Yamaha V Star 950 Service Manual

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Summary of Contents for Yamaha V Star 950

Page 2: How To Use This Manual
EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •...
Page 3 EAS20100 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine Gear oil mounted Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
Page 5: Table Of Contents
EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING...
Page 7: General Information
GENERAL INFORMATION IDENTIFICATION ..................1-1 VEHICLE IDENTIFICATION NUMBER...........1-1 MODEL LABEL ..................1-1 FEATURES ....................1-2 OUTLINE OF THE FI SYSTEM ..............1-2 FI SYSTEM .....................1-3 INSTRUMENT FUNCTIONS ..............1-4 IMPORTANT INFORMATION ...............1-6 PREPARATION FOR REMOVAL AND DISASSEMBLY......1-6 REPLACEMENT PARTS.................1-6 GASKETS, OIL SEALS AND O-RINGS..........1-6 LOCK WASHERS/PLATES AND COTTER PINS ........1-6 BEARINGS AND OIL SEALS ..............1-7 CIRCLIPS ....................1-7 CHECKING THE CONNECTIONS ...............1-8...
Page 8: Identification
IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the steering head pipe. EAS20150 MODEL LABEL The model label “1” is affixed to the frame. This information will be needed to order spare parts.
Page 9: Features
FEATURES EAS20170 FEATURES EAS5S71022 OUTLINE OF THE FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture.
Page 10: Fi System
FEATURES EAS5S71020 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the fuel injector at only 392 kPa (3.92 kg/cm², 56.9 psi). Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, caus- ing the fuel to be injected into the intake manifold only during the time the passage remains open.
Page 11: Instrument Functions
FEATURES EAS5S71021 Speedometer INSTRUMENT FUNCTIONS Multi-function meter unit EWA5S71001 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. 1. Speedometer The speedometer shows the riding speed. When the key is turned to “ON”, the speedom- eter needle will sweep once across the speed range and then return to zero in order to test the electrical circuit.
Page 12 FEATURES Odometer, tripmeter, and fuel reserve trip- odometer/tripmeter/clock display will indicate a meter modes two-digit error code (e.g., 12, 13, 14). If the odometer/tripmeter/clock display indi- cates any error codes, note the code number, and then check the vehicle. Refer to “FUEL INJECTION SYSTEM”...
Page 13: Important Information
5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but...
Page 14: Bearings And Oil Seals
IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing oil seals “1”, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appro- priate.
Page 15: Checking The Connections
CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •...
Page 16: Special Tools
SPECIAL TOOLS EAS20260 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
Page 17 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Extension 5-22 90890-04136 Extension 5-22 90890-04082 Oil filter wrench 3-24 90890-01426 YU-38411 Belt tension gauge 3-18 90890-03170 Rear drive belt tension gauge YM-03170 Steering nut wrench 3-20, 4-58 90890-01403 Exhaust flange nut wrench YU-A9472 Damper rod holder 4-51, 4-53...
Page 18 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Rotor holding tool 5-13, 5-17, 5-18 90890-01235 Universal magneto & rotor holder YU-01235 Slide hammer bolt 5-14 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 5-14 90890-01084 YU-01083-3 YU-01083-3 Valve spring compressor 5-25, 5-30 90890-04019 YM-04019...
Page 19 Piston pin puller set 5-33 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder 5-41, 5-42, 5- 90890-01701 48, 5-50 Primary clutch holder YS-01880-A Flywheel puller set 5-41 90890-01468 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-42, 5-63 90890-85505 (Three Bond No.1215®) 1-12...
Page 20 SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Universal clutch holder 5-48, 5-51 90890-04086 YM-91042 Pressure gauge 6-9, 6-11 90890-03153 YU-03153 Fuel pressure adapter 6-11 90890-03176 YM-03176 Digital circuit tester 5-57, 6-12 90890-03174 Model 88 Multimeter with tachometer YU-A1927 Ignition checker 7-88 90890-06754 Opama pet-4000 spark checker...
Page 21: Specifications
SPECIFICATIONS GENERAL SPECIFICATIONS ..............2-1 ENGINE SPECIFICATIONS................2-2 CHASSIS SPECIFICATIONS................2-8 ELECTRICAL SPECIFICATIONS...............2-11 TIGHTENING TORQUES................2-14 GENERAL TIGHTENING TORQUE SPECIFICATIONS.......2-14 ENGINE TIGHTENING TORQUES ............2-15 CHASSIS TIGHTENING TORQUES ............2-18 LUBRICATION POINTS AND LUBRICANT TYPES ........2-22 ENGINE ....................2-22 CHASSIS ....................2-23 LUBRICATION SYSTEM CHART AND DIAGRAMS .........2-25 ENGINE OIL LUBRICATION CHART ...........2-25 LUBRICATION DIAGRAMS ..............2-27 CABLE ROUTING ..................2-35...
Page 22: General Specifications
GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model XVS95Y 49B1 (U49) XVS95Y 5S71 (U49) XVS95YC 49B2 (CAL) XVS95YC 5S72 (CAL) XVS95CTY 49C1 (U49) XVS95CTY 26S1 (U49) XVS95CTYC 49C2 (CAL) XVS95CTYC 26S2 (CAL) Dimensions Overall length 2435 mm (95.9 in) Overall width 1000 mm (39.4 in) Overall height XVS95Y/XVS95YC 1080 mm (42.5 in)
Page 23: Engine Specifications
ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Air cooled 4-stroke, SOHC Displacement 942.0 cm Cylinder arrangement V-type 2-cylinder Bore × stroke 85.0 × 83.0 mm (3.35 × 3.27 in) Compression ratio 9.00 : 1 Standard compression pressure (at sea level) 1400 kPa/400 r/min (14.0 kgf/cm /400 r/min, 199.1 psi/400 r/min)
Page 24 ENGINE SPECIFICATIONS Cylinder head Volume 40.50–42.70 cm (2.47–2.61 cu.in) Warpage limit 0.05 mm (0.0020 in) Camshaft Drive system Chain drive (left and right) Camshaft journal diameter 20.959–20.980 mm (0.8252–0.8260 in) Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720–1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583–1.4622 in)
Page 25 ENGINE SPECIFICATIONS Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in) Limit 1.6 mm (0.06 in) Valve margin thickness D (intake) 1.00 mm (0.0394 in) Valve margin thickness D (exhaust) 1.00 mm (0.0394 in) Valve stem diameter (intake) 5.975–5.990 mm (0.2352–0.2358 in) Limit 5.945 mm (0.2341 in) Valve stem diameter (exhaust)
Page 26 ENGINE SPECIFICATIONS Spring tilt (intake) 2.5°/1.9 mm (0.075 in) Spring tilt (exhaust) 2.5°/1.9 mm (0.075 in) Winding direction (intake) Clockwise Winding direction (exhaust) Clockwise Cylinder Bore 85.000–85.010 mm (3.3465–3.3468 in) Wear limit 85.100 mm (3.3504 in) Out of round limit 0.050 mm (0.0020 in) Piston Piston-to-cylinder clearance...
Page 27 ENGINE SPECIFICATIONS Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in) Limit 0.130 mm (0.0051 in) Oil ring Dimensions (B × T) 2.00 × 2.50 mm (0.08 × 0.10 in) End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in) Connecting rod Oil clearance (using plastigauge®) 0.022–0.046 mm (0.0009–0.0018 in) Limit 0.09 mm (0.0035 in)
Page 28 ENGINE SPECIFICATIONS Transmission Transmission type Constant mesh 5-speed Primary reduction system Spur gear Primary reduction ratio 72/43 (1.674) Secondary reduction system Belt drive Secondary reduction ratio 70/30 (2.333) Operation Left foot operation Gear ratio 46/15 (3.067) 33/16 (2.063) 30/19 (1.579) 34/27 (1.259) 25/24 (1.042) Main axle runout limit...
Page 29: Chassis Specifications
CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Double cradle Caster angle 32.10° Trail 145.0 mm (5.71 in) Front wheel Wheel type Cast wheel 18M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 135.0 mm (5.31 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)
Page 30 Spring stroke K1 0.0–135.0 mm (0.00–5.31 in) Inner tube outer diameter 41.0 mm (1.61 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 488.0 cm (16.50 US oz, 17.21 Imp oz) Level 107.0 mm (4.21 in) Rear suspension...
Page 31 CHASSIS SPECIFICATIONS Spring preload adjusting positions Minimum Standard Maximum Swingarm Swingarm end free play limit (radial) 1.0 mm (0.04 in) Swingarm end free play limit (axial) 1.0 mm (0.04 in) Drive belt Model/manufacturer MD01/MITSUBOSHI Drive belt slack (on the sidestand) 3.0–5.0 mm (0.12–0.20 in) Drive belt slack (on a suitable stand) 3.0–5.0 mm (0.12–0.20 in)
Page 32: Electrical Specifications
ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system TCI (digital) Advancer type Throttle position sensor and electrical Ignition timing (B.T.D.C.) 5.0°/1000 r/min Engine control unit Model/manufacturer FUA0028/MITSUBISHI Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) 2.16–2.64 Ω...
Page 33 ELECTRICAL SPECIFICATIONS Indicator light Neutral indicator light Turn signal indicator light Oil level warning light High beam indicator light Fuel level warning light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Power output 0.80 kW 0.0050–0.0150 Ω...
Page 34 ELECTRICAL SPECIFICATIONS Fuses Main fuse 40.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 10.0 A Ignition fuse 15.0 A Fuel injection system fuse 10.0 A Backup fuse 10.0 A Reserve fuse 20.0 A Reserve fuse 15.0 A Reserve fuse 10.0 A...
Page 35: Tightening Torques
TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFI- CATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for spe- cial components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Page 36: Engine Tightening Torques
TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Cylinder head stud bolt (exhaust 15 Nm (1.5 m·kgf, 11 ft·lbf) pipe) Oil check bolt 15 Nm (1.5 m·kgf, 11 ft·lbf) Cylinder head nut 65 Nm (6.5 m·kgf, 47 ft·lbf) See TIP Cylinder head bolt 13 Nm (1.3 m·kgf, 9.4 ft·lbf)
Page 37 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Muffler and muffler bracket bolt 35 Nm (3.5 m·kgf, 25 ft·lbf) Rear exhaust pipe joint nut 15 Nm (1.5 m·kgf, 11 ft·lbf) Exhaust pipe bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) Rear exhaust pipe joint cover bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Exhaust pipe stay and exhaust...
Page 38 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Speed sensor bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Speed sensor bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Speed sensor lead bracket screw 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Cylinder head nut 1.
Page 39: Chassis Tightening Torques
TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting nut (front upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (front lower 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear upper 88 Nm (8.8 m·kgf, 64 ft·lbf) side) Engine mounting nut (rear lower...
Page 40 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Seat lock bracket bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Seat bracket bolt 19 Nm (1.9 m·kgf, 13 ft·lbf) Passenger seat bracket bolt 16 Nm (1.6 m·kgf, 11 ft·lbf) Passenger seat guide bolt 16 Nm (1.6 m·kgf, 11 ft·lbf) Passenger seat bolt 16 Nm (1.6 m·kgf, 11 ft·lbf)
Page 41 TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Headlight body screw 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Headlight stay bolt 7 Nm (0.7 m·kgf, 5.1 ft·lbf) Front turn signal light nut 11 Nm (1.1 m·kgf, 8.0 ft·lbf) Air temperature sensor screw 4 Nm (0.4 m·kgf, 2.9 ft·lbf) Throttle cable locknut 4 Nm (0.4 m·kgf, 2.9 ft·lbf)
Page 42 TIGHTENING TORQUES Passenger seat bolt Tighten the left side first, then the right side. Front wheel axle pinch bolt Tighten the front wheel axle pinch bolts to specification twice. Tighten the inside and outside bolts alternately, starting with the inside bolt. Lower ring nut 1.
Page 43: Lubrication Points And Lubricant Types
Clutch boss nut and washer Transmission gears (wheel and pinion) and collar Shift forks and shift fork guide bars Shift drum Shift shaft and shift shaft oil seal (lip) Yamaha bond Crankcase (mating surface) No.1215 (Three Bond No.1215®) Yamaha bond Crankshaft position sensor lead grommet No.1215 (Three Bond...
Page 44: Chassis
LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings and upper bearing race cover (lip) Lower bearing steering seal (lip) Front wheel oil seals (lip) Rear wheel oil seal (lip) Rear wheel drive hub (mating surface) Brake pedal shaft (pivoting point) Shift pedal (pivoting point) Sidestand (pivoting point) and metal-to-metal moving parts Throttle grip tube guide (inner surface) and throttle cables...
