston #1 is at TDC on the com- pression stroke, align the TDC mark a on the generator rotor with the mark b on the crankcase. TDC on the compression stroke can be found when the camshaft lobes are turned away from each other . c. Measure[...]

3-7 ADJUSTING THE V AL VE CLEARANCE CHK ADJ NOTE: NOTE: 7. Remove:  timing chain tensioner bolt 1  timing chain tensioner assembly 2 8. Remove:  timing chain guide 1  timing chain guide (upper) 2  camshaft cap 3 9. Remove:  camshaft 1  Refer to “DISASSEMBLING THE ENGINE – CAMSHAFT AND CYLINDER HEAD” in chapter 4.  When[...]

3-8 ADJUSTING THE V AL VE CLEARANCE CHK ADJ NOTE: NOTE:  The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter .  Since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original. c. Round off[...]

3-9 ADJUSTING THE V AL VE CLEARANCE CHK ADJ Measured clearance # exa ! INST ALLED P AD NUMBER EXAMPLE: V AL VE CLEARANCE: 0.1 1  0.20 mm Installed is 150 Measured clearance is 0.25 mm Replace 150 pad with 160 pad 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00  0.02 120 125 130 135 140 [...]

3-10 ADJUSTING THE V AL VE CLEARANCE CHK ADJ a NOTE: NOTE: CAUTION: NOTE: e. Install the new valve pad 1 and the valve lifter 2 .  Apply molybdenum disulfide grease to the valve pad.  Lubricate the valve lifter with molybdenum disulfide oil.  The valve lifter must turn smoothly when rotated by hand.  Install the valve lifter and the val[...]

3-1 1 ADJUSTING THE V AL VE CLEARANCE / SYNCHRONIZING THE CARBURETORS CHK ADJ NOTE: NOTE: 14. Install:  cylinder head cover  spark plugs Bolt (cylinder head cover): 10 Nm (1.0 m  kg) Spark plug: 13 Nm (1.3 m  kg) EB303010 SYNCHRONIZING THE CARBURETORS Prior to synchronizing the carburetors, the valve clearance and the engine idling spee[...]

3-12 SYNCHRONIZING THE CARBURETORS CHK ADJ NOTE: NOTE: 6. Adjust:  carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same. After each step, rev the engine two or three times, each time for less than a second, and check the synchronization a[...]

3-13 ADJUSTING THE ENGINE IDLING SPEED CHK ADJ 1 NOTE: a b EB303020 ADJUSTING THE ENGINE IDLING SPEED Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly , the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sever- al minutes. [...]

3-14 a b a b ADJUSTING THE THROTTLE CABLE FREE PLA Y CHK ADJ NOTE: NOTE: a b NOTE: a b EB303032 ADJUSTING THE THROTTLE CABLE FREE PLA Y Prior to adjusting the throttle cable free play , the engine idling speed and carburetor syn- chronization should be adjusted properly . 1. Check:  throttle cable free play a Out of specification  Adjust. Thr[...]

3-15 ADJUSTING THE THROTTLE CABLE FREE PLA Y / CHECKING THE SP ARK PLUGS CHK ADJ CAUTION: NOTE: After adjusting the throttle cable free play , turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. 4. Install:  fuel pump  ignition coil  bracket EB303040 CHECKING THE SP ARK PLUG[...]

3-16 CHECKING THE SP ARK PLUGS / CHECKING THE IGNITION TIMING CHK ADJ NOTE: NOTE: 8. Connect:  spark plug cap EB303053 CHECKING THE IGNITION TIMING Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Remove:  timing plug 1 2. Inst[...]

3-17 MEASURING THE COMPRESSION PRESSURE CHK ADJ NOTE: CAUTION: EB303060 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. Insufficient compression pressure will result in a loss of performance. 1. Check:  valve clearance Out of specification  Adjust. Refer to “ADJUSTING THE V AL VE CLEARANCE”. 2[...]

3-18 MEASURING THE COMPRESSION PRESSURE / CHECKING THE ENGINE OIL LEVEL CHK ADJ NOTE: NOTE: Compression pressure (at sea level) Standard 1,500 kPa (15.0 kg / cm 2 ) Minimum 1,200 kPa (12.0 kg / cm 2 ) a. T urn the main switch to “ON”. b. With the throttle wide open, crank the en- gine until the reading on the compression gauge stabilizes. T o p[...]

3-19 TEMP SAE 10W-30 SAE 10W-30 SAE 10W-30 2 CHECKING THE ENGINE OIL LEVEL / CHANGING THE ENGINE OIL CHK ADJ CAUTION: NOTE: Recommended engine oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard  SE or higher grade ACEA standard  G4 or G5  Engine oil also lubricates the cl[...]

3-20 3 1 CHANGING THE ENGINE OIL CHK ADJ CAUTION: 43 Nm (4.3 m  kg) a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01469 b. Apply a thin coat of engine oil onto the O- ring 3 of the new oil filter cartridge. Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter car- tridge[...]

3-21 2 MEASURING THE ENGINE OIL PRESSURE CHK ADJ CAUTION: EB303090 MEASURING THE ENGINE OIL PRESSURE 1. Check:  engine oil level Below the minimum level mark  Add the recommended engine oil to the proper lev- el. 2. Start the engine, warm it up for several min- utes, and then turn it off. When the engine is cold, the engine oil will have a hi[...]

3-22 MEASURING THE ENGINE OIL PRESSURE / ADJUSTING THE CLUTCH CABLE FREE PLA Y CHK ADJ c d b a Engine side Handlebar side 8 Nm (0.8 m  kg) a b NOTE: c d 6. Install:  oil gallery bolt EB303100 ADJUSTING THE CLUTCH CABLE FREE PLA Y 1. Check:  clutch cable free play a Out of specification  Adjust. Clutch cable free play (at the end of the [...]

3-23 CLEANING THE AIR FIL TER ELEMENT CHK ADJ CAUTION: EB303130 CLEANING THE AIR FIL TER ELEMENT 1. Remove:  Seat  Fuel tank  Cover 1 2. Remove:  air filter case cover 1  air filter element 2 3. Clean:  air filter element Apply compressed air to the outer surface of the air filter element. 4. Check:  air filter element Damage ?[...]

3-24 CLEANING THE AIR FIL TER ELEMENT / CHECKING THE CARBURETOR JOINTS AND IN T AKE MANIFOLDS / CHECKING THE FUEL HOSES AND FUEL FIL TER CHK ADJ NOTE: NOTE: When installing the air filter element into the air filter case cover , be sure their sealing sur- faces are aligned to prevent any air leaks. 6. Install:  cover  fuel tank  seat EB303[...]

3-25 CHECKING THE CRANKCASE BREA THER HOSE / CHECKING THE EXHAUST SYSTEM CHK ADJ 2 7 5 6 4 4 4 3 1 1 1 CAUTION: EB303190 CHECKING THE CRANKCASE BREA THER HOSE 1. Remove:  seat  fuel tank  carburetor 2. Check:  crankcase breather hose 1 Cracks / damage  Replace. Loose connection  Connect properly . Make sure that the crankcase brea[...]

3-26 b a 7 6 CHECKING THE COOLANT LEVEL / CHECKING THE COOLING SYSTEM CHK ADJ CAUTION: NOTE: EB303220 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface.  Place the motorcycle on a suitable stand.  Make sure that the motorcycle is upright. 2. Remove:  side cover (right) 3. Check:  coolant level The coolant level shoul[...]

3-27 CHANGING THE COOLANT CHK ADJ 10 Nm (1.0 m  kg) EB303240 CHANGING THE COOLANT 1. Remove:  seat  fuel tank 2. Disconnect:  coolant reservoir hose 1 3. Drain:  coolant (from the coolant reservoir) 4. Remove:  radiator cap A hot radiator is under pressure. There- fore, do not remove the radiator cap when the engine is hot. Scaldi[...]

3-28 CHANGING THE COOLANT CHK ADJ CAUTION: 9. Coonect:  coolant reservoir hose 10. Fill:  cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines Mix ratio 50% antifreeze / 50 % water Quantity T otal amount 1[...]

3-29 CHANGING THE COOLANT CHK ADJ NOTE: 12. Fill:  coolant reservoir (with the recommended coolant to the maximum level mark a ) 13. Install:  coolant reservoir cap 14. Start the engine, warm it up for several min- utes, and then turn if off. 15. Check:  coolant level Refer to “CHECKING THE COOLANT LEVEL”. Before checking the coolant l[...]

3-30 ADJUSTING THE FRONT BRAKE / ADJUSTING THE REAR BRAKE CHK ADJ c b a NOTE: a a a b EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust:  brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. Be sure to a[...]

3-31 ADJUSTING THE REAR BRAKE / CHECKING THE BRAKE FLUID LEVEL CHK ADJ A B CAUTION: NOTE: After adjusting the brake pedal position, check that the end of the adjusting bolt 2 is visible through the hole c . c. T ighten the locknut 1 to specification. A soft or spongy feeling in the brake ped- al can indicate the presence of air in the brake system.[...]

3-32 a b CHECKING THE BRAKE FLUID LEVEL / ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ CAUTION: NOTE: NOTE: a b  Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance.  Refill with the same type of brake fluid that is already in the system. Mixing bra[...]

3-33 CHECKING THE BRAKE HOSES / BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ NOTE: EB304062 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check:  brake hose Cracks / damage / wear  Replace. 2. Check:  brake hose clamp Loose connection  T ighten. 3. Hold the motorcycle upright and apply [...]

3-34 Rear Front a b BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL CHK ADJ a b 2. Bleed:  hydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the diaphragm (brake master cylin- der reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2 . d. Place [...]

3-35 ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ a b NOTE: CAUTION: NOTE: a b NOTE: EB304090 ADJUSTING THE DRIVE CHAIN SLACK The drive chain slack must be checked at the tightest point on the chain. A drive chain that is too tight will over- load the engine and other vital parts, and one that is too loose can skip and dam- age the swingarm or cause an [...]

3-36 ADJUSTING THE DRIVE CHAIN SLACK /LUBRICA TING THE DRIVE CHAIN /CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ NOTE: c. T ighten the wheel axle nut to specifica- tion. Wheel axle nut 1 17 Nm (1 1.7 m  kg) Locknut 16 Nm (1.6 m  kg) EB304100 LUBRICA TING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chai[...]

3-37 1 2 3 4 8 7 6 a b CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ NOTE: NOTE: 4. Adjust:  steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . Set the torque wrench at a right angle to the ring nut wrench. [...]

3-38 CHECKING ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK / ADJUSTING THE REAR SHOCK ABSORBER ASSEMBL Y CHK ADJ CAUTION: NOTE: 5. Install:  upper bracket  handlebar Steering stem nut 1 10 Nm (1 1.0 m  kg) Upper bracket pinch bolt 30 Nm (3.0 m  kg) Handlebar upper holder bolt 23 Nm (2.3 m  kg) EB304140 CHECKING THE FRONT FOR[...]

3-39 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBL Y / CHECKING THE TIRES CHK ADJ a b adjusting position a b a. T urn the adjusting ring 1 in direction a or b . b. Align the desired position on the adjusting ring with the stopper . Direction  Spring preload is increased (suspension is harder). Direction  Spring preload is decreased (suspension is[...]

3-40 A B 3 2 1 CHECKING THE TIRES CHK ADJ Basic weight (with oil and a full fuel tank) 210 kg Maximum load 187 kg Cold tire pressure Front tire Rear tire Up to 90 kg load* 225 kPa (2.25 kg / cm 2 ) 250 kPa (2.50 kg / cm 2 ) 90 kg maximum load* 225 kPa (2.25 kg / cm 2 ) 280 kPa (2.80 kg / cm 2 ) High speed riding 225 kPa (2.25 kg / cm 2 ) 280 kPa (2[...]

3-41 CHECKING THE TIRES / CHECKING THE WHEELS CHK ADJ NOTE: NOTE:  After extensive tests, the tires listed be- low have been approved by Y amaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same de- sign. No guarantee concerning han- dling characteristics can be given if a tire com[...]

