Yamaha FZS1000(N) 2001 Service Manual
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Yamaha FZS1000(N) 2001 Service Manual

Fzs1000(n) 2001
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  • Page 3 EAS00000 FZS1000 (N) SERVICE MANUAL 2000 by Yamaha Motor Co.Ltd. First edition, December 2000 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
  • Page 4 If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed- eral environmental quality objectives.

  • Page 5: How To Use This Manual

    EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

  • Page 6: General Information

    EAS00008 SYMBOLS The following symbols are not relevant to every SPEC vehicle. INFO Symbols 1 to 9 indicate the subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Cooling system 7 Carburetor(-s) COOL 8 Electrical system...

  • Page 7: Table Of Contents

    EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL CARBURETORS CARB ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
  • Page 10 INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ....... VEHICLE IDENTIFICATION NUMBER .
  • Page 11 INFO...

  • Page 12: General Information

    MOTORCYCLE IDENTIFICATION INFO EAS00014 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head. EAS00018 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.

  • Page 13: Important Information

    5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

  • Page 14: Bearings And Oil Seals

    IMPORTANT INFORMATION INFO EAS00024 BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturer’s marks or numbers are vis- ible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips.

  • Page 15: Checking The Connections

    CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead 1 S coupler 2 S connector 3 2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect sev- eral times.

  • Page 16: Special Tools

    SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
  • Page 17 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench 90890-01426 This tool is needed to loosen or tighten the oil filter cartridge. Rod holder 90890-01434 This tool is used to support the damper ad- justing rod. Rod puller Rod puller 90890-01437 Rod puller attachment...
  • Page 18 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Timing light 90890-03141 This tool is used to check the ignition tim- ing. Carburetor angle driver 2 90890-03173 This tool is used to turn the pilot screw when adjusting the engine idling speed. Valve spring com- Valve spring compressor pressor...
  • Page 19 SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating sur- faces (e.g., crankcase mating surfaces).

  • Page 21: Engine

    SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........ENGINE SPECIFICATIONS .
  • Page 22 SPEC...

  • Page 23: Chapter 2. Specifications

    SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5VL1 (A) (B) (D) (DK) (E) (GB) (GR) (I) (N) (NL) (S) (SF) (CH) (P) 5LV2 (F) 5LV3 (D) 5LV4 (AUS) Dimensions Overall length 2,125 mm Overall width 765 mm Overall height 1,190 mm Seat height...

  • Page 24: Engine Specifications

    SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 998 cm Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 58 mm Compression ratio 11.4 : 1 1,050 X 1,150 r/min Engine idling speed Vacuum pressure at engine idling 30 kPa (225 mm Hg) speed Standard compression pressure...

  • Page 25: Cooling System

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Cartridge (paper) 180 X 220 kPa (1.8 X 2.2 kg/cm Bypass valve opening pressure Oil pump Oil pump type Trochoid 0.09 X 0.15 mm Inner-rotor-to-outer-rotor-tip clearance 0.03 X 0.08 mm Outer-rotor-to-oil-pump-housing clearance Cooling system...
  • Page 26 SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 24.500 X 24.521 mm Camshaft cap inside diameter 24.459 X 24.472 mm Camshaft journal diameter 0.028 X 0.062 mm Camshaft-journal-to-camshaft- cap clearance Intake camshaft lobe dimensions 32.5 X 32.6 mm Measurement A 32.4 mm 24.95 X 25.05 mm...
  • Page 27 SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links RH2015/130 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.11 X 0.20 mm Intake 0.21 X 0.25 mm Exhaust Valve dimensions Head Diameter Face Width Seat Width Margin Thickness Valve head diameter A 22.9 X 23.1 mm...
  • Page 28 SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake 38.9 mm Exhaust 40.67 mm Installed length (valve closed) Intake 34.5 mm Exhaust 35 mm Compressed spring force (installed) 82 X 96 N (8.36 X 9.79 kg) Intake 110 X 126 N (11.22 X 12.85 kg) Exhaust Spring tilt Intake...
  • Page 29 SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston 0.030 X 0.055 mm Piston-to-cylinder clearance 0.12 mm 73.955 X 73.970 mm Diameter D Height H 5 mm Piston pin bore (in the piston) 17.002 X 17.013 mm Diameter 17.043 Offset Offset direction Intake side Piston pins 16.991 X 17.000 mm...
  • Page 30 SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.031 X 0.055 mm Crankshaft-pin-to-big-end-bearing clearance Bearing color code –1 = Violet 0 = White 1 = Blue 2 = Black Crankshaft 52.40 X 57.25 mm Width A 300.75 X 302.65 mm Width B Max.
  • Page 31 SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 68/43 (1.581) Secondary reduction system Chain drive Secondary reduction ratio 44/16 (2.750) Operation Left-foot operation Gear ratios 1st gear 35/14 (2.500) 2nd gear 35/19 (1.842) 3rd gear...

  • Page 32: Spec

    SPEC ENGINE SPECIFICATIONS Item Standard Limit Carburetors Model (manufacturer) quantity BSR37 (MIKUNI) 3 X 5 mm Throttle cable free play (at the flange of the throttle grip) ID mark 5LV1 00 Main jet Carburetors 1 and 4: #132.5 Carburetors 2 and 3: #130 Main air jet Jet needle Carburetor 1 and 4: 5D129-3/5...

  • Page 33: Chassis Specifications

    SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle Caster angle Trail 104 mm Front wheel Wheel type Cast wheel Size MT3.50 Material Aluminum Wheel travel 140 mm Wheel runout Max. radial wheel runout 1 mm Max.
  • Page 34 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 180/55 ZR17 (73W) Model (manufacturer) MEZ4Y (METZELER) BT020R U (BRIDGESTONE) Tire pressure (cold) 0 X 90 kg 270 kPa (2.7 kgf/cm , 2.7 bar) 90 X 201 kg 290 kPa (2.9 kgf/cm , 2.9 bar) High-speed riding...
  • Page 35 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 140 mm Spring Free length 344.0 mm Spacer length 78.5 mm Installed length 320.0 mm Spring rate (K1) 8.1 N/mm (0.83 kg/mm) Spring rate (K2) 11.8 N/mm (1.2 kg/mm) 0 X 55 mm...
  • Page 36 SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular ball bearings Rear suspension Suspension type Swingarm (link suspension) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 65 mm travel Spring Free length 182.5 mm Installed length 163 mm Spring rate (K1)

  • Page 37: Electrical Specifications

    SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type Transistorized coil ignition Ignition timing 5_ BTDC at 1,100 r/min Advanced timing 55_ BTDC at 5,000 r/min Advancer type Throttle position sensor and electrical 248 X 372 Ω/Gy-B Pickup coil resistance/color Transistorized coil ignition unit...
  • Page 38 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light (voltage /wattage quantity) Neutral indicator light 14 V 1.4 W High beam indicator light 14 V 1.4 W Oil level indicator light 14 V 1.4 W Turn signal indicator light 14 V 1.4 W Fuel indicator light 12 V 2 W Water temperature indicator light...
  • Page 39 SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 30 A Headlight fuse 20 A Signaling system fuse 20 A Ignition fuse 20 A Radiator fan fuse 10 A Turn signal relay fuse 10 A Backup fuse (odometer) 10 A Reserve fuse 30 A...

  • Page 40: Tightening Torques

    SPEC TIGHTENING TORQUES EAS00029 TIGHTENING TORQUE GENERAL TIGHTENING TORQUES This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a criss- cross pattern and progressive stages until the specified tightening torque is reached.

  • Page 41: Engine Tightening Torques

    SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size size mSkgf Spark plugs – Cylinder head Cylinder head Cap nut Cylinder head Bolt Camshaft caps Bolt Cylinder head cover Bolt Cylinder head (exhaust pipe) Stud bolt Connecting rod caps Generator rotor Bolt...
  • Page 42 SPEC TIGHTENING TORQUES Tightening Thread torque Item Fastener Q’ty Remarks size size Nm mSkgf AC magneto cover Bolt Drive sprocker cover Bolt Plate Bolt Clutch cover Bolt Timing chain cap bolt Bolt Shift shaft cover Bolt Breather plate Bolt Timing mark accessing screw Bolt Starter clutch idle gear shaft Bolt...
  • Page 43 SPEC TIGHTENING TORQUES Crankcase tightening sequence: 2-21...

  • Page 44: Chassis Tightening Torques

    SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Item Item Thread size Thread size Remarks Remarks mSkgf Upper bracket pinch bolt Upper bracket cap nut Upper bracket and handlebar holder Handlebar holder Lower bracket pinch bolt – Lower bracket ring nut See note Front brake master cylinder Front brake hose union bolt...

  • Page 45: Lubrication Points And Lubricant Types

    Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Yamaha bond Cylinder head cover mating surface No.1215 Yamaha bond Crankcase mating surface No.1215 Yamaha bond Clutch cover (crankcase mating surface) No.1215...

  • Page 46: Chassis

    SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings, steering seal lips and ball race cover lips Pivot shaft Swing arm pivoting points and connecting arm bearings Connecting arm oil seal lips Swing arm oil seal lips Relay arm bearings Relay arm oil seal lips Rear shock absorber upper bolt...

  • Page 47: Cooling System Diagrams

    SPEC COOLING SYSTEM DIAGRAMS EAS00033 COOLING SYSTEM DIAGRAMS 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Water pump 2-25...
  • Page 48 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator cap 2 Thermostat housing 3 Radiator 4 Oil cooler 5 Water jacket joint 2-26...
  • Page 49 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator cap 2 Thermostat 3 Thermo unit 2-27...
  • Page 50 SPEC COOLING SYSTEM DIAGRAMS 1 Radiator 2-28...

  • Page 51: Engine Oil Lubrication Chart

    SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Exhaust camshaft Intake camshaft Main gallery Oil filter Main axle cooler Relief Strainer valve Drive axle 2-29...

  • Page 52: Lubrication Diagrams

    SPEC LUBRICATION DIAGRAMS EAS00034 LUBRICATION DIAGRAMS 1 Oil cooler 2 Oil filter cartridge 3 Drain bolt 4 Oil level switch 5 Oil strainer 6 Oil pump 2-30...
  • Page 53 SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Oil cooler 4 Oil strainer 5 Oil pump 2-31...
  • Page 54 SPEC LUBRICATION DIAGRAMS 1 Intake camshaft 2 Exhaust camsahft 3 Oil filter cartridge 4 Oil level switch 2-32...
  • Page 55 SPEC LUBRICATION DIAGRAMS 1 Cylinder head 2 Crankshaft 2-33...
  • Page 56 SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle 2-34...