Page 45 LUBRICATION POINTS AND LUBRICANT TYPES 2-24...
Page 46: Lubrication System Chart And Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20390 LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20400 ENGINE OIL LUBRICATION CHART 2-25...
Page 47 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil strainer 2. Oil pump assembly 3. Oil delivery pipe 2 4. Relief valve assembly 5. Drive axle 6. Oil filter cartridge 7. Main axle 8. Main gallery 9. Crankshaft 10.Clutch cover 11.Valve stem end (intake side) 12.Rear cylinder camshaft 13.Front cylinder camshaft 2-26...
Page 48: Lubrication Diagrams
LUBRICATION SYSTEM CHART AND DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27...
Page 49 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil filter cartridge 2. Oil delivery pipe 2 3. Relief valve assembly 2-28...
Page 50 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-29...
Page 51 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Camshaft 2. Crankshaft 2-30...
Page 52 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-31...
Page 53 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Oil drain bolt 2. Crankshaft 2-32...
Page 54 LUBRICATION SYSTEM CHART AND DIAGRAMS 2-33...
Page 55 LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Drive axle 2. Oil delivery pipe 1 3. Main axle 4. Oil delivery pipe 2 5. Oil pump assembly 6. Oil strainer 2-34...
Page 56: Cable Routing
CABLE ROUTING EAS20430 CABLE ROUTING 2-35...
Page 57 CABLE ROUTING 1. Clamp 2. Front brake master cylinder 3. Clutch cable guide 4. Clutch cable 5. Throttle cable (pull side) 6. Throttle cable (return side) 7. Rear brake light switch coupler 8. Starter motor lead 9. Rectifier/regulator lead 10.Rectifier/regulator 11.Corrugate tube 12.Rear brake light switch lead 13.Front brake hose...
Page 58 CABLE ROUTING 2-37...
Page 59 CABLE ROUTING 1. Main switch couplers 2. Left handlebar switch couplers 3. Intake air temperature sensor lead 4. Clamp 5. Right handlebar switch couplers 6. Front turn signal light coupler 7. Wire harness A. Route the main switch and left handlebar switch lead.
Page 60 CABLE ROUTING 2-39...
Page 61 CABLE ROUTING 1. Handlebar switch lead 2. Front brake hose 3. Throttle cable 4. TPS (throttle position sensor) lead 5. Plastic band 6. Wire harness 7. Clutch cable A. Route the handlebar switch lead outside of the throttle cable. B. To the throttle bodies C.
Page 62 CABLE ROUTING 2-41...
Page 63 CABLE ROUTING 1. Relay unit 2. Relay unit lead 3. Lean angle sensor lead 4. O sensor lead coupler 5. O sensor lead 6. Starter motor lead 7. Bracket 8. Taillight lead 9. Rear brake hose A. Route the seat lock cable under the joint coupler lead.
Page 64 CABLE ROUTING 2-43...
Page 65 CABLE ROUTING 1. Brake fluid reservoir 2. Clip 3. Brake fluid reservoir hose 4. Rear brake master cylinder 5. Rear brake hose 6. Clamp 7. Rear brake hose holder 8. Rear brake light switch 9. Rear brake light switch lead 10.Brake fluid reservoir cover A.
Page 66 CABLE ROUTING 2-45...
Page 67 CABLE ROUTING U. When fitting to the front brake hose, soap- 1. Fuel delivery hose suds or silicon fluid can be applied. 2. Sidestand switch lead V. Press the brake hose against the stopper 3. Clamp and tighten. 4. Front brake hose W.
Page 68 CABLE ROUTING 2-47...
Page 69 CABLE ROUTING Q. Clamp the wire harness. Face the end 1. Plastic band inside. 2. Clamp R. Clamp the starter motor lead and O sen- 3. Speed sensor lead bracket sor lead. Face the opening outside. 4. Neutral switch S. Clamp the starter motor lead. Face the 5.
Page 70 CABLE ROUTING 2-49...
Page 71 CABLE ROUTING 1. Intake air pressure sensor 2. Clamp 3. Crankcase breather hose 4. Clutch cable 5. Meter lead 6. Plastic band 7. Spark plug lead 8. Starter motor lead (black) 9. Battery lead (red) 10.Relay unit 11.Wire lead 12.Lean angle sensor 13.Lean angle sensor lead 14.Relay unit lead A.
Page 72 CABLE ROUTING 2-51...
Page 73 CABLE ROUTING 1. Meter lead 2. Clip 3. Fuel tank drain hose 4. Frame 5. Clamp 6. Fuel tank breather hose 7. Rollover valve 8. Wire harness 9. Crankcase breather hose 10.Fuel tank 11.Canister 12.Canister breather hose 13.Spark plug lead A.
Page 74 CABLE ROUTING 2-53...
Page 75 CABLE ROUTING 1. Tail/brake light wire harness 2. Tail/brake light wire harness (from taillight) 3. Tail/brake light assembly 4. Rear turn signal light lead 5. Rear turn signal light bracket cover 6. Grommet 7. License plate light coupler 8. Rear right turn signal light coupler 9.
Page 76 CABLE ROUTING 2-55...
Page 77 CABLE ROUTING 1. ISC (idle speed control) lead 2. Clamp 3. Engine temperature sensor lead 4. ISC (idle speed control) coupler 5. Fuel sender coupler (natural) 6. Fuel pump coupler (black) 7. Side cover (cylinder head) 8. Rear cylinder ignition coil 9.
Page 78 CABLE ROUTING 2-57...
Page 79 CABLE ROUTING 1. Clip 2. Canister purge hose (for california) 3. Throttle body 4. Intake air pressure sensor 5. Intake air pressure hose A. Face the knob to the front and install at the white paint mark. (for California) B. Face the white paint upward and insert until contacting with the throttle body nip- ple.
Page 80 CABLE ROUTING 2-59...
Page 81 CABLE ROUTING 1. Crankcase breather hose 2. Clamp 3. Crankcase breather pipe 4. Right crankcase 5. Air filter case 6. Clip A. The opening can face either right or left. B. Install by aligning with the white paint. C. Adjust the knob diagonally to the back. D.
Page 82 CABLE ROUTING 2-61...
Page 83: Periodic Checks And Adjustments
PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE .................3-1 INTRODUCTION ..................3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM................3-1 GENERAL MAINTENANCE AND LUBRICATION CHART .....3-2 CHECKING THE FUEL LINE ..............3-4 CHECKING THE SPARK PLUGS............3-4 CHECKING THE IGNITION TIMING ............3-5 ADJUSTING THE VALVE CLEARANCE ..........3-5 CHECKING THE CRANKCASE BREATHER HOSE ......3-8 SYNCHRONIZING THE THROTTLE BODIES ........3-8 CHECKING THE EXHAUST SYSTEM ..........3-10...
Page 84 CHECKING THE THROTTLE CABLE OPERATION ......3-27 ADJUSTING THE THROTTLE CABLE FREE PLAY ......3-27 LUBRICATING THE THROTTLE GRIP HOUSING AND CABLE ..3-28 CHECKING AND CHARGING THE BATTERY........3-28 CHECKING THE FUSES..............3-28 CHECKING THE SWITCHES...............3-28 ADJUSTING THE HEADLIGHT BEAM ..........3-28 REPLACING THE HEADLIGHT BULB ..........3-28...
Page 86: Periodic Maintenance
Evaporative emis- • Check control system for dam- sion control sys- √ age. tem (For California • Replace if necessary. only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 87: General Maintenance And Lubrication Chart
PERIODIC MAINTENANCE EAS5S71019 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months 24 months...
Page 88 • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.
Page 89: Checking The Fuel Line
PERIODIC MAINTENANCE EAS21030 ECA13320 CHECKING THE FUEL LINE The following procedure applies to all of the Before removing the spark plugs, blow fuel and breather hoses. away any dirt accumulated in the spark 1. Remove: plug wells with compressed air to prevent it •...
Page 90: Checking The Ignition Timing
PERIODIC MAINTENANCE 10. Install: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Rear cylinder right plastic cover a. Start the engine, warm it up for several Refer to “ENGINE REMOVAL” on page 5- minutes, and then let it run at the specified engine idling speed. Engine idling speed EAS20700 CHECKING THE IGNITION TIMING 950–1050 r/min...
Page 91 PERIODIC MAINTENANCE • Fuel tank Valve clearance (cold) Refer to “FUEL TANK” on page 6-1. Intake • Front cylinder upper plastic cover 0.08–0.12 mm (0.0032–0.0047 • Front cylinder lower plastic cover • Rear cylinder left plastic cover Exhaust • Rear cylinder right plastic cover 0.22–0.26 mm (0.0087–0.0102 •...
Page 92 PERIODIC MAINTENANCE Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Rear cylinder a. Turn the crankshaft counterclockwise from the front cylinder piston TDC by 300 b. Insert a thickness gauge “2” between the degrees. end of the adjusting screw “3” and the valve b.
Page 93: Checking The Crankcase Breather Hose
PERIODIC MAINTENANCE 9. Install: • Rear cylinder tappet covers • Front cylinder tappet covers Rear cylinder tappet cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Front cylinder tappet cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) 10. Install: • Crankshaft end accessing screw (along with the O-ring 3.
Page 94 PERIODIC MAINTENANCE 3. Remove: • Rider seat • Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. • Fuel tank Refer to “FUEL TANK” on page 6-1. 4. Disconnect: • Intake air pressure sensor hose “1” • Cap “2” 5.
Page 95: Checking The Exhaust System
PERIODIC MAINTENANCE 9. Connect: • Intake air pressure sensor hose • Cap 10. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-27. Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 11. Install: EAS21090 •...
Page 96: Checking The Clutch Operation
PERIODIC MAINTENANCE the check-up. While checking the clutch operation, do not rev up the engine. a. Place the vehicle on a level surface, and start the engine. b. Grab the clutch lever and make sure that you can shift the gear smoothly. c.
Page 97: Checking The Brake Operation
PERIODIC MAINTENANCE If the specified clutch lever free play cannot be Drive on the dry road, operate the front and obtained on the handlebar side of the cable, rear brakes separately and check to see if the use the adjusting nut on the engine side. brakes are operating fully.
Page 98: Adjusting The Front Brake Lever Free Play
PERIODIC MAINTENANCE • 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 perfor- mance. • When refilling, be careful that water does not enter the brake master cylinder reser- voir and brake fluid reservoir.
Page 99: Adjusting The Rear Disc Brake
PERIODIC MAINTENANCE EAS21190 ECA5S71011 ADJUSTING THE REAR DISC BRAKE 1. Check: After adjusting the brake pedal adjusting • Brake pedal adjusting bolt position bolt position, make sure there is no brake Adjust the end of the brake pedal adjust- drag. ing bolt “a”...
Page 100 PERIODIC MAINTENANCE brake system, considerably lengthening the bleeding procedure. • If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared. 1.
Page 101: Checking The Front Brake Hose
PERIODIC MAINTENANCE 3. Check: Brake fluid reservoir bolt • Brake hose clamp 9 Nm (0.9 m·kgf, 6.5 ft·lbf) Loose → Tighten the clamp bolt. 4. Hold the vehicle upright and apply the EAS21280 brake several times. CHECKING THE FRONT BRAKE HOSE 5.
Page 102 90– concerning handling characteristics can be 190 kg (198–419 lb) given if a tire combination other than one Front approved by Yamaha is used on this vehi- 225 kPa (2.25 kgf/cm , 33 psi) cle. Rear 250 kPa (2.50 kgf/cm...
Page 103: Checking The Wheel Bearings
PERIODIC MAINTENANCE EWA5S71008 keep the drive belt slack within the speci- WARNING fied limits. New tires have a relatively low grip on the road surface until they have been slightly Measure the drive belt slack when the engine worn. Therefore, approximately 100 km (60 is cold, and when the drive belt is dry.
Page 104: Checking And Adjusting The Steering Head
PERIODIC MAINTENANCE 3. Remove: d. Tighten the locknuts to specification. • Muffler Locknut Refer to “ENGINE REMOVAL” on page 5- 16 Nm (1.6 m·kgf, 11 ft·lbf) 4. Adjust: e. Tighten the rear wheel axle nut to specifi- • Drive belt slack cation.
Page 105 PERIODIC MAINTENANCE Lower ring nut (initial tightening torque) 52 Nm (5.2 m·kgf, 37 ft·lbf) c. Loosen the lower ring nut completely and then tighten it to specification with a steer- ing nut wrench. EWA13140 WARNING Do not overtighten the lower ring nut. 3.
Page 106: Lubricating The Steering Bearings
PERIODIC MAINTENANCE EAS5S71029 LUBRICATING THE STEERING BEARINGS Lubricate the steering bearings. Recommended lubricant Lithium-soap-based grease EAS5S7102 CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are properly tightened. Refer to “CHASSIS TIGHTENING TORQUES” 2. Adjust: on page 2-18. •...
Page 107: Checking The Sidestand
PERIODIC MAINTENANCE EAS5S71034 EAS21530 CHECKING THE SIDESTAND CHECKING THE FRONT FORK 1. Stand the vehicle on a level surface. 1. Stand the vehicle on a level surface. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there Securely support the vehicle so that there is no danger of it falling over.