3-42 CHECKING AND LUBRICA TING THE CABLES / LUBRICA TING THE LEVERS AND PEDALS / LUBRICA TING THE SIDEST AND / LUBRICA TING THE CENTER ST AND / LUBRICA TING THE REAR SUSPENSION CHK ADJ NOTE: EB304200 CHECKING AND LUBRICA TING THE CABLES The following procedure applies to all of the cable sheaths and cables. Damaged cable sheaths may cause the cable[...]

3-43 CHECKING AND CHARGING THE BA TTER Y CHK ADJ CAUTION: EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BA TTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preven- tive measures:  Wear protective eye gear when han- dling or w[...]

3-44 CHECKING AND CHARGING THE BA TTER Y CHK ADJ NOTE: CAUTION: NOTE: Since MF batteries are sealed, it is not pos- sible to check the charge state of the battery by measuring the specific gravity of the elec- trolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove:  seat 2. Di[...]

3-45 CHECKING AND CHARGING THE BA TTER Y CHK ADJ Do not quick charge a battery .  Make sure that the battery vent is free of obstructions.  Never remove the MF battery sealing caps.  Do not use a high-rate battery charger . They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damag[...]

3-46 CHECKING AND CHARGING THE BA TTER Y 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 dial, set the charging voltage at 20  24 V [...]

3-47 CHECKING AND CHARGING THE BA TTER Y CHK ADJ Measure the open-circuit voltage prior to charging. Connect a charger and AMP meter to the battery and start charging. NOTE: V oltage should be measured 30 minutes after the machine is stopped. Make sure that the current is higher than the standard charging current written on the battery . Charge the[...]

3-48 CHECKING AND CHARGING THE BA TTER Y / CHECKING THE FUSES CHK ADJ CAUTION: CAUTION: NOTE: 6. Install:  battery 7. Connect:  battery leads (to the battery terminals) First, connect the positive lead 1 , then the negative lead 2 . 8. Check:  battery terminals Dirt  Clean with a wire brush. Loose connection  Connect properly . 9. Lu[...]

3-49 CHECKING THE FUSES / REPLACING THE HEADLIGHT BLUBS CHK ADJ 3. Replace:  blown fuse a. T urn off the ignition. b. Install a new fuse of the correct amperage rating. c. T urn on the switches to verify if the electri- cal circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. Fuses Amperage rating Quantit[...]

3-50 REPLACING THE HEADLIGHT BULBS / ADJUSTING THE HEADLIGHT BEAMS CHK ADJ a a a a b b b b CAUTION: a b 2. Remove:  headlight bulb holder 1 3. Remove:  headlight bulb 2 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install:  headlight bulb (New) Secure th[...]

3-51 ADJUSTING THE HEADLIGHT BEAMS CHK ADJ a b a b 2. Adjust:  headlight beam (horizontally) a. T urn the adjusting knob 2 4 in direction a or b . Left headlight 2 Direction  Headlight beam moves to the right. Direction  Headlight beam moves to the left. Right headlight 4 Direction  Headlight beam moves to the left. Direction  Headli[...]

CHK ADJ[...]

ENG 4[...]

ENG CHAPTER 4 OVERHAULING THE ENGINE REMOVING THE ENGINE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET AND EXHAUST PIPE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LEADS AND HOSES 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

ENG AC MAGNETO AND ST ARTER CLUTCH 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST A TOR COIL 4-41 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ST ARTER CLUTCH 4-42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

4-1 70 Nm (7.0 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 25 Nm (2.5 m  kg) 17 Nm (1.7 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 Removing the drive sprocket and exhaust pipe Drain the coolant Drain the engine oil Front cowling Fuel tank Battery negative terminal Radiator Carburetor Starter motor Exha[...]

4-2 25 Nm (2.5 m  kg) 70 Nm (7.0 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) 17 Nm (1.7 m  kg) Order Job name / Part name Q’ty Remarks 4 5 6 7 8 9 Shift arm Drive sprocket cover Drive chain sprocket gasket Dowel pin Lock washer Drive sprocket / Drive chain 1 1 1 2 1 1/1 Refer to “INST ALLING THE ENGINE” sect[...]

4-3 12 Nm (1.2 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Disconnecting the leads and hoses Magneto / sidestand / neutral / engine oil level switch lead Ground lead Plug cap Crankcase breather hose Cover W ater pump outlet hose Radiator outlet hose Engine outlet hose Engine outlet hose 1/1/1/1 1 4 1 1 1 1 1 1 Disconnect t[...]

4-4 33 Nm (3.3 m  kg) 55 Nm (5.5 m  kg) 33 Nm (3.3 m  kg) 55 Nm (5.5 m  kg) 33 Nm (3.3 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Removing the engine bracket and engine Engine mounting bolt (front left) Engine mounting bolt (front right) Engine bracket (front) Engine mounting bolt (rear upper) Engine bracket (rear[...]

4-5 REMOVING THE ENGINE ENG NOTE: NOTE: EB400700 INST ALLING THE ENGINE 1. Install:  bolt 1  bolt 2  bolt 3  bolt 4  engine bracket 5  engine bracket 6 Do not fully tighten the bolts. 2. T ighten the bolts in the following order . Bolt 1 55 Nm (5.5 m  kg) Bolt 2 55 Nm (5.5 m  kg) Bolt 3 55 Nm (5.5 m  kg) Bolt 4 55 Nm (5.5[...]

4-6 10 Nm (1.0 m  kg) 9 Nm (0.9 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 Removing the cylinder head cover Front cowling Seat and fuel tank Drain the coolant Radiator Carburetor Exhaust pipe Plug cap Cylinder head side cover Cylinder head cover Cylinder head cover gasket 4 1 1 Remove the parts in the order listed. Refer to “FRO[...]

4-7 10 Nm (1.0 m  kg) 20 Nm (2.0 m  kg) 13 Nm (1.3 m  kg) 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the camshafts Spark plug Magneto cover T iming chain guide (upper) T iming chain tensioner assembly T iming chain guide (exhaust side) Camshaft cap Dowel pin Camshaft (i[...]

4-8 CAMSHAFT ENG 2 NOTE: NOTE: EB401 102 REMOVING THE CAMSHAFTS 1. Remove:  magneto cover 2. Align:  “T” mark on the magneto rotor (with the stationary pointer on the crank- case) a. T urn the crankshaft counterclockwise. b. When piston #1 is at TDC on the com- pression stroke, align the “T” mark a with the stationary pointer b . TDC [...]

4-9 1 3 2 CAMSHAFT ENG CAUTION: NOTE: T o prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the out- side in. 8. Remove:  intake camshaft 1  exhaust camshaft 2 T o prevent the timing chain from falling into the crankcase, fasten it with a wire 3 .[...]

4-10 CAMSHAFT ENG 1 NOTE: 4. Measure:  camshaft-journal-to-camshaft-cap clear- ance Out of specification  Measure the cam- shaft journal diameter . Camshaft-journal-to- camshaft-cap clearance 0.08 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of Plastigauge  1 onto the cam[...]

4-1 1 2 1 3 2 2 3 4 4 CAMSHAFT ENG NOTE: NOTE: NOTE: EB401430 CHECKING THE TIMING CHAIN TENSIONER 1. Check:  timing chain tensioner Cracks / damage  Replace. 2. Check:  one-way cam operation Rough movement  Replace the timing chain tensioner housing. 3. Check:  cap bolt 1  copper washer 2  ball 3  spring 4  ball 5  one[...]

4-12 4 6 5 3 2 1 “E” “I” C C CAMSHAFT ENG CAUTION: NOTE: CAUTION: The camshaft cap bolts must be tight- ened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Camshaft cap bolt 10 Nm (1.0 m  kg) 4. Install:  intake camshaft sprocket  exhaust camshaft sprocket a. T urn the crankshaft counterclockwise. [...]

4-13 CAMSHAFT ENG c c d d CAUTION: Always use a new gasket. Timing chain tensioner bolt 10 Nm (1.0 m  kg) d. Install the springs 3 , washer 2 , and cap bolt 1 . Cap bolt 20 Nm (2.0 m  kg) 7. T urn:  crankshaft (several full turns counterclockwise) 8. Check:  “T” mark a Make sure that the “T” mark on the magne- to rotor is aligne[...]

4-14 35 Nm (3.5 m  kg) 20 Nm (2.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Removing the cylinder head Camshaft Union bolt Copper washer Oil delivery pipe Cylinder head Cylinder head gasket Dowel pin 2 4 1 1 1 2 Remove the parts in the order listed. Refer to “CAMSHAFT”section. Refer to “REMOVING / INST ALLING THE CYLI[...]

4-15 CYLINDER HEAD ENG NOTE: NOTE: NOTE: EB402101 REMOVING THE CYLINDER HEADS 1. Remove:  cylinder head nuts  Loosen the nuts in the proper sequence as shown.  Loosen each nut 1 / 2 of a turn at a time. After all of the nuts are fully loosened, re- move them. EB402403 CHECKING THE CYLINDER HEADS The following procedure applies to all of th[...]

4-16 CYLINDER HEAD ENG NOTE: NOTE: EB402702 INST ALLING THE CYLINDER HEAD 1. Install:  gasket (New) 1  dowel pins 2 The “UP” mark a on the gasket must face up. 2. Install:  cylinder head  Apply engine oil onto the threads of the cyl- inder head nuts.  T ighten the cylinder head nuts in the prop- er tightening sequence as shown an[...]

4-17 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the valves and valve springs Camshaft Cylinder head V alve lifter Adjusting pad V alve cotters Upper spring seat V alve spring V alve (intake) V alve (exhaust) Oil seal Lower spring seat 4 4 8 4 4 2 2 4 4 Remove the parts in the order listed. Refer to “CAMSHAFT” section. [...]

4-18 V AL VES AND V AL VE SPRINGS ENG 1 a NOTE: NOTE: NOTE: NOTE: EB403100 REMOVING THE V AL VES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove:  valve lifter 1  v[...]

4-19 a b V AL VES AND V AL VE SPRINGS ENG a b NOTE: NOTE: EB403400 CHECKING THE V AL VES AND V AL VE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: S valve-stem-to-valve-guide clearance V alve-stem-to-valve-guide clearance = V alve guide inside diameter – V alve stem diameter Out of specification  Rep[...]

4-20 V AL VES AND V AL VE SPRINGS ENG a 4. Check:  valve face Pitting / wear  Grind the valve face.  valve stem end Mushroom shape of diameter larger than the body of the valve stem  Replace the valve. 5. Measure:  valve margin thickness a Out of specification  Replace the valve. V alve margin thickness 0.5 mm 6. Measure:  valv[...]

4-21 V AL VES AND V AL VE SPRINGS ENG NOTE: CAUTION: NOTE: a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d. Measure the valve seat width. Where the valve seat and valve face contacted one anothe[...]

4-22 V AL VES AND V AL VE SPRINGS ENG a a EB403420 CHECKING THE V AL VE SPRINGS The following procedure applies to all of the valve springs. 1. Measure:  valve spring free length a Out of specification  Replace the valve spring. V alve spring free length (intake and exhaust) Spring 40.09 mm (Limit 37.5 mm) 2. Measure:  compressed spring fo[...]

4-23 V AL VES AND V AL VE SPRINGS ENG 2 1 2 2 1 5 4 3 2 a b Large Small NOTE: NOTE: EB403440 CHECKING THE CAMSHAFT CAP 1. Check:  camshaft case  camshaft caps 1 Cracks / damage  Replace th camshaft case and camshaft caps as a set, and check the camshafts (Refer to “CHECK- ING THE CAMSHAFTS”.).  camshaft bearing surfaces 2 Damage / p[...]

4-24 V AL VES AND V AL VE SPRINGS ENG CAUTION: NOTE: V alve spring compressor 90890-04019 Attachment 90890-041 14 5. T o secure the valve cotters 1 onto the a valve stem, lightly tap the valve tip with a soft-face hammer . Hitting the valve tip with excessive force could damage the valve. 6. Install:  valve pad 1  valve lifter 2  Apply mol[...]

4-25 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 Removing the cylinder and pistons Cylinder head W ater jacket joint O-ring Cylinder Cylinder gasket Dowel pin O-ring Piston pin circlip Piston pin Piston Piston ring set 1 2 1 1 2 4 8 4 4 4 Remove the parts in the order listed. Refer to “CYLINDER HEAD” sect[...]