  • Page 57: Cable Routing

    SPEC CABLE ROUTING EAS00035 CABLE ROUTING A Fasten the handlebar switch lead (right) and han- F Route the horn lead outside the motorcycle body, dlebar with a plastic band. and fasten with the under bracket. Do not loose be- B Route the handlebar switch lead (right) backward tween the horn and under bracket.
  • Page 58 SPEC CABLE ROUTING Fuel pump lead Handle crown Fuel pump Handlebar switch lead EXUP cable Brake hose guide Handlebar switch lead (right) Throttle cable 1 A Fasten the fuel pump lead, pickup coil lead, neutral switch lead, speed Throttle cable 2 sensor lead, rear brake light switch lead and fuel pump with a plastic Water-carburetor hose clamp.
  • Page 59 SPEC CABLE ROUTING I Route the water-carburetor hose between the Q Insert the all couplers into the rubber cover. frame cross pipe and fan motor lead. R Route the rear brake light switch lead inside the J To the carburetor another leads.
  • Page 60 SPEC CABLE ROUTING Starter cable A Fasten the main switch lead and handlebar switch lead with a plastic Clutch cable guide. Handlebar switch lead (left) B Fasten the water-head hose and water-carburetor hose with a plastic Main switch lead band. EXUP servo motor C Fasten the clutch cable with a plastic band.
  • Page 61 SPEC CABLE ROUTING N Fasten the sidestand switch lead, oil level switch lead, and rectifier regulator lead. ACgenerator lead, starter motor lead, battery negative U Route the water carburetor hose outside the coolant lead and air cleaner case drain hose with a plastic clamp. hose.
  • Page 62 SPEC CABLE ROUTING Clutch cable Ignition coil lead Handlebar switch lead Battery Main switch lead Emergency engine stop switch Starter cable Flasher relay Thermo unit lead Fuse box Throttle cable 1 Igniter unit Throttle cable 2 Flasher light lead Handlebar switch lead (right) Taillight lead Coolant reservoir hose Alarm coupler (free)
  • Page 63 SPEC CABLE ROUTING A Fasten the flasher light lead and headlight lead with K Fasten the fuel hose and air induction system hose a plastic clamp. with a plastic clamp. B Route the rectifier / regulator lead upper the fan mo- L Route the coolant reservoir hose under the frame tor lead and EXUP servomotor lead.
  • Page 64 SPEC CABLE ROUTING T Fasten the ignition coil lead and frame cross pipe AA Put the seat lock cable into the groove on the rear with a plastic clamp. Do not fasten the red / black fender. lead and orange lead. AB Fasten the battery positive lead with a plastic band.
  • Page 66 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ..........PERIODIC MAINTENANCE/LUBRICATION INTERVALS .
  • Page 67 CHECKING AND LUBRICATING THE CABLES ....3-50 LUBRICATING THE LEVERS AND PEDALS ....3-50 LUBRICATING THE SIDESTAND .

  • Page 68: Periodic Checks And Adjustments

    D From 50,000 km, repeat the maintenance intervals starting from 10,000 km. D Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (...
  • Page 69 S Adjust headlight beam. (See page 8-30) (See page 8-35) *: It is recommended that these items be serviced by a Yamaha dealer. NOTE: D The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

  • Page 70: Front Cowling/Seat/Side Cover/Fuel Tank

    FRONT COWLING EAS00038 FRONT COWLING/SEAT/SIDE COVER/FUEL TANK FRONT COWLING Order Job/Part Q’ty Remarks Removing the fron cowling Remove the4 parts in the order listed. Inner panel Headlight/meter coupler Disconnect. Front cowling assembly Back view mirror Meter unit Headlight unit For installation, reverse the removal procedure.

  • Page 71: Seat, Side Cover And Fuel Tank

    SEAT, SIDE COVER AND FUEL TANK EAS00040 SEAT, SIDE COVER AND FUEL TANK 19 Nm (1.9 mSkg) 10 Nm (1.0 mSkg) 4 Nm (0.4 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the seat, side cover and Remove the parts in the order listed. fuel tank Seat Side cover (left and right)

  • Page 72: Engine

    ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.
  • Page 73 ADJUSTING THE VALVE CLEARANCE A Front d. For each cylinder, starting with cylinder #1 at TDC, turn the crankshaft clockwise as speci- fied in the following table. B Degrees that the crankshaft is turned clockwise C Cylinder D Combustion cycle #2 Cylinder 180_ #4 Cylinder...
  • Page 74 ADJUSTING THE VALVE CLEARANCE NOTE: S Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. S Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place.
  • Page 75 ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED PAD NUMBER clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...
  • Page 76 ADJUSTING THE VALVE CLEARANCE e. Install the new valve pad 1 and the valve lift- er 2 . NOTE: S Apply molybdenum disulfide to the valve pad. S Lubricate the valve lifter with molybdenum dis- ulfide oil. S The valve lifter must turn smoothly when ro- tated by hand.

  • Page 77: Synchronizing The Carburetors

    SYNCHRONIZING THE CARBURETORS EAS00050 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand.
  • Page 78 SYNCHRONIZING THE CARBURETORS 6. Adjust: S carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in ei- ther direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.

  • Page 79: Adjusting The Engine Idling Speed

    ADJUSTING THE ENGINE IDLING SPEED EAS00052 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for several minutes.

  • Page 80: Adjusting The Throttle Cable Free Play

    ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY c. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained. Engine idling speed is in- Direction creased. Engine idling speed is Direction decreased.
  • Page 81 ADJUSTING THE THROTTLE CABLE FREE PLAY 3. Adjust: S throttle cable free play NOTE: When the motorcycle is accelerating, the accel- erator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable.

  • Page 82: Checking The Spark Plugs

    ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS 4. Install: S fuel tank S seat EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Disconnect: S spark plug cap 2. Remove: S spark plug CAUTION: Before removing the spark plugs, blow away...

  • Page 83: Checking The Ignition Timing

    CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 7. Install: S spark plug 13 Nm (1.3 mSkg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Connect: S spark plug cap EAS00063 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system.

  • Page 84: Measuring The Compression Pressure

    CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range ! Check the ignition system. NOTE: The ignition timing is not adjustable. 4.
  • Page 85 MEASURING THE COMPRESSION PRESSURE 6. Measure: S compression pressure Above the maximum pressure ! Inspect the cylinder head, valve surfaces, and piston crown for carbon deposits. Below the minimum pressure ! Squirt a few drops of oil into the affected cylinder and measure again.

  • Page 86: Checking The Engine Oil Level

    CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Let the engine idle for a few minutes. 3.

  • Page 87: Changing The Engine Oil

    CHANGING THE ENGINE OIL EAS00073 CHANGING THE ENGINE OIL 1. Start the engine, warm it up for several min- utes, and then turn it off. 2. Place a container under the engine oil drain bolt. 3. Remove: S engine oil filler cap 1 S engine oil drain bolt 2 (along with the gasket) 4.
  • Page 88 CHANGING THE ENGINE OIL c. Tighten the new oil filter cartridge to specifi- cation with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 mSkg) 6. Check: S engine oil drain bolt gasket Damage ! Replace. 7. Install: S engine oil drain bolt 43 Nm (4.3 mSkg) 8.

  • Page 89: Adjusting The Clutch Cable Free Play

    CHANGING THE ENGINE OIL/ ADJUSTING THE CLUTCH CABLE FREE PLAY Oil gallery bolt 10 Nm (1.0 mSkg) EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm 2.

  • Page 90: Cleaning The Air Filter Element

    CLEANING THE AIR FILTER ELEMENT EAS00086 CLEANING THE AIR FILTER ELEMENT 1. Remove: S seat S fuel tank S side cover S cover 1 2. Remove: S air filter case cover 1 S air filter element 3. Clean: S air filter element Apply compressed air to the outer surface of the air filter element.

  • Page 91: Checking The Carburetor Joints And Intake Manifolds

    CLEANING THE AIR FILTER ELEMENT / CHECKING THE CARBURETOR JOINTS AND INTAKE MANIFOLDS / CHECKING THE FUEL HOSES AND FUEL FILTER NOTE: When installing the air filter element into the air filter case cover, be sure their sealing surfaces are aligned to prevent any air leaks. 6.

  • Page 92: Checking The Crankcase Breather Hose

    CHECKING THE FUEL HOSES AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM NOTE: S Drain and flush the fuel tank if abrasive dam- age to any components of the fuel line is evi- dent. S The arrow mark a on the fuel filter should face to the side of the fuel pump 1 .

  • Page 93: Adjusting The Exup Cables

    ADJUSTING THE EXUP CABLES EAS00101 ADJUSTING THE EXUP CABLES 1. Remove: S seat S fuel tank 2. Remove: S EXUP valve pulley cover 1 3. Check: S EXUP operation a. Disconnect the EXUP servomotor connector b. Connect the battery to the EXUP servomotor connector and check if the servomotor oper- ates properly.

  • Page 94: Checking The Coolant Level

    ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL 4. Check: S EXUP cable free play a EXUP cable free play 1.5 mm max. 5. Adjust: S EXUP cable free play a. Loosen both locknuts 1 . b. Insert a 4 mm long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover.
  • Page 95 CHECKING THE COOLANT LEVEL CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and correct the antifreeze concentration of the coolant. S Use only distilled water. Soft water may be used if distilled water is not available.

  • Page 96: Checking The Cooling System

    CHECKING THE COOLING SYSTEM EAS00104 CHECKING THE COOLING SYSTEM 1. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler inlet hose 4 S oil cooler outlet hose 5 S water jacket inlet joint 6 S water pump outlet joint 7 Cracks/damage ! Replace.

  • Page 97: Changing The Coolant

    CHANGING THE COOLANT EAS00105 CHANGING THE COOLANT 1. Remove S seat S fuel tank S front cowling S rear suspension Refer to “REAR SHOCK ABSORBER AS- SEMBLY” in chapter 4. 2. Disconnect: S coolant reservoir hose 1 3. Drain: S coolant (from the coolant reservoir) 4.
  • Page 98 CHANGING THE COOLANT 7. Check: S copper washer 1 S coolant drain bolt 2 Damage ! Replace. 8. Install: S coolant drain bolt 7 Nm (0.7 mSkg) 9. Connect: S coolant reservoir hose 10. Fill: S cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti...
  • Page 99 CHANGING THE COOLANT CAUTION: S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. S Use only distilled water. Soft water may be used if distilled water is not available.

  • Page 100: Chassis

    ADJUSTING THE FRONT BRAKE EAS00107 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.

  • Page 101: Adjusting The Rear Brake

    ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 40 mm 2.

  • Page 102: Checking The Brake Fluid Level

    ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL 3. Adjust: S rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”. EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright.