Page 108: Adjusting The Rear Shock Absorber Assembly
PERIODIC MAINTENANCE EAS21590 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload ECA13590 Never go beyond the maximum or minimum ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ adjustment positions. 3. Install: •...
Page 109: Changing The Engine Oil
PERIODIC MAINTENANCE 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check the engine oil level again. Before checking the engine oil level, wait a few minutes until the oil has settled. EAS20780 CHANGING THE ENGINE OIL 1.
Page 110 PERIODIC MAINTENANCE Engine oil quantity Total amount 4.30 L (4.55 US qt, 3.78 Imp.qt) Without filter cartridge replacement 3.70 L (3.91 US qt, 3.26 Imp.qt) With oil filter cartridge replace- ment 4.00 L (4.23 US qt, 3.52 Imp.qt) 9. Start the engine, warm it up for several b.
Page 111: Checking The Front And Rear Brake Light Switch
PERIODIC MAINTENANCE EAS21330 ADJUSTING THE REAR BRAKE LIGHT SWITCH The rear brake light switch is operated by movement of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.
Page 112 PERIODIC MAINTENANCE 2. Check: Throttle cable free play • Cable operation Rough movement → Lubricate or 4.0–6.0 mm (0.16–0.24 in) replace. 2. Remove: • Rider seat Recommended lubricant • Side cover (cylinder head) Engine oil or a suitable cable Refer to “GENERAL CHASSIS” on page lubricant 4-1.
Page 113 PERIODIC MAINTENANCE Direction “a” Direction “a” Throttle cable free play is increased. Headlight beam is raised. Direction “b” Direction “b” Throttle cable free play is decreased. Headlight beam is lowered. c. Tighten the locknut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4. Install: •...
Page 114 PERIODIC MAINTENANCE EWA13320 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 7. Install: • Headlight bulb Secure the new headlight bulb with the headlight bulb holder. ECA13690 2.
Page 115: Chassis
CHASSIS GENERAL CHASSIS..................4-1 FRONT WHEEL ....................4-9 REMOVING THE FRONT WHEEL ............4-11 DISASSEMBLING THE FRONT WHEEL ..........4-11 CHECKING THE FRONT WHEEL............4-11 ASSEMBLING THE FRONT WHEEL ...........4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE .......4-12 INSTALLING THE FRONT WHEEL (FRONT BRAKE DISC) ....4-13 REAR WHEEL ....................4-15 REMOVING THE REAR WHEEL (DISC) ..........4-19 DISASSEMBLING THE REAR WHEEL ..........4-19...
Page 116 HANDLEBAR....................4-44 REMOVING THE HANDLEBAR ............4-45 CHECKING THE HANDLEBAR............4-45 INSTALLING THE HANDLEBAR ............4-45 FRONT FORK .....................4-48 REMOVING THE FRONT FORK LEGS ..........4-51 DISASSEMBLING THE FRONT FORK LEGS ........4-51 CHECKING THE FRONT FORK LEGS..........4-52 ASSEMBLING THE FRONT FORK LEGS ...........4-52 INSTALLING THE FRONT FORK LEGS ..........4-54 STEERING HEAD..................4-56 REMOVING THE LOWER BRACKET ..........4-58 CHECKING THE STEERING HEAD ............4-58...
Page 118 GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the windshield (for XVS95CTY/XVS95CTYC) Order Job/Parts to remove Q’ty Remarks Turn signal light bracket cover Refer to “GENERAL CHASSIS” on page 4-1. Windshield Stay (left and right) Plate (left and right) Bracket (left and right) Front plate For installation, reverse the removal proce- dure.
Page 119 Sidebag (left and right) Polish the dry leather with a soft cloth, and then treat with Yamaha Mink Oil or another high-quality leather protectant for increased water resistance. Backrest...
Page 120 GENERAL CHASSIS Removing the rider seat and side cover Order Job/Parts to remove Q’ty Remarks Rider seat Passenger seat Right side cover Left side cover Seat lock cable assembly Disconnect. Key cylinder (seat lock) Meter coupler Disconnect. Seat lock bracket Side cover (cylinder head) For installation, reverse the removal proce- dure.
Page 121 GENERAL CHASSIS Removing the headlight Order Job/Parts to remove Q’ty Remarks Turn signal light bracket cover Headlight lens unit Headlight coupler Disconnect. Turn signal light coupler Disconnect. Wire harness clamp Disconnect. Headlight body For installation, reverse the removal proce- dure.
Page 122: General Chassis
GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Rider seat/Side cover Refer to “GENERAL CHASSIS” on page 4-1. Battery band Tool kit Negative battery lead Disconnect. Positive battery lead (battery) Disconnect. Battery ECU coupler Disconnect. ECU (engine control unit) Starter relay coupler Disconnect.
Page 123 GENERAL CHASSIS Removing the battery Order Job/Parts to remove Q’ty Remarks Lean angle sensor coupler Disconnect. Lean angle sensor For installation, reverse the removal proce- dure.
Page 124 GENERAL CHASSIS Removing the air filter case Order Job/Parts to remove Q’ty Remarks Air filter case cover Air filter element Air filter case Crankcase breather hose Disconnect. For installation, reverse the removal proce- dure.
Page 125 GENERAL CHASSIS Removing the rear fender Order Job/Parts to remove Q’ty Remarks Rider seat/Passenger seat/Seat lock bracket Refer to “GENERAL CHASSIS” on page 4-1. Tail/brake light wire harness coupler Disconnect. Rear fender bracket Passenger seat bracket Passenger seat guide Rear fender Mudguard (front) Rear turn signal light bracket cover Rear turn signal light coupler...
Page 126 FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake disc Order Job/Parts to remove Q’ty Remarks Place the vehicle on a suitable stand so that the front wheel is elevated. Reflector (left) Front brake caliper Front wheel axle pinch bolt Loosen.
Page 127: Front Wheel
FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-10...
Page 128: Removing The Front Wheel
FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Reflector (left) • Front brake caliper ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 129: Assembling The Front Wheel
FRONT WHEEL 4. Check: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Wheel bearings Front wheel turns roughly or is loose → EAS21970 ADJUSTING THE FRONT WHEEL STATIC Replace the wheel bearings. BALANCE • Oil seals Damage/wear → Replace. • After replacing the tire, wheel or both, the front wheel static balance should be adjusted.
Page 130: Installing The Front Wheel (Front Brake Disc)
FRONT WHEEL ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot. g. The spot where all the marks come to rest b.
Page 131 FRONT WHEEL Install the tire and wheel with the marks “1” pointing in the direction of wheel rotation. 5. Tighten: • Front wheel axle • Front wheel axle pinch bolts Front wheel axle 59 Nm (5.9 m·kgf, 43 ft·lbf) Front wheel axle pinch bolt 20 Nm (2.0 m·kgf, 14 ft·lbf) ECA3D81011 Before tightening the wheel axle, push...
Page 132: Rear Wheel
REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Place the vehicle on a suitable stand so that the rear wheel is elevated. Muffler Refer to “ENGINE REMOVAL” on page 5-1. Rear brake caliper Rear brake pad Brake pad spring Drive belt upper guard...
Page 133 REAR WHEEL Removing the rear wheel Order Job/Parts to remove Q’ty Remarks Rear brake caliper bracket Collar (right) Black Collar (left) Silver Rear wheel For installation, reverse the removal proce- dure. 4-16...
Page 134 REAR WHEEL Removing the rear brake disc and rear wheel drive hub Order Job/Parts to remove Q’ty Remarks Rear brake disc Rear wheel pulley Oil seal Circlip Rear wheel drive hub Circlip Bearing Collar Bearing Rear wheel drive hub damper Rear wheel For installation, reverse the removal proce- dure.
Page 135 REAR WHEEL Disassembling the rear wheel Order Job/Parts to remove Q’ty Remarks Collar Bearing Oil seal Circlip Bearing Spacer For assembly, reverse the disassembly pro- cedure. 4-18...
Page 136: Removing The Rear Wheel (Disc)
REAR WHEEL EAS28760 • Oil seals REMOVING THE REAR WHEEL (DISC) Refer to “CHECKING THE FRONT 1. Stand the vehicle on a level surface. WHEEL” on page 4-11. EWA13120 2. Check: WARNING • Tire Securely support the vehicle so that there •...
Page 137: Assembling The Rear Wheel
REAR WHEEL Rear wheel pulley self-locking Rear brake disc bolt 23 Nm (2.3 m·kgf, 17 ft·lbf) 95 Nm (9.5 m·kgf, 68 ft·lbf) LOCTITE® Tighten the self-locking nuts in stages and in a • Apply locking agent (LOCTITE®) to the crisscross pattern. threads of the brake disc bolts.
Page 138: Front Brake
FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Reflector (left) Refer to “GENERAL CHASSIS” on page 4-1. Front brake caliper retaining bolt Front brake caliper Front brake pad Front brake pad spring...
Page 139 FRONT BRAKE Removing the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. Right rear view mirror Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Brake lever...
Page 140 FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-23...
Page 141 FRONT BRAKE Removing the front brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. Reflector (left) Refer to “GENERAL CHASSIS” on page 4-1. Front brake hose union bolt Washer Front brake hose Front brake caliper bracket bolt...
Page 142 FRONT BRAKE Disassembling the front brake caliper Order Job/Parts to remove Q’ty Remarks Front brake caliper retaining bolt Brake pad spring Brake pad Brake pad support Brake caliper bracket Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure.
Page 143: Introduction
FRONT BRAKE EAS22220 INTRODUCTION Brake disc deflection limit EWA14100 0.15 mm (0.0059 in) WARNING ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Disc brake components rarely require dis- a. Place the vehicle on a suitable stand so assembly. Therefore, always follow these that the front wheel is elevated. preventive measures: b.
Page 144: Replacing The Front Brake Pads
FRONT BRAKE Always install new brake pads and a new brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose “1” tightly to the bleed screw “2”. Put the other end of the hose into an open container. d.
Page 145: Removing The Front Brake Caliper
FRONT BRAKE LOWER 6. Check: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Brake lever operation a. Blow compressed air into the brake hose Soft or spongy feeling → Bleed the brake joint opening “a” to force out the piston from system. the brake caliper. Refer to “BLEEDING THE HYDRAULIC EWA3D81009 WARNING BRAKE SYSTEM”...
Page 146: Assembling The Front Brake Caliper
FRONT BRAKE • Brake caliper cylinders “2” EAS22440 INSTALLING THE FRONT BRAKE CALIPER Scratches/wear → Replace the brake cal- 1. Install: iper assembly. • Front brake caliper “1” • Brake caliper body “3” (temporarily) Cracks/damage → Replace the brake • Washers caliper assembly.
Page 147: Removing The Front Brake Master Cylinder
FRONT BRAKE EAS22490 REMOVING THE FRONT BRAKE MASTER Recommended fluid CYLINDER DOT 4 EWA3D81010 Before removing the front brake master cylin- WARNING der, drain the brake fluid from the entire brake • Use only the designated brake fluid. system. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and 1.
Page 148: Assembling The Front Brake Master Cylinder
FRONT BRAKE EAS22520 EWA13530 ASSEMBLING THE FRONT BRAKE MAS- WARNING TER CYLINDER Proper brake hose routing is essential to EWA13520 insure safe vehicle operation. Refer to WARNING “CABLE ROUTING” on page 2-35. • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid.
Page 149 FRONT BRAKE ECA13540 Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. 5. Check: • Brake fluid level Below the minimum level mark “a”...
Page 150: Rear Brake
REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt Rear brake caliper Rear brake pad Brake pad spring For installation, reverse the removal proce- dure. 4-33...
Page 151 REAR BRAKE Removing the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. Brake fluid reservoir cap cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose...
Page 152 REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake hose joint Bush Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-35...
Page 153 REAR BRAKE Removing the rear brake caliper Order Job/Parts to remove Q’ty Remarks Drain. Brake fluid Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. Rear brake hose union bolt Copper washer Rear brake hose Rear brake caliper retaining bolt Rear brake caliper For installation, reverse the removal proce- dure.
Page 154 REAR BRAKE Disassembling the rear brake caliper Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw For assembly, reverse the disassembly pro- cedure. 4-37...
Page 155: Introduction
