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_;YAMAHA
YZF-R3
Service Manual
EAS20003
IMPORTANT
This manual was produced by the Yamaha Motor Corporation, U.S.A. primarily for use by Yamaha
dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types of
vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render
the vehicle unsafe and unfit for use.
Yamaha Motor Corporation, U.S.A. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
EAS30001
1. Check:
Installed c ompression spring Valve titter
force (i ntake) Damage/scratches --+ Replace the valve lift-
159.6<>-183.60 N (16.27- 18.72 ers and cylinder head
kgl, 35.88-41 .27 lbl)
Installed compression spring
force (exhausl) mrALLING THE VALVES
159.6<>-183.60 N (16.27- 18.72 The following procedure applies to all of the
kgl, 35.88-41 .27 lbl) 'V alves and related componen1s.
Installed lenglh (Intake) 1. Deburr:
30.90 mm (1.22 in) Valvestem end
Installed length (exhaust) (wilh an oil stone)
30.90 mm (1.22 in)
5-28 5-33
EAS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
1
m Engine oil Replace the part with a new one.
1
m Silicone fluid
,,,,_ TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
CHASSIS
ENGINE
COOLING SYSTEM
FUEL SYSTEM
ELECTRICA L SYSTEM
TROUBLESHOOTING
GENERAL INFORMATION
EAS20007
IDENTIFICATION
EAS30002
EAS30003
MODEL LABEL
The model label "1" is affixed to the frame under
the passenger seat. This information will be
needed to order spare parts.
1-1
FEATURES
EAS20008
FEATURES
EAS30005
16 15 14 13 12 11 10 9
1. Engine trouble warning light 1O. ISC (idle speed control) unit
2. Ignition coils 11. Throttle body sensor assembly
3. Air induction system solenoid 12. 0 2 sensor
4. Coolant temperature sensor 13. Sidestand switch
5. Fuel pump 14. Crankshaft position sensor
6. Battery 15. Speed sensor
7. ECU (engine control unit) 16. Spark plugs
8. Lean angle sensor
9. Fuel injectors
1-2
FEATURES
EAS30617
Fl SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the
fuel pressure that is applied to the fuel injector at a certain level. Accordingly, when the energizing signal
from the ECU energizes the fuel injector, the fuel passage opens , causing the fuel to be injected into
the intake manifold only during the time the passage remains open. Therefore, the longer the length of
time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied.
Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser
the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from the
throttle position sensor, coolant temperature sensor, lean angle sensor, crankshaft position sensor, in-
take air pressure sensor, intake air temperature sensor, speed sensor and 0 2 sensor enable the ECU
to determine the injection duration. The injection timing is determined through the signals from the
crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be supplied
at all times in accordance with the driving conditions.
8
B
16
11-------- ---------------------------------
----
10
1-3
FEATURES
EAS30982
Tachometer
MULTI-FUNCTION METER UNIT
2
1. Tachometer
1. "SEL' button
2. Tachometer red zone
2. "RES" button
3. Tachometer The tachometer allows the rider to monitor the
4. Fuel meter engine speed and keep it within the ideal power
5. Shift timing indicator light range.
6. Clock When the key is turned to"()", the tachometer
7. Transmission gear display will sweep across the r/min range and then re-
8. Speedometer turn to zero r/min in order to test the electrical cir-
9. Multi-function display cuit.
ECA 19660
10. Coolant temperature meter
EWA12423
1-4
FEATURES
6. Push the "SEL" button and then release it to When the key is turned to"()", the display seg-
start the clock. ments of the digital coolant temperature gauge
will sweep once across the temperature range
Fuel meter and then return to "C" in order to test the electri-
cal circuit.
If the last segment on the right flashes, stop the
vehicle, then stop the engine, and let the engine
0 cool.
ECA10022
This fuel meter is equipped with a self-diagnosis 1. Neutral indicator light" N"
system. If a problem is detected in the electrical
2. Transmission gear display
circuit, the following cycle is repeated until the
malfunction is corrected: fuel level segments This display shows the selected gear. The neu-
flash eight times, then go off for approximately tral position is indicated by " - " and by the neu-
three seconds. If this occurs, check the electrical tral indicator light.
circuit. Refer to "SIGNALING SYSTEM" on page
8-21. Multi-function display
H'
c
.1
I
1. Multi-function display
1-5
FEATURES
1-6
FEATURES
Oil change tripmeter Activation point: this function allows you to se-
lect the engine speed at which the indicator
light is activated.
Deactivation point: this function allows you to
select the engine speed at which the indicator
light is deactivated.
Brightness: this function allows you to adjust
the brightness of the indicator light.
1-7
FEATURES
1riatiia
1f the display indicates a fault code, the vehi-
The shift timing indicator light deactivation
cle should be checked as soon as possible
point can be set between 7000 r/min and
in order to avoid engine damage.
13000 r/min . From 7000 r/min to 12000 r/min,
the indicator light can be set in increments of
500 r/min. From 12000 r/min to 13000 r/min,
the indicator light can be set in increments of
200 r/min.
Be sure to set the deactivation point to a higher
engine speed than for the activation point, oth-
erwise the shift timing indicator light will not
come on.
1. Push the "RES" button to select the desired
engine speed for deactivating the indicator
light.
2. Push the "SEL" button to confirm the selected
engine speed. The control mode changes to
the brightness setting mode.
Self-diagnosis device
1-8
IMPORTANT INFORMATION
EAS20009
IMPORTANT INFORMATION
EAS30006
EAS30008
1. Oil
2. Lip
3. Spring
4. Grease
EAS30009
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-9
IMPORTANT INFORMATION
EAS30010 EAS30012
_____________
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
..
EAS30011
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip "1", make sure the
sharp-edged corner "2" is positioned opposite
the thrust "3" that the circlip receives.
3c)
1-10
BASIC SERVICE INFORMATION
EAS20010
QUICK FASTENERS
. -- ;
Rivet type -'
1. Remove:
Quick fastener
2. Install:
Quick fastener
1-11
BASIC SERVICE INFORMATION
EC A1 6760
EAS300 14
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECA 16600 tery lead connections could damage the
llllli -------------- electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECA 16771
- - - - - - - - - - - - - -
ECA16610
-mili-i --------------
Turn the main switch to "OFF" before dis-
connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to ponent.
rust on the battery terminal , remove the rust us-
ing hot water.
1-12
BASIC SERVICE INFORMATION
______________
ECA16620
fJ"arles+
''''''' '""'' ' ' ' ' ;,,,,.,,,,,,,,,,,,,,,,,,,,,,,,,,,;,;:,:,:
Checking the electrical system
Handle electrical components with special
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
______________
ECA16630 ECA14371
:'N<:iii:csr
\,,,,,,,,,,,,,,,,,,,/ ,,,,,,.,,\":'/:
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end "a" of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECA16640
,.;.
i _ _ _ _ _ _ _ _ _ _ __
When resetting the ECU by turning the main
switch to "OFF", be sure to wait approximately 5 For waterproof couplers, never insert the
seconds before turning the main switch back to tester probes directly into the coupler. When
"ON". performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-13
BASIC SERVICE INFORMATION
2. Check:
Checking the connections Lead
Check the leads, couplers, and connectors for Coupler
stains, rust, moisture, etc. Connector
1 . Disconnect: Moisture ---7 Dry with an air blower.
Lead Rust/stains ---7 Connect and disconnect sev-
Coupler eral times.
Connector
ECA1 6780
3. Check:
All connections
Loose connection ---7 Connect properly.
ECA 16790
1-14
BASIC SERVICE INFORMATION
4. Connect:
Lead
Coupler
Connector
6. Check:
Resistance
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
The resistance values shown were obtained at
the standard measuring temperature of 20 C
(68 F). If the measuring temperature is not 20
0
c (68 F), the specified measuring conditions
\\I// will be shown.
1-15
BASIC SERVICE INFORMATION
1-16
SPECIAL TOOLS
EAS20012
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.
For U.S.A. and Canada, use part number starting with "YM-", "YU-", or "ACC-".
For others, use part number starting with "90890-".
1-17
SPECIAL TOOLS
Reference
Tool name/Tool No. Illustration
pages
Vacuum gauge 3-8
90890-03094
90890-03094
Vacuummate
YU-44456
YU-44456
YM-A9409-7/Y M-A5142-4
1-18
SPECIAL TOOLS
Extension 5-1
90890-04136
YU -33223
1-19
SPECIAL TOOLS
Reference
Tool namefTool No. Illustration
pages
Valve guide reamer (04.5) 5-31
90890-0411 8
Valve guide reamer (4.5 mm)
YM-04118
YU-01304
M35x P1 .5
YM-91042
1-20
SPECIAL TOOLS
YU -24460-A
YU-33984
1-21
SPECIAL TOOLS
Reference
Tool nameffool No. Illustration
pages
Ignition checker 8-92
90890-06754
Oppama pet-4000 spark checker
YM-34487
1-22
SPECIAL TOOLS
1-23
SPECIFICATIONS
EAS20013
GENERAL SPECIFICATIONS
Model
Model 2MS1
Dimensions
Overall length 2090 mm (82.3 in)
Overall width 720 mm (28.3 in)
Overall height 1135 mm (44.7 in)
Seat height 780 mm (30.7 in)
Wheelbase 1380 mm (54.3 in)
Ground clearance 160 mm (6.30 in)
Minimum turning radius 2700 mm (106.3 in)
Weight
Curb weight 167 kg (368 lb)
Maximum load 160 kg (353 lb)
2-1
ENGINE SPECIFICATIONS
EAS20014
ENGINE SPECIFICATIONS
Engine
Engine type Liquid cooled 4-stroke, DOHC
Displacement 321 cm 3
Cylinder arrangement lnline 2-cylinder
Bore x stroke 68.0 x 44.1 mm (2.68 x 1.74 in)
Compression ratio 11.2 : 1
Standard compression pressure (at sea level) 1440 kPa/390 r/min (14.4 kgf/cm 2/390 r/min,
204.8 psi/390 r/min)
Minimum-maximum 1250-1610 kPa/390 r/min (12.5-16.1
kgf/cm 2/390 r/min, 177.8-229.0 psi/390 r/min)
Starting system Electric starter
Fuel
Recommended fuel Regular unleaded gasoline (Gasohol (E10)
acceptable)
Fuel tank capacity 14.0 L (3.70 US gal, 3.08 Imp.gal)
Fuel reserve amount 3.0 L (0.79 US gal, 0.66 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 1OW-30, 1OW-40, 1OW-50, 15W-40, 20W-
40 or 20W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Quantity (disassembled) 2.40 L (2.54 US qt, 2.11 Imp.qt)
Without oil filter cartridge replacement 1.80 L (1.90 US qt, 1.58 Imp.qt)
With oil filter cartridge replacement 2.10 L (2.22 US qt, 1.85 Imp.qt)
Oil pressure 206.0 kPa/5000 r/min at 130 C (29.9 psi/5000
r/min at 266 F)
Oil filter
Oil filter type Cartridge
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance 0.060-0.120 mm (0.0024-0.0047 in)
Limit 0.20 mm (0.0079 in)
Outer-rotor-to-oil-pump-housing clearance 0.09-0.17 mm (0.0035-0.0067 in)
Limit 0.24 mm (0.0094 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.05-0.09 mm (0.0020-0.0037 in)
Limit 0.170 mm (0.0067 in)
Bypass valve opening pressure 80.0-120.0 kPa (0.80-1.20 kgf/cm 2 , 11.6-17.4
psi)
Relief valve operating pressure 650.0-770.0 kPa (6.50-7.70 kgf/cm 2 , 94.3-
111. 7 psi)
2-2
ENGINE SPECIFICATIONS
Cooling system
Radiator (including all routes) 0.96 L (1.01 US qt, 0.84 Imp.qt)
Coolant reservoir (up to the maximum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt)
Radiator cap opening pressure 108.0-137.4 kPa (1.08-1.37 kgf/cm 2 , 15. 7-19.9
psi)
Thermostat
Valve opening temperature 80.5-83.5 C (176.90-182.30 F)
Valve full open temperature 95.0 C (203.00 F)
Valve lift (full open) 3.0 mm (0.12 in)
Radiator core
Width 145.8 mm (5.74 in)
Height 270.0 mm (10.63 in)
Depth 24.0 mm (0.94 in)
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio 41/23 (1.783)
Spark plug(s)
Manufacturer/model NGK/CR8E
Spark plug gap 0.7-0.8 mm (0.028-0.031 in)
Cylinder head
Combustion chamber volume 10.80-11.60 cm 3 (0.66-0. 71 cu.in)
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Drive system Chain drive (right)
Camshaft cap inside diameter 22.500-22.521 mm (0.8858-0.886 7 in)
Camshaft journal diameter 22.459-22.47 2 mm (0.8842-0.884 7 in)
Camshaft-journal-to-camshaft-cap clearance 0.028-0.062 mm (0.0011-0.002 4 in)
Camshaft lobe dimensions
Lobe height (Intake) 32.650-32.75 0 mm (1.2854-1.289 4 in)
Limit 32.550 mm (1.2815 in)
Base circle diameter (Intake) 24.972-25.07 2 mm (0.9831-0.9871 in)
Limit 24.872 mm (0.9792 in)
Lobe height (Exhaust) 30.750-30.85 0 mm (1.2106-1.214 6 in)
Limit 30.650 mm (1.2067 in)
Base circle diameter (Exhaust) 25.027-25.12 7 mm (0.9853-0.9893 in)
Limit 24.927 mm (0.9814 in)
Camshaft runout limit 0.030 mm (0.0012 in)
2-3
ENGINE SPECIFICATIONS
Valve spring
Free length (intake) 38.21 mm (1 .50 in)
Limit 36.30 mm (1.43 in)
Free length (exhaust) 38.21 mm (1.50 in)
Limit 36.30 mm (1.43 in)
Installed length (intake) 32.00 mm (1.26 in)
Installed length (exhaust) 32.00 mm (1.26 in)
Spring rate K1 (intake) 27.64 N/mm (2.82 kgf/mm, 157.82 lbf/in)
Spring rate K2 (intake) 38.73 N/mm (3.95 kgf/mm, 221.15 lbf/in)
Spring rate K1 (exhaust) 27.64 N/mm (2.82 kgf/mm, 157.82 lbf/in)
Spring rate K2 (exhaust) 38.73 N/mm (3.95 kgf/mm, 221.15 lbf/in)
Installed compression spring force (intake) 159.60-183.60 N (16 .27-18.72 kgf, 35.88-
41.27 lbf)
Installed compression spring force (exhaust) 159.60-183.60 N (16.27-18.72 kgf, 35.88-
41.27 lbf)
Spring tilt (intake) 1.7 mm (0.07 in)
Spring tilt (exhaust) 1.7 mm (0.07 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 68.000-68.01 O mm (2.6772-2.6776 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.015-0.048 mm (0.0006-0.0019 in)
Diameter 67.962-67.985 mm (2 .6757-2.6766 in)
Measuring point (from piston skirt bottom) 7.0 mm (0.28 in)
Offset 0.25 mm (0.0098 in)
Offset direction Intake side
Piston pin bore inside diameter 15.002-15.013 mm (0.5906-0.5911 in)
Limit 15.043 mm (0.5922 in)
Piston pin outside diameter 14.995-15.000 mm (0.5904-0.5906 in)
Limit 14.975 mm (0.5896 in)
Piston-pin-to-piston-pin-bore clearance 0.002-0.018 mm (0.0001-0.0007 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) 0.15-0.25 mm (0.0059-0.0098 in)
2-4
ENGINE SPECIFICATIONS
Connecting rod
Oil clearance 0.036-0.060 mm (0.0014-0.0024 in)
Bearing color code 1. Blue 2. Black 3. Brown 4. Green
Crankshaft
Runout limit 0.030 mm (0.0012 in)
Journal oil clearance 0.021-0.045 mm (0.0008-0.001 8 in)
Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow
Balancer
Balancer shaft journal to balancer shaft bearing
clearance 0.021-0.045 mm (0.0008-0.0018 in)
Bearing color code 1. Blue 2. Black 3. Brown 4. Green 5. Yellow
Clutch
Clutch type Wet, multiple-disc
Clutch release method Outer pull , rack and pinion pull
Clutch lever free play 10.0-15.0 mm (0.39-0.59 in)
Friction plate thickness 2.92-3.08 mm (0.115-0.121 in)
Wear limit 2.82 mm (0.111 in)
Plate quantity 7 pcs
Clutch plate thickness 1.50-1. 70 mm (0 .059-0.067 in)
Plate quantity 6 pcs
Warpage limit 0.10 mm (0.004 in)
Clutch spring free length 49.80 mm (1 .96 in)
Limit 47.30 mm (1.86 in)
Spring quantity 4 pcs
Transmission
Transmission type Constant mesh 6-speed
Primary reduction ratio 3.043 (70/23)
Final drive Chain
Secondary reduction ratio 3.071 (43/14)
Operation Left foot operation
Gear ratio
1st 2.500 (35/14)
2nd 1.824 (31/17)
3rd 1.348 (31/23)
4th 1.087 (25/23)
5th 0.920 (23/25)
6th 0.800 (24/30)
2-5
ENGINE SPECIFICATIONS
Shifting mechanism
Shift fork guide bar bending limit 0.050 mm (0.0020 in)
Shift fork thickness 5.76-5.89 mm (0.2268-0.2319 in)
Air filter
Air filter element Oil-coated paper element
Fuel pump
Pump type Electrical
Maximum consumption amperage 1.7 A
Fuel injector
Model/quantity 297500-2370/2
Throttle body
Type/quantity 32EHDW-2
ID mark 2MS1 00
Idling condition
Fuel line pressure at idling 220-300 kPa (2.2-3.0 kgf/cm 2 , 31.9-43.5 psi)
Engine idling speed 1300-1500 r/min
Intake vacuum 52.0-58.0 kPa (390-435 mmHg, 15.4-17.1
inHg)
Water temperature 95.0-105.0 C (203.00-221.00 F)
Throttle grip free play 3.0-5.0 mm (0.12-0.20 in)
2-6
CHASSIS SPECIFICATIONS
EAS200 15
CHASSIS SPECIFICATIONS
Chassis
Frame type Diamond
Caster angle 25.00
Trail 95 mm (3. 7 in)
Front wheel
Wheel type Cast wheel
Rim size 17M/C x MT2.75
Rim material Aluminum
Wheel travel 130 mm (5.1 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Rear wheel
Wheel type Cast wheel
Rim size 17M/C x MT4.00
Rim material Aluminum
Wheel travel 125 mm (4.9 in)
Radial wheel runout limit 1.0 mm (0.04 in)
Lateral wheel runout limit 0.5 mm (0.02 in)
Front tire
Type Tubeless
Size 110/70-1 ?M/C (54H)
Manufacturer/model MICHELIN/PILOT STREET
Wear limit (front) 1.0 mm (0.04 in)
Rear tire
Type Tubeless
Size 140/70-1 ?M/C (66H)
Manufacturer/model MICHELIN/PILOT STREET
Wear limit (rear) 1.0 mm (0.04 in)
Front brake
Type Single disc brake
Operation Right hand operation
Front disc brake
Disc outside diameter x thickness 298.0 x 4.5 mm (11.73 x 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 5.3 mm (0.21 in)
2-7
CHASSIS SPECIFICATIONS
Rear brake
Type Single disc brake
Operation Right foot operation
Rear disc brake
Disc outside diameter x thickness 220.0 x 4.5 mm (8.66 x 0.18 in)
Brake disc thickness limit 4.0 mm (0.16 in)
Brake disc runout limit (as measured on wheel) 0.15 mm (0.0059 in)
Brake pad lining thickness (inner) 7.7 mm (0.30 in)
Limit 0.8 mm (0.03 in)
Brake pad lining thickness (outer) 7.7 mm (0.30 in)
Limit 0.8 mm (0.03 in)
Master cylinder inside diameter 12.7 mm (0.50 in)
Caliper cylinder inside diameter 33.34 mm (1.31 in)
Specified brake fluid DOT4
Steering
Steering bearing type Angular bearing
Center to lock angle (left) 34.0
Center to lock angle (right) 34.0
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm (5.12 in)
Fork spring free length 297.8 mm (11.72 in)
Limit 294.4 mm (11.59 in)
Collar length 229.0 mm (9.02 in)
Spring rate K1 6.45 N/mm (0.66 kgf/mm, 36.83 lbf/in)
Spring stroke K1 0.0-130.0 mm (0.00-5.12 in)
Inner tube outer diameter 41.0 mm (1.61 in)
Inner tube bending limit 0.2 mm (0.01 in)
Recommended oil Fork oil 1OW or equivalent
Quantity 487.0 cm 3 (16.47 US oz, 17.18 Imp.oz)
Level 121.0 mm (4. 76 in)
Rear suspension
Type Swing arm
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 45.0 mm (1.77 in)
Spring installed length 157.0 mm (6.18 in)
Spring rate K1 161.60 N/mm (16.48 kgf/mm, 922.74 lbf/in)
Spring stroke K1 0.0--45.0 mm (0.00-1. 77 in)
Spring preload adjusting positions
Minimum 1
Standard 3
2-8
CHASSIS SPECIFICATIONS
Maximum 7
Drive chain
Size/manufacturer 520VF/DAIDO
Number of links 112
15-link length limit 239.3 mm (9.42 in)
Drive chain slack 35.0-45.0 mm (1.38-1.77 in)
2-9
ELECTRICAL SPECIFICATIONS
EAS20016
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 v
Ignition system
Ignition system TCI
Ignition timing (B.T.D.C.) 5.0 /1400 r/min
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 2.16-2.64 n
Secondary coil resistance 8.64-12.96 kn
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.1-14.9 v
Rectifier capacity 35.0 A
Battery
Model GTZ8V
Voltage, capacity 12 V, 7.0 Ah
Specific gravity 1.350
Manufacturer GS
Ten hour rate charging current 0.70A
Headlight
Bulb type Halogen bulb
Indicator light
Neutral indicator light LED
Turn signal indicator light LED
2-10
ELECTRICAL SPECIFICATIONS
Starter motor
Power output 0.40kW
Armatur e coil resistan ce 0.0630- 0.0770 Q
Brush overall length 7.0 mm (0.28 in)
Limit 3.00 mm (0.12 in)
Brush spring force 6.08-9.1 2 N (620-93 0 gt, 21.89-3 2.83 oz)
Mica undercu t (depth) 1.50 mm (0.06 in)
Starter relay
Ampera ge 150.0 A
Coil resistan ce 3.06-3.7 4 Q
Horn
Horn type Plane
Quantity 1
Maximu m ampera ge 3.5A
Fuses
Main fuse 30.0 A
Headligh t fuse 15.0 A
Signalin g system fuse 15.0 A
Ignition fuse 15.0 A
Radiato r fan motor fuse 7.5A
Backup fuse 7.5A
Spare fuse 30.0 A
Spare fuse 15.0 A
Spare fuse 7.5A
2-11
TIGHTENING TORQUES
EAS20017
TIGHTENING TORQUES
EAS30015
2-12
TIGHTENING TORQUE S
EAS300 16
Item Thread
Q'ty Tightening torque Remarks
size
Air filter case joint clamp screw MS 2 2.S Nm (0.2S m-kgf, 1.S ftlbf)
Air filter case bolt M6 2 7 Nm (0.7 m-kgf, S.1 ft lbf)
Air filter case side cover screw (left) MS 3 2.5 Nm (0.25 m-kgf, 1.S ftlbf)
Air filter case side cover screw (right) MS s 1.3 Nm (0.13 m-kgf, 0.94 ftlbf)
Spark plug M10 2 13 Nm (1.3 m-kgf, 9.4 ft -lbf)
0 2 sensor M12 1 25 Nm (2.5 m-kgf, 1S ftlbf)
2-13
TIGHTENING TORQUES
Thread
Item Q'ty Tightening torque Remarks
size
Clutch boss nut M18 1 100 Nm (1 O mkgf, 72 ft lbf)
Clutch spring bolt M6 4 1O Nm (1 .0 mkgf, 7 .2 ftlbf)
Clutch cover bolt M6 7 1O Nm (1.0 mkgf, 7.2 ftlbf)
Clutch cable holder bolt M6 2 1O Nm (1.0 mkgf, 7.2 ftlbf) -1fl
Shift shaft spring stopper MS 1 22 Nm (2.2 mkgf, 16 ftlbf) -1fl
Oil pump cover screw M4 1 2.0 Nm (0.20 mkgf, 1.4 ft lbf)
Oil pump bolt M6 4 10 Nm (1.0 mkgf, 7.2 ftlbf)
Oil pan bolt M6 11 1O Nm (1.0 mkgf, 7.2 ftlbf)
Engine oil drain bolt M12 1 20 Nm (2.0 mkgf, 14 ftlbf)
Crankcase bolt MS 6 See TIP.
Shift fork guide bar retainer bolt M6 2 1O Nm (1.0 mkgf, 7.2 ftlbf) -(]
Shift drum segment screw M6 1 12 Nm (1.2 mkgf, 8.7 ftlbf) -1fl
Radiator bolt M6 2 1O Nm (1.0 mkgf, 7.2 ftlbf)
Radiator fan cover bolt M6 3 9 Nm (0.9 mkgf, 6.5 ftlbf)
Coolant reservoir cover bolt MS 2 1.S Nm (0.15 mkgf, 1.1 ftlbf)
Radiator outlet hose clamp screw MS 1 2.0 Nm (0.20 m kgf, 1.4 ftlbf)
Radiator inlet hose clamp screw MS 1 2.0 Nm (0.20 mkgf, 1.4 ftlbf)
Thermostat cover bolt M6 2 1 O Nm (1.0 mkgf, 7.2 ft lbf)
Water pump housing bolt M6 3 1O Nm (1.0 mkgf, 7.2 ftlbf)
Coolant drain bolt M6 1 1O Nm (1 .0 mkgf, 7.2 ftlbf)
Impeller shaft retaining plate bolt M6 2 1O Nm (1.0 mkgf, 7.2 ftlbf) -1fl
Throttle body joint bolt M6 3 1O Nm (1.0 mkgf, 7.2 ft-lbf)
ISC (idle speed control) unit plate
M6 1 S Nm (O .S mkgf, 3.6 ftlbf)
screw
2-14
TIGHTENING TORQUES
Item Thread
Q'ty Tightening torque Remarks
size
Fuel rail bolt MS 2 3.S Nm (0.35 m-kgf, 2.5 ftlbf)
Throttle body joint clamp screw MS 2 2.5 Nm (0.25 m-kgf, 1.8 ftlbf)
Throttle cable bracket bolt MS 2 5 Nm (0.5 m-kgf, 3.6 ft-lbf)
Reed valve cover bolt M6 2 1O Nm (1.0 m-kgf, 7.2 ftlbf)
x6
[!]