  • Page 103: Checking The Brake Pads

    CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH EAS00122 CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S front brake pad S rear brake pad Wear indicator groove 1 almost disap- peared ! Replace the brake pads as a set.

  • Page 104: Checking The Brake Hoses

    CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00131 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check: S brake hose 1 Cracks/damage/wear ! Replace. 2. Check: S brake hose clamp 2 Loose connection ! Tighten.

  • Page 105: Adjusting The Shift Pedal

    BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL 2. Bleed: S hydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). c. Connect a clear plastic hose 1 tightly to the bleed screw 2 .

  • Page 106: Adjusting The Drive Chain Slack

    ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK 2. Adjust: S adjusting bolt length a. Loosen both locknuts 1 . b. Turn the adjusting bolt 2 in direction a or b to obtain the correct shift pedal position. Direction Shift pedal is raised.
  • Page 107 ADJUSTING THE DRIVE CHAIN SLACK 4. Adjust: S drive chain slack a. Loosen the brake caliper bracket bolt. b. Loosen the wheel axle nut 1 . c. Loosen both locknuts 2 . d. Turn both adjusting nuts 3 in direction a or b until the specified drive chain slack is ob- tained.

  • Page 108: Lubricating The Drive Chain

    LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained proper- ly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas.
  • Page 109 CHECKING AND ADJUSTING THE STEERING HEAD b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . NOTE: Set the torque wrench at a right angle to the ring nut wrench. Ring nut wrench 90890-01403 Lower ring nut (initial tightening...

  • Page 110: Checking The Front Fork

    CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK / ADJUSTING THE FRONT FORK LEGS Steering stem nut 110 Nm (11 mSkg) Upper bracket pinch bolt 30 Nm (3.0 mSkg) Handlebar holder bolt 23 Nm (2.3 mSkg) EAS00149 CHECKING THE FRONT FORK 1.
  • Page 111 ADJUSTING THE FRONT FORK LEGS 1. Adjust: S spring preload a. Turn the adjusting bolt 1 in direction a or Spring preload is Direction increased (suspension is harder). Spring preload is Direction decreased (suspension is softer). Adjusting positions Standard: 2 Minimum: 5* Maximum: 1 *fully turned out position...

  • Page 112: Adjusting The Rear Shock Absorber Assembly

    ADJUSTING THE FRONT FORK LEGS/ ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S compression damping a. Turn the adjusting screw 1 in direction a or Compression damping is Direction increased (suspension is harder).
  • Page 113 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY a. Turn the adjusting ring 1 in direction a or b. Align the desired position on the adjusting ring with the stopper 2 . Spring preload is Direction Direction increased (s spension is increased (suspension is harder).

  • Page 114: Checking The Tires

    ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/ CHECKING THE TIRES Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S compression damping a. Turn the adjusting screw 1 in direction a or Compression damping is Direction increased (suspension is harder).
  • Page 115 CHECKING THE TIRES Basic weight (with oil and a 231 kg full fuel tank) Maximum 189 kg load* Cold tire Front tire Rear tire pressure Up to 90 kg 250 kPa 270 kPa load* (2.5 kgf/cm (2.7 kgf/cm 90 kg X 250 kPa 290 kPa maximum load*...
  • Page 116 No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. Front tire Manufacturer Type...
  • Page 117 CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00170 CHECKING LUBRICATING CABLES The following procedure applies to all of the cable sheaths and cables. WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its move- ment.

  • Page 118: Chk Adj

    CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.
  • Page 119 CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
  • Page 120 CHECKING AND CHARGING THE BATTERY 5. Charge: Charging S battery Ambient temperature 20_C (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Make sure that the battery vent is free of ob- structions.
  • Page 121 CHECKING AND CHARGING THE BATTERY Charging method using a variable voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
  • Page 122 CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
  • Page 123 CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Check: S battery vent Obstruction ! Clean. Damage ! Replace. 7. Install: S battery 8. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 .
  • Page 124 CHECKING THE FUSES Pocket tester 90890-03112 b. If the pocket tester indicates “ ”, replace the fuse. 3. Replace: S blown fuse a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electrical circuit is operational.
  • Page 125 REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: S headlight coupler 1 S bulb cover 2 2. Remove: S headlight bulb holder 1 3. Remove: S headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands...
  • Page 126 ADJUSTING THE HEADLIGHT BEAMS/ ADJUSTING THE DIGITAL CLOCK EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or Direction Headlight beam is raised. Direction Headlight beam is lowered.

  • Page 129: Chas

    CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS ......FRONT WHEEL ..........REMOVING THE FRONT WHEEL .
  • Page 130 CHAS FRONT FORK ..........4-44 REMOVING THE FRONT FORK LEGS .

  • Page 131: Chassis

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 72 Nm (7.2 mSkg) 40 Nm (4.0 mSkg) 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. NOTE: discs Place the motorcycle on a suitable stand...

  • Page 132: Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 FRONT WHEEL Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure.

  • Page 133: Removing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00521 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

  • Page 134: Checking The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00525 CHECKING THE FRONT WHEEL 1. Check: S wheel axle Roll the wheel axle on a flat surface. Bends ! Replace. WARNING Do not attempt to straighten a bent wheel axle. 2. Check: S tire S front wheel Damage/wear ! Replace.

  • Page 135: Checking The Brake Discs

    CHAS FRONT WHEEL AND BRAKE DISCS c. Remove the wheel bearings 3 with a gener- al bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing center race 1 or balls 2 .

  • Page 136: Assembling The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) 4.5 mm 4. Adjust: S brake disc deflection a.

  • Page 137: Installing The Front Wheel

    CHAS FRONT WHEEL AND BRAKE DISCS EAS00544 INSTALLING THE FRONT WHEEL The following procedure applies to both brake discs. 1. Lubricate: S wheel axle S oil seal lips Recommended lubricant Lithium soap base grease 2. Tighten: S wheel axle 1 72 Nm (7.2 mSkg) S wheel axle pinch bolt 2 23 Nm (2.3 mSkg)
  • Page 138 CHAS FRONT WHEEL AND BRAKE DISCS 2. Find: S front wheel’s heavy spot a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90_ so that the “X ”...

  • Page 139: Rear Wheel And Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 150 Nm (15 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.
  • Page 140 CHAS REAR WHEEL AND BRAKE DISC EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Spacer Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 4-10...
  • Page 141 CHAS REAR WHEEL AND BRAKE DISC 18 Nm (1.8 mSkg) 69 Nm (6.9 mSkg) Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel sprocket Brake disc Rear wheel sprocket Collar (left and right) Oil seal Bearing Rear wheel drive hub...

  • Page 142: Removing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00561 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 143: Checking The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC EAS00565 CHECKING THE REAR WHEEL 1. Check: S wheel axle S rear wheel S wheel bearings S oil seals Refer to “FRONT WHEEL”. 2. Check: S tire S rear wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS”...

  • Page 144: Checking The Brake Disc

    CHAS REAR WHEEL AND BRAKE DISC Rear wheel sprocket self-locking 69 Nm (6.9 mSkg) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. EAS00531 CHECKING THE BRAKE DISC 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection Out of specification ! Correct the brake disc deflection or replace the brake disc.

  • Page 145: Installing The Rear Wheel

    CHAS REAR WHEEL AND BRAKE DISC 4. Adjust: S brake disc deflection a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.

  • Page 146: Front And Rear Brakes

    CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring brake pad...
  • Page 147 CHAS FRONT AND REAR BRAKES 40 Nm (4.0 mSkg) 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw For installation, reverse the removal...

  • Page 148: Replacing The Front Brake Pads

    CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.
  • Page 149 CHAS FRONT AND REAR BRAKES 2. Remove: S brake pad clips 1 S brake pad pins 2 S brake pad spring 3 3. Remove: S brake pads 1 (along with the brake pad shims) 4. Measure: S brake pad wear limit Out of specification ! Replace the brake pads as a set.

  • Page 150: Replacing The Rear Brake Pads

    CHAS FRONT AND REAR BRAKES d. Install new brake pad shims onto the new brake pads. e. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. 6.
  • Page 151 CHAS FRONT AND REAR BRAKES 3. Measure: S brake pad wear limit Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: S brake pad shims (onto the brake pads) S brake pads S brake pad spring NOTE: Always install new brake pads, brake pad...
  • Page 152 CHAS FRONT AND REAR BRAKES 5. Install: S brake pad cover S brake pad pins S brake pad clips S brake caliper 40 Nm (4.0 mSkg) 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

  • Page 153: Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 10 Nm (1.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Brake lever Brake switch lead Brake switch Union bolt...
  • Page 154 CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 4-24...

  • Page 155: Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg) 4 Nm (0.4 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Side cover (right) Brake fluid Drain.
  • Page 156 CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake master Disassemble the parts in the order listed. cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 4-26...

  • Page 157: Disassembling The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00588 DISASSEMBLING THE FRONT BRAKE MAS- TER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: S brake switch coupler (from the brake switch) 2.

  • Page 158: Checking The Front And Rear Brake Master Cylinders

    CHAS FRONT AND REAR BRAKES EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder Damage/scratches/wear ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air.

  • Page 159: Assembling And Installing The Front Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING INSTALLING FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
  • Page 160 CHAS FRONT AND REAR BRAKES 3. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 161: Assembling The Rear Brake Master Cylinder

    CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: S copper washers 1 S brake hose 2 S union bolt 3 30 Nm (3.0 mSkg) CAUTION: When installing the brake hose onto the brake master cylinder, make sure that the brake pipe touches the projection a as shown.
  • Page 162 CHAS FRONT AND REAR BRAKES 3. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”...

  • Page 163: Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 6 Nm (0.6 mSkg) 40 Nm (4.0 mSkg) 30 Nm (3.0 mSkg) Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose...
  • Page 164 CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the front brake calipers Disassemble the parts in the order listed. The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Brake pad...

  • Page 165: Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain. Union bolt Copper washer Brake hose Brake caliper For installation, reverse the removal...
  • Page 166 CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw For assembly, reverse the disassembly...

  • Page 167: Disassembling The Front Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00625 DISASSEMBLING THE FRONT BRAKE CAL- IPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE:...

  • Page 168: Disassembling The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00628 DISASSEMBLING THE REAR BRAKE CAL- IPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.

  • Page 169: Checking The Front And Rear Brake Calipers

    CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Every two years and whenever the Brake fluid brake is disas- sembled.
  • Page 170 CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING INSTALLING FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 171 CHAS FRONT AND REAR BRAKES 4. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 172: Assembling And Installing The Rear Brake Caliper

    CHAS FRONT AND REAR BRAKES EAS00644 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solevents on internal brake com- ponents as they will cause the piston seals to swell and distort.
  • Page 173 CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.