REAR BRAKE EAS22560 4. Measure: INTRODUCTION • Brake disc thickness EWA14100 Measure the brake disc thickness at a WARNING few different locations. Disc brake components rarely require dis- Out of specification → Replace. assembly. Therefore, always follow these Refer to “CHECKING THE FRONT preventive measures: BRAKE DISC”...
Page 156: Removing The Rear Brake Caliper
REAR BRAKE 2. Install: 5. Check: • Brake pads • Brake pedal operation • Brake pad springs Soft or spongy feeling → Bleed the brake system. Always install new brake pads and brake pad Refer to “BLEEDING THE HYDRAULIC springs as a set. BRAKE SYSTEM”...
Page 157: Checking The Rear Brake Caliper
REAR BRAKE EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • Never try to pry out the brake caliper pis- ton. EAS22650 ASSEMBLING THE REAR BRAKE CALIPER EWA3D84004...
Page 158: Removing The Rear Brake Master Cylinder
REAR BRAKE 5. Bleed: • Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-14. 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 2.
Page 159: Checking The Rear Brake Master Cylinder
REAR BRAKE Rear brake hose union bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) EWA13530 WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” on page 2-35. ECA3D81005 When installing the brake hose onto the EAS22720 CHECKING THE REAR BRAKE MASTER brake master cylinder, make sure the brake...
Page 160 REAR BRAKE ECA13540 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” on page 3-14. 4. Check: • Brake fluid level Below the minimum level mark “a”...
Page 161 HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Rear view mirror (right)/Front brake master cylin- Refer to “FRONT BRAKE” on page 4-21. Rear view mirror (left) Plastic clamp Right handlebar switch Throttle cable Disconnect. Grip end Throttle grip Clutch switch coupler Disconnect.
Page 162: Handlebar
HANDLEBAR EAS22860 • Turn the handlebar all the way to the left REMOVING THE HANDLEBAR and right. If there is any contact with the 1. Stand the vehicle on a level surface. fuel tank, adjust the handlebar position. EWA13120 WARNING Align the end of the upper handlebar holder Securely support the vehicle so that there with the punch mark “a”...
Page 163 HANDLEBAR 7. Install: 5. Install: • Right handlebar switch “1” • Handlebar grip “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Align the projection “a” on the right handlebar a. Apply a thin coat of rubber adhesive onto switch with the hole “b” in the handlebar. the left end of the handlebar.
Page 164 HANDLEBAR 10. Adjust: • Throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” on page 3-27. Throttle cable free play 4.0–6.0 mm (0.16–0.24 in) 4-47...
Page 165: Front Fork
FRONT FORK EAS22950 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. For XVS95CTY/XVS95CTYC only Windshield bracket (left and right) Refer to “GENERAL CHASSIS” on page 4-1. Headlight body Refer to “GENERAL CHASSIS”...
Page 166 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Upper front fork cover Upper front fork cover spacer Cable bracket Lower front fork cover bolt Lower bracket pinch bolt Loosen. Lower front fork cover Front fork leg For installation, reverse the removal proce- dure.
Page 167 FRONT FORK Disassembling the front fork legs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Spring seat Fork spring Dust seal Oil seal clip Damper rod bolt Copper washer Damper rod Inner tube...
Page 168: Removing The Front Fork Legs
FRONT FORK EAS22960 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 3.
Page 169: Checking The Front Fork Legs
• Oil flow stopper Damage → Replace. 2. Lubricate: • Inner tube’s outer surface ECA14200 Recommended oil • The front fork leg has a built-in damper Yamaha fork oil 10WT adjusting rod and a very sophisticated 4-52...
Page 170 FRONT FORK 3. Install: • Inner tube (in the outer tube) 4. Install: • Copper washer • Damper rod bolt 5. Tighten: • Damper rod bolt “1” Damper rod bolt 30 Nm (3.0 m·kgf, 22 ft·lbf) 7. Install: LOCTITE® • Oil seal “1” (with the fork seal driver “2”) ECA14220 While holding the damper rod assembly with...
Page 171: Installing The Front Fork Legs
Make sure the inner tube end is flush with the Imp oz) top of the upper bracket. Recommended oil Yamaha fork oil 10WT 11. Measure: • Front fork leg oil level “a” (from the top of the inner tube, with the...
Page 172 FRONT FORK 2. Tighten: • Lower bracket pinch bolts Lower bracket pinch bolt 45 Nm (4.5 m·kgf, 32 ft·lbf) 3. Remove: • Upper bracket 4. Tighten: • Lower front fork cover bolts Lower front fork cover bolt 18 Nm (1.8 m·kgf, 13 ft·lbf) 5.
Page 173: Steering Head
STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Upper bracket/Front fork legs Refer to “FRONT FORK” on page 4-48. Front turn signal light Air temperature sensor coupler Disconnect. Front turn signal light bracket Air temperature sensor Front brake hose holder Front brake hose joint...
Page 174 STEERING HEAD Removing the lower bracket Order Job/Parts to remove Q’ty Remarks Bearing outer race For installation, reverse the removal proce- dure. 4-57...
Page 175: Removing The Lower Bracket
STEERING HEAD EAS23110 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ REMOVING THE LOWER BRACKET a. Remove the bearing races from the steer- 1. Stand the vehicle on a level surface. ing head pipe with a long rod “1” and ham- EWA13120 mer. WARNING b. Remove the bearing race from the lower Securely support the vehicle so that there bracket with a floor chisel “2”...
Page 176 STEERING HEAD Recommended lubricant Lithium-soap-based grease 2. Install: • Lower ring nut “1” • Rubber washer “2” • Upper ring nut “3” • Lock washer “4” Refer to “CHECKING AND ADJUSTING THE STEERING HEAD” on page 3-19. 3. Install: • Front brake hose joint “1” •...
Page 177: Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly Order Job/Parts to remove Q’ty Remarks Battery box Refer to “GENERAL CHASSIS” on page 4-1. Muffler Refer to “ENGINE REMOVAL” on page 5-1. Rear wheel Refer to “REAR WHEEL”...
Page 178: Handling The Rear Shock Absorber
REAR SHOCK ABSORBER ASSEMBLY EAS23180 EWA13120 HANDLING THE REAR SHOCK ABSORBER WARNING EWA13740 Securely support the vehicle so that there WARNING is no danger of it falling over. This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make Place the vehicle on a suitable stand so that sure you understand the following informa- the rear wheel is elevated.
Page 179: Checking The Rear Shock Absorber Assembly
REAR SHOCK ABSORBER ASSEMBLY EAS23240 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: • Rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • Rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •...
Page 180 REAR SHOCK ABSORBER ASSEMBLY 4. Tighten: • Rear shock absorber assembly upper nut Rear shock absorber assembly upper nut 48 Nm (4.8 m·kgf, 35 ft·lbf) • Rear shock absorber assembly lower nut Rear shock absorber assembly lower nut 48 Nm (4.8 m·kgf, 35 ft·lbf) 5.
Page 181: Swingarm
SWINGARM EAS23330 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Drive belt puller/Drive belt upper guard Refer to “REAR WHEEL” on page 4-15. Refer to “REAR SHOCK ABSORBER Connecting arms ASSEMBLY” on page 4-60. Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-1. Drive belt lower guard Right side cover (lower) Pivot shaft nut cover...
Page 182: Removing The Swingarm
SWINGARM EAS23350 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on a suitable stand so that the rear wheel is elevated. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲...
Page 183: Installing The Swingarm
SWINGARM 6. Check: • Spacer Damage/scratches → Replace. EAS28780 INSTALLING THE SWINGARM 1. Lubricate: • Bearings • Spacers • Dust covers • Pivot shaft Recommended lubricant Lithium-soap-based grease 2. Install: • Bearings “1” 2. Swingarm A. Left side B. Right side Installed depth “a”...
Page 184: Belt Drive
BELT DRIVE EAS23510 BELT DRIVE Removing the drive belt Order Job/Parts to remove Q’ty Remarks Rear wheel Refer to “REAR WHEEL” on page 4-15. Swingarm Refer to “SWINGARM” on page 4-64. Refer to “REAR SHOCK ABSORBER Rear shock absorber ASSEMBLY” on page 4-60. Air duct Drive pulley cover Drive belt...
Page 185: Removing The Drive Belt And Drive Pulley
BELT DRIVE EAS23520 REMOVING THE DRIVE BELT AND DRIVE PULLEY Loosen the drive pulley nut before removing the rear wheel. 1. Loosen: • Drive pulley nut When loosening the drive pulley nut, press 3. Check: down on the brake pedal so the drive pulley •...
Page 186 BELT DRIVE • When tightening the drive pulley nut, press down on the brake pedal so the drive pulley does not move. 5. Adjust: • Drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK” on page 3-18. 4-69...
Page 187: Engine
ENGINE ENGINE REMOVAL ..................5-1 INSTALLING THE EXHAUST PIPE AND MUFFLER......5-2 INSTALLING THE CYLINDER COVERS ..........5-5 INSTALLING THE SHIFT ARM...............5-5 INSTALLING THE ENGINE ..............5-9 CAMSHAFTS....................5-11 REMOVING THE CAMSHAFTS AND ROCKER ARMS.......5-13 CHECKING THE CAMSHAFTS ............5-14 CHECKING THE CAMSHAFT SPROCKETS........5-15 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ..5-15 CHECKING THE TIMING CHAIN TENSIONERS.........5-16 INSTALLING THE ROCKER ARMS AND CAMSHAFTS......5-16 INSTALLING THE CYLINDER HEAD COVERS ........5-19...
Page 188 CHECKING THE CLUTCH PLATES.............5-49 CHECKING THE CLUTCH SPRING PLATE ........5-49 CHECKING THE CLUTCH HOUSING ..........5-49 CHECKING THE CLUTCH BOSS ............5-49 CHECKING THE PRESSURE PLATE ..........5-50 CHECKING THE PRIMARY DRIVE GEAR ..........5-50 CHECKING THE PRIMARY DRIVEN GEAR........5-50 CHECKING THE PULL LEVER SHAFT AND PULL ROD....5-50 CHECKING THE OIL PUMP DRIVE SPROCKET AND OIL PUMP DRIVE CHAIN ..............5-50 INSTALLING THE PRIMARY DRIVE GEAR.........5-50...
Page 189 INSTALLING THE SHIFT FORKS AND SHIFT DRUM ASSEMBLY..5-77...
Page 190: Engine Removal
ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the muffler and exhaust pipe Order Job/Parts to remove Q’ty Remarks Right footrest Refer to “REAR BRAKE” on page 4-33. sensor coupler Disconnect. Muffler Clamp Gasket Exhaust pipe stay Exhaust pipe Silencer plate Gasket Clamp Exhaust pipe protector 1 Exhaust pipe protector 3...
Page 191: Installing The Exhaust Pipe And Muffler
ENGINE REMOVAL EAS5S71005 INSTALLING THE EXHAUST PIPE AND MUFFLER 1. Install: • Exhaust pipe cover clamp screws Exhaust pipe cover clamp screw 5 Nm (0.5 m·kgf, 3.6 ft·lbf) Do not retighten the exhaust pipe cover clamp screws; always replace them with new ones if they are loosened.
Page 192 ENGINE REMOVAL Removing the sidestand and drive pulley housing Order Job/Parts to remove Q’ty Remarks Drive belt Refer to “BELT DRIVE” on page 4-67. Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Refer to “FUEL TANK”...
Page 193 ENGINE REMOVAL Removing the sidestand and drive pulley housing Order Job/Parts to remove Q’ty Remarks Drive pulley housing Damper Dowel pin For installation, reverse the removal proce- dure.
Page 194: Installing The Cylinder Covers
ENGINE REMOVAL EAS5S71006 INSTALLING THE CYLINDER COVERS 1. Install: • Front cylinder lower plastic cover “1” • Front cylinder upper plastic cover “2” • Rear cylinder left plastic cover bracket “3” • Rear cylinder right plastic cover bracket “4” • Rear cylinder left plastic cover “5” •...
Page 195 ENGINE REMOVAL Disconnecting the leads and hoses Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Intake manifold assembly Refer to “THROTTLE BODIES”...
Page 196 ENGINE REMOVAL Removing the down tube and engine Order Job/Parts to remove Q’ty Remarks Rear brake hose bracket Refer to “REAR BRAKE” on page 4-33. Engine oil Drain. Rectifier/regulator bracket Engine mounting nut (front lower side) Engine mounting bolt (front lower side) Down tube bolt (front side) Down tube bolt (rear side) Down tube...
Page 197 ENGINE REMOVAL Removing the down tube and engine Order Job/Parts to remove Q’ty Remarks For installation, reverse the removal proce- dure.
Page 198: Installing The Engine
ENGINE REMOVAL EAS23720 2. Tighten: INSTALLING THE ENGINE • Engine bracket bolts (front upper side) “3” 1. Install: • Engine bracket bolts (rear lower side) “7” • Engine “1” • Engine bracket bolts (rear upper side) “9” • Engine bracket (front upper side) “2” •...
Page 199 ENGINE REMOVAL Engine mounting nut (front upper side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (rear lower side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (rear upper side) 88 Nm (8.8 m·kgf, 64 ft·lbf) Engine mounting nut (front lower side) 88 Nm (8.8 m·kgf, 64 ft·lbf) 5-10...
