Yamaha MANUAL Manuals

Manuals and User Guides for Yamaha MANUAL. We have 1 Yamaha MANUAL manual available for free PDF download: Owner's Service Manual

Yamaha MANUAL Owner's Service Manual

Yamaha MANUAL Owner's Service Manual (358 pages)

Brand: Yamaha | Category: Motorcycle | Size: 11.51 MB

Table of Contents

Table of Contents

9
- General Information
  11
- Location of Important Labels
  13
- Description
  14
- Identification
  15
- Engine Serial Number
  15
- Model Label
  15
- Vehicle Identification Number
  15
- Features
  16
- Outline of the Fi System
  16
- Fi System
  17
- Handlebar Protector
  18
- Coupler for Connecting Optional Part
  18
- Fuel Hose Joint Cover
  18
- Spark Plug Wrench
  18
- Nipple Wrench
  18
- Included Parts
  18
- Sidestand
  18
- Important Information
  20
- Preparation for Removal and Disassembly
  20
- Replacement Parts
  20
- Bearings and Oil Seals
  21
- Circlips
  21
- Gaskets, Oil Seals and O-Rings
  21
- Lock Washers/Plates and Cotter Pins
  21
- Basic Service Information
  22
- Electrical System
  22
- Special Tools
  25
- Control Functions
  30
- Engine Stop Switch
  30
- Clutch Lever
  30
- Shift Pedal
  30
- Kickstarter Lever
  30
- Throttle Grip
  30
- Front Brake Lever
  30
- Fuel Tank Cap
  31
- Rear Brake Pedal
  31
- Starter Knob/Idle Screw
  31
- Starting and Break-In
  32
- Fuel
  32
- Starting a Cold Engine
  32
- Starting a Warm Engine
  33
- Break-In Procedures
  33
- Maintenance after Break-In
  34
- Major Maintenance
  34
- Torque-Check Points
  36
- Storage
  37
- Cleaning
  37
- Cleaning and Storage
  37
Specifications

39
- General Specifications
  40
- Engine Specifications
  41
- Chassis Specifications
  50
- Electrical Specifications
  51
- General Tightening Torque Specifications
  52
- Tightening Torques
  52
- Engine Tightening Torques
  53
- Chassis Tightening Torques
  57
- Engine
  60
- Lubrication Points and Lubricant Types
  60
- Chassis
  62
- Lubrication Diagrams
  64
- Lubrication System Chart and Diagrams
  64
- Cable Routing Diagram
  72
Periodic Checks and Adjustments

83
- Maintenance Intervals
  85
- General Inspection and Maintenance
  91
- Pre-Operation Inspection and Maintenance
  91
- Changing the Coolant
  92
- Checking the Coolant Level
  92
- Checking the Cooling System
  92
- Engine
  92
- Checking the Radiator Cap
  93
- Checking the Radiator Cap Opening Pressure
  93
- Adjusting the Clutch Lever Position
  94
- Checking the Coolant Circulatory System for Leaks
  94
- Adjusting the Clutch Lever Free Play
  95
- Adjusting the Throttle Grip Free Play
  95
- Cleaning the Air Filter Element
  96
- Lubricating the Throttle Cable
  96
- Checking the Breather Hoses
  97
- Checking the Throttle Body Joint
  97
- Checking the Engine Oil Level
  98
- Checking the Exhaust System
  98
- Checking the Fuel Line
  98
- Changing the Engine Oil
  99
- Adjusting the Engine Idling Speed
  100
- Adjusting the Valve Clearance
  101
- Bleeding the Brake System
  105
- Chassis
  105
- Adjusting the Front Brake
  106
- Checking the Brake Hose
  106
- Adjusting the Rear Brake
  107
- Checking the Front Brake Pads
  107
- Checking the Rear Brake Pads
  109
- Checking the Brake Fluid Level
  110
- Checking the Rear Brake Pad Insulator
  110
- Adjusting the Drive Chain Slack
  111
- Checking the Front Fork Legs
  112
- Checking the Front Fork Protector Guide
  112
- Cleaning the Front Fork Oil Seal and Dust Seal
  112
- Adjusting the Front Fork Legs
  113
- Air Bleeding from Front Fork
  113
- Adjusting the Rear Shock Absorber Assembly
  114
- Checking the Rear Suspension
  114
- Checking the Swingarm Operation
  114
- Checking and Tightening the Spokes
  117
- Checking the Tires
  117
- Checking the Wheel Bearings
  117
- Checking the Wheels
  117
- Checking and Adjusting the Steering Head
  118
- Lubricating the Levers
  119
- Lubricating the Pedal
  119
- Checking the Ignition Timing
  120
- Checking the Spark Plug
  120
- Electrical System
  120
Chassis