  • Page 174: Front Fork

    CHAS FRONT FORK EAS00647 FRONT FORK 30 Nm (3.0 mSkg) 25 Nm (2.5 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.
  • Page 175 CHAS FRONT FORK EAS00648 25 Nm (2.5 mSkg) 35 Nm (3.5 mSkg) Order Job/Part Q’ty Remarks Disassembly the front fork Disassemble the parts in the order listed. Cap bolt O-ring Spacer Spring seat Fork spring Damper adjusting rod Dust seal Oil seal clip Damper rod bolt Copper washer...

  • Page 176: Removing The Front Fork Legs

    CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
  • Page 177 CHAS FRONT FORK 2. Remove: S spacer 1 S spring seat 2 S spring 3 S damper adjusting rod 4 3. Drain: S fork oil 4. Remove: S oil seal clip 1 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 5.

  • Page 178: Checking The Front Fork Legs

    CHAS FRONT FORK CAUTION: S Excessive force will damage the oil seal and bushing. A damaged oil seal or bush- ing must be replaced. S Avoid bottoming the inner tube into the outer tube during the above procedure, as the oil flow stopper will be damaged. EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the...

  • Page 179: Assembling The Front Fork Legs

    CHAS FRONT FORK EAS00660 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Make sure that the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor han- dling and a loss of stability.
  • Page 180 (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.44 L (440 cm Recommended oil Yamaha suspension oil “01” or equivalent CAUTION: S Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
  • Page 181 CHAS FRONT FORK 7. Install: S rod puller 1 S rod puller attachment 2 (onto the damper rod 3 ) Rod puller 90890-01437 Rod puller attachment 90890-01436 8. After filling the front fork leg, slowly stroke the damper rod 1 up and down (at least ten times) to distribute the fork oil.
  • Page 182 CHAS FRONT FORK 12. Install: S spring 1 S spring seats 2 S spacer 3 S nut 4 S damper adjusting rod 5 S cap bolt 6 a. Install the fork spring, spring seats, and spacer. NOTE: Install the fork spring with the larger pitch a fac- ing up.

  • Page 183: Installing The Front Fork Legs

    CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder.

  • Page 184: Handlebar

    CHAS HANDLEBAR EAS00664 HANDLEBAR 23 Nm (2.3 mSkg) 26 Nm (2.6 mSkg) 10 Nm (1.0 mSkg) 26 Nm (2.6 mSkg) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Front brake master cylinder Right handlebar switch Throotle cable Grip end (right) Throttle grip...

  • Page 185: Removing The Handlebar

    CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S throttle cable housing 1 S throttle grip 2 3.

  • Page 186: Installing The Handlebar

    CHAS HANDLEBAR 3.Install: S handlebar grip a. Apply a light coat of rubber adhesive onto the left end of the handlebar. b. Slide the handlebar grip over the left end of the handlebar. c. Wipe off any excess rubber adhesive with a clean rag.
  • Page 187 CHAS HANDLEBAR 5. Install: S left handlebar switch NOTE: Align the pins a on the right handlebar switch with the holes b in the handlebar. 6. Install: S clutch lever holder NOTE: Align the slit in the clutch lever holder with the punch mark a in the left handlebar.

  • Page 188: Steering Head

    CHAS STEERING HEAD EAS00676 STEERING HEAD 110 Nm (11.0 mSkg) 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) Order Job/Part Q’ty Remarks Removing the steering head Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL” Front fork Refer to “FRONT FORK”...

  • Page 189: Removing The Lower Bracket

    CHAS STEERING HEAD EAS00677 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S lower ring nut 1 (with the special tool 2 ) Ring nut wrench 90890-01403 WARNING...

  • Page 190: Installing The Steering Head

    CHAS STEERING HEAD b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. c. Install a new rubber seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: S Always replace the bearings and bearing races as a set.

  • Page 191: Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) 48 Nm (4.8 mSkg) 48 Nm (4.8 mSkg) 40 Nm (4.0 mSkg) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Rear wheel Refer to “REAR WHEEL”...

  • Page 192: Handling The Rear Shock Absorber And Gas Cylinder

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you under- stand following information.

  • Page 193: Removing The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 194: Checking The Rear Shock Absorber Assembly

    CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber Gas leaks/oil leaks ! Replace the rear shock absorber assembly. S spring Damage/wear ! Replace the rear shock ab- sorber assembly.

  • Page 195: Swingarm And Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00700 SWINGARM AND DRIVE CHAIN 125 Nm (12.5 mSkg) 85 Nm (8.5 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Removing the swing arm and drive Remove the parts in the order listed. chain Rear wheel Refer to “REAR WHEEL”...
  • Page 196 CHAS SWINGARM AND DRIVE CHAIN 125 Nm (12.5 mSkg) 85 Nm (8.5 mSkg) 23 Nm (2.3 mSkg) Order Job/Part Q’ty Remarks Bearing Spacer Shoft pedal assembly Drive sprocket cover Drive chain guide Drive sprocket Drive chain For installation, reverse the removal procedure.

  • Page 197: Removing The Swingarm

    CHAS SWINGARM AND DRIVE CHAIN EAS00703 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 198: Removing The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00704 REMOVING THE DRIVE CHAIN 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

  • Page 199: Checking The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN 4. Check: S dust covers 1 S spacer 2 S oil seals 3 Damage/wear ! Replace. S bearings 4 Damage/pitting ! Replace. 5. Check: S connecting arms 1 S relay arm 2 Damage/wear ! Replace. S bearings 3 S oil seals 4 Damage/pitting ! Replace.
  • Page 200 CHAS SWINGARM AND DRIVE CHAIN 3. Clean: S drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosine and remove any remaining dirt. c. Remove the drive chain from the kerosine and completely dry it. CAUTION: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain...

  • Page 201: Installing The Drive Chain

    CHAS SWINGARM AND DRIVE CHAIN EAS00713 INSTALLING THE DRIVE CHAIN 1. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2. Install: S drive chain 1 S drive sprocket 2 S washer 3 S drive sprocket nut 4 85 Nm (8.5 mSkg) S drive chain guide 5 NOTE:...
  • Page 202 CHAS SWINGARM AND DRIVE CHAIN NOTE: Install the connecting arm front bolt 1 from the right. 3. Install: S rear shock absorber assembly S rear wheel Refer to “INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY” ”REAR WHEEL”. 4. Adjust: S drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK”...

  • Page 204: Eng

    CHAPTER 5 OVERHAULING THE ENGINE ENGINE ............DRIVE SPROCKET AND EXHAUST PIPE .
  • Page 205 CLUTCH ............5-36 CLUTCH COVER .
  • Page 206 TRANSMISSION ..........5-78 TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS...

  • Page 208: Overhauling The Engine

    ENGINE EAS00188 OVERHAULING THE ENGINE ENGINE DRIVE SPROCKET AND EXHAUST PIPE 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 85 Nm (8.5 mSkg) 20 Nm (2.0 mSkg) Order Job/Part Q’ty Remarks Removing the drive sprocket and Remove the parts in the order listed. exhaust pipe Carburetor Refer to “CARBURETOR”...

  • Page 209: Leads And Hoses

    ENGINE EAS00189 LEADS AND HOSES Order Job/Part Q’ty Remarks Removing the leads and hoses Remove the parts in the order listed. Cover Clutch cable Nuetral switch/speed sensor/pickup 1/1/1 Disconnect. coil lead Water head pipe Coolant outlet hose For installation, reverse the removal pro- cedure.

  • Page 210: Engine

    ENGINE EAS00191 ENGINE 55 Nm (5.5 mSkg) 55 Nm (5.5 mSkg) 24 Nm (2.4 mSkg) 24 Nm (2.4 mSkg) 33 Nm (3.3 mSkg) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. Down tube Engine mounting bolt (front) Engine bracket Engine mounting bolt (rear upper) Engine mounting bolt (rear lower)

  • Page 211: Installing The Engine

    ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: S engine mount bolt 1 S engine mount bolt 2 S engine mount bolt 3 S engine bracket 4 S engine mount bolt 5 S down tube 6 NOTE: Do not fully tighten the bolts. 2.

  • Page 212: Camshaft

    CAMSHAFT EAS00194 CAMSHAFT CYLINDER HEAD COVERS 13 Nm (1.3 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Carburetor assembly Refer to “CARBURETORS” in chapter 6. Radiator assembly and thermostat Refer to “RADIATOR”...

  • Page 213: Camshafts

    CAMSHAFT EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Pickup coil rotor cover Refer to “PICKUP COIL”.
  • Page 214 CAMSHAFT 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Intake camshaft sprocket Exhaust camshaft sprocket Timing chain guide (intake side) For installation, reverse the removal procedure.

  • Page 215: Removing The Camshafts

    CAMSHAFT EAS00198 REMOVING THE CAMSHAFTS 1. Remove: S pickup rotor coil cover 2. Align: S “T” mark on the pickup coil rotor a (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the “T”...

  • Page 216: Checking The Camshafts

    CAMSHAFT 7. Remove S timing chain guide (exhaust side) 1 S camshaft caps S dowel pins CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a criss- cross pattern, working from the outside in. 8.
  • Page 217 CAMSHAFT 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout Less than 0.03 mm 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ³ Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 X 0.062 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps).

  • Page 218: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

    CAMSHAFT EAS00208 CHECKING THE TIMING CHAIN, CAMSHAFT SPROCKETS, AND TIMING CHAIN GUIDES The following procedure applies to all of the camshaft sprockets and timing chain guides. 1. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and camshaft sprockets as a set. 2.

  • Page 219: Installing The Camshafts

    CAMSHAFT 2. Check: S one-way cam operation Rough movement ! Replace the timing chain tensioner housing. a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. NOTE: While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops.
  • Page 220 CAMSHAFT 3. Install: S camshaft cap bolts 10 Nm (1.0 mSkg) NOTE: Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. CAUTION: The camshaft cap bolts must be tightened evenly or damage to the cylinder head, cam- shaft caps, and camshafts will result.
  • Page 221 CAMSHAFT d. Turn both camshafts opposite each other so that the punch marks c in the camshaft are aligned with the arrow marks d in the cam- shaft caps as shown. e. While holding the camshafts, temporarily tighten the camshaft sprocket bolts. 5.
  • Page 222 CAMSHAFT 7. Check: S “T” mark a Make sure that the “T” mark a on the pickup coil rotor is aligned with the crankcase mat- ing surface b . S camshaft punch marks c Make sure that the marks c on the camshaft are aligned with the arrow marks d in the comshaft caps.

  • Page 223: Cylinder Head

    CYLINDER HEAD EAS00221 CYLINDER HEAD 20 Nm (2.0 mSkg) 50 Nm (5.0 mSkg) 20 Nm (2.0 mSkg) 50 Nm (5.0 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Engine Refer to “ENGINE”.