Page 200: Camshafts
CAMSHAFTS EAS23740 CAMSHAFTS Removing the cylinder head covers Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Tappet cover O-ring Front cylinder side cover Front cylinder side cover gasket Rear cylinder side cover Rear cylinder side cover gasket For installation, reverse the removal proce- dure.
Page 201 CAMSHAFTS Removing the camshafts and rocker arms Order Job/Parts to remove Q’ty Remarks Spark plug Locknut Valve clearance adjusting screw Timing chain tensioner Timing chain tensioner gasket Camshaft bolt Camshaft sprocket Camshaft retainer Front cylinder camshaft Rear cylinder camshaft Intake rocker arm shaft Intake rocker arm Exhaust rocker arm shaft Exhaust rocker arm...
Page 202: Removing The Camshafts And Rocker Arms
CAMSHAFTS EAS5S71008 REMOVING THE CAMSHAFTS AND ROCKER ARMS 1. Align: • “I” mark on the front cylinder camshaft sprocket (with the arrow mark on the front cylinder head) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Front cylinder a. Turn the crankshaft counterclockwise. 3. Remove: b. When the front cylinder piston is at TDC on •...
Page 203: Checking The Camshafts
CAMSHAFTS Slide hammer bolt 90890-01083 Slide hammer bolt 6 mm YU-01083-1 Weight 90890-01084 YU-01083-3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Remove: • Rear cylinder timing chain tensioner • Rear cylinder camshaft sprocket • Camshaft retainer • Rear cylinder camshaft • Intake rocker arm shaft •...
Page 204: Checking The Camshaft Sprockets
CAMSHAFTS Camshaft lobe dimensions Intake A 42.470–42.570 mm (1.6720– 1.6760 in) Limit 42.370 mm (1.6681 in) Intake B 37.041–37.141 mm (1.4583– 1.4622 in) Limit a. 1/4 tooth 36.941 mm (1.4544 in) b. Correct Exhaust A 42.138–42.238 mm (1.6590– 1. Timing chain roller 1.6629 in) 2.
Page 205: Checking The Timing Chain Tensioners
CAMSHAFTS Rocker arm shaft outside diam- eter 11.981–11.991 mm (0.4717– 0.4721 in) EAS24040 INSTALLING THE ROCKER ARMS AND CAMSHAFTS The following procedure applies to all of the rocker arms and camshafts. 5. Calculate: 1. Lubricate: • Rocker-arm-to-rocker-arm-shaft clear- • Rocker arm shafts ance Recommended lubricant Engine oil...
Page 206 CAMSHAFTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ While holding the camshaft sprocket with the Front cylinder rotor holding tool “2”, tighten the camshaft a. Turn the crankshaft counterclockwise. sprocket bolt. b. When the front cylinder piston is at TDC on the compression stroke, align the TDC Rotor holding tool mark “a”...
Page 207 CAMSHAFTS ECA13740 Do not turn the crankshaft when installing the camshaft(s) to avoid damage or improper valve timing. • To position the rear cylinder piston at TDC on the compression stroke, align the “I” mark “c” on the camshaft sprocket with the arrow mark “d”...
Page 208: Installing The Cylinder Head Covers
CAMSHAFTS 13. Measure: • Valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” on page 3-5. EAS5S71009 INSTALLING THE CYLINDER HEAD COV- 1. Install: • Rear cylinder side cover • Tappet covers 11. Install: • Rear cylinder timing chain tensioner gas- Rear cylinder side cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) ket “1”...
Page 209: Cylinder Heads
CYLINDER HEADS EAS24110 CYLINDER HEADS Removing the cylinder heads Order Job/Parts to remove Q’ty Remarks Oil check bolt Engine temperature sensor Cylinder head nut Cylinder head bolt Front cylinder head Rear cylinder head Dowel pin Cylinder head gasket Timing chain guide (exhaust side) Timing chain guide (intake side) Rear exhaust pipe joint cover Rear exhaust pipe joint...
Page 210: Removing The Cylinder Heads
CYLINDER HEADS EAS24150 REMOVING THE CYLINDER HEADS 1. Remove: • Cylinder head bolts • Cylinder head nuts • Loosen the cylinder head nuts in the proper sequence as shown. • Loosen each cylinder head nut 1/2 of a turn at a time. After all of the cylinder head nut 2.
Page 211: Measuring The Compression Pressure
CYLINDER HEADS Cylinder head nut Tighten the rear exhaust pipe joint nuts, and 1st: 15 Nm (1.5 m·kgf, 11 ft·lbf) then install the rear exhaust pipe joint cover 2st: 25 Nm (2.5 m·kgf, 18 ft·lbf) and bolts. Final: 65 Nm (6.5 m·kgf, 47 ft·lbf) Cylinder head bolt EAS20710...
Page 212 CYLINDER HEADS Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without Piston ring(s) wear or damage → Replace. Piston, valves or cyl- inder head gasket Same as without oil possibly defective → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Measure: 8.
Page 213 VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks The following procedure applies to both cyl- inders. Cylinder heads Refer to “CYLINDER HEADS” on page 5-20. Valve cotter Upper spring seat Valve spring Intake valve...
Page 214: Valves And Valve Springs
VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES The following procedure applies to all of the valves and related components. Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, and valve seats), make sure the valves properly seal. 1.
Page 215 VALVES AND VALVE SPRINGS Valve-stem-to-valve-guide clear- ance (intake) 0.010–0.037 (0.0004– 0.0015 in) Limit 0.080 mm (0.0032 in) Valve-stem-to-valve-guide clear- ance (exhaust) 0.025–0.052 (0.0010– 0.0020 in) Limit b. Install the new valve guide with the valve 0.100 mm (0.0039 in) guide installer “2” and valve guide remover “1”.
Page 216: Checking The Valve Seats
VALVES AND VALVE SPRINGS • If the valve is removed or replaced, always Valve guide remover (ø6) replace the valve stem seal. 90890-04064 Valve guide remover (6.0 mm) Valve stem runout YM-04064-A 0.010 mm (0.0004 in) Valve guide installer (ø6) 90890-04065 Valve guide installer (6.0 mm) YM-04065-A...
Page 217 VALVES AND VALVE SPRINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing dye (Dykem) “b” onto the valve face. c. Install the valve into the cylinder head. d. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound.
Page 218: Checking The Valve Springs
VALVES AND VALVE SPRINGS Measure the valve seat width “c” again. If Installed compression spring the valve seat width is out of specification, force (intake) reface and lap the valve seat. 171–197 N (17.44–20.09 kgf, 38.45–44.30 lbf) Installed compression spring force (exhaust) 171–197 N (17.44–20.09 kgf, 38.45–44.30 lbf)
Page 219 VALVES AND VALVE SPRINGS 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 3. Lubricate: • Valve stem end (with the recommended lubricant) a. Larger pitch b. Smaller pitch Recommended lubricant Engine oil 5.
Page 220 VALVES AND VALVE SPRINGS 6. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer. ECA13800 Hitting the valve tip with excessive force could damage the valve. 5-31...
Page 221 CYLINDERS AND PISTONS EAS24360 CYLINDERS AND PISTONS Removing the cylinders and pistons Order Job/Parts to remove Q’ty Remarks Cylinder heads Refer to “CYLINDER HEADS” on page 5-20. Front cylinder Rear cylinder Front cylinder gasket Rear cylinder gasket Dowel pin Circlip Piston pin Piston Top ring...
Page 222: Cylinders And Pistons
CYLINDERS AND PISTONS EAS24380 REMOVING THE PISTONS When removing a piston ring, open the end The following procedure applies to all of the gap with your fingers and lift the other side of pistons. the ring over the piston crown. 1.
Page 223: Checking The Piston Rings
CYLINDERS AND PISTONS Bore = maximum of D –D • Piston-to-cylinder clearance = Cylinder bore “C” - Wear limit = maximum of D or D Piston skirt diameter “D” Out of round limit = maximum of D or D minimum of D or D Piston-to-cylinder clearance 0.030–0.055...
Page 224: Checking The Piston Pins
CYLINDERS AND PISTONS 2. Install: EAS24440 CHECKING THE PISTON PINS • Piston ring The following procedure applies to all of the (into the cylinder) piston pins. 1. Check: Level the piston ring in the cylinder with the • Piston pin piston crown.
Page 225: Installing The Pistons And Cylinders
CYLINDERS AND PISTONS • Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter “b” - Piston pin outside diameter “a” Piston-pin-to-piston-pin-bore clearance 0.004–0.024 (0.00016– 0.00094 in) EAS24460 INSTALLING THE PISTONS AND CYLIN- DERS The following procedure applies to all of the pistons and cylinders. 1.
Page 226 CYLINDERS AND PISTONS 5. Install: • Rear cylinder gasket “1” • Front cylinder gasket “2” A. Intake side B. Exhaust side 6. Install: • Cylinder “1” • While compressing the piston rings with one hand, install the cylinder with the other hand. •...
Page 227 GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the stator coil Order Job/Parts to remove Q’ty Remarks Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. Side stand Refer to “ENGINE REMOVAL” on page 5-1. Left footrest assembly Refer to “ENGINE REMOVAL”...
Page 228: Generator And Starter Clutch
GENERATOR AND STARTER CLUTCH Removing the stator coil Order Job/Parts to remove Q’ty Remarks Crankshaft position sensor Stator coil For installation, reverse the removal proce- dure. 5-39...
Page 229 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch Order Job/Parts to remove Q’ty Remarks Generator rotor Starter clutch Woodruff key Starter clutch gear Starter clutch idle gear 2 shaft Starter clutch idle gear 2 Starter clutch idle gear 1 shaft Starter clutch idle gear 1 For installation, reverse the removal proce- dure.
Page 230: Removing The Generator
GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator rotor bolt “1” • Washer • Starter clutch bolts “2” • While holding the generator rotor “3” with the sheave holder “4”, loosen the generator rotor bolt. • Do not allow the sheave holder to touch the EAS24560 projection on the generator rotor.
Page 231: Installing The Starter Clutch
While holding the generator rotor “1” with the sheave holder “2”, tighten the starter clutch bolts. Sheave holder 90890-01701 3. Apply: Primary clutch holder • Sealant YS-01880-A (onto the crankshaft position sensor lead grommet) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) 5-42...
Page 232: Installing The Generator Cover
GENERATOR AND STARTER CLUTCH EAS5S71011 INSTALLING THE GENERATOR COVER 1. Install: Generator cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Temporally tighten “a” and “b” and then tighten the generator cover bolts in the order shown in the illustration. 5-43...
Page 233: Clutch
CLUTCH EAS25060 CLUTCH Removing the primary drive gear Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Rear brake master cylinder Refer to “REAR BRAKE” on page 4-33. Rear brake light switch Refer to “REAR BRAKE” on page 4-33. Right footrest assembly Refer to “REAR BRAKE”...
Page 234 CLUTCH Removing the primary drive gear Order Job/Parts to remove Q’ty Remarks Primary drive gear nut Lock washer Spacer Primary drive gear Woodruff key For installation, reverse the removal proce- dure. 5-45...
Page 235 CLUTCH Removing the pull lever shaft Order Job/Parts to remove Q’ty Remarks Circlip Pull lever shaft Oil seal Bearing Bearing Oil seal retainer Oil seal For installation, reverse the removal proce- dure. 5-46...
Page 236 CLUTCH Removing the clutch Order Job/Parts to remove Q’ty Remarks Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Bearing Friction plate 1 Inside diameter: 124 mm (4.88 in) Clutch plate Friction plate 2 Inside diameter: 124 mm (4.88 in) Clutch boss nut Conical spring washer...
Page 237: Removing The Clutch
CLUTCH EAS25080 REMOVING THE CLUTCH 1. 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 90890-04086 YM-91042 EAS25100 CHECKING THE FRICTION PLATES 2.
Page 238: Checking The Clutch Plates
CLUTCH EAS25130 CHECKING THE CLUTCH SPRING PLATE 1. Check: • Clutch spring plate Damage → Replace. 2. Check: • Clutch spring plate seat Damage → Replace. EAS25150 CHECKING THE CLUTCH HOUSING 1. Check: • Clutch housing dogs Damage/pitting/wear → Deburr the clutch housing dogs or replace the clutch hous- ing.
Page 239: Checking The Pressure Plate
CLUTCH EAS25170 EAS5S71001 CHECKING THE PRESSURE PLATE CHECKING THE OIL PUMP DRIVE 1. Check: SPROCKET AND OIL PUMP DRIVE CHAIN • Pressure plate 1. Check: Cracks/damage → Replace. • Oil pump drive sprocket Cracks/damage/wear → Replace the oil • Bearing Damage/wear →...
Page 240: Installing The Clutch
CLUTCH 2. Bend lock washer tab along a flat side of the nut. EAS25240 INSTALLING THE CLUTCH 1. Install: • Oil pump drive sprocket “1” • Oil pump drive chain “2” Install the oil pump drive sprocket with its pro- 3.