Crankcase bolt
Tighten the crankcase bolts "1 "-"21" in the proper tightening sequence as follows:
1. Lubricate the crankcase bolts "1 "-"15" and "17"-"21" threads, mating surfaces with the engine oil.
2. Lubricate the mating surface of the bolt "16" with engine oil and apply Yamaha bond No. 1215 to the
bolt threads.
3. Tighten the crankcase bolts "1 "-"6" to 20 Nm (2.0 m-kgf, 14 ft-lbf).
4. Loosen and retighten the crankcase bolts "1 "-"6'' to 24 Nm (2.4 m-kgf, 17 ftlbf) in the proper tight-
ening sequence (after loosening a bolt, retighten it before loosening the next bolt).
5. Tighten the crankcase bolts "7"-"8" to 20 Nm (2.0 m-kgf, 14 ft-lbf).
2-15
TIGHTENING TORQUES
6. Loosen and retighten the crankcase bolts "7"-"8" to 26 Nm (2.6 m-kgf, 19 ft-lbf) in the proper tight-
ening sequence (after loosening a bolt, retighten it before loosening the next bolt).
7. Tighten the crankcase bolts "9"-"21" to 1O Nm (1.0 m-kgf, 7.2 ftlbf) in the proper tightening se-
quence.
[!][!]
[!][!]
2-16
TIGHTENING TORQUES
[!][IJ[!][!J
A. Lower crankcase
B. Upper crankcase
2-17
TIGHTENING TORQUES
EAS300 17
2-18
TIGHTENING TORQUES
Item Thread
Q'ty Tightening torque Remarks
size
Rearview mirror bolt M6 4 7 Nm (0.7 mkgf, 5.1 ftlbf)
Front cowling assembly bolt MS 2 33 Nm (3.3 mkgf, 24 ft lbf)
Meter assembly bracket bolt M6 2 7 Nm (0.7 mkgf, 5.1 ftlbf)
Meter assembly screw M5 3 1.3 Nm (0.13 mkgf, 0.94 ft lbf)
Windshield assembly screw M5 2 0.4 Nm (0. 04 mkgf, 0.29 ftlbf)
Front cowling screw M5 4 1.S Nm (0.1S mkgf, 1.3 ft lbf)
Front cowling inner panel screw M5 5 1.S Nm (0.1S mkgf, 1.3 ftlbf)
Headlight assembly screw M5 4 1.S Nm (0.1S mkgf, 1.3 ftlbf)
Front brake hose holder bolt M6 1 7 Nm (0. 7 mkgf, 5.1 ftlbf)
Front brake caliper bolt
Front wheel axle nut
Front brake disc bolt
Rear brake caliper bolt
M10
M14
MS
2
1
5
35 Nm (3.5 m-kgf, 25 ftlbf)
52 Nm (5.2 mkgf, 3S ftlbf)
23 Nm (2.3 mkgf, 17 ftlbf)
.....
-id
MS 1 23 Nm (2.3 mkgf, 17 ftlbf)
Drive chain puller locknut MS 2 16 Nm (1 .6 m-kgf, 12 ftlbf)
Drive chain puller adjusting nut
Rear wheel axle nut
Rear brake caliper bolt
Rear wheel sprocket nut
MS
M16
M12
M10
2
1
1
6
1.5 Nm (0.15 mkgf, 1.1 ftlbf)
57 Nm (5.7 mkgf, 41 ftlbf)
31 Nm (3.1 mkgf, 22 ft lbf)
6S Nm (6.S mkgf, 49 ftlbf)
.....
Rear wheel sprocket stud bolt M10 6 27 Nm (2.7 mkgf, 20 ftlbf) -td
Rear brake disc bolt MS 3 23 Nm (2.3 mkgf, 17 ftlbf) -id
Brake caliper bleed screw M7 2 6 Nm (0.6 mkgf, 4.3 ftlbf)
Front brake master cylinder reservoir
cap screw M4 2 1.5 Nm (0.15 mkgf, 1.1 ftlbf)
Front brake lever pivot bolt M6 1 6 Nm (0.6 mkgf, 4.3 ftlbf)
Front brake lever pivot nut M6 1 6 Nm (0.6 mkgf, 4.3 ftlbf)
Front brake light switch screw M4 1 1.1 Nm (0.11 mkgf, O.SO ft-lbf) -id
Front brake hose union bolt (master
cylinder side) M10 1 29 Nm (2.9 mkgf, 21 ft lbf)
Front brake hose union bolt (brake
caliper side) M10 1 29 Nm (2.9 mkgf, 21 ft lbf)
Front brake master cylinder holder
bolt M6 2 1O Nm (1 .0 m-kgf, 7.2 ftlbf)
Rear brake fluid reservoir holder bolt M6 1 7 Nm (0.7 mkgf, 5.1 ftlbf)
Rear brake hose union bolt (master
cylinder side) M10 1 29 Nm (2.9 m-kgf, 21 ftlbf)
Rear brake hose union bolt (brake
caliper side) M10 1 29 Nm (2.9 mkgf, 21 ftlbf)
Rear brake light switch bracket bolt M6 2 7 Nm (0.7 mkgf, 5.1 ftlbf)
Footrest assembly bolt MS 4 30 Nm (3.0 m-kgf, 22 ft lbf)
Rear brake master cylinder bolt MS 2 23 Nm (2.3 mkgf, 17 ftlbf)
Rear brake pedal bolt M10 1 30 Nm (3.0 mkgf, 22 ftlbf)
-td
Rear brake hose guide bolt M6 1 7 Nm (0.7 mkgf, 5.1 ftlbf)
2-19
TIGHTENING TORQUES
2-20
TIGHTENING TORQUES
Item Thread
Q'ty Tightening torque Remarks
size
Footrest plate bolt M6 2 10 Nm (1.0 mkgf, 7.2 ftlbf)
Fuel pump bolt MS 6 4.0 Nm (0.40 mkgf, 2.9 ftlbf)
Rear fuel tank bracket bolt (fuel tank) M6 2 10 Nm (1.0 mkgf, 7.2 ftlbf)
Rear fuel tank bracket bolt (frame) M8 2 12 Nm (1.2 mkgf, 8.7 ftlbf)
Front fuel tank bracket bolt (fuel
tank) M6 2 1O Nm (1.0 mkgf, 7.2 ftlbf)
Front fuel tank bracket bolt (frame) M6 2 12 Nm (1.2 mkgf, 8.7 ft lbf)
Throttle cable guide bolt MS 2 S Nm (O.S m-kgf, 3.6 ftlbf)
Sidestand nut M10 1 34 Nm (3.4 mkgf, 2S ftlbf)
Passenger footrest assembly bolt M8 4 28 Nm (2.8 mkgf, 20 ftlbf)
Rear fender bolt M6 4 9 Nm (0.9 mkgf, 6.S ftlbf)
Taillight unit assembly bolt M6 2 3 .3 Nm (0.33 mkgf, 2.4 ftlbf)
Sidestand switch bolt MS 2 4.0 Nm (0.40 mkgf, 2.9 ftlbf)
Canister bracket bolt (Engine) M6 2 7 Nm (0.7 mkgf, S.1 ftlbf)
Canister bracket bolt (Frame) M8 1 16 Nm (1.6 mkgf, 12 ftlbf)
2-21
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20018
ENGINE
Lubrication point Lubricant
--41@
...-...
Bearings
0-rings
Oil seal lips ...-...
Cylinder head bolt seats, cylinder head bolt threads and washers -cMI
Crankshaft big ends --41@
Connecting rod bolts --41@
2-22
LUBRICATION POINTS AND LUBRICANT TYPES
2-23
LUBRICATION POINTS AND LUBRICANT TYPES
2-24
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS200 19
10
11
5 6
2 3
15
1
D O DD
16
2-25
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil strainer
2. Oil pump
3. Relief valve
4. Oil filter cartridge
5. Sub gallery
6. Oil pressure switch
7. Main gallery
8. Crankshaft
9. Oil nozzle
10. Balancer shaft assembly
11. Timing chain tensioner
12. Intake camshaft
13.
14. Main axle
15. Transmission shower
16. Drive axle
2-26
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS3002 1
LUBRICATION DIAGRAMS
Crankcase, cylinder, and cylinder head (right side view)
2-27
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-28
LUBRICATION SYSTEM CHART AND DIAGRAMS
5
1
2-29
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Crankshaft
2. Balancer shaft assembly
3. Connecting rod
4. Oil drain bolt
5. Oil filter cartridge
6. Oil pressure switch
2-30
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-31
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Oil pump
2. Relief valve
2-32
LUBRICATION SYSTEM CHART AND DIAGRAMS
.. .
..
I Q
2-33
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Main gallery
2. Oil filter cartridge
3. Sub gallery
4. Oil strainer
2-34
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-35
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Intake camshaft
2. Exhaust camshaft
3. Cylinder head
2-36
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-37
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Crankshaft
2. Oil nozzle
3. Piston
4. Main gallery
5. Sub gallery
2-38
LUBRICATION SYSTEM CHART AND DIAGRAMS
2-39
LUBRICATION SYSTEM CHART AND DIAGRAMS
1. Crankshaft
2. Balancer shaft assembly
3. Main axle
4. Drive axle
2-40
COOLING SYSTEM DIAGRAMS
EAS20020
2-41
COOLING SYSTEM DIAGRAMS
1. Radiator
2. Radiator outlet hose
3. Water pump
4. Thermostat
5. Radiator inlet hose
2-42
CABLE ROUTING
EAS20021
CABLE ROUTING
Handlebar (front view)
2-43
CABLE ROUTING
2-44
CABLE ROUTING
2-45
CABLE ROUTING
2-46
CABLE ROUTING
2-47
CABLE ROUTING
1. Fuse box
2. Rear fender
3. Fuse box lead
4. Rear brake light switch coupler
5. Rear brake light switch lead
6. Fuel tank overflow hose
7. Down tube
8. Stay
9. Engine stay
10. Frame
A. Install the fuse box onto the tab on the rear fender.
B. Pass a plastic locking tie through the rider seat
bracket and through the hole in the stay. Face the
buckle of the plastic locking tie outward with the
end pointing downward. Cut off the excess end of
the plastic locking tie to 3 mm (0.12 in) or less.
C. Position the plastic locking tie at the location
shown in the illustration.
D. Route the rear brake light switch lead to the front of
the frame cross member.
E. Route the fuel tank overflow hose between the stay
and the engine stay.
F. Fasten the rear brake light switch lead at the white
tape to the down tube with a plastic locking tie.
Face the buckle of the plastic locking tie outward
with the end pointing upward. Cut off the excess
end of the plastic locking tie to 3 mm (0.12 in) or
less.
2-48
CABLE ROUTING
En gme(leftside
- - - - - -
view)
2-49
CABLE ROUTING
1. Auxiliary light lead L. The gear position switch lead , negative battery
2. Fuel tank breather hose sub-wire harness, and starter motor lead niay be
3. Guide routed in any order.
4. Coolant reservoir hose M. Insert the projection on the wire harness holder
into the hole in the frame.
5. 0 2 sensor lead
N. Face the paint mark on the fuel tank breather hose
6. 0 2 sensor coupler forward.
7. Sidestand switch connector 0. Route the fuel tank breather hose under the stator
8. Stator coil lead coil lead.
9. Gear position switch lead P. Route the oil pressure switch lead, gear position
10. Fuel tank overilow hose switch lead , and fuel tank breather hose to the
outside of the rib on the drive sprocket cover.
11 . Sidestand switch
Q. When installing the drive chain cover, be sure not
12. Oil pressure switch lead
to pinch the leads.
13. Coolant temperature sensor coupler
R. Route the oil pressure switch lead, fuel tank
14. Front turn signal light lead (left turn signal light) breather hose, gear position switch lead and
15. Front cowling assembly bracket sidestand switch lead may be routed in any order.
16. Meter assembly lead S. Route the fuel tank breather hose to the outside of
17. Bracket the coolant reservoir.
18. Wire harness T. Route the fuel tank breather hose through the
19. Frame guide.
20. Drive sprocket cover U. Hold lead wires thoroughly with clamp. ACM, water
temperature sensor, pressure sensor, neutral
21. Coolant reservoir cover
switch , 0 2 sensor, minus lead wire, starter lead
22. Coolant reservoir
wire, and sidestand switch in any order.
23. Cylinder head
V. Pass breather hose and sidestand switch lead wire
24. Sidestand switch lead wire to guide of chain case cover.
25. Chain case cover W. Pass sidestand switch lead wire to clamp.
A. Route the auxiliary light lead as shown in the
illustration.
B. Fasten the fuel tank breather hose, oil pressure
switch lead, gear position switch lead and
sidestand switch lead at the location shown in the
illustration with a plastic locking tie. The leads may
be routed in any order. Cut off the excess end of
the plastic locking tie to 3 mm (0.12 in) or less.
C. Fasten the oil pressure switch lead and gear
position switch lead at the location shown in the
illustration with a plastic locking tie. The leads may
be routed in any order.
0. Route the fuel tank breather hose through the
guide on the sidestand bracket.
E. Point the end of the plastic locking tie downward.
F. Position the white paint mark on the fuel tank
breather hose at the location shown in the
illustration.
G. Insert the projection on the wire harness holder
into the hole in the front cowling assembly bracket.
H. Fasten the meter assembly lead to the bracket with
a plastic locking tie. Face the buckle of the plastic
locking tie outward with the end pointing
downward. Cut off the excess end of the plastic
locking tie to 3 mm (0.12 in) or less.
I. Fasten the main switch lead, left handlebar switch
lead, and right handlebar switch lead at the white
tape on each lead with a plastic locking tie.
J. Fasten the main switch lead, left handlebar switch
lead, and right handlebar switch lead with a plastic
locking tie as shown in the illustration. Fit the end
of the plastic locking tie into the electrical
components tray.
K. The main switch lead, left handlebar switch lead,
and right handlebar switch lead may be routed in
any order.
2-50
CABLE ROUTING
. .. ..
2-51
CABLE ROUTING
1. Coolant reservoir breather hose K. Fasten the wire harness and tail/brake light lead to
2. Gear position switch coupler the frame with a plastic locking tie as shown in the
3. Starting circuit cut-off relay illustration. Point the end of the plastic locking tie
outward. Cut off the excess end of the plastic
4. Starter motor lead terminal locking tie to 3 mm (0.12 in) or less.
5. Starter relay coupler L. Install the starter relay completely onto the tabs on
6. Yamaha diagnostic tool coupler the rear fender.
7. Tail/brake light lead M. Route the rear left turn signal light lead, rear right
8. Lean angle sensor lead turn signal light lead , and license plate light lead
9. Rectifier/regulator coupler under the starter relay. The leads may be routed in
any order.
10. License plate light connector
N. Route the rear left turn signal light lead, rear right
11. Tail/brake light coupler
turn signal light lead, and license plate light lead
12. Stator coil lead through the guides on the mudguard.
13. Negative battery lead 0. Insert the projection on the wire harness holder
14. Wire harness into the hole in the rear fender.
15. Frame P. Fasten the starter motor lead and negative battery
16. Starter relay sub-wire harness to the wire harness with a plastic
17. Rear fender locking tie as shown in the illustration. Face the
buckle of the plastic locking tie outward with the
18. Mudguard
end pointing upward. Cut off the excess end of the
19. Rear turn signal light lead (left turn signal light) plastic locking tie to 3 mm (0.12 in) or less.
20. License plate light lead
21. Rear turn signal light lead (right turn signal light)
22. ECU (engine control unit)
23. Battery
24. Negative battery sub-wire harness
25. Positive battery lead
A. Fasten the starter motor lead, negative battery
sub-wire harness, stator coil lead, and gear
position switch lead to the wire harness with a
plastic locking tie. Do not install the plastic locking
tie on the section of the stator coil lead that is not
covered by the protective sleeve.
B. Insert the end of the coolant reservoir breather
hose into the frame pipe. Make sure that the end of
the hose protector on the coolant reservoir
breather hose contacts the edge of the hole in the
frame.
C. Install the starting circuit cut-off relay onto the tab
on the rear fender.
D. Install the starter motor lead and positive battery
lead terminals so that the crimped section of the
terminal that secures the lead is facing upward.
E. Fasten the starter motor lead and negative battery
sub-wire harness to the wire harness with a plastic
locking tie at the location shown in the illustration.
F. Make sure that there is no slack in the starter
motor lead and negative battery sub-wire harness
between the plastic locking ties.
G. The stator coil lead and gear position switch lead
may be routed in any order.
H. Fasten the starter motor lead, negative battery
sub-wire harness, stator coil lead, and gear
position switch lead to the wire harness with a
plastic locking tie as shown in the illustration. Face
the buckle of the plastic locking tie outward with the
end pointing upward. Cut off the excess end of the
plastic locking tie to 3 mm (0.12 in) or less.
I. The negative battery sub-wire harness and starter
motor lead may be routed in any order.
J. The wire harness and tail/brake light lead may be
routed in any order.
2-52
CABLE ROUTING
2-53
CABLE ROUTING
1. Clutch cable
2. Handlebar switch lead (left handlebar switch)
3. Front turn signal light lead (left turn signal light)
4. Headlight lead (left)
5. Auxiliary light lead
6. Meter assembly
7. Meter assembly lead
8. Throttle cable (accelerator cable)
9. Throttle cable (decelerator cable)
10. Horn lead
11 . Headlight lead (right)
12. Front turn signal light lead (right turn signal light)
13. Front brake hose
14. Handlebar switch coupler (right handlebar switch)
15. Coolant reservoir hose
16. Fuel tank overflow hose
17. Frame
18. Fuel tank breather hose
19. Electrical components tray
20. Handlebar switch coupler (left handlebar switch)
21. Main switch coupler
22. Front side cowling inner panel (left)
23. Front side cowling inner panel (right)
24. Fuel injector lead
25. Fuel rail
26. Spark plug lead
A. Place the left handlebar switch coupler, right
handlebar switch coupler, and main switch coupler
in the electrical components tray so that the leads
to the switches are routed upward.
B. Insert the projection on the wire harness holder
into the hole in the frame.
C. To fuel pump
D. Route the headlight lead through the guides on the
front side cowling inner panel.
E. Insert the projection on the plastic locking tie into
the hole in the electrical components tray.
F. The main switch lead, left handlebar switch lead,
and right handlebar switch lead may be routed in
any order.
G. Fasten the main switch lead, left handlebar switch
lead, and right handlebar switch lead at the white
tape on each lead with the plastic locking tie. Point
the end of the plastic locking tie outward. Cut off
the excess end of the plastic locking tie to 3 mm
(0.12 in) or less.
H. Fasten the fuel injector lead at the white tape to the
fuel rail with a plastic locking tie. Face the buckle of
the plastic locking tie rearward with the end
pointing downward. Cut off the excess end of the
plastic locking tie to 3 mm (0.12 in) or less.
I. Cross the throttle cables above the plastic locking
tie.
J. White tape
K. Fasten the throttle cable (accelerator cable) and
throttle cable (decelerator cable) with the plastic
locking tie. Be sure to route the throttle cable
(accelerator cable) above the throttle cable
(decelerator cable). Cut off the excess end of the
plastic locking tie to 3 mm (0.12 in) or less.
L. Route the spark plug lead to the front of the
projection on the electrical components tray.
2-54
CABLE ROUTING
2-55
CABLE ROUTING
1. Fuel tank overilow hose K. The starter motor lead , negative battery sub-wire
2. 0 2 sensor lead harness, tail/brake light lead , and wire harness
may be routed in any order.
3. Negative battery sub-wire harness
4. Frame
5. Rear brake light switch lead
6. Fuse box lead
7. Turn signal relay
8. Fuse box
9. ECU (engine control unit)
10. Rectifier/regulator
11. Yamaha diagnostic tool coupler
12. Yamaha diagnostic tool coupler lead
13. Rear turn signal light lead (right turn signal light)
14. License plate light lead
15. Rear turn signal light lead (left turn signal light)
16. Lean angle sensor
17. Tail/brake light lead
18. Rear fender
19. Starter relay
20. Rectifier/regulator lead
21 . Starting circuit cut-off relay
22. ECU (engine control unit) lead
23. Wire harness
24. Negative battery sub-wire harness coupler
25. Battery
26. Gear position switch coupler
27. Crankshaft position sensor coupler
28. Stator coil coupler
29. Negative battery sub-wire harness
30. Positive battery lead
A. Insert the projection on the holder at the white tape
on the wire harness into the frame hole shown in
the illustration.
B. Insert the projection on the wire harness holder
into the hole in the frame.
C. Fit the turn signal relay into the hole in the ECU
band.
D. Route the negative battery sub-wire harness under
the ECU (engine control unit) .
E. Route the rear turn signal light leads, license plate
light lead, and Yamaha diagnostic tool coupler
lead through the guide on the rear fender.
F. Fasten the wire harness to the frame with a plastic
locking tie. Position the plastic locking tie to the
front of where the leads branch off from the wire
harness.
G. Route the rear turn signal light leads between the
turn signal relay lead and the negative battery sub-
wire harness.
H. Fit the negative battery sub-wire harness coupler
into the hole in the ECU band.
I. The rear turn signal light leads may be routed in
any order.
J. Fasten the wire harness to the frame with a plastic
locking tie as shown in the illustration . Face the
buckle of the plastic locking tie outward with the
end pointing downward. Cut off the excess end of
the plastic locking tie to 3 mm (0.12 in) or less.
2-56
CABL E ROUTING
2-57
CABLE ROUTING
2-58
CABLE ROUTING
0 0 0 0 0 0
0 0
2-59
CABLE ROUTING
2-60
CABLE ROUTING
\
I - - -...
2-61
CABLE ROUTING
1. Fuel tank
2. Fuel hose (fuel tank to fuel rail)
3. Fuel pump
4. Fuel tank breather hose (fuel tank to hose joint)
5. Fuel tank breather hose
6. Hose joint
7. Fuel tank overflow hose
8. Fuel tank overflow hose (fuel tank to hose joint)
A. Connect the orange connector of the fuel hose
(fuel tank to fuel rail) to the fuel pump.
B. Forward
C. Face the white paint mark on the fuel tank overflow
hose (fuel tank to hose joint) forward .
D. Face the white paint mark on the fuel tank breather
hose (fuel tank to hose joint) forward .
E. Install the fuel tank breather hose (fuel tank to
hose joint) so that it contacts the tapered portion of
the hose fitting on the fuel tank and it contacts the
stopper on the hose joint.
F. Align the yellow paint mark on the fuel tank
breather hose with the yellow paint mark on the
fuel tank breather hose (fuel tank to hose joint).
G. Align the yellow paint mark on the fuel tank
overflow hose with the yellow paint mark on the
fuel tank overflow hose (fuel tank to hose joint).
H. Install the fuel tank overflow hose (fuel tank to
hose joint) so that it contacts the tapered portion of
the hose fitting on the fuel tank and it contacts the
stopper on the hose joint.
2-62
CABLE ROUTING
2-63
CABLE ROUTING
1. Throttle bodies
2. Fuel hose (fuel tank to fuel rail)
3. Crankcase breather hose
4. Air filter case assembly
5. Clip
6. Crankcase breather cover
7. Pipe balance (canister purge hose)
8. ISC (idle speed control) unit inlet hose
9. Way (joint pipe)
10. Clamp
A. Direction of yellow paint shall be left side of
vehicle.
B. Part should install yellow paint being part side and
left of vehicle.
C. Part should insert indicate rear end of pipe.
D. Part should not get on pipe spool.
E. Front
F. Direction of clip shall be back side of vehicle, and
one side ear is parallel to a vehicle direction, and
the other ear is parallel to a vehicle direction, and
the other ear turning to the body inside.
G. Attach black side to throttle body assy.
H. Part should install yellow paint being part side and
right of vehicle.
I. Direction of clip shall be lower side of vehicle.
J. Direction of clip shall be back side of vehicle.
K. Direction of clip shall be right slant lower direction
of vehicle.
L. Direction of white paint shall be right side of
vehicle.
M. Direction of clip shall be right side of vehicle.
N. Direction of clip shall be front side of vehicle.
2-64
CABLE ROUTING
J\
\ \
2-65
CABLE ROUTING
2-66
CABLE ROUTING
2-67
CABLE ROUTING
1. Radiator
2. Radiator outlet hose
3. Coolant reservoir hose
4. Coolant reservoir cap
5. Coolant reservoir breather hose
6. Coolant reservoir
7. Radiator inlet hose
8 . Coolant hose
A. 13
B. Face the white paint mark on the coolant reservoir
hose upward.
C. 40
D. 3 mm (0.12 in) or more. Make sure not to install the
hose clamp on the raised portion of the hose
fitting .
E. Downward
F. Install the coolant reservoir hose until the end of
the hose contacts the raised portion of the hose
fitting.
G. 10 mm (0.39 in) or more
H. 5 mm (0 .20 in)
I. Install the pipe up to the groove in the coolant
reservoir cap.
J. Install the coolant reservoir breather hose
completely onto the hose fitting of the coolant
reservoir.
K. Left side
L. Install the coolant hose so that the end of the hose
is positioned as shown in the illustration.
2-68
CABLE ROUTING
2-69
CABLE ROUTING
2-70
CABLE ROUTING
2-71
CABLE ROUTING
2-72
CABL E ROUTING
Canister
2-73
CABLE ROUTING
2-74
CABL E ROUTING
2-75
PERIODIC CHECKS AND ADJUSTMENTS
EAS20022
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustme
nts. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation
, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles
already
in service as well as to new vehicles that are being prepared for sale. All service technicians should
be
familiar with this entire chapter.
EAS30614
From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000
mi
(11000 km) or 12 months.
Items marked with an asterisk require special tools, data and technical skills, have a Yamaha
dealer
perform the service.
EAS30615
From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000
mi
(11000 km) or 12 months.
Items marked with an asterisk require special tools, data and technical skills, have a Yamaha
dealer
perform the service.
3-1
PERIODIC MAINTENANCE
20 * Sidestand switch Check operation and replace '1 '1 '1 '1 '1 '1
if necessary.
Check operation and for oil
21 * Front fork leakage. '1 '1 '1 '1 '1
Replace if necessary.
3-2
PERIODIC MAINTENANCE
Air filter
This model's air filter is equipped with a disposable oil-coated paper element, which must not
be
cleaned with compressed air to avoid damaging it.
The air filter element needs to be replaced more frequently when riding in unusually wet or dusty
areas.
Hydraulic brake service
After disassembling the brake master cylinders and calipers, always change the fluid. Regularly
check the brake fluid levels and fill the reservoirs as required.
Every two years replace the internal components of the brake master cylinders and calipers,
and
change the brake fluid.
Replace the brake hoses every four years and if cracked or damaged.
3-3
PERIODIC MAINTENANCE
EAS30619
Manufacturer/model
NGK/CASE
4. Install: 5. Check:
Front fuel tank bracket bolt (frame) Electrode "1"
Rear fuel tank bracket bolt (frame) Damage/wear Replace the spark plug.