  • Page 224: Removing The Cylinder Heads

    CYLINDER HEAD EAS00223 REMOVING THE CYLINDER HEADS 1. Remove: S cylinder head nuts S cylinder head cap nuts S cylinder head bolts NOTE: S Loosen the nuts in the proper sequence as shown. S Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

  • Page 225: Installing The Cylinder Head

    CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: S gasket S dowel pins 2 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: S cylinder head nuts 1 X 20 Nm (2.0 mSkg) 50 Nm (5.0 mSkg) S cylinder head bolt 11 12...

  • Page 226: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal...
  • Page 227 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure.

  • Page 228: Removing The Valves

    VALVES AND VALVE SPRINGS EAS00237 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1.

  • Page 229: Checking The Valves And Valve Guides

    VALVES AND VALVE SPRINGS 4. Remove: S upper spring seat 1 S valve spring 2 S oil seal 3 S lower spring seat 4 S valve 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place. EAS00239 CHECKING THE VALVES AND VALVE GUIDES...
  • Page 230 VALVES AND VALVE SPRINGS 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C in an oven. a. Remove the valve guide with a valve guide remover 1 .

  • Page 231: Checking The Valve Seats

    VALVES AND VALVE SPRINGS 3. Eliminate: S carbon deposits (from the valve face and valve seat) 4. Check: S valve face Pitting/wear ! Grind the valve face. S valve stem end Mushroom shape or diameter larger than the body of the valve stem ! Replace the valve. 5.
  • Page 232 VALVES AND VALVE SPRINGS a. Apply Mechanic’s blueing dye (Dykem) 1 onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern. d.

  • Page 233: Checking The Valve Springs

    VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length Intake spring 38.9 mm Exhaust spring 40.67 mm...

  • Page 234: Checking The Valve Lifters

    VALVES AND VALVE SPRINGS EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the valve lifters. 1. Check: S valve lifter Damage/scratches ! Replace the valve lift- ers and cylinder head. EAS00245 INSTALLING THE VALVES The following procedure applies to all of the valves and related components.
  • Page 235 VALVES AND VALVE SPRINGS 4. Install: S valve cotters 1 NOTE: Install the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3 . Valve spring compressor 90890-04019 Attachment Intake valve 90890-04114 Exhaust valve 90890-04108 5.

  • Page 236: Generator

    GENERATOR EB410000 GENERATOR 14 Nm (1.4 mSkg) 65 Nm (6.5 mSlkg) + 60_ 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the stator coil assembly Remove the parts in the order listed. Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in chapter 3.

  • Page 237: Removing The Generator

    3 ) Flywheel puller 90890-01080 INSTALLING THE GENERATOR 1. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No. 1215 90890-85505 2. Install: S generator rotor S washer S generator rotor bolt WARNING Always use a new generator rotor bolt.
  • Page 238 GENERATOR 3. Tighten: S generator rotor bolt 1 65 Nm (6.5 mSkg) + 60_ NOTE: S While holding the generator rotor 2 with the rotor holding tool 3 , tighten the generator ro- tor bolt. S After tightening to 65 Nm (6.5 mSkg), tighten another 60_.

  • Page 239: Pickup Coil

    PICKUP COIL PICKUP COIL 60 Nm (6.0 mSkg) 12 Nm (1.2 mSkg) 15 Nm (1.5 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the pickup coil and Remove the parts in the order listed. pickup coil rotor Rider seat and fuel tank Refer to “SEATS”...
  • Page 240 PICKUP COIL 60 Nm (6.0 mSkg) 12 Nm (1.2 mSkg) 15 Nm (1.5 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Pickup coil coupler Disconnect. Pickup coil Pickup coil rotor For installation, reverse the removal procedure. 5-33...

  • Page 241: Removing The Plckup Coil Rotor

    PICKUP COIL REMOVING THE PICKUP COIL ROTOR 1. Remove: S pickup coil lead holder 1 S pickup coil rotor cover 2 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
  • Page 242 Rotor holding tool 90890-01235 3. Apply: S sealant (onto the pickup coil lead grommet) Yamaha bond No. 1215 90890-85505 4. Install: S pickup coil rotor cover S pickup coil lead holder NOTE: S When installing the pickup coil rotor cover, align the timing chain guide (intake side) pin 1 with the hole 2 in the pickup coil rotor cover.

  • Page 243: Clutch

    CLUTCH EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 mSkg) 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Engine oil Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Clutch cable Clutch cover Clutch cover gasket...
  • Page 244 CLUTCH EB405010 Order Job/Part Q’ty Remarks Removing the pull lever shaft Remove the parts in the order listed. Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing For installation, reverse the removal procedure. 5-37...

  • Page 245: Clutch

    CLUTCH EAS00274 CLUTCH 12 Nm (1.2 mSkg) 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Clutch cover Pull rod Friction plate Clutch plate Select. Friction plate Color code: Black Clutch plate Friction plate...
  • Page 246 CLUTCH 12 Nm (1.2 mSkg) 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job/Part Q’ty Remarks Clutch boss nut Lock washer Clutch boss Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear For installation, reverse the removal procedure.

  • Page 247: Removing The Clutch

    CLUTCH EAS00277 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the univer- sal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder 90890-04086 3.
  • Page 248 CLUTCH 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness Friction plate a 3.42 X 3.58 mm <Limit>: 3.32 mm Friction plate b 2.92 X 3.08 mm <Limit>: 2.82 mm 3.

  • Page 249: Checking The Clutch Plates

    CLUTCH EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: S clutch plate Damage ! Replace the clutch plates as a set. 2. Measure: S clutch plate warpage (with a surface plate and thickness gauge 1 ) Out of specification ! Replace the clutch plates as a set.

  • Page 250: Checking The Clutch Housing

    CLUTCH EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing. NOTE: Pitting on the clutch housing dogs will cause er- ratic clutch operation. 2. Check: S bearing Damage/wear ! Replace the clutch hous- ing.

  • Page 251: Checking The Starter Clutch

    CLUTCH 2. Check: S pull rod bearing Damage/wear ! Replace. EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch rollers Damage/wear ! Replace. 2. Check: S starter clutch idle gear S starter clutch drive gear S starter clutch gear Burrs/chips/roughness/wear Replace the defective part(-s).

  • Page 252: Installing The Clutch

    CLUTCH 4. Check: S starter clutch operation a. Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch drive gear clockwise A , the starter clutch and the start- er clutch drive gear should engage.
  • Page 253 CLUTCH 3. Bend the lock washer tab along a flat side of the nut. 4. Lubricate: S friction plates S clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 5. Install: S friction plates S clutch plates NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate.
  • Page 254 CLUTCH 7. Install: S pressure plate 1 NOTE: Align the punch mark b in the pressure plate with the punch mark a in the clutch boss. 8. Install: S clutch springs S clutch spring bolts 8 Nm (0.8 mSkg) NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern.

  • Page 255: Shift Shaft

    SHIFT SHAFT EAS00326 SHIFT SHAFT GENERATOR ROTOR COVER 12 Nm (1.2 mSkg) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Drive sprocket cover Refer to “ENGINE”. Shift shaft cover Shift shaft cover gasket Dowel pin Shift shaft Shift shaft spring...

  • Page 256: Checking The Shift Shaft

    SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift shaft spring 3 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.

  • Page 257: Oil Pan And Oil Pump

    OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 43 Nm (4.3 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks...
  • Page 258 OIL PAN AND OIL PUMP EB411001 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 43 Nm (4.3 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Drain pipe Oil strainer Oil pipe Oil delivery pipe...
  • Page 259 OIL PAN AND OIL PUMP EAS00360 10 Nm (1.0 mSkg) 15 Nm (1.5 mSkg) Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. Oil/water pump assembly driven sprocket Washer Oil pump housing Bearing Oil pump outer rotor Oil pump inner rotor For assembly, reverse the disassembly procedure.

  • Page 260: Removing The Oil Pan

    OIL PAN AND OIL PUMP EAS00362 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S engine oil drain bolt 3 S gasket S dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern.

  • Page 261: Checking The Relief Valve

    OIL PAN AND OIL PUMP EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 S O-ring 4 Damage/wear ! Replace the defective part(-s). EAS00366 CHECKING THE OIL DELIVERY PIPE 1. Check: S oil delivery pipe 1 S oil pipe 2 Damage ! Replace.

  • Page 262: Installing The Oil Pump

    OIL PAN AND OIL PUMP 2. Install: S pin 1 S inner rotor 2 S outer rotor 3 S oil pump housing 4 Oil pump housing screw 10 Nm (1.0 mSkg) NOTE: When installing the inner rotor, align the pin 1 in the oil pump shaft with the groove a on the in- ner rotor 2 .

  • Page 263: Installing The Oil Pan

    OIL PAN AND OIL PUMP EAS00380 INSTALLING THE OIL PAN 1. Install: S dowel pins S gasket S oil pan 1 10 Nm (10 mSkg) S oil level switch 2 10 Nm (10 mSkg) S engine oil drain bolt 3 43 Nm (4.3 mSkg) WARNING Always use new copper washers.

  • Page 264: Crankcase

    CRANKCASE EAS00381 CRANKCASE CRANKCASE 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Pickup coil and pickup coil rotor Refer to “PICKUP COIL”.
  • Page 265 CRANKCASE 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Oil/water pump assembly drive sprocket Washer Plate Lower crankcase Dowel pin For installation, reverse the removal procedure. 5-58...

  • Page 266: Connecting Rods And Pistons

    CRANKCASE EAS00382 CONNECTING RODS AND PISTONS 36 Nm (3.6 mSkg) Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing Top ring...

  • Page 267: Crankshaft

    CRANKCASE CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft assembly Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal procedure.

  • Page 268: Disassembling The Crankcase

    CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: S crankcase bolts NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).

  • Page 269: Removing The Connecting Rods And Pistons

    CRANKCASE EAS00393 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: S connecting rod cap 1 S big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 270: Removing The Crankshaft Assembly

    CRANKCASE 3. Remove: S top ring S 2nd ring S oil ring NOTE: When removing a piston ring, open the end gap with your fingers and lift the other side of the ring over the piston crown. EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1.

  • Page 271: Checking The Cylinders And Pistons

    CRANKCASE EAS00256 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Check: S piston wall S cylinder wall Vertical scratches ! Rebore or replace the cylinder, and replace the piston and piston rings as a set.

  • Page 272: Checking The Piston Rings

    CRANKCASE c. Measure piston skirt diameter “P” with the micrometer. a 0.5 mm from the bottom edge of the piston. Piston size “P” 73.955 X 73.970 mm d. If out of specification, replace the piston and piston rings as a set. e.