Page 241 CLUTCH 7. Install: • Primary drive gear cover Primary drive gear cover bolt 10 Nm (1.0 m·kgf, 7.2 ft·lbf) Temporally tighten “a” and “b” and then tighten the primary drive gear cover bolts in the order shown in the illustration. 4.
Page 242: Shift Shaft
SHIFT SHAFT EAS25410 SHIFT SHAFT Removing the shift shaft and stopper lever Order Job/Parts to remove Q’ty Remarks Drive pulley cover Refer to “BELT DRIVE” on page 4-67. Shift arm Refer to “ENGINE REMOVAL” on page 5-1. Primary drive gear cover Refer to “CLUTCH”...
Page 243: Checking The Shift Shaft
SHIFT SHAFT EAS25420 CHECKING THE SHIFT SHAFT 1. Check: • Shift shaft Bends/damage/wear → Replace. • Shift shaft spring Damage/wear → Replace. EAS25430 CHECKING THE STOPPER LEVER 1. Check: • Stopper lever Bends/damage → Replace. Roller turns roughly → Replace the stop- per lever.
Page 244: Electric Starter
ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor Order Job/Parts to remove Q’ty Remarks Starter motor lead Disconnect. Starter motor For installation, reverse the removal proce- dure. 5-55...
Page 245 ELECTRIC STARTER Disassembling the starter motor Order Job/Parts to remove Q’ty Remarks O-ring Starter motor front cover Armature assembly Starter motor yoke Gasket Starter motor rear cover Brush set assembly O-ring For assembly, reverse the disassembly pro- cedure. 5-56...
Page 246: Checking The Starter Motor
ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator.
Page 247: Assembling The Starter Motor
ELECTRIC STARTER 6. Check: • Gear teeth Damage/wear → Replace the starter motor. 7. Check: • Bearing Damage/wear → Replace the starter motor. EAS24800 ASSEMBLING THE STARTER MOTOR 1. Install: • Brush set assembly 2. Install: • Starter motor yoke “1” •...
Page 248: Crankcase
CRANKCASE EAS25540 CRANKCASE Removing the oil delivery pipes and timing chains Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Refer to “CYLINDERS AND PISTONS” on Piston page 5-32. Clutch Refer to “CLUTCH” on page 5-44. Primary drive gear Refer to “CLUTCH”...
Page 249 CRANKCASE Separating the crankcase Order Job/Parts to remove Q’ty Remarks Oil baffle plate 1 Left crankcase Dowel pin Joint pipe O-ring Oil baffle plate 2 Gasket Right crankcase Stud bolt l = 239 mm (9.41 in) Stud bolt l = 210 mm (8.27 in) For installation, reverse the removal proce- dure.
Page 250 CRANKCASE Removing the oil seal and bearings Order Job/Parts to remove Q’ty Remarks Oil pump assembly Refer to “OIL PUMP” on page 5-65. Crankshaft Refer to “CRANKSHAFT” on page 5-68. Transmission Refer to “TRANSMISSION” on page 5-73. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.
Page 251: Disassembling The Crankcase
CRANKCASE EAS25560 3. Check: DISASSEMBLING THE CRANKCASE • Crankcase 1. Remove: Cracks/damage → Replace. • Crankcase bolts • Oil delivery passages Obstruction → Blow out with compressed Loosen each bolt 1/4 of a turn at a time, in air. stages and in a crisscross pattern. After all of EAS3D81029 the bolts are fully loosened, remove them.
Page 252: Assembling The Crankcase
1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. 2. Apply: • Sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 (Three bond No.1215®) • M6 × 120 mm bolts: “a” Do not allow any sealant to come into contact •...
Page 253 CRANKCASE 5. Apply: • Engine oil (onto the crankshaft pin bearings and oil delivery holes) 6. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-64...
Page 254: Oil Pump
OIL PUMP EAS24910 OIL PUMP Removing the oil pump assembly Order Job/Parts to remove Q’ty Remarks Crankcase Refer to “CRANKCASE” on page 5-59. Relief valve assembly Oil pump assembly Dowel pin Oil pump housing Dowel pin Impeller shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing cover Bearing...
Page 255: Checking The Oil Pump
OIL PUMP EAS24960 CHECKING THE OIL PUMP 1. Check: • Oil pump housing Cracks/damage/wear → Replace the oil pump assembly. 2. Measure: • Inner-rotor-to-outer-rotor-tip clearance “a” • Outer-rotor-to-oil-pump-housing clear- ance “b” • Oil-pump-housing-to-inner-rotor-and- outer-rotor clearance “c” Out of specification → Replace the oil pump assembly.
Page 256: Checking The Oil Strainer
OIL PUMP 3. Check: EAS24990 CHECKING THE OIL STRAINER • Oil pump operation 1. Check: Refer to “CHECKING THE OIL PUMP” on • Oil strainer “1” page 5-66. Damage → Replace. Contaminants → Clean with solvent. EAS5S71004 INSTALLING THE OIL PUMP ASSEMBLY 1.
Page 257: Crankshaft
CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-59. Crankshaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal proce- dure.
Page 258: Removing The Connecting Rods
CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS clearance (using plasti- 1. Remove: gauge®) • Connecting rod caps “1” 0.022–0.046 (0.0009– • Connecting rods 0.0018 in) • Big end bearings The following procedure applies to all of the connecting rods. Identify the position of each big end bearing so ECA13930 that it can be reinstalled in its original place.
Page 259 CRANKSHAFT • Do not move the connecting rod or crank- • The numbers “a” on the connecting rods are shaft until the clearance measurement has used to determine the replacement big end been completed. bearing sizes. • Lubricate the bolts threads and nut seats •...
Page 260: Installing The Connecting Rods
CRANKSHAFT EAS26150 INSTALLING THE CONNECTING RODS 1. Lubricate: • Bolt threads (with the recommended lubricant) Recommended lubricant Molybdenum disulfide grease 2. Lubricate: • Crankshaft pin 6. Measure: • Big end bearings • Crankshaft journal bearing inside diame- • Connecting rod inner surface ter “a”...
Page 261: Installing The Crankshaft Assembly
CRANKSHAFT EWA5S71003 4. Tighten: WARNING • Connecting rod bolts When a bolt is tightened more than the ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ specified angle, do not loosen and then EWA5S71002 retighten it. WARNING Replace the bolt with a new one and per- • Replace the connecting rod bolts with form the procedure again.
Page 262: Transmission
TRANSMISSION EAS26240 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-59. Long shift fork guide bar Short shift fork guide bar Shift drum assembly Shift fork 1 Shift fork 2 Main axle assembly Drive axle assembly...
Page 263 TRANSMISSION Disassembling the main axle assembly Order Job/Parts to remove Q’ty Remarks Circlip 2nd pinion gear Toothed lock washer Toothed lock washer retainer 4th pinion gear Collar Toothed washer Circlip 3rd pinion gear Circlip Toothed washer 5th pinion gear Collar Main axle/1st pinion gear For assembly, reverse the disassembly pro- cedure.
Page 264 TRANSMISSION Disassembling the drive axle assembly Order Job/Parts to remove Q’ty Remarks Washer 1st wheel gear Collar 5th wheel gear Circlip Toothed washer 3rd wheel gear Collar Toothed lock washer Toothed lock washer retainer 4th wheel gear Circlip Toothed washer 2nd wheel gear Collar Drive axle...
Page 265: Checking The Shift Forks
TRANSMISSION EAS26260 EAS26270 CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM ASSEMBLY The following procedure applies to all of the 1. Check: shift forks and shift fork guide bars. • Shift drum grooves Damage/scratches/wear → Replace the 1. Check: • Shift fork cam follower “1” shift drum assembly.
Page 266: Assembling The Main Axle And Drive Axle
TRANSMISSION 3. Check: 2. Install: • Transmission gears • Toothed lock washer retainer “1” Blue discoloration/pitting/wear → • Toothed lock washer “2” Replace the defective gear(s). • Transmission gear dogs • With the toothed lock washer retainer in the Cracks/damage/rounded edges → groove “a”...
Page 267 TRANSMISSION 2. Check: • Transmission Rough movement → Repair. • Apply molybdenum disulfide grease to each gear and bearing thoroughly. • Before assembling the crankcase, make sure that the transmission is in neutral and that the gears turn freely. 5-78...
Page 268 TRANSMISSION 5-79...
Page 269: Fuel System
FUEL SYSTEM FUEL TANK ....................6-1 REMOVING THE FUEL TANK ..............6-4 REMOVING THE FUEL PUMP...............6-4 CHECKING THE FUEL PUMP BODY ............6-4 CHECKING THE ROLLOVER VALVE ............6-4 INSTALLING THE FUEL PUMP..............6-4 THROTTLE BODIES..................6-6 CHECKING THE INJECTORS ...............6-9 INSTALLING THE INJECTORS ..............6-9 CHECKING THE INJECTOR PRESSURE ..........6-9 CHECKING THE THROTTLE BODIES ..........6-10 CHECKING AND CLEANING THE THROTTLE BODIES ....6-10 CHECKING THE INTAKE MANIFOLD JOINTS........6-11...
Page 270: Fuel Tank
FUEL TANK EAS26620 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Side cover (cylinder head) Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank bracket bolt Meter coupler 1 Disconnect.
Page 271 FUEL TANK Removing the fuel tank Order Job/Parts to remove Q’ty Remarks Fuel sender gasket For installation, reverse the removal proce- dure.
Page 272 FUEL TANK Removing the rollover valve and canister Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Fuel tank drain hose Refer to “FUEL TANK” on page 6-1. Canister purge hose California only Fuel tank breather hose...
Page 273: Removing The Fuel Tank
FUEL TANK EAS5S71013 EAS5S71041 REMOVING THE FUEL TANK CHECKING THE ROLLOVER VALVE 1. Extract the fuel in the fuel tank through the 1. Check: fuel tank cap with a pump. • Rollover valve “1” Damage/faulty → Replace. EAS5S71014 REMOVING THE FUEL PUMP •...
Page 274 FUEL TANK 2. Install: • Fuel hose ECA5S71006 When installing the fuel hose, make sure that it is securely connected, and that the fuel hose connector cover on the fuel hose is in the correct position, otherwise the fuel hose will not be properly installed. •...
Page 275 THROTTLE BODIES EAS26970 THROTTLE BODIES Removing the throttle body Order Job/Parts to remove Q’ty Remarks Rider seat Refer to “GENERAL CHASSIS” on page 4-1. Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Throttle position sensor coupler Disconnect.
Page 276 THROTTLE BODIES Removing the intake manifold assembly Order Job/Parts to remove Q’ty Remarks Air filter case Refer to “GENERAL CHASSIS” on page 4-1. Fuel tank Refer to “FUEL TANK” on page 6-1. Throttle body Refer to “THROTTLE BODIES” on page 6-6. Fuel hose Clutch cable holder 2 Fuel injector coupler...
Page 277 THROTTLE BODIES Disassembling the intake manifold Order Job/Parts to remove Q’ty Remarks Fuel return hose Pressure regulator O-ring Fuel delivery pipe 2 Fuel delivery hose Fuel delivery pipe 1 Injector O-ring Gasket Intake manifold For assembly, reverse the disassembly pro- cedure.
Page 278: Throttle Bodies
THROTTLE BODIES EAS26980 4. Check the injector pressure after the injec- CHECKING THE INJECTORS tors are installed to the throttle bodies. EWA5S71011 Refer to “CHECKING THE INJECTOR WARNING PRESSURE” on page 6-9. • Check the injectors in a well-ventilated area free of combustible materials. Make EAS5S71043 CHECKING THE INJECTOR PRESSURE sure that there is no smoking or use of...
Page 279: Checking The Throttle Bodies
THROTTLE BODIES f. Close the valve on the injector pressure ECA5S71015 adapter. g. Check that the specified air pressure is • Observe the following precautions; other- held for about one seconds. wise, the throttle bodies may not operate Pressure drops → Properly install or properly.
Page 280: Checking The Intake Manifold Joints
THROTTLE BODIES Pressure gauge When removing foreign material, do not rub 90890-03153 inside of the bore with something that would YU-03153 cause damages such as a wire brush. Fuel pressure adapter 90890-03176 h. After cleaning, air blow dry immediately YM-03176 and check that there are no foreign materi- als.
Page 281: Installing The Intake Manifold Assembly
THROTTLE BODIES Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 c. Turn the main switch to “ON”. d. Measure the throttle position sensor output voltage. e. Adjust the throttle position sensor angle so that the output voltage is within the speci- b.
Page 282 THROTTLE BODIES 6-13...
Page 283: Electrical System
ELECTRICAL SYSTEM IGNITION SYSTEM..................7-1 CIRCUIT DIAGRAM................7-1 ENGINE STOPPING DUE TO SIDESTAND OPERATION .....7-3 TROUBLESHOOTING ................7-5 ELECTRIC STARTING SYSTEM..............7-7 CIRCUIT DIAGRAM................7-7 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION......7-9 TROUBLESHOOTING ................7-11 CHARGING SYSTEM .................7-13 CIRCUIT DIAGRAM................7-13 TROUBLESHOOTING ................7-15 LIGHTING SYSTEM ...................7-17 CIRCUIT DIAGRAM................7-17 TROUBLESHOOTING ................7-19 SIGNALING SYSTEM.................7-21 CIRCUIT DIAGRAM................7-21 TROUBLESHOOTING ................7-23...