4-26 1 2 4 CYLINDER AND PISTON ENG CAUTION: NOTE: NOTE: NOTE: EB404101 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Remove:  piston pin clip 1  piston pin 2  piston 3 Do not use a hammer to drive the piston pin out.  Before removing the piston pin clip, cover the crankcase [...]

4-27 CYLINDER AND PISTON ENG P a “C” = X + Y 2 NOTE: Standard Wear limit Cylinder bore “C” 62.00  62.01 62.1 mm b. If out of specification, replace the cylin- der , piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer . a 5 mm from the bottom edge of the piston. Piston size P Standard 61.960  [...]

4-28 CYLINDER AND PISTON ENG a a NOTE: NOTE: 2. Install:  piston ring 1 (into the cylinder) Level the piston ring in the cylinder with the piston crown as shown. a 20 mm 3. Measure:  piston ring end gap Out of specification  Replace the piston ring. The oil ring expander spacer ’s end gap can- not be measured. If the oil ring rail’s ga[...]

4-29 CYLINDER AND PISTON ENG b 1 2 4 5 3 a NOTE: NOTE: 3. Calculate:  piston-pin-to-piston clearance Out of specification  Replace the piston pin. Piston-pin-to-piston clearance = Piston pin bore size b – Piston pin outside diameter a Piston-pin-to-piston clearance 0.01 1  0.013 mm <Limit>: 0.023 mm EB404701 INST ALLING THE PISTON [...]

4-30 1 2 2 d c e a b CYLINDER AND PISTON ENG NOTE: 5. Offset:  piston ring end gaps a T op ring b Lower oil ring rail c Upper oil ring rail d 2nd ringe e Oil ring expander 6. Install:  cylinder 1  O-ring 2  First, install pistons #2 and #3.  Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity .[...]

4-31 12 Nm (1.2 m  kg) 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the clutch cover Drain the engine oil Clutch cover Clutch cover gasket Dowel pin Drive sprocket cover Clutch cable 1 1 2 1 1 Remove the parts in the order listed. Refer to “CHANGING THE ENGINE OIL” section in chapter 3. For installation, [...]

4-32 8 Nm (0.8 m  kg) 70 Nm (7.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Removing the clutch Compression spring Pressure plate Short clutch push rod O-ring Ball Long clutch push rod Friction plate Clutch plate Fricition plate (large) Clutch spring plate Nut 6 1 1 1 1 1 8 8 1 1 1 Remove the parts in the order l[...]

4-33 8 Nm (0.8 m  kg) 70 Nm (7.0 m  kg) Order Job name / Part name Q’ty Remarks 12 13 14 15 16 17 18 19 Lock washer Clutch boss Thrust washer Spacer Bearing Clutch housing Thrust washer Spacer 1 1 1 1 1 1 1 1 Refer to “REMOVING / INST ALLING THE CLUTCH” section. Refer to “INST ALLING THE CLUTCH” section. Refer to “REMOVING / INST [...]

4-34 CLUTCH ENG 3 2 1 NOTE: NOTE: NOTE: EB405100 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen:  clutch boss nut 1 While holding the clutch boss 2 with the uni- versal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder 3 90890-04086 3. Remove:  spacer 1  bearing 2 Insert two M6-mm bolts 3 into the spac[...]

4-35 CLUTCH ENG 2 a NOTE: EB405420 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check:  clutch spring Damage  Replace the clutch springs as a set. 2. Measure:  clutch spring free length a Out of specification  Replace the clutch springs as a set. Clutch spring free length 34.9 mm <Limit[...]

4-36 CLUTCH ENG 1 1 2 NOTE: NOTE: EB405450 CHECKING THE CLUTCH BOSS 1. Check:  clutch boss splines 1 Damage / pitting / wear  Replace the clutch boss. Pitting on the clutch boss splines will cause erratic clutch operation. EB405450 CHECKING THE PRESSURE PLA TE 1. Check:  pressure plate 1 Cracks / damage  Replace.  bearing 2 Damage / [...]

4-37 CLUTCH ENG 1 2 2 1 3 70 Nm (7.0 m  kg) NOTE: 8.0 Nm (0.8 m  kg) NOTE: 2. T ighten:  clutch boss nut 1 While holding the clutch boss with the uni- versal clutch holder 2 , tighten the clutch boss nut. Universal clutch holder 90890-04086 3. Bend the lock washer 3 tab along a flat side of the nut. 4. Lubricate:  long clutch push rod 1[...]

4-38 CLUTCH ENG 12 Nm (1.2 m  kg) NOTE: 9. Install:  clutch cover 1 T ighten the clutch cover bolts in stages and in a crisscross pattern.[...]

4-39 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the shift shaft Oil pump Drive sprocket cover Collar Shift shaft Shift lever spring Stopper lever SHift lever spring 1 1 1 1 1 Remove the parts in the order listed. Refer to “OIL PUMP” section. Refer to “REMOVING THE ENGINE” section. Refer to “INST ALLING THE SHIFT SHAFT”[...]

4-40 1 2 4 2 1 2 3 SHIFT SHAFT ENG NOTE: NOTE: EB408400 CHECKING THE SHIFT SHAFT 1. Check:  shift shaft 1  shift lever 2 Bends / damage / wear  Replace.  shift lever spring 3  stopper lever spring 4 Damage / wear  Replace. EB408700 INST ALLING THE SHIFT SHAFT 1. Install:  stopper lever 1  stopper lever spring 2  shift sha[...]

4-41 5 Nm (0.5 m  kg) 10 Nm (1.0 m  kg) 12 Nm (1.2 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the stator coil Seat Fuel tank Stator / pickup coil lead Cover Generator cover Dowel pin Stator coil 1/1 1 1 2 1 Remove the parts in the order listed. Refer to “FRONT COWLING / SEA T / SIDE COVER / FUEL T ANK” section [...]

4-42 12 Nm (1.2 m  kg) 80 Nm (8.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Removing the starter clutch Generator cover Starter clutch cover Dowel pin Gasket Starter clutch assembly Wood ruf f key Starter wheel gear Shaft (Primary) Starter idle gear (primary) Shaft (Secondary) Starter idle gear (secondary) Shaft[...]

4-43 130 Nm (13.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 Removing the generator roter Bolt / washer Rotor Woodruf f key 1/1 1 1 Remove the parts in the order listed. Refer to “REMOVING / INST ALLING THE AC MAGNETO” section. For installation, reverse the removal procedure. AC MAGNETO AND ST ARTER CLUTCH ENG AC MAGNETO ROT OR[...]

4-44 AC MAGNETO AND ST ARTER CLUTCH ENG NOTE: NOTE: NOTE: EB410100 REMOVING THE ST ARTER CLUTCH 1. Remove:  starter clutch cover 1 Loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove:  starter clutch bolt 1  While holding the magneto rotor 2 wi[...]

4-45 2 1 3 AC MAGNETO AND ST ARTER CLUTCH ENG NOTE: 2. Remove:  AC magneto rotor 1  Woodruf f key Use a flywheel puller 2 to remove the AC magneto rotor 1 . Flywheel puller: 90890-01362 EB410401 CHECKING THE ST ARTER CLUTCH 1. Check:  starter clutch idle gear 1  starter clutch drive gear 2  starter clutch gear 3 Burrs / chips / rough[...]

4-46 AC MAGNETO AND ST ARTER CLUTCH ENG NOTE: NOTE: NOTE: INST ALLING THE AC MAGNETO 1. Install:  Woodruf f key 1  AC magneto rotor 2  Bolt (AC magneto rotor)  Clean the tapered portion of the crankshaft and the AC magneto rotor .  When installing the AC magneto rotor , make sure that the woodruff key is properly seated in the key wa[...]

4-47 63 Nm (6.3 m  kg) 10 Nm (1.0 m  kg) 12 Nm (1.2 m  kg) 43 Nm (4.3 m  kg) 7 Nm (0.7 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the oil strainer Engine Oil level warning switch / O-ring Oil pan Dowel pin Oil pan gasket Relief valve / O-ring Oil strainer Oil strainer housing Oil bypass valve Oil cool[...]

4-48 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 Removing the oil pump Clutch Oil pump assembly Oil pump gasket Dowel pin 1 1 1 Remove the parts in the order listed. Refer to “CLUTCH” section. Refer to “INST ALLING THE OIL PUMP” section. For installation, reverse the removal procedure. OIL P AN AND OIL STRAINER ENG [...]

4-49 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Disassembling the oil pump Oil pump rotor housing Dowel pin Inner rotor / outer rotor Dowel pin Oil pump shaft assembly Oil pump cover W asher 1 2 1/1 1 1 1 1 Disassembly the parts in the order listed. Refer to “ASSEMBLING THE OIL PUMP” section. For assembly , reverse the disassembly [...]

4-50 OIL P AN AND OIL STRAINER ENG NOTE: EB41 1 100 REMOVING THE OIL P AN 1. Remove:  oil level switch 1  oil pan 2  gasket  dowel pins Loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EB41 1401 CHECKING THE OIL PUMP 1. Check:  oil pump drive ge[...]

4-51 OIL P AN AND OIL STRAINER ENG b a 4 6 5 7 6 7.0 Nm (0.7 m  kg) NOTE: EB41 1430 CHECKING THE OIL STRAINER 1. Check:  oil strainer 1 Damage  Replace. Contaminants  Clean with engine oil. EB41 1470 CHECKING THE OIL NOZZLE 1. Check:  oil nozzle 1  check ball 2 Damage / wear  Replace the oil nozzle.  O-ring 3 Damage / wear ?[...]

4-52 OIL P AN AND OIL STRAINER ENG d c b 10 Nm (1.0 m  kg) CAUTION: NOTE: NOTE: 10 Nm (10 m  kg) NOTE: NOTE: EB41 1710 INST ALLING THE OIL PUMP Install:  oil pump 1 After tightening the bolts, make sure that the oil pump turns smoothly . Align the projection a on the oil pump shaft with the slot b on the water pump shaft. Align the arrow c[...]

4-53 OIL P AN AND OIL STRAINER ENG NOTE:  T ighten the oil pan bolts in stages and in a crisscross pattern.  Lubricate the oil level switch’s O-ring with engine oil. Oil pan bolt 12 Nm (1.2 m  kg) Oil level switch bolt 7 Nm (0.7 m  kg)[...]

4-54 10 Nm (1.0 m  kg) 24 Nm (2.4 m  kg) 24 Nm (2.4 m  kg) 12 Nm (1.2 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 Disassembling the crankcase Engine Camshaft Cylinder head Cylinder , piston Clutch Oil pump Shift shaft Magneto rotor Starter clutch Oil strainer W ater pump Oil seal stopper plate Neutral switch lead Neutral swit[...]

4-55 10 Nm (1.0 m  kg) 24 Nm (2.4 m  kg) 24 Nm (2.4 m  kg) 12 Nm (1.2 m  kg) Order Job name / Part name Q’ty Remarks 4 5 6 7 8 9 O-ring Upper crankcase Dowel pin Oil seal Oil jet O-ring 1 1 1 1 1 1 Refer to “DISASSEMBLING / ASSEMBLING THE CRANKCASE” section. For assembly , reverse the disassembly procedure. CRANKCASE ENG[...]

4-56 A B CRANKCASE ENG NOTE: CAUTION: NOTE: EB412100 DISASSEMBLING THE CRANKCASE 1. Remove:  crankcase bolts 1  15 A Upper crankcase  Loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.  Loosen the bolts in decreasing numerical order (refer to the num[...]

4-57 CRANKCASE ENG 2 b a NOTE: NOTE: CAUTION: EB412742 ASSEMBLING THE CRANKCASE 1. Lubricate:  crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply:  sealant (onto the crankcase mating surfaces) Y amaha bond No. 1215 90890-85505 Do not allow any sealant to come into con- tact with the oil gall[...]

4-58 CRANKCASE ENG A B NOTE: 7. Install:  upper crankcase bolts  lower crankcase bolts  Lubricate the bolt threads with engine oil.  T ighten the bolts in increasing numerical order .  Install washers on bolts 1  12 .  Install the cable holder on bolt #35. A Upper crankcase B Lower crankcase M8 bolt 24 Nm (2.4 m  kg) M6 bolt[...]