  • Page 273: Checking The Piston Pins

    CRANKCASE 2. Install: S piston ring (into the cylinder) NOTE: Level the piston ring in the cylinder with the pis- ton crown as shown. a 5 mm 3. Measure: S piston ring end gap Out of specification ! Replace the piston ring.

  • Page 274: Checking The Crankshaft And Connecting Rods

    CRANKCASE 3. Measure: S piston pin bore inside diameter Out of specification Replace the piston. Piston pin bore inside diameter 17.002 X 17.013 mm 4. Calculate: S piston-pin-to-piston clearance Out of specification ! Replace the piston pin and piston as a set. Piston-pin-to-piston clearance = Piston pin bore size –...
  • Page 275 CRANKCASE CAUTION: Do not interchange the crankshaft journal bearings. To obtain the correct crankshaft- journal-to-crankshaft-journal-bearing clear- ance and prevent engine damage, the crank- shaft journal bearings must be installed in their original positions. a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase.
  • Page 276 CRANKCASE f. Tighten the bolts to specification in the tight- ening sequence cast on the crankcase. Crankcase bolt Bolt 1 X 1st: 15 Nm (1.5 mSkg) 2nd: 15 Nm (1.5 mSkg) + 45 X 50_ Bolt 12 Nm (1.2 mSkg) Bolt 14 Nm (1.4 mSkg) Bolt...
  • Page 277 CRANKCASE CRANKSHAFT JOURNAL BEARING COLOR CODE –1 Pink/violet Pink/white Pink/blue Pink/black Pink/brown 5. Measure: S crankshaft-pin-to-big-end-bearing clear- ance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.031 X 0.055 mm The following procedure applies to all of the connecting rods.
  • Page 278 CRANKCASE 1 on the crank- c. Put a piece of Plastigauge shaft pin. d. Assemble the connecting rod halves. NOTE: S Do not move the connecting rod or crankshaft until the clearance measurement has been completed. S Apply molybdenum disulfide grease onto the bolts, threads, and nut seats.

  • Page 279: Checking The Crankcase

    CRANKCASE 6. Select: S big end bearings (P NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S “P1” X “P5” refer to the bearings shown in the crankshaft illustration.

  • Page 280: Checking The Sprockets And Chains

    CRANKCASE CHECKING THE SPROCKETS AND CHAINS 1. Check: S crankshaft sprocket 1 S oil/water pump assembly drive sprocket 2 Cracks/damage/wear ! Replace the de- fective part(-s). 2. Check: S timing chain 1 Damage/stiffness ! Replace the timing chain and crankshaft sprocket as a set. S oil/water pump assembly drive chain 2 Damage/stiffness ! Replace the oil/water pump assembly drive chain and oil/water...

  • Page 281: Installing The Connecting Rod And Piston

    CRANKCASE EAS00268 INSTALLING THE CONNECTING ROD AND PISTON The following procedure applies to all of the connecting rods and pistons. 1. Install: S top ring 1 S 2nd ring 2 S upper oil ring rail 3 S oil ring expander 4 S lower oil ring rail 5 NOTE: Be sure to install the piston rings so that the...
  • Page 282 CRANKCASE 5. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 6. Install: S big end bearings S connecting rod assembly (into the cylinder and onto the crankshaft pin).

  • Page 283: Assembling The Crankcase

    Recommended lubricant Engine oil 2. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings.
  • Page 284 CRANKCASE 6. Install: S upper crankcase 1 (onto the lower crankcase 2 ) CAUTION: Before tightening the crankcase bolts, make sure that the transmission gears shift cor- rectly when the shift drum assembly is turned by hand. 7. Install: S crankcase bolts NOTE: S Lubricate the bolt threads with engine oil.

  • Page 285: Transmission

    TRANSMISSION EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE”.
  • Page 286 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassembly the parts in the order listed. assembly 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Toothed spacer Toothed washer Circlip 3rd/4th pinion gears 5th pinion gear Collar 5-79...
  • Page 287 TRANSMISSION Order Job/Part Q’ty Remarks Main axle/1st pinion gear Bearing Main axle bearing housing For assembly, reverse the disassembly procedure. 5-80...
  • Page 288 TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Disassembly the parts in the order listed. assembly Washer 1st wheel gear Spacer 5th wheel gear Circlip Washer 3rd wheel gear Toothed spacer Toothed lock washer Toothed lock washer retainer 5-81...
  • Page 289 TRANSMISSION Order Job/Part Q’ty Remarks 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer For assembly, reverse the disassembly procedure. 5-82...

  • Page 290: Removing The Transmission

    TRANSMISSION EAS00420 REMOVING THE TRANSMISSION 1. Remove: S main axle assembly 1 (with the Torx wrench T30) a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crank- case surface.

  • Page 291: Checking The Shift Drum Assembly

    TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum. S shift drum segment 1 Damage/wear ! Replace. S shift drum bearing 2 Damage/pitting ! Replace. EAS00425 CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge 1 ) Out of specification ! Replace the main...

  • Page 292: Installing The Transmission

    TRANSMISSION EAS00428 INSTALLING THE TRANSMISSION S main axle assembly S shift fork “C” S shift drum assembly S shift fork “R” S shift fork “L” S springs S shift fork guide bars S drive axle assembly NOTE: S Carefully position the shift forks so that they are installed correctly into the transmission gears.

  • Page 295: Cool

    COOL CHAPTER 6 COOLING SYSTEM RADIATOR ........... . CHECKING THE RADIATOR .
  • Page 296 COOL...

  • Page 297: Cooling System

    COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Coolant Drain. Water inlet hose Carburetor hose Oil cooler hose Water outlet hose Radiator Fan motor For installation, reverse the removal procedure.

  • Page 298: Checking The Radiator

    COOL RADIATOR EAS00455 CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the radia- tor. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.

  • Page 299: Installing The Radiator

    COOL RADIATOR EAS00456 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. a.

  • Page 300: Thermostat

    COOL THERMOSTAT EAS00460 THERMOSTAT Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Front cowling Refer to “FRONT COWLING” in chapter 3. Coolant reservoir hose Water inlet hose Water outlet hose Thermostat housing For installation, reverse the removal procedure.
  • Page 301 COOL THERMOSTAT EAS00461 15 Nm (1.5 mSkg) Order Job/Part Q’ty Remarks Disassembling the thermostat housing Disassemble the parts in the order listed. Thermostat housing cover Thermostat /O-ring Thermostat housing Thermo unit For assembly, reverse the disassembly procedure.

  • Page 302: Checking The Thermostat

    COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat Does not open at 71 X 85_C ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.

  • Page 303: Installing The Thermostat

    COOL THERMOSTAT 2. Install: S thermo unit 1 15 Nm (1.5 mSkg) CAUTION: Use extreme care when handling the thermo unit. Replace any part that was dropped or subjected to a strong impact. EAS00466 INSTALLING THE THERMOSTAT 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT”...

  • Page 304: Water Pump

    COOL WATER PUMP EAS00469 WATER PUMP 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. NOTE: S The water pump and oil pump are combined into one unit (oil/water pump assembly).
  • Page 305 COOL WATER PUMP 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Water pump seal Oil seal Bearing For assembly, reverse the disassembly procedure.

  • Page 306: Disassembling The Water Pump

    COOL WATER PUMP EAS00470 DISASSEMBLING THE WATER PUMP 1. Remove: S water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: S oil sesal 1 S bearing 2 NOTE: Tap out the bearing and oil seal from the outside...

  • Page 307: Assembling The Water Pump

    NOTE: S Install the water pump seal with the water pump seal installers. S Before installing the water pump seal, apply Yamaha bond No.1215 2 to the water pump housing 3 . Water pump seal installer 4 90890-04078 Middle driven shaft bearing...
  • Page 308 COOL WATER PUMP 3. Install: S rubber damper S rubber damper holder NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface. 4. Measure: S tilt Out of specification ! Repeat steps (3) and (4). CAUTION: Make sure that the rubber damper and rub- ber damper holder are flush with the impel-...

  • Page 310: Carb

    CARB CHAPTER 7 CARBURETORS CARBURETORS ..........AIR FILTER CASE .
  • Page 311 CARB...

  • Page 312: Carburetors

    CARB CARBURETORS CARBURETORS CARBURETORS AIR FILTER CASE Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seat, fueltank and sidecovers Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. Drain the coolant Refer to “CHANGING THE COOLANT”...
  • Page 313 CARB CARBURETORS EAS00481 Order Job/Part Q’ty Remarks Removing the carburetors Remove the parts in the order listed. Throttle position sensor lead Disconnect. Air filter joint screw Carburetors joint screw Carburetor inlet/outlet hose Carburetors assembly Starter cable Throttle cable For installation, reverse the removal procedure.
  • Page 314 CARB CARBURETORS EAS00482 Order Job/Part Q’ty Remarks Separating the carburetor Remove the parts in the order listed. Throttle stop screw Coolant hose Starter plunger link Connecting bolt Spacer Connecting bolt Spacer Fuel inlet pipe Fuel feed pipe Spring Vacuum chamber air vent hose Float chamber air vent hose Throttle position sensor Throttle position sensor bracket...
  • Page 315 CARB CARBURETORS EAS00484 Order Job/Part Q’ty Remarks Disassembling the carburetor Disassemble the parts in the order listed. NOTE: The following procedure applies to all of the carburetors. Starter plunger Pilot air jet Vacuum chamber cover Piston valve spring Piston valve Jet needle holder Jet needle kit Pilot screw...
  • Page 316 CARB CARBURETORS Order Job/Part Q’ty Remarks Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Needle jet For assembly, reverse the disassembly procedure.

  • Page 317: Checking The Carburetors

    CARB CARBURETORS EAS00486 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: S carburetor body S float chamber S jet housing Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleum-based solvent.
  • Page 318 CARB CARBURETORS 8. Check: S piston valve 1 Damage/scratches/wear! Replace. S rubber diaphragm 2 Cracks/tears ! Replace. 9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 Cracks/damage ! Replace. 10. Check: S jet needle kit 1 S needle jet 2 S main jet 3 S main jet holder 4...

  • Page 319: Assembling The Carburetors

    CARB CARBURETORS EAS00489 ASSEMBLING THE CARBURETORS The following procedure applies to both of the carburetors. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleum-based sol- vent. S Always use a new gasket. 1. Install: S jet needle kit 2.

  • Page 320: Installing The Carburetors

    CARB CARBURETORS d. If either the needle valve seat or needle valve is worn, replace them both. e. If both the needle valve seat and needle valve are fine, adjust the float height by bend- ing the float tang 1 . f.