Page 284 CHECKING THE CRANKSHAFT POSITION SENSOR .......7-89 CHECKING THE LEAN ANGLE SENSOR ...........7-89 CHECKING THE STARTER MOTOR OPERATION......7-90 CHECKING THE STATOR COIL............7-90 CHECKING THE RECTIFIER/REGULATOR ........7-91 CHECKING THE HORN ...............7-91 CHECKING THE OIL LEVEL SWITCH ..........7-91 CHECKING THE FUEL SENDER ............7-92 CHECKING THE FUEL LEVEL WARNING LIGHT ......7-92 CHECKING THE OIL LEVEL WARNING LIGHT ........7-93 CHECKING THE SPEED SENSOR .............7-93...
Page 286: Ignition System
IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM...
Page 287 IGNITION SYSTEM 1. Main switch 4. Main fuse 5. Battery 9. Relay unit 12.Neutral switch 13.Sidestand switch 15.ECU (engine control unit) 16.Rear cylinder ignition coil 17.Spark plug 18.Front cylinder ignition coil 23.Crankshaft position sensor 28.Lean angle sensor 53.Right handlebar switch 55.Engine stop switch 65.Ignition fuse...
Page 288: Engine Stopping Due To Sidestand Operation
IGNITION SYSTEM EAS3D81009 ENGINE STOPPING DUE TO SIDESTAND OPERATION When the engine is running and the transmission is in gear, the engine will stop if the sidestand is moved down. This is because the electric current from the ignition coils does not flow to the ECU when both the neutral switch and sidestand switch are set to “OFF”, thereby preventing the spark plugs from producing a spark.
Page 289 IGNITION SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU (engine control unit) 9. Sidestand switch 10.Relay unit (diode) 11.Neutral switch...
Page 290: Troubleshooting
IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 3. Battery 4. Battery box 5. Fuel tank 6. Side cover (cylinder head) NG→...
Page 291 IGNITION SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-77. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 7-77. OK↓...
Page 292: Electric Starting System
ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM...
Page 293 ELECTRIC STARTING SYSTEM 1. Main switch 4. Main fuse 5. Battery 6. Starter motor 7. Starter relay 9. Relay unit 10.Starting circuit cut-off relay 12.Neutral switch 13.Sidestand switch 46.Left handlebar switch 47.Clutch switch 53.Right handlebar switch 55.Engine stop switch 56.Start switch 65.Ignition fuse...
Page 294: Starting Circuit Cut-Off System Operation
ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •...
Page 295 ELECTRIC STARTING SYSTEM a. WHEN THE TRANSMISSION IS IN NEU- TRAL b. WHEN THE SIDESTAND IS UP AND THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6.
Page 296: Troubleshooting
ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 1. Check the fuses. NG→ (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUSES” on page 7-81.
Page 297 ELECTRIC STARTING SYSTEM 8. Check the main switch. NG→ Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 7-77. OK↓ 9. Check the engine stop switch. NG→ Refer to “CHECKING THE Replace the right handlebar switch. SWITCHES” on page 7-77. OK↓...
Page 298: Charging System
CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 7-13...
Page 299 CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 4. Main fuse 5. Battery 7-14...
Page 300: Troubleshooting
CHARGING SYSTEM EAS27230 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 1. Check the fuse. NG→ (Main) Replace the fuse. Refer to “CHECKING THE FUSES” on page 7-81. OK↓...
Page 301 CHARGING SYSTEM 7-16...
Page 302: Lighting System
LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 7-17...
Page 303 LIGHTING SYSTEM 1. Main switch 4. Main fuse 5. Battery 15.ECU (engine control unit) 31.Meter assembly 33.Multi-function meter 37.Meter light 38.High beam indicator light 41.Accessory light (OPTION) 42.Headlight relay 43.Headlight 46.Left handlebar switch 50.Dimmer switch 51.Front right turn signal light 52.Front left turn signal light 61.License plate light 62.Tail/brake light...
Page 304: Troubleshooting
LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, posi- tion light, meter light and accessory light (OPTION). • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 3.
Page 305 LIGHTING SYSTEM 7. Check the entire lighting system’s NG→ wiring. Properly connect or repair the lighting Refer to “CIRCUIT DIAGRAM” on system’s wiring. page 7-17. OK↓ Replace the ECU or meter assembly. 7-20...
Page 306: Signaling System
SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 7-21...
Page 307 SIGNALING SYSTEM 1. Main switch 4. Main fuse 5. Battery 9. Relay unit 12.Neutral switch 15.ECU (engine control unit) 27.Speed sensor 30.Oil level switch 31.Meter assembly 32.Neutral indicator light 33.Multi-function meter 34.Oil level warning light 36.Fuel level warning light 39.Turn signal indicator light 40.Fuel sender 44.Horn 45.Turn signal relay...
Page 308: Troubleshooting
SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The speedometer fails to operate. • Before troubleshooting, remove the following part(s): 1.
Page 309 SIGNALING SYSTEM 3. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring. page 7-21. OK↓ This circuit is OK. The brake light fails to come on. NG→ 1. Check the brake light bulb and socket.
Page 310 SIGNALING SYSTEM 3. Check the turn signal relay. NG→ Refer to “CHECKING THE Replace the turn signal relay. RELAYS” on page 7-85. OK↓ 4. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM” on ing system’s wiring.
Page 311 SIGNALING SYSTEM The fuel level warning light fails to come on. 1. Check the fuel sender. NG→ Refer to “CHECKING THE FUEL Replace the fuel sender. SENDER” on page 7-92. OK↓ 2. Check the entire signaling system’s NG→ wiring. Properly connect or repair the signal- Refer to “CIRCUIT DIAGRAM”...
Page 312: Fuel Injection System
FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 7-27...
Page 313 FUEL INJECTION SYSTEM 1. Main switch 4. Main fuse 5. Battery 8. Fuel injection system fuse 9. Relay unit 11.Fuel pump relay 12.Neutral switch 13.Sidestand switch 14.Fuel pump 15.ECU (engine control unit) 16.Rear cylinder ignition coil 17.Spark plug 18.Front cylinder ignition coil 19.Rear cylinder injector 20.Front cylinder injector 21.O...
Page 314: Ecu Self-Diagnostic Function
FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 315: Fail-Safe Actions
FUEL INJECTION SYSTEM EAS27363 FAIL-SAFE ACTIONS (SUBSTITUTE CHARACTERISTICS OPERATION CONTROL) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illu- minates the engine trouble warning light and provides the engine with alternate operating instruc- tions that are appropriate for the type of malfunction.
Page 316: Trouble Shooting Chart
FUEL INJECTION SYSTEM EAS5S71040 TROUBLE SHOOTING CHART 7-31...
Page 317: Diagnostic Mode
FUEL INJECTION SYSTEM EAS27420 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.
Page 318: Troubleshooting Details
FUEL INJECTION SYSTEM EAS27460 TROUBLESHOOTING DETAILS This section describes the measures per fault code number displayed on the meter. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given. After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method.
Page 319 FUEL INJECTION SYSTEM Fault code No. Normal signals are not received from the crankshaft position sen- Symptom sor. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause...
Page 320 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No.
Page 321 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air pressure sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. When engine is stopped: Make sure that the atmospheric pressure Meter display is indicated.
Page 322 FUEL INJECTION SYSTEM If fault codes 13 and 14 are indicated simultaneously, take the actions specified for fault code 13 first. Fault code No. The intake air pressure sensor has failed (due to clogging of hose or Symptom sensor disconnection). Engine startup: Possible Fail-safe action Riding: Possible...
Page 323 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- ing code No. Display the throttle opening (between 0 and 125 degrees) Meter display When throttle is fully closed: 15 to 18 degrees When throttle is fully opened: 97 to 102 degrees...
Page 324 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- ing code No. Display the throttle opening (between 0 and 125 degrees) Meter display When throttle is fully closed: 15 to 18 degrees When throttle is fully opened: 97 to 102 degrees...
Page 325 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. Sidestand retracted: ON indication Meter display Sidestand extended: OFF indication Make sure that the ON and OFF indication is switched when the sid- Checking method estand is retracted and extended.
Page 326 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of ECU input line (Blue/Yellow lead) Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. Sidestand retracted: ON indication Meter display Sidestand extended: OFF indication Make sure that the ON and OFF indication is switched when the sid- Checking method estand is retracted and extended.
Page 327 FUEL INJECTION SYSTEM *Check the sensor only when the engine is cold. Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
Page 328 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of intake air temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
Page 329 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure...
Page 330 FUEL INJECTION SYSTEM Fault code No. The O sensor does not operate. Symptom Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure...
Page 331 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of engine temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
Page 332 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of engine temperature sensor lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. -30 to 120 °C During cold starting: A temperature close to the ambient tempera- Meter display ture is indicated.
Page 333 FUEL INJECTION SYSTEM Fault code No. Symptom Turnover of vehicle Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. The lean angle sensor value is indicated. 0 to 0.5 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.4 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees, Checking method...
Page 334 FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
Page 335 FUEL INJECTION SYSTEM Fault code No. Symptom Front cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
Page 336 FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
Page 337 FUEL INJECTION SYSTEM Fault code No. Symptom Rear cylinder ignition coil primary lead malfunction Engine startup: Possible (depending on the number of failed cylin- ders) Fail-safe action Riding: Possible (depending on the number of failed cylinders) Diagnostic monitor- ing code No. Each ignition coil turns On or Off 5 times per second.
Page 338 FUEL INJECTION SYSTEM Fault code No. Symptom Engine speed is high when the engine is idling Engine startup: Possible (stuck fully closed unable) Fail-safe action Riding: Possible Diagnostic monitor- ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order...
Page 339 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of injector lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. When engine is stopped: Make sure that the atmospheric pressure Meter display is indicated. When engine is cranking: The indication value changes because the Checking method injector changes.
Page 340 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. The lean angle sensor value is indicated. 0 to 5.0 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.4 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees,...
Page 341 FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit of lean angle sensor lead Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- ing code No. The lean angle sensor value is indicated. 0 to 5.0 V Meter display The vehicle is in a vertical position: 0.4–1.4 V The vehicle is turned over: 3.7–4.2 V Remove the lean angle sensor, tilt the vehicle more than 65 degrees,...
Page 342 FUEL INJECTION SYSTEM Fault code No. Symptom A. Normal signals are not received from the speed sensor. B. Open or short circuit of neutral switch lead Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- 07 (Speed sensor) ing code No. Meter display Vehicle speed pulses: 0–999 Make sure that the indication value increases when the rotation...