4-59 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the crankshaft Disassembly the crankcase T iming chain guide (intake side) Crankshaft assembly Oil seal T iming chain Crankshaft journal bearing 1 1 1 1 12 Remove the parts in the order listed. Refer to “CRANKCASE” section. Refer to “REMOVING / INST ALLING [...]

4-60 15 Nm (1.5 m S kg) + 90 _ Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the connecting rod Nut Connecting rod bolt Connecting rod Connecting rod cap Connecting rod big end bearing 8 8 4 4 8 Remove the parts in the order listed. Refer to “INST ALLING THE CONNECTING RODS” section. Refer to “REMOVING / INST ALLING THE CONNECT[...]

4-61 1 2 1 2 CRANKSHAFT ENG NOTE: NOTE: EB4121 10 REMOVING THE CRANKSHAFT ASSEMBL Y 1. Remove:  crankshaft assembly 1  crankshaft journal upper bearing 2 (from the upper crankcase)  timing chain guide (intake side) Identify the position of each crankshaft jour- nal upper bearing so that it can be reinstalled in its original place. EB412121[...]

4-62 CRANKSHAFT ENG 2 b a b a CAUTION: NOTE: NOTE: NOTE: Crankshaft-journal-to-crank - shaft-journal-bearing clearance 0.025  0.043 mm Limit 0.08 mm Do not interchange the crankshaft jour- nal bearings. T o obtain the correct crank- shaft journal-to-crankshaft-journal-bear- ing clearance and prevent engine damage, the crankshaft journal bearings[...]

4-63 CRANKSHAFT ENG A B C NOTE: NOTE: f. T ighten the bolts to specification in the tightening sequence cast on the crank- case. Crankcase bolt M8: 24 Nm (2.4 m  kg) M6: 12 Nm (1.2 m  kg) A Upper crankcase B Lower crankcase Lubricate the crankcase bolt threads (M8) and (M6) with engine oil. g. Remove the lower crankcase and the crankshaft jou[...]

4-64 CRANKSHAFT ENG A 1 1 b a 1 1 CAUTION: NOTE: For example, if the crankcase “J 1 ” and crankshaft web “J1” numbers are “6” and “2” respectively , then the bearing size for “J1” is: Bearing size for J1: J 1 (crankcase) – J1 (crankshaft web) + 1 = 6 – 2 + 1 = 5 (yellow) CRANKSHAFT JOURNAL BEARING COLOR CODE 1 1 2 3 4 5 6 bl[...]

4-65 c e A CRANKSHAFT ENG NOTE: NOTE: S Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. S Apply molybdenum disulfide grease onto the bolts, threads, and nut seats. S Make sure that the “Y” mark c on the con- necting rod faces towards the left side of the crankshaft. S Make sure that the charact[...]

4-66 CRANKSHAFT ENG 2 2 3 2 2 NOTE: For example, if the connecting rod “P 1 ” and the crankshaft web “P1” numbers are “4” and “1” respectively , then the bearing size for “P 1 ” is: Bearing size for P 1 : P 1 (connecting rod) – P1 (crankshaft- web) = 4 – 1 = 3 (brown) BIG END BEARING COLOR CODE 1 2 3 4 blue black brown green[...]

4-67 CRANKSHAFT ENG CAUTION: CAUTION: NOTE: 4. Align: S bolt heads 1 (with the connecting rod caps) 5. T ighten: S Nuts (connecting rod) Nut (connecting rod): 15 Nm (1.5 m S kg) + (turn the nut another 90 _ ) a. Replace the connecting rod bolts and nuts with new ones. Tighten the connecting rod bolts using the plastic-region tightening angle meth- [...]

4-68 CRANKSHAFT ENG b a NOTE: NOTE: 10 Nm (1.0 m  kg) EB412720 INST ALLING THE CRANKSHAFT 1. Install:  crankshaft journal upper bearings 1 (into the upper crankcase)  Align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase.  Be sure to install each crankshaft journal upper bearing in its orig[...]

4-69 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 Removing the transmission Disassembly the crankcase Main axle assembly Circlip Bearing Bearing Drive axle assembly Circlip Nozzle Bearing Plate washer Oil seal / collar Bearing 1 1 1 1 1 1 1 1 1 1/1 1 Remove the parts in the order listed. Refer to “CRANKCASE” section. Refer [...]

4-70 Order Job name / Part name Q’ty Remarks Disassembling the transmission 1st wheel gear 5th wheel gear Circlip W asher 4th wheel gear 3rd wheel gear 6th wheel gear 2nd wheel gear W asher Circlip Drive axle 2nd pinion gear 6th pinion gear 1 1 1 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed. 10 1 2 3 4 5 6 7 8 9 11 12 13 TRANSMIS[...]

4-71 Order Job name / Part name Q’ty Remarks 3rd / 4th pinion gear Circlip W asher 5th Main axle 1 1 1 1 1 For assembly , reverse the disassembly procedure. 14 15 16 17 18 TRANSMISSION ENG[...]

4-72 TRANSMISSION ENG EB413422 CHECKING THE TRANSMISSION 1. Measure:  main axle runout (with a centering device and dial gauge 1 ) Out of specification  Replace the main axle. Main axle runout limit 0.02 mm 2. Measure:  drive axle runout (with a centering device and dial gauge 1 ) Out of specification  Replace the drive axle. Drive axle[...]

4-73 TRANSMISSION ENG NOTE: NOTE: NOTE: EB413710 INST ALLING THE TRANSMISSION 1. Install:  oil baffle plate 1  crankcase breather hose 2 Insert the metal clamp 3 on the crankcase breather hose into the slots 4 in the crank- case. 2. Install:  main axle assembly 1  drive axle assembly 2  oil seals  circlips  lock washer  Make[...]

4-74 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) Remove the parts in the order listed. Refer to “CRANKCASE” section. Refer to “TRANSMISSION” section. Refer to “INST ALLING THE SHIFT FORKS AND SHIFT DRUM” section. For installation, reverse the removal procedure. Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the shift d[...]

4-75 SHIFT DRUM AND SHIFT FORKS ENG 1 2 1 2 EB413400 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check:  shift fork cam follower 1  shift fork pawl 2 Bends / damage / scoring / wear  Replace the shift fork. 2. Check:  shift fork guide bar Roll the shift fork guide bar on [...]

4-76 SHIFT DRUM AND SHIFT FORKS ENG 1 1 2 3 NOTE: 10 Nm (1.0 m S kg) 10 Nm (1.0 m S kg)r 2. Install: S shift fork guide bars 1 S shift fork “L” 2 S shift fork “C” 3 S shift fork “R” 4 S The embossed marks on the shift forks should face towards the left side of the en- gine and be in the following sequence: “L”, “C”, “R”. S T[...]

COOL 5[...]

COOL CHAPTER 5 COOLING SYSTEM RADIA TOR 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE RADIA TOR 5-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INST ALLING THE RADIA TOR 5-3 . . . . . . . . . . . . . . . . . .[...]

COOL[...]

5-1 7 Nm (0.7 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the radiator Seat Fuel tank Drain the coolant Fan motor leads Radiator outlet hose Radiator inlet hose Radiator Fan 1 1 1 1 1 Remove the parts in the order listed. Refer to “FRONT COWLING / SEA T / SIDE COVER / FUEL T ANK” section in chapter 3. Refer to “CHAN[...]

5-2 RADIA TOR COOL NOTE: EB500010 CHECKING THE RADIA TOR 1. Check:  radiator fins Obstruction  Clean. Apply compressed air to the rear of the ra- diator . Damage  Repair or replace. Straighten any flattened fins with a thin, flat- head screwdriver . 2. Check:  radiator hoses  radiator pipes Cracks / damage  Replace. 3. Measure: ?[...]

5-3 RADIA TOR COOL EB500020 INST ALLING THE RADIA TOR 1. Fill:  cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check:  cooling system Leaks  Repair or replace any faulty part. a. Attach the radiator cap tester 1 to the radiator . Radiator cap tester: 90890-01325 [...]

5-4 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the thermostat Seat Fuel tank Drain the coolant Thermo switch lead (engine temperature) Thermo switch lead (fan motor) Reservoir tank hose Carburetor inlet hose Engine outlet hose Engine outlet hose Radiator inlet hose Thermostat housing Ground read 1 1 1 [...]

5-5 23 Nm (2.3 m  kg) 8 Nm (0.8 m  kg) 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks Disassembling the thermostat Thermo switch (fan motor) Thermo switch (engine temperature) Thermostat housing cover O-ring Thermostat Thermostat housing 1 1 1 1 1 1 Disassembly the parts in the order listed. Refer to “ASSEMBLING THE THERMOST[...]

5-6 THERMOST A T COOL 1 1 3 4 2 80.5 _  83.5 _ 95 _ C 8 mm NOTE: EB502021 CHECKING THE THERMOST A T 1. Check: S thermostat 1 Does not open at 80.5  83.5 _ C  Replace. a. Suspend the thermostat in a container filled with water . b. Slowly heat the water . c. Place a thermometer in the water . d. While stirring the water , observe the ther- [...]

5-7 THERMOST A T COOL NOTE: 23 Nm (2.3 m  kg) 8 Nm (0.8 m  kg) CAUTION: EB502030 ASSEMBLING THE THERMOST A T 1. Install:  thermostat housing 1  thermostat 2  O-ring (New) 3  thermostat housing cover 4 Install the thermostat with its breather hole a facing up. 2. Install:  thermo switch (fan motor) 1  thermo switch (engine te[...]

5-8 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Removing the water pump Drain the coolant Shift arm, drive chain cover Radiator outlet hose W ater pump outlet hose W ater pump outlet pipe W ater pump housing cover O-ring W ater pump assembly O-ring 1 1 1 1 1 1 1 Remove the parts in the order lis[...]

5-9 W A TER PUMP COOL 1 2 NOTE: EB503020 REMOVING THE W A TER PUMP 1. Remove:  water pump housing 1 T ap out the water pump seal from the inside of the water pump housing. EB503032 CHECKING THE W A TER PUMP 1. Check:  water pump housing cover  water pump housing 1  impeller 2 2. Check:  water pump seal 1  oil seal 2 Cracks / damag[...]

5-10 W A TER PUMP COOL a b NOTE: NOTE: 10 Nm (1.0 m  kg) 10 Nm (1.0 m  kg) NOTE:  Align the slot a on the impeller shaft with the projection b on the oil pump shaft.  Before installing the water pump housing, apply a thin coat of lithium soap base grease onto the O-ring. 2. Install:  water pump housing cover 1  water pump outlet p[...]

CARB 6[...]

CARB CHAPTER 6 CARBURET ORS CARBURETORS 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR FIL TER CASE 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETORS 6-2 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

CARB[...]

6-1 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the air filter case Seat, fueltank and sidecovers Drain the coolant Air filter case (left / right) Battery negative lead Battery positive lead Battery Stay 1/1 1 1 1 1 Remove the parts in the order listed. Refer to “FRONT COWLING / SEA T / SIDE COVER / FUEL T ANK” section in chapt[...]

6-2 CARBURET ORS CARB Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 Removing the carburetors Throttle position sensor lead Air filter joint screw Carburetors joint screw Carburetor inlet / outlet hose Carburetors assembly Starter cable Throttle cable 4 4 1/1 1 1 2 Remove the parts in the order listed. Disconnect the coupler . For installati[...]

6-3 CARBURET ORS CARB Order Job name / Part name Q’ty Remarks Disassembling the carburetors Starter plunger link Carburetors assembly V acuum chamber cover Piston valve spring Piston valve Needle kit Float chamber Float chamber gasket Float pin Float Needle valve assembly Main jet 1 4 1 1 1 1 1 1 1 1 1 1 Disassembly the parts in the order listed.[...]

6-4 CARBURET ORS CARB Order Job name / Part name Q’ty Remarks Main jet holder Needle jet Pilot jet Pilot screw set Starter plunger kit 1 1 1 1 1 Refer to “ASSEMBLING THE CARBURETORS” section. For assembly , reverse the disassembly procedure. 13 14 15 16 17[...]