3-4
PERIODIC MAINTENANCE
Insulator "2"
Abnorm al color -7 Replace the spark plug.
Valve clearanc e adjustm ent should be made on
Normal color is tan. a cold engine, at room tempera ture.
6. Clean:
Spark plug 1. Remove :
(with a spark plug cleaner or wire brush) Rider seat
7. Measure: Refer to "GENER AL CHASS IS (1 )"on page
Spark plug gap "a" 4-1.
(with a wire thickness gauge) Side panels
Out of specification -7 Regap. Refer to "GENER AL CHASS IS (2)" on page
4-3.
Spark plug gap Fuel tank cover assemb ly
0.7-0.8 mm (0.028-0 .031 in) Front side cowling assemb ly (right)
Refer to "GENER AL CHASS IS (3)" on page
4-5.
Fuel tank
Refer to "FUEL TANK" on page 7-1.
Air cut-off valve/Re ed valve
Refer to "AIR INDUCT ION SYSTEM " on
J 1
page 7-15.
2. Disconn ect:
Spark plug cap
1 2 Refer to "CAMSH AFTS" on page 5-13.
3. Remove :
8. Install: Spark plugs
Spark plugs Cylinder head cover
Cylinder head cover gasket
Spark plug Refer to "CAMSH AFTS" on page 5-13.
13 Nm (1.3 m-kgf, 9.4 ftlbf) 4. Remove :
Cranksh aft end cover "1"
Timing mark accessin g bolt "2"
Before installing the spark plug, clean the spark
plug and gasket surface.
9. Connect:
Spark plug caps
1O.lnstall:
Fuel tank
Refer to "FUEL TANK" on page 7-1.
Fuel tank cover assemb ly
Refer to "GENER AL CHASS IS (3)" on page
4-5.
Side panels 5. Measure :
Refer to "GENER AL CHASS IS (2)" on page Valve clearanc e
4-3. Out of specification -7 Adjust.
Rider seat
Valve clearance (cold)
Refer to "GENER AL CHASS IS (1 )"on page
Intake
4-1.
0.11-0.1 8 mm (0.0043 -0.0071 in)
EAS30622 Exhaust
ADJUSTING THE VALVE CLEARANCE 0.21-0.3 0 mm (0.0083 -0.0118 in)
The following procedu re applies to all of the
valves.
If the valve clearanc e is incorrect, record u.e
measure d reading.
3-5
PERIODIC MAINTENANCE
Measure the valve clearance in the following e. Measure the valve clearance #2 with a thick-
sequence. ness gauge.
Thickness gauge
Valve clearance measuring sequence 90890-03180
Cylinder #1 ____, #2 Feeler gauge set
YU-26900-9
#2 #1
6. Remove:
Camshaft
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
3-6
PERIODIC MAINTENANCE
b. Calculate the difference between the speci- Valve pad thickness 1.50- 2.40 mm
(0.0590- 0.0944 in)
fied valve clearance and the measured valve
clearance. 19 thicknesse s in 0.050
Available va lve pads mm (0.0020 in) incre-
Example:
ments
Specified valve clearanc e= 0.11-0.18 mm
(0.0043-0.0071 in) Example:
Measured valve clearance = 0.25 mm Valve pad number = 165
(0.0098 in) Rounded value = 165
0.25 mm (0.0098 in)-0.18 mm (0.0071 in) = New valve pad number = 165
0.07 mm (0.0028 in) f. Install the new valve pad "1" and the valve lift-
c. Check the thickness of the current valve pad. er "2".
The thickness "a" of each valve pad is marked in Lubricate the valve lifter with engine oil.
hundredths of millimeters on the side that touch- Install the valve lifter and the valve pad in the
es the valve lifter. correct place.
The valve lifter must turn smoothly when rotat-
Example:
ed by hand.
If the valve pad is marked "158", the pad
thickness is 1.58 mm (0.0622 in).
3-7
PERIODIC MAINTENANCE
EAS30797
Turn the crankshaft counterclockwise several
SYNCHRONIZING THE THROTILE BODIES
full turns to seat the parts.
h. Measure the valve clearance again. Before synchronizing the throttle bodies , check
i. If the valve clearance is still out of specifica- the following items:
tion, repeat all of the valve clearance adjust- Va Ive clearance
ment steps until the specified clearance is Spark plugs
obtained. Air filter element
Throttle body joint
8. Install: Fuel hose
All removed parts Exhaust system
Crankcase breather hose
For installation, reverse the removal procedure.
Checking the throttle body synchronization
EAS310 17 1. Stand the vehicle on a level surface.
CHECKING THE ENGINE IDLING SPEED
3-8
PERIODIC MAINTENANCE
5. Install:
Carburetor angle driver 2
Fuel tank
90890- 03173
Refer to "FUEL TANK" on page 7-1.
6. Check:
Throttle body synchronization
TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT
a. Start the engine, warm it up for several min-
utes, and then let it run at the specified en-
gine idling speed.
3-9
PERIODIC MAINTENANCE
EAS30626
5. Adjust:
CHECKING THE CANISTER
Throttle grip free play
1. Remove:
Referto"CHECKING THE THROTTLE GRIP
Fuel tank
OPERATION" on page 3-26.
Refer to "FUEL TANK" on page 7-1.
Throttle grip free play 2. Check:
3.0-5.0 mm (0.12-0.20 in) Canister
Canister purge hoses
EAS3 1318 Fuel tank breather hoses
CHECKING THE THROTTLE BODY JOINT Canister breather hose
1. Remove: Cracks/damage-7 Replace.
Rider seat 3. Install:
Refer to "GENERAL CHASSIS (1 )" on page Fuel tank
4-1. Refer to "FUEL TANK" on page 7-1.
Side panels
EAS30625
Refer to "GENERAL CHASSIS (2)" on page CHECKING THE EXHAUST SYSTEM
4-3. 1. Remove:
Fuel tank cover assembly Side panels
Refer to "GENERAL CHASSIS (3)" on page Refer to "GENERAL CHASSIS (2)" on page
4-5. 4-3.
Fuel tank Front side cowling assembly (left)
Refer to "FUEL TANK" on page 7-1. Refer to "GENERAL CHASSIS (3)" on page
2. Remove: 4-5.
Throttle bodies Coolant reservoir
Refer to "THROTTLE BODIES" on page 7-6. Refer to "RADIATOR" on page 6-1 .
3. Check: Footrest assembly (right)
Throttle body joint "1" Refer to "REAR BRAKE" on page 4-48.
Cracks/damage -7 Replace. 2. Check:
Exhaust pipe "1"
Muffler assembly "2"
Cracks/damage -7 Replace.
Gasket "3", "4"
Exhaust gas leaks -7 Replace.
3. Check:
1 Tightening torque
Exhaust pipe nuts "5"
Exhaust pipe bolt "6''
Muffler assembly bolt "7"
4. Install: Exhaust pipe joint bolt "8"
Throttle bodies
Refer to "THROTTLE BODIES" on page 7-6. Exhaust pipe nut
5. Install: 15 Nm (1.5 mkgf, 11 ftlbf)
Fuel tank Exhaust pipe bolt
Refer to "FUEL TANK" on page 7-1. 20 Nm (2.0 m-kgf, 14 ftlbf)
Fuel tank cover assembly Muffler assembly bolt
Refer to "GENERAL CHASSIS (3)" on page 20 Nm (2.0 m-kgf, 14 ftlbf)
4-5. Exhaust pipe joint bolt
20 Nm (2.0 mkgf, 14 ftlbf)
Side panels
Refer to "GENERAL CHASSIS (2)" on page
4-3.
Rider seat
Refer to "GENERAL CHASSIS (1 )"on page
4-1.
3-10
PERIODIC MAINTENANCE
3. Install:
Coolant reservoir
Refer to "RADIAT OR" on page 6-1.
Front bottom cowling (left)
Refer to "GENERA L CHASSIS (3)" on page
4-5.
Side panel (left)
Refer to "GENERA L CHASSIS (2)" on page
4-3.
EAS30627
3. Remove:
Air filter element "1"
3-11
PERIODIC MAINTENANCE
4. Check: 2. Remove:
Air filter element Side panel (right)
Damage Replace. Refer to "GENERAL CHASSIS (2)" on page
4-3.
The air filter needs more frequent service if you Front bottom cowling (right)
are riding in unusually wet or dusty areas. Refer to "GENERAL CHASSIS (3)" on page
4-5.
5. Install: 3. Adjust:
Air filter element Clutch lever free play
Air filter case side cover (left)
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
Air filter case side cover screw Handlebar side
(left) a. Loosen the locknut "1 ".
2.5 Nm (0.25 mkgf, 1.8 ftlbf) b. Turn the adjusting bolt "2" in direction "a" or
ECA20710
"b" until the specified clutch lever free play is
obtained.
Never operate the engine without the air filter Direction "a"
element installed. Unfiltered air will cause Clutch lever free play is increased.
rapid wear of engine parts and may damage Direction "b"
the engine. Operating the engine without the Clutch lever free play is decreased.
air filter element will also affect throttle body
synchronization, leading to poor engine per-
formance and possible overheating.
6. Install:
Side panel (left)
Refer to "GENERAL CHASSIS (2)" on page
4-3.
EAS30629
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
Engine side
a. Loosen the locknut "1 ".
3-12
PERIODIC MAINTENANCE
b. Turn the adjusting nut "2" in direction "a" or "b" 1. Operate the brake.
until the specified clutch lever free play is ob- 2. Check:
tairied. Front brake pad
Wear indicator grooves "a" almost disap-
Direction "a" peared -7 Replace the brake pads as a set.
Clutch lever free play is increased.
Refer to "FRONT BRAKE" on page 4-35.
Direction "b"
Clutch lever free play is decreased.
EAS30634
EAS30633
2. Check:
Brake hose holder
Loose -7 Tighten the holder bolt.
3-13
PERIODIC MAINTENANCE
Brake hose guide caution could allow air to enter the hydraulic
Loose Tighten the guide bolt. brake system, considerably lengthening the
3. Hold the vehicle upright and apply the brake bleeding procedure.
several times. If bleeding is difficult, it may be necessary to let
4. Check: the brake fluid settle for a few hours. Repeat
Brake hose the bleeding procedure when the tiny bubbles
Brake fluid Replace the damaged in the hose have disappeared.
hose. 1. Bleed:
Refer to "FRONT BRAKE" on page 4-35.
Hydraulic brake system
EAS30636 TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
CHECKING THE REAR BRAKE HOSE a. Fill the brake fluid reservoir to the proper level
1. Check: with the specified brake fluid.
Brake hose "1" b. Install the diaphragm (brake master cylinder
Cracks/damage Replace. reservoir or brake fluid reservoir).
c. Connect a clear plastic hose "1" tightly to the
bleed screw "2".
2. Check:
Brake hose guide
Loose Tighten the bolt.
3. Hold the vehicle upright and apply the rear
brake several times.
4. Check:
Brake hose
Brake fluid Replace the damaged
hose.
Refer to "REAR BRAKE" on page 4-48.
EAS30637
AwARNING A. Front
Bleed the hydraulic brake system whenever: B. Rear
the system is disassembled. d. Place the other end of the hose into a con-
a brake hose is loosened, disconnected or tainer.
replaced. e. Slowly apply the brake several times.
the brake fluid level is very low. f. Fully pull the brake lever or fully press down
brake operation is faulty. the brake pedal and hold it in position.
g. Loosen the bleed screw.
Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake Loosening the bleed screw will release the pres-
fluid reservoir to overflow. sure and cause the brake lever to contact the
When bleeding the hydraulic brake system, throttle grip or the brake pedal to fully extend.
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
3-14
PERIODIC MAINTENANCE
EAS30632
ECA 13540
A WARNING
Never attempt to make any repairs to the
wheel.
3-15
PERIODIC MAINTENANCE
11 1
EWA13181
1 . Ti re tread depth
AwARNING 2. Side wall
The tire pressure should only be checked 3. Wear indicator
and regulated when the tire temperature
equals the ambient air temperature.
Wear limit (front)
The tire pressure and the suspension must 1.0 mm (0.04 in)
be adjusted according to the total weight' Wear limit (rear)
(including cargo, rider, passenger and ac- 1.0 mm (0.04 in)
cessories) and the anticipated riding
speed. EWA14090
2. Check: EWA1 32 10
3-16
PERIODIC MAINTENANCE
Align the mark "2" with the valve installatio n arm or cause an accident . Therefore , keep
point. the drive chain slack within the specified lim-
its.
1. Stand the vehicle on a level surface .
EWA13120
A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
LUBRICATING THE SWINGARM PIVOT 4. Remove the drive chain puller cap "1 ", and
1. Lubricate : then loosen the axle nut "2".
Bearing s
Spacer
Dust covers
3-17
PERIODIC MAINTENANCE
Recommended lubricant
Chain lubricant suitable for 0-
ring chains
EAS30645
A
WARNING
Securely support the vehicle so that there is
no danger of it falling over.
c. Tighten the wheel axle nut to specification .
Rear wheel axle nut Place the vehicle on a suitable stand so that the
57 Nm (5.7 mkgf, 41 ftlbf) front wheel is elevated.
2. Check:
Steering head
Apply lithium-soap-based grease to the contact Grasp the bottom of the front fork legs and
surface and threads of the rear wheel axle nut. gently rock the front fork.
d. Tighten the drive chain puller adjusting nuts Blinding/looseness the steering
and the drive chain puller locknuts to specifi- head.
cation. 3. Remove:
Upper bracket
Refer to "STEERING HEAD" on page 4-76.
4. Adjust:
Steering head
3-18
PERIODIC MAINTENANCE
TTTTTTT TTTTTTT TTTTTTT TTTTTTT TTTT d. Check the steering head for looseness or
a. Remove the lock washer "1 ", the upper ring
binding by turning the front fork all the way in
nut "2", and the washer "3".
both directions. If any binding is felt, remove
the lower bracket and check the upper and
lower bearings.
Refer to "STEERING HEAD" on page 4-76.
e. Install the washer "3".
f. Install the upper ring nut "2".
g. Finger tighten the upper ring nut, then align
the slots of both ring nuts. If necessary, hold
3 the lower ring nut and tighten the upper ring
nut until their slots are aligned.
h. Install the lock washer "1".
b. Loosen the lower ring nut "4" and then tighten
it to specification with a steering nut wrench
"5". Make sure the lock washer tabs "a" sit correctly
in the ring nut slots "b".
Steering nut wrench
90890-01403
Exhaust flange nut wrench
YU-A9472
Set the torque wrench at a right angle to the AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAA
steering nut wrench . 5. Install:
Upper bracket
Refer to "STEERING HEAD" on page 476.
EAS30646
3-19
PERIODIC MAINTENANCE
EAS30805
Recommended lubricant
Lithium-soap-based grease
EAS30650
3-20
PERIODIC MAINTENANCE
Direction "a"
Spring preload is increased (suspen-
sion is harder).
Direction "b"
Spring preload is decreased (suspen-
sion is softer).
0 10 30 50 70 90 110 130 F
:SAE 1OW-30 :
10"}'-40 :
SAE
. 15W-40
. ' .
20W-40 [
EAS30656 : SAE 20W-56
i I i i i i
CHECKING THE ENGINE OIL LEVEL -10 0 10 20 30 40 c
1. Stand the vehicle on a level surface.
ECA 13361
3-21
PERIODIC MAINTENANCE
EAS30657
b. Lubricate the 0-ring "3" of the new oil filter
CHANGING THE ENGINE OIL cartridge with a thin coat of engine oil.
1. Start the engine, warm it up for several min- ECA1 3390
6. Install:
Engine oil drain bolt "1"
(along with the gasket "2" Im)
Engine oil drain bolt
20 Nm (2.0 mkgf, 14 ftlbf)
4. Drain:
Engine oil
Install the new gasket as shown in the illustra-
(completely from the oil pan)
tion.
5. If the oil filter cartridge is also to be replaced,
perform the following procedure.
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
a. Remove the oil filter cartridge "1" with an oil
filter wrench "2".
7. Fill:
Oil pan
(with the specified amount of the recom-
mended engine oil)
3-22
PERIODIC MAINTENANCE
3-23
PERIODIC MAINTENANCE
4. Remove:
Coolant reservoir cover "1"
Coolant reservoir cap "2"
Coolant reservoir
Refer to "RADIATOR" on page 6-1.
EAS30813
AwARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam may
);
5. Drain:
be blown out, which could cause serious in- Coolant
jury. When the engine has cooled, open the (from the coolant reservoir)
radiator cap as follows: 6. Remove:
Place a thick rag or a towel over the radiator Coolant drain bolt "1"
cap and slowly turn the radiator cap counter- (along with the copper washer)
clockwise toward the detent to allow any re-
sidual pressure to escape. When the hissing
sound has stopped, press down on the radi-
ator cap and turn it counterclockwise to re-
move.
3-24
PERIODIC MAINT ENAN CE
essary, correct the antifreez e concentr a- CHECKING THE BRAKE LIGHT SWITCHES
tion of the coolant. 1. Check:
Use only distilled water. However , if dis- Front brake light switch operation
tilled water is not available , soft water may Rear brake light switch operation
be used. When operating the brake lever and brake
pedal, confirm that the brake light turns on.
3-25
PERIODIC MAINTENANCE
Recommended lubricant
Suitable cable lubricant
TIP _ _ __ _ __ _ _ _ _ _ _ _ _
With the engine stopped, turn the throttle grip
slowly and release it. Make sure that the throttle
grip turns smoothly and returns properly when
released.
Repeat this check with the handlebar turned all
the way to the left and right.
3. Check:
EAS30660 Throttle grip free play "a"
CHECKING AND LUBRICATING THE Out of specification -7 Adjust.
CABLES
The following procedure applies to all of the in- Throttle grip free play
ner and outer cables. 3.0-5.0 mm (0.12-0.20 in)
EWA1 3270
AwARNING
Damaged outer cable may cause the cable to
corrode and interfere with its movement. Re-
place damaged outer cable and inner cables
as soon as possible.
1. Check:
Outer cable
Damage -7 Replace.
3-26
PERIODIC MAINTENANCE
4. Adjust:
Throttle grip free play
Direction "a"
Throttle grip free play is increased.
Direction "b"
Throttle grip free play is decreased .
3. Unhook:
Headlight bulb holder "3"
4. Remove:
Headlight bulb "4"
EAS30663
SIGNALS AwARNIN G
1. Check that all switches operate and that all Since the headlight bulb gets extremely hot,
lights come on. keep flammable products and your hands
Refer to "INSTRUMENT AND CONTROL away from the bulb until it has cooled down.
FUNCTIONS" in Owner's manual.
5. Install:
Faulty Refer to "CHECKING THE
SWITCHES" on page 8-81 and "CHECKING Headlight bulb Hm!I
THE BULBS AND BULB SOCKETS" on Secure the new headlight bulb with the head-
page 8-84. light bulb holder.
ECA 13690
.. '
EAS30665
REPLACING THE HEADLIGH T BULBS Avoid touching the glass part of the head-
The following procedure applies to both of the light bulb to keep it free from oil, otherwise
headlight bulbs. the transparen cy of the glass, the life of the
1. Remove: bulb and the luminous flux will be adversely
Headlight bulb cover "1"
3-27
PERIODIC MAINTENANCE
EAS30664
Direction "a"
Headlight beam is raised.
Direction "b"
Headlight beam is lowered .
2. Adjust:
Headlight beam (horizontally)
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
a. Turn the adjusting bolts "1" in direction "a" or
"b".
Left headlight
3-28
PERIODIC MAINTENANCE
3-29
CHASSIS
FRONT FORK .......... ....... ............. ...................... ......... ............... .................... 4-67
REMOVING THE FRONT FORK LEGS ................ .................................. 4-70
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-70
CHECKING THE FRONT FORK LEGS ........ .. ....................................... .4-71
ASSEMBLING THE FRONT FORK LEGS ..............................................4-71
INSTALLING THE FRONT FORK LEGS ........... .. .. ........ ......................... 4-74
STEERING HEAD ............. ............................................. ................................ 4-76
REMOVING THE LOWER BRACKET ..... ..................... ........................... 4-78
CHECKING THE STEERING HEAD ....................................................... 4-78
INSTALLING THE STEERING HEAD ................ ..................................... 4-78
EAS20026
4-1
GENERAL CHASSIS (1)
EAS31189
EAS31190
EAS30697
EAS31 126
EAS31 125
lnsert the projections "a" on the front of the pas-
INSTALLING THE RIDER SEAT
senger seat into the grooves "b" as shown, and
1. Install:
then push the rear of the seat down to lock it in
Rider seat "1"
place.
Rider seat bolt
7 Nm (0.7 mkgf, 5.1 ftlbf)
4-2
GENE RA L CHAS SIS (2)
EAS20155
GENER A L CHASS IS
e rear s1"d e cowl(2)
Removing th
mgs
4-3
GENERAL CHASSIS (2)
EAS31290
b. Slide the upper tail panel rearward and re-
REMOVING THE SIDE PANELS
move it.
The following procedure applies to both of the
side panels.
1. Remove:
Side panel "1"
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
a. Remove the side panel bolts.
b. Remove the projections "a" on the side panel
from the grommets, and then remove the pro-
jection "b" on the panel from the front upper
cowling.
EAS31293
EAS31292
4-4
GENERAL CHASSIS (3)
EAS20156
I
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I
I
I
4-5
GENERAL CHASSIS (3)
1 Bottom cowling
2 Front bottom cowling (left)
3 Front side cowling assembly (left)
4 Front turn signal light connector (left) 2 Disconnect.
5 Front side cowling inner panel (left)
6 Front upper cowling (left)
7 Front lower cowling (left)
8 Front side cowling (left)
9 Front bottom cowling (right)
10 Front side cowling assembly (right) 1
11 Front turn signal light connector (right) 2 Disconnect.
12 Front side cowling inner panel (right)
13 Front upper cowling (right)
4-6
GENERAL CHASSIS (3)
4-7
GENERAL CHASSIS (3)
EAS31352
b. Install the front panel bolts and quick fasten-
REMOVING THE FRONT PANELS
ers, and then tighten the bolts to specifica-
The following procedure applies to both of the
tion.
front panels.
1. Remove: Front panel bolt
Front panel "1" 1.8 Nm (0.18 mkgf, 1.3 ftlbf)
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
a. Remove the front panel bolts "2" and quick
fasteners "3".
EAS31354
a EAS31355
4-8
GENERAL CHASSIS (3)
EAS31456
EAS31358
4-9
GENERAL CHASSIS (3)
EAS31359
4-10
GENERAL CHASSIS (3)
EAS3 1362
INSTALL ING THE FRONT SIDE COWLIN G Slide the front upper cowling in the direction of
ASSEMB LY the arrow shown in the illustration to remove the
The following procedure applies to both of the projections "a" on the front side cowling "2" from
front side cowling assembly. the holes "b" in the front upper cowling.
1. Install:
Front side cowling assembly "1"
TTTTTTT TTTTTTT TTTTTTT TTTTTTT TTTT
a. Fit the projections "a" on the front side cowl-
ing assembly into the holes "b" in the front
cowling inner panel, slide the front side cowl-
ing assembly rearward, and then fit the por-
tion "c" of the front cowling inner panel into
the slot "d" in the front side cowling assembly.
b. Fit the projection "e" on the front side cowling
assembly into the grommet.
EAS31363
4-11
GENERAL CHASSIS (3)
1. Install:
Front upper cowling "1"
4-12
GENERAL CHASSIS (4)
EAS20157
()
4-13
GENERAL CHASSIS (4)
EAS31296
TIP _ _ _ _ __ _ _ _ __ _ __
Fit the projection "a" on the front cowling assem-
bly bracket into the hole "b" in the frame.
4-14
GENERAL CHASSIS (5)
EAS20158
I
I
:4
I
. 7 Nm (0.7 mkgf, 5.1 ftlbf)
I
I
I
Qf
11
4-15
GENERAL CHASSIS (5)
EAS31374
EAS31299
c. Remove the projections "a" on the windshield REMOVING THE FRONT COWLING CENTER
assembly from the holes "b" in the front cowl- COVER
ing inner panel. 1. Remove:
Front cowling center cover "1"
EAS31375
4-16
GENERAL CHASSIS (5)
"...
' .- - '
.
4-17
GENERAL CHASSIS (6)
EAS20159
v
I
4
'
I :
I (8)
4-18
GENE RAL CHASSIS (6)
8
(8)
I
4-19
GENERAL CHASSIS (6)
EAS31303
TIP _ _ _ _ __ _ __ _ _ _ __
Align the projection "a" on the air filter case joint
with the slot "b" in the air filter case joint clamp.
1 1
A. Right side
B. Left side
4-20
FRONT WHEEL
EAS20028
FRONT WHEE L
Removin g the front wheel and brake disc
,,' \, 7
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
4-21
FRONT WHEEL
4-22
FRONT WHEEL
EAS30145
A WARNING
Securel y suppor t the vehicle so that there is
no danger of it falling over.
2. Remove:
Front brake hose holder
Front brake caliper
TIP _ _ _ _ _ _ _ _ _ _ __ _ __
Do not apply the brake lever when removing the EAS30 147
brake caliper. CHECKING THE FRONT WHEEL
3. Elevate: 1. Check:
Front wheel Wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
Place the vehicle on a suitable stand so that the EWA13460
4-23
FRONT WHEEL
4. Check:
Wheel bearings
+
Front wheel turns roughly or is loose Re-
place the wheel bearings.
Oil seals 1
Replace. 4
5
EAS30152
ASSEMBLING THE FRONT WHEEL Adjust the front wheel static balance with the
1. Install: brake disc installed.
4-24
FRONT WHEEL
d. Release the front wheel. c. If the heavy spot does not stay in that posi-
e. When the wheel stops, put an "X " mark at tion, install a heavier weight.
2
the bottom of the wheel. d. Repeat steps (b) and (c) until the front wheel
is balanced.
AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAA
4. Check:
Front wheel static balance
TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TT
a. Turn the front wheel and make sure it stays at
each position shown.
x
4-25
FRONT WHEEL
ECA14140
A WARNING
Recommended lubricant
Make sure the brake hose is routed properly.
Lithium-soap-based grease
TIP ___________________ _________
4. Install: While holding the front brake hose holder so that
Collars the portion "a" of the holder contacts the portion
Front wheel "b" of the front fork, tighten the front brake hose
Front wheel axle holder bolt.
Front wheel axle nut
TIP ___________________ _________
Install the front wheel with the mark "a" on the
front tire pointing in the direction of wheel rota-
tion.
Apply lithium-soap-based grease to the con-
tact surface and threads of the front wheel axle
nut.