Page 343 FUEL INJECTION SYSTEM A. Speed sensor system malfunction Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure Poor connection → Connection of speed Start the engine, and sensor (meter) coupler Connect it securely, or check the connection of Check the connection repair/replace the wire the coupler is secure.
Page 344 FUEL INJECTION SYSTEM B. Neutral switch system malfunction Item/components and Check or mainte- Sensor inspection Order probable cause nance job procedure Poor connection → Connection of neutral Start the engine, and switch coupler Reconnect or repair the check the secure con- Check the connection coupler.
Page 345 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. The relay turns On or Off 5 times per second. Meter display The engine warning light flashes according to the On/Off switching.
Page 346 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage supplied to the fuel injector and fuel pump Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. The relay turns On or Off 5 times per second. Meter display The engine warning light flashes according to the On/Off switching.
Page 347 FUEL INJECTION SYSTEM Fault code No. Symptom An error is detected while reading or writing on EEP-ROM Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- ing code No. The in self diagnostic code 44 detected EEP-ROM errors are indi- cated.
Page 348 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
Page 349 FUEL INJECTION SYSTEM Fault code No. Symptom Incorrect voltage is supplied to the ECU. Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
Page 350 FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signal is received from the ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
Page 351 FUEL INJECTION SYSTEM Fault code No. Er-2 Symptom No signal is sent from ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause nance job...
Page 352 FUEL INJECTION SYSTEM Fault code No. Er-3 Symptom Correct data cannot be received from the ECU. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause...
Page 353 FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom No registration data can be received from the meter unit. Engine startup: Impossible Fail-safe action Riding: Impossible Diagnostic monitor- — ing code No. Meter display — Checking method — Item/components and Check or mainte- Sensor inspection Order probable cause...
Page 354: Fuel Pump System
FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 7-69...
Page 355 FUEL PUMP SYSTEM 1. Main switch 4. Main fuse 5. Battery 8. Fuel injection system fuse 9. Relay unit 11.Fuel pump relay 14.Fuel pump 15.ECU (engine control unit) 53.Right handlebar switch 55.Engine stop switch 65.Ignition fuse 7-70...
Page 356: Troubleshooting
FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING The fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Rider seat 2. Seat lock bracket 3. Fuel tank NG→ 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUSES”...
Page 357 FUEL PUMP SYSTEM 7-72...
Page 358: Electrical Components
ELECTRICAL COMPONENTS EAS27970 ELECTRICAL COMPONENTS 7-73...
Page 359 ELECTRICAL COMPONENTS 1. Engine temperature sensor 2. Intake air pressure sensor 3. Rear cylinder ignition coil 4. Front cylinder ignition coil 5. Sub-wire harness 6. ECU (engine control unit) 7. Turn signal relay 8. Speed sensor 9. Neutral switch 10.Oil level switch 11.Horn 12.Air temperature sensor 7-74...
Page 360 ELECTRICAL COMPONENTS 7-75...
Page 361 ELECTRICAL COMPONENTS 1. Main switch 2. Rectifier/regulator 3. Fuse box 4. Headlight fuse 5. Backup fuse 6. Taillight fuse 7. Ignition fuse 8. Signaling system fuse 9. Main fuse 10.Battery 11.Lean angle sensor 12.Starter relay 13.Fuel injection system fuse 14.Relay unit 15.Headlight relay 16.Sidestand switch 17.Rear brake light switch...
Page 362: Checking The Switches
ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES 7-77...
Page 363 ELECTRICAL COMPONENTS 1. Main switch 2. Rear brake light switch 3. Front brake light switch 4. Reset switch 5. Select switch 6. Engine stop switch 7. Start switch 8. Neutral switch 9. Sidestand switch 10.Dimmer switch 11.Turn signal switch 12.Horn switch 13.Clutch switch 7-78...
Page 364 ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
Page 365: Checking The Bulbs And Bulb Sockets
ELECTRICAL COMPONENTS EAS27990 EWA13320 CHECKING THE BULBS AND BULB SOCK- WARNING Since the headlight bulb gets extremely Check each bulb and bulb socket for damage hot, keep flammable products and your or wear, proper connections, and also for conti- hands away from the bulb until it has nuity between the terminals.
Page 366: Checking The Fuses
ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect the pocket tester to the fuse and check the continuity. Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C Checking the condition of the bulb sockets b. If the pocket tester indicates “∞”, replace The following procedure applies to all of the the fuse.
Page 367: Checking And Charging The Battery
ELECTRICAL COMPONENTS 4. Install: • Rider seat Since MF batteries are sealed, it is not possi- Refer to “GENERAL CHASSIS” on page ble to check the charge state of the battery by 4-1. measuring the specific gravity of the electro- lyte.
Page 368 ELECTRICAL COMPONENTS • If it is impossible to regulate the charging Example current on the battery charger, be careful Open-circuit voltage = 12.0 V not to overcharge the battery. Charging time = 6.5 hours • When charging a battery, be sure to Charge of the battery = 20–30% remove it from the vehicle.
Page 369 ELECTRICAL COMPONENTS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Charging method using a variable-current Charging method using a constant voltage (voltage) charger charger a. Measure the open-circuit voltage prior to a. Measure the open-circuit voltage prior to charging. charging. Voltage should be measured 30 minutes after Voltage should be measured 30 minutes after the engine is stopped.
Page 370: Checking The Relays
ELECTRICAL COMPONENTS Starter relay 1. Positive battery terminal 8. Check: 2. Negative battery terminal • Battery terminals 3. Positive tester probe Dirt → Clean with a wire brush. 4. Negative tester probe Loose connection → Connect properly. 9. Lubricate: Result •...
Page 371: Checking The Turn Signal Relay
ELECTRICAL COMPONENTS Result Continuity (between “3” and “4”) Headlight relay b. Turn the main switch to “ON”. c. Measure the turn signal relay input voltage. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Check: • Turn signal relay output voltage 1. Positive battery terminal Out of specification → Replace. 2.
Page 372: Checking The Diodes
ELECTRICAL COMPONENTS EAS28050 CHECKING THE DIODES Continuity Positive tester probe → sky Relay unit (diode) blue “1” 1. Check: Negative tester probe → black/ • Relay unit (diode) yellow “2” Out of specification → Replace. No continuity Positive tester probe → black/ Pocket tester yellow “2”...
Page 373: Checking The Ignition Spark Gap
ELECTRICAL COMPONENTS b. Connect the pocket tester (Ω × 1) to the EAS28070 CHECKING THE SPARK PLUG CAPS relay unit terminals as shown. The following procedure applies to all of the c. Check the relay unit (diode) for continuity. spark plug caps. d.
Page 374 ELECTRICAL COMPONENTS EAS28120 • Positive tester probe → CHECKING THE CRANKSHAFT POSITION black/red “1” SENSOR • Negative tester probe → 1. Disconnect: orange or gray/red “2” • Crankshaft position sensor coupler (from the wire harness) 2. Check: • Crankshaft position sensor resistance Out of specification →...
Page 375 ELECTRICAL COMPONENTS EWA13810 Lean angle sensor output voltage WARNING Less than 45° • A wire that is used as a jumper lead must 0.4–1.4 V have at least the same capacity of the bat- More than 45° tery lead, otherwise the jumper lead may 3.7–4.4 V burn.
Page 376 ELECTRICAL COMPONENTS c. Start the engine and operate it run at • Positive tester probe → approximately 5000 r/min. white “2” d. Measure the charging voltage. • Negative tester probe → white “3” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EAS28180 CHECKING THE HORN 1. Check: •...
Page 377 ELECTRICAL COMPONENTS 3. Check: 2. Remove: • Oil level switch resistance • Fuel sender Out of specification → Replace the oil (from the fuel tank) level switch. 3. Check: • Fuel sender resistance Oil level switch Out of specification → Replace the fuel Minimum level position resis- sender.
Page 378: Specifications
ELECTRICAL COMPONENTS • Positive tester probe → white/yellow “1” • Negative tester probe → black/blue “2” EAS3D81015 CHECKING THE OIL LEVEL WARNING LIGHT This model is equipped with a self-diagnosis device for the oil level detection circuit. 1. Check: b. Set the main switch to “ON”. •...
Page 379 ELECTRICAL COMPONENTS • Tester positive probe → black/blue “1” • Negative tester probe → brown “2” b. Measure the throttle position sensor maxi- mum resistance. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ b. Measure the engine temperature sensor 3. Install: resistance. • Throttle position sensor ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3.
Page 380 ELECTRICAL COMPONENTS d. Slowly heat the water, and then let it cool b. Set the main switch to “ON”. down to the specified temperature. c. Measure the intake air pressure sensor e. Measure the air temperature sensor resis- output voltage. tance.
Page 381: Troubleshooting
TROUBLESHOOTING TROUBLESHOOTING ..................8-1 GENERAL INFORMATION ..............8-1 STARTING FAILURES ................8-1 INCORRECT ENGINE IDLING SPEED ..........8-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ......8-2 FAULTY GEAR SHIFTING ..............8-2 SHIFT PEDAL DOES NOT MOVE............8-2 JUMPS OUT OF GEAR ................8-2 FAULTY CLUTCH ...................8-2 OVERHEATING ..................8-2 POOR BRAKING PERFORMANCE ............8-3 FAULTY FRONT FORK LEGS ..............8-3 UNSTABLE HANDLING................8-3 FAULTY LIGHTING OR SIGNALING SYSTEM ........8-3...
Page 382 TROUBLESHOOTING EAS28450 Electrical system TROUBLESHOOTING 1. Battery • Discharged battery EAS28460 • Faulty battery GENERAL INFORMATION 2. Fuse(s) • Blown, damaged or incorrect fuse The following guide for troubleshooting does • Improperly installed fuse not cover all the possible causes of trouble. It 3.
Page 383 TROUBLESHOOTING • Improper throttle cable free play • Foreign object between transmission gears • Flooded throttle body • Improperly assembled transmission Electrical system EAS28550 JUMPS OUT OF GEAR 1. Battery • Discharged battery Shift shaft • Faulty battery • Incorrect shift pedal position 2.
Page 384 TROUBLESHOOTING • Incorrect oil level • Incorrect oil viscosity • Incorrect oil viscosity • Incorrect oil level • Inferior oil quality EAS28670 UNSTABLE HANDLING Fuel system 1. Handlebar 1. Throttle body(-ies) • Bent or improperly installed handlebar • Damaged or loose throttle body joint 2.
Page 385 TROUBLESHOOTING Headlight bulb burnt out • Wrong headlight bulb • Faulty battery • Faulty rectifier/regulator • Improperly grounded circuit • Faulty main switch • Headlight bulb life expired Tail/brake light does not come on • Wrong tail/brake light bulb • Too many electrical accessories •...
Page 386: Wiring Diagram
EAS28740 55. Engine stop switch Yellow/Black WIRING DIAGRAM 56. Start switch Yellow/Green 57. Select switch XVS95Y/XVS95YC/ Yellow/Blue 58. Reset switch XVS95CTY/XVS95CTYC Yellow/Red 59. Rear right turn signal light 2009 60. Rear left turn signal light 1. Main switch 61. License plate light 2.
Page 387 WIRING DIAGRAM XVS95Y/XVS95YC/XVS95CTY/XVS95CTYC 2009...
Page 388 WIRING DIAGRAM XVS95Y/XVS95YC/XVS95CTY/XVS95CTYC 2009...

Yamaha V Star 950 Service Manual

Table of Contents

Specifications

Periodic Checks and Adjustments

Chassis

General Chassis

Front Wheel

Rear Wheel

Front Brake

Rear Brake

Handlebar

Front Fork

Steering Head

Rear Shock Absorber Assembly

Swingarm

Belt Drive

Engine

Engine Removal

Camshafts

Cylinder Heads

Valves and Valve Springs

Cylinders and Pistons

Generator and Starter Clutch

Clutch

Shift Shaft

Electric Starter

Crankcase

Oil Pump

Crankshaft

Transmission

Fuel System

Fuel Tank

Throttle Bodies

Electrical System

Ignition System

Electric Starting System

Charging System

Lighting System

Signaling System

Fuel Injection System

Fuel Pump System

Electrical Components

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Yamaha V Star 950