6-5 CARBURET ORS CARB EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check:  carburetor body  float chamber  main jet holder Cracks / damage  Replace. 2. Check:  fuel passages Obstruction  Clean. a. W ash the carburetor in a petroleumbased solvent. Do not use any caustic-carbure- [...]

6-6 CARBURET ORS CARB 8. Check:  piston valve 1 Damage / scratches / wear  Replace.  rubber diaphragm 2 Cracks / tears  Replace. 9. Check:  vacuum chamber cover 1  piston valve spring 2  jet needle holder 3 Cracks / damage  Replace. 10. Check:  jet needle kit 1  needle jet 2  main jet 3  pilot jet 4  pilot scr[...]

6-7 CARBURET ORS CARB CAUTION: NOTE: EB600041 ASSEMBLING THE CARBURETORS The following procedure applies to all of the car- buretors.  Before assembling the carburetors, wash all of the parts in a petroleum- based solvent.  Always use a new gasket. 1. Install:  O-ring (New)  washer  pilot screw spring  pilot screw 1 Pilot screw 2 [...]

6-8 CARBURET ORS CARB NOTE: 4. Install:  fuel feed joints 1  hose joints 2  spacer 3  connecting bolt 4  starter plunger link 5  throttle cable holder 6  spacer 7  connecting bolt 8  Do not tighten the connecting bolts yet.  Install the throttle arm 9 onto carburetors #1, #2, and #4 between the spring 10 and synchroniz[...]

6-9 CARBURET ORS CARB 2 3 NOTE: EB600062 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure:  fuel level a Out of specification  Adjust Fuel level (above the float chamber mating surface) 4.5 mm a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Inst[...]

6-10 CARBURET ORS CARB NOTE: 1 2 3 2 EB600070 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR S Before adjusting the throttle position sen- sor , the engine idling speed should be properly adjusted. S When installing the throttle position sen- sor , adjust its angle according to the RPM which is displayed on the tachometer . Refer to the adjust[...]

6-1 1 CARBURET ORS CARB 2 3 NOTE: NOTE: 1 2 3 a b NOTE: b. Disconnect the throttle position sensor coupler . c. Reconnect the throttle position sensor coupler . After reconnecting the throttle position sen- sor coupler , the tachometer switches to the throttle position sensor adjustment mode. d. Loosen the throttle position sensor screws 1 . e. Adj[...]

6-12 CARB[...]

CHAS 7[...]

CHAS CHAPTER 7 CHASSIS FRONT WHEEL AND BRAKE DISCS 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FRONT WHEEL 7-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL 7-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

CHAS STEERING HEAD 7-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOWER BRACKET 7-53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE LOWER BRACKET 7-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

7-1 23 Nm(2.3 m  kg) 40 Nm(4.0 m  kg) 67 Nm (6.7 m  kg) 20 Nm (2.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the flont wheel and brake discs Wheel axle pinch bolt Brake hose horder (left / right) Brake caliper (left / right) Wheel axle Front wheel assembly Speed sensor unit Collar Brake disc (left / right[...]

7-2 Order Job name / Part name Q’ty Remarks Disassembling the front wheel Oil seal Bearing Spacer Bearing 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly prodedure. 1 2 3 4 FRONT WHEEL AND BRAKE DISC CHAS FRONT WHEEL[...]

7-3 FRONT WHEEL AND BRAKE DISC CHAS NOTE: NOTE: CAUTION: NOTE: EB700102 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove:  wheel axle pinch bolt  brake hose[...]

7-4 FRONT WHEEL AND BRAKE DISC CHAS 2 1 NOTE: CAUTION: NOTE: 3. Measure:  front wheel radial runout 1  front wheel lateral runout 2 Over the specified limits  Replace. Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 4. Check:  wheel bearings Front wheel turns roughly or is loose  Replace the wheel beari[...]

7-5 FRONT WHEEL AND BRAKE DISC CHAS NOTE: EB700414 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake disc Damage / galling  Replace. 2. Measure: S brake disc deflection a Out of specification  Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) [...]

7-6 FRONT WHEEL AND BRAKE DISC CHAS NOTE: NOTE: CAUTION: EB700722 INST ALLING THE FRONT WHEEL 1. Lubricate:  wheel axle  wheel bearings  oil seal lips Recommended lubricant Lithium soap base grease 2. Install:  Speed sensor unit Make sure that the speed sensor unit and the wheel hud are installed with the two pro- jections a meshed into[...]

7-7 FRONT WHEEL AND BRAKE DISC CHAS A B C D X 1 X NOTE: NOTE: NOTE: EB700901 ADJUSTING THE FRONT WHEEL ST A TIC BALANCE S After replacing the tire. wheel or both, the front wheel static balance should be ad- justed. S Adjust the front wheel static balance with the brake discs installed. 1. Remove: S balancing weight(-s) Place the front wheel on a s[...]

7-8 1 17 Nm (1 1.7 m  kg) 40 Nm (4.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the rear wheel Brake caliper Nut W asher Wheel axle W asher Drive chain puller (left) Drive chain puller (right) Rear wheel assembly 1 1 1 1 1 1 1 1 Remove the parts in the order listed. Refer to “REMOVING / INST ALLING THE REAR WH[...]

7-9 23 Nm (2.3 m  kg) 60 Nm (6.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the brake disk and rear wheel sprocket Collar (left / right) Brake disc Rear wheel sprocket Collar Drive hub damper Rear wheel drive hub Oil seal Bearing 1/1 1 1 1 6 1 1 1 Remove the parts in the order listed. For instalation, reverse th[...]

7-10 Order Job name / Part name Q’ty Remarks Disassembling the rear wheel Oil seal Bearing Collar Bearing 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. 1 2 3 4 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS DIASSEMBL Y THE REAR WHEEL[...]

7-1 1 1 1 2 3 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS NOTE: NOTE: NOTE: EB701 100 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. Remove:  brake caliper 1[...]

7-12 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS NOTE: 3. Measure:  rear wheel radial runout  rear wheel lateral runout Refer to “FRONT WHEEL AND BRAKE DISC”. EB701440 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check:  rear wheel sprocket More than 1 / 4 tooth a wear  Replace the rear wheel sprocket. Bent teeth  Re[...]

7-13 REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET CHAS NOTE: EB701900 ADJUSTING THE REAR WHEEL ST A TIC BALANCE  After replacing the tire, wheel or both, the rear wheel static balance should be ad- justed.  Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust:  rear wheel static balance R[...]

7-14 40 Nm (4.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the front brake pads Brake caliper Brake pads clip Brake pad pin Brake pad spring Brake pad 1 2 1 1 2 Remove the parts in the order listed. Refer to “REPLACING THE FRONT BRAKE P ADS” section. For installation, reverse the removal procedure. FRONT AND REAR BRA[...]

7-15 40 Nm (4.0 m  kg) 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 Removing the rear brake pads Caliper Brake pad pin Brake pad / shim Brake pad spring 1 2 2/2 1 Remove the parts in the order listed. Refer to “REPLACING THE REAR BRAKE P ADS” section. For instalation, reverse the removal procedure. FRONT AND REAR BR[...]

7-16 FRONT AND REAR BRAKES CHAS CAUTION: NOTE: EB702100 Disc brake componets rarely require dis- assembly . T ehrefore, always follow these preven- tive measures:  Never disassemble brake components unless absolutely necessary .  If any connection on the hydraulic brake system is disconnected, the en- tire brake system must be disas- sembled,[...]

7-17 FRONT AND REAR BRAKES CHAS NOTE: 6 Nm (0.6 m  kg) 40 Nm (4.0 m  kg) NOTE: 3. Remove:  brake pads 1 (along with the brake pad shims) 4. Measure:  brake pad wear limit a Out of specification  Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5. Install:  brake pad shims (onto the brake pads)  brake pads  brake [...]

7-18 FRONT AND REAR BRAKES CHAS NOTE: NOTE: 6 Nm (6 m  kg) EB7021 13 REPLACING THE REAR BRAKE P ADS When replacing the brake pads, it is not nec- essary to disconnect the brake hose or dis- assemble the brake caliper . 1. Remove:  brake caliper 1 2. Remove:  brake pad pins 1 3. Remove:  brake pads 2 (along with the brake pad shims)  [...]

7-19 FRONT AND REAR BRAKES CHAS 10 Nm (1.0 m  kg) 40 Nm (4.0 m  kg) 6. Install:  brake pad pins 1  brake caliper 7. Check:  brake fluid level Below the minimum level mark a  Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 8. Check:  brake lever operation Soft or s[...]

7-20 10 Nm(1.0 m  kg) 30 Nm(3.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Removing the front brake master cylinder Drain the brake fluid Brake lever Brake switch lead Brake switch Union bolt Copper washer / brake hose Master cylinder bracket Master cylinder 1 2 1 1 2/1 1 1 Remove the parts in the order listed. Refer to ?[...]

7-21 Order Job name / Part name Q’ty Remarks Disassembling the front brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. 1 2 3 4 FRONT AND REAR BRAKES CHAS[...]

7-22 30 Nm(3.0 m  kg) 4 Nm(0.4 m  kg) 23 Nm(2.3 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the rear brake master cylinder Side cover (right) Drain the brake fluid Master cylinder bolt Union bolt Copper washer / brake hose Clip / hose Cotter pin Pin W asher Master cylinder 2 1 2/1 2/1 1 1 1 1 Remove the parts [...]

7-23 Order Job name / Part name Q’ty Remarks 1 2 3 4 Disassembling the rear brake master cylinder Master cylinder boot Circlip Master cylinder kit Spring 1 1 1 1 Disassembly the parts in the order listed. For assembly , reverse the disassembly procedure. FRONT AND REAR BRAKES CHAS[...]

7-24 FRONT AND REAR BRAKES CHAS NOTE: NOTE: NOTE: EB702210 REMOVING THE FRONT BRAKE MASTER CYLINDER Befor disassembling the front brake master cylinder , drain the brake fluid from the entire brake system. 1. Disconnect:  brake switch coupler 1 (from the brake switch) 2. Remove:  union bolt 2  copper washers 3  brake hoses 4 T o collect[...]

7-25 FRONT AND REAR BRAKES CHAS D A B C EB702242 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check:  brake master cylinder Damage / scratches / wea  Replace.  brake fluid delivery passages (brake master cylinder body) Obstruction  Blow out with compress[...]

7-26 a FRONT AND REAR BRAKES CHAS 30 Nm (3.0 m  kg) CAUTION: NOTE: EB702270 ASSEMBLING AND INST ALLING THE FRONT BRAKE MASTER CYLINDER  Before installation, all internal brake components should be cleaned and lu- bricated with clean or new brake fluid.  Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Insta[...]

7-27 FRONT AND REAR BRAKES CHAS CAUTION: 30 Nm (3.0 m  kg) CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately . 3. Bleed:  brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check:  brake fluid level Below the minimum level mark a ?[...]

7-28 FRONT AND REAR BRAKES CHAS CAUTION:  Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.  Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake p[...]

7-29 30 Nm(3.0 m  kg) 40 Nm(4.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 Removing the front brake calipers Drain the brake fluid Union bolt Copper washer Brake hose Brake caliper assembly 1 2 1 1 Remove the parts in the order listed. Refer to “ASSEMBLING AND INST ALLING THE FRONT BRAKE CALIPERS” section. For installation, [...]

7-30 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Disassembling the front brake calipers Clip Pad pin Brake pad spring Brake pad Bleed screw kit Brake caliper piston Dust seal Piston seal 2 1 1 2 1 4 4 4 Disassembly the parts in the order listed. Refer to “REPLACING THE FRONT BRAKE P ADS” section. Refer to “DISASSEMBLING THE FRON[...]

7-31 Order Job name / Part name Q’ty Remarks 1 2 3 4 Removing the rear brake caliper Drain the brake fluid Union bolt Copper washer Brake hose Rear brake caliper 1 2 1 1 Remove the parts in the order listed. Refer to “ASSEMBLING AND INST ALLING THE REAR BRAKE CALIPER” section. For installation, revers the removal procedure. 30 Nm(3.0 m  kg[...]

7-32 10 Nm (1.0 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Disassembling the rear brake caliper Pad pin Pad spring Brake pad assembly / shim Bleed screw kit Brake caliper piston Dust seal Piston seal 2 1 2/2 2 2 2 2 Disassembly the parts in the order listed. Refer to “REPLACING THE REAR BRAKE P AD” section. Refer to “DI[...]