123
- General Chassis
  125
- Removing the Left Side Cover
  126
- Removing the Number Plate
  126
- Removing the Seat
  126
- Checking the Front Wheel
  128
- Front Wheel
  128
- Removing the Front Wheel
  128
- Assembling the Front Wheel
  129
- Disassembling the Front Wheel
  129
- Installing the Front Wheel
  130
- Checking and Replacing the Rear Wheel Sprocket
  132
- Checking the Rear Wheel
  132
- Disassembling the Rear Wheel
  132
- Rear Wheel
  132
- Removing the Rear Wheel
  132
- Assembling the Rear Wheel
  133
- Installing the Rear Wheel
  134
- Front Brake
  136
- Checking the Front Brake Disc
  140
- Disassembling the Front Brake Caliper
  140
- Introduction
  140
- Removing the Front Brake Caliper
  140
- Assembling the Front Brake Caliper
  141
- Checking the Front Brake Caliper
  141
- Installing the Brake Caliper Piston
  141
- Installing the Front Brake Caliper
  142
- Assembling the Front Brake Master Cylinder
  143
- Checking the Front Brake Master Cylinder
  143
- Removing the Front Brake Master Cylinder
  143
- Installing the Front Brake Master Cylinder
  144
- Rear Brake
  146
- Checking the Rear Brake Disc
  150
- Introduction
  150
- Assembling the Rear Brake Caliper
  151
- Checking the Rear Brake Caliper
  151
- Disassembling the Rear Brake Caliper
  151
- Removing the Rear Brake Caliper
  151
- Installing the Brake Caliper Piston
  152
- Installing the Rear Brake Caliper
  152
- Checking the Rear Brake Master Cylinder
  153
- Removing the Rear Brake Master Cylinder
  153
- Assembling the Rear Brake Master Cylinder
  154
- Installing the Rear Brake Master Cylinder
  154
- Checking the Handlebar
  158
- Handlebar
  158
- Installing the Handlebar
  158
- Removing the Handlebar
  158
- Front Fork
  162
- Disassembling the Front Fork Legs
  164
- Removing the Front Fork Legs
  164
- Checking the Front Fork Legs
  165
- Assembling the Front Fork Legs
  166
- Installing the Front Fork Legs
  172
- Steering Head
  175
- Checking the Steering Head
  176
- Installing the Steering Head
  176
- Removing the Lower Bracket
  176
- Rear Shock Absorber Assembly
  179
- Disposing of a Rear Shock Absorber
  182
- Handling the Rear Shock Absorber
  182
- Removing the Rear Shock Absorber Assembly
  182
- Checking the Connecting Arm and Relay Arm
  183
- Checking the Rear Shock Absorber Assembly
  183
- Installing the Relay Arm
  183
- Removing the Bearing
  183
- Installing the Rear Shock Absorber Assembly
  184
- Swingarm
  186
- Checking the Swingarm
  187
- Removing the Bearing
  187
- Removing the Swingarm
  187
- Installing the Swingarm
  188
- Chain Drive
  189
- Checking the Drive Chain
  190
- Removing the Drive Chain
  190
- Checking the Drive Sprocket
  191
- Checking the Rear Wheel Sprocket
  191
- Installing the Drive Chain
  191
Engine