  • Page 321: Measuring And Adjusting The Fuel Level

    CARB CARBURETORS EAS00495 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust. Fuel level (below the line on the float chamber) 3.0 X 4.0 mm a. Stand the motorcycle on a level surface. b.

  • Page 322: Checking And Adjusting The Throttle Position Sensor

    CARB CARBURETORS EAS00500 CHECKING ADJUSTING THROTTLE POSITION SENSOR NOTE: S Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. S When installing the throttle position sensor, adjust its angle according to the RPM which is displayed on the tachometer.
  • Page 323 CARB CARBURETORS 2. Adjust: S throttle position sensor angle a. Turn the main switch to “ON”. b. Disconnect the throttle position sensor cou- pler. c. Reconnect the throttle position sensor cou- pler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode.

  • Page 324: Checking The Fuel Pump

    CARB CARBURETORS EAS00504 CHECKING THE FUEL PUMP 1. Check: S fuel pump 1 a. Place a container under the end of the fuel hose. b. Start the engine and check if fuel flows from the fuel hose 2 . Fuel flows. Fuel pump is OK.

  • Page 325: Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned ex- haust gases by injecting fresh air (secondary air) into the exhaust port, reducing the emission of hydrocarbons. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port.

  • Page 326: Air Induction System Diagrams

    CARB AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Reed valve 2 Air cleaner 3 Air cutoff valve 4 Carburetor joint (cylinder #4) A To the air cutoff valve B To cylinder #1 C To cylinder #2 D To cylinder #3 E To cylinder #4 7-15...

  • Page 327: Checking The Air Induction System

    CARB AIR INDUCTION SYSTEM EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: S hoses Loose connection ! Connect properly. Cracks/damage ! Replace. S pipes Cracks/damage ! Replace. 2. Check: S fibre reed 1 S fibre reed stopper S reed valve seat Cracks/damage ! Replace the reed valve.

  • Page 329: Elec

    ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ........ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS .
  • Page 330 ELEC EXUP SYSTEM ..........8-51 CIRCUT DIAGRAM .

  • Page 331: Electrical Components

    ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL ELECTRICAL COMPONENTS Main switch Starting circuit cutoff relay Oil level gauge Fuel sender Flasher relay Ignition coil Rear brake switch Speed sensor Rectifier/ Regulator Battery Sidestand switch Thermo unit Ignitor unit Neutral switch Horn Starter relay Emargency stop switch Fan motor relay...

  • Page 332: Arrangement Of The Electrical Components And Couplers

    ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS Thermo unit T.P.S. Starter motor Pickup rotor Pickup coil...
  • Page 333 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Ignitor unit Fuse box Battery Fuel pump Fuel pump coupler Brake light switch coupler Newtral switch coupler Pickup coil coupler Speed sensor coupler...
  • Page 334 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Ignition coil #2.3 Ignition coil #1.4 Rectifier/ regulator Stator coil...
  • Page 335 ARRANGEMENT OF THE ELECTRICAL ELEC COMPONENTS AND COUPLERS Emargency stop switch Flasher relay Starter relay Fan motor relay Starting circuit cutoff relay Stator coil coupler Sidestand switch coupler Fuel sender coupler Oil level switch coupler...

  • Page 336: Instrument Functions

    ELEC INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS INDICATOR LIGHTS Turn indicator light “ ” “ ” This indicator flashes when the turn switch is moved to the left or right, and the hazard switch is on. Neutral indicator light “ ” This indicator comes on when the transmis- sion is in neutral.
  • Page 337 ELEC INSTRUMENT FUNCTIONS DIGITAL CLOCK Clock To set the clock: 1. Push both the “SELECT” 1 and “RESET” 2 buttons for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button 2 to set the hours. 3.

  • Page 338: Checking Switch Continuity

    ELEC CHECKING SWITCH CONTINUITY EAS00730 CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1 .

  • Page 339: Checking The Switches

    ELEC CHECKING THE SWITCHES EAS00731 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the termi- nals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear ! Repair or replace the switch. Improperly connected ! Properly connect. Incorrect continuity reading ! Replace the switch.

  • Page 340: Checking The Bulbs And Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS EAS00732 CHECKING BULBS BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continu- ity between the terminals. Damage/wear ! Repair or replace the bulb, bulb socket or both. Improperly connected ! Properly connect.

  • Page 341: Checking The Condition Of The Bulbs

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING CONDITION BULBS The following procedure applies to all of the bulbs. 1. Remove: S bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: S Be sure to hold the socket firmly when re- moving the bulb.

  • Page 342: Checking The Condition Of The Bulb Sockets

    ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: S bulb socket (for continuity) (with the pocket tester) No continuity ! Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the...

  • Page 343: Ignition System

    ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Ignitor Ignition coil Spark plug Pickup coil Engine stop switch Fuse (ignition) 8-13...
  • Page 344 ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING THE BATTERY” in spark or intermittent spark). CHAPTER 3. Check: Minimum open-circuit voltage 1. Main and ignition fuses 12.8 V or more at 20_C 2.
  • Page 345 ELEC IGNITION SYSTEM EAS00743 Spark plug cap resistance 4. Ignition spark gap 10 kΩ at 20_C The following procedure applies to all of the S Is the spark plug cap OK? spark plugs. S Disconnect the spark plug cap from the spark plug.
  • Page 346 ELEC IGNITION SYSTEM EAS00748 Secondary coil resistance 9. Pickup coil resistance 12 X 18 kΩ at 20_C S Disconnect the pickup coil coupler from the S Is the ignition coil OK? wire harness. S Connect the pocket tester (Ω 100) to the pickup coil terminal as shown.

  • Page 347: Electric Starting System

    ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starter relay Starter motor Starting circuit cutoff relay Side stand switch Neutral switch Engine stop switch Start switch Clutch switch Fuse (ignition) Alarm 8-17...

  • Page 348: Starting Circuit Cutoff System Operation

    ELEC ELECTRIC STARTING SYSTEM EAS00756 STARTING CIRCUIT CUTOFF SYSTEM OP- ERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: S The transmission is in neutral (the neutral switch is closed).

  • Page 349: Troubleshooting

    ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING THE BATTERY” in Check: CHAPTER 3. 1. Main and ignition fuses Minimum open-circuit voltage 2. Battery 12.8 V or more at 20_C 3.
  • Page 350 ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cutoff relay S Disconnect the starting circuit cutoff relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cutoff relay coupler as shown.
  • Page 351 ELEC ELECTRIC STARTING SYSTEM EAS00751 EAS00766 8. Neutral switch 12. Wiring S Check the neutral switch for continuity. S Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. S Is the neutral switch OK? S Is the starting system’s wiring properly con- nected and without defects? Replace the neutral...

  • Page 352: Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00767 STARTER MOTOR Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Carburetor Refer to “CARBURETOR” in chapter 7. Starter motor lead Starter motor/O-ring For installation, reverse the removal procedure. 8-22...
  • Page 353 ELEC ELECTRIC STARTING SYSTEM EAS00768 5 Nm (0.5 mSkg) 10 Nm (1.0 mSkg) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassemble the parts in the order listed. Starter motor front cover Lock washer Refer to “ASSEMBLING THE STARTER Oil seal MOTOR”.

  • Page 354: Checking The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM EAS00769 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600-grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm 3. Measure: S mica undercut a Out of specification ! Scrape the mica to the proper measurement with a hacksaw blade...

  • Page 355: Assembling The Starter Motor

    ELEC ELECTRIC STARTING SYSTEM b. If any resistance is out of specification, re- place the starter motor. 5. Measure: S brush length a Out of specification ! Replace the brushes as a set. Brush length wear limit 4 mm 6. Measure: S brush spring force Out of specification ! Replace the brush springs as a set.
  • Page 356 ELEC ELECTRIC STARTING SYSTEM 2. Install: S starter motor front cover 1 S starter motor rear cover 2 S O-ring 3 NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.

  • Page 357: Charging System

    ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM Rectifire/ reguretor AC magneto Battery Fuse (main) 8-27...
  • Page 358 ELEC CHARGING SYSTEM EAS00774 TROUBLESHOOTING The battery is not being charged. S Clean the battery terminals. Check: S Recharge 1. Main fuse place the battery. 2. Battery 3. Charging voltage 4. Stator coil resistance EAS00775 3. Charging voltage 5. Wiring connections (of the entire charging system) S Connect the engine tachometer to the spark NOTE:...
  • Page 359 ELEC CHARGING SYSTEM EAS00776 4. Stator coil resistance S Remove the generator cover. S Connect the pocket tester (Ω 1) to the sta- tor coils as shown. Positive tester probe ! white Negative tester probe ! white Positive tester probe ! white Negative tester probe ! white S Measure the stator coil resistances.
  • Page 360 ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM Dimmer switch Main switch Headlight Battery Fuse (main) Tail / brake light Hi-beam indicator light Fuse (Alarm) Fuse (headlight) Meter light Headlight relay (on / off) Headlight switch Pass switch Headlight relay (dimmer) 8-30...
  • Page 361 ELEC LIGHTING SYSTEM EAS00781 TROUBLESHOOTING Any of the following fail to light: headlight, S Clean the battery high beam indicator light, taillight, auxilia- terminals. ry light or meter light. S Recharge Check: place the battery. 1. Main, headlight and alarm fuses 2.
  • Page 362 ELEC LIGHTING SYSTEM EAS00786 Low-beam 6. Pass switch Positive tester probe ! black/blue S Check the pass switch for continuity. Negative tester probe ! black/green Refer to “CHECKING THE SWITCHES”. S Is the pass switch OK? The pass switch is faulty.
  • Page 363 ELEC LIGHTING SYSTEM EAS00788 S Set the main switch to “ON”. CHECKING THE LIGHTING SYSTEM S Set the light switch to “ON”. 1. The headlight and the high beam indicator S Set the dimmer switch to “ ” or “ ”.

  • Page 364: Lighting System

    ELEC LIGHTING SYSTEM S Set the main switch to “ON”. S Set the main switch to “ON”. S Set the light switch to “PO” or “ON”. S Set the light switch to “PO” or “ON”. S Measure the voltage (12 V) of blue S Measure the voltage (12 V) of blue/red on the meter light coupler (wire harness side).

  • Page 365: Circuit Diagram

    ELEC SIGNAL SYSTEM EAS00793 SIGNAL SYSTEM CIRCUIT DIAGRAM 8-35...
  • Page 366 ELEC SIGNAL SYSTEM 1 Main switch 5 Battery 7 Fuse (main) 9 Starting circuit cutoff relay Neutral switch Fuel level warning light Oil level warning light Neutral indicator light Combination meter Fuel gauge Turn signal indicator light (left) Turn signal indicator light (right) Oil level gauge Fuel sender Turn signal relay...