7-33 FRONT AND REAR BRAKES CHAS NOTE: NOTE: EB702317 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. Before disassembling either brake caliper , drain the brake fluid from the entire brake system. 1. Remove:  union bolt 1  copper washers 2  brake hose 3 Put the end of the brake hose int[...]

7-34 FRONT AND REAR BRAKES CHAS NOTE: NOTE: EB702322 DISASSEMBLING THE REAR BRAKE CALIPER Before disassembling the brake caliper , drain the brake fluid from the entire brake system. 1. Remove:  union bolt 1  copper washers 2  brake hose 3 Put the end of the brake hose into a contain- er and pump out the brake fluid carefully . 2. Remove: [...]

7-35 FRONT AND REAR BRAKES CHAS A B 30 Nm (30 m  kg) 1. Check:  brake caliper pistons 1 Rust / scratches / wear  Replace the brake caliper .  brake caliper cylinders 2 Scratches / wear  Replace the brake cali- per .  brake calipers 3 Cracks / damage  Replace.  brake fluid delivery passages (brake caliper body) Obstruction ?[...]

7-36 FRONT AND REAR BRAKES CHAS CAUTION: CAUTION: When installing the brake hose onto the brake caliper , make sure that the brake pipe a touches the projection a on the brake caliper . 2. Remove:  brake caliper 3. Install:  brake pads  brake spring  brake caliper pins  brake caliper clips  brake caliper  brake hose holder Refe[...]

7-37 1 3 2 FRONT AND REAR BRAKES CHAS 30 Nm (3.0 m  kg) CAUTION: 5. Bleed:  brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 6. Check:  brake fluid level Below the minimum level mark a  Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: [...]

7-38 FRONT AND REAR BRAKES CHAS CAUTION: 2. Remove:  brake caliper 3. Install:  brake pad spring  brake pads  brake pad pins  brake caliper  brake hose holder Refer to “REPLACING THE BRAKE P ADS”. Brake caliper pad pin 10 Nm (1.0 m  kg) Brake caliper bolt 40 Nm (4.0 m  kg) 4. Fill:  brake fluid reservoir (with the spe[...]

7-39 FRONT AND REAR BRAKES CHAS 6. Check:  brake fluid level Below the minimum level mark a  Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check:  brake pedal operation Soft or spongy feeling  Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” [...]

7-40 30 Nm (3.0 m  kg) 30 Nm (3.0 m  kg) 7 Nm (0.7 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 Removing the front fork Front wheel Front brake calipers Front fender Bolt (upper bracket) Cap bolt Bolt (lower bracket) Front fork assembly (left / right) 1 2 2 2 1/1 Remove the parts in the order listed. Refer to “FRONT WHEEL A[...]

7-41 10 23 Nm (2.3 m  kg) 30 Nm (3.0 m  kg) 6 7 9 8 11 14 13 12 15 Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Disassembling the front fork Cap bolt O-ring Spacer W asher Front fork spring Dust seal Oil seal clip Bolt Gasket Damper rod / rebound spring Inner tube / Inner tube bushing Oil seal W asher 1 1 1 1 1 1 1 [...]

7-42 10 23 Nm (2.3 m  kg) 30 Nm (3.0 m  kg) 7 9 8 11 14 13 12 15 Order Job name / Part name Q’ty Remarks 14 15 Outer tube bushing Oil flow stopper 1 1/1 Refer to “ASSEMBLING THE FRONT FORK LEGS” section. For assembly , reverse the disassembly procedure. 6 FRONT FORK CHAS[...]

7-43 FRONT FORK CHAS NOTE: CAUTION: NOTE: EB703100 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. L[...]

7-44 FRONT FORK CHAS CAUTION: CAUTION: 3. Remove:  inner tube a. Hold the front fork leg horizontally . b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully .  Excessive force will damage the oil seal and bushing. A damaged oil s[...]

7-45 FRONT FORK CHAS 1 NOTE: CAUTION: 30 Nm (3.0 m  kg) NOTE: 4. Check:  cap bolt O-ring Damage / wear  Replace. EB703700 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.  Make sure that the oil levels in both front fork legs are equal.  Uneven oil levels can result in poor handling and a[...]

7-46 FRONT FORK CHAS CAUTION: NOTE: NOTE: 4. Install:  outer tube bushing 1 (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 2 90890-01367 Adapter 3 90890-01381 5. Install:  washer  oil seal 1 (with the fork seal driver weight 2 and adapter 3 ) Fork seal driver weight 2 90890-01367 Adapter 3 90890-01381 Make sure[...]

7-47 FRONT FORK CHAS NOTE: NOTE: NOTE:  While filling the front fork leg, keep it up- right.  After filling, slowly pump the front fork leg up and down to distribute the fork oil. 9. Install:  spring 1  spring seat 2  spacer 3  cap bolt  Install the spring with the smaller pitch fac- ing up.  Before installing the cap bolt, [...]

7-48 7 Nm (0.7 m  kg) 10 Nm (1.0 m  kg) 23 Nm (2.3 m  kg) 7 Nm (0.7 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 10 11 12 13 Removing the handle bar Master cylinder bracket Master cylinder assembly Throttle cable housing cover Handle bar switch (right) Throttle cable housing Throttle cable Grip end Grip assembly Cl[...]

7-49 7 Nm (0.7 m  kg) 10 Nm (1.0 m  kg) 23 Nm (2.3 m  kg) 7 Nm (0.7 m  kg) Order Job name / Part name Q’ty Remarks 14 15 16 17 Grip (left) Clutch lever holder Upper handlebar holder Handle bar 1 1 2 1 Refer to “REMOVING THE HANDLEBAR” section. Refer to “INST ALLING THE HANDLEBAR” section. For installation, reverse the removal [...]

7-50 HANDLEBAR CHAS 1 1 NOTE: NOTE: EB704100 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . 2. Remove:  throttle cable housing 1  throttle grip 2 While removing the throttle cable housing, pull back the rubber cover 3 . 3. Remove:  left hand[...]

7-51 HANDLEBAR CHAS b 23 Nm (2.3 m  kg) CAUTION: NOTE: NOTE: NOTE: NOTE: EB704701 INST ALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . 2. Install:  handlebar 1  upper handlebar holders 2  First, tighten the bolts on the front side a of the h[...]

7-52 HANDLEBAR CHAS NOTE: NOTE: NOTE: 6. Install:  throttle grip 1  throttle cable housing 2  throttle cables 3 Apply a thin coat of lithium soap base grease onto the inside of the throttle grip and install it onto the handlebar .  Align the projection a on the throttle cable housing with the hole b in the handlebar . 7. Install:  ri[...]

7-53 1 10 Nm (1 1.0 m  kg) 52 Nm (5.2 m  kg) 1st 18 Nm (1.8 m  kg) 2nd Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 Removing the lower bracket Front cowling Fuel tank Front wheel Front fork Handle bar Main switch lead coupler Brake hose joint / cover Steering stem nut Upper bracket Lock washer Ring nut (upper) Rubber washer 1 [...]

7-54 1 10 Nm (1 1.0 m  kg) 52 Nm (5.2 m  kg) 1st 18 Nm (1.8 m  kg) 2nd Order Job name / Part name Q’ty Remarks 9 10 11 12 13 Lower bracket Ball race cover Ball bearing Rubber washer 1 Ball bearing 1 1 1 1 1 Refer to “INST ALLING THE STEERING HEAD” section. For installation, reverse the removal procedure. STEERING HEAD CHAS[...]

7-55 STEERING HEAD CHAS NOTE: EB705102 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over . 2. Remove:  upper ring nut  lower ring nut 1 Hold the lower ring nut with the exhaust and steering nut wrench 2 , then remove the up- per ring nut with th[...]

7-56 STEERING HEAD CHAS 4 3 2 1 CAUTION: NOTE: NOTE: NOTE: b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer . c. Install a new dust seal and new bearing races. If the bearing race is not installed proper- ly , the steering head pipe could be dam- aged.  Always replace the bearing balls and bear- ing races as a s[...]

7-57 40 Nm (4.0 m  kg) 48 Nm (4.8 m  kg) 40 Nm (4.0 m  kg) 48 Nm (4.8 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 Removing the rear shock absorber assembly and relay arm Side covers Rear wheel Self-locking nut / washer Bolt Self-locking nut / washer Bolt Self-locking nut / bolt Rear shock absorber assembly Self-lockin[...]

7-58 40 Nm (4.0 m  kg) 48 Nm (4.8 m  kg) 40 Nm (4.0 m  kg) 48 Nm (4.8 m  kg) Order Job name / Part name Q’ty Remarks 8 9 10 11 12 13 14 15 16 17 18 19 Bolt Relay arm Self-locking nut / washer Bolt Connecting plate Spacer Spacer Spacer Oil seal Bearing Bearing Bearing 1 1 1/1 1 2 1 2 1 2 2 1 1  = 80 mm  = 120 mm For installation,[...]

7-59 REAR SHOCK ABSORBER AND RELA Y ARM CHAS EB706101 HANDLING THE REAR SHOCK ABSORBER This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber , read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may re-[...]

7-60 REAR SHOCK ABSORBER AND RELA Y ARM CHAS NOTE: CAUTION: NOTE: NOTE: EB706204 REMOVING THE REAR SHOCK ABSORBER ASSEMBL Y 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. Disconnect:  batter[...]

7-61 REAR SHOCK ABSORBER AND RELA Y ARM CHAS NOTE: CAUTION: EB706401 CHECKING THE REAR SHOCK ABSORBER ASSEMBL Y 1. Check:  rear shock absorber rod Bends / damage  Replace the rear shock absorber assembly .  rear shock absorber oil leaks  Replace the rear shock absorb- er assembly .  spring Damage / wear  Replace the rear shock abs[...]

7-62 1 15 Nm (1 1.5 m  kg) 23 Nm (2.3 m  kg) 7 Nm (0.7 m  kg) Order Job name / Part name Q’ty Remarks 1 2 3 4 5 6 7 8 9 Removing the swingarm and drive chain Rear wheel Rear shock absorber assembly Relay arm Rear wheel sprocket Drive chain guard Brake hose holder Caliper bracket Compression bar Drive chain guide Pivot shaft Swingarm Driv[...]

7-63 1 15 Nm (1 1.5 m  kg) 23 Nm (2.3 m  kg) 7 Nm (0.7 m  kg) Order Job name / Part name Q’ty Remarks 10 11 12 Spacer Bearing W asher 1 2 2 For installation, reverse the removal procedure. SWINGARM AND DRIVE CHAIN CHAS[...]

7-64 A B SWINGARM AND DRIVE CHAIN CHAS NOTE: NOTE: NOTE: EB707100 Before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a ten-link sec- tion of the drive chain. EB7071 1 1 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no d[...]

7-65 SWINGARM AND DRIVE CHAIN CHAS EB707400 CHECKING THE SWINGARM 1. Check:  swingarm Bends / cracks / damage  Replace. 2. Check:  pivot shaft Roll the pivot shaft on a flat surface. Bends  Replace. Do not attempt to straighten a bent pivot shaft. 3. W ash:  pivot shaft  dust covers  spacer  washers  bearings Recommended [...]

7-66 SWINGARM AND DRIVE CHAIN CHAS NOTE: CAUTION: EB707410 CHECKING THE DRIVE CHAIN 1. Measure:  ten-link section a of the drive chain Out of specification  Replace the drive chain. T en-link drive chain section limit (maximum) 150 mm  While measuring the ten-link section, push down on the drive chain to increase its ten- sion.  Measure[...]

7-67 SWINGARM AND DRIVE CHAIN CHAS NOTE: 5. Lubricate:  drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check:  drive sprocket  rear wheel sprocket More than 1 / 4 tooth a wear  Replace the drive chain sprockets as a set. Bent teeth  Replace the drive chain sprockets as a set. b Correct 1[...]

7-68 SWINGARM AND DRIVE CHAIN CHAS 70 Nm (7.0 m  kg) NOTE: CAUTION: CAUTION: 4. Adjust:  drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Drive chain slack 30  45 mm EB707710 INST ALLING THE DRIVE CHAIN 1. Lubricate:  drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains[...]