5. Tighten:
Front wheel axle nut
4-26
REAR WHEEL
EAS20029
REAR WHEEL
Removing the rear wheel
4-27
REAR WHEEL
13 Chain puller 2
14 Collar (left)
15 Collar (right)
4-28
REAR WHEEL
4-29
REAR WHEEL
.... .
.. .
4-30
REAR WHEE L
EAS30156
EAS30 161
4-31
REAR WHEEL
b. Correct
1. Drive chain roller EAS30 163
4-32
REAR WHEE L
3. Check:
Rear brake disc
+ Refer to "CHECKING THE REAR BRAKE
DISC" on page 4-54.
4. Lubricate:
1 Oil seal lips
4 Recomm ended lubricant
Lithium-s oap-base d grease
5
5. Install:
Collar (right)
EAS30164 Collar (left)
ADJUST ING THE REAR WHEEL STATIC Chain pullers
BALANC E Brake caliper bracket "1"
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __ Rear wheel
After replacing the tire, wheel or both, the rear Rear wheel axle
wheel static balance should be adjusted. Washer s
Adjust the rear wheel static balance with the Rear wheel axle nut
brake disc and rear wheel drive hub installed. Swingarm end plates
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
1. Adjust:
Rear wheel static balance Install the rear wheel with the mark "a" on the
Refer to "ADJUSTING THE FRONT WHEEL rear tire pointing in the direction of wheel rota-
STATIC BALANCE" on page 4-24. tion.
Align the projection "b" in the swingarm with the
EAS30165
slot "c" of the brake caliper bracket.
INSTALL ING THE REAR WHEEL (REAR
Apply lithium-soap-based grease to the con-
BRAKE DISC)
tact surface and threads of the rear wheel axle
1. Install:
nut.
Rear brake disc "1"
TIP _ _ _ _ _ _ _ _ _ _ __ _ _
Install the rear brake disc with its chamfered side
"a" facing inward.
2. Install:
Rear wheel sprocket
Refer to "CHECKING AND REPLACING 6. Lubricate:
THE REAR WHEEL SPROCKET" on page Rear brake caliper bolt
4-31.
4-33
REAR WHEEL
Recommended lubricant
Silicone grease
7. Install:
Rear brake caliper
Rear brake caliper bolt
8. Adjust:
Drive chain slack
Refer to "ADJUSTING THE DRIVE CHAIN
SLACK" on page 3-17.
9. Tighten:
Rear wheel axle nut
Rear brake caliper bolt
AwARNING
Make sure the brake hose is routed properly.
4-34
FRONT BRAKE
EAS20030 NT BRAKE
FRO ads
Remov1ng the front brake p
4-35
FRONT BRAKE
1 I
I
1.5 Nm (0.15 mkgf, 1.1 ftlbf)
Drain.
Brake fluid Refer to "BLEEDING THE HYDRAULIC
BRAKE SYSTEM" on page 3-14.
Front brake master cylinder reservoir cap
Brake master cylinder reservoir diaphragm hold-
2 er
3 Brake master cylinder reservoir diaphragm
4 Brake lever
5 Front brake light switch connector 2 Disconnect.
6 Front brake light switch
Front brake hose union bolt (master cylinder
7 side)
8 Brake hose gasket 2
4-36
FRONT BRAK E
4-37
FRONT BRAKE
4-38
FRONT BRAKE
3
29 Nm (2.9 mkgf, 21 ftlbf)
4-39
FRONT BRAKE
glmlJ
4-40
FRONT BRAK E
EAS30168
EAS30169
a. Place the vehicle on a suitable stand so that Replace the brake disc bolts with new ones.
the front wheel is elevated.
b. Before measuring the brake disc deflection,
Install the front brake disc "1" with its cham-
turn the handlebar to the left or right to ensure
fered side "a" facing inward.
that the front wheel is stationary.
Tighten the brake disc bolts in stages and in a
c. Remove the brake caliper.
crisscross pattern.
d. Hold the dial gauge at a right angle against
the brake disc surface.
4-41
FRONT BRAKE
1 [8J
1
u
=ffrZ B lf=lsfa
ill]
4-42
FRONT BRAKE
REMOVING THE FRONT BRAKE CALIPER Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
Never try to pry out the brake caliper pis-
Before removing the brake caliper, drain the ton.
brake fluid from the entire brake system.
1. Remove:
Brake hose union bolt "1"
Brake hose gaskets "2"
Brake hose "3"
4-43
FRONT BRAKE
EAS30 173
Whenever a brake caliper is disassembled,
CHECKING THE FRONT BRAKE CALIPER replace the brake caliper piston dust seals
Recommended brake component and brake caliper piston seals.
replacement schedule
Brake pads If necessary Specified brake fluid
Piston seals Every two years DOT4
Brake hose Every four years INSTALLING THE FRONT BRAKE CALIPER
Every two years and 1. Install:
Brake fluid whenever the brake is Front brake caliper "1"
disassembled (temporarily)
2. Remove:
EAS30 174
Front brake caliper
ASSEMBLING THE FRONT BRAKE CALIPER
EWA1362 1
3. Install:
AwARNING Brake pad spring
Brake pads
Before installation, all internal brake com-
Brake pad pin
ponents should be cleaned and lubricated
Brake pad clips
with clean or new brake fluid.
Never use solvents on internal brake com- Front brake caliper bolt
ponents as they will cause the brake caliper 35 Nm (3.5 m-kgf, 25 ftlbf)
piston dust seals and brake caliper piston
seals to swell and distort. Refer to "REPLACING THE FRONT BRAKE
PADS" on page 4-42.
4-44
FRON T BRAKE
4. Fill: EAS30179
4-45
FRONT BRAKE
4. Check:
Brake hose
Cracks/damage/wear -7 Replace.
FWD . . .
EAS30181
AwARNING
Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid. 2. Install:
Never use solvents on internal brake com- Brake hose
ponents. Brake hose gaskets o:m
Brake hose union bolt
Specified brake fluid
DOT4 Front brake hose union bolt
(master cylinder side)
EAS30182 29 Nm (2.9 m-kgf, 21 ftlbf)
INSTALLING THE FRONT BRAKE MASTER
CYLINDER EWA13531
1. Install: A WARNING
Front brake master cylinder assembly Proper brake hose routing is essential to in-
Front brake master cylinder holder sure safe vehicle operation.
TIP _ __ _ __ __ _ _ __ __ _
Front brake master cylinder hold-
er bolt Attach the brake hose so that its angle is 75 to
1O Nm (1.0 mkgf, 7.2 ftlbf) 85 against the straight line in parallel with the
ceiling plane of the master cylinder.
TIP _ _ _ _ _ _ _ __ _ _ __ __ While holding the brake hose, tighten the union
Install the front brake master cylinder holder bolt as shown.
with the "UP" mark "a" facing up. Turn the handlebar to the left and right to make
Align the mating surfaces of the front brake sure the brake hose does not touch other parts
master cylinder holder with the punch mark "b" (e.g ., wire harness, cables, leads). Correct if
on the handlebar (right), or install the front necessary.
brake master cylinder so that the distance "c"
between the bottom of the handlebar (right)
and the bottom of the front brake master cylin-
der is 11 mm (0.43 in) as shown in the illustra-
tion.
First, tighten the upper bolt, then the lower bolt.
4-46
FRONT BRAKE
3. Fill: 6. Check:
Brake master cylinder reservoir Brake lever operation
(with the specified amount of the specified Soft or spongy Bleed the brake sys-
brake fluid) tem.
Refer to "BLEEDING THE HYDRAULIC
Specified brake fluid BRAKE SYSTEM" on page 3-14.
DOT4
EWA1 3540
AwARN ING
Use only the designat ed brake fluid. Other
brake fluids may cause the rubber seals to
deteriora te, causing leakage and poor
brake performa nce.
Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemica l reaction,
leading to poor brake performa nce.
When refilling, be careful that water does
not enter the brake master cylinder reser-
voir. Water will significa ntly lower the boil-
ing point of the brake fluid and could cause
vapor lock.
ECA1 3540
4-47
REAR BRAKE
EAS20031 BRAKE
REAR ads
.
Removing the rear brake p
4-48
REAR BRAKE
4-49
REAR BRAKE
4-50
REAR BRAKE
4-51
REAR BRAKE
4-52
REAR BRAK E
g
5
4-53
REAR BRAKE
EAS30 183
4. Measure:
Brake disc thickness
Measure the brake disc thickness at a few dif-
ferent locations.
Out of specification Replace.
Refer to "CHECKING THE FRONT BRAKE
DI SC" on page 4-4 1.
4-54
REAR BRAK E
TIP _ _ _ _ __ _ _ __ _ _ _ _
The longer tangs "a" of the brake pad spring
must point in the direction of the brake caliper
piston.
A. Inner
B. Outer
2. Install:
Brake pad shims
(onto the brake pads) AAAAAAA AAAAAAA AAAAAAA AAAAAAA AAAA
Brake pad spring 3. Lubricate:
(into the rear brake caliper) Rear brake caliper bolt
Brake pads
TIP _ _ __ _ _ __ _ _ _ _ __ _ Recomm ended lubrican t
Always install new brake pads, brake pad shims, Silicone grease
and brake pad spring as a set.
TTTTTTT TTTTTTT TTTTTTT TTTTTTT TTTT
a. Connect a clear plastic hose "1" tightly to the Do not allow grease to contact the brake
bleed screw "2". Put the other end of the hose pads.
into an open container. Remove any excess grease.
b. Loosen the bleed screw and push the brake
caliper piston into the brake caliper with your 4. Install:
finger. Rear brake caliper
Rear brake caliper bolt
5. Check:
Brake fluid level
Below the minimum level mark "a" -7 Add the
specified brake fluid to the proper level.
Refer to "CHECKING THE BRAKE FLUID
LEVEL" on page 3-15.
c. Tighten the bleed screw.
4-55
REAR BRAKE
Refer to "BLEEDING THE HYDRAULIC Never try to pry out the brake caliper pis-
BRAKE SYSTEM" on page 3-14. ton.
EAS30186
0--2 assembly.
Brake fluid delivery passages
A WARNING
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT Whenever a brake caliper is disassembled,
a. Blow compressed air into the brake hose joint
replace the brake caliper piston dust seal
opening "a" to force out the piston from the
and brake caliper piston seal.
brake caliper.
EWA13550
A WARNING
Cover the brake caliper piston with a rag.
Be careful not to get injured when the pis-
ton is expelled from the brake caliper.
4-56
REAR BRAK E
EWA 13531
AwARN ING
EAS30189
ASSEMB LING THE REAR BRAKE CALIPER Proper brake hose routing is essentia l to in-
EWA17080 sure safe vehicle operation .
AwARN ING ECA19080
EAS30190
4-57
REAR BRAKE
EWA 13090
EAS30194
6. Check:
Brake pedal operation
Soft or spongy Bleed the brake sys-
tem. 4. Check:
Refer to "BLEEDING THE HYDRAULIC Brake hose
BRAKE SYSTEM" on page 3-14. Brake fluid reservoir hose
Cracks/damage Replace.
EAS30193
4-58
REAR BRAK E
EAS30 195
A WARNING
Brake hose gaskets "2" em
Brake hose union bolt "3"
Before installat ion, all internal brake com-
ponents should be cleaned and lubricat ed Rear brake hose union bolt (mas-
with clean or new brake fluid. ter cylinde r side)
Never use solvent s on internal brake com- 29 Nm (2.9 mkgf, 21 ftlbf)
ponents . EWA1 3531
A WARNIN G
Specifie d brake fluid Proper brake hose routing is essenti al to in-
DOT4 sure safe vehicle operatio n.
1. Install: ECA141 ?9, , ''"'"
Niifiss - - - - - - - - - - - -
Brake hose joint .:.:.'.'\/.:--
... .
--
When installin g the brake hose onto the
Brake master cylinder kit em brake master cylinder , make sure the brake
Brake master cylinder joint "1"
pipe touches the projecti on "a" as shown.
TIP _ _ _ _ __ _ _ _ _ __ _ __
The rear brake master cylinder joint installation
length "a" should be 74.8 mm (2.94 in).
3. Fill:
Brake fluid reservoir
(with the specified amount of the specified
EAS30 196 brake fluid)
INSTALLING THE REAR BRAKE MASTER
CYLINDER Specifie d brake fluid
1. Install: DOT4
Rear brake hose guide "1"
EWA13090
TIP _ __ _ _ _ _ _ _ _ __ _ _ _
AwARN ING
Make sure that the projection "a" on the rear Use only the designa ted brake fluid. Other
brake hose guide contacts the swingarm. brake fluids may cause the rubber seals to
deterior ate, causing leakage and poor
Rear brake hose guide bolt brake perform ance.
7 Nm (0.7 m-kgf, 5.1 ftlbf) Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids
may result in a harmful chemica l reaction ,
leading to poor brake perform ance.
When refilling , be careful that water does
not enter the brake fluid reservo ir. Water
will signific antly lower the boiling point of
the brake fluid and could cause vapor lock.
4-59
REAR BRAKE
ECA1 3540
6. Adjust:
Rear brake light operation timing
Refer to "ADJUSTING THE REAR BRAKE
LIGHT SWITCH" on page 3-26.
4-60
HANDLEBARS
EAS20033
HANDLEBARS
Removing the handlebar (right)
13 Nm (1.3 mkgf, 9.4 ftlbf)
' \
...
2.5 Nm (0.25 mkgf, 1.8 ftlbf)
4-61
HANDLEBARS
10
4-62
HANDLEBARS
EAS30203
b a
A. Left
B. Right
3. Install:
Clutch switch
Clutch lever holder "1 "
EAS30204
Clutch lever
CHECKING THE HANDLEB ARS
1. Check: Clutch switch screw
Handlebar (left) 0.6 Nm (0.06 m-kgf, 0.43 ftlbf)
Handlebar (right) LOCTITE
Bends/cracks/damage --7 Replace. Clutch lever holder pinch bolt
EWA13690
7 Nm (0.7 mkgf, 5.1 ftlbf)
AwARNIN G Clutch lever pivot nut
Do not attempt to straighten a bent handle- 7 Nm (0. 7 mkgf, 5.1 ftlbf)
bar as this may dangerous ly weaken it.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
EAS30205
Align the projection "a" on the clutch lever hold-
INSTALLIN G THE HANDLEB ARS
er with the punch mark "b" on the handlebar.
1. Stand the vehicle on a level surface.
EWA 13120
Fit the projection "c" on the bottom of the bolt
AwARNIN G head into the slot "d" in the bolt hole in the
clutch lever holder.
Securely support the vehicle so that there is
no danger of it falling over.
2. Install:
Handlebar weights "1"
(to the handlebars "2")
4-63
HANDLEBARS
AwARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
TIP _ _ __ _ _ _ __ _ _ __ __
Align the projection "a" on the grip end with the
slot "b" in the handlebar weight.
While holding the grip end, tighten the grip end
bolt.
There should be 2-5 mm (0.08-0.20 in) of
clearance "c" between the handlebar grip and
the grip end.
4. Connect: 2
Clutch cable
@
TIP _ _ _ _ _ _ _ __ _ __ _ __
Lubricate the end of the clutch cable with a thin
coat of lithium-soap-based grease.
5. Install:
Handlebar switch (left) "1" a
Handlebar switch screw (left)
1.5 Nm (0.15 mkgf, 1.1 ftlbf)
7.
Install:
Front brake master cylinder "1"
Front brake master cylinder holder "2"
4-64
HANDLEBARS
Align the mating surfaces of the front brake
master cylinder holder with the punch mark "b"
on the handlebar (right), or install the front
brake master cylinder so that the distance "c"
between the bottom of the handlebar (right)
and the bottom of the front brake master cylin-
der is 11 mm (0.43 in) as shown in the illustra-
tion.
First, tighten the upper bolt, then tighten the
lower bolt.
9. Install:
Grip end (right) "1"
8. Install:
Throttle grip "1"
Throttl e cables
Handlebar switch (right) "2"
4-65
HANDLEBARS
11.Adjust:
Clutch lever free play
Refer to "ADJUSTING THE CLUTCH LEVER
FREE PLAY" on page 3-12.
12.Adjust:
Throttle grip free play
Refer to "CHECKING THE THROTTLE GRIP
OPERATION" on page 3-26.
4-66
FRONT FOR K
EAS20034
FRONT FORK
Remov ing the front fork legs
7 -- --1
4-67
FRONT FORK
I
I I
4-68
FRONT FORK
----; --- -;
---
I 14
Dm11-;;
21
11
,/
l
C---1 -,
3-.1-30-Nm-(3-.0-m-.-kg-f,-2-2-ft-lb-f).....-I
B
Order Job/Parts to remove Q'ty Remarks
11 Damper rod
12 Damper rod ring
13 Rebound spring
14 Inner tube
. ... 15 Oil seal
16 Washer
17 Outer tube bushing
18 Inner tube bushing
19 Oil flow stopper
20 Spring
21 Outer tube
4-69
FRONT FORK
EAS30206
AwARNING
Securely support the vehicle so that there is
no danger of it falling over.
2. Loosen:
Front fork cap bolt "1" 2. Remove:
Handlebar pinch bolt "2" Dust seal "1"
Upper bracket pinch bolt "3" Oil seal clip "2"
Lower bracket pinch bolt "4" (with a flathead screwdriver)
EWA1 3640 ECA 14180
AwARNING
Before loosening the upper and lower brack- Do not scratch the inner tube.
et pinch bolts, support the front fork leg.
3. Remove:
Front fork damper rod bolt "1"
Copper washer
4-70
FRON T FORK
4. Remove:
Inner tube
TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TT
a. Hold the front fork leg horizontally.
b. Securely clamp the brake caliper bracket in a
vise with soft jaws.
c. Separate the inner tube from the outer tube
by pulling the inner tube forcefully but careful-
ly.
ECA14190
EAS30209
EAS30208
A WARNING
CHECKING THE FRONT FORK LEGS Make sure the oil levels in both front fork
The following procedure applies to both of the legs are equal.
front fork legs. Uneven oil levels can result in poor han-
1. Check: dling and a loss of stability.
Inner tube
Outer tube
Bends/damage/scratches -7 Replace. When assembling the front fork leg, be sure to
EWA13650 replace the following parts:
A WARNING -Inner tube bushing
Do not attempt to straighten a bent inner -Outer tube bushing
tube as this may dangerously weaken it. -Oil seal
-Oil seal clip
2. Measure:
-Dust seal
Fork spring free length "a"
-0-ring
Out of specification -7 Replace.
-Coppe r washer
Fork spring free length Before assembling the front fork leg, make
297.8 mm (11.72 in) sure all of the components are clean.
Limit 1. Install:
294.4 mm (11.59 in)
Oil flow stopper spring "1"
Oil flow stopper "2"
Damper rod ring "3"
Rebound spring
Damper rod "4"
Inner tube bushing "5" mll!I
4-71
FRONT FORK
TTTTTTTTTT TTTTTTTTTT TTTTTTTTTT TT d. Install the oil flow stopper and inner tube
a. Install the oil flow stopper spring into the oil bushing onto the inner tube "6".
flow stopper.
TIP _ _ __ _ _ _ __ __ _ __ _ >(
6
Make sure that the oil flow stopper spring is in-
stalled securely into the grooves "a" in the oil
flow stopper.
0
Recommend ed oil
Yamaha fork oil 1OWT
b. Install the damper rod ring onto the damper
rod. 3. Install:
TIP _ _ __ _ __ _ _ _ _ _ _ __ Inner tube
Fit the damper rod ring into the damper rod (in the outer tube)
groove so that the side of the ring with the pro- 4. Install:
jections is facing in the direction shown in the il- Copper washer lmlJ
lustration. Front fork damper rod bolt
5. Tighten:
Front fork damper rod bolt "1"
3
\ 4
Front fork damper rod bolt
30 Nm (3.0 mkgf, 22 ftlbf)
LOCTITE
tube. YM-01326
4-72
FRONT FOR K
6. Install:
Outer tube bushing "1" em
Wash er "2"
(with the fork seal driver attachment "3" and
fork seal driver weight "4")
8. Install:
Oil seal clip "1" em
7. Install: Adjust the oil seal clip so that it fits into the outer
tube's groove.
Oil seal "1" em
(with the fork seal driver attachment "2" and
fork seal driver weight "3")
ECA 14220
':'"':':':'>,,,.,,,,,,.,.,.,.,............ .... - - - - - - - -
-----
4-73
FRONT FORK
EAS30210
11.Measure:
Front fork leg oil level "a"
(from the top of the inner tube, with the outer
tube fully compressed and without the fork
spring)
Out of specification Correct. 2. Tighten:
Lower bracket pinch bolt
Level Upper bracket pinch bolt
121.0 mm (4.8 in)
Handlebar pinch bolt
Front fork cap bolt
TIP _ _ __ __ __ _ __ __ __
While filling the front fork leg, keep it upright. Lower bracket pinch bolt
After filling, slowly pump the front fork leg up 30 Nm (3.0 mkgf, 22 ftlbf)
and down to distribute the fork oil. Upper bracket pinch bolt
21 Nm (2.1 mkgf, 15 ftlbf)
Handlebar pinch bolt
21 Nm (2.1 mkgf, 15 ftlbf)
Front fork cap bolt
23 Nm (2.3 mkgf, 17 ftlbf)
3. Install:
Front fender bracket "1"
Front fender
4-74
FRONT FORK
4-75
STEERING HEAD
EAS20035
STEERING HEAD
Removing the upper bracket and lower bracket
4-76
STEERING HEAD
4-77
STEERING HEAD
EAS302 14
2. Check: EAS30216
4-78
STEERING HEAD
Recommended lubricant
Lithium-soap-based grease
2. Install:
Lower ring nut "1"
Rubber washer "2"
Upper ring nut "3"
Lock washer "4"
Refer to "CHECKING AND ADJUSTING
THE STEERING HEAD" on page 3-18.
3. Install:
Cable guide (right) "1"
Cable guide (left) "2"
4-79
SWINGARM AND REAR SHOCK ABSORB ER ASSEMBLY
EAS20 197
4-80
SWINGARM AND REAR SHOCK ABSORBER ASS EMB LY
Remov ing the swinga rm and rear shock absorb er assem bly
9
: :
7
4-81
SWINGA RM AND REAR SHOCK ABSORBER ASSEMB LY
AwARNING
I
Securely support the vehicle so that there is
no danger of it falling over.
EAS31305
A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
4-82
SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY
Bearings "3"
Replace.
4. Adjust:
Drive chain slack
EAS31308
Refer to "ADJUSTING THE DRIVE CHAIN
INSTA LLING THE SWING ARM SLACK" on page 3-17.
1. Lubricate:
Spac er Drive chain slack
Dust covers 35.0-4 5.0 mm (1.38- 1.77 in)
Bear ings
EAS31 366
3. Install:
The following procedure applies to both of the
pivot shaft cap.
Pivot shaft cap "1"
4-83
SWINGARM AND REAR SHOCK ABSORB ER ASSEMBLY
4-84
CHAIN DRIVE
4-85
CHAIN DRIVE
EAS30229
A WARNING
Securely support the vehicle so that there is
no danger of it falling over.
b
Place the vehicle on a suitable stand so that the
c
rear wheel is elevated.
AAAAAAAAAA AAAAAAAAAA AAAAAAAAAA AA
EAS30230
4-86
CHAIN DRIVE
EAS30231
I I 1 a
b. Correct
4. Check:
1. Drive chain roller
2. Drive sprocket
0-ring s "1"
Damage --7 Replace the drive chain. EAS30232
Drive chain rollers "2" CHEC KING THE REAR WHEE L SPRO CKET
Dama ge/we ar --7 Replace the drive chain. Refer to "CHECKING AND REPLACING THE
Drive chain side plates "3" REAR WHEE L SPROCKET" on page 4-31.
Damage/wear/cracks --7 Replace the drive EAS30233
chain. CHEC KING THE REAR WHEE L DRIVE HUB
Refer to "CHECKING THE REAR WHEE L
DRIVE HUB" on page 4-31.
II
I \ "' I I
I EAS3 1116
DD
s=j INSTA LLING THE DRIVE SPRO CKET
1. Install:
1 Drive sprocket "1"
Wash er
I Drive sprocket nut
4-87
CHAIN DRIVE
EAS30234
4-88
-- - - - - -- - - -- - - - - -
CHAIN DRIVE
4-89
ENGINE
. ..
CYLINDER AND PISTONS ........................................................................... 5-36
REMOVING THE PISTONS .................................................................... 5-37
CHECKING THE CYLINDERS AND PISTONS ...................................... 5-37
CHECKING THE PISTON RINGS ....................................................... .... 5-38
CHECKING THE PISTON PINS ....................................................... .... ... 5-39
INSTALLING THE PISTONS AND CYLINDER ....................................... 5-39
CRANKCASE ................................................................................
................ 5-72
DISAS SEMB LING THE CRAN KCAS E ...................... ....................
.......... 5-75
CHEC KING THE BALAN CER DRIVE GEAR ..............................
............ 5-76
CHEC KING THE TIMIN G CHAIN AND TIMIN G CHAIN GUIDE
(INTAK E SIDE) ................................................................................
....... 5-76
CHEC KING THE CRAN KCAS E ..................................................
............ 5-76
CHEC KING THE OIL NOZZ LES ..................................................
.......... . 5-76
ASSE MBLIN G THE CRAN KCAS E ........................................
.................. 5-76
INSTA LLING THE OIL PRES SURE SWITC H AND
GEAR POSIT ION SWITC H ............................................................
........ 5-79
CRANKSHAF T AND BALANCER SHAFT ................................................... 5-81
REMOVING THE BALANCER SHAFT JOURNAL BEARINGS .............. 5-84
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ...................... 5-84
REMOVING THE CONNECTING RODS .................. .............................. 5-84
CHECKING THE BALANCER SHAFT .................................................... 5-84
CHECKING THE CRANKSHAFT ...... ...................................................... 5-86
CHECKING THE CONNECTING RODS ........................................... ...... 5-87
INSTALLING THE CONNECTING RODS ............................................... 5-89
INSTALLING THE CRANKSHAFT .......................................................... 5-90
ASSEMBLING THE BALANCER SHAFT ASSEMBLY ........................... 5-90
INSTALLING THE BALANCER SHAFT ASSEMBLY .............................. 5-91
AwAR NING
To preve nt sparki ng, groun d all spark plug
leads before crank ing the engine .
5. Remov e:
Spark plugs The differe nce in compr ession pressu re be-
ECA 13340
tween cylinde rs should not excee d 100 kPa (1
kg/cm 2 , 14 psi).
Before remov ing the spark plugs, use com-
c. If the compr ession pressu re is above the
presse d air to blow away any dirt accum ulat-
maxim um specifi cation , check the cylinde r
ed in the spark plug wells to preve nt it from
head, valve surfac es and piston crown for
falling into the cylind ers.
carbon depos its.