  • Page 367: Troubleshooting

    ELEC SIGNAL SYSTEM EAS00794 EAS00749 TROUBLESHOOTING 3. Main switch S Any of the following fail to come on: turn S Check the main switch for continuity. signal light, brake light or indicator light. Refer to “CHECKING THE SWITCHES”. S The horn fails to sound. S Is the main switch OK? Check: 1.
  • Page 368 ELEC SIGNAL SYSTEM Positive tester probe ! pink 4. Voltage Negative tester probe ! black S Connect the pocket tester (DC 20 V) to the horn connector at the black terminal as shown. Positive tester probe ! black Negative tester probe ! ground S Set the main switch to “ON”.
  • Page 369 ELEC SIGNAL SYSTEM 3. Voltage 2. Turn signal switch S Connect the pocket tester (DC 20 V) to the S Check the turn signal switch for continuity. tail/brake light coupler (wire harness side) Refer to “CHECKING THE SWITCHES”. as shown. S Is the turn signal switch OK? Positive tester probe ! yellow Negative tester probe ! black...
  • Page 370 ELEC SIGNAL SYSTEM 4. Voltage S Connect the pocket tester (DC 20 V) to the flasher relay coupler (wire harness side) as shown. Positive tester probe ! brown/white Negative tester probe ! ground S Set the main switch to “ON”. S Set the turn signal switch to “...
  • Page 371 ELEC SIGNAL SYSTEM 3. Voltage 2. Engine oil level switch S Connect the pocket tester (DC 20 V) to the S Drain the engine oil and remove the engine meter light bulb coupler (wire harness side) oil level switch from the oil pan. S Check the engine oil level switch for conti- as shown.
  • Page 372 ELEC SIGNAL SYSTEM EAS00804 S Set the main switch to “ON”. 5. The fuel level gauge fails to operate. S Measure the voltage (12 V) of brown 1. Fuel sender the meter light coupler (wire harness side). S Remove the fuel sender from the fuel tank. S Is the voltage within specification? S Connect the pocket tester to the fuel sender coupler (wire harness side) as shown.

  • Page 373: Cooling System

    ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Thermo unit Combination meter Water temp warning light Fues (fan) Fan motor relay Fan motor 8-43...
  • Page 374 ELEC COOLING SYSTEM EAS00808 S Is the battery OK? TROUBLESHOOTING S The radiator fan motor fails to turn. S The water temperature gauge needle fails to move when the engine is warm. S Clean the battery terminals. Check: S Recharge 1.
  • Page 375 ELEC COOLING SYSTEM EAS00812 EAS00759 5. Thermo unit 6. Fan motor relay S Remove the thermo unit from the thermostat S Disconnect the fan motor relay coupler from housing. the wire harness. S Connect the pocket tester (Ω  1) to the ter- S Connect the pocket tester (Ω...

  • Page 376: Fuel Pump System

    ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) Starting circuit cutoff relay Fuel pump Ignitor Engine stop switch Fuse (ignition) 8-46...

  • Page 377: Fuel Pump Circuit Operation

    ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP CIRCUIT OPERATION Battery The ignitor unit includes the control unit for the Main fuse fuel pump. Main switch Ignition fuse Engine stop switch Ignitor unit Fuel pump relay Fuel pump 8-47...

  • Page 378: Troubleshooting

    ELEC FUEL PUMP SYSTEM EAS00816 EAS00749 TROUBLESHOOTING 3. Main switch If the fuel pump fails to operate. S Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. Check: S Is the main switch OK? 1. Main and ignition fuses 2.
  • Page 379 ELEC FUEL PUMP SYSTEM EAS00817 6. Fuel pump resistance S Disconnect the fuel pump coupler from the wire harness. S Connect the pocket tester (Ω 1) to the fuel pump coupler as shown. Positive tester probe ! black/blue Negative tester probe ! black S Measure the fuel pump resistance.

  • Page 380: Checking The Fuel Pump

    ELEC FUEL PUMP SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: S Stop the engine before refuelling. S Do not smoke, and keep away from open flames, sparks, or any other source of fire.

  • Page 381: Exup System

    ELEC EXUP SYSTEM EAS00827 EXUP SYSTEM CIRCUIT DIAGRAM Main switch Battery Fuse (main) EXUP servomotor Ignitor Fuse (ignition) 8-51...

  • Page 382: Troubleshooting

    ELEC EXUP SYSTEM EAS00828 EAS00829 Procedure 1 TROUBLESHOOTING 1. EXUP servomotor operation (with the When the engine speed changes, the EXUP servomotor coupler connected to EXUP servomotor does not operate. the wire harness) Procedure 1 S Disconnect the EXUP cables at the EXUP Check: servomotor pulley side.
  • Page 383 ELEC EXUP SYSTEM EAS00831 3. EXUP servomotor operation (with the servomotor coupler disconnected to the wire harness) S Disconnect the EXUP cables from the EXUP servomotor pulley. S Disconnect the EXUP servomotor coupler from the wire harness. S Connect the battery leads to the EXUP ser- vomotor coupler as shown.
  • Page 384 ELEC EXUP SYSTEM EAS00750 Procedure 2 4. Engine stop switch EAS00738 1. Main and ignition fuses S Check the engine stop switch for continuity. S Check the main and ignition fuses for conti- Refer to “CHECKING THE SWITCHES”. nuity. S Is the engine stop switch OK? Refer to “CHECKING THE FUSES”...

  • Page 385: Self-Diagnosis

    ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The FZS1000 features a self-diagnosing system for the following circuit(-s): S Throttle position sensor S EXUP S Speed sensor S Emargency stop switch If any of these circuits are defective, their respective condition codes will be displayed on the tachome- ter when the main switch is set to “ON”...
  • Page 386 ELEC SELF-DIAGNOSIS Tachometer display sequence Revolution 0 r / min ... 3 seconds r / min) Condition code ... 2.5 seconds Tachometer display Engine speed ... 3 seconds Engine speed Time (seconds) When more than one item is being monitored, the tachometer needle displays the condition codes in ascending order, cycling through the sequence repeatedly.
  • Page 387 ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The tachometer starts to display the self- S Check the wire harness for continuity. diagnosis sequence. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Check: 1. Throttle position sensor 2. EXUP 3. Speed sensor 4.
  • Page 388 ELEC SELF-DIAGNOSIS 2. EXUP 2. EXUP servomotor CIRCUIT DIAGRAM S Check the EXUP servomotor for continuity. Refer to “EXUP SYSTEM”. S Is the EXUP servomotor OK? Replace the ignitor Replace the EXUP unit. servomotor. EXUP servomotor Ignitor unit 1. Wire harness S Check the wire harness for continuity.
  • Page 389 ELEC SELF-DIAGNOSIS 3. Speed sensor 1. Wire harness CIRCUIT DIAGRAM S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Replace the speed sensor. Replace the ignitor Repair or replace the unit. wire harness. lgnitor unit Speed sensor 8-59...
  • Page 390 ELEC SELF-DIAGNOSIS 4. Emargency stop switch 1. Wire harness CIRCUIT DIAGRAM S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Replace the emar- gency stop switch. Replace the ignitor Repair or replace the unit.

  • Page 392: Trbl Shtg

    TRBL SHTG CHAPTER 9 TROUBLESHOOTING STARTING PROBLEMS ENGINE ........... FUEL SYSTEM .
  • Page 393 TRBL SHTG FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT ......HEADLIGHT BULB BURNT OUT .

  • Page 394: Starting Problems Engine

    TRBL TROUBLESHOOTING SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.

  • Page 395: Electrical Systems

    TRBL TROUBLESHOOTING SHTG ELECTRICAL SYSTEMS Battery Ignition system S Discharged battery S Faulty ignitor unit S Faulty battery S Faulty pickup coil S Broken generator rotor woodruff key Fuse(s) S Blown, damaged or incorrect fuse Switches and wiring S Improperly installed fuse S Faulty main switch S Faulty engine stop switch S Broken or shorted wiring...

  • Page 396: Fuel System

    TRBL TROUBLESHOOTING SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING PROBLEMS”. ENGINE FUEL SYSTEM Air filter Carburetor(s) S Clogged air filter element S Faulty diaphragm S Incorrect fuel level S Loose or clogged main jet Fuel pump S Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT...

  • Page 397: Faulty Clutch Clutch Slips

    TRBL TROUBLESHOOTING SHTG EAS00851 FAULTY CLUTCH CLUTCH SLIPS CLUTCH DRAGS Clutch Clutch S Improperly assembled clutch S Unevenly tensioned clutch springs S Improperly adjusted clutch cable S Warped pressure plate S Loose or fatigued clutch spring S Bent clutch plate S Worn friction plate S Swollen friction plate S Worn clutch plate...

  • Page 398: Overcooling Cooling System

    TRBL TROUBLESHOOTING SHTG EAS00856 OVERCOOLING COOLING SYSTEM Thermostat S Thermostat stays open EAS00857 POOR BRAKING PERFORMANCE S Worn brake pad S Worn brake disc S Air in hydraulic brake system S Leaking brake fluid S Faulty brake caliper seal S Loose union bolt S Damaged brake hose S Oil or grease on the brake disc S Oil or grease on the brake pad...

  • Page 399: Unstable Handling

    TRBL TROUBLESHOOTING SHTG EAS00862 UNSTABLE HANDLING Handlebar Rear shock absorber assembly(-ies) S Bent or improperly installed handlebar S Faulty rear shock absorber spring S Leaking oil or gas Steering head components S Improperly installed upper bracket Tire(s) S Improperly installed lower bracket S Uneven tire pressures (front and rear) S Incorrect tire pressure (improperly tightened ring nut)

  • Page 400: Faulty Lighting Or Signaling System

    TRBL TROUBLESHOOTING SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT LIGHT TURN SIGNAL DOES NOT LIGHT S Wrong headlight bulb S Faulty turn signal switch S Too many electrical accessories S Faulty turn signal relay S Hard charging S Burnt-out turn signal bulb S Incorrect connection S Incorrect connection...
  • Page 402 FZS1000 2001 WIRING DIAGRAM (EUR) Main switch Oil level gauge Rectifier/ regulator Fuel sender Turn signal relay AC magneto Fuse (back up) Handlebar switch (right) Battery Front brake light switch Headlight switch Starter relay Fuse (main) Engine stop switch Starter motor Start switch Starting circuit cutoff relay Horn...
  • Page 403 FZS1000 N 2001 WIRING DIAGRAM (OCE) Main switch Turn signal indicator light (left) Rectifier/ regulator Turn signal indicator light (right) AC magneto Meter light Fuse (back up) Oil level gauge Battery Fuel sender Starter relay Turn signal relay Handlebar switch (right) Fuse (main) Starter motor Front brake light switch...

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