ELEC 8 –+[...]

ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS 8-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAM 8-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING SWITCHES 8-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

ELEC[...]

8-1 ELECTRICAL COMPONENTS ELEC 13 Rectifier / Regulator 14 Thermo switch (warning light) 15 Thermo switch (fan motor) 16 Horn 17 Diode 7 Starting circuit cut-of f relay 8 Flasher relay 9 Sidestand switch 10 Neutral switch 11 Oil level gauge 12 Ignition coil 1 Main switch 2 Fuel sender 3 Rear brake switch 4 Battery 5 Ignitor unit 6 Starter relay EB8[...]

8-2 CIRCUIT DIAGRAM ELEC CIRCUIT DIAGRAM[...]

8-3 1 A.C. magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse (back up) 6 Fuse (main) 7 Starter relay 8 Starter motor 9 Starting circuit cut-off relay 10 Fuel pump relay 11 Ignitor unit 12 Ignition coil 13 Spark plug 14 Pickup coil 15 Throttle position sensor 16 Neutral switch 17 Speed sensor 18 Fuel sender 19 Thermo switch (warning light[...]

8-4 CHECKING SWITCHES ELEC NOTE: YP-N CHECKING SWITCHES CHECKING STEPS Using pocket tester , check switches for continu- ity between their terminals to determine whether they are correctly connected. Replace the switch component if any of the com- binations does not produce the correct reading. Pocket tester: 90890-031 12  Turn the switch to the[...]

8-5 Before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault  Repair or replace. * indicates coupler positions. CHECKING SWITCHES ELEC YP****** SWITCH POSITION AND TERMINAL CONNEC[...]

8-6 Fuse (main) 3 4 6 22 11 12 13 14 16 56 54 Main switch Battery Sidestand switch Ignitor unit Ignition coil Spark plug Pickup coil Neutral switch Fuse (ignition) Engine stop switch IGNITION SYSTEM ELEC EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM[...]

8-7 IGNITION SYSTEM ELEC NOTE: EB80201 1 1. Fuses (main and ignition) S Remove the fuses. S Connect the pocket tester ( Ω  1) to the fuses. S Check the fuses for continuity . Replace the fuses. CONTINUITY NO CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C EB802012 : 2. Battery S Check the battery condition. Refer to “BA TTERY INSPE[...]

8-8 EB802013 3. Spark plugs S Check the spark plug condition. S Check the spark plug type. S Check the spark plug gap. Refer to “SP ARK LUG INSPECTION” in CHAPTER 3. Standard spark plug: CR9E, CR8E / U27ESR-N, U24ESR-N NGK / NIPPONDENSO Spark plug gap: 0.7 X 0.8 mm CORRECT INCORRECT EB802014 4. Ignition spark gap S Disconnect the spark plug cap[...]

8-9 EB802015 5. Spark plug cap resistance S Remove the spark plug cap. S Connect the pocket tester ( Ω 1k) to the spark plug cap. S Check if the spark plug cap has the speci- fied resistance. Replace the spark plug cap. Spark plug cap resistance: 10 k Ω at 20 _ C OUT OF SPECIFICA TION 6. Ignition coil resistance S Disconnect the ignition coil c[...]

8-10 EB802017 7. Main switch S Disconnect the main switch couplers from the wire harness. S Check for continuity as follows: Red – Brown / Blue Replace the main switch. CONTINUITY NO CONTINUITY 1 : EB802018 8. Engine stop switch S Disconnect the right handlebar switch cou- pler from the wire harness. S Check for continuity as follows: Red / White[...]

8-1 1 Replace the main switch. CONTINUITY NO CONTINUITY EB80201A 10. Sidestand switch  Disconnect the sidestand switch coupler from the wire harness.  Check for continuity as follows: Black – Black Replace the sidestand switch. NO CONTINUITY 1 2 CONTINUITY 1 1. Diode (starting circuit cut-off relay unit)  Remove the relay unit from the w[...]

8-12 T ester  lead ! Blue / Y ellow T ester  lead ! Light green Replace the relay unit. CORRECT INCORRECT 1 T ester (+) lead ! Y ellow terminal T ester (–) lead ! Blue terminal EB80201C 12. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester ( Ω 100) to the pickup coil terminal. 1[...]

8-13 54 16 22 33 55 56 Engine stop switch Starter motor Starting circuit cut-off relay Neutral switch Sidestand switch Clutch switch Start switch Fuse (ignition) 8 9 Fuse (main) 3 4 6 Main switch Battery Starter relay 7 ELECTRIC ST ARTING SYSTEM ELEC EB803000 ELECTRIC ST ARTING SYSTEM CIRCUIT DIAGRAM[...]

8-14 ELECTRIC ST ARTING SYSTEM ELEC EB803010 ST ARTING CIRCUIT OPERA TION The starting circuit on this model consists of the starter motor , starter relay , and the starting cir- cuit cut-off relay . If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can op- erate only if. The [...]

8-15 ELECTRIC ST ARTING SYSTEM ELEC NOTE: EB80201 1 1. Fuses (main and ignition) S Remove the fuses. S Connect the pocket tester ( Ω  1) to the fuses. S Check the fuses for continuity . Replace the fuses. CONTINUITY NO CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C EB802012 : 2. Battery S Check the battery condition. Refer to “BA [...]

8-16 : : S A wire that is used as a jumper lead must have the equivalent capacity or more as that of the battery lead, otherwise the jumper lead may burn. S This check is likely to reduce sparks, so be sure that no flammable gas or fluid is in the vicinity . EB803021 3. Starter motor S Connect the battery positive terminal and starter motor cable u[...]

8-17 EB803024 5. Starter relay S Disconnect the relay unit coupler from the wire harness. S Connect the pocket tester ( Ω  1) and bat- tery (12 V) to the relay unit coupler termi- nals. Replace the starter relay . NO CONTINUITY : CONTINUITY EB802017 6. Main switch S Disconnect the main switch couplers from the wire harness. S Check for continu[...]

8-18 EB802018 7.Engine stop switch S Disconnect the right handlebar switch cou- pler from the wire harness. S Check for continuity as follows: Red / White – Red / White Replace the right handlebar switch. CONTINUITY NO CONTINUITY 1 : EB802019 8. Neutral switch S Disconnect the neutral switch / lead from the neutral switch. S Check for continuity [...]

8-19 EB80201A 9. Sidestand switch S Disconnect the sidestand switch coupler from the wire harness. S Check for continuity as follows: Black – Black Replace the sidestand switch. CONTINUITY NO CONTINUITY 1 : EB803025 10. Clutch switch S Disconnect the clutch switch coupler from the wire harness. S Check for continuity as follows: Black / Y ellow ?[...]

8-20 EB803027 1 1. Start switch S Disconnect the right handlebar switch cou- pler from the wire harness. S Check for continuity as follows: Blue / White – Black Replace the right handlebar switch. CONTINUITY NO CONTINUITY 1 : EB803026 12. Diode (starting circuit cut-off relay) S Remove the relay unit from the wire har- ness. S Check for continuit[...]

8-21 EB803028 13. Wiring connection S Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the starting system. POOR CONNECTION : ELECTRIC ST ARTING SYSTEM ELEC[...]

8-22 Order Job name / Part name Q’ty Remarks 1 2 Starter motor removal Starter motor Starter motor lead Starter motor disassembly Front bracket W ashers Rear bracket Shims Brush holder / Brush Armature ass’y 1 1 1 1 2 1 1/1 1 Remove the parts in order . Reverse the removal procedure for installation. Disassembly the parts in order . Reverse the[...]

8-23 ELECTRIC ST ARTING SYSTEM ELEC CHECKING THE ST ARTER MOTOR 1. Measure: S Brush length a Out of specification  Replace. Brush length wear limit: 4 mm 2. Measure: S Brush spring force Fatigue / out of specification  Replace as a set. Brush spring force: 780 X 1,020 g 3. Inspect: S Commutator Dirty  Clean it with #600 grit sandpaper . 4.[...]

8-24 ELECTRIC ST ARTING SYSTEM ELEC NOTE: 5. Measure:  Commutator diameter a Out of specification  Replace the starter motor . Commutator wear limit: 27 mm 6. Measure:  Mica undercut a Out of specification  Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator . Mica undercut: 0.7 [...]

8-25 Battery 1 2 4 AC magneto Rectifier/regulator Fuse (main) 6 CHARGING SYSTEM ELEC EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM[...]

8-26 CHARGING SYSTEM ELEC NOTE: EB80201 1 1. Fuses (main) S Remove the fuses. S Connect the pocket tester ( Ω  1) to the fuses. S Check the fuses for continuity . Replace the fuses. CONTINUITY NO CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C EB802012 : 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTION” in [...]

8-27 Stator coil resistance: 0.36 X 0.44 Ω at 20 _ C EB80401 1 3. Charging voltage S Connect the engine tachometer to the spark plug lead. S Connect the pocket tester (DC 20 V) to the battery . The charging circuit is not faulty . Charging voltage = measured voltage-terminal voltage: 0.2 X 2.5 V up OUT OF SPECIFICA TION MEETS SPECIFICA TION : EB8[...]

8-28 CHARGING SYSTEM ELEC EB804015 5. Wiring connections S Check the connections of the entire charg- ing system. Refer to “CIRCUIT DIAGRAM”. Properly connect the charging system. POOR CONNECTION : Replace the rectifier / regulator . CORRECT[...]

8-29 3 4 38 30 32 37 43 44 Main switch Battery Dimmer switch High beam indicator light Meter light Pass switch Headlight T ail/brake light 49 45 53 Fuse (head) Auxiliary light Lights switch 6 Fuse (main) LIGHTING SYSTEM ELEC EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM[...]

8-30 LIGHTING SYSTEM ELEC NOTE: EB80201 1 1. Fuses (main and head) S Remove the fuses. S Connect the pocket tester ( Ω  1) to the fuses. S Check the fuses for continuity . Replace the fuses. CONTINUITY NO CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C EB802012 : 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTI[...]

8-31  Disconnect the right handlebar switch cou- pler from the wire harness.  T urn the lights switch to “ON” or “PO”.  Check for continuity as follows: Red / Y ellow – Blue  T urn the lights switch to “ON”.  Check for continuity as follows: Red / Y ellow – Blue Red / Y ellow – Blue / Black 1 1 2 1 2 1 2 2 1 EB80201[...]

8-32 5. Dimmer switch  Disconnect the left handlebar switch cou- plers from the wire harness.  T urn the dimmer switch to “HI”.  Check for continuity as follows: Blue / Black – Y ellow The dimmer switch is faulty . Replace the left handlebar switch. CONTINUITY NO CONTINUITY 1  EB805012 6. Pass switch  Disconnect the left handle[...]

8-33 LIGHTING SYSTEM ELEC B 1. Bulb and bulb socket.  Check the bulb and bulb socket for continu- ity . Replace the bulb and / or bulb socket. CONTINUITY NO CONTINUITY When the dimmer switch is on “LO”. When the dimmer switch is ON “HI”. 2. V oltage  Connect the pocket tester (DC 20 V) to the headlight and high beam indicator light co[...]

8-34 LIGHTING SYSTEM ELEC 1 1. Bulb and bulb socket  Check the bulb and bulb socket for continu- ity . Replace the bulb and / or bulb socket. CONTINUITY NO CONTINUITY T ester (+) lead  Blue terminal T ester (–) lead  Black terminal 2. V oltage  Connect the pocket tester (20 V) to the bulb socket coupler .  T urn the main switch to [...]

8-35 LIGHTING SYSTEM ELEC  T urn the main switch to “ON”.  T urn the lights switch to “ON” or “PO”.  Check the voltage (12 V) of the “Blue” lead on the bulb socket connector . The wiring circuit from the main switch to the bulb socket connector is faulty , repair it. MEETS SPECIFICA TION OUT OF SPECIFICA TION This circuit i[...]

8-36 SIGNAL SYSTEM ELEC EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM[...]

8-37 3 Main switch 4 Battery 6 Fuse (main) 16 Neutral switch 18 Fuel sender 20 Diode 25 Fuel meter 26 Fuel level warning light 28 Neutral indicator light 29 Oil level warning light 31 T urn indicator light 34 Oil level switch 35 Flasher relay 36 Horn 39 Horn switch 40 T urn switch 41 Front turn signal light 42 Rear turn signal light 44 T ail / brak[...]

8-38 SIGNAL SYSTEM ELEC NOTE: EB80201 1 1. Fuses (main and signal) S Remove the fuses. S Connect the pocket tester ( Ω  1) to the fuses. S Check the fuses for continuity . Replace the fuses. CONTINUITY NO CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C EB802012 : 2. Battery S Check the battery condition. Refer to “BA TTERY INSPECTI[...]

8-39 EB802017 3. Main switch  Disconnect the main switch coupler from the wire harness.  Check for continuity as follows: Red – Brown / Blue Replace the main switch. CONTINUITY NO CONTINUITY 2 EB80601 1 4. Wiring connections  Check the connections of the entire signal system. Refer to “CIRCUIT DIAGRAM”. Properly connect the signal sy[...]

8-40 SIGNAL SYSTEM ELEC 1  Disconnect the left handlebar switch cou- pler from the wire harness.  Disconnect the “Black / White” lead at the horn terminal.  Check for continuity as follows: Pink – Black Replace the left handlebar switch. CONTINUITY NO CONTINUITY T ester (+) lead  Brown lead T ester (–) lead  Frame ground 2. V[...]

8-41 1 The horn is not faulty . HORN DOES NOT SOUND HORN SOUNDS T ester (+) lead  Brown lead T ester (–) lead  Pink 4. V oltage  Connect the pocket tester (DC 20 V) to the horn at the “Pink” terminal.  T urn the main switch to “ON”.  Check the voltage (12 V) of the “Pink” lead at the horn terminal. Replace the horn. MEE[...]

8-42 B A 1 Replace the brake switch. CONTINUITY NO CONTINUITY T ester (+) lead  Y ellow terminal T ester (–) lead  Black terminal 3. V oltage  Connect the pocket tester (DC 20 V) to the bulb socket connector .  T urn the main switch to “ON”.  The brake lever is pulled in or the brake ped- al is pressed down.  Check the volta[...]

8-43 SIGNAL SYSTEM ELEC T ester (+) lead  Brown terminal T ester (–) lead  Frame ground 1 1. Bulb and bulb socket  Check the bulb and bulb socket for continu- ity . Replace the bulb and / or bulb socket. CONTINUITY NO CONTINUITY 3. V oltage  Connect the pocket tester (DC 20 V) to the flasher relay coupler .  T urn the main switch t[...]

8-44 A B  T urn the main switch to “ON”.  T urn the turn switch to “L” or “R”.  Check the voltage (12 V) on the “Brown / White” lead at the flasher relay terminal. The flasher relay is faulty , replace it. MEETS SPECIFICA TION OUT OF SPECIFICA TION At the flasher light (left): T ester (+) lead  Chocolate lead T ester (?[...]

8-45 SIGNAL SYSTEM ELEC 1 2 1 1. Bulb and bulb socket  Check the bulb and bulb socket for continu- ity . Replace the bulb and / or bulb socket. CONTINUITY NO CONTINUITY 3. Diode  Remove the diode from the wire harness.  Check for continuity as follows: Sky blue – Light green Replace the diode. CORRECT INCORRECT  2. Neutral switch  [...]

8-46 T ester (+) lead  Brown terminal T ester (–) lead  Frame ground 4. V oltage S Connect the pocket tester (DC 20 V) to the bulb socket coupler . S T urn the main switch to “ON”. S Check the voltage (12 V). The wiring circuit from the main switch to the bulb socket connector is faulty , repair it. MEETS SPECIFICA TION OUT OF SPECIFICA[...]

8-47 T ester (+) lead  Black / Red terminal T ester (–) lead  Frame ground 3. Oil level switch  Drain the engine oil and remove the oil level switch from the oil pan.  Connect the pocket tester ( Ω  1) to the oil level switch.  Check the oil level switch for continuity . Replace the oil level switch. NO CONTINUITY 1 4. Diode ([...]

8-48 2 T ester (+) lead  Brown lead T ester (–) lead  Black / Red lead 6. V oltage  Connect the pocket tester (DC 20 V) to the bulb socket connector .  T urn the main switch to “ON”.  Check the voltage (12 V). The wiring circuit from the main switch to the bulb socket connector is faulty , repair it. MEETS SPECIFICA TION OUT OF[...]

8-49 SIGNAL SYSTEM ELEC Fuel sender resistance : 4 X 10 Ω at 20 _ C : 90 X 100 Ω at 20 _ C T ester (+) lead  Green / Red terminal T ester (–) lead  Black terminal 1. Bulb and bulb socket S Check the bulb and bulb socket for continu- ity . Replace the bulb and / or bulb socket. CONTINUITY NO CONTINUITY 2. Fuel sender S Drain the fuel and[...]

8-50 2 T ester (+) lead  Brown terminal T ester (–) lead  Green / Red terminal 3. V oltage  Connect the pocket tester (DC 20 V) to the bulb socket connector .  Drain the fuel.  T urn the main switch to “ON”.  Check the voltage (12 V). The wiring circuit from the main switch to the bulb socket connector is faulty , repair it.[...]

8-51 Fuse (main) 3 4 6 19 Main switch Battery Thermo switch (warning light) 27 46 47 48 Fan motor Fuse (fan) 51 Fuse (signal) Thermo switch (fan) Engine temperature warning light COOLING SYSTEM ELEC EB807000 COOLING SYSTEM CIRCUIT DIAGRAM[...]

8-52 COOLING SYSTEM ELEC NOTE: EB80201 1 1. Fuses (main, signal and fan) S Remove the fuses. S Connect the pocket tester ( Ω  1) to the fuses. S Check the fuses for continuity . Replace the fuse(s). CONTINUITY NO CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C EB802012 : 2. Battery S Check the battery condition. Refer to “BA TTERY [...]

8-53  Disconnect the main switch coupler from the wire harness.  Check for continuity as follows: Red – Brown / Blue  Disconnect the fan motor coupler .  Connect the battery (12 V) as shown. 2 EB802017 3. Main switch Replace the main switch. CONTINUITY NO CONTINUITY  EB80701 1 The fan motor is faulty , replace it. MOVES DOES NOT MO[...]

8-54 Les than 98 _ C f 3* 105 to 98 _ C S Remove the thermo switch from the thermo- static valve housing. S Connect the pocket tester ( Ω 1) to the thermo switch . S Immerse the thermo switch in coolant . S Check the thermo switch for continuity . While heating the coolant use a thermome- ter to record the temperatures. 2 EB802017 5. Thermo switc[...]

8-55 T ester (+) lead  Brown lead T ester (–) lead  Green / White lead 7. V oltage  Connect the pocket tester (DC 20 V) to the bulb socket connector .  T urn the main switch to “ON”.  Check the voltage (12 V). The wiring circuit from the main switch to the bulb socket connector is faulty , repair it. MEETS SPECIFICA TION OUT OF[...]

8-56 Fuse (main) 3 4 6 10 11 21 54 56 Main switch Battery Fuel pump relay Ignitor unit Fuel pump Engine stop switch Fuse (ignition) FUEL PUMP SYSTEM ELEC EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM[...]

8-57 FUEL PUMP SYSTEM ELEC 1 Battery 2 Fuse (main) 3 Main switch 4 Fuse (ignition) 5 Engine stop switch 6 Ignitor unit 7 Fuel pump relay 8 Fuel pump EB808010 FUEL PUMP CIRCUIT OPERA TION The fuel pump circuit consists of the fuel pump relay , fuel pump, engine stop switch and ignitor unit. The ignitor unit includes the control unit for the fuel pum[...]

8-58 COOLING SYSTEM ELEC NOTE: EB80201 1 1. Fuses (main and ignition) S Remove the fuses. S Connect the pocket tester ( Ω  1) to the fuses. S Check the fuses for continuity . Replace the fuse(s). CONTINUITY NO CONTINUITY Open-circuit voltage: 12.8 V or more at 20 _ C EB802012 : 2. Battery S Check the battery condition. Refer to “BA TTERY INS[...]

8-59  Disconnect the right handlebar switch cou- pler from the wire harness.  Check for continuity as follows: Red / White – Red / White 1 2 2 1 EB802017 3. Main switch  Disconnect the main switch coupler from the wire harness.  Check for continuity as follows: Red – Brown / Blue Replace the main switch. CONTINUITY NO CONTINUITY [...]

8-60 Battery (+) terminal  Red / Black terminal Battery (–) terminal  Blue / Red terminal 6. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester ( Ω 1) to the fuel pump coupler terminals. S Check if the fuel pump has the specified re- sistance. Replace the fuel pump. MEETS SPECIFICA T[...]

8-61 FUEL PUMP SYSTEM ELEC 2 1 EB808030 FUEL PUMP TEST Gasoline is extremely flammable and un- der certain circumstances there can be danger of an explosion or combustion. Be extremely careful and note the follow- ing points:  Stop the engine before refuelling.  Do not smoke and keep away from open flames, sparks, or any other source of fire.[...]

8-62 T achometer display Engine speed Engine speed T achometer display Revolusion Revolusion Second Second SELF-DIAGNOSIS ELEC SELF-DIAGNOSIS The YZF600R features self-diagnosis. When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the tachometer (irrespective of whether the engine i[...]

8-63 SELF-DIAGNOSIS ELEC NOTE: 11 15 Ignitor unit Throttle position sensor (TPS) 1. Wire harness  Check the wire harness for continuity . Refer to “CIRCUIT DIAGRAM”. Repair or replace the wire harness. CONTINUITY NO CONTINUITY 2. TPS  Check the TPS for continuity .  Refer to “THROTTLE POSITION SENSOR (TPS) ADJUSTMENT AND INSPECTION?[...]

8-64 SELF-DIAGNOSIS ELEC 11 Ignitor unit 17 Speed sensor 1. Wire harness  Check the wire harness for continuity . Refer to “CIRCUIT DIAGRAM”. Repair or replace the wire harness. CONTINUITY NO CONTINUITY Replace the speed sensor . 2. Speed sensor CIRCUIT DIAGRAM[...]

TRBL SHTG 9[...]

TRBL SHTG CHAPTER 9. TROUBLESHOOTING ST ARTING F AILURE / HARD ST ARTING 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM 9-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM 9-1 . . . . . . . . . . . . . . . . . . . . . . . . .[...]

TRBL SHTG[...]

9-1 ST ARTING F AILURE / HARD ST ARTING TRBL SHTG NOTE: EB900000 TROUBLESHOOTING The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however , as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. ST ARTING F AI[...]

9-2 ST ARTING F AILURE / HARD ST ARTING / POOR ENGINE IDLE SPEED PERFORMANCE / POOR MEDIUM-AND HIGH-SPEED PERFORMANCE TRBL SHTG COMPRESSION SYSTEM Cylinder and cylinder head  Loose spark plug  Loose cylinder head or cylinder  Faulty cylinder head gasket  Worn, damaged or seized cylinder  Improperly sealed valve  Improper valve-to-[...]

9-3 F AUL TY GEAR SHIFTING / F AUL TY CLUTCH PERFORMANCE TRBL SHTG EB903000 F AUL TY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft  Improperly adjusted shift pedal link  Bent shift shaft Shift cam, shift fork  Groove jammed with impurities  Seized shift fork  Bent shift fork guide b[...]

9-4 OVERHEA TING / OVERCOOLING / POOR BRAKING / F AUL TY FRONT FORK LEGS TRBL SHTG EB905000 OVERHEA TING OVERHEA TING Ignition system  Improper spark plug gap  Improper spark plug heat range  Faulty ignitor unit Fuel system  Improper carburetor main jet setting  Improper fuel level  Clogged air filter element Cooling system  Fa[...]

9-5 UNST ABLE HANDLING / F AUL TY LIGHTING AND SIGNAL SYSTEMS TRBL SHTG EB908000 UNST ABLE HANDLING UNST ABLE HANDLING Handlebar  Improperly installed or bent Steering  Improperly installed handlebar crown  Bent steering stem  Improperly installed steering shaft (improperly tightened ring nut)  Damaged ball bearing or bearing race Sw[...]

TRBL SHTG[...]