6. Install: Carbo n depos its ---7 Elimin ate.
Extens ion "1 "
Compr ession gauge "2"
5-1
ENGINE INSPECTION
Spark plug
13 Nm (1.3 m-kgf, 9.4 ftlbf)
9. Connect:
Spark plug caps
1O.lnstall:
Fuel tank
Refer to "FUEL TANK" on page 7-1.
Fuel tank cover assembly
Refer to "GENERAL CHASSIS (3)" on page
4-5.
Side panels
Refer to "GENERAL CHASSIS (2)" on page
4-3.
Rider seat
Refer to "GENERAL CHASSIS (1 )"on page
4-1.
5-2
ENGINE REMOVAL
EAS20042
ENGINE REMOVAL
Removing the muffler and exhaust pipe
5-3
ENGINE REMOVAL
5-4
ENGINE REMOVAL
5-5
ENGINE REMOVAL
5-6
ENGINE REMOVAL
5-7
ENGINE REMOVAL
5-8
ENGINE REMOVAL
16
15
5-9
ENGINE REMOVAL
EAS3025 1
b
-z;::==========:;t__ a
2. Tighten:
Engine mounting nut (rear upper side) "4"
Sidestand bracket bolts "6''
Engine mounting nut (rear lower side) "8''
Engine mounting bolt (right front side) "1 O"
Engine mounting bolt (left front side) "11"
Engine bracket bolts (right) "13"
Engine bracket bolts (left) "15"
Engine mounting bolt (right upper side) "16"
Engine mounting bolt (left upper side) "17"
5-10
ENGINE REMOVAL
2. Install:
Exhaus t pipe "2"
Exhaus t pipe nuts "3"
Exhaus t pipe bolt "4"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
Tempo rarily tighten the bolt and nuts.
3. Tighten :
Exhaus t pipe nuts "3"
Exhaus t pipe bolt "4"
5. Install:
Muffler assemb ly "6"
Muffler assemb ly bolt "7"
TIP _ _ _ _ _ _ _ _ _ _ _ _ __
5-11
ENGINE REMOVAL
5-12
CAMSHAFTS
EAS20043
CAMSHAFTS
Removing the cylinder head cover
5-13
CAMSHAFTS
10
5-14
CAMSHAFTS
EAS30256
REMOVING THE CAMS HAFT S TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT
a. Insert the hexagon wrench "2" (part No.:
1. Remove:
1WS-12228-00) into the timing chain tension-
Crankshaft end cover "1"
er.
Timing mark accessing bolt "2"
b. Remove the timing chain tensioner.
2. Align:
Marks "a" on the generator rotor
4. Remove:
(with the slots "b" in the generator rotor cover)
TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT Intake camshaft cap "1"
a. Turn the crankshaft counterclockwise. Exhaust camshaft cap "2"
b. Position the marks "a" on the generator rotor ECA13720
on both sides of the slots "b" in the generator ___ ___ ___ ____
rotor cover. To prevent damag e to the cylinder head,
camshafts or camsh aft caps, loosen the
camshaft cap bolts in stages and in a criss-
cross pattern, working from the outside in.
3. Remove:
Timin g chain tensioner "1"
Timin g chain tensioner gasket
5-15
CAMSHAFTS
6. Remove:
Camshaft sprocket "1 "
3. Measure:
Camshaft runout
Out of specification Replace.
EAS30257
5-16
CAMSHAFTS
a. 1/4 tooth
d. Remove the camshaft caps, and then mea- b. Correct
sure the width of the Plastigauge "1 ". 1. Timing chain
2. Camsha ft sprocket
EAS30266
5-17
CAMSHAFTS
ECA 19980
t:lofics
8 e sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
EAS30269
3. Install:
Timing chain "1"
(onto the camshaft sprockets "2")
Exhaust camshaft "3"
2. Install:
Intake camshaft "4"
Intake camshaft sprocket "1"
Exhaust camshaft sprocket "2" The exhaust camshaft is identified by the groove
"a" in the portion of the camshaft shown in the il-
Camshaft sprocket bolt lustration.
20 Nm (2.0 mkgf, 14 ftlbf)
5-18
CAMSHAFTS
4. Install:
Exhaust camshaft cap "1 "
Intake camshaft cap "2"
5. Tighten:
Camshaft cap bolts
__ __ __ __ __ ___
Lubricate the camshaft cap bolts with the
b. Install the timing chain onto the intake cam- engine oil.
shaft sprocket, and then install the intake The camshaft cap bolts must be tightened
camshaft onto the cylinder head. evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
Align the alignment mark "d" on the intake Do not turn the crankshaft when installing
camshaft sprocket with the edge "e" of the cyl- the camshaft to avoid damage or improper
inder head as shown in the illustration. valve timing.
Be sure to install the timing chain so that the
exhaust side of the chain is taut and the intake
side is slack. Tighten the camshaft cap bolts in the tightening
sequence as shown.
5-19
CAMSHAFTS
6. Install:
Timing chain tensioner gasket llm
Timing chain tensioner
TTTTTTTTTTTTT TTTTTTTTTTTTT TTTTTT
a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the timing chain ten-
sioner rod fully counterclockwise with a
hexagon wrench "1" (Part No.: 1WS-12228-
00).
5-20
CAMSHAFTS
9. Measure:
Valve clearance
Out of specification Adjust.
Refer to "ADJUSTING THE VALVE CLEAR -
ANCE" on page 3-5.
1O.lnstall:
Timing mark accessing bolt "1"
EAS30274
5-21
CYLINDER HEAD
EAS20044
CYLINDER HEAD
Removing the cylinder head
10 Nm (1.0 mkgf, 7.2 ft-lbf) 1st 10 Nm (1.0 mkgf, 7.2 ft-lbf)
2nd 30 Nm (3.0 mkgf, 22 ft-lbf)
*3rd 12 Nm (1.2 mkgf, 8. 7 ftlbf)
Specified angle 115-125
68 Nm (6.8 mkgf, 49 ft-lbf)
r1 10
"" 12
9
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after
loosening a bolt, retighten it before loosening the next bolt).
5-22
CYLINDER HEAD
*Follow ing the tightening order, loosen the bolt one by one, and then
loosening a bolt, retighten it before loosening the next bolt). retighten it to the specific torque (after
5-23
CYLINDER HEAD
I 12 10
9
*Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after
loosening a bolt, retighten it before loosening the next bolt).
5-24
CYLINDER HEAD
'
5-25
CYLINDER HEAD
[!] i x6
TTTTTTTTTTTTT TTTTTTTTTTTTT TTTTTT
a. Place a straightedge "1" and a thickness
gauge "2" across the cylinder head.
5-26
CYLINDER HEAD
bolt cap with the portion "d" of the front cowlin g iiifiiice - - - - - -
,. ,,,,,,'"''''''''''''''', -------
assem bly stay. Do not use a torqu e wrenc h to tighte n the
bolt to the speci fied angle .
b
Tighte n the cylind er head bolts in the tightening
a seque nce as shown and torque them in 3 stag-
es.
! rn
x6
2. Install:
Cylind er head
Cylind er head bolt (M 10) (x6) Olm
Cylind er head bolt (M6) (x2)
5-27
VALVES AND V Al VE SPRINGS
EAS20045
1 1
Bm10
71:1
Order Job/Parts to remove Q 'ty Remarks
5-28
VAL VES AND V Al VE SPR INGS
EAS30283
2
EX @@ @
IN @@ @
2 1
2. Check:
Valve sealing 4. Remove:
Leakage at the valve seat -7 Check the valve Valve spring retainer "1"
face, valve seat, and valve seat width. Valve spring "2"
Refer to "CHECKING THE VALVE SEATS" Valve "3"
on page 5-31 . Valve stem seal "4"
TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT Valve spring seat "5"
a. Pour a clean solvent "a" into the intake and
exhaust ports.
Identify the position of each part very carefully so
b. Check that the valves properly seal.
that it can be reinstalled in its original place.
EAS30284
5-29
VALVES AND VALVE SPRINGS
1. Measure:
Valve-stem-to -valve-guide clearance
Out of specification --7 Replace the valve
guide.
Valve-stem-to-valve-guide clearance=
Valve guide inside diameter "a" -
Valve stem diameter "b"
Valve-stem-to-valve-guide clear-
ance (intake)
0.010-0.037 mm (0.0004-0.00 15 b. Install the new valve guide with the valve
in) guide installer "2" and valve guide remover
Limit "1 ".
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear- Valve guide position
ance (exhaust) 11.3-11.7 mm (0.44-0.46 in)
0.025-0.052 mm (0.0010-0.00 20
in)
Limit
0.100 mm (0.0039 in)
2. Replace:
Valve guide
5-30
VALVES AND VALVE SPRINGS
2. Check:
Valve guide remover (04.5)
Valve seat
90890 -04116
Valve guide remover (4.5 mm) Pitting/wear Replace the cylinder head.
YM-04 116 3. Measure:
Valve guide installer (04.5) Valve seat width "a"
90890 -04117 Out of specification Replace the cylinder
Valve guide installer (4.5 mm) head.
YM-04 117
Valve guide reamer (04.5) Valve seat contact width (intake)
90890 -04118 0.90-1 .20 mm (0.035 4-0.04 72 in)
Valve guide reamer (4.5 mm) Valve seat contact width (ex-
YM-04 118 haust)
0.90-1 .20 mm (0.035 4-0.04 72 in)
AAAAA AAAAA AAAAA AAAAA AAAAA AAAAA AA
3. Eliminate:
Carbon deposits
(from the valve face and valve seat)
4. Check:
Valve face
Pitting/wear Grind the valve face.
Valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
5. Measure:
TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT
Valve stem runout
a. Apply blue layout fluid "b" onto the valve face.
Out of specification Replace the valve.
5-31
VALVES AND V Al VE SPRINGS
"NC>7flcE
Do not let the lapping compound enter the
h. Install the valve into the cylinder head.
gap between the valve stem and the valve
i. Press the valve through the valve guide and
guide.
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width "c" again. If the
valve seat width is out of specification, reface
and lap the valve seat.
5-32
VAL VES AND VAL VE SPR INGS
2. Measure:
EAS30287
Compressed valve spring force "a" CHECKING THE VALVE LIFTERS
Out of specification Replace the valve The following procedure applies to all of the
spring. valve lifters.
1. Check:
Installed compression spring
Valve lifter
force (intake)
159.60 -183.6 0 N (16.27 -18.72 Damage/scratches Replace the valve lift-
kgf, 35.88 -41.27 lbf) ers and cylinder head.
Installed compression spring EAS30288
force (exhaust) INSTALLING THE VALVES
159.60 -183.6 0 N (16.27 -18. 72 The following procedure applies to all of the
kgf, 35.88 -41.27 lbf) valves and related components.
Installed length (intake) 1. Deburr:
32.00 mm (1.26 in)
Valve stem end
Installed length (exhaust)
(with an oil stone)
32.00 mm (1.26 in)
2. Lubricate:
b. Installed length Valve stem "1"
Valve stem end
3. Measure: (with the recommended lubricant)
Valve spring tilt "a"
Out of specification Replace the valve Recommended lubricant
spring. Molybdenum disulfide oil
5-33
VALVES AND V Al VE SPRINGS
7. Lubricate:
Valve pad
Recommend ed lubricant
Molybdenum disulfide oil
b. Smaller pitch
Valve lifter
5. Install: (with the recommended lubricant)
Valve cotters
Recommend ed lubricant
Engine oil
Install the valve cotters by compressing the
valve spring with the valve spring compressor 8. Install:
"1" and the valve spring compressor attachment Valve pad
"2". Valve lifter
5-34
VALV ES AND VALVE SPR INGS
TIP _ _ __ _ _ __ _ __ _ __
The valve lifter must move smoothly when ro-
tated with a finger.
Each valve lifter and valve pad must be rein-
stalled in their original position.
5-35
CYLINDER AND PISTONS
7 ----......JI
1
5-36
CYLINDER AND PISTONS
EAS30289
For reference during installation, put an identi- CHECKING THE CYLINDERS AND PISTONS
fication mark on each piston crown. The following procedure applies to both of the
Before removing the piston pin, deburr the pis- cylinders and pistons.
ton pin clip grooves and the piston pin bore ar- 1. Check:
ea. If both areas are deburred and the piston Pisto n wall
pin is still difficult to remove, remove it with the Cylinder wall
piston pin puller set "4". Vertical Rebore or replace the
cylinder, and replace the piston and piston
Piston pin puller set rings as a set.
90890 -01304 2. Measure:
Piston pin puller Piston-to-cylinder clearance
YU-01 304 TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT
a. Measure cylinder bore "C" with the cylinder
bore gauge.
Bore
68.000 -68.01 O mm (2.677 2-
2.6776 in)
Taper limit
0.050 mm (0.002 0 in)
Out of round limit
0.050 mm (0.002 0 in)
5-37
CYLINDER AND PISTONS
1. Measure:
Piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
Piston ring
b. If out of specification, replace the cylinder, Top ring
and replace the piston and piston rings as a Ring side clearance
set. 0.030-0.065 mm (0.0012-
c. Measure piston skirt diameter D "a" with the 0.0026 in)
micrometer. Limit
0.115 mm (0.0045 in)
Diameter 2nd ring
67.962-67.985 mm (2.6757- Ring side clearance
2.6766 in) 0.020-0.055 mm (0.0008-
0.0022 in)
Limit
0.115 mm (0.0045 in)
b
5-38
CYLINDER AND PISTONS
Piston ring
Top ring
End gap (installed)
0.15-0 .25 mm (0.005 9-0.00 98
in)
Limit
0.50 mm (0.0197 in)
2nd ring
End gap (installed)
0.30-0 .50 mm (0.011 8-0.01 97
in) 3. Measure:
Limit Piston pin bore diameter "b"
0.85 mm (0.0335 in) Out of specification
Oil ring Replace the piston.
End gap (installed) Piston pin bore inside diameter
0.10-0 .35 mm (0.003 9-0.01 38 15.002 -15.01 3 mm (0.590 6-
in) 0.5911 in)
Limit
15.043 mm (0.5922 in)
a. Bottom of cylinder
b. Upper of cylinder
4. Calculate:
EAS30293 Piston-pin-to-piston-pin-bore clearance
CHECKING THE PISTON PINS Out of Replace the piston pin
The following procedure applies to both of the and piston as a set.
piston pins.
Piston-pin-to-piston-pin-bore clearance =
1. Check: Piston pin bore inside diameter "b" -
Piston pin Piston pin outside diameter "a"
Blue discoloration/grooves Replace the
piston pin and then check the lubrication sys-
tem. Piston-pin-to-piston-pin-bore
clearance
2. Measure:
0.002- 0.018 mm (0.000 1-0.00 07
Piston pin outside diameter "a" in)
Out of specification Replace the piston pin.
EAS30294
Piston pin outside diameter INSTALLING THE PISTONS AND CYLINDER
14.995 -15.00 0 mm (0.590 4- The following procedure applies to both of the
0.5906 in) pistons.
Limit
1. Install:
14.975 mm (0.5896 in)
Oil ring expander "1"
Lower oil ring rail "2"
Upper oil ring rail "3"
2nd ring "4"
Top ring "5"
5-39
CYLINDER AND PISTONS
TIP _ _ _ __ __ __ _ __ _ __
Install the oil ring expander as shown in the il-
lustration.
Be sure to install the piston rings so that the
manufacturer marks "a" face up. 1
3. Lubricate:
Piston
Piston rings
Cylinder
(with the recommended lubricant)
5. Install:
Dowel pins
0-ring Gm
Cylinder gasket Gm
6. Install:
Cylinder "1"
5-40
CYLINDER AND PISTONS
5-41
GENERATOR AND STARTER CLUTCH
EAS20140
5-42
GENERATOR AND STARTER CLUTCH
5-43
GENERATOR AND STARTER CLUTCH
2. Remove:
Generator rotor assembly "1"
.,
(with the flywheel puller "2")
Woodruff key 3
ECA13880
ltiift:lce. . \
@s
;ii" ......................,,, _ _ _ _ _ _ _ _ _ _ _ __
EAS30868
5-44
GENERATOR AND STARTER CLUTCH
EAS30871
5-45
GENERATOR AND STARTER CLUTCH
EAS30872
3. Apply:
INSTALLING THE GENERATOR Sealant
1. Install: (onto the stator coil lead grommet)
Woodruff key
Generator rotor assembly Yamaha bond No. 1215
Washer "1" 90890-85505
Generator rotor bolt (Three bond No.1215)
TIP _ _ _ _ __ _ __ _ _ __ __
Clean the tapered portion of the crankshaft and
the generator rotor hub.
When installing the generator rotor assembly,
make sure the Woodruff key is properly seated
in the keyway of the crankshaft.
Install the washer with its chamfered side "a"
facing away from the generator rotor.
Lubricate the generator rotor bolt threads and
washer mating surfaces with molybdenum dis-
ulfide grease.
4. Install:
Generator cover gasket llm
Generator cover
2. Tighten: 5. Connect:
Generator rotor bolt "1" Stator coil coupler
Crankshaft position sensor coupler
Generator rotor bolt TIP _ _ __ __ __ __ _ _ _ __
60 Nm (6.0 m-kgf, 43 ftlbf) To route the stator coil lead, refer to "CABLE
ROUTING" on page 2-43.
5-46
ELECTRIC STARTER
EAS20052
5-47
ELECTRIC STARTER
5-48
ELE CTR IC ST ART ER
EAS30325
CHEC KING THE STAR TER MOTO R TTTT TTTT TTTT TTTT TTTT TTTT TTTT TTTT
a. Measure the armature assembly resistances
1. Check:
with the digital circuit tester.
Commutator
Clean with 600 grit sandpaper. Digital circuit tester
2. Measure: 90890 -0317 4
Diameter "a" Model 88 Multim eter with ta-
Out of specification Replace the starter chom eter
motor YU-A1 927
Diame ter
24.5 mm (0.96 in) Armat ure coil
Limit Comm utator resistance "1"
23.5 mm (0.93 in) 0.063 -0.077 Q
Insula tion resist ance "2"
No contin uity (Above 1 MQ at 20
C (68 F))
3. Measure:
Mica undercut "a"
Out of specification the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
4. Measure:
Arma ture assembly resistances (commutator
and insulation)
Out of specification Replace the starter 6. Measure:
motor. Brush spring force
Out of specification Replace the spring.
5-49
ELECTRIC ST ARTER
7. Check:
Gear teeth
Damage/wear -7 Replace the starter motor.
8. Check:
Bearing
Oil seal
Damage/wear -7 Replace the starter motor
front cover.
EAS30326
b a b
2
1-------1
1 3
EAS30327
5-50
CLUTCH
5-51
CLUTCH
--9
5-52
CLUTCH
5-53
CLUTCH
EAS30346 5. Loosen:
REMOVING THE CLUTCH Clutch boss nut "1"
1. Remove: TIP _ __ _ _ __ _ _ __ _ __
Clutch cover "1"
While holding the clutch boss "2" with the univer-
Clutch cover gasket
sal clutch holder "3", loosen the clutch boss nut.
TIP _ _ __ _ __ __ _ _ __ _ _
Loosen each bolt 1/4 of a turn at a time, in stag-
Universal clutch holder
es and in a crisscross pattern. After all of the
90890-04086
bolts are fully loosened, remove them. Universal clutch holder
YM-91042
2. Remove:
Compressio n spring bolts "1"
Compression springs "2"
CHECKING THE FRICTION PLATES
5
5-54
CLUTCH
EAS30349
2. Check:
EAS30351 Oil pump drive gear "1"
CHECKING THE CLUTCH SPRINGS Cracks/damage/wear -7 Replace the clutch
The following procedure applies to all of the housing, oil pump idle gear and oil pump driv-
clutch springs. en gear as a set.
1. Check:
Clutch spring
Damage -7 Replace the clutch springs as a
set.
2. Measure:
Clutch spring free length "a"
Out of specification -7 Replace the clutch
springs as a set.
5-55
CLUTCH
EAS30358
2 1
1
2. Check:
Pull rod bearings
Damage/wear -7 Replace.
EAS30363
5-56
CLUTCH
Bend the lock washer tab "a" along a flat side Clutch spring bolts "4"
of the nut.
Clutch spring bolt
Universal clutch holder 10 Nm (1.0 mkgf, 7.2 ftlbf)
90890-04086
Universal clutch holder
YM-91042 Apply lithium-soap-based grease onto the pull
rod.
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
4. Install:
Bear ings "1"
Oil seal "2" Im
(to the clutch cover)
3. Install:
Bear ing
(to the pressure plate)
Pull rod "1"
Pressure plate "2"
Clutch springs "3"
5-57
CLUTCH
5. Install: TIP _ _ _ __ _ __ __ __ _ __
Dowel pins "1" Install the clutch cable so that the clutch cable
Clutch cover gasket "2" Gm length "a" is 52.6-64.1 mm (2.07-2.52 in) as
Clutch cover "3" shown in the illustration.
Clutch cable holder "4" After installing the clutch cable, bend the pro-
Holders (0 2 sensor lead) jection "b" on the pull lever as shown in the il-
lustration.
Clutch cover bolt
1O Nm (1.0 mkgf, 7.2 ftlbf)
Clutch cable holder bolt
1O Nm (1.0 mkgf, 7.2 ftlbf)
LOCTITE
TIP _ _ __ _ _ __ _ __ __ __
Face the serrations on the clutch pull rod "5"
rearward and align the rod with the hole "a" in
the clutch cover.
Make sure that the pull rod teeth and pull lever
shaft pinion gear are engaged. 7. Adjust:
Clutch lever free play
Apply locking agent (LOCTITE) to the
Referto"ADJUSTI NG THE CLUTCH LEVER
threads of only the clutch cable holder bolts "6"
FREE PLAY" on page 3-12.
shown in the illustration.
Tighten the bolts in stages and in a crisscross Clutch lever free play
pattern. 10.0-15.0 mm (0.39-0.59 in)
After installing the clutch cover, make sure that
the alignment mark "b" on the clutch cover is
aligned with the punch mark "c" on the pu!I le-
ver "7".
6. Connect:
Clutch cable "1"
5-58
SHIFT SHA FT
EAS20057
SHIFT SHA FT
Remov ing the shift pedal
5-59
SHIFT SHAFT
5-60
SHIFT SHA FT
5-61
SHIFT SHAFT
EAS30377
EAS30381
5-62
SHIFT SHA FT
3. Adjust:
Installed shift rod length
TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT
a. Loosen both locknuts "1 ".
5-63
OIL PUMP
5-64
OIL PUMP
5-65
OIL PUMP
5-66
OIL PUMP
EAS31 312
2. Measur e:
Inner-ro tor-to-o uter-rot or-tip clearan ce "a"
Outer-r otor-to- oil-pum p-hous ing clearan ce
"b"
Inner-rotor-to-outer-rotor-tip
clearance
0.060- 0.120 mm (0.002 4-0.00 47
in) EAS30342
2. Lubricate:
1 Oil pump driven gear
(with the recomm ended lubricant)
5-67
OIL PUMP
TIP _ _ __ _ __ _ __ _ _ __
Align the pin in the oil pump shaft with the
grooves "a" in the inner rotor.
'fC4
3
4. Check:
Oil pump operation
Refer to "CHECKING THE OIL PUMP" on
page 5-67.
EAS30343
-------- ---:--::-
the bolts, make sure the oil
pump turns smoothly.
5-68
OIL PAN
EAS20177
OIL PAN
5-69
OIL PAN
5-70
OIL PAN
EAS3 1069
2. Install:
Oil pan gasket lmlJ
Oil pan
Front bottom cowling bracket "1"
5-71
CRANKCASE
EAS20059
CRANKCASE
Removing the crankcase breather cover and switches
. 10 Nm (1.0 mkgf, 7.2 ftlbf)
5-72
CRANKCASE
Removing the crankcase breather cover and switches
. 10 Nm (1.0 mkgf, 7.2 ftlbf)
5-73
CRANKCASE
* Following the tightening order, loosen the bolt one by one, and then retighten it to the specific torque (after
loosening a bolt, retighten it before loosening the next bolt).
5-74
CRANKCASE
EAS30389
DISAS SEMB LING THE CRAN KCAS E M6 x 35 mm bolt (x2): "1 ", "2"
1. Remove: M6 x 45 mm bolt (x 5): "3", "7", "8'', "12", "13"
Oil filter cartridge "1" M6 x 45 mm bolt (x 1) (with coppe r washe r):
"12A"
M6 x 65 mm bolt (x 3) (bolt with coppe r wash-
Remov e the oil filter cartridge with an oil filter
er): "4", "5", "9"
wrench "2".
M6 x 65 mm bolt (x3): "6", "1 O", "11"
M8 x 50 mm bolt (x2): "14", "15"
Oil filter wrenc h MB x 80 mm bolt (x6): "16"-"2 1"
90890 -01426
[!I!J[l][!J
Oil filter wrenc h
YU-38411
2. Install:
Clutch housing (temporarily)
Refer to "CLUT CH" on page 5-51.
3. Remove:
Primar y drive gear bolt "1"
Wash er "2"
Primar y drive gear "3"
[!][!][!][!]
Place an alumin um plate "a" betwee n the prima-
ry drive gear and the clutch housing "4", and
then loosen the primar y drive gear bolt.
4. Remov e:
Crank case bolt (x21)
5-75
CRANKCASE
EAS30397
5. Remove: ASSEMBLING THE CRANKCASE
Upper crankcase
1. Lubricate:
Dowel pins Crankshaft journal bearing inner surface
ECA 13900
(with the recommended lubricant)
Tap on one side of the crankcase with a soft- Recommended lubricant
face hammer. Tap only on reinforced por- Engine oil
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully 2. Apply:
and make sure the crankcase halves sepa- Sealant
rate evenly. (onto the crankcase mating surfaces)
EAS30880
5-76
CRANKCASE
ECA13980
"NoilcE
8 efore tightening the crankcase bolts, make
sure the transmission gears shift correctly
when the shift drum assembly is turned by
hand.
[!][!][!][!]
Be sure to fit the pin "a" on the main axle as-
sembl y into the hole "b" in the upper crank-
case.
Thorou ghly wipe off any sealan t that protrud es
onto the contac t surfac es of the genera tor cov-
er gaske t and clutch cover gasket .
When assem bling the crankc ase, check that
sealan t protrud es from betwee n the crankc ase
halves . Do not wipe off the protrud ing sealan t.
6. Install:
Cran kcase bolt (x21)
[!IIJ!I!J
Lubric ate the bolts "1 "-"15" and "17"-"21"
thread s and mating surfac es with engine oil.
Lubric ate the mating surfac e of the bolt "16"
with engine oil and apply Yamah a bond No.
1215 to the bolt thread s.
Finger tighten the crankc ase bolts.
5-77
CRANKCASE
[!][!]
