YZF-R1 ’98 4XV1-AE1 SERVICE MANUAL
EB001000 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. 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.
EB003000 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. 2 Each chapter is divided into sections.
EB004000 1 SYMBOLS 2 GEN INFO The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. SPEC 3 4 CHK ADJ 1 General information 2 Specifications 3 Periodic checks and adjustments 4 Engine 5 Cooling system 6 Carburetor(-s) 7 Chassis 8 Electrical system 9 Troubleshooting ENG 5 6 COOL CARB 7 8 CHAS ELEC 9 – Symbols 0 to G indicate the following.
CHAPTER TITLES GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS ENGINE COOLING CARBURETION CHASSIS GEN INFO 1 SPEC 2 CHK ADJ 3 ENG 4 COOL 5 CARB 6 CHAS 7 – ELECTRICAL TROUBLESHOOTING + ELEC 8 TRBL SHTG 9
GEN INFO 1
GEN INFO CHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION .................................................................1-1 VEHICLE IDENTIFICATION NUMBER ..................................................1-1 MODEL CODE .......................................................................................1-1 IMPORTANT INFORMATION .......................................................................1-2 PREPARATION FOR REMOVAL AND DISASSEMBLY .......................1-2 REPLACEMENT PARTS .........
GEN INFO
MOTORCYCLE IDENTIFICATION GEN INFO EB100000 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION EB100010 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe. EB100020 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.
IMPORTANT INFORMATION GEN INFO EB102000 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust, and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
IMPORTANT INFORMATION GEN INFO USING A DYNAMOMETER The YZF-R1 has a carbon muffler that may change color when exposed to high temperatures. Therefore, when using a dynamometer always use a fan to cool the muffler. EB102030 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/ plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut. EB102040 BEARINGS AND OIL SEALS 1.
CHECKING THE CONNECTIONS GEN INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains → Connect and disconnect several times. 3. Check: • all connections Loose connection → Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up. 4.
SPECIAL TOOLS GEN INFO EB104000 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool No. Tool name/Function Flywheel puller 90890-01080 This tool is used to remove the generator rotor.
SPECIAL TOOLS Tool No. Tool name/Function Oil filter wrench 90890-01426 This tool is needed to loosen or tighten the oil filter cartridge. Rod holder 90890-01434 This tool is used to support the damper adjusting rod. Rod puller 90890-01437 Rod puller attachment 90890-01436 Rod puller Rod puller attachment These tools are used to pull up the front fork damper rod. Fork spring compressor 90890-01441 This tool is used to disassemble or assemble the front fork legs.
SPECIAL TOOLS Tool No. Tool name/Function Engine tachometer 90890-03113 This tool is used to check engine speed. Timing light 90890-03141 This tool is used to check the ignition timing. Carburetor angle driver 90890-03158 This tool is used to turn the pilot screw when adjusting the engine idling speed.
SPECIAL TOOLS Tool No. Tool name/Function Ignition checker 90890-06754 This tool is used to check the ignition system components. Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).
SPEC 2
SPEC CHAPTER 2. SPECIFICATIONS GENERAL SPECIFICATIONS ........................................................................2-1 ENGINE SPECIFICATIONS ...........................................................................2-2 CHASSIS SPECIFICATIONS .......................................................................2-11 ELECTRICAL SPECIFICATIONS .................................................................2-15 TIGHTENING TORQUES ...................................................................
SPEC
GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Maximum load (total of cargo, rider, passenger, and accessories) Standard Limit 2,035 mm (except for N, S, SF) 2,095 mm (for N, S, SF) 695 mm 1,095 mm 815 mm 1,395 mm 140 mm 3,400 mm ------------------------- 198 kg 177 kg 197 kg --------
ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Engine oil Lubrication system Recommended oil Standard Limit Liquid-cooled, 4-stroke, DOHC 998 cm3 Forward-inclined parallel 4-cylinder 74 × 58 mm 11.8:1 1,050 ~ 1,150 r/min 29.
ENGINE SPECIFICATIONS Item Oil filter Oil filter type Bypass valve opening pressure Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Max. impeller shaft tilt Starting system type Spark plugs Model (manufacturer) × quantity Spark plug gap Cylinder head Max.
ENGINE SPECIFICATIONS Item Standard Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Intake camshaft lobe dimensions Chain drive (right) 24.500 ~ 24.521 mm 24.437 ~ 24.450 mm 0.050 ~ 0.084 mm SPEC Limit ------------- C A B Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions 32.5 ~ 32.6 mm 24.95 ~ 25.05 mm 7.45 ~ 7.65 mm 32.4 mm 24.85 mm ---- 32.95 ~ 33.05 mm 24.95 ~ 25.05 mm 7.75 ~ 7.95 mm ---- 32.
ENGINE SPECIFICATIONS Item Standard Timing chain Model/number of links Tensioning system Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions SPEC Limit RH2015 / 130 Automatic ------- 0.11 ~ 0.20 mm 0.21 ~ 0.
ENGINE SPECIFICATIONS Item Valve springs Free length Intake Exhaust Installed length (valve closed) Intake Exhaust Compressed spring force (installed) Intake Exhaust Spring tilt Standard ------- 34.5 mm 35 mm ------- 82 ~ 96 N (8.36 ~ 9.79 kgf) 110 ~ 126 N (11.22 ~ 12.85 kgf) ------- ---- Exhaust ---- Cylinders Cylinder arrangement Bore × stroke Compression ratio Bore Max. taper Max. out-of-round Limit 38.9 mm 40.67 mm Intake Winding direction (top view) Intake Exhaust SPEC 2.5˚ / 1.7 mm 2.
ENGINE SPECIFICATIONS Item Standard Pistons Piston-to-cylinder clearance Diameter D 0.03 ~ 0.055 mm 73.955 ~ 73.970 mm SPEC Limit 0.12 mm ---- H D Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pins Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring 5 mm ---- 17.002 ~ 17.013 mm 0.5 mm Intake side ---------- 16.991 ~ 17.000 mm 0.002 ~ 0.022 mm ---0.
ENGINE SPECIFICATIONS Item Standard Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code Crankshaft F C SPEC C Limit 0.016 ~ 0.040 mm ---- –1 = Violet 0 = White 1 = Blue 2 = Black ---- C E D A B Width A Width B Max.
ENGINE SPECIFICATIONS Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Max. main axle runout Max. drive axle runout Shifting mechanism Shift mechanism type Max.
ENGINE SPECIFICATIONS Item Starter jet 1 Starter jet 2 Butterfly valve size Fuel level (below the line on the float chamber) Max. EXUP cable free play (at the EXUP valve pulley) Standard SPEC Limit #35 0.7 #100 4.1 ~ 5.1 mm ------------- 1.
CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg 90 ~ 197 kg High-speed riding Min.
CHASSIS SPECIFICATIONS Item Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 ~ 90 kg 90 ~ 197 kg High-speed riding Min. tire tread depth Front brakes Brake type Operation Recommended fluid Brake discs Diameter × thickness Min. thickness Max. deflection Brake pad lining thickness Standard Limit Tubeless 190/50 ZR17 (73W) MEZ3 (METZELER) (for GB) TX25 (MICHELIN) (for N, D, NL, B, E, P, I, GR) ---------- 250 kPa (2.5 kg/cm2, 2.5 bar) 290 kPa (2.9 kg/cm2, 2.9 bar) 250 kPa (2.
CHASSIS SPECIFICATIONS Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the inner tube, with the inner tube fully compressed, and without the fork spring) Damper adjusting rod locknut distance Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum*
CHASSIS SPECIFICATIONS Item Steering Steering bearing type Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard spring preload gas/air pressure Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* * from the fully tur
ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item System voltage Ignition system Ignition system type Ignition timing Advanced timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug caps Material Resistance Throttle position sensor standard resistance Charging system System type Model (manufacturer) Nominal output Stator c
ELECTRICAL SPECIFICATIONS Item Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut Starter relay Model (manufacturer) Amperage Coil resistance Horn Horn type Model (manufacturer) × quantity Max.
ELECTRICAL SPECIFICATIONS Item Temperature sender Model (manufacturer) Resistance Fuses (amperage × quantity) Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fuse (odometer) Standard SPEC Limit 2YK (NIPPON SEIKI) 47.5 ~ 56.8 Ω at 80 ˚C 16.5 ~ 20.5 Ω at 115 ˚C ------- 30 A × 1 20 A × 1 20 A × 1 15 A × 1 7.5 A × 1 7.
SPEC CONVERSION TABLE/TIGHTENING TORQUES EB201000 EB202001 CONVERSION TABLE TIGHTENING TORQUES All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. GENERAL TIGHTENING TORQUES This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual.
TIGHTENING TORQUES SPEC ENGINE TIGHTENING TORQUES Item Tightening torque Fastener Thread size Q’ty Nm m·kgf Remarks Spark plugs Cylinder head – Nut M10 M10 4 8 13 50 1.3 5.0 E Cylinder head Cap nut M10 2 50 5.0 E Cylinder head Camshaft caps Bolt Bolt M6 M6 2 28 12 10 1.2 1.0 E Bolt Bolt Stud bolt M6 M8 M8 6 1 8 12 20 15 1.2 2.0 1.5 E Connecting rod caps Generator rotor Nut Bolt M8 M10 8 1 36 95 3.6 9.5 Crankshaft sprocket Bolt M10 1 60 6.
TIGHTENING TORQUES Item SPEC Tightening torque Fastener Thread size Q’ty Nm m·kgf Clutch cover Pickup coil rotor cover Shift shaft cover Oil baffle plate Timing mark accessing screw Starter clutch idle gear shaft Starter clutch Bolt Bolt Bolt Bolt – Bolt Bolt M6 M6 M6 M6 M8 M6 M6 8 8 5 5 1 1 3 12 12 12 10 15 10 12 1.2 1.2 1.2 1.0 1.5 1.0 1.2 Clutch boss Nut M20 1 70 7.0 Clutch springs Bolt M6 6 8 0.8 Drive sprocket Nut M22 1 85 8.
TIGHTENING TORQUES Crankcase tightening sequence: 2 - 21 SPEC
TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Item Thread size Upper bracket pinch bolts Steering stem nut Handlebar pinch bolts Lower ring nut Lower bracket pinch bolts Brake fluid reservoir cap stopper Front brake hose union bolts Front brake master cylinder Engine mounting Left front mounting bolts Right front mounting bolt Rear mounting bolts Pinch bolts Exhaust pipe bracket Pivot shaft nut Connecting arms Relay arm and connecting arms Relay arm Rear shock absorber and relay arm Rear shock abs
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EB202000 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Oil seal lips LS O-rings LS Bearings E Crankshaft pins E Piston surfaces E Piston pins E Connecting rod bolts and nuts M Crankshaft journals E Camshaft lobes M Camshaft journals M Valve stems (intake and exhaust) M Valve stem ends (intake and exhaust) E Water pump impeller shaft E Oil pump rotors (inner and outer)
LUBRICATION POINTS AND LUBRICANT TYPES SPEC EB202010 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant Steering bearings and bearing races (upper and lower) LS Front wheel oil seal (right and left) LS Rear wheel oil seal LS Rear wheel drive hub oil seal LS Rear wheel drive hub mating surface LS Rear brake pedal LS Sidestand pivoting point and metal-to-metal moving parts LS Throttle grip inner surface LS Brake lever pivoting point and metal-to-metal moving parts
OIL FLOW DIAGRAMS EB203000 OIL FLOW DIAGRAMS 1 Intake camshaft 2 Exhaust camshaft 3 Crankshaft 4 Oil cooler 5 Oil pipe 6 Oil strainer 7 Oil pump 2 - 25 SPEC
OIL FLOW DIAGRAMS 1 Exhaust camshaft 2 Intake camshaft 3 Oil filter 2 - 26 SPEC
OIL FLOW DIAGRAMS 1 Cylinder head 2 Crankshaft 2 - 27 SPEC
OIL FLOW DIAGRAMS 1 Main axle 2 Oil delivery pipe 3 Drive axle 2 - 28 SPEC
OIL FLOW DIAGRAMS EB203000 COOLANT FLOW DIAGRAMS 1 Thermostat 2 Radiator cap 3 Coolant reservoir 4 Radiator 5 Oil cooler 6 Water jacket joint 2 - 29 SPEC
OIL FLOW DIAGRAMS 1 Thermostat housing 2 Water pump 3 Radiator 4 Radiator fan 2 - 30 SPEC
OIL FLOW DIAGRAMS 1 Radiator cap 2 Thermostat 3 Thermostat housing 4 Water pump 2 - 31 SPEC
OIL FLOW DIAGRAMS 1 Radiator 2 Thermo switch 3 Temperature sender 2 - 32 SPEC
CABLE ROUTING SPEC EB206000 CABLE ROUTING 1 Throttle cables 2 Front brake hose 3 Clutch cable 4 Starter cable 5 Left handlebar switch lead 6 Main switch lead 7 Right handlebar switch lead Å Properly insert the meter assembly coupler and rubber boot into the meter assembly. ı Route the meter assembly lead through the left side of the headlight housing. Ç Install the headlight relays onto the headlight housing bridge. Î Connect to the right front turn signal connectors.
CABLE ROUTING Ï Fasten the auxiliary light leads with a plastic locking tie. Ì Fasten the wire harness to the headlight housing boss with a plastic locking tie. Ó Route the headlight lead through the plastic guide. È Route the right handlebar switch lead behind the throttle cables. Do not cross the throttle cables and the right handlebar switch lead. Ô Route the thermo switch/temperature sender subwire harness to the outside of the radiator cap.
CABLE ROUTING 1 Rear brake switch lead 2 Charcoal canister (California only) 3 Rollover valve (California only) 4 Thermostat assembly breather hose 5 Radiator inlet hose 6 Coolant reservoir breather hose 7 Clutch cable 8 Pickup coil lead Å Route the rollover-valve-to-fuel-tank hose to the inside of the fuel hose (California only). ı Route the coolant reservoir breather hose SPEC over the timing chain tensioner.
CABLE ROUTING 1 Air filter case breather hose 2 Water pump breather hose 3 Sidestand switch lead 4 Oil level switch lead 5 Right handlebar switch lead 6 Throttle cables 7 Coolant reservoir breather hose 8 Fuel tank overflow hose and fuel tank breather hose SPEC Å Route the air filter case breather hose to the inside of the wire harness. ı Route the stator coil lead over all of the hoses and leads and then fasten them with a plastic clip. Ç Align the wire harness with the indent in the upper rear fender.
CABLE ROUTING Ó 50 mm È Fasten the sidestand switch lead, engine oil level switch lead, and water pump breather hose with a plastic clip. Ô Do not crush the water pump breather hose and plastic clip. Route both of the leads (3 and 4) to the inside of the radiator outlet hose. Ò Route the fuel tank overflow hose and fuel tank breather hose over the radiator outlet hose. Route the air filter case drain hose and 2 - 37 SPEC coolant reservoir breather hose to the inside of the radiator outlet hose.
CABLE ROUTING 1 Speed sensor lead 2 Charcoal canister (California only) 3 Neutral switch lead 4 EXUP cables Å Route the EXUP cables on the outside of the engine mount. ı Fasten the EXUP cables with a plastic locking tie.
CABLE ROUTING 1 Headlight sub-wire harness 2 Left handlebar switch lead 3 Main switch lead 4 Starter cable 5 Right handlebar switch coupler 6 Throttle cables 7 Ignition coil coupler 8 Pickup coil coupler 9 Rear brake switch coupler 0 Fuel pump coupler A Speed sensor coupler B Neutral switch connector SPEC C Fuel tank overflow hose D Fuel tank breather hose (except for California) E Starter motor lead F Battery positive lead G Battery negative lead H Crankcase breather hose I Fuel sender coupler J Sidestan
CABLE ROUTING Å Route the horn lead over the horn bracket and make sure that the lead has no slack. ı Do not cross the throttle cables and right handlebar switch lead. Ç Fasten the wire harness with a plastic clamp. Î Route the ignition coil sub-wire harness under the throttle position sensor. ‰ Route the coolant reservoir breather hose over the battery negative lead and starter motor lead. Ï Fasten the wire harness and ignition coil sub- SPEC wire harness with a plastic clamp.
CABLE ROUTING Ô Route the wire harness and turn signal leads under the rear cowling mounting post on the tail/brake light bracket. Insert the tail/brake light coupler and turn signal leads between the tail/brake light and tail/brake light bracket. Ò Position the ground coupler over the oil level relay lead. ˜ Fasten the starter relay lead, ground lead, and wire harness with a plastic locking tie. ˆ Fasten the battery negative lead and wire SPEC harness with a plastic locking tie.
CABLE ROUTING Œ Fasten the wire harness with a plastic clamp and then insert the clamp into the frame.  Route the charcoal canister hose under the EXUP servomotor lead, battery negative lead, starter motor lead, and EXUP cables (California only). Í Insert the plastic clamp into the hole in the frame. Ê Route the radiator fan lead over the wire harness. SPEC Ë Fasten the wire harness and radiator fan lead to the plastic frame panel with a plastic locking tie.
CABLE ROUTING Á Install the rubber baffle over the carburetor air funnels. Û The end of the plastic locking tie must face in and down.
SPEC 2 - 44
CHK ADJ 3
CHK ADJ CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION ...........................................................................................3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS ...................3-1 SEATS ...........................................................................................................3-3 FUEL TANK ...................................................................................................3-4 COWLINGS ............................................
CHK ADJ CHECKING THE BRAKE PADS ...........................................................3-41 ADJUSTING THE REAR BRAKE LIGHT SWITCH ..............................3-41 CHECKING THE BRAKE HOSES ........................................................3-42 BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................3-42 ADJUSTING THE SHIFT PEDAL ........................................................3-44 ADJUSTING THE DRIVE CHAIN SLACK ...........................................
INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS CHK ADJ EB300000 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer 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.
PERIODIC MAINTENANCE/LUBRICATION INTERVALS CHK ADJ EVERY No. 15 * 16 ITEM CHECKS AND MAINTENANCE JOBS INITIAL (1,000 km) 12,000 km 6,000 km or or 6 months 12 months (whichever (whichever comes first) comes first) Chassis fasteners • Make sure that all nuts, bolts and screws are properly tightened. • Tighten if necessary. √ √ Sidestand • Check operation. • Lubricate and repair if necessary. √ √ √ √ 17 * Sidestand switch • Check operation. • Replace if necessary.
SEATS CHK ADJ EB302000 SEATS Order 1 2 Job/Part Removing the seats Passenger seat Rider seat Q’ty Remarks Remove the parts in the order listed. 1 1 For installation, reverse the removal procedure.
FUEL TANK CHK ADJ EB302010 FUEL TANK Order Q’ty 1 2 3 4 Job/Part Removing the fuel tank Rider seat Bolt Bolt Fuel sender coupler Fuel hose 5 6 7 8 Fuel tank overflow hose Fuel tank breather hose Fuel tank Fuel tank side panel 1 1 1 2 Remarks Remove the parts in the order listed. Refer to “SEATS”. Disconnect. NOTE: Before disconnecting the fuel hose, set the fuel cock to “OFF”. For installation, reverse the removal procedure.
COWLINGS CHK ADJ EB302020 COWLINGS Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the cowlings Rider and passenger seats Rear cowling Bottom cowling Front cowling inner panel (left) Front cowling inner panel (right) Left side cowling Right side cowling Windshield Rear view mirror Front cowling Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS”. 1 1 1 1 1 1 1 2 1 For installation, reverse the removal procedure.
COWLINGS CHK ADJ REMOVAL 1. Remove: • rear cowling • side cowlings NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: • side cowlings • rear cowling NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver. Make sure that the pin is flush with the fastener’s head.
AIR FILTER CASE AND IGNITION COIL PLATE CHK ADJ EB302040 AIR FILTER CASE AND IGNITION COIL PLATE Order 1 2 3 4 5 6 7 8 9 10 Job/Part Q’ty Remarks Removing the air filter case and igniRemove the parts in the order listed. tion coil plate Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK”. Crankcase breather hose 1 Air filter case breather hose 1 Clamp screw 4 Loosen. Bolt 1 Air filter case 1 Quick fastener 2 Ignition coil coupler 1 Disconnect.
AIR FILTER CASE AND IGNITION COIL PLATE CHK ADJ REMOVAL 1. Remove: • rubber baffle NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out. INSTALLATION 1. Install: • rubber baffle NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the rubber baffle and push the pin a in with a screwdriver. Make sure that the pin is flush with the fastener’s head.
ADJUSTING THE VALVE CLEARANCE CHK ADJ EB303001 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • Valve clearance adjustment should be made on a cold engine, at room temperature. • When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: • rider seat • fuel tank Refer to “SEATS” and “FUEL TANK”.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 4. Measure: • valve clearance Out of specification → Adjust. Valve clearance (cold) Intake valve 0.11 ~ 0.20 mm Exhaust valve 0.21 ~ 0.30 mm ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the pickup coil rotor with the crankcase mating surface b. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c.
ADJUSTING THE VALVE CLEARANCE CHK ADJ 5. Remove: • timing chain tensioner • timing chain guide (exhaust side) • intake camshaft caps • exhaust camshaft caps • timing chain (from the camshaft sprockets) • intake camshaft • exhaust camshaft NOTE: • Refer to “CAMSHAFTS” in chapter 4. • When removing the timing chain and camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase. 6. Adjust: • valve clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ADJUSTING THE VALVE CLEARANCE CHK ADJ c. Round off the original valve pad number according to the following table. Last digit Rounded value 0 or 2 0 5 5 8 10 EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation.
ADJUSTING THE VALVE CLEARANCE CHK ADJ VALVE PAD SELECTION TABLE INTAKE Å ORIGINAL VALVE PAD NUMBER ı MEASURED VALVE CLEARANCE 0.00 ~ 0.02 0.03 ~ 0.07 0.08 ~ 0.10 0.11 ~ 0.20 0.21 ~ 0.22 0.23 ~ 0.27 0.28 ~ 0.32 0.33 ~ 0.37 0.38 ~ 0.42 0.43 ~ 0.47 0.48 ~ 0.52 0.53 ~ 0.57 0.58 ~ 0.62 0.63 ~ 0.67 0.68 ~ 0.72 0.73 ~ 0.77 0.78 ~ 0.82 0.83 ~ 0.87 0.88 ~ 0.92 0.93 ~ 0.97 0.98 ~ 1.02 1.03 ~ 1.07 1.08 ~ 1.12 1.13 ~ 1.17 1.18 ~ 1.22 1.23 ~ 1.27 1.28 ~ 1.32 1.33 ~ 1.
ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS CHK ADJ g. Measure the valve clearance again. h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Install: • all removed parts NOTE: For installation, reverse the removal procedure. Note the following points. 8.
SYNCHRONIZING THE CARBURETORS CHK ADJ 3. Remove: • bolts 1 • copper washers 4. Install: • vacuum gauge attachments (into the bolt holes) • vacuum gauge 1 (onto the vacuum gauge attachments) • engine tachometer 2 (onto the spark plug lead of cylinder #1) Vacuum gauge 90890-03094 Vacuum gauge attachment 90890-03060 Engine tachometer 90890-03113 5. Start the engine and let it warm up for several minutes. 6. Measure: • engine idling speed Out of specification → Adjust.
SYNCHRONIZING THE CARBURETORS/ ADJUSTING THE ENGINE IDLING SPEED CHK ADJ NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same. c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in either direction until both gauges read the same.
ADJUSTING THE ENGINE IDLING SPEED CHK ADJ 2. Remove: • air filter case • quick fasteners 1 Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”. 3. Install: • engine tachometer (onto the spark plug lead of cylinder #1) Engine tachometer 90890-03113 4. Install: • air filter case Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”. 5. Measure: • engine idling speed Out of specification → Adjust. Engine idling speed 1,050 ~ 1,150 r/min 6. Adjust: • engine idling speed ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 7. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY”. Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm EB303031 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly. 1. Measure: • throttle cable free play a Out of specification → Adjust.
ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ 3. Adjust: • throttle cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE: When the throttle is opened, the accelerator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. c. Loosen the locknut 4 on the accelerator cable. d. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained.
CHECKING THE SPARK PLUGS CHK ADJ EB303040 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • rider seat • fuel tank Refer to “SEATS” and “FUEL TANK”. • air filter case • ignition coil plate (along with the ignition coils) Refer to “AIR FILTER CASE AND IGNITION COIL PLATE”. 2. Disconnect: • spark plug cap 3.
CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING T. R. 8. Install: • spark plug CHK ADJ 13 Nm (1.3 m · kg) NOTE: Before installing the spark plug, clean the spark plug and gasket surface. EB303050 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion. 1. Remove: • bottom cowling Refer to “COWLINGS”.
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE CHK ADJ b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range → Check the ignition system. NOTE: The ignition timing is not adjustable. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EB303060 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1.
MEASURING THE COMPRESSION PRESSURE CHK ADJ 5. Install: • compression gauge 1 Compression gauge 90890-03081 Adapter 90890-04136 6. Measure: • compression pressure Out of specification → Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1,350 kPa (13.5 kg/cm2, 13.5 bar) Standard 1,450 kPa (14.5 kg/cm2, 14.5 bar) Maximum 1,500 kPa (15.0 kg/cm2, 15.0 bar) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b.
MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL CHK ADJ Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than without oil Piston wear or damage → Repair. Same as without oil Piston ring(-s), valve(-s), cylinder head gasket or piston possibly defective → Repair. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ T. R. 7. Install: • spark plug 13 Nm (1.3 m · kg) EB303070 CHECKING THE ENGINE OIL LEVEL 1.
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL CHK ADJ CAUTION: ACHTUNG: • Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled “ENERGY CONSERVING II” d or higher. • Do not allow foreign materials to enter the crankcase. 4. Start the engine, warm it up for several minutes, and then turn it off. 5.
CHK ADJ CHANGING THE ENGINE OIL b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil. CAUTION: ACHTUNG: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter cartridge. c. Tighten the new oil filter cartridge to specification with an oil filter wrench. T. Oil filter cartridge 17 Nm (1.7 m • kg) R. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 7. Check: • engine oil drain bolt washer Damage → Replace. 8. Install: • engine oil drain bolt T. R. 43 Nm (4.
CHANGING THE ENGINE OIL CHK ADJ 15.Check: • engine oil pressure ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Slightly loosen the oil gallery bolt 1. b. Start the engine and keep it idling until engine oil starts to seep from the oil gallery bolt. If no engine oil comes out after one minute, turn the engine off so that it will not seize. c. Check the engine oil passages, the oil filter cartridge and the oil pump for damage or leakage. Refer to “OIL PAN AND OIL PUMP” in chapter 4. d.
ADJUSTING THE CLUTCH CABLE FREE PLAY CHK ADJ EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm 2. Adjust: • clutch cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Handlebar side a. Turn the adjusting bolt 1 in direction a or b until the specified clutch cable free play is obtained. Direction a Clutch cable free play is increased.
CLEANING THE AIR FILTER ELEMENT/ CHECKING THE CARBURETOR JOINTS CHK ADJ EB303130 CLEANING THE AIR FILTER ELEMENT 1. Remove: • fuel tank Refer to “FUEL TANK”. • air filter case cover 1 • air filter element 2. Clean: • air filter element Apply compressed air to the outer surface of the air filter element. 3. Check: • air filter element Damage → Replace. 4. Install: • air filter element • air filter case cover CAUTION: ACHTUNG: Never operate the engine without the air filter element installed.
CHECKING THE CARBURETOR JOINTS/ CHECKING THE FUEL HOSES AND FUEL FILTER/ CHECKING THE CRANKCASE BREATHER HOSE CHK ADJ 2. Check: • carburetor joint 1 Cracks/damage → Replace. Refer to “CARBURETORS” in chapter 6. 3. Install: • carburetor assembly Refer to “CARBURETORS” in chapter 6. EB303181 CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1. Remove: • fuel tank Refer to “FUEL TANK”. 2. Check: • fuel hose 1 Cracks/damage → Replace.
CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM CHK ADJ 2. Check: • crankcase breather hose 1 Cracks/damage → Replace. Loose connection → Connect properly. CAUTION: ACHTUNG: Make sure that the crankcase breather hose is routed correctly. 3. Install: • fuel tank Refer to “FUEL TANK”. EB303200 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: • radiator assembly Refer to “RADIATOR” in chapter 5. 2.
ADJUSTING THE EXUP CABLES CHK ADJ EB303210 ADJUSTING THE EXUP CABLES 1. Remove: • fuel tank • bottom cowling Refer to “FUEL TANK” and “COWLINGS”. 2. Remove: • EXUP valve pulley cover 1 3. Check: • EXUP system operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the EXUP servomotor coupler 1. b. Connect the battery to the EXUP servomotor coupler and check if the servomotor operates properly.
ADJUSTING THE EXUP CABLES/ CHECKING THE COOLANT LEVEL CHK ADJ 5. Adjust: • EXUP cable free play ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts 1. b. Insert a 4-mm long pin through the notch in the EXUP valve pulley and into the hole in the EXUP valve cover. c. Turn both adjusting bolts 2 counterclockwise until there is no EXUP cable free play. d. Turn both adjusting bolts 1/2 of a turn clockwise. e. Tighten both locknuts remove the pin. and then ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 6.
CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM CHK ADJ 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: • coolant level NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. EB303230 CHECKING THE COOLING SYSTEM 1. Remove: • bottom cowling • side cowlings Refer to “COWLINGS”. 2.
CHANGING THE COOLANT CHK ADJ EB303240 CHANGING THE COOLANT 1. Remove: • bottom cowling • right side cowling Refer to “COWLINGS”. 2. Disengage: • clutch cable holder 1 (from the coolant reservoir) 3. Remove: • coolant reservoir bolts 2 • coolant reservoir cap 3 NOTE: When draining the coolant from the coolant reservoir, be sure to tilt the reservoir so that coolant cannot flow through the coolant reservoir breather hose 4. 4. Drain: • coolant (from the coolant reservoir) 5.
CHK ADJ CHANGING THE COOLANT 8. Remove: • coolant drain bolt 1 (along with the copper washer) 9. Drain: • coolant 10.Check: • copper washer 1 • coolant drain bolt 2 Damage → Replace. T. R. 11.Install: • coolant drain bolt 7 Nm (0.7 m · kg) 12.Fill: • cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 2.75 L (2.
CHANGING THE COOLANT CHK ADJ CAUTION: ACHTUNG: • Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. • Use only distilled water. However, soft water may be used if distilled water is not available. • If coolant comes into contact with painted surfaces, immediately wash them with water. • Do not mix different types of antifreeze. 13.Install: • radiator cap 14.
ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE CHK ADJ EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance a from the throttle grip to the brake lever) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder. Position #1 Distance a is the largest.
ADJUSTING THE REAR BRAKE CHK ADJ 2. Adjust: • brake pedal position ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the locknut 1. b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Brake pedal is raised. Direction b Brake pedal is lowered. WARNING WARNING After adjusting the brake pedal position, check that the end of the adjusting bolt c is visible through the hole d. c. Tighten the locknut 1 to specification. T. Locknut 16 Nm (1.6 m • kg) R.
CHECKING THE BRAKE FLUID LEVEL CHK ADJ EB304020 CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure that the motorcycle is upright. 2. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Å Recommended brake fluid DOT 4 Å Front brake ı Rear brake WARNING WARNING ı • Use only the designated brake fluid.
CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH CHK ADJ EB304032 Å CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: • front brake pad • rear brake pad Brake pad wear limit a Wear limit reached → Replace the brake pads as a set. Refer to “FRONT AND REAR BRAKES” in chapter 7. ı Brake pad wear limit 0.
CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EB304062 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: • brake hose 1 Cracks/damage/wear → Replace. 2. Check: • brake hose clamp Loose → Tighten the clamp bolt. 3. Hold the motorcycle upright and apply the brake several times. 4. Check: • brake hose Brake fluid leakage → Replace the damaged hose. Refer to “FRONT AND REAR BRAKES” in chapter 7.
BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ 5. Bleed: • hydraulic brake system Å ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the brake fluid reservoir diaphragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2. Å Front brake ı Rear brake ı d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f.
ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ EB304081 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Measure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 305 mm 2. Adjust: • installed shift rod length a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen both locknuts 1. b. Turn the shift rod 2 in direction b or c to obtain the correct shift pedal position.
ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Measure: • drive chain slack a Out of specification → Adjust. Drive chain slack 40 ~ 50 mm 4. Adjust: • drive chain slack ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Loosen the wheel axle nut 1. b. Loosen both locknuts 2. c. Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is obtained. Direction a Drive chain slack is reduced.
LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber O-rings between each side plate.
CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ 3. Remove: • front brake fluid reservoir 1 • plastic caps 2 4. Loosen: • upper bracket pinch bolts 1 • handlebar pinch bolts 2 5. Remove: • upper bracket bolts 3 • handlebars (from the upper bracket) 6. Remove: • steering stem nut 1 • washer 2 • upper bracket 3 7. Adjust: • steering head ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. b.
CHK ADJ CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut completely, then tighten it to specification. WARNING WARNING Do not overtighten the lower ring nut. T. R. Lower ring nut (final tightening torque) 9 Nm (0.9 m • kg) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to “STEERING HEAD” in chapter 7. e.
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK CHK ADJ d. Hold the spring gauge at a 45˚ angle from the handlebar, pull the spring gauge, and record the measurement when the handlebar starts to turn. Steering head tension 200 ~ 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specification (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g.
ADJUSTING THE FRONT FORK LEGS CHK ADJ EB304153 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. • Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: ACHTUNG: • Grooves are provided to indicate the adjustment position. • Never go beyond the maximum or minimum adjustment positions.
ADJUSTING THE FRONT FORK LEGS CHK ADJ Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw 1 in direction a or b. Rebound damping is Direction a increased (suspension is harder). Rebound damping is Direction b decreased (suspension is softer).
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ EB304162 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: ACHTUNG: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • spring preload NOTE: Adjust the spring preload with the special wrench and extension bar included in the owner’s tool kit. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting ring 1 in direction a or b.
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ Rebound damping CAUTION: ACHTUNG: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw 1 in direction a or b. Rebound damping is Direction a increased (suspension is harder). Rebound damping is Direction b decreased (suspension is softer).
CHECKING THE TIRES CHK ADJ EB304170 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: • tire pressure Out of specification → Regulate. WARNING WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. • The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed.
CHECKING THE TIRES CHK ADJ 2. Check: • tire surfaces Damage/wear → Replace the tire. Minimum tire tread depth 1.6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator WARNING WARNING Å ı • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using a tube tire, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set.
CHECKING THE TIRES/ CHECKING THE WHEELS Rear tire Manufacturer BRIDGESTONE METZELER METZELER DUNLOP MICHELIN MICHELIN PIRELLI PIRELLI CHK ADJ Size 190/50 ZR17 (73W) 190/50 ZR17 (73W) 190/50 ZR17 (73W) 190/50 ZR17 (73W) 190/50 ZR17 (73W) 190/50 ZR17 (73W) 190/50 ZR17 (73W) 190/50 ZR17 (73W) Model BT56R BT57R MEZ1 RACING MEZ3 D207L TX25 MACADAM 90X MTR02 MTR02 CORSA WARNING WARNING After mounting a new tire, ride conservatively for a while to become accustomed to the “feel” of the new tire and to allow th
CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION CHK ADJ EB304200 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. WARNING WARNING Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: • cable sheath Damage → Replace. 2.
CHECKING AND CHARGING THE BATTERY CHK ADJ EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g.
CHECKING AND CHARGING THE BATTERY CHK ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • rider seat Refer to “SEATS”. 2. Disconnect: • battery leads (from the battery terminals) CAUTION: ACHTUNG: First, disconnect the negative lead 1, then the positive lead 2. 3. Remove: • battery 4.
CHECKING AND CHARGING THE BATTERY CHK ADJ 5. Charge: • battery (refer to the appropriate charging method illustration) WARNING WARNING Do not quick charge a battery. CAUTION: ACHTUNG: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
CHECKING AND CHARGING THE BATTERY Charging method using a variable-voltage charger 3 - 61 CHK ADJ
CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage charger 3 - 62 CHK ADJ
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES CHK ADJ 6. Install: • battery 7. Connect: • battery leads (to the battery terminals) CAUTION: ACHTUNG: First, connect the positive lead 1, then the negative lead 2. 8. Check: • battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • battery terminals Recommended lubricant Dielectric grease 10.Install: • rider seat Refer to “SEATS”.
CHECKING THE FUSES CHK ADJ 3. Replace: • blown fuse ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage. c. Set the main switch to “ON” and verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Item Amperage Q’ty Main fuse 30 A 1 Headlight fuse 20 A 1 Signaling system fuse 20 A 1 Ignition fuse 15 A 1 Radiator fan motor fuse 7.
REPLACING THE HEADLIGHT BULBS CHK ADJ EB305051 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: • headlight coupler 1 • headlight bulb holder cover 2 2. Detach: • headlight bulb holder 1 3. Remove: • headlight bulb 2 WARNING WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4.
ADJUSTING THE HEADLIGHT BEAMS CHK ADJ EB305061 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: • headlight beam (vertically) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting screw 1 in direction a or b. Direction a Headlight beam is raised. Direction b Headlight beam is lowered. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Adjust: • headlight beam (horizontally) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the adjusting knob 1 in direction a or b.
ENG 4
ENG CHAPTER 4. OVERHAULING THE ENGINE ENGINE .........................................................................................................4-1 INSTALLING THE ENGINE ...................................................................4-7 CAMSHAFTS .................................................................................................4-8 REMOVING THE CAMSHAFTS ..........................................................4-11 CHECKING THE CAMSHAFTS .............................................
ENG SHIFT SHAFT ..............................................................................................4-49 CHECKING THE SHIFT SHAFT ...........................................................4-50 CHECKING THE STOPPER LEVER .....................................................4-50 INSTALLING THE SHIFT SHAFT ........................................................4-50 OIL PAN AND OIL PUMP ...........................................................................4-51 REMOVING THE OIL PAN .............
4 ENGINE ENG EB400011 OVERHAULING THE ENGINE ENGINE Order 1 2 3 4 5 6 Job/Part Removing the drive sprocket Locknut Shift rod Drive sprocket cover Lock washer Drive sprocket Shift arm Q’ty Remarks Remove the parts in the order listed. 2 1 1 1 1 1 For installation, reverse the removal procedure.
ENGINE Order Job/Part Removing the exhaust assembly Rider seat and fuel tank Q’ty Bottom cowling and side cowlings Coolant 1 2 3 4 5 6 7 8 Radiator assembly EXUP valve pulley cover Spring Washer EXUP valve pulley Locknut EXUP cable Exhaust pipe assembly Exhaust pipe gasket 1 1 1 1 2 2 1 4 4-2 ENG Remarks Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in chapter 3. Refer to “COWLINGS” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
ENGINE Order 9 10 11 12 13 14 Job/Part Muffler EXUP cable holder EXUP valve cover Spacer EXUP valve Spacer Q’ty 1 1 1 1 1 1 ENG Remarks For installation, reverse the removal procedure.
ENGINE Order Job/Part Disconnecting the leads and hoses Air filter case Q’ty Carburetor assembly and carburetor joints Engine oil and oil filter cartridge Battery negative lead Battery positive lead 1 1 4-4 Remarks Disconnect the parts in the order listed. Refer to “AIR FILTER CASE AND IGNITION COIL PLATE” in chapter 3. Refer to “CARBURETORS” in chapter 6. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “OIL COOLER” and “THERMOSTAT ASSEMBLY” in chapter 5.
ENGINE Order 3 4 5 6 7 8 9 10 11 12 Job/Part Clutch cable Crankcase breather hose Starter motor lead Ground lead Starter motor Stator coil assembly coupler Pickup coil coupler Oil level switch connector Neutral switch Speed sensor Q’ty 1 1 1 1 1 1 1 1 1 1 ENG Remarks Disconnect. Disconnect. Disconnect. Disconnect. Disconnect. For connecting, reverse the disconnection procedure.
ENGINE Order Job/Part Removing the engine Q’ty ENG Remarks Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. 1 2 3 4 5 6 7 8 9 Pinch bolt Right front mounting bolt Washer Spacer Left front mounting bolt Washer Self-locking nut Rear mounting bolt Spacer 2 1 1 1 2 2 2 2 1 Loosen. For installation, reverse the removal procedure.
ENG ENGINE EB400700 INSTALLING THE ENGINE 1. Install: • spacer 1 • rear mounting bolts 2 • self-locking nuts 3 • washers 4 • left front mounting bolts 5 • spacer 6 • washer 7 • right front mounting bolt 8 NOTE: • Lubricate the rear mounting bolt threads with lithium soap base grease. • Do not fully tighten the nuts and bolts. T. 2. Tighten: 55 Nm (5.5 m · kg) • self-locking nut • left front mounting bolts R. T. R. 40 Nm (4.0 m · kg) • right front mounting bolt T. R. R. T. R. 3.
CAMSHAFTS ENG EB401000 CAMSHAFTS Order 1 2 3 4 Job/Part Removing the cylinder head cover Carburetor assembly Radiator assembly and thermostat assembly Spark plug Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) Q’ty Remarks Remove the parts in the order listed. Refer to “CARBURETORS” in chapter 6. Refer to “RADIATOR” and “THERMOSTAT ASSEMBLY” in chapter 5. 4 1 1 1 For installation, reverse the removal procedure.
CAMSHAFTS ENG EB401011 Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the camshafts Pickup coil rotor cover Float chamber air vent hose holder Timing chain tensioner Timing chain tensioner gasket Timing chain guide (exhaust side) Intake camshaft cap Dowel pin Exhaust camshaft cap Dowel pin Intake camshaft Exhaust camshaft Q’ty 1 1 1 1 3 6 3 6 1 1 4-9 Remarks Remove the parts in the order listed. Refer to “PICKUP COIL”. NOTE: During removal, the dowel pins may still be connected to the camshaft caps.
CAMSHAFTS Order 11 12 13 14 Job/Part Intake camshaft sprocket Exhaust camshaft sprocket Pin Timing chain guide (intake side) Q’ty 1 1 1 1 ENG Remarks For installation, reverse the removal procedure.
CAMSHAFTS ENG EB401101 REMOVING THE CAMSHAFTS 1. Align: • TDC mark on the pickup coil rotor (with the crankcase mating surface) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the pickup coil rotor with the crankcase mating surface b. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2.
CAMSHAFTS ENG EB401401 CHECKING THE CAMSHAFTS 1. Check: • camshaft lobes Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • camshaft lobe dimensions a and b Out of specification → Replace the camshaft. Camshaft lobe dimensions limit Intake camshaft a 32.40 mm b 24.85 mm Exhaust camshaft a 32.85 mm b 24.85 mm 3. Measure: • camshaft runout Out of specification → Replace. Max. camshaft runout 0.03 mm 4.
CAMSHAFTS ENG NOTE: • Tighten the camshaft cap bolts in stages and in a crisscross pattern, working from the inner caps out. • Do not turn the camshaft when measuring the camshaft-journal-to-camshaft-cap clearance with the Plastigauge. T. Camshaft cap bolt 10 Nm (1.0 m • kg) R. d. Remove the camshaft caps and then measure the width of the Plastigauge 1. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 5. Measure: • camshaft journal diameter a Out of specification → Replace the camshaft.
CAMSHAFTS ENG 2. Check: • camshaft sprocket More than 1/4 tooth wear a → Replace the camshaft sprockets and the timing chain as a set. a 1/4 tooth b Correct 1 Timing chain roller 2 Camshaft sprocket 3. Check: • timing chain guide (exhaust side) 1 • timing chain guide (intake side) 2 • timing chain guide (top side) 3 Damage/wear → Replace the defective part(-s). EB401430 CHECKING THE TIMING CHAIN TENSIONER 1. Check: • timing chain tensioner Cracks/damage/rough movement → Replace.
ENG CAMSHAFTS EB401701 INSTALLING THE CAMSHAFTS 1. Install: • timing chain guide (intake side) 1 2. Install: • intake camshaft sprocket T. R. 24 Nm (2.4 m · kg) • exhaust camshaft sprocket T. R. 24 Nm (2.4 m · kg) 3. Install: • exhaust camshaft • intake camshaft • exhaust camshaft caps • intake camshaft caps ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the crankshaft clockwise. b.
CAMSHAFTS ENG 4. Install: • timing chain guide (exhaust side) 5. Install: • timing chain tensioner ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Lightly press the timing chain tensioner rod into the timing chain tensioner housing by hand. b. While pressing the timing chain tensioner rod, wind it clockwise with a thin screwdriver 1 until it stops. c.
CAMSHAFTS ENG 7. Check: • TDC mark a Make sure that the TDC mark is aligned with the crankcase mating surface b. • camshaft punch mark c Make sure that the camshaft punch mark is aligned with the arrow mark d on the camshaft cap. Out of alignment → Adjust. Refer to the installation steps above. 8. Measure: • valve clearance Out of specification → Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE” in chapter 3. 9.
CYLINDER HEAD ENG EB402000 CYLINDER HEAD Order 1 2 3 Job/Part Removing the cylinder head Engine Intake and exhaust camshafts Cylinder head Cylinder head gasket Dowel pin Q’ty Remarks Remove the parts in the order listed. Refer to “ENGINE”. Refer to “CAMSHAFTS”. 1 1 2 For installation, reverse the removal procedure.
CYLINDER HEAD ENG EB402102 REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head bolts • cylinder head nuts NOTE: Loosen each bolt and nut 1/2 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts and nuts are fully loosened, remove them. EB402402 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads • valve seats 2.
ENG CYLINDER HEAD d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EB402702 INSTALLING THE CYLINDER HEAD T. R. T. R. 1. Install: • cylinder head • cylinder head nut • cylinder head bolt 50 Nm (5.0 m · kg) 12 Nm (1.2 m · kg) NOTE: • Lubricate the cylinder head nuts with engine oil.
VALVES AND VALVE SPRINGS ENG EB403000 VALVES AND VALVE SPRINGS Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the valves and valve springs Cylinder head Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring Intake valve oil seal Intake valve lower spring seat Intake valve Intake valve guide Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”.
VALVES AND VALVE SPRINGS Order 10 11 12 13 14 15 16 17 18 Job/Part Exhaust valve lifter Exhaust valve pad Exhaust valve cotter Exhaust valve upper spring seat Exhaust valve spring Exhaust valve oil seal Exhaust valve lower spring seat Exhaust valve Exhaust valve guide Q’ty 12 12 24 12 12 12 12 12 12 ENG Remarks For installation, reverse the removal procedure.
VALVES AND VALVE SPRINGS ENG EB403100 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylinder head (e.g., valves, valve springs, valve seats), make sure that the valves properly seal. 1. Remove: • valve lifter 1 • valve pad 2 NOTE: Make a note of the position of each valve lifter and valve pad so that they can be reinstalled in their original place. 2.
VALVES AND VALVE SPRINGS ENG 3. Remove: • valve cotters 1 NOTE: Remove the valve cotters by compressing the valve spring with the valve spring compressor 2 and attachment 3. Valve spring compressor 90890-04019 Attachment (for the intake valve) 90890-04114 (for the exhaust valve) 90890-04108 4. Remove: • upper spring seat 1 • valve spring 2 • valve 3 • oil seal 4 • lower spring seat 5 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
VALVES AND VALVE SPRINGS ENG 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 ˚C in an oven. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the valve guide with a valve guide remover 1. b. Install the new valve guide with the valve guide installer 2 and valve guide remover 1. c. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valvestem-to-valve-guide clearance.
VALVES AND VALVE SPRINGS ENG 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness 0.5 ~ 0.9 mm 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: • When installing a new valve, always replace the valve guide. • If the valve is removed or replaced, always replace the oil seal. Valve stem runout 0.01 mm EB403410 CHECKING THE VALVE SEATS The following procedure applies to all of the valves and valve seats. 1.
VALVES AND VALVE SPRINGS ENG ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply Mechanic’s blueing (Dykem) b onto the valve face. dye b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear impression. d. Measure the valve seat width. NOTE: Where the valve seat and valve face contacted one another, the blueing will have been removed. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4.
VALVES AND VALVE SPRINGS ENG e. Apply a fine lapping compound to the valve face and repeat the above steps. f. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. g. Apply Mechanic’s blueing (Dykem) b onto the valve face. dye h. Install the valve into the cylinder head. i. Press the valve through the valve guide and onto the valve seat to make a clear impression. j. Measure the valve seat width c again.
VALVES AND VALVE SPRINGS ENG 2. Measure: • compressed spring force a Out of specification → Replace the valve spring. b Installed length Compressed spring force (installed) Intake valve spring 8.36 ~ 9.79 kg at 34.5 mm Exhaust valve spring 11.22 ~ 12.85 kg at 35.0 mm 3. Measure: • valve spring tilt a Out of specification → Replace the valve spring. Max. spring tilt Intake valve spring 1.7 mm Exhaust valve spring 1.
VALVES AND VALVE SPRINGS ENG 3. Install: • lower spring seat 1 • oil seal 2 New • valve 3 • valve spring 4 • upper spring seat 5 (into the cylinder head) NOTE: • Make sure that each valve is installed in its original place. Refer to the following embossed marks. Right and left intake valve(-s): “4XV:” Middle intake valve(-s): “4XV.” Exhaust valve(-s): “4XV” • Install the valve spring with the larger pitch a facing up. b Smaller pitch 4.
VALVES AND VALVE SPRINGS ENG 6. Lubricate: • valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil 7. Install: • valve pad • valve lifter NOTE: • The valve lifter must move smoothly when rotated with a finger. • Each valve lifter and valve pad must be reinstalled in its original position.
GENERATOR ENG EB410000 GENERATOR Order Job/Part Removing the stator coil assembly Rider seat and fuel tank Q’ty Bottom cowling Engine oil 1 2 3 4 5 6 7 8 Generator rotor cover Generator rotor cover gasket Dowel pin Generator rotor bolt Generator rotor Stator coil assembly coupler Stator coil assembly lead holder Stator coil assembly 1 1 2 1 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in chapter 3. Refer to “COWLINGS” in chapter 3. Drain.
GENERATOR ENG EB410110 REMOVING THE GENERATOR 1. Remove: • generator rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • generator rotor bolt 1 • washer NOTE: While holding the generator rotor 2 with the rotor holding tool 3, loosen the generator rotor bolt. Rotor holding tool 90890-01235 3.
ENG GENERATOR 3. Tighten: • generator rotor bolt 1 New T. R. 95 Nm (9.5 m · kg) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the generator rotor bolt. Rotor holding tool 90890-01235 4. Install: • generator rotor cover NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern.
PICKUP COIL ENG PICKUP COIL Order Job/Part Removing the pickup coil and pickup coil rotor Rider seat and fuel tank Q’ty Refer to “SEATS” and “FUEL TANK” in chapter 3. Refer to “COWLINGS” in chapter 3. Bottom cowling and right side cowling Engine oil 1 2 3 4 5 6 Generator rotor cover Clutch cable Clutch cable holder Pickup coil lead holder Pickup coil rotor cover Pickup coil rotor cover gasket Dowel pin Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Refer to “GENERATOR”.
PICKUP COIL Order Job/Part 7 Pickup coil coupler 8 Pickup coil 9 Pickup coil rotor ENG Q’ty Remarks 1 Disconnect. 1 1 For installation, reverse the removal procedure.
PICKUP COIL ENG REMOVING THE PICKUP COIL ROTOR 1. Remove: • clutch cable holder 1 • pickup coil lead holder 2 • pickup coil rotor cover 3 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • pickup coil rotor bolt 1 • washer • pickup coil rotor 2 NOTE: While holding the generator rotor 3 with the rotor holding tool 4, loosen the pickup coil rotor bolt.
ENG PICKUP COIL 2. Tighten: • pickup coil rotor bolt 1 T. R. 60 Nm (6.0 m · kg) NOTE: While holding the generator rotor 2 with the rotor holding tool 3, tighten the pickup coil rotor bolt. Rotor holding tool 90890-01235 3. Apply: • sealant (onto the pickup coil lead grommet) Yamaha bond No. 1215 90890-85505 4.
CLUTCH ENG EB405000 CLUTCH Order 1 2 3 4 Job/Part Removing the clutch cover Bottom cowling and right side cowling Engine oil Q’ty Clutch cable Clutch cover Clutch cover gasket Dowel pin Remarks Remove the parts in the order listed. Refer to “COWLINGS” in chapter 3. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. 1 1 1 2 For installation, reverse the removal procedure.
CLUTCH ENG EB405010 Order 1 2 3 4 5 6 Job/Part Removing the pull lever shaft Circlip Pull lever Pull lever spring Pull lever shaft Oil seal Bearing Q’ty Remarks Remove the parts in the order listed. 2 1 1 1 1 2 For installation, reverse the removal procedure.
CLUTCH Order 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Job/Part Removing the clutch Clutch spring plate retainer Clutch spring plate Clutch spring plate seat Pressure plate Pull rod Friction plate Clutch plate Lock washer Wire circlip Clutch plate Friction plate Clutch damper spring Clutch damper spring seat Clutch boss Q’ty 1 1 1 1 1 7 6 1 1 1 1 1 1 1 4 - 41 ENG Remarks Remove the parts in the order listed.
CLUTCH Order 15 16 17 18 19 20 21 22 Job/Part Thrust washer Clutch housing Bearing Starter clutch gear Bearing Starter clutch assembly Circlip Starter clutch idle gear Q’ty 1 1 1 1 1 1 1 1 ENG Remarks For installation, reverse the removal procedure.
CLUTCH ENG EB405102 REMOVING THE CLUTCH 1. Remove: • clutch cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Straighten the lock washer tab. 3. Loosen: • clutch boss nut 1 NOTE: While holding the clutch boss 2 with the clutch holding tool 3, loosen the clutch boss nut. Clutch holding tool 90890-04086 4.
CLUTCH ENG EB405410 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates. 1. Check: • clutch plate Damage → Replace the clutch plates as a set. 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge 1) Out of specification → Replace the clutch plates as a set. Max. clutch plate warpage 0.1 mm EB405430 CHECKING THE CLUTCH SPRING PLATE 1. Check: • clutch spring plate Damage → Replace. 2. Check: • clutch spring plate seat Damage → Replace.
CLUTCH ENG EB405450 CHECKING THE CLUTCH BOSS 1. Check: • clutch boss splines Damage/pitting/wear → Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EB405460 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EB405470 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1.
CLUTCH ENG 2. Check: • starter clutch operation ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install the starter clutch gear 1 onto the starter clutch 2 and hold the starter clutch. b. When turning the starter clutch gear clockwise Å, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be replaced. c. When turning the starter clutch gear counterclockwise ı, it should turn freely, otherwise the starter clutch is faulty and must be replaced.
ENG CLUTCH T. R. 3. Install: • lock washer New • clutch boss nut 1 70 Nm (7.0 m · kg) NOTE: While holding the clutch boss 2 with the clutch holding tool 3, tighten the clutch boss nut. Clutch holding tool 90890-04086 4. Bend the lock washer tab along a flat side of the nut. 5. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Engine oil 6.
ENG CLUTCH T. R. 9. Install: • clutch cover 12 Nm (1.2 m · kg) NOTE: • When installing the clutch cover, push the pull lever and check that the punch mark a on the pull lever aligns with the mark b on the clutch cover. Make sure that the pull rod teeth and pull lever shaft pinion gear are engaged. • Tighten the clutch cover bolts in stages and in a crisscross pattern.
SHIFT SHAFT ENG EB408000 SHIFT SHAFT Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Removing the shift shaft and stopper lever Drive sprocket cover Throttle stop screw holder Shift shaft cover Shift shaft cover gasket Dowel pin Shift shaft Shift shaft spring Spacer Stopper lever spring Stopper lever Circlip Collar Shift shaft spring stopper Q’ty Remarks Remove the parts in the order listed. Refer to “ENGINE”. 1 1 1 2 1 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
ENG SHIFT SHAFT EB408401 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 Bends/damage/wear → Replace. • shift shaft spring 2 Damage/wear → Replace. EB408410 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever. EB408703 INSTALLING THE SHIFT SHAFT 1. Install: • shift shaft spring stopper 1 T. R. 22 Nm (2.
OIL PAN AND OIL PUMP ENG EB411000 OIL PAN AND OIL PUMP Order Job/Part Removing the oil pan and oil pump Engine oil Q’ty Coolant 1 2 3 4 5 6 Radiator assembly and water pump outlet pipe Exhaust pipe assembly Oil level switch connector Oil level switch Oil level switch lead holder Oil pan Oil pan gasket Dowel pin 4 - 51 1 1 1 1 1 2 Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
OIL PAN AND OIL PUMP ENG EB411001 Order 7 8 9 10 11 12 13 14 Job/Part Drain pipe Oil strainer Oil pipe Oil delivery pipe Oil/water pump assembly drive sprocket cover Dowel pin Oil/water pump assembly Relief valve assembly Q’ty 1 1 1 1 1 Remarks 1 1 1 For installation, reverse the removal procedure.
OIL PAN AND OIL PUMP ENG EB411003 Order 1 2 3 4 5 6 7 8 Job/Part Removing the oil pump Oil/water pump assembly driven sprocket Washer Oil pump housing Bearing Pin Oil pump outer rotor Oil pump inner rotor Pin Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 2 1 1 1 For installation, reverse the removal procedure.
OIL PAN AND OIL PUMP ENG EB411100 REMOVING THE OIL PAN 1. Remove: • oil level switch 1 • oil pan 2 • oil pan gasket • dowel pins NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. EB411400 CHECKING THE OIL PUMP 1. Check: • oil/water pump assembly driven sprocket 1 • oil pump housing 2 Cracks/damage/wear → Replace the defective part(-s). 2.
OIL PAN AND OIL PUMP ENG 3. Check: • oil pump operation Unsmooth → Repair or replace the defective part(-s). Refer to “WATER PUMP” in chapter 5. EB411410 CHECKING THE RELIEF VALVE 1. Check: • relief valve body 1 • relief valve 2 • spring 3 • O-ring 4 Damage/wear → Replace the defective part(-s). EB411421 CHECKING THE OIL DELIVERY PIPE AND OIL PIPE 1. Check: • oil delivery pipe 1 • oil pipe 2 Damage → Replace. Obstruction → Wash and blow out with compressed air. EB411430 CHECKING THE OIL STRAINER 1.
ENG OIL PAN AND OIL PUMP 2. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. EB411710 INSTALLING THE OIL PUMP 10 Nm (1.0 m · kg) T. R. 1. Install: • oil pump 1 NOTE: Install the oil/water pump assembly drive chain onto the oil/water pump assembly driven sprocket. EB411720 INSTALLING THE OIL STRAINER 10 Nm (1.0 m · kg) T. R. 1. Install: • oil strainer 1 NOTE: The arrow a on the oil strainer housing must point towards the front of the engine. EB411730 INSTALLING THE OIL PAN T. 1.
CRANKCASE ENG CRANKCASE Order 1 2 3 4 5 Job/Part Separating the crankcase Engine Cylinder head Pickup coil and pickup coil rotor Stator coil assembly Clutch housing and starter clutch idle gear Oil/water pump assembly Timing chain Crankshaft sprocket Pin Oil/water pump assembly drive chain guide Oil/water pump assembly drive chain Q’ty Remarks Remove the parts in the order listed. Refer to “ENGINE”. Refer to “CYLINDER HEAD”. Refer to “PICKUP COIL”. Refer to “GENERATOR”. Refer to “CLUTCH”.
CRANKCASE Order Job/Part 6 Oil/water pump assembly drive sprocket 7 Washer 8 Plate 9 Lower crankcase 10 Dowel pin Q’ty 1 ENG Remarks 1 1 1 3 For installation, reverse the removal procedure.
CRANKCASE Order 1 2 3 4 5 6 7 Job/Part Removing the oil baffle plates and oil filter bolt Connecting rod assemblies Q’ty ENG Remarks Remove the parts in the order listed. Refer to “CONNECTING RODS AND PISTONS”. Refer to “CRANKSHAFT”. Refer to “TRANSMISSION”. Crankshaft Transmission Oil baffle plate Oil baffle plate Oil delivery pipe Bearing Upper crankcase Oil filter bolt Lower crankcase 1 1 1 1 1 1 1 For installation, reverse the removal procedure.
CRANKCASE ENG EB412100 DISASSEMBLING THE CRANKCASE 1. Remove: • crankcase bolts NOTE: • Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. • Loosen the bolts in decreasing numerical order (refer to the numbers in the illustration). • The numbers embossed on the crankcase indicate the crankcase tightening sequence. 2. Place the engine upside down. 3.
CRANKCASE ENG EB412420 CHECKING THE CRANKCASE 1. Thoroughly wash the crankcase halves in a mild solvent. 2. Thoroughly clean all the gasket surfaces and crankcase mating surfaces. 3. Check: • upper crankcase • lower crankcase Cracks/damage → Replace. • oil delivery passages Obstruction → Blow out with compressed air. EB412440 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace.
CRANKCASE ENG EB412743 ASSEMBLING THE CRANKCASE 1. Lubricate: • crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: • sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 ~ 3 mm of the crankshaft journal bearings. 3. Install: • dowel pin 4.
CRANKCASE ENG 6. Install: • lower crankcase 1 (onto the upper crankcase 2) CAUTION: ACHTUNG: Before tightening the crankcase bolts, make sure that the transmission gears shift correctly when the shift drum assembly is turned by hand. 7. Install: • crankcase bolts NOTE: • Lubricate the bolt threads with engine oil. • Install a washer on bolts 1 ~ @. • Tighten the bolts in the tightening sequence cast on the crankcase.
CONNECTING RODS AND PISTONS ENG EB404001 CONNECTING RODS AND PISTONS Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the connecting rods and pistons Crankcase Q’ty Connecting rod cap Big end lower bearing Piston pin clip Piston pin Piston Connecting rod Big end upper bearing Top ring 2nd ring Oil ring Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. 4 4 8 4 4 4 4 4 4 4 For installation, reverse the removal procedure.
CONNECTING RODS AND PISTONS ENG EB412131 REMOVING THE CONNECTING RODS AND PISTONS The following procedure applies to all of the connecting rods and pistons. 1. Remove: • connecting rod cap 1 • big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place. 2. Remove: • piston pin clips 1 • piston pin 2 • piston 3 • connecting rod 4 CAUTION: ACHTUNG: Do not use a hammer to drive the piston pin out.
ENG CONNECTING RODS AND PISTONS EB404403 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: • piston wall • cylinder wall Vertical scratches → Replace the crankcases, and the piston and piston rings as a set. 2. Measure: • piston-to-cylinder clearance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-to-side and front-to-back measurements of the cylinder.
CONNECTING RODS AND PISTONS ENG e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance 0.030 ~ 0.055 mm : 0.12 mm f. If out of specification, replace the crankcases, and the pistons and piston rings as a set. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ EB404410 CHECKING THE PISTON RINGS 1.
CONNECTING RODS AND PISTONS ENG 3. Measure: • piston ring end gap Out of specification → Replace the piston ring. NOTE: The oil ring expander spacer’s end gap cannot be measured. If the oil ring rail’s gap is excessive, replace all three piston rings. Piston ring end gap Top ring 0.19 ~ 0.31 mm : 0.56 mm 2nd ring 0.30 ~ 0.45 mm : 0.80 mm Oil ring 0.10 ~ 0.35 mm EB404421 CHECKING THE PISTON PINS The following procedure applies to all of the piston pins. 1.
CONNECTING RODS AND PISTONS ENG 4. Calculate: • piston-pin-to-piston-pin-bore clearance Out of specification → Replace the piston pin. Piston-pin-to-piston-pin-bore clearance = Piston pin bore diameter (in the piston) – Piston pin outside diameter Piston-pin-to-piston-pin-bore clearance 0.002 ~ 0.022 mm : 0.072 mm CHECKING THE BIG END BEARINGS 1. Measure: • crankshaft-pin-to-big-end-bearing clearance Out of specification → Replace the big end bearings. Crankshaft-pin-to-big-endbearing clearance 0.
CONNECTING RODS AND PISTONS ENG c. Put a piece of Plastigauge 1 on the crankshaft pin. d. Assemble the connecting rod halves. NOTE: • Do not move the connecting rod or crankshaft until the clearance measurement has been completed. • Lubricate the bolt threads and nut seats with molybdenum disulfide grease. • Make sure that the “Y” mark c on the connecting rod faces towards the left side of the crankshaft. • Make sure that the characters d on both the connecting rod and connecting rod cap are aligned. e.
CONNECTING RODS AND PISTONS ENG 2. Select: • big end bearings (“P1”~ “P4”) NOTE: • The numbers stamped into the crankshaft web and the numbers on the connecting rods are used to determine the replacement big end bearing sizes. • “P1”~“P4” refer to the bearings shown in the crankshaft illustration.
CONNECTING RODS AND PISTONS ENG 2. Install: • piston 1 (onto the respective connecting rod 2) • piston pin 3 • piston pin clip 4 New NOTE: • Apply engine oil onto the piston pin. • Make sure that the “Y” mark a on the connecting rod faces left when the arrow mark b on the piston is pointing up. Refer to the illustration. • Reinstall each piston into its original cylinder (numbering order starting from the left: #1 to #4). 3.
ENG CONNECTING RODS AND PISTONS 6. Lubricate: • crankshaft pins • big end bearings • connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant Engine oil 7. Install: • big end bearings • connecting rod assembly (into the cylinder and onto the crankshaft pin) • connecting rod cap (onto the connecting rod) NOTE: • Align the projections on the big end bearings with the notches in the connecting rods and connecting rod caps.
CRANKSHAFT ENG EB412000 CRANKSHAFT Order Job/Part Removing the crankshaft assembly Crankcase Q’ty Connecting rod caps 1 2 3 Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. Refer to “CONNECTING RODS AND PISTONS”. 1 5 5 For installation, reverse the removal procedure.
CRANKSHAFT ENG EB412110 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft 1 • crankshaft journal upper bearings (from the upper crankcase) NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. EB412403 CHECKING THE CRANKSHAFT 1. Measure: • crankshaft runout Out of specification → Replace the crankshaft. Max. crankshaft runout 0.03 mm 2.
CRANKSHAFT ENG a. Clean the crankshaft journal bearings, crankshaft journals, and bearing portions of the crankcase. b. Place the upper crankcase upside down on a bench. c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crankcase. NOTE: Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. d. Put a piece of Plastigauge 2 on each crankshaft journal.
CRANKSHAFT ENG g. Remove the lower crankcase and the crankshaft journal lower bearings. h. Measure the compressed Plastigauge width c on each crankshaft journal. If the clearance is out of specification, select replacement crankshaft journal bearings. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Select: • crankshaft journal bearings (J1 ~ J5) NOTE: • The numbers stamped into the crankshaft web and the numbers stamped into the lower crankcase are used to determine the replacement crankshaft journal bearing sizes.
CRANKSHAFT ENG EB412720 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft journal upper bearings (into the upper crankcase) NOTE: • Align the projections a on the crankshaft journal upper bearings with the notches b in the upper crankcase. • Be sure to install each crankshaft journal upper bearing in its original place.
TRANSMISSION ENG EB413000 TRANSMISSION Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the transmission, shift drum assembly, and shift forks Crankcase Q’ty Remarks Remove the parts in the order listed. Separate. Refer to “CRANKCASE”. Refer to “SHIFT SHAFT”.
TRANSMISSION Order Job/Part 10 Shift drum assembly 11 Shift fork “C” 12 Main axle assembly Q’ty 1 1 1 ENG Remarks For installation, reverse the removal procedure.
TRANSMISSION Order 1 2 3 4 5 6 7 8 9 @ ENG Job/Part Q’ty Remarks Disassembling the main axle assemRemove the parts in the order listed.
TRANSMISSION Order Job/Part A Main axle/1st pinion gear B Bearing C Main axle bearing housing Q’ty 1 1 1 ENG Remarks For installation, reverse the removal procedure.
TRANSMISSION Order 1 2 3 4 5 6 7 8 9 @ ENG Job/Part Q’ty Remarks Disassembling the drive axle assemRemove the parts in the order listed.
TRANSMISSION Order A B C D E F G Job/Part 4th wheel gear 6th wheel gear 2nd wheel gear Spacer Drive axle Bearing Spacer Q’ty 1 1 1 1 1 1 1 ENG Remarks For installation, reverse the removal procedure.
TRANSMISSION ENG EB413100 REMOVING THE TRANSMISSION 1. Remove: • main axle assembly 1 (with the Torx wrench T30) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. b. Tighten the bolts until they contact the crankcase surface. c. Continue tightening the bolts until the main axle assembly comes free from the upper crankcase.
TRANSMISSION ENG 3. Check: • shift fork movement (along the shift fork guide bar) Rough movement → Replace the shift fork(-s) and shift fork guide bar as a set. EB413410 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage/scratches/wear → Replace the shift drum assembly. • shift drum segment 1 Damage/wear → Replace the shift drum assembly. • shift drum bearing 2 Damage/pitting → Replace the shift drum assembly. EB413422 CHECKING THE TRANSMISSION 1.
TRANSMISSION ENG 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(-s). 6. Check: • circlips Bends/damage/looseness → Replace. INSTALLING THE TRANSMISSION 1.
ENG 4 - 88
COOL 5
COOL CHAPTER 5. COOLING SYSTEM RADIATOR .....................................................................................................5-1 CHECKING THE RADIATOR .................................................................5-3 INSTALLING THE RADIATOR ..............................................................5-4 OIL COOLER ..................................................................................................5-5 CHECKING THE OIL COOLER .................................................
COOL
RADIATOR COOL EB500000 COOLING SYSTEM RADIATOR Order Job/Part Removing the radiator Rider seat and fuel tank Q’ty Air filter case and rubber cover Bottom cowling and side cowlings Drive sprocket cover Coolant 1 2 3 4 5 6 Coolant reservoir breather hose Coolant reservoir hose Coolant reservoir Thermo switch coupler Temperature sender connector Ground lead 1 1 1 1 1 1 5-1 Remarks Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in chapter 3.
RADIATOR Order 7 8 9 10 11 12 13 14 15 16 17 18 Job/Part Thermo switch Temperature sender Thermostat assembly breather hose Radiator inlet hose Oil cooler outlet hose Water pump breather hose Radiator outlet hose Water pump inlet pipe Radiator fan motor coupler Horn bracket Radiator Radiator fan COOL Q’ty Remarks 1 1 1 Disconnect. 1 1 Disconnect. 1 1 1 1 Disconnect. 1 1 1 For installation, reverse the removal procedure.
RADIATOR COOL EB500010 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flat-head screwdriver. 2. Check: • radiator hoses Cracks/damage → Replace. 3. Measure: • radiator cap opening pressure Below the specified pressure Replace the radiator cap. → Radiator cap opening pressure 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm2, 0.95 ~ 1.
RADIATOR COOL EB500020 INSTALLING THE RADIATOR 1. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
OIL COOLER COOL EB501000 OIL COOLER Order 1 2 3 4 5 6 7 8 Job/Part Removing the oil cooler Radiator assembly Exhaust pipe assembly Engine oil Q’ty Oil cooler outlet hose Bolt Lock washer Oil cooler Oil cooler inlet hose Water pump outlet pipe Water jacket joint inlet hose Water jacket joint Remarks Remove the parts in the order listed. Refer to “RADIATOR”. Refer to “ENGINE” in chapter 4. Drain. Refer to “CHANGING THE ENGINE OIL” in chapter 3.
OIL COOLER COOL EB501010 CHECKING THE OIL COOLER 1. Check: • oil cooler Cracks/damage → Replace. 2. Check: • oil cooler inlet hose • oil cooler outlet hose Cracks/damage/wear → Replace. 3. Check: • water jacket joint • water jacket joint inlet hose • water pump outlet hose Cracks/damage → Replace. EB501020 INSTALLING THE OIL COOLER 1. Clean: • mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thinner) 2.
OIL COOLER COOL 4. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. • crankcase (with the specified amount of the recommended engine oil) Refer to “CHANGING THE ENGINE OIL” in chapter 3. 5. Check: • cooling system Leaks → Repair or replace any faulty part. 6. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
THERMOSTAT ASSEMBLY COOL EB502000 THERMOSTAT ASSEMBLY Order Job/Part Removing the thermostat assembly Rider seat and fuel tank Q’ty Air filter case and rubber cover Carburetor assembly Coolant 1 2 3 4 Radiator inlet hose Thermostat assembly breather hose Thermostat assembly inlet hose (left) Thermostat assembly inlet hose (right) 5-8 1 1 1 1 Remarks Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in chapter 3.
THERMOSTAT ASSEMBLY Order Job/Part Q’ty 5 Thermostat assembly 1 6 Thermostat assembly inlet pipe (left) 1 7 Thermostat assembly inlet pipe 1 (right) COOL Remarks For installation, reverse the removal procedure.
THERMOSTAT ASSEMBLY COOL EB502010 Order 1 2 3 Job/Part Disassembling the thermostat assembly Thermostat housing cover Thermostat Thermostat housing Q’ty Remarks Remove the parts in the order listed. 1 1 1 For assembly, reverse the disassembly procedure.
THERMOSTAT ASSEMBLY COOL EB502020 CHECKING THE THERMOSTAT 1. Check: • thermostat 1 Does not open at 71 ~ 85 ˚C → Replace. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d. While stirring the water, observe the thermostat and thermometer’s indicated temperature.
THERMOSTAT ASSEMBLY COOL EB502040 INSTALLING THE THERMOSTAT ASSEMBLY 1. Fill: • cooling system (with the specified amount of the recommended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: • cooling system Leaks → Repair or replace any faulty part. 3. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR”.
WATER PUMP COOL EB503000 WATER PUMP Order Job/Part Removing the impeller shaft Q’ty Remarks Remove the parts in the order listed. NOTE: • The water pump and oil pump are combined into one unit (oil/water pump assembly). • It is not necessary to remove the impeller shaft unless the coolant level is extremely low or coolant leaks from the oil pan.
WATER PUMP Order Job/Part 5 Water pump seal 6 Oil seal 7 Bearing Q’ty 1 1 1 COOL Remarks For installation, reverse the removal procedure.
WATER PUMP COOL EB503020 DISASSEMBLING THE WATER PUMP 1. Remove: • water pump seal 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. 2 Water pump housing 2. Remove: • oil seal 1 • bearing 2 NOTE: Tap out the bearing and oil seal from the outside of the water pump housing. 3 Water pump housing 3. Remove: • rubber damper holder 1 • rubber damper 2 (from the impeller, with a thin, flathead screwdriver) NOTE: Do not scratch the impeller shaft.
WATER PUMP COOL EB503040 ASSEMBLING THE WATER PUMP 1. Install: New • oil seal 1 (into the water pump housing 2) NOTE: • Before installing the oil seal, apply tap water or coolant onto its outer surface. • Install the oil seal with a socket that matches its outside diameter. 2. Install: • water pump seal 1 New CAUTION: ACHTUNG: Never lubricate the water pump seal surface with oil or grease. NOTE: • Install the water pump seal with the special tools.
WATER PUMP COOL 4. Measure: • impeller shaft tilt Out of specification → Repeat steps (3) and (4). CAUTION: ACHTUNG: Make sure that the rubber damper and rubber damper holder are flush with the impeller. Max. impeller shaft tilt 0.
COOL 5 - 18
CARB 6
CARB CHAPTER 6. CARBURETORS CARBURETORS ............................................................................................6-1 CHECKING THE CARBURETORS .........................................................6-6 ASSEMBLING THE CARBURETORS ...................................................6-8 INSTALLING THE CARBURETORS ....................................................6-10 MEASURING AND ADJUSTING THE FUEL LEVEL ..........................6-11 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ..
CARB
CARBURETORS CARB EB600001 CARBURETORS CARBURETORS Order Job/Part Removing the carburetors Rider seat and fuel tank Q’ty Air filter case and rubber baffle 1 2 3 4 5 6 7 8 9 Starter cable Fuel hose Throttle position sensor coupler Float chamber air vent hose Throttle stop screw Carburetor joint clamp screw Throttle cable Carburetor assembly Carburetor joint 1 1 1 2 1 8 2 1 4 Remarks Remove the parts in the order listed. Refer to “SEATS” and “FUEL TANK” in chapter 3.
CARBURETORS CARB EB600010 Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job/Part Separating the carburetors Starter plunger link Connecting bolt Copper washer Connecting bolt Spacer Spacer Spacer Hose joint Float chamber air vent hose Float chamber air vent hose Spring Vacuum chamber air vent hose Vacuum chamber pipe Q’ty 1 1 1 1 1 1 1 2 1 1 2 2 1 6-2 Remarks Remove the parts in the order listed.
CARBURETORS Order 14 15 16 17 18 19 20 21 22 23 Job/Part Fuel feed pipe Fuel feed pipe Fuel feed pipe Pipe Pipe Pipe Throttle stop screw Throttle position sensor Throttle position sensor bracket Carburetor Q’ty 1 1 1 1 1 1 1 1 1 4 CARB Remarks R = 37 mm R = 32 mm R= 29 mm R = 73 mm R= 68 mm R = 66 mm For installation, reverse the removal procedure.
CARBURETORS CARB EB600021 Order Job/Part Disassembling the carburetor Q’ty Remarks Remove the parts in the order listed. NOTE: The following procedure applies to all of the carburetors.
CARBURETORS Order B C D E F G H I Job/Part Float chamber Float pivot pin Float Needle valve Needle valve seat Main jet Main jet holder Pilot jet Q’ty 1 1 1 1 1 1 1 1 CARB Remarks For assembly, reverse the disassembly procedure.
CARBURETORS CARB EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the carburetors. 1. Check: • carburetor body • float chamber Cracks/damage → Replace. 2. Check: • fuel passages Obstruction → Clean. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Wash the carburetor in a petroleumbased solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 3. Check: • float chamber body Dirt → Clean. 4.
CARBURETORS CARB 8. Check: • piston valve 1 Damage/scratches/wear → Replace. • piston valve diaphragm 2 Cracks/tears → Replace. 9. Check: • vacuum chamber cover 1 • piston valve spring 2 • jet needle holder 3 • jet needle spring 4 Cracks/damage → Replace. 10.Check: • jet needle kit 1 • main jet 2 • main jet holder 3 • pilot jet 4 • pilot screw 5 • starter plunger 6 • pilot air jet 7 Bends/damage/wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 11.
CARBURETORS CARB 13.Check: • fuel hoses Cracks/damage/wear → Replace. Obstruction → Clean. Blow out the hoses with compressed air. EB600043 ASSEMBLING THE CARBURETORS The following procedure applies to all of the carburetors. CAUTION: ACHTUNG: • Before assembling the carburetors, wash all of the parts in a petroleumbased solvent. • Always use a new gasket. 1. Install: • pilot screw kit 1 Pilot screw setting 2-1/2 turns out 2.
CARBURETORS CARB 3. Install: • pipes • fuel feed pipes • vacuum chamber pipe • vacuum chamber air vent hose • springs • float chamber air vent hoses • hose joints • spacers • copper washer • connecting bolts NOTE: • Do not tighten the connecting bolts, yet. • Install the throttle valve lever 1 onto carburetors #1, #2, and #4 between the spring 2 and synchronizing screw 3. 4. Install: • starter plunger link 1 NOTE: Install the starter plunger link 1 onto each starter plunger. T. R. 5.
CARBURETORS CARB EB600051 INSTALLING THE CARBURETORS 1. Adjust: • carburetor synchronization Refer to “SYNCHRONIZING THE CARBURETORS” in chapter 3. 2. Adjust: • engine idling speed Engine idling speed 1,050 ~ 1,150 r/min Refer to “ADJUSTING THE ENGINE IDLING SPEED” in chapter 3. 3. Adjust: • throttle cable free play Throttle cable free play (at the flange of the throttle grip) 3 ~ 5 mm Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3.
CARBURETORS CARB EB600063 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel level a Out of specification → Adjust. Fuel level (below the line on the float chamber) 4.1 ~ 5.1 mm ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Stand the motorcycle on a level surface. b. Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. c. Install the fuel level gauge 1 onto the fuel drain pipe 2. Fuel level gauge 90890-01312 d. Loosen the fuel drain bolt 3. e.
CARBURETORS CARB EB600072 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly adjusted. 1. Check: • throttle position sensor (installed on the carburetor) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the throttle position sensor coupler. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Tester positive probe → blue 1 Tester negative probe → black/blue 2 c.
CARBURETORS CARB 2. Check: • throttle position sensor (removed from the carburetor) ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Disconnect the throttle position sensor coupler. b. Remove the throttle position sensor from the carburetor. c. Connect the pocket tester (Ω × 1k) to the throttle position sensor. Tester positive probe → blue 1 Tester negative probe → black/blue 2 d. Measure the throttle position sensor maximum resistance. Out of specification → Replace the throttle position sensor.
CARBURETORS CARB 3. Adjust: • throttle position sensor angle ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Set the main switch to “ON”. b. Disconnect the throttle position sensor coupler. c. Reconnect the throttle position sensor coupler. NOTE: After reconnecting the throttle position sensor coupler, the tachometer switches to the throttle position sensor adjustment mode. d. Loosen the throttle position sensor screws 1. e. Adjust the throttle position sensor angle according to the following table.
CARBURETORS CARB EB600090 CHECKING THE FUEL PUMP 1. Check: • fuel pump 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the fuel tank. Refer to “FUEL TANK” in chapter 3. b. Disconnect the fuel-pump-to-carburetor fuel hose 2 from the carburetor. c. Connect the fuel-tank-to-fuel-pump fuel hose to the fuel tank and then set the fuel cock to “ON”. d. Place a container under the end of the fuel hose 2. e. Start the engine and check if fuel flows from the fuel hose 2. Fuel flows. Fuel pump is OK. Fuel does not flow.
CARB 6 - 16
CHAS 7
CHAS CHAPTER 7. CHASSIS FRONT WHEEL AND BRAKE DISCS ............................................................7-1 REMOVING THE FRONT WHEEL .........................................................7-3 DISASSEMBLING THE FRONT WHEEL ..............................................7-3 CHECKING THE FRONT WHEEL ..........................................................7-4 CHECKING THE BRAKE DISCS ............................................................7-5 ASSEMBLING THE FRONT WHEEL ...........................
CHAS HANDLEBARS .............................................................................................7-56 REMOVING THE HANDLEBARS ........................................................7-58 CHECKING THE HANDLEBARS .........................................................7-58 INSTALLING THE HANDLEBARS ......................................................7-59 STEERING HEAD ........................................................................................7-61 REMOVING THE LOWER BRACKET ........
6 FRONT WHEEL AND BRAKE DISCS CHAS EB700002 CHASSIS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. discs NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
FRONT WHEEL AND BRAKE DISCS CHAS EB700010 Order 1 2 3 Job/Part Disassembling the front wheel Oil seal (left and right) Wheel bearing (left and right) Spacer Q’ty Remarks Remove the parts in the order listed. 2 2 1 For assembly, reverse the disassembly procedure.
FRONT WHEEL AND BRAKE DISCS CHAS EB700102 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2. Remove: • left brake caliper • right brake caliper NOTE: Do not squeeze the brake lever when removing the brake calipers. 3.
FRONT WHEEL AND BRAKE DISCS CHAS EB700400 CHECKING THE FRONT WHEEL 1. Check: • wheel axle Roll the wheel axle on a flat surface. Bends → Replace. WARNING WARNING Do not attempt to straighten a bent wheel axle. 2. Check: • tire • front wheel Damage/wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Max. radial wheel runout 1.0 mm Max. lateral wheel runout 0.5 mm 4.
FRONT WHEEL AND BRAKE DISCS CHAS c. Remove the wheel bearings 3 with a general bearing puller. d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: ACHTUNG: Do not contact the wheel bearing center race 4 or balls 5. Contact should be made only with the outer race 6. NOTE: Use a socket 7 that matches the diameter of the wheel bearing outer race and oil seal.
FRONT WHEEL AND BRAKE DISCS CHAS 3. Measure: • brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification → Replace. Min. brake disc thickness Front: 4.5 mm Rear: 4.5 mm 4. Adjust: • brake disc deflection ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. T. R. Brake disc bolt 18 Nm (1.8 m • kg) LOCTITE d.
FRONT WHEEL AND BRAKE DISCS CHAS EB700725 INSTALLING THE FRONT WHEEL 1. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium soap base grease 18 Nm (1.8 m · kg) T. R. 2. Install: • brake discs NOTE: • Apply LOCTITE 648 to the threads of the brake disc bolts. • Tighten the brake disc bolts in stages and in a crisscross pattern. T. 3. Tighten: 72 Nm (7.2 m · kg) • wheel axle 1 • wheel axle pinch bolt 2 R. T. R. 23 Nm (2.
FRONT WHEEL AND BRAKE DISCS CHAS 1. Remove: • balancing weight(-s) 2. Find: • front wheel’s heavy spot ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Place the front wheel on a suitable balancing stand. b. Spin the front wheel. c. When the front wheel stops, put an “X1” mark at the bottom of the wheel. d. Turn the front wheel 90˚ so that the “X1” mark is positioned as shown. e. Release the front wheel. f. When the front wheel stops, put an “X2” mark at the bottom of the wheel. g.
FRONT WHEEL AND BRAKE DISCS CHAS 4. Check: • front wheel static balance ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Turn the front wheel and make sure that it stays at each position shown. b. If the front wheel does not remain stationary at all of the positions, rebalance it.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EB701000 REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET Order 1 2 3 4 5 6 7 8 9 10 Job/Part Removing the rear wheel Q’ty Brake caliper Locknut (left and right) Adjusting bolt (left and right) Wheel axle nut Washer Rear wheel axle Left adjusting block Right adjusting block Rear wheel Brake caliper bracket 1 2 2 2 1 1 1 1 1 1 Remarks Remove the parts in the order listed.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EB701010 Order 1 2 3 4 5 6 7 8 9 Job/Part Removing the brake disc and rear wheel sprocket Brake disc Rear wheel sprocket Oil seal cover (left and right) Spacer (left and right) Oil seal Bearing Rear wheel drive hub Rear wheel drive hub damper Rear wheel Q’ty Remarks Remove the parts in the order listed. 1 1 2 2 1 1 1 6 1 For installation, reverse the removal procedure.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET Order 1 2 3 4 5 6 Job/Part Disassembling the rear wheel Spacer Bearing Spacer Oil seal Circlip Bearing Q’ty CHAS Remarks Remove the parts in the order listed. 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EB701100 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: • brake caliper NOTE: Do not depress the brake pedal when removing the brake caliper. 3.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS 3. Measure: • radial wheel runout • lateral wheel runout Refer to “FRONT WHEEL”. Over the specified limits → Replace. Max. radial wheel runout 1.0 mm Max. lateral wheel runout 0.5 mm EB701430 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub 1 Cracks/damage → Replace. • rear wheel drive hub dampers 2 Damage/wear → Replace. EB701440 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1.
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET CHAS EB701710 INSTALLING THE REAR WHEEL 1. Lubricate: • wheel axle • wheel bearings • oil seal lips Recommended lubricant Lithium soap base grease 2. Adjust: • drive chain slack a Drive chain slack 40 ~ 50 mm Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. T. R. 3. Tighten: • wheel axle nut • brake caliper bolts 150 Nm (15.0 m · kg) T. R. 40 Nm (4.0 m · kg) WARNING WARNING Make sure that the brake hose is routed properly.
FRONT AND REAR BRAKES CHAS EB702001 FRONT AND REAR BRAKES Order 1 2 3 4 5 6 Job/Part Removing the front brake pads Q’ty Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. 2 1 1 2 2 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EB702002 Order 1 2 3 4 5 6 Job/Part Removing the rear brake pads Brake pad clip Brake pad pin Brake pad spring Brake pad Brake pad shim Bleed screw Q’ty Remarks Remove the parts in the order listed. 4 2 1 2 2 2 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EB702100 CAUTION: ACHTUNG: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components.
FRONT AND REAR BRAKES CHAS 2. Remove: • brake pad clips 1 • brake pad pin 2 • brake pad spring 3 • brake pads (along with the brake pad shims) 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: • brake pad shims (onto the brake pads) • brake pads • brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT AND REAR BRAKES T. R. 5. Install: • brake pad pin • brake pad clips • brake caliper CHAS 40 Nm (4.0 m · kg) 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.5 mm 4. Install: • brake pad shims (onto the brake pads) • brake pads • brake pad spring NOTE: Always install new brake pads, brake pad shims, and a brake pad spring as a set. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Connect a clear plastic hose 1 tightly to the bleed screw 2. Put the other end of the hose into an open container. b.
FRONT AND REAR BRAKES T. R. 5. Install: • brake pad pins • brake pad clips • brake pad cover • brake caliper CHAS 40 Nm (4.0 m · kg) 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: • brake pedal operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
FRONT AND REAR BRAKES CHAS EB702200 Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Removing the front brake master cylinder and brake fluid reservoir Brake fluid Brake fluid reservoir cap stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir Brake fluid reservoir hose Circlip Hose joint Brake lever Front brake switch connector Union bolt Copper washer Q’ty Remarks Remove the parts in the order listed. Drain.
FRONT AND REAR BRAKES Order 13 14 15 16 Job/Part Brake hose Brake master cylinder holder Brake master cylinder Front brake switch Q’ty 2 1 1 1 CHAS Remarks For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EB702201 Order 1 2 3 4 Job/Part Disassembling the front brake master cylinder Dust boot Circlip Brake master cylinder kit Brake master cylinder Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EB702202 Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Q’ty Remarks Removing the rear brake master cylRemove the parts in the order listed. inder and brake fluid reservoir Brake fluid Drain.
FRONT AND REAR BRAKES CHAS EB702203 Order 1 2 Job/Part Disassembling the rear brake master cylinder Brake master cylinder kit Brake master cylinder Q’ty Remarks Remove the parts in the order listed. 1 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EB702210 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hoses 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. EB702220 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 1.
FRONT AND REAR BRAKES CHAS 2. Check: • brake master cylinder kit Damage/scratches/wear → Replace. Å Å Front ı Rear ı Å 3. Check: • brake fluid reservoir 1 Cracks/damage → Replace. • brake fluid reservoir diaphragm 2 Cracks/damage → Replace. ı 4. Check: • brake hoses Cracks/damage/wear → Replace. EB702283 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid.
FRONT AND REAR BRAKES CHAS 1. Install: • brake master cylinder 1 T. R. 13 Nm (1.3 m · kg) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. • Align the end of the brake master cylinder holder with the punch mark a in the right handlebar. • First, tighten the upper bolt, then the lower bolt. New T. R. 2. Install: • copper washers • brake hose • union bolt 30 Nm (3.0 m · kg) WARNING WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
FRONT AND REAR BRAKES CHAS CAUTION: ACHTUNG: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system.
FRONT AND REAR BRAKES CHAS 2. Fill: • brake fluid reservoir Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. • When refilling, be careful that water does not enter the reservoir.
FRONT AND REAR BRAKES CHAS EB702301 Order 1 2 3 4 Job/Part Removing the front brake calipers Q’ty Brake fluid Union bolt Copper washer Brake hose Brake caliper Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. Drain. 1 2 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EB702303 Order Job/Part Disassembling the front brake calipers Q’ty Remarks Remove the parts in the order listed. The following procedure applies to both of the front brake calipers. 1 2 3 4 5 6 7 Brake pad clip Brake pad pin Brake pad spring Brake pad Brake caliper piston Brake caliper piston seal Bleed screw 2 1 1 2 4 8 1 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EB702304 Order 1 2 3 4 Job/Part Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake caliper Q’ty Remarks Remove the parts in the order listed. Drain. 1 2 1 1 For installation, reverse the removal procedure.
FRONT AND REAR BRAKES CHAS EB702305 Order 1 2 3 4 5 6 7 Job/Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. Brake pad clip 4 Brake pad pin 2 Brake pad spring 1 Brake pad 2 Brake caliper piston 2 Brake caliper piston seal 4 Bleed screw 2 For assembly, reverse the disassembly procedure.
FRONT AND REAR BRAKES CHAS EB702317 DISASSEMBLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. NOTE: Before disassembling either brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • brake caliper pistons 1 • brake caliper piston seals 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a.
FRONT AND REAR BRAKES CHAS EB702322 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • brake caliper pistons 1 • brake caliper piston seals 2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Secure the right side brake caliper piston with a piece of wood a. b.
FRONT AND REAR BRAKES CHAS EB702343 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every two years Brake fluid Every two years and whenever the brake is disassembled 1. Check: • brake caliper pistons 1 Rust/scratches/wear → Replace the brake caliper. • brake caliper cylinders 2 Scratches/wear → Replace the brake caliper. • brake calipers Cracks/damage → Replace.
FRONT AND REAR BRAKES CHAS EB702376 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals.
FRONT AND REAR BRAKES CHAS 4. Fill: • brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT AND REAR BRAKES CHAS EB702378 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components as they will cause the piston seals to swell and distort. • Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Recommended brake fluid DOT 4 New T. R. 1.
FRONT AND REAR BRAKES CHAS 4. Fill: • brake fluid reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
FRONT FORK CHAS EB703001 FRONT FORK Order Job/Part Removing the front fork legs Q’ty Front wheel 1 2 3 4 5 6 Front cowling inner panels Front fender Upper bracket pinch bolt Cap bolt Handlebar pinch bolt Lower bracket pinch bolt Front fork leg Remarks Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Refer to “FRONT WHEEL AND BRAKE DISCS”. Refer to “COWLINGS” in chapter 3. 1 1 1 1 2 1 For installation, reverse the removal procedure.
FRONT FORK CHAS EB703002 Order 1 2 3 4 5 6 7 8 9 0 A B Job/Part Disassembling the front fork legs Q’ty Cap bolt O-ring Spacer Nut Spring seat Fork spring Damper adjusting rod Outer tube Dust seal Oil seal clip Oil seal Washer 1 1 1 1 1 1 1 1 1 1 1 1 7 - 45 Remarks Remove the parts in the order listed. The following procedure applies to both of the front fork legs.
FRONT FORK Order C D E F Job/Part Damper rod assembly bolt Copper washer Damper rod assembly Inner tube Q’ty 1 1 1 1 CHAS Remarks For assembly, reverse the disassembly procedure.
FRONT FORK CHAS EB703100 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. 2.
FRONT FORK CHAS NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring compressor WARNING WARNING The fork spring is compressed. f. Remove the spacer and nut. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Drain: • fork oil NOTE: Stroke the damper rod 1 several times while draining the fork oil. 3. Remove: • dust seal • oil seal clip 1 • oil seal • washer (with a flat-head screwdriver) 4.
FRONT FORK CHAS EB703401 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube 1 • outer tube 2 Bends/damage/scratches → Replace. WARNING WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Measure: • spring free length a Out of specification → Replace. Spring free length limit 255 mm 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil passages with compressed air.
FRONT FORK CHAS 4. Check: • cap bolt O-ring Damage/wear → Replace. EB703702 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING WARNING • Make sure that the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor handling and a loss of stability.
FRONT FORK CHAS 3. Tighten: • damper rod assembly bolt 1 T. R. 40 Nm (4.0 m · kg) NOTE: While holding the damper rod with the damper rod holder 2, tighten the damper rod assembly bolt. Damper rod holder 90890-01423 4. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION: ACHTUNG: Make sure that the numbered side of the oil seal faces up. NOTE: • Before installing the oil seal, lubricate its lips with lithium soap base grease.
FRONT FORK CHAS 8. Install: • dust seal 1 (with the fork seal driver 2) 9. Install: • rod puller 1 • adapter 2 (onto the damper rod 3) Rod puller 90890-01437 Adapter 90890-01436 10.Fully compress the front fork leg. 11.Fill: • front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 477 cm3 Recommended oil Yamaha fork and shock oil 01 or equivalent CAUTION: ACHTUNG: • Be sure to use the recommended fork oil.
FRONT FORK CHAS 13.Slowly stroke the outer tube 1 up and down to distribute the fork oil once more (1 stroke = about 100 mm). NOTE: Be careful not to stroke the inner tube over 100 mm as this will cause air to enter. If the inner tube is stroked more than 100 mm, repeat steps (12) and (13). 14.Before measuring the fork oil level, wait ten minutes until the oil has settled and the air bubbles have dispersed. NOTE: Be sure to bleed the front fork leg of any residual air. 15.
FRONT FORK CHAS c. Install the rod puller and adapter onto the damper rod. Rod puller 90890-01437 Adapter 90890-01436 d. Install the fork spring, spring seat, and spacer. NOTE: Install the spring with the smaller pitch a facing up Å. e. Press down on the spacer with the fork spring compressor 7. f. Pull up the rod puller and install the rod holder 8 between the nut 1 and the spacer 4. NOTE: Use the side of the rod holder that is marked “B”. Fork spring compressor 90890-01441 Rod holder 90890-01434 g.
FRONT FORK CHAS 17.Install: • outer tube (onto the inner tube) NOTE: Temporarily tighten the cap bolt. EB703710 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: • lower bracket pinch bolt T. R. 23 Nm (2.3 m · kg) • handlebar pinch bolt 1 T. R. 17 Nm (1.7 m · kg) T.
HANDLEBARS CHAS EB704001 HANDLEBARS Order 1 2 3 4 5 6 7 8 9 10 11 12 Job/Part Removing the handlebars Left grip end Handlebar grip Clutch switch connector Left handlebar switch Starter cable Starter lever Clutch cable Clutch lever Right grip end Throttle cable housing Throttle cable Throttle grip Q’ty 1 1 2 1 1 1 1 1 1 1 2 1 7 - 56 Remarks Remove the parts in the order listed. Disconnect. Disconnect. Disconnect.
HANDLEBARS Order 13 14 15 16 17 18 19 20 21 22 23 Job/Part Front brake switch connector Right handlebar switch Brake master cylinder holder Brake master cylinder Handlebar pinch bolt Upper bracket bolt Upper bracket pinch bolt Steering stem nut Upper bracket Left handlebar Right handlebar CHAS Q’ty Remarks 2 Disconnect. 1 1 1 2 2 2 1 1 1 1 For installation, reverse the removal procedure.
HANDLEBARS CHAS EB704101 REMOVING THE HANDLEBARS 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • handlebar grip NOTE: Blow compressed air between the left handlebar and the handlebar grip, and gradually push the grip off the handlebar. 3. Remove: • throttle cable housing 1 • throttle grip 2 NOTE: Pull back the rubber cover 3 when removing the throttle cable housing.
HANDLEBARS CHAS EB704704 INSTALLING THE HANDLEBARS 1. Install: • right handlebar switch 1 NOTE: Align the projection a on the right handlebar switch with the hole b in the right handlebar. 2. Install: • brake master cylinder holder 1 CAUTION: ACHTUNG: • Install the brake master cylinder holder with the “UP” mark facing up. • First, tighten the upper bolt, then the lower bolt. NOTE: • Align the mating surfaces of the brake master cylinder holder with the punch mark a in the right handlebar.
HANDLEBARS CHAS 5. Install: • left handlebar switch 1 NOTE: Align the projection a on the left handlebar switch with the hole b in the left handlebar. 6. Install: • handlebar grip ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Apply a thin coat of rubber adhesive onto the end of the left handlebar. b. Slide the handlebar grip over the end of the left handlebar. c. Wipe off any excess rubber adhesive with a clean rag. WARNING WARNING Do not touch the handlebar grip until the rubber adhesive has fully dried.
STEERING HEAD CHAS EB705001 STEERING HEAD Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the lower bracket Front wheel Q’ty Front fork legs Main switch coupler Upper bracket bolt Left handlebar assembly Right handlebar assembly Steering stem nut Upper bracket Lower bracket panel Brake hose holder bolt Lock washer Upper ring nut Rubber washer 2 2 1 1 1 1 1 2 1 1 1 7 - 61 Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISCS”. Refer to “FRONT FORK”. Disconnect.
STEERING HEAD Order 12 13 14 15 16 17 18 19 Job/Part Lower ring nut Lower bracket Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal Bearing outer race Q’ty 1 1 1 2 1 1 1 2 CHAS Remarks For installation, reverse the removal procedure.
STEERING HEAD CHAS EB705100 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: • lower ring nut 1 (with the special tool 2) Ring nut wrench 90890-01403 WARNING WARNING Securely support the lower bracket so that there is no danger of it falling. EB705401 CHECKING THE STEERING HEAD 1. Wash: • bearing balls • bearing races Recommended cleaning solvent Kerosine 2.
STEERING HEAD CHAS b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. c. Install a new dust seal and new bearing races. CAUTION: ACHTUNG: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: • Always replace the bearing balls and bearing races as a set. • Whenever the steering head is disassembled, replace the dust seal. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 4.
CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the upper and lower bracket pinch bolts, and handlebar pinch bolts. 5. Tighten: • steering stem nut T. R. 115 Nm (11.5 m · kg) • lower bracket pinch bolt T. R. 23 Nm (2.3 m · kg) • upper bracket pinch bolt T. R. 23 Nm (2.3 m · kg) • upper bracket bolt T. R. 13 Nm (1.3 m · kg) • handlebar pinch bolt T. R.
REAR SHOCK ABSORBER ASSEMBLY CHAS EB706000 REAR SHOCK ABSORBER ASSEMBLY Order 1 2 3 4 5 6 7 8 9 10 11 Job/Part Removing the rear shock absorber assembly Self-locking nut/bolt Self-locking nut/bolt Self-locking nut/bolt/spacer Rear shock absorber assembly Spacer/oil seal/bearing Self-locking nut/bolt Relay arm Spacer/oil seal/bearing Self-locking nut/bolt/spacer Connecting arm Spacer/oil seal/bearing Q’ty Remarks Remove the parts in the order listed.
REAR SHOCK ABSORBER ASSEMBLY CHAS EB706101 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder.
REAR SHOCK ABSORBER ASSEMBLY CHAS EB706204 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2. Remove: • rear shock absorber assembly lower bolt 1 • relay-arm-to-swingarm bolt 2 NOTE: While removing the rear shock absorber assembly lower bolt, hold the swingarm so that it does not drop down.
REAR SHOCK ABSORBER ASSEMBLY CHAS CHECKING THE RELAY ARM AND CONNECTING ARM 1. Check: • relay arm 1 • connecting arm 2 Damage/wear → Replace. • bearings • oil seals Damage/pitting → Replace. • spacers Damage/scratches → Replace. EB706701 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1. Lubricate: • bearings • oil seals • spacers Recommended lubricant Lithium soap base grease 2.
SWINGARM AND DRIVE CHAIN CHAS EB707000 SWINGARM AND DRIVE CHAIN Order Job/Part Removing the swingarm and drive chain Drive sprocket Rear wheel Q’ty Refer to “ENGINE” in chapter 4. Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET”. Refer to “REAR SHOCK ABSORBER ASSEMBLY”. Rear shock absorber assembly 1 2 3 4 5 6 7 Adjusting bolt/locknut Drive chain guard Rear fender Brake hose holder Pivot shaft nut/washer Pivot shaft Swingarm Remarks Remove the parts in the order listed.
SWINGARM AND DRIVE CHAIN Order 8 9 10 11 12 13 Job/Part Drive chain Dust cover Drive chain guide Spacer Left bearing Right bearing Q’ty 1 2 1 1 1 1 CHAS Remarks For installation, reverse the removal procedure.
SWINGARM AND DRIVE CHAIN CHAS EB707100 NOTE: Before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a tenlink section of the drive chain. EB707111 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. WARNING WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated. 2.
SWINGARM AND DRIVE CHAIN CHAS EB707120 REMOVING THE DRIVE CHAIN 1. Remove: • drive chain (with the drive chain cutter) Drive chain cutter 90890-01286 NOTE: Only cut the drive chain if it or the swingarm is to be replaced. EB707400 CHECKING THE SWINGARM 1. Check: • swingarm Bends/cracks/damage → Replace. NOTE: If the swingarm must be replaced, the drive chain must be cut with a drive chain cutter. 2. Check: • pivot shaft Roll the pivot shaft on a flat surface. Bends → Replace.
SWINGARM AND DRIVE CHAIN CHAS 4. Check: • dust covers • spacer • oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EB707410 CHECKING THE DRIVE CHAIN 1. Measure: • ten-link section a of the drive chain Out of specification → Replace the drive chain. Max. ten-link drive chain section 150.1 mm NOTE: • While measuring the ten-link section, push down on the drive chain to increase its tension. • Measure the length between drive chain roller 1 and A as shown.
SWINGARM AND DRIVE CHAIN CHAS c. Remove the drive chain from the kerosine and completely dry it. CAUTION: ACHTUNG: This motorcycle has a drive chain with small rubber O-rings 1 between the drive chain side plates. Never use highpressure water or air, steam, gasoline, certain solvents (e.g., benzine), or a coarse brush to clean the drive chain. High-pressure methods could force dirt or water into the drive chain’s internals, and solvents will deteriorate the Orings.
CHAS SWINGARM AND DRIVE CHAIN EB707700 INSTALLING THE SWINGARM 1. Lubricate: • bearings • spacers • dust covers • pivot shaft Recommended lubricant Lithium soap base grease T. R. 2. Install: • swingarm • pivot shaft • washer • pivot shaft nut 125 Nm (12.5 m · kg) 3. Install: • rear shock absorber assembly • rear wheel Refer to “REAR SHOCK ABSORBER ASSEMBLY” and “REAR WHEEL”. 4. Adjust: • drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3.
– ELEC + 8
ELEC CHAPTER 8. ELECTRICAL ELECTRICAL COMPONENTS .......................................................................8-1 INSTRUMENT FUNCTIONS .........................................................................8-2 INDICATOR LIGHTS .............................................................................8-2 OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT .................8-2 COMBINATION METER ........................................................................8-3 SWITCHES ........................
ELEC SIGNALING SYSTEM .................................................................................8-35 CIRCUIT DIAGRAM .............................................................................8-35 TROUBLESHOOTING .........................................................................8-37 CHECKING THE SIGNALING SYSTEM .............................................8-38 COOLING SYSTEM .....................................................................................8-44 CIRCUIT DIAGRAM ...........
ELECTRICAL COMPONENTS ELEC EB800000 ELECTRICAL ELECTRICAL COMPONENTS 1 Wire harness 2 Main switch 3 Front brake light switch 4 Ignition coils 5 Clutch switch 6 EXUP servomotor 7 Relay unit 8 Fuse box 9 Turn signal relay 0 Ignitor unit A Starter relay B Main fuse C Oil level relay D Battery E Rectifier/regulator F Rear brake light switch G Neutral switch H Speed sensor I Sidestand switch J Stator coil assembly 8-1 K Oil level switch L Pickup coil M Radiator fan N Horn O Temperature sender P Thermo swit
INSTRUMENT FUNCTIONS ELEC – + INSTRUMENT FUNCTIONS INDICATOR LIGHTS 1 Neutral indicator light “ ” 2 High beam indicator light “ 3 Turn indicator light “ ” 4 Fuel indicator light “ ” Turn indicator light “ ” This indicator flashes when the turn switch is moved to the left or right. Neutral indicator light “ ” This indicator comes on when the transmission is in neutral. High beam indicator light “ ” This indicator comes on when the headlight high beam is used.
INSTRUMENT FUNCTIONS Coolant temperature Display Conditions ELEC – + What to do 0 ˚C ~ 40 ˚C Symbol is on and Go ahead with riding. “LO” is displayed. 41 ˚C ~ 117 ˚C Symbol is on and temperature is dis- Go ahead with riding. played. 118 ˚C ~ 140 ˚C Stop the motorcycle and allow it to idle until Symbol and tem- the coolant temperature perature flashes goes down. and indicator light If the temperature does comes on. not go down, stop the engine. Refer to “OVERHEATING” in chapter 9.
INSTRUMENT FUNCTIONS ELEC – + When the fuel level indicator light comes on the odometer display will automatically change to the fuel reserve trip meter mode “TRIP F” and start counting the distance traveled from that point. Push the “SELECT” button to change between the fuel odometer, trip odometer and odometer modes in the following order: “TRIP F” → “TRIP 1” → “TRIP 2” → “ODO” → “TRIP F” To reset a trip odometer to 0.
SWITCHES ELEC – + EB801000 SWITCHES CHECKING SWITCH CONTINUITY Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. CAUTION: ACHTUNG: Never insert the tester probes into the coupler terminal slots 1. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.
CHECKING THE SWITCHES ELEC – + EB801010 CHECKING THE SWITCHES Check each switch for damage or wear, proper connections, and also for continuity between the terminals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect. Incorrect continuity reading → Replace the switch.
CHECKING THE SWITCHES 1 Main switch 2 Pass switch 3 Dimmer switch 4 Turn signal switch 5 Horn switch 6 Clutch switch 7 Light switch 8 Engine stop switch 9 Start switch 0 Front brake light switch A Fuse B Sidestand switch C Rear brake light switch D Neutral switch E Oil level switch 8-7 ELEC – +
CHECKING THE BULBS AND BULB SOCKETS ELEC – + EB801020 CHECKING THE BULBS AND BULB SOCKETS Check each bulb and bulb socket for damage or wear, proper connections, and also for continuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both. Improperly connected → Properly connect. Incorrect continuity reading → Repair or replace the bulb, bulb socket or both. TYPES OF BULBS The bulbs used on this motorcycle are shown in the illustration on the left.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + WARNING WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: ACHTUNG: • Be sure to hold the socket firmly when removing the bulb. Never pull the lead, otherwise it may be pulled out of the terminal in the coupler.
CHECKING THE BULBS AND BULB SOCKETS ELEC – + CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester 90890-03112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a. Install a good bulb into the bulb socket. b.
8 - 11 L Br/L Br/L Br/L Br/L L/R Br/L L/Y B B B L j k l (Option) m n B L B B L i h Br B B B B B B B (BLACK) R/Y Br B B B B B B B B B B B B B B B B B R/W R Br/L R Br/L B B L/Y L/R L 3 L/Y L/B L L/R Br L B R W W W Br Y (BLACK) B B R/Y L Y B R/Y B A Y L/R R/Y R/Y Y B B B/Y W/Y R/Y B/Y B R/Y W/Y L/R B A f A L/R L/B u B A L/R B Br G e L/R B d B/W L/R B/L B/Y B B/Y Br B Br G B/Y B/L B/L — [ B B e G W/Y W/G Y B B L/W B B
IGNITION SYSTEM ELEC – + EB802401 EB802011 TROUBLESHOOTING 2.Battery The ignition system fails to operate (no spark or intermittent spark). • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. spark plugs 4. ignition spark gap 5. spark plug cap resistance 6. ignition coil resistance 7. pickup coil resistance 8. main switch 9. engine stop switch 10. neutral switch 11. sidestand switch 12. relay unit 13.
IGNITION SYSTEM ELEC – + EB802405 Spark plug cap resistance 10 kΩ at 20 ˚C 4.Ignition spark gap • • • • • • The following procedure applies to all of the spark plugs. Disconnect the spark plug cap from the spark plug. Connect the ignition checker 1 as shown. 2Spark plug cap Set the main switch to “ON”. Measure the ignition spark gap a. Crank the engine by pushing the start switch and gradually increase the spark gap until a misfire occurs.
IGNITION SYSTEM – ELEC + EB802411 8.Main switch • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? YES NO Replace the main switch. Secondary coil resistance 12 ~ 18 kΩ at 20 ˚C • Is the ignition coil OK? EB802412 9.Engine stop switch NO YES • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? Replace the ignition coil. YES EB802410 NO 7.
IGNITION SYSTEM ELEC – + EB802416 EB802415 12.Relay unit 13.Wiring • Remove the relay unit from the wire harness. • Connect the pocket tester (Ω × 1) to the relay unit terminals as shown. • Check the starting circuit cutoff relay for continuity. • Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”.
8 - 16 L Br/L Br/L Br/L Br/L L/R Br/L L/Y B B j k l (Option) m n B L B B Br B B B B B B B L i (BLACK) R/Y Br B B B B B B B B B B B B B B B B B R/W R Br/L R Br/L B B L/Y L/R L 3 L/Y L/B L L/R Br L B R W W W Br Y B B L (BLACK) B R/Y Y L Y B B R/Y Y L/R R/Y R/Y B B B/Y W/Y R/Y B/Y B R/Y W/Y L/R B A L/R L/B u B A L/R B Br G e L/R B d B/W L/R B/L B/Y B B/Y Br B Br G B/Y B/L B/L — [ B B e G W/Y W/G Y B B L/W B B \ c B B C
ELECTRIC STARTING SYSTEM ELEC – + EB803010 STARTING CIRCUIT CUTOFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed) and the sidestand is up (the sidestand switch is closed).
ELECTRIC STARTING SYSTEM ELEC – + EB802401 EB803020 TROUBLESHOOTING 2.Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. starter motor 4. starting circuit cutoff relay 5. relay unit 6. starter relay 7. main switch 8. engine stop switch 9. neutral switch 10. sidestand switch 11. clutch switch 12. start switch 13.
ELECTRIC STARTING SYSTEM ELEC – + EB803403 EB803402 4.Starting circuit cutoff relay 5.Relay unit • Disconnect the relay unit from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the relay unit terminals as shown. • Disconnect the relay unit from the coupler. • Connect the pocket tester (Ω × 1) to the relay unit terminals as shown. • Measure the starting circuit cutoff relay for continuity as follows.
ELECTRIC STARTING SYSTEM – ELEC + EB802412 EB803404 6.Starter relay 8.Engine stop switch • Disconnect the starter relay from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the starter relay coupler as shown. • Check the engine stop switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the engine stop switch OK? YES Battery positive terminal → red/white 1 Battery negative terminal → blue/white 2 NO Replace the right handlebar switch.
ELECTRIC STARTING SYSTEM EB803406 12.Start switch • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the start switch OK? YES NO Replace the right handlebar switch. EB803408 13.Wiring • Check the entire starting system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the starting system’s wiring properly connected and without defects? NO Properly connect or repair the starting system’s wiring. YES The starting system circuit is OK.
STARTER MOTOR ELEC – EB803500 STARTER MOTOR Order 1 2 3 4 Job/Part Removing the starter motor Rider seat Fuel tank Left side cowling EXUP servomotor Throttle stop screw Starter motor lead Starter motor assembly Q’ty Remarks Remove the parts in the order listed. Refer to “SEATS” in chapter 3. Refer to “FUEL TANK” in chapter 3. Refer to “COWLINGS” in chapter 3. 1 1 1 1 For installation, reverse the removal procedure.
STARTER MOTOR ELEC – + EB803501 Order 1 2 3 4 5 6 7 8 9 0 A B Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed.
STARTER MOTOR ELEC – + EB803511 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter 27 mm 3. Measure: • mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut 0.7 mm NOTE: The mica must be undercut to ensure proper operation of the commutator. 4.
STARTER MOTOR ELEC – + 5. Measure: • brush length a Out of specification → Replace the brushes as a set. Min. brush length 5 mm 6. Measure: • brush spring force Out of specification → Replace the brush springs as a set. Brush spring force 7.03 ~ 10.63 N (717 ~ 1,084 gf) 7. Check: • gear teeth Damage/wear → Replace the gear. 8. Check: • bearing • oil seal Damage/wear → Replace the defective part(-s). EB803701 ASSEMBLING THE STARTER MOTOR 1.
– ELEC CHARGING SYSTEM + EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 2 R/G R/G R W W W W W W R R R R R R R R L/W R/W 6 5 R/W B B R W W W R 3 P OFF ON L/R Br/L L/Y L Br/L L/Y L/B L L/R B L/Y L/R L R Br/L R Br/L W W W W 4 B 1 W W B n 8 B B B B B B B B B B B B B B B B B B B B B W R/L Br B (BLACK) R/L r Br o W (BROWN) Br/R L L/B B B B B (BROWN) (BLACK) l Br R/W B R/B B G/Y R/W Br R/B B G/Y L/W (BROWN) s t • B (Option) Br/L B R/W m Br/L B L/W B B
CHARGING SYSTEM ELEC – + EB802401 EB804010 TROUBLESHOOTING 2.Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main fuse 2. battery 3. charging voltage 4. stator coil assembly resistance 5. wiring (of the entire charging system) Open-circuit voltage 12.
CHARGING SYSTEM ELEC – + EB804404 5.Wiring NOTE: Make sure that the battery is fully charged. • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly connected and without defects? • Is the charging voltage within specification? NO YES NO The charging circuit is OK. Properly connect or repair the charging system’s wiring. EB804401 4.Stator coil assembly resistances • Remove the generator cover.
P OFF ON 1 L 8 - 29 Br/L Br/L Br/L Br/L L/R Br/L L/Y R B B B L j k l (Option) m n L i B h Br B B B B B B B (BLACK) B B R/Y Br (BLACK) B L B B B B B B B B B B B B B B B B B R/W R Br/L R Br/L B B L/Y L/R L 3 L/Y L/B L L/R Br L B R W W W R Br Y B R/Y A • L Y B R/Y B A Y L/R R/Y R/Y Y B B B/Y W/Y R/Y B/Y B R/Y W/Y L/R B A L/R L/B u B A d B e L/R B Br G B/W L/R B/L B/Y B B/Y Br L/R B Br G B/Y B/L B/L — [ B B e G W/Y W/G Y
LIGHTING SYSTEM ELEC – + EB802401 EB805010 TROUBLESHOOTING 2.Battery Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light or meter light. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Open-circuit voltage 12.8 V or more at 20 ˚C Check: 1. main, signaling system, and headlight fuses 2. battery 3. main switch 4. lights switch 5. dimmer switch 6. pass switch 7.
LIGHTING SYSTEM EB805401 ELEC – + EB805410 CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator light fail to come on. 5.Dimmer switch • Check the dimmer switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the dimmer switch OK? YES 1.Headlight bulb and socket • Check the headlight bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. • Are the headlight bulb and socket OK? NO The dimmer switch is faulty. Replace the left handlebar switch.
LIGHTING SYSTEM ELEC – + Headlight Tester positive probe → black/yellow 1 or black/blue 2 Tester negative probe → black 3 High beam indicator light Tester positive probe → yellow 4 Tester negative probe → black 5 Meter assembly coupler (wire harness side) • Does the headlight relay have continuity between white/yellow (white/green) and black? NO YES This circuit is OK. • Set the main switch to “ON”. • Set the light switch to “ ”. • Set the dimmer switch to “ ” or “ ”.
LIGHTING SYSTEM This circuit is OK. – + • Set the main switch to “ON”. • Set the light switch to “ ” or “ ”. • Measure the voltage (12 V) of blue/red 1 on the tail/brake light coupler (wire harness side). • Is the voltage within specification? • Set the main switch to “ON”. • Set the light switch to “ ” or “ ”. • Measure the voltage (12 V) of blue 1 on the meter assembly coupler (wire harness side). • Is the voltage within specification? NO YES ELEC NO YES This circuit is OK.
LIGHTING SYSTEM • Set the main switch to “ON”. • Set the light switch to “ ” or “ ”. • Measure the voltage (12 V) of blue/red 1 on the auxiliary light couplers (wire harness side). • Is the voltage within specification? YES This circuit is OK. NO The wiring circuit from the main switch to the auxiliary light connectors is faulty and must be repaired.
P OFF ON 1 L 8 - 35 Br/L Br/L Br/L Br/L L/R Br/L L/Y R B B B L j k l (Option) m n L i B h Br B B B B B B B (BLACK) B B R/Y Br (BLACK) B L B B B B B B B B B B B B B B B B B R/W R Br/L R Br/L B B L/Y L/R L 3 L/Y L/B L L/R Br L B R W W W R Br Y B R/Y A • L Y B R/Y B A Y L/R R/Y R/Y Y B B B/Y W/Y R/Y B/Y B R/Y W/Y L/R B A L/R L/B u B A L/R B Br G e L/R B d B/W L/R B/L B/Y B B/Y Br B Br G B/Y B/L B/L — [ B B e G W/Y W/G Y
SIGNALING SYSTEM 1 Main switch 5 Battery 6 Main fuse D Fuel sender K Neutral switch O Fuel level indicator light P Oil level/coolant temperature warning light Q Neutral indicator light R Tachometer S Combination meter V Turn signal indicator light [ Horn switch \ Horn _ Turn signal switch a Turn signal relay b Rear turn signal light c Front turn signal light g Tail/brake light l Signaling system fuse o Oil level relay p Oil level switch q Rear brake light switch s Front brake light switch 8 - 36 ELEC –
SIGNALING SYSTEM ELEC – + EB802401 EB806010 TROUBLESHOOTING 2.Battery • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • Check the condition of the battery. Refer to “CHECKING THE BATTERY” in chapter 3. Open-circuit voltage 12.8 V or more at 20 ˚C Check: 1. main and signaling system fuses 2. battery 3. main switch 4. wiring (of the entire signaling system) • Is the battery OK? YES NO • Clean the battery terminals.
SIGNALING SYSTEM ELEC – + EB806410 3.Horn CHECKING THE SIGNALING SYSTEM 1. The horn fails to sound. • Disconnect the black connector at the horn terminal. • Connect a jumper lead 1 to the horn terminal and ground the jumper lead. • Set the main switch to “ON”. • Push the horn switch. • Does the horn sound? 1.Horn switch • Check the horn switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the horn switch OK? YES NO Replace the left handlebar switch. 2.
SIGNALING SYSTEM ELEC – + EB806411 • Set the main switch to “ON”. • Pull in the brake lever or push down on the brake pedal. • Measure the voltage (12 V) of yellow at the tail/brake light coupler (wire harness side). • Is the voltage within specification? 2. A tail/brake light fails to come on. 1.Tail/brake light bulb and socket • Check the tail/brake light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”.
SIGNALING SYSTEM – + Tester positive probe → brown/white 1 Tester negative probe → ground 3.Turn signal switch • Check the turn signal switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the turn signal switch OK? YES ELEC NO Replace the left handlebar switch. • Set the main switch to “ON”. • Set the turn signal switch to “ ” or “ ”. • Measure the voltage (12V) of brown/ white at the turn signal relay coupler (wire harness side). • Is the voltage within specification? 4.
SIGNALING SYSTEM + • Connect the pocket tester (DC 20V) to the meter assembly coupler (wire harness side) as shown. Tester positive probe → brown 1 Tester negative probe → sky blue 2 NO YES The wiring circuit from the turn signal switch to the turn signal light connector is faulty and must be repaired. • Set the main switch to “ON”. • Measure the voltage (12 V) of brown 1 and sky blue 2 at the meter assembly coupler. • Is the voltage within specification? EB806414 4.
SIGNALING SYSTEM ELEC – + 2.Oil level switch 4.Voltage • Drain the engine oil and remove the oil level switch from the oil pan. • Check the oil level switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the oil level switch OK? • Connect the pocket tester (DC 20V) to the meter assembly coupler (wire harness side) as shown. YES Tester positive probe → brown 1 Tester negative probe → black/red 2 NO Replace the oil level switch. 3.
SIGNALING SYSTEM • Disconnect the fuel sender coupler from the wire harness. • Drain the fuel from the fuel tank and remove the fuel sender from the fuel tank. • Check the fuel sender for continuity. YES This circuit is OK. Tester positive probe → green 1 Tester negative probe → black 2 • Is the fuel sender OK? NO Replace sender. the – + • Set the main switch to “ON”. • Measure the voltage (12V). • Is the voltage within specification? 2.Fuel sender YES ELEC fuel 3.
P OFF ON 1 L 8 - 44 Br/L Br/L Br/L Br/L L/R Br/L L/Y R B B B L j k l (Option) m n L i B h Br B B B B B B B (BLACK) B B R/Y Br (BLACK) B L B B B B B B B B B B B B B B B B B R/W R Br/L R Br/L B B L/Y L/R L 3 L/Y L/B L L/R Br L B R W W W R Br Y B R/Y A • L Y B R/Y B A Y L/R R/Y R/Y Y B B B/Y W/Y R/Y B/Y B R/Y W/Y L/R B A f A L/R L/B u B A L/R B Br G e L/R B d B/W L/R B/L B/Y B B/Y Br B Br G B/Y B/L B/L — [ B B e G W/Y
COOLING SYSTEM – ELEC + EB807010 • Is the battery OK? TROUBLESHOOTING • The radiator fan motor fails to turn. • The coolant temperature meter needle fails to move when the engine is warm. NO YES • Clean the battery terminals. • Recharge or replace the battery. Check: 1. main, signal system, and radiator fan motor fuses 2. battery 3. main switch 4. radiator fan motor 5. thermo switch 6. temperature sender 7. wiring (the entire cooling system) EB802411 3.
COOLING SYSTEM – ELEC + EB807400 5.Radiator fan motor (test 2) • Disconnect the thermo switch coupler. • Set the main switch to “ON”. • Connect the brown 1 and blue 2 terminals with a jumper lead 3 as shown.
COOLING SYSTEM ELEC – + • Does the thermo switch operate properly as described above? NO YES Replace the thermo switch. 7.Temperature sender WARNING WARNING • Remove the temperature sender from the radiator. • Connect the pocket tester (Ω × 10) to the temperature sender 1 as shown. • Immerse the temperature sender in a container filled with water 2. • Place a thermometer 3 in the water. • Slowly heat the water, then let it cool down to the specified temperature.
8 - 48 L Br/L Br/L Br/L Br/L L/R Br/L L/Y R B B B L j k l (Option) m n Br L L i B h Br B B B B B B B (BLACK) B B R/Y Br (BLACK) B L B B B B B B B B B B B B B B B B B R/W R Br/L R Br/L B B L/Y L/R L L/Y L/B L L/R 3 Br Y B R/Y A • L Y B R/Y B A Y L/R R/Y R/Y Y B B B/Y W/Y R/Y B/Y B R/Y W/Y L/R B A L/R L/B u B A d B e L/R B Br G B/W L/R B/L B/Y B B/Y Br L/R B Br G B/Y B/L B/L — [ B B e G W/Y W/G Y B B L/W B B \ L/R c
FUEL PUMP SYSTEM EB808010 FUEL PUMP CIRCUIT OPERATION The ignitor unit includes the control unit for the fuel pump.
FUEL PUMP SYSTEM ELEC – + EB802401 EB808020 TROUBLESHOOTING 2.Battery The fuel pump fails to operate. • Check the condition of the battery. Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. Check: 1. main and ignition fuses 2. battery 3. main switch 4. engine stop switch 5. fuel pump relay 6. fuel pump 7. wiring (the entire fuel pump system) Open-circuit voltage 12.
FUEL PUMP SYSTEM ELEC – + • Measure the fuel pump resistance. 5.Fuel pump relay Fuel pump resistance 4 ~ 30 Ω at 20 ˚C • Disconnect the relay unit from the coupler. • Connect the pocket tester (Ω × 1) and battery (12 V) to the relay unit terminals as shown. • Is the fuel pump OK? YES Battery positive terminal → red/black 1 Battery negative terminal → blue/red 2 NO Replace the fuel pump. Tester positive probe → red/black 1 Tester negative probe → blue/black 3 EB808401 7.
FUEL PUMP SYSTEM ELEC – + EB808410 CHECKING THE FUEL PUMP WARNING WARNING Gasoline is extremely flammable and under certain circumstances there can be a danger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refuelling. • Do not smoke and keep away from open flames, sparks or any other source of fire. • If you do accidentally spill gasoline, wipe it up immediately with dry rags. • If gasoline touches the engine when it is hot, a fire may occur.
8 - 53 L Br/L Br/L Br/L Br/L L/R Br/L L/Y R B B B L j k l (Option) m n Br L L i B h Br B B B B B B B (BLACK) B B R/Y Br (BLACK) B L B B B B B B B B B B B B B B B B B R/W R Br/L R Br/L B B L/Y L/R L L/Y L/B L L/R 3 Br Y B R/Y A • L Y B R/Y B A Y L/R R/Y R/Y Y B B B/Y W/Y R/Y B/Y B R/Y W/Y L/R B A L/R L/B u B A d B e L/R B Br G B/W L/R B/L B/Y B B/Y Br L/R B Br G B/Y B/L B/L — [ B B e G W/Y W/G Y B B L/W B B \ L/R c
EXUP SYSTEM ELEC – + EB811010 TROUBLESHOOTING When the engine speed changes, the EXUP servomotor does not operate. Procedure 1 Check: 1. Exup servomotor operation (with the EXUP servomotor coupler connected to the wire harness) 2. voltage 3. Exup servomotor operation 4. (with the EXUP servomotor coupler disconnected from the wire harness) 5. Exup servomotor resistance 6. wiring (the entire EXUP system) Procedure 2 Check: 1. main and ignition fuses 2. battery 3. main switch 4. engine stop switch 5.
EXUP SYSTEM ELEC – + EB811402 3.EXUP servomotor operation (with the servomotor coupler disconnected from the wire