193
- Engine Removal
  196
- Removing the Drive Sprocket
  201
- Removing the Exhaust Pipe 2
  201
- Removing the Silencer
  201
- Changing the Silencer Fiber
  202
- Checking the Silencer and Exhaust Pipe
  202
- Removing the Engine
  202
- Installing the Engine
  203
- Installing the Brake Pedal
  204
- Installing the Drive Sprocket
  204
- Installing the Exhaust Pipe and Muffler
  205
- Camshaft
  207
- Removing the Camshaft
  209
- Checking the Camshaft
  210
- Checking the Timing Chain and Camshaft Sprocket
  211
- Checking the Timing Chain Tensioners
  211
- Checking the Decompression System
  212
- Installing the Camshafts
  212
- Cylinder Head
  215
- Checking the Cylinder Head
  217
- Checking the Timing Chain Guide (Intake Side)
  217
- Removing the Cylinder Head
  217
- Installing the Cylinder Head
  218
- Checking the Valves and Valve Guides
  222
- Valves and Valve Springs
  222
- Checking the Valve Seats
  223
- Checking the Valve Springs
  225
- Checking the Valve Lifters
  226
- Installing the Valves
  226
- Checking the Cylinder and Piston
  229
- Cylinder and Piston
  229
- Removing the Piston
  229
- Checking the Piston Rings
  230
- Checking the Piston Pin
  231
- Installing the Piston and Cylinder
  231
- Clutch
  234
- Checking the Clutch Plates
  236
- Checking the Clutch Springs
  236
- Checking the Friction Plates
  236
- Removing the Clutch
  236
- Checking the Clutch Boss
  237
- Checking the Clutch Housing
  237
- Checking the Clutch Push Rods
  237
- Checking the Pressure Plate
  237
- Checking the Primary Drive Gear
  237
- Checking the Push Lever Shaft
  237
- Checking the Primary Driven Gear
  238
- Installing the Oil Seal
  238
- Installing the Right Crankcase Cover
  238
- Installing the Clutch
  239
- Installing the Kickstarter Lever
  241
- Checking the Kick Gear, Kick Idle Gear and Ratchet Wheel
  243
- Checking the Kick Shaft and Ratchet Wheel
  243
- Installing the Kick Shaft Assembly
  243
- Kickstater
  243
- Removing the Kick Shaft Assembly
  243
- Installing the Kick Idle Gear
  244
- Shift Shaft
  245
- Checking the Shift Guide and Shift Lever Assembly
  247
- Checking the Shift Shaft
  247
- Checking the Stopper Lever
  247
- Removing the Segment
  247
- Removing the Shift Guide and Shift Lever Assembly
  247
- Installing the Segment
  248
- Installing the Shift Guide and Shift Lever Assembly
  248
- Installing the Stopper Lever
  248
- Installing the Shift Pedal
  249
- Installing the Shift Shaft
  249
- Oil Pump and Balancer Gear
  251
- Checking the Balancer
  252
- Checking the Oil Pump
  252
- Checking the Primary Drive Gear, Balancer Shaft Drive Gear, and Balancer Weight Gear
  252
- Removing the Balancer
  252
- Assembling the Oil Pump
  253
- Installing the Oil Pump and Balancer Gear
  253
- Ac Magneto
  255
- Checking the Ac Magneto
  256
- Checking the Woodruff Key
  256
- Installing the Ac Magneto
  256
- Removing the Ac Magneto
  256
- Crankcase
  259
- Checking the Timing Chain, Timing Chain Guide, Oil Strainer
  261
- Disassembling the Crankcase
  261
- Removing the Crankcase Bearing
  261
- Assembling the Crankcase
  262
- Checking the Crankcase
  262
- Crankshaft Assembly and Balancer Shaft
  263
- Checking the Crankshaft Assembly
  264
- Removing the Balancer Shaft
  264
- Removing the Crankshaft Assembly
  264
- Installing the Crankshaft Assembly
  265
- Checking the Shift Forks
  267
- Removing the Transmission
  267
- Transmission
  267
- Checking the Shift Drum Assembly
  268
- Checking the Transmission
  268
- Installing the Transmission
  268
- Cooling System
  271
Fuel System

279
- Fuel Tank
  280
- Checking the Fuel Pump Body
  281
- Installing the Fuel Pump
  281
- Removing the Fuel Pump
  281
- Removing the Fuel Tank
  281
- Checking the Fuel Pressure
  282
- Installing the Fuel Tank
  282
- Checking the Damper
  283
- Throttle Body
  284
- Checking the Injector
  287
- Checking the Throttle Body
  287
- Checking the Throttle Body Joint
  287
- Adjusting the Throttle Position Sensor
  288
Electrical System

289
- Circuit Diagram
  292
- Ignition System
  292
- Troubleshooting
  294
- Charging System
  296
- Circuit Diagram
  296
- Troubleshooting
  298
- Circuit Diagram
  300
- Fuel Injection System
  300
- Yamaha Diagnostic Tool
  302
- Troubleshooting Details
  303
- Circuit Diagram
  322
- Fuel Pump System
  322
- Troubleshooting
  324
- Electrical Components
  326
- Checking the Switches
  328
- Checking the Ignition Coil
  331
- Checking the Ignition Spark Gap
  331
- Checking the Spark Plug Cap
  331
- Checking the Crankshaft Position Sensor
  332
- Checking the Ecu
  332
- Checking the Stator Coil
  332
- Checking the Coolant Temperature Sensor
  333
- Checking the Rectifier/Regulator
  333
- Checking the Throttle Position Sensor
  334
- Checking the Intake Air Pressure Sensor
  335
- Checking the Intake Air Temperature Sensor
  335
- Checking the Throttle Position Sensor Input Voltage
  335
- Checking the Fuel Injector
  336
- Checking the Neutral Switch
  336
Troubleshooting

337
- General Information
  338
- Incorrect Engine Idling Speed
  338
- Starting Failures
  338
- Troubleshooting
  338
- Faulty Clutch
  339
- Faulty Gear Shifting
  339
- Jumps out of Gear
  339
- Overheating
  339
- Poor Medium-And-High-Speed Performance
  339
- Shift Pedal Does Not Move
  339
- Faulty Front Fork Legs
  340
- Overcooling
  340
- Poor Braking Performance
  340
- Unstable Handling
  340
- List of Self-Diagnostic and Fail-Safe Actions
  342
Tuning

345
- Chassis
  346
- Drive and Rear Wheel Sprockets Setting Parts
  346
- Selection of the Secondary Reduction Ratio (Sprocket)
  346
- Change in Amount and Characteristics of Fork Oil
  347
- Front Fork Setting
  347
- Tire Pressure
  347
- Choosing Set Length
  348
- Front Fork Setting Parts
  348
- Rear Suspension Setting
  348
- Setting of Spring after Replacement
  348
- Setting of Spring after Replacement
  349
- Rear Shock Absorber Setting Parts
  350
- Suspension Setting (Front Fork)
  351
- Suspension Setting (Rear Shock Absorber)
  352

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