Crankcase bolts "1 "-"6"
1st: 20 Nm (2.0 mkgf, 14 ftlbf)
*2nd: Loosen and retighten the
bolts one at a time to 24 Nm (2.4
mkgf, 17 ftlbf).
Crankcase bolts "7"-"8"
1st: 20 Nm (2.0 mkgf, 14 ftlbf)
*2nd: Loosen and retighten the
bolts one at a time to 26 Nm (2.6
mkgf, 19 ftlbf).
[!][!]
8. Tighten:
Crankcase bolts "9"-"21"
5-78
CRANKCASE
1O.lnstall:
11.lnstall:
Timin g chain guide (lower side)
Holder 2 "1"
Timing chain sprocket
Holder 1 "2"
Timing chain
TIP _ _ _ _ _ _ _ _ _ _ __ _ __
Primary drive gear "1"
Wash er "2" Position the holder 2 within the range shown in
Primary drive gear bolt "3" the illustration.
Clutch housing (temporarily) Make sure that the holder 1 contacts the pro-
Refer to "CLUT CH" on page 5-51. jection "a" on the crankcase breather cover.
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Lubricate the threads and contact surface of
the primary drive gear bolt and the contact sur-
faces of the washe r with molybdenum disulfide
grease.
Install the washe r with its chamfered side "a"
facing away from the primary drive gear.
Place an aluminum plate "b" between the pri-
mary drive gear and the clutch housing "4", and
then tighten the primary drive gear bolt.
EAS313 13
5-79
CRANKCASE
2. Install:
0-ring "1" mm
Gear position switch "2"
5-80
CRANKSHAFT AND BALANCER SHAFT
EAS20178
2nd
5-81
CRANKSHAFT AND BALANCER SHAFT
11 Oil nozzle
5-82
CRA NKS HAF T AND BAL ANC ER SHA FT
/
I
9
5-83
CRANKSHAFT AND BALANCER SHAFT
Identify the position of each balancer shaft jour- Balancer shaft journal to balanc-
nal bearing so that it can be reinstalled in its orig- er shaft bearing clearance
inal place. 0.021 - 0.045 mm (0.0008-0.0018
in)
EAS31074
ECA 18400
REMOVING THE CRANKSHAFT JOURNAL
BEARINGS
Do not interchange the balancer shaft jour-
1. Remove:
nal bearings. To obtain the correct balancer
Crankshaft journal lower bearings
shaft-journal-to-balancer shaft-journal-bear-
(from the lower crankcase)
ing clearance and prevent engine damage,
Crankshaft journal upper bearings
the balancer shaft journal bearings must be
(from the upper crankcase)
installed in their original positions.
TTTTTTTTTTTTT TTTTTTTTTTTTT TTTTTT
Identify the position of each crankshaft journal a. Clean the balancer shaft journal bearings,
bearing so that it can be reinstalled in its original balancer shaft journals, and bearing portions
place. of the crankcase.
b. Install the balancer shaft journal lower bear-
EAS313 14
ings "1" and the balancer shaft assembly into
REMOVING THE CONNECTING RODS
the lower crankcase.
The following procedure applies to both of the
connecting rods.
1. Remove: Align the projections "a" on the balancer shaft
Connecting rod cap journal lower bearings with the notches "b" in the
Connecting rod lower crankcase.
Big end bearings
EAS31076
5-84
CRANKSHAFT AND BALANCER SHAFT
4. Select:
Balancer shaft journal bearings (J -J )
1 2
TIP _ __ _ _ _ __ _ _ _ _ __ _
The numbers "A" stamped into the lower crank-
case and the numbers "B" stamped into the
balancer shaft web are used to determine the
replacement balancer shaft journal bearing siz-
es.
J 1-J 2 refer to the bearings shown in the crank-
d. Install the balancer shaft journal upper bear- case and balancer shaft web illustration.
ings "3" into the upper crankcase and assem- If J 1-J 2 are the same, use the same size for all
ble the crankcase halves. of the bearings.
TIP _ __ __ __ _ _ __ _ _ _ _
Align the projections "c" of the balancer shaft
journal upper bearings with the notches "d" in
the upper crankcase.
Do not move the balancer shaft until the clear-
ance measurement has been completed.
5-85
CRANKSHAFT AND BALANCER SHAFT
Runout limit
0.030 mm (0.0012 in)
2. Check:
Crankshaft journal surfaces
Crankshaft pin surfaces
Bearing surfaces
Scratches/wear Replace the crankshaft.
3. Measure:
Crankshaft-journal-to-crankshaft-journal-
bearing clearance d. Install the crankshaft journal upper bearings
Out of specification Replace the crank- "3" into the upper crankcase and assemble
shaft journal bearings. the crankcase halves.
Journal oil clearance Align the projections "c" of the crankshaft jour-
0.021-0.045 mm (0.0008-0.0018 nal upper bearings with the notches "d" in the
in) upper crankcase.
ECA1 3920 Do not move the crankshaft until the clearance
measurement has been completed.
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.
TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
a. Clean the crankshaft journal bearings, crank-
shaft journals, and bearing portions of the
crankcase.
b. Install the crankshaft journal lower bearings e. Tighten the bolts to specification in the proper
"1" and the crankshaft into the lower crank- tightening sequence.
case.
5-86
CRA NKS HAF T AND BALANCER SHAFT
4. Select:
5.Yellow
5-87
CRANKSHA FT AND BALANCER SHAFT
P1 P2
22 333
5-88
CRA NKS HAF T AND BALANCER SHAFT
f
Make sure that the projections "e" on the con-
necting rod cap faces the same direction as the
"Y" mark "c" on the connecting rod.
EAS31316
Recommended lubricant
Molybdenum disulfide oil
4. Tighten:
2. Lubricate: Conn ecting rod nuts
Crankshaft pins EWA1 3390
Big end bearings AwAR NING
Connecting rod inner surface
Repl ace the connecting rod bolts and nuts
(with the recommended lubricant)
with new ones.
Recommended lubricant Clea n the connecting rod bolts and nuts.
Engine oil TIP _ _ _ _ _ _ __ _ _ __ _ __
3. Install: Tighten the connecting rod nuts using the follow-
Big end bearings ing procedure.
Connecting rods a. Tighten the connecting rod nuts with a torque
Connecting rod caps wrench.
(onto the crankshaft pins)
Connecting rod nut (1st)
Align the projections "a" on the big end bear- 15 Nm (1.5 mkgf, 11 ftlbf)
ings with the notches "b" in the connecting rods
b. Put a mark "1" on the corner of the connecting
and connecting rod caps.
rod nut "2" and the connecting rod cap "3".
Be sure to reinstall each big end bearing in its
original place.
5-89
CRANKSHAFT AND BALANCER SHAFT
EWA13400
A WARNING
A. Upper crankcase
If the connecting rod nut is tightened more
B. Lower crankcase
than the specified angle, do not loosen the
nut and then retighten it. Instead, replace the EAS31122
connecting rod bolt and nut with a new one ASSEMBLING THE BALANCER SHAFT
and perform the procedure again. ASSEMBLY
ECA19930 1. Assemble:
Balancer driven gear assembly "1"
Do not use a torque wrench to tighten the
connecting rod nut to the specified angle. Align the punch mark "a" in the balancer driven
Tighten the nut until it is at the specified an- gear with the punch mark "b" in the buffer boss.
gle.
EAS31077
5-90
CRANKSHAFT AND BALANCER SHAFT
TIP _ _ _ _ _ _ _ _ _ _ _ _ _ __
Lubricate the balancer driven gear bolt threads
and mating surface with engine oil.
Make sure that the balancer shaft "3" is insert-
ed into the washer, and then tighten the bal-
ancer driven gear bolt to specification.
A. Upper crankcase
B. Lower crankcase
EAS31078
5-91
TRANSMISSION
EAS20062
TRANSMISSION
Separate.
Crankcase Refer to "CRANKCASE" on page 5-72.
Shift shaft Refer to "SHIFT SHAFT" on page 5-59.
Drive axle assembly
2 Clip 2
3 Oil seal 2
4 Bearing
5 Main axle assembly
6 Clip
7 Oil seal
8 Bearing
9 Shift fork guide bar retainer 1
5-92
TRANSMISSION
' .
14 Shift fork "R"
, .
5-93
TRANSMISSION
x Ie assembly
Disassembrmg the mama
D?l!l4
Remarks
5-94
TRANSMISSION
5-95
TRANSMISSION
EAS30431 EAS30432
2. Check:
Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends --7 Replace. EAS30433
EWA 12840 CHECKING THE TRANSMISSION
A WARNING 1. Measure:
Do not attempt to straighten a bent shift fork Main axle runout
guide bar. (with a centering device and dial gauge "1 ")
Out of specification --7 Replace the main axle.
319-010
3. Check:
Shift fork movement
(along the shift fork guide bar)
Rough movement --7 Replace the shift forks
and shift fork guide bar as a set.
2. Measure:
Drive axle runout
(with a centering device and dial gauge "1 ")
Out of specification --7 Replace the drive axle.
319-011
5-96
TRANSMISSION
3. Check: 2. Install:
Trans missio n gears
Blue discoloration/pitting/wear Replace
Circlip "1" Im
the defective gear( s). TIP _ __ _ _ _ _ _ __ _ _ _ __
Trans missio n gear dogs Align the opening between the ends "a" of the
Cracks/damage/rounded edges Replace circlip with a groove "b" in the axle.
the defective gear(s).
EAS30438
4. Check: INSTALLING THE TRANSMISSION
Trans missio n gear engagement 1. Install:
(each pinion gear to its respective wheel Oil pump idle gear shaft "1"
gear) TIP _ _ _ __ _ _ __ _ _ _ _ __
Incorrect Reassemble the transmission
axle assemblies. Install the oil pump idle gear shaft until its flange
5. Check: "a" contacts the lower crankcase.
Transmission gear movement
Rough movem ent Replace the defective
part(s).
EAS30435
Press the 2nd pinion gear onto the main axle un-
2. Install:
til the press-fitting height "a" is 122.1- 122.3 mm
Shift drum assembly
(4.80-4.81 in) as shown in the illustration.
Shift fork "C"
Shift fork "R"
Shift fork "L"
Sprin gs
Shift fork guide bars
Shift fork guide bar retainer 2 "1"
Shift fork guide bar retainer 1 "2"
5-97
TRANSMISSION
3. Install:
Main axle clip "1"
Drive axle clip "2"
Main axle assembly "3"
Drive axle assembly "4"
TIP _ __ _ _ _ __ _ __ _ _ __
Make sure that the main axle clip and drive
axle clip are installed onto the bearing so that
the clips overlap both the upper crankcase and
lower crankcase as shown in the illustration.
Make sure that the ends of the clips are posi-
tioned within the range shown in the illustra-
tion.
Install shift fork "C" "5" into the groove in the 3rd
pinion gear on the main axle.
Install shift fork "L" "6" into the groove in the 6th
wheel gear and shift fork "R" "7" into the groove
in the 5th wheel gear on the drive axle.
A. Upper crankcase
B. Lower crankcase
5-98
TRANSMISSION
5-99
COOLING SYSTEM
6-1
RADIATOR
. .. .
6-2
RAD IATO R
EAS30439
6-3
THERMOSTAT
EAS20065
THERMOSTAT
Removing the thermostat
;---
(
6-4
THER MOS TAT
. 2.0 Nm (0.20 mkgf, 1.4 ft-lbf) 1O Nm (1.0 mkgf, 7.2 ftlbf) 17 Nm (1.7 mkgf, 12 ftlbf)
6-5
THERMOST AT
EAS30443 2. Check:
CHECKING THE THERMOSTAT Thermostat cover
1. Check: Cracks/damage Replace.
Thermostat
Does not open at 80.5-83.5 C (176.90- EAS30939
- 4
2. Fill:
Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to "CHANGING THE COOLANT" on
page 3-24.
3. Check:
Cooling system
Repair or replace any faulty part.
3mm
(0 .12 in) 4. Measure:
Radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Refer to "CHECKING THE RADIATOR" on
82 1.5C 95 C
(179 .6 2.7 F) (203F)
page 6-3.
A. Fully closed
8. Fully open
6-6
WATER PUMP
- ....
-
6-7
WATER PUMP
6-8
WAT ER PUMP
. . .
6-9
WATER PUMP
EAS30446
EAS30447
6-10
WATER PUMP
TIP _ __ _ __ _ _ __ _ _ __ _
Face the serrati ons on the clutch pull rod "5"
rearwa rd and align the rod with the hole "a" in
the clutch cover.
Apply looking agent (LOCT ITE) to the
thread s of only the clutch cable holder bolts "6''.
Tight en the bolts in stages and in a crisscr oss
pattern .
After installi ng the clutch cover, make sure that
3. Adjust :
the alignm ent mark "b" on the clutch cover is
Clutch lever free play
aligne d with the punch mark "c" on the pull le-
Refert o"ADJ USTIN G THE CLUTC H LEVER
ver "7".
FREE PLAY" on page 3-12.
6-11
WATER PUMP
4. Fill:
Cooling system
(with the specified amount of the recom-
mended coolant)
Refer to "CHANG ING THE COOLANT" on
page 3-24.
5. Check:
Cooling system
Repair or replace the faulty part.
6. Measure:
Radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Referto"ADJUSTING THE CLUTCH LEVER
FREE PLAY" on page 3-12.
6-12
WATER PUMP
6-13
FUEL SYSTEM
FUEL TANK
Removing the fuel tank and fuel pump
1O Nm (1.0 mkgf, 7.2 ftlbf)
12 Nm (1.2 mkgf, 8.7 ft-lbf)
7-1
FUEL TANK
7 Fuel tank 1
8 Front fuel tank bracket bolt (fuel tank) 2
9 Front fuel tank bracket
7-2
FUEL TAN K
[
2
7-3
FUEL TANK
EAS30450 ECA14721
AwARNING
EAS30454
Cover fuel hose connections with a cloth CHECKING THE FUEL PUMP BODY
when disconnecting them. Residual pres- 1. Check:
sure in the fuel lines could cause fuel to Fuel pump body
spurt out when removing the hose. Obstruction -7 Clean.
ECA20020 Cracks/damage -7 Replace fuel pump as-
lliil ---------- ---- sembly.
A Ith o ugh the fuel has been removed from EAS31249
the fuel tank, be careful when removing the CHECKING THE FUEL FILTER
fuel hose, since there may be fuel remaining 1. Check:
in it. Fuel filter
Damage -7 Replace.
Contaminants -7 Clean with solvent.
To remove the fuel hose from the fuel rail and
fuel pump , slide the fuel hose connector cover EAS30699
"1" on the end of the hose in the direction of the CHECKING THE ROLLOVER VALVE
arrow shown , press the two buttons "2" on the 1. Check:
sides of the connector, and then remove the Rollover valve "1"
hose. Damage/faulty -7 Replace.
Remove the fuel hose manually without using
any tools. Check that air flows smoothly only in the direc-
Before removing the hose, place a few rags in tion of the arrow shown in the illustration.
the area under where it will be removed. The rollover valves must be in an upright posi-
tion when checking the airflow.
+
3. Remove:
Fuel tank EAS30456
7-4
FUEL TAN K
EAS30457
FWD =J
7-5
THROTTLE BODIES
EAS20070
THROTTLE BODIES
Removing the throttle bodies
s Nm (O.S m . kgf, 3.6 ft . lbfj h
\
7-6
THROTTLE BODIES
7-7
THROTTLE BODIES
7-8
THROTTLE BODIES
EAS30475
EAS30479
CHECK ING THE INJECT ORS (BEFO RE CHECK ING THE THROT TLE BODIE S
REMOVING)
1. Check:
Injectors Before checking the throttle bodies, check the
Use the diagnostic code numbers "36-37" . following items:
Refer to "SELF-DIAGNOSTIC FUNCTION Valve clearance
AND DIAGNOSTIC CODE TABLE" on page Spark plugs
9-5. Air filter element
Throttle body joint
EAS30476 Fuel hose
REMOVING THE INJECT ORS Air induction system
EWA 17330
:mefite s:
' ' ' ' ' ' ' ' "' ' ' ' ' ' ' "' ' ' ' ' ' '"' ' '' ' ' '''' - - - -----------
Obse rve the followi ng precau tions; other-
wise, the throttle bodies may not operat e
proper ly.
Do not open the throttle valves quickly .
EAS30477
Do not subjec t the throttle bodies to exces-
CHECK ING THE INJECT ORS sive force.
1. Check: Wash the throttle bodies in a petrole um-
Inject ors based solven t.
Obstruction Replace and check the fuel Do not use any caustic carbur etor cleanin g
pump/fuel supply system. solutio n.
Deposit Replace. Do not apply cleanin g solven t directl y to
Damage Replace. any plastic parts, sensor s, or seals.
2. Check: Do not directl y push the throttle valves to
Injector resistance open them.
Refer to "CHECKING THE FUEL INJEC-
TORS" on page 8-98.
7-9
THROTTLE BODIES
______ _______
ECA18470
Do not turn the bypass air screws "a"; oth-
erwise, the throttle body synchronization
will be affected. Do not use a tool, such as a wire brush, to
remove the carbon deposits; otherwise, the
inside of the throttle bodies may be dam-
aged.
Do not allow carbon deposits or other for-
eign materials to enter any of the passages
in each throttle body or in the space be-
tween the throttle valve shaft and the throt-
tle body.
e. After removing the carbon deposits, clean the
inside of the throttle bodies with a petroleum-
TTTTTTTTTTTTT TTTTTTTTTTTTT TTTTTT based solvent, and then dry the throttle bod-
a. Place the throttle bodies on a flat surface with ies using compressed air.
the air filter case side facing up. f. Make sure that there are no carbon deposits
b. Push the lever in the direction shown in the il- or other foreign materials in any of the pas-
lustration to hold the throttle valves in the sages "a" in each throttle body or in the space
open position. "b" between the throttle valve shaft and the
EWA16680
throttle body.
A WARNING
When cleaning the throttle bodies, be careful
not to injure yourself on the throttle valves or
other components of the throttle bodies.
ECA21190
...
:-:-:-:::-:-:-::.: :.:-:-:-:-:-:.-:............. -:-:::-:
A. #1 cylinder
B. #2 cylinder
d. Remove the carbon deposits from the inside Recommended cleaning agent:
of each throttle body in a downward direction, Yamaha oil & brake cleaner
from the air filter case side of the throttle body
to the engine side.
7-10
THROTTLE BODIES
ECA2 1920
Clean the area "a" of the ISC unit and the ISC
unit installation hole "b" in the throttle bodies.
7-11
THROTTLE BODIES
EAS30481
3. Adjust:
CHECKING THE INJECTOR PRESSURE
Throttle bodies synchronizing
Out of specification --7 Replace the throttle
bodies. After installing the fuel injectors, perform the
Refer to "SYNCHRONIZING THE THROT- following steps to check the injector pressure.
TLE BODIES" on page 3-8. Do not allow any foreign materials to enter the
fuel lines.
EAS31317
7-12
THROTTLE BODIES
Pressure Check the pressure gauge c. Connect the pressure gauge "3" and adapter
and adapter. "4" to the fuel hose "2".
Check the seals and 0-rings, and then rein-
stall. Pressur e gauge
Replace the fuel injectors . 90890-03153
EAS30482
Pressur e gauge
YU-03153
CHECKING THE FUEL PRESSURE Fuel pressur e adapter
1. Check: 90890-03176
Fuel pressur e adapter
Fuel pressure
YM-03176
TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TT
a. Remove the fuel tank bracket bolts "1 " and
holdup the fuel tank.
ECA20070
b. Disconnect the fuel hose "2" from the throttle Faulty Replace the fuel pump.
bodies.
EWA1 6640
AwARN ING
Cover fuel hose connec tions with a cloth 2. Install:
when disconn ecting them. Residua l pres- Fuel tank
sure in the fuel lines could cause fuel to
spurt out when removin g the hoses. Rear fuel tank bracket bolt
(frame)
ECA200 10
12 Nm (1.2 mkgf, 8.7 ftlbf)
Front fuel tank bracket bolt
Be sure to disconn ect the fuel hose by hand. (frame)
Do not forceful ly disconn ect the hose with 12 Nm (1.2 mkgf, 8. 7 ftlbf)
tools.
Refer to "FUEL TANK" on page 7-1.
EAS30937
TIP _ __ __ _ _ __ __ _ _ __
Align the projection "a" on the throttle body joint
with the slot "b" in the throttle body joint clamp.
7-13
THROTTLE BODIES
c. #1 cylinder
d. #2 cylinder
A. Left
B. Right
EAS31 160
4. Reset:
A/F control learning valves using the Yamaha
diagnostic tool.
Execute the diagnostic mode (code No. 87)
Refer to "DIAGNOSTIC CODE: SENSOR
OPERATION TABLE" on page 9-6.
5. Check:
Engine idling speed
Start the engine, warm it up, and then mea-
sure the engine idling speed.
7-14
AIR INDUCTION SYSTEM
EAS20071
7-15
AIR INDUCTION SYSTEM
7-16
AIR INDUCTION SYSTEM
I '
7-17
AIR INDUCTION SYSTEM
7-18
AIR INDUCTION SYSTEM
EAS30488
2. Install:
Reed valve assembly
A. Intake side
A. From the air filter case
B. To the reed valve
1. Check:
Hose s
Loose connections -7 Conne ct properly.
Cracks /dama ge -7 Replace.
7-19
ELECTRICAL SYSTEM
CIRCUIT DIAGRAM
-::::_- ::::::
'::::::::.
_::::::
> _ .
... -:
.. '
..- ..
:-.-:.
.:'.:.
. . -;. .
-.
":>>.
.......... .-.
l .
.....
1. . ., :
.
....
:._ ...
....
- ......
... _ "'
. :_:_::-::::
.. . .")
.. ... ::;: :. : .. .. .... . . .. :-... ........ .., ... -... . ........... . .......
8-1
IGNITION SYSTEM
1. Main switch
2. Diode 1
3. Ignition fuse
5. Backup fuse
9. Crankshaft position sensor
11.Battery
12. Engine ground
13.Main fuse
17.Diode 3
18.Sidestand switch
28.Lean angle sensor
30. ECU (engine control unit)
31. Ignition coil #1
32.Spark plug
33. Ignition coil #2
52.Gear position switch
68.Handlebar switch (right)
71. Engine stop switch
8-2
IGNITION SYSTEM
EAS30491
13 2
11
1. Battery
2. Main fuse
3. Main switch
4. Ignition fuse
5. Start switch/Engine stop switch
6. Ignition coil
7. Spark plug
8. ECU (engine control unit)
9. Diode 1
10. Gear position switch (neutral circuit)
11. Diode 3
12. Sidestand switch
13. Battery negative lead
8-3
IGNITION SYSTEM
EAS30492
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
OKl
OKl
NG l
5. Check the spark plug caps.
Refer to "CHECKING THE SPARK Replace the spark plug cap(s).
PLUG CAPS" on page 8-91.
OKl
OK l
7. Check the crankshaft position sen-
sor.
Replace the stator coil assembly (Stator
Refer to "CHECKING THE CRANK- coil/Crankshaft position sensor).
SHAFT POSITION SENSOR" on
page 8-92.
OKl
8-4
IGNITION SYSTEM
OK J-
11.Check the diodes (Diode 1 and 3).
Refer to "CHECKING THE DI- Replace the diode(s).
ODES" on page 8-90.
OK J-
12.Check the lean angle sensor.
Refer to "CHECKING THE LEAN Replace the lean angle sensor.
ANGLE SENSOR" on page 8-93.
8-5
IGNITION SYSTEM
8-6
ELECTRIC STARTING SYSTEM
EAS20073
CIRCUIT DIAGRAM
. . .. . . .. . . . . .
. '.::::_..:.::
. :.
...
..
:
. ."<. >
_.... :'.. ..=.<.
.:.: ...... .._. .. :::-:". ..
>. ) ..:::..j
r . <
..
: . ........:.
..... ;.:-. .....
.. ..... ........... .
. . ............. .
. ''
...............
:: .. :...:.........
.... . . ...
.-:: : .......
..........:.'
/
.. ::
........ . !J@r! .
.........
.. -:: .-..: . . :. .: .:_. .. . ..........
....-..:: ..
.
:':: . .. ...
-: :
8-7
ELECTRIC STARTING SYSTEM
1. Main switch
2. Diode 1
3. Ignition fuse
11.Battery
12. Engine ground
13. Main fuse
14.Starter relay
15.Starter motor
16.Diode 2
17.Diode 3
18.Sidestand switch
19.Starting circuit cut-off relay
20 .Diode 4
52.Gear position switch
54.Handlebar switch (left)
59.Clutch switch
68.Handlebar switch (right)
70.Start switch
71. Engine stop switch
8-8
ELECTRIC STARTING SYSTEM
EAS30494
8 I
:a
9
b 10
1
l12 1
13
8-9
ELECTRIC STARTING SYSTEM
EAS30495
TROUBLESHOOTING
The starter motor fails to turn.
OK j,
OK j,
NG j,
OK j,
OKJ.-
OK j,
OKJ.-
8-10
ELECTRIC STARTING SYSTEM
OK j,
OK J,
1a.Check the sidestand switch. NG --7
Refer to "CHECKING THE Replace the sidestand switch.
SWITCH ES" on page 8-81.
OK J,
11 .Check the clutch switch. NG --7
Refer to "CHECKING THE Replace the clutch switch.
SWITCHES" on page 8-81.
OK J,
12.Check the engine stop switch. NG --7
Refer to "CHECKING THE The engine stop switch is faulty.
SWITCHES" on page 8-81. Replace the right handlebar switch.
OK J,
13.Check the start switch. NG --7
Refer to "CHECKING THE The start switch is faulty.
SWITCHES" on page 8-81 . Replace the right handlebar switch.
. .
OK J,
14.Check the entire starting system NG --7
wiring. Properly connect or replace the wiring har-
Refer to "CIRCUIT DIAGRAM" on ness.
page 8-7.
OK J,
8-11
ELECTRIC STARTING SYSTEM
8-12
CHARGING SYSTEM
EAS20074
CHARGING SYST EM
EAS30496
CIRCUIT DIAGRAM
.. .. .. .
. . ::.:.: ...
_:-:__, :,_.
.....
.. . :::-.-;
: , _::: ::;:;.: . .: : ::::. ::< :: .
. .
:.. _::.
; . ...:.:: ..'::: .... :. . .. ::
... . :..
........
. . :::::... :_:::::: .
. > >
...... ....: ... __ . _ .
11 ...
.1
.: ...
.
> .....
. ..
...
...... .
.:.
/. : . < . .. .. ;: : . .:. ;.,....
. : ...
:::
( . ..
.
;.::-->
..
.: ...
.
.. .
.....
:..
.:
. :._::-:.:.:
. .......
....:.: .)
:....
.. . ... . .
. -..< __.:.-:-
:. ::: ...
.<
....
.. 1.)
. . . .
. (/'. ... .. !:
, .::
:- ,___ J .:,:
":::::. . i:: :_ .
.: ffilh.: _'. -. ':>' :... .:.
;. :-:-
.
. > . . .
. t : ..
........ :.
;
. ' .. ":.::..:( l . .
.. . .
.
','t,"':"'- - -::<:. . . . . . ' . . .
.. : ::.. :.
... -:-:.
r. s: l:L } . ..........................
<
.: ..
:-:-:- :( +;;_ - -- -
@} e @)
' .o+
\ I
:""- .......... _ _ t
>.
; .. ,., './'::'<t ?(it ........ :
: < .. ., .. ... f
..
/ .......
.:... :....:
1.
. __ ..;;:;_ __ . <
.. . .
-;:
. . ...
...... :.. /:' .. .....
.. .:x .. .. ; .....
\ . / :: . :..
................. . .... ..... . ....:..::. %
8-13
CHARGING SYSTEM
8. AC magneto
10. Rectifier/regulator
11.Battery
12. Engine ground
13.Main fuse
8-14
CHARGING SYSTEM
EAS30497
OK1
2. Check the battery.
Refer to "CHECK ING AND Clean the battery terminals.
CHARG ING THE BATTERY" on Recharg e or replace the battery.
page 8-86.
OK1
OK1
4. Check the rectifier/regulator.
Refer to "CHECK ING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR" on page 8-94.
OK1
5. Check the entire charging system
wiring. Properly connect or replace the wiring har-
Refer to "CIRCU IT DIAGRA M" on ness.
page 8-13.
OK1
The charging system circuit is OK.
8-15
CHARGING SYSTEM
8-16
LIGHTING SYSTEM
EAS20075
LIGHTING SYSTEM
EAS30498
CIRCUIT DIAGRAM
. < I < . .. .
.: ....... : .. .
.............. .
. ..... :::: > .. :.
:
;'. . . ,. : 1r:.:.
.. ;.._
.\ ..
. .. .. ?
... . I I I .. .. . I . L .... . ..
.: 1: :: .. .
. . 1 {.. .. .
> . !
. . lli'J 11111
Eltlillll?il 11
<) ....
> .. ..:: . ..
.......
:...
... .
...
:. . ....
.:.......... .
.... ..
.. :..
... .:. .
...
.... :
.........
.
. . H i .
. ..... / 1.. . .
....
.-:::--._.
!I 11;
. . } <
,,.:.. ..
.. .
8-17
LIGHTING SYSTEM
1. Main switch
3. Ign ition fuse
4. Signaling system fuse
5. Backup fuse
6. Headlight fuse
11.Battery
12. Engine ground
13.Main fuse
30.ECU (engine control unit)
40.Meter assembly
48.High beam indicator light
SO.Meter light
54.Handlebar switch (left)
55. Pass switch
56 .Dimmer switch
63.Front turn signal/position light (left)
64.Front turn signal/position light (right)
65.Headlight (right)
66.Headlight (left)
67.Auxiliary light
73. Tail/brake light
74.License plate light
75.License plate light connector
76.Headlight relay
8-18
LIGHTING SYSTEM
EAS30499
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight
, license plate light, position
light, auxiliary light or meter light.
OK l
2. Check the fuses.
(Ignition, signaling system, backup,
headlight, and main) Replac e the fuse(s).
Refer to "CHEC KING THE FUS-
ES" on page 8-85.
OKl
3. Check the battery.
Refer to "CHEC KING AND Clean the battery terminals.
CHARG ING THE BATTERY" on Rechar ge or replace the battery.
page 8-86.
OK l
4. Check the main switch.
Refer to "CHEC KING THE Replac e the main switch.
SWITC H ES" on page 8-81 .
OKl
5. Check the dimme r switch.
Refer to "CHEC KING THE The dimme r switch is faulty.
SWITC HES" on page 8-81. Replace the left handle bar switch.
OKl
6. Check the pass switch.
Refer to "CHEC KING THE The pass switch is faulty.
SWITC H ES" on page 8-81 . Replace the left handle bar switch.
OKl
8-19
LIGHTING SYSTEM
OKt
8. Check the entire lighting system NG----)
wiring. Properly connect or replace the wiring har-
Refer to "CIRCUIT DIAGRAM" on ness.
page8-17.
OK t
Replace the ECU, meter assembly, or
tail/brake light. Refer to"REPLACING
THE ECU (engine control unit)" on
page 8-85.
8-20
SIGNALING SYSTEM
EAS20076
SIGNALING SYSTEM
EAS30500
CIRCUIT DIAGR AM
.. ....
...
. '
.... . .. ....
...<.
... ,...
8-21
SIGNALING SYSTEM
1. Main switch
3. Ignition fuse
4. Signaling system fuse
5. Backup fuse
11.Battery
12. Engine ground
13.Main fuse
22. Fuel sender
29.Speed sensor
30.ECU (engine control unit)
38.Coolant temperature sensor
39. Yamaha diagnostic tool coupler
40.Meter assembly
41.0il pressure warning light
42. Neutral indicator light
43. Tachometer
44.Multi-function meter 1
46.Shift timing indicator light
47.Multi-function meter 2
51.0il pressure switch
52.Gear position switch
53.Turn signal relay
54. Handlebar switch (left)
57.Horn switch
58.Horn
60.Turn signal switch
61.Rear turn signal light (left)
62.Rear turn signal light (right)
63. Front turn signal/position light (left)
64. Front turn signal/position light (right)
68.Handlebar switch (right)
69.Front brake light switch
72. Rear brake light switch
73. Tail/brake light
8-22
SIGNALING SYSTEM
EAS30501
TROUBLESHOOTING
Any of the following fail to light: a turn signal light, the brake light or an
indicator light.
The horn fails to sound.
The fuel meter fails to come on.
The speedometer fails to operate.
OKl
2. Check the battery.
Refer to "CHECKING AND Clean the battery terminals.
CHARGING THE BATTERY" on Recharge or replace the battery.
page 8-86.
OKl
3. Check the main switch.
Refer to "CHECKING THE Replace the main switch.
SWITCHES" on page 8-81.
OKl
4. Check the entire signaling system
wiring. Properly connect or replace the wiring har-
Refer to "CIRCUIT DIAGRAM" on ness.
page 8-21.
OKl
Check the condition of each of the sig-
naling system circuits. Refer to
"Checking the signaling system".
OKl
8-23
SIGNALING SYSTEM
OKt
OKt
OKt
The turn signal light, turn signal indicator light or both fail to blink.
OKt
OKt
OKt
8-24
SIGNALING SYSTEM
OK j,
OK j,
The oil pressure warning light fails to come on when the main switch
is set to "ON".
1. Check the entire signaling system
wiring. Proper ly connec t or replace the wiring har-
Refer to "CIRCU IT DIAGR AM" on ness
page 8-21.
OK j,
OK j,
The oil pressure warning light remains on after the engine is started .
OK j,
OKt
Replace the oil pressu re switch.
8-25
SIGNALING SYSTEM
OKJ-
8-26
SIGNALING SYSTEM
OKl
2. Check the entire signaling system's NG -t
wiring. Properly connect or repair the signaling
Refer to "CIRCUIT DIAGRAM" on system's wiring.
page 8-21.
OKl
Replace the meter assembly.
8-27
SIGNALING SYSTEM
8-28
COOLING SYSTEM
EAs20on
COOLING SYSTEM
EAS30502
CIRCUIT DIAGRAM
........................ .
. . !
......... . < .......... .
: !. ...... .
....... . ... ..
.:...:::::
..............
..
:
.. . ..... . .. . .: . ... /... . .. ..... /. ..
)
....
.:.
1
.. I>:/.<;\
.. ... :!Iii I I ji . ;;1_.._ .. .
.. 1:1:...!H .. I.. I:' <. .. :
).)
.>.>./.
..............................................,.;.: .. :. .
<.
..
<+'
. < ..
. . . ... .. __ ._ ; .. ............. ...
..
. ...
.. .
. .... < "'w .
. . .. I,1.:I/.1v.11...<. .+ 1 >
1 -.::--:-.. : ::::.. :=:
.
":::::;::..:,: 1
... . .
. .. u. rF: 1m1>.':.u... Ti uv u'.: . 1
.. 1.:1> .
... '
... . .. ...... :1
'4
,
........... [.
. .
. 1. ..
i: .
./' 1
:. ..
. . .
: .. ... ,
..
../<} . .
-.1. ... :::.:: .
\
...... .
............. .
-. '\::::.:-: .
.:::.-:':-'
.. . :
: . . . ..
. ........ .
. ::
..... :.. ... __....... ....
.......... .... .
.... .
8-29
COOLING SYSTEM
1. Main switch
3. Ignition fuse
5. Backup fuse
7. Radiator fan motor fuse
11.Battery
12.Engine ground
13.Main fuse
30.ECU (engine control unit)
38.Coolant temperature sensor
77.Radiator fan motor relay
78.Radiator fan motor
8-30
COOLING SYSTEM
EAS30503
TROUBLESHOOTING
The radiator fan motor fails to turn.
OK J,
OK J,
OK J,
OK J,
OK J,
OK J,
8-31
COOLING SYSTEM
OK -1-
8-32
FUEL INJECTION SYSTEM
EAS20078
CIRCUIT DIAGRAM
. .: ... .... ...........
... .J <.
.
::.. ::: . : .....: .....: ......: ...:
': .:.>
.... :.: ....:...
::::: :;:::.:;:-::.
.... ... ::...
. . ....
>. : .< ..
:: ... : . .... .. . 1...... >.... <
.
. . . . . 1 :> v.: .. :
. .... : }
I .
.. : :..
1. .i
. i.
:
... :. )
. . -:
. 1
I
. . .../>
.. r<
..: .. . i, : :; .
-.- '."; . :'. .:
.::
.. I .
:
.: :.::
<. j
y
: . . : I
.. >
.(. . . > :.
:. 1:
I .. <:::.
.+: .
.:.:.:
:. r .:..
.:.
.
.
<
.. ::-:- ... :
.. :.:....
>:.
..:::.
::: .: ....
.........: ... :
8-33
FUEL INJECTION SYSTEM
1. Main switch
2. Diode 1
3. Ignition fuse
5. Backup fuse
6. Headlight fuse
9. Crankshaft position sensor
11.Battery
12. Engine ground
13.Main fuse
17.Diode3
18.Sidestand switch
19.Starting circuit cut-off relay
20.Diode 4
21.Fuel pump
23.Throttle body sensor assembly
24.lntake air pressure sensor
25.lntake air temperature sensor
26.Throttle position sensor
27.0 2 sensor
28.Lean angle sensor
29.Speed sensor
30.ECU (engine control unit)
31.lgnition coil #1
32.Spark plug
33 .lgnition coil #2
34.Fuel injector #1
35.Fuel injector #2
36.Air induction system solenoid
37.ISC (idle speed control) unit
38.Coolant temperature sensor
39. Yamaha diagnostic tool coupler
40.Meter assembly
44.Multi-function meter 1
45.Engine trouble warning light
52.Gear position switch
54.Handlebar switch (left)
59.Clutch switch
68.Handlebar switch (right)
71.Engine stop switch
76.Headlight relay
77. Radiator fan motor relay
8-34
FUEL INJECTION SYSTEM
EAS30505
Engine trouble warning light indication and fuel injection system operation
Warning light indication ECU operation Fuel injection operation Vehicle operation
Flashing* Warning provided when
unable to start engine Operation stopped Cannot be operated
*The warning light flashes when any one of the following conditions is present and
the start switch is
pushed:
12: Crankshaft position sensor Lean angle sensor
41:
(open or short circuit)
19: Sidestand switch ECU internal malfunction
(open circuit in the wire to the ECU) 50:
(memory check error)
30: Lean angle sensor
(latch up detected)
The engine operation is not normal and the engine trouble warning light comes
on.
1. Check:
Fault code number
TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT
TTTTTT TTTTTT TTTTTT TT
a. Check the fault code number displayed on the meter.
8-35
FUEL INJECTION SYSTEM
If another fault code number is displayed, repeat steps (1) to (4) until no fault code number is displayed.
5. Erase the malfunction history in the diagnostic mode. Refer to "Sensor operation table (Diagnostic
code No. 62)".
Turning the main switch to "OFF" will not erase the malfunction history.
The engine operation is not normal, but the engine trouble warning light does not come on.
1. Check the operation of the following sensors and actuators in the diagnostic mode. Refer to "TROU-
BLESHOOTING DETAILS" on page 8-39.
01: Throttle position sensor signal (throttle angle)
30: Cylinder-#1 ignition coil
31: Cylinder-#2 ignition coil
36: Fuel injector #1
37: Fuel injector #2
If a malfunction is detected in the sensors or actuators, repair or replace all faulty parts.
If no malfunction is detected in the sensors and actuators, check and repair the inner parts of the
engine.
EAS3095 1
8-36
FUEL INJECTION SYSTEM
When the Yamaha diagnostic tool is connected to the vehicle, "Er-1" or "Er-4" will
be displayed on the
multi-function meter.
Operation of the Yamaha diagnostic tool (Malfunction mode)
Malfunction results are displayed in the top part of the window area.
8-37
FUEL INJECTION SYSTEM
3 4 5 6 7 8 9 10 11 12
1 R e cov e
Re cove:
Op e n or shcrt circuit of th rottle po:1tion 1enro...
Oo en " ' shcrt circ u it of i;o olent terri pe retur e s..
01 , 13
06
D
D
17:07:12
17:08:40
1. Recovered
The item list of the malfunction detected in the past (already recovered) are displayed.
2. Detected
The item list of the malfunction currently occurred are displayed.
3. Code
The following icons and the fault code numbers for the detected malfunctions are displayed.
A. Detected malfunction
B. Recovered malfunction
4. ECU
The types of the control units are displayed.
5. Item
The item names of the detected malfunction are displayed.
8-38
FUEL INJECTION SYSTEM
6. Condition
The current conditions are displayed. (Detected/Recovered)
7. Symptom
The symptoms of the detected malfunction are displayed.
8. Diagnosis code
The diagnosis codes related to the detected malfunction are displayed.
9. FFD (only for models that can display freeze frame data)
The mark " o " is displayed when the freeze frame data is available.
1O.ECU conduction time (hour: minute: second)
The total ECU conduction time (total hours the vehicle's main switch was
ON) when the malfunction
was detected is displayed.
11 .Numbe r of main switch operation after detection
The number of times the main switch was turned on between the malfunc
tion detection and code
reading is displayed.
12.Number of occurrences
The numbe r of malfunction occurrences between the malfunction detectio
n and code reading is dis-
played.
EAS30508
Item Cranks haft positio n sensor : no normal signals are receive d from
the
cranks haft positio n sensor.
Unable to start engine
Fail-saf e system
Unable to drive vehicle
Diagno stic code No. -
Tool display -
Proced ure -
8-39
FUEL INJECTION SYSTEM
5 Defective crankshaft position Check the crankshaft position Crank the engine.
sensor. sensor. Fault code number is not dis-
Refer to "CHECKING THE played -7 Service is finished.
CRANKSHAFT POSITION Fault code number is displayed
SENSOR" on page 8-92. -7 Go to item 6.
Replace if defective.
6 Malfunction in ECU. Replace the ECU.
Refer to "REPLACING THE
ECU (engine control unit)" on
page 8-85.
Do not remove the throttle body sensor assembly from the throttle body.
If fault code numbers "13" and "14" are both indicated, take the actions specified for fault code number
"13" first.
a..40
FUEL INJECTION SYSTEM
8-41
FUEL INJECTION SYSTEM
If fault code numbers "13" and "14" are both indicated, take the actions specified for fault code number
"13" first.
8-42
FUEL INJECTION SYSTEM
Item Intake air pressure sensor: hose system malfunc tion (clogged hole
or loose).
2 Defective intake air pressure Execute the diagnost ic mode.
sensor. (Code No. 03)
When engine is stopped:
Atmosph eric pressure at the
current altitude and weather
conditions is indicated.
At sea level: Approx. 101 kPa
(757.6 mmHg, 29.8 inHg)
1000 m (3300 ft) above sea lev-
el: Approx. 90 kPa (675.1
mmHg, 26.6 inHg)
2000 m (6700 ft) above sea lev-
el: Approx. 80 kPa (600.0
mmHg , 23.6 inHg)
3000 m (9800 ft) above sea lev-
el: Approx. 70 kPa (525.0
mmHg, 20. 7 inHg)
When engine is cranking: Make
sure that the indication value
changes.
The value does not change
when engine is cranking . Re-
place the throttle bodies if de-
fective.
Refer to "REPLAC ING THE
THROTT LE BODIES " on page
7-14.
Do not remove the throttle body sensor assembly from the throttle body.
8-43
FUEL INJECTION SYSTEM
1 Connection of throttle body sen- Improperly connected -7 Con- Turn the main switch to "ON".
sor assembly coupler. nect the coupler securely or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played -7 Service is finished.
the coupler. Fault code number is displayed
Disconnect the coupler and -7 Go to item 2.
check the pins (bent or broken
terminals and locking condition
of the pins) .
2 Connection of ECU coupler. Improperly connected -7 Con- Turn the main switch to "ON".
Check the locking condition of nect the .coupler securely or re- Fault code number is not dis-
the coupler. place the wire harness. played -7 Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken -7 Go to item 3.
terminals and locking condition
of the pins).
3 Wire harness continuity. Open or short circuit -7 Replace Turn the main switch to "ON".
the wire harness. Fault code number is not dis-
Between throttle body sensor played -7 Service is finished.
assembly coupler and ECU cou- Fault code number is displayed
pier. -7 Go to item 4.
black/blue-black/blue
yellow-yellow
blue-blue
4 Installed condition of throttle Check for looseness or pinch- Turn the main switch to "ON".
body sensor assembly. ing. Fault code number is not dis-
Check for looseness or pinch- Improperly installed sensor -7 played -7 Service is finished.
ing. Replace the throttle bodies. Fault code number is displayed
Refer to "REPLACING THE -7 Go to item 5.
THROTTLE BODIES" on page
7-14.
5 Defective throttle position sen- Check throttle position sensor Turn the main switch to "ON".
sor. signal. Fault code number is not dis-
Execute the diagnostic mode. played -7 Service is finished.
(Code No. 01) Fault code number is displayed
When the throttle valves are ful- -7 Go to item 6.
ly closed:
A value of 14-20 is indicated.
When throttle valves are fully
open:
A value of 97-107 is indicated.
An indicated value is out of the
specified range -7 Replace the
throttle bodies if defective.
Refer to "REPLACING THE
THROTTLE BODIES" on page
7-14.
6 Malfunction in ECU. Replace the ECU.
Refer to "REPLACING THE
ECU (engine control unit)" on
page 8-85.
8-44
FUEL INJECTION SYSTEM
8-45
FUEL INJECTION SYSTEM
1 Connection of sidestand switch Improperly connected -7 Con- Turn the main switch to "ON",
coupler. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
the coupler. Fault code number is not dis-
Disconnect the coupler and played -7 Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition -7 Go to item 2.
of the pins) .
2 Connection of wire harness Improperly connected -7 Con- Turn the main switch to "ON",
ECU coupler. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
the coupler. Fault code number is not dis-
Disconnect the coupler and played -7 Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition -7 Go to item 3.
of the pins).
3 Connection of main switch cou- Improperly connected -7 Con- Turn the main switch to "ON",
pier. nect the coupler securely or re- and then extend and retract the
Check the locking condition of place the wire harness. sidestand.
the coupler. Fault code number is not dis-
Disconnect the coupler and played -7 Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition -7 Go to item 4.
of the pins).
4 Wire harness continuity. Open or short circuit -7 Replace Turn the main switch to "ON",
the wire harness. and then extend and retract the
Between main switch coupler sidestand.
and ECU coupler. Fault code number is not dis-
black/red-black/red played -7 Service is finished.
Between main switch coupler Fault code number is displayed
and sidestand switch coupler. -7 Go to item 5.
blue/yellow-blue/white
5 Defective sidestand switch. Execute the diagnostic mode. Turn the main switch to "ON",
(Code No. 20) and then extend and retract the
Shift the transmission into gear. sidestand.
Sidestand retracted : "ON" Fault code number is not dis-
Sidestand extended: "OFF" played -7 Service is finished.
Replace if defective. Fault code number is displayed
-7 Go to item 6.
Make sure that the engine is completely cool before checking the following items.
8-46
FUEL INJECTION SYSTEM
8-47
FUEL INJECTION SYSTEM
Do not remove the throttle body sensor assembly from the throttle body.
Make sure that the engine is completely cool before checking the following items.
8-48
FUEL INJECTION SYSTEM
8-49
FUEL INJECTION SYSTEM
4 Wire harness continuity. Open or short Replace Start the engine, warm it up,
the wire harness. and then race it, or execute the
Between 0 2 sensor coupler and diagnostic mode. (Code No. 63)
ECU coupler. Fault code number is not dis-
gray/green-gray/green played Service is finished.
pink/black-pink/black Fault code number is displayed
black/blue-black/blue Go to item 5.
Between 0 2 sensor coupler and
starter relay coupler.
red/white-red/white
Between starter relay coupler
and ignition fuse.
red/white-red/white
5 Check fuel pressure. Refer to "CHECKING THE Start the engine, warm it up,
FUEL PRESSURE" on page and then race it, or execute the
7-13. diagnostic mode. (Code No. 63)
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 6.
6 Defective 0 2 sensor. Check the 0 2 sensor. Start the engine , warm it up,
Replace if defective. and then race it, or execute the
Refer to "ENGINE REMOVAL' diagnostic mode. (Code No. 63)
on page 5-3. Fault code number is not dis-
played Service is finished.
Fault code number is displayed
to item 7.
7 Malfunction in ECU. Replace the ECU.
Refer to "REPLACING THE
ECU (engine control unit)" on
page 8-85.
8-50
FUEL INJECTION SYSTEM
Item Cylinder-#1 ignition coil: open or short circuit detected in the prima-
ry lead of the cylinder-#1 ignition coil.
Able to start engine (depending on the number of faulty cylinders)
Fail-safe system
Able to drive vehicle (depending on the number of faulty cylinders)
Diagno stic code No. 30
Actuates the cylinder-#1 ignition coil five times at one-second intervals
Actuati on .
The "CHECK" indicator and "a" on the Yamaha diagnostic tool screen
comes on each time the ignition coil is actuated.
Proced ure Check that a spark is generated five times.
Connect an ignition checker.
Probable cause of malfun c- Confirm ation of service com-
Item Mainten ance job
tion and check pletion
1 Connection of cylinder-#1 igni- Improperly connected --7 Con- Start the engine and let it idle for
tion coil coupler. nect the coupler securely or re- approximately 5 seconds.
Check the locking condition of place the wire harness. Fault code number is not dis-
the coupler. played --7 Service is finished.
Disconnect the coupler and Fault code number is displayed
check the pins (bent or broken --7 Go to item 2.
terminals and locking condition
of the pins).
2 Connection of ECU coupler. Improperly connected --7 Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securely or re- approximately 5 seconds.
the coupler. place the wire harness. Fault code number is not dis-
Disconnect the coupler and played --7 Service is finished.
check the pins (bent or broken Fault code number is displayed
terminals and locking condition --7 Go to item 3.
of the pins).
8-51
FUEL INJECTION SYSTEM
3 Wire harness continuity. Open or short Replace Start the engine and let it idle for
the wire harness. approximately 5 seconds.
Between cylinder-#1 ignition coil Fault code number is not dis-
connector and ECU coupler. Service is finished.
orange-orange Fault code number is displayed
Go to item 4.
4 Installed condition of cylinder-#1 Improperly installed ignition coil Start the engine and let it idle for
ignition coil. Reinstall or replace the igni- approximately 5 seconds.
Check for looseness or pinch- tion coil. Fault code number is not dis-
ing. played Service is finished.
Fault code number is displayed
Go to item 5.
5 Defective cylinder-#1 ignition Measure the primary coil resis- Start the engine and let it idle for
coil. tance of the cylinder-#1 ignition approximately 5 seconds.
coil. Fault code number is not dis-
Replace if out of specification. played Service is finished .
Refer to "CHECKING THE IG- Fault code number is displayed
NITION COILS" on page 8-91 . Go to item 6.
6 Malfunction in ECU. Execute the diagnostic mode.
(Code No. 30)
No Replace the ECU.
Refer to "REPLACING THE
ECU (engine control unit)" on
page 8-85.
8-52
FUEL INJECTION SYSTEM
Item Cylinde r-#2 ignition coil: open or short circuit detecte d in the prima-
ry lead of the cylinde r-#2 ignition coil.
2 Connec tion of ECU coupler. Imprope rly connect ed 4 Con- Start the engine and let it idle for
Check the locking condition of nect the coupler securel y or re- approxi mately 5 seconds.
the coupler. place the wire harness. Fault code number is not dis-
Disconn ect the coupler and
played 4 Service is fin ished.
check the pins (bent or broken
Fault code number is displayed
termina ls and locking condition
4 Go to item 3.
of the pins) .
3 Wire harness continuity. Open or short circuit 4 Replace Start the engine and let it idle for
the wire harness. approxi mately 5 seconds.
Between cylinder -#2 ignition coil Fault code number is not dis-
connec tor and ECU coupler. played 4 Service is finished.
gray/red -gray/re d Fault code number is displayed
4 Go to item 4.
4 Installed condition of cylinder-#2 Imprope rly installed ignition coil Start the engine and let it idle for
ignition coil. 4 Reinstall or replace the igni- approxi mately 5 seconds.
Check for loosene ss or pinch- tion coil. Fault code number is not dis-
ing. played 4 Service is finished.
Fault code number is displayed
4 Go to item 5.
5 Defective cylinder -#2 ignition Measur e the primary coil resis- Start the engine and let it idle for
coil. tance of the cylinder-#2 ignition approxi mately 5 seconds .
coil. Fault code number is not dis-
Replace if out of specification. played 4 Service is finished.
Refer to "CHECK ING THE IG- Fault code number is displayed
NITION COILS" on page 8-91. 4 Go to item 6.
6 Malfunction in ECU. Execute the diagnos tic mode.
(Code No. 31)
No spark 4 Replace the ECU.
Refer to "REPLA CING THE
ECU (engine control unit)" on
page 8-85.
Proced ure Disconn ect the fuel pump coupler, and then check that fuel injector #1
is
actuated five times by listening for the operating sound.
Actuates fuel injector #2 five times at one-second intervals.
Actuati on The "CHECK " indicato r and "a" on the Yamaha diagnos tic tool screen
37 comes on each time the fuel injector is actuated.
Proced ure Disconn ect the fuel pump coupler, and then check that fuel injector #2
is
actuated five times by listening for the operating sound.
Item Probab le cause of malfun c-
Mainten ance job I
Confirm ation of service com-
tion and check
I pletion
8-53
FUEL INJECTION SYSTEM
8-54
FUEL INJECTION SYSTEM
8-55
FUEL INJECTION SYSTEM
8-56
FUEL INJECTION SYSTEM
Item I
Probable cause of malfunc-
tion and check Maintenance job I
Confirm ation of service com-
pletion
8-57
FUEL INJECTION SYSTEM
8-58
FUEL INJECTION SYSTEM
8-59
FUEL INJECTION SYSTEM
8-60
FUEL INJECTION SYSTEM
8-61
FUEL INJECTION SYSTEM
Procedure -
8-62
FUEL INJECTION SYSTEM
8-63
FUEL INJECTION SYSTEM
Tool display -
Procedure -
8-64
FUEL INJECTION SYSTEM
Item Faulty ECU memory. (When this malfunction is detected in the ECU,
the fault code number might not appear on the meter display.)
Unable to start engine
Fail-safe system
Unable to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Malfunction in ECU. Replace the ECU. Turn the main switch to "ON".
Refer to "REPLACING THE Check that the fault code num-
ECU (engine control unit)" on ber is not displayed.
page 8-85.
8-65
FUEL INJECTION SYSTEM
Tool display -
Procedure -
8-66
FUEL INJECTION SYSTEM
Item ECU (engine control unit) internal malfunction (output signal error):
no signals are received from the ECU within the specified duratio
n.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
Item Probable cause of malfunc- Confirmation of service com-
tion and check Maintenance job
pletion
1 Connec tion of meter assemb ly Imprope rly connect ed Con- Turn the main switch to "ON".
coupler. nect the coupler securel y or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played Service is finished.
the coupler.
Fault code number is displayed
Disconn ect the coupler and
Go to item 2.
check the pins (bent or broken
termina ls and locking condition
of the pins).
2 Connec tion of wire harness Imprope rly connected Con- Turn the main switch to "ON".
ECU coupler. nect the coupler securel y or re- Fault code number is not dis-
Check the locking condition of place the wire harness. played Service is finished.
the coupler.
Fault code number is displayed
Disconn ect the coupler and
Go to item 3.
check the pins (bent or broken
termina ls and locking condition
of the pins).
8-67
FUEL INJECTION SYSTEM
Tool display -
Procedure -
8-68
FUEL INJECTION SYSTEM
Item ECU (engine control unit) internal malfunction (output signal error):
data from the ECU cannot be received correctly.
3 Wire harness continuity. Open or short circuit -7 Replace Turn the main switch to "ON".
the wire harness. Fault code number is not dis-
Between ECU coupler and played -7 Service is finished.
Yamaha diagnost ic tool coupler. Fault code number is displayed
yellow/bl ue-yellow /blue -7 Go to item 4.
Between Yamaha diagnost ic
tool coupler and meter assem-
bly coupler.
yellow/bl ue-yellow /blue
4 Defective meter assembly. Replace the meter assembly. Turn the main switch to "ON".
Fault code number is not dis-
played -7 Service is finished.
Fault code number is displayed
-7 Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to "REPLAC ING THE
ECU (engine control unit)" on
page 8-85.
Item ECU (engine control unit) internal malfunction (input signal error):
non-registered data has been received from the meter.
Able to start engine
Fail-safe system
Able to drive vehicle
Diagnostic code No. -
Tool display -
Procedure -
8-69
FUEL INJECTION SYSTEM
Procedure -
Probable cause of malfunc- Confirmation of service com-
Item Maintenance job
tion and check pletion
1 Connection of Yamaha diagnos- Improperly connected Con- Connect the Yamaha diagnostic
tic tool coupler. nect the coupler securely or re- tool and turn the main switch to
Check the locking condition of place the wire harness. "ON".
the coupler. Fault code number is not dis-
Disconnect the coupler and played Service is finished.
check it (bent or broken termi- Fault code number is displayed
nals and locking condition). Go to item 2.
2 Connection of wire harness Improperly connected Con- Connect the Yamaha diagnostic
ECU coupler. nect the coupler securely or re- tool and turn the main switch to
Check the locking condition of place the wire harness. "ON".
the coupler. Fault code number is not dis-
Disconnect the coupler and played Service is finished .
check the pins (bent or broken Fault code number is displayed
terminals and locking condition Go to item 3.
of the pins).
8-70
FUEL INJECTION SYSTEM
Item ECU (engine control unit) internal malfunction (input signal error):
no normal signals are received from the Yamaha diagnostic tool.
3 Wire harness continuity. Open or short Replace Connec t the Yamaha diagnos tic
the wire harness. tool and turn the main switch to
Between ECU coupler and "ON".
Yamaha diagnos tic tool coupler. Fault code number is not dis-
yellow/b lue-yell ow/blue played Service is finished.
Fault code number is displayed
Go to item 4.
4 Defective Yamaha diagnos tic Replace the Yamaha diagnos tic Connec t the Yamaha diagnos tic
tool. tool. tool and turn the main switch to
"ON".
Fault code number is not dis-
played Service is finished.
Fault code number is displayed
Go to item 5.
5 Malfunction in ECU. Replace the ECU.
Refer to "REPLA CING THE
ECU (engine control unit)" on
page 8-85.
8-71
FUEL INJECTION SYSTEM
8-72
FUEL PUMP SYSTEM
EAS2008 1
CIRCUIT DIAGRA M
..... .
......
...
)
.........
...:...:
. :
. : &: r@
:::>
. :::
:.., , . , ....:
: :: 1::.
..:
....
{ @ii
.;,_;:;._
.. :.:: :... ,. '1._ ::=:
.:>: .. ,
...:.: ...... ........
, . . .
. :.'..
...
.-:/
...... . ::::.::..... ::
. ........ :. .
..... ::
8-73
FUEL PUMP SYSTEM
1. Main switch
3. Ignition fuse
5. Backup fuse
11 .Battery
12.Engine ground
13.Main fuse
21.Fuel pump
30.ECU (engine control unit)
68.Handlebar switch (right)
71. Engine stop switch
8-74
FUEL PUMP SYSTEM
EAS30514
OKl
2. Check the battery. NG --7
Refer to "CHEC KING AND Clean the battery terminals.
CHARG ING THE BATTERY" on Rechar ge or replace the battery.
page 8-86.
OKl
3. Check the main switch.
Refer to "CHEC KING THE Replac e the main switch.
SWITC HES" on page 8-81.
OKl
4. Check the engine stop switch. NG --7
Refer to "CHEC KING THE The engine stop switch is faulty.
SWITC HES" on page 8-81. Replac e the right handle bar switch.
OKl
5. Check the fuel pump.
Refer to "CHEC KING THE FUEL Replac e the fuel pump assembly.
PUMP BODY" on page 7-4.
OKl
6. Check the entire fuel pump system
wiring. Proper ly connec t or replace the wiring har-
Refer to "CIRCU IT DIAGR AM" on ness.
page 8-73.
OKl
Replace the ECU. Refer to "REPL AC-
ING THE ECU (engine control unit)"
on page 8-85.
8-75
FUEL PUMP SYSTEM
8-76
ELECTRICAL COMPONENTS
EAS20089
4
3
17
15 14
8-77
ELECTRICAL COMPONENTS
1. Main switch
2. Clutch switch
3. Front brake light switch
4. Ignition coil
5. Fuse box
6. Diode 1
7. Starter relay
8. Main fuse
9. Rectifier/regulator
10. ECU (engine control unit)
11. Diode 2
12. Diode 3
13. Diode 4
14. Battery
15. Rear brake light switch
16. Sidestand switch
17. 0 2 sensor
18. Gear position switch
19. Oil pressure switch
20. Radiator fan motor
21. Horn
8-78
ELECTRICAL COMPONENTS
2
1
6
12
11
10
8-79
ELECTRICAL COMPONENTS
1. Headlight relay
2. Radiator fan motor relay
3. Fuel pump
4. Throttle body sensor assembly
5. Fuel injector
6. Lean angle sensor
7. Starting circuit cut-off relay
8. Turn signal relay
9. Speed sensor
10. Crankshaft position sensor
11 . Coolant temperature sensor
12. Air induction system solenoid
8-80
ELECTRICAL COMPONENTS
EAS30549
I
I
I
1
I
LOCK
OFF
: :---ui-- --
I I I
I
ON
- - - - - - - - - --- - - ----- - -
I
I
I I Y/B ------ - - --- - ---- -
I I 1
I I I
I I I
I I._ __ _____ _ I
y UY
Y/B B Br Ch
: 10 Y UB
I 1 - - -.,.,.----i- - + - - ----+---l
:
I
I
4 Br
I I
I I
I I
I I
:8
I
I
:
I
Co=i
I -
I
I
1 _ _____ _ __ __ _ _ _ ___ _ _ _ 1
J:
I
:s
I
I I
I I
I I
- - - - - - - - - - - - - _J
-- - -- - - - - -- - - -- - - - - - - I
8-81
ELECTRICAL COMPONENTS
1. Main switch
2. Start switch
3. Engine stop switch
4. Front brake light switch
5. Rear brake light switch
6. Sidestand switch
7. Horn switch
8. Turn signal switch
9. Pass switch
10. Dimmer switch
11. Clutch switch
8-82
ELECTRICAL COMPONENTS
Check each switch for continuity with the pocket tester. If the continuity reading
is incorrect, check the
wiring connect ions and if necessary, replace the switch.
ECA18520
fi'QrJeE;
Never insert the tester probes into the coupler terminal slots "a". Always insert
the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-0 3112
Analog pocket tester
YU-031 12-C
Before checkin g for continuity, set the pocket tester to "O" and to the ".Q x 1"
range.
When checkin g for continuity, switch back and forth between the switch position
s a few times.
The switches and their terminal connect ions are illustrated as in the following
example of the main
switch.
The switch position s "a" are shown in the far left column and the switch lead colors
"b" are shown in the
top row.
The continui ty (i. e., a closed circuit) between switch terminal s at a given switch
position is indicated by
''0---0 ''.
There is continui ty between red and brown/red, black/re d and blue/yel low when
the switch is set to
"ON".
R Br/R B/R UY
LOCK
a{ OFF
ON
8-83
ELECTRICAL COMPONENTS
2
Checking the condition of the bulbs
The following procedure applies to all of the
bulbs.
1. Remove:
Bulb Checking the condition of the bulb sockets
EWA13320
The following procedure applies to all of the bulb
AwARNING
sockets.
Since the headlight bulb gets extremely hot, 1. Check:
keep flammable products and your hands Bulb socket (for continuity)
away from the bulb until it has cooled down. (with the pocket tester)
No continuity Replace.
8-84
ELECTRICAL COMPONENTS
8-85
ELECTRICA L COMPONENTS
8-86
ELECTRICAL COMPONENTS
2. Disconnect:
Battery leads A
13.0
(from the battery terminals)
ECA13640
12.5
FioFi:fC.E
12.0
First, disconnect the negative battery lead
"1 ", and then positive battery lead "2". 11 .5
5 6.5 10 B
D
A. Open-circuit voltage (V)
B. Charging time (hours)
C. Relationship between the open-circuit voltage
and the charging time at 20 C (68 F)
D. These values vary with the temperature, the
condition of the battery plates, and the
electrolyte level.
3. Remove:
Batte ry A
14
Refer to "GENE RAL CHASSIS (1 )"on page 13 1 - - -----1- -
4-1. c
4. Check:
Battery charge
TTTTT TTTTT TTTTT TTTTT TTTTT TTTTT TT
a. Connect a pocket tester to the battery termi-
nals.
1 . - -_ _. . _ __ __.___ _.....__._-' -'-1
_ __.__ _ B
Positive tester probe 100 75 50 30 25 20 0
positive battery terminal
Negative tester A. Open-circuit voltage (V)
negative battery terminal B. Charging condition of the battery (%)
C. Ambient temperature 20 C (68 F)
TIP _____ _____ _____ _____ _____ _____
The charge state of a VRLA (Valve Regulated
5. Charge:
Lead Acid) battery can be checked by measur-
ing its open-circuit voltage (i.e., the voltage Batte ry
when the positive battery terminal is discon- (refer to the appropriate charging method)
EWA13300
nected).
No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V. Do not quick charge a battery.
ECA1367 1
b. Check the charge of the battery, as shown in
,:
8-87
ELECTRICAL COMPONENTS
8-88
ELECTRICAL COMPONENTS
Passeng er seat
lf the current is lower than the standard charging Refer to "GENER AL CHASS IS (1 )"on page
current written on the battery, this type of battery 4-1.
charger cannot charge the VALA (Valve Regu-
EAS30553
lated Lead Acid) battery. A variable voltage CHECKING THE RELAYS
charger is recomm ended. Check each switch for continui ty with the pocket
d. Charge the battery until the battery's charg- tester. If the continuity reading is incorrect, re-
ing voltage is 15 V. place the relay.
Pocket tester
Set the charging time at 20 hours (maximum). 90890-0 3112
e. Measure the battery open-cir cuit voltage after Analog pocket tester
YU-031 12-C
leaving the battery unused for more than 30
minutes. 1. Disconn ect the relay from the wire harness.
12.8 V or more --- Charging is complete. 2. Connec t the pocket tester (Q x 1) and battery
12.7 V or less --- Recharging is required. (12 V) to the relay terminal as shown.
Under 12.0 V --- Replace the battery.
Check the relay operation.
AAAAAA AAAAAA AAAAAA AAAAAA AAAAAA AA Out of specification --7 Replace.
6. Install:
Starter relay
Battery
Refer to "GENER AL CHASS IS (1 )"on page
4-1.
7. Connect :
Battery leads
(to the battery terminals)
ECA1 3630
EtttF
First, connect the positive battery lead "1 ",
and then the negative battery lead "2".
Relay operation
Continuity
(between "3" and "4")
1O.lnstall:
Rider seat 1. Positive battery terminal
Center cover 2. Negative battery terminal
8-89
ELECTRICAL COMPONENTS
Diode 1
Continuity
Positive tester probe - j sky blue
"1"
Negative tester probe - j
blue/yellow "2"
Continuity
Positive tester probe - j sky blue
"1"
1. Positive battery terminal Negative tester probe - j yel-
2. Negative battery terminal
low/black "3"
No continuity
3. Positive tester probe
Positive tester probe - j
4. Negative tester probe blue/yellow "2"
Negative tester probe - j sky
Result blue "1"
Continuity No continuity
(between "3" and "4") Positive tester probe - j yel-
low/black "3"
Negative tester probe --4 sky
Radiator fan motor relay blue "1"
Diode 3
Continuity
Positive tester probe - j black
"4"
Negative tester probe - j
blue/yellow "5"
No continuity
Positive tester probe - j
blue/yellow "5"
Negative tester probe - j black
"4"
1. Positive battery terminal Diode 4
2. Negative battery terminal Continuity
3. Positive tester probe Positive tester probe - j
4. Negative tester probe black/yellow, yellow/black "6"
Negative tester probe - j yel-
Result low/white "7"
Continuity No continuity
(between "3" and "4") Positive tester probe - j yel-
low/white "7"
EAS30555
Negative tester probe - j
CHECKING THE DIODES black/yellow, yellow/black "6"
1. Check:
Diodes
Out of specification - j Replace.
8-90
ELECTRICAL COMPONENTS
Pocket tester
90890-0 3112
2 1 3 Analog pocket tester
YU-031 12-C
[}J E l
EAS30558
Resista nce
3. 75-6.25 k.Q
8-91
ELECTRICAL COMPONENTS
Pocket tester
90890-03112
Analog pocket tester 2. Spark plug cap
YU-03112-C
c. Turn the main switch to "ON" and set the en-
Positive tester probe gine stop switch to "n ".
red/black "1" d. Measure the ignition spark gap "a".
Negative tester probe e. Crank the engine by pushing the start switch
spark plug lead "2"
"(i)" and gradually increase the spark gap un-
til a misfire occurs.
AAAAAAAAAAAAA AAAAAAAAAAAAA AAAAAA
EAS30560
2
CHECKING THE CRANKSHAFT POSITION
SENSOR
1. Disconnect:
Crankshaft position sensor coupler
(from the wire harness)
2. Check:
1 Crankshaft position sensor resistance
c. Measure the secondary coil resistance. Out of Replace the stator coil
AAAAAAAAAAAAA AAAAAAAAAAAAA AAAAAA
assembly (Stator coil/Crankshaft position
sensor).
EAS30556
8-92
ELECTRICAL COMPONENTS
EAS30561
OPERATION
1. Check:
CHECKING THE LEAN ANGLE SENSOR Starter motor operation
1. Remove: Does not operate --7 Perform the electric
Lean angle sensor starting system troubleshooting, starting with
2. Check: step 4.
Lean angle sensor output voltage Refer to "TROUBLESHOOTING" on page
Out of specification --7 Replace. 8-10.
TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TT
Lean angle sensor output voltage a. Connect the positive battery terminal "1" and
Less than 45: 0.4-1.4 V starter motor lead "2" with a jumper lead "3".
More than 45: 3.7-4.4 V EWA 13810
A WARNING
TTTTTT TTTTTT TTTTTT TTTTTT TTTTTT TT A wire that is used as a jumper lead must
a. Connect the test harness - lean angle sensor have at least the same capacity of the bat-
(6P) "1" to the lean angle sensor and wire tery lead, otherwise the jumper lead may
harness as shown. burn.
b. Connect the pocket tester (DC 20 V) to the This check is likely to produce sparks,
test harness - lean angle sensor (6P). therefore, make sure no flammable gas or
fluid is in the vicinity.
Pocket tester
90890-0 3112
Analog pocket tester
YU-031 12-C
Test harnes s- lean angle sensor
(GP)
90890-0 3209
Test harnes s- lean angle sensor
(GP)
YU-032 09
8-93
ELECTRICAL COMPONENTS
EAS30680
b. Check the starter motor operation.
CHECKING THE RECTIFIER/REGULATOR
AAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAA 1. Check:
EAS30566
Charging voltage
CHECKING THE STATOR COIL Out of specification -7 Replace the rectifi-
1. Disconnect: er/regulator.
Stator coil coupler
(from the wire harness) Charging voltage
2. Check: 14.1-14.9 V at 5000 r/min
Stator coil resistance
Out of specification -7 Replace the stator coil TTTTTTTTTTTTTTTTTTT TTTTTTTTTTTTT
assembly (Stator coil/Crankshaft position a. Connect the pocket tester (DC 20 V) to the
sensor). battery terminals as shown.
8-94
ELECTRICAL COMPONENTS
Pocket tester
90890- 03112
Analog pocket tester
YU-031 12-C
EAS30576
Positive tester probe
CHECK ING THE SPEED SENSOR
Fuel pump terminal "1"
Negative tester probe 1. Check:
Fuel pump terminal "2" Speed sensor output voltage
Out of specification --7 Replace.
8-95
ELECTRICAL COMPONENTS
+
12V
3
c. Measure the radiator fan motor movement.
AAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAA
EAS30578
A WARNING
Handle the coolant temperature sensor
with special care.
Never subject the coolant temperature sen-
sor to strong shocks. If the coolant temper-
ature sensor is dropped, replace it.
d. Heat the coolant or let it cool down to the
2. Check: specified temperatures.
Coolant temperature sensor resistance e. Measure the coolant temperature sensor re-
Out of specification Replace. sistance.
AAAAAAAAAAAAAAAAAAA AAAAAAAAAAAAA
3. Install:
Coolant temperature sensor
8-96
ELECTRICAL COMPONENTS
8-97
ELECTRICAL COMPONENTS
6 4 2 1
0 Y/W WISb
7 5 3
EAS30681
Resistance
12.0 Q
TTTTTTTTTTTTTTTTTTTTTTTTTTTTTTTT
a. Disconnect the fuel injector coupler from the
fuel injector.
b. Connect the pocket tester (Q x 10) to the fuel
injector coupler as shown .
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
8-98
ELECT RICAL COMPONENTS
8-99
TROUBLESHOOTING
EAS20090
Sucked -in air
TROU BLES HOOT ING
EAS30599 Electrical system
GENER AL INFORM ATION 1. Battery
Discharged battery
The following guide for troubleshooting does not Faulty battery
cover all the possible causes of trouble. It should 2. Fuse(s)
be helpful, however, as a guide to basic trouble- Blown, damaged or incorrect fuse
shooting. Refer to the relative procedure in this Improperly installed fuse
manual for checks, adjustments, and replace- 3. Spark plug(s)
ment of parts. Incorrect spark plug gap
Incorrect spark plug heat range
EAS30600
Fouled spark plug
STARTI NG FAILUR E Worn or damaged electrode
Worn or damaged insulator
Engine Faulty spark plug cap
1. Cylinder(s) and cylinder head 4. Ignition coil(s)
Loose spark plug Cracked or broken ignition coil body
Loose cylinder head or cylinder Broken or shorted primary or secondary coils
Damaged cylinder head gasket Faulty spark plug lead
Damaged cylinder gasket 5. Ignition system
Worn or damaged cylinder Faulty ECU
Incorrect valve clearance Faulty crankshaft position sensor
Improperly sealed valve Broken generator rotor straight key
Incorrect valve-to-valve-seat contact 6. Switches and wiring
Incorrect valve timing Faulty main switch
Faulty valve spring Faulty engine stop switch
Seized valve Broken or shorted wiring
2. Piston(s) and piston ring(s) Faulty gear position sensor
Improperly installed piston ring Faulty sidestand switch
Damaged, worn or fatigued piston ring Faulty clutch switch
Seized piston ring Improperly grounded circuit
Seized or damaged piston Loose connections
3. Air filter 7. Starting system
Improperly installed air filter Faulty starter motor
Clogged air filter element Faulty starter relay
4. Crankcase and crankshaft Faulty relay unit (starting circuit cut-off relay)
Improperly assembled crankcase Faulty starter clutch
Seized crankshaft
EAS30601
9-1
TROUBLESHOOTING
9-2
TROUBLESHOOTING
EAS30607
9-3
TROUBLESHOOTING
9-4
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS20116
For details of the fault code, refer to "TROU BLESH OOTIN G METHOD"
on page 8-35.
Fault code
No. Item
12 Crankshaft position sensor: no normal signals are received from the cranksh
aft position sen-
sor.
13 Intake air pressure sensor: open or short circuit detected.
14 Intake air pressure sensor: hose system malfunction (clogged hole or
loose).
15 Throttle position sensor: open or short circuit detected.
50 Faulty ECU memory. (When this malfunction is detected in the ECU, the
fault code number
might not appear on the meter display.)
70 Engine idling stop
EAS3 1373
For details of the fault code, refer to "TROU BLESH OOTIN G METHOD"
on page 8-35.
Fault code No. Item
ECU (engine control unit) internal malfunction (output signal error): sig-
Er-1 (fault code display) nals cannot be transmitted between the ECU and the multi-function
meter.
9-5
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Waiting for connection (Yamaha ECU (engine control unit) internal malfunction (output signal error): Sig-
diagnostic tool) nals cannot be transmitted between the ECU and Yamaha diagnostic tool.
ECU (engine control unit) internal malfunction (output signal error): no
Er-2
signals are received from the ECU within the specified duration.
ECU (engine control unit) internal malfunction (output signal error): data
Er-3
from the ECU cannot be received correctly.
ECU (engine control unit) internal malfunction (input signal error): non-
Er-4 (fault code display)
registered data has been received from the meter.
ECU (engine control unit) internal malfunction (input signal error): no nor-
Er-4 (Yamaha diagnostic tool)
mal signals are received from the Yamaha diagnostic tool.
EAS31120
9-6
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
code No. Item Meter display Procedure
20 Sidestand switch Extend and retract the side-
stand (with the transmission
in gear).
Stand retracted ON
Stand extended OFF
21 Neutral switch and clutch Operate the transmission
switch and clutch lever.
Transmission is in neutral ON
Transmission is in gear or OFF
the clutch lever released
Clutch lever is squeezed ON
with the transmission in
gear
60 EEPROM fault code display
No history 00 -
No malfunctions detected
(If the self-diagnosis fault
code 44 is indicated, the
ECU is defective.)
History exists 11 (Data error for ISC (idle -
speed control) learning val-
ues)
61 Malfunction history code dis-
play
No history 00 -
History exists Fault codes 12-70 -
(If more than one code
number is detected, the
display alternates every
two seconds to show all the
detected code numbers.
When all code numbers are
shown, the display repeats
the same process.)
62 Malfunction history code era-
sure
No history 00 -
History exists Displays the total number Save the malfunction history
of malfunctions, including to the computer, and then
the current malfunction, delete the fault codes.
that have occurred since To erase the history, set the
the history was last erased. engine stop switch from" !:><J"
(For example, if there have to "O".
been three malfunctions,
"03" is displayed.)
9-7
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
EAS311 21
9-8
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
code No. Item Actuation Procedure
36 Fuel injector #1 Actuates fuel injector #1 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that fuel injector #1 is
The "CHECK " indicator and actuated five times by listen-
"o" on the Yamaha diag- ing for the operating sound.
nostic tool screen come on
each time the fuel injector is
actuated.
37 Fuel injector #2 Actuates fuel injector #2 five Disconnect the fuel pump
times at one-second inter- coupler.
vals. Check that fuel injector #2 is
The "CHECK " indicator and actuated five times by listen-
"o " on the Yamaha diag- ing for the operating sound.
nostic tool screen come on
each time the fuel injector is
actuated.
48 Air cut-off valve Actuates air cut-off valve five Check fuel operating sound
times at one-sec ond inter- of the air cut-off valve five
vals. time.
The "CHECK " indicator and
"o" on the Yamaha diag-
nostic tool screen come on
each time the air cut-off
valve is actuated.
50 Fuel pump Actuates the fuel pump five Check that the fuel pump is
times at one-sec ond inter- actuated five times by listen-
vals. ing for the operating sound.
The "CHECK " indicator and
"o " on the Yamaha diag-
nostic tool screen come on
each time the fuel pump is
actuated.
51 Radiator fan motor relay Actuates the radiator fan mo- Check that the radiator fan
tor relay five times at five- motor relay is actuated five
second intervals. times by listening for the op-
The "CHECK " indicato r and erating sound.
"o " on the Yamaha diag-
nostic tool screen come on
each time the relay is actuat-
ed.
52 Headlight relay Actuates the headlight relay Check that the headlight re-
five times at five-second in- lay is actuated five times by
tervals. listening for the operating
The "CHECK " indicator and sound.
"o" on the Yamaha diag-
nostic tool screen come on
each time the relay is actuat-
ed.
9-9
SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE
Diagnostic
Item Actuation Procedure
code No.
54 ISC valve Fully closes the ISC valve, The ISC unit vibrates when
and then opens the valve. the ISC valve operates.
Then, opens it to the standby
opening position when the
engine is started.
This operation takes approxi-
mately 6 seconds.
The "CHECK" indicator and
"a" on the Yamaha diag-
nostic tool screen come on
during the operation.
9-10
EAS2009 1
58. Horn EAS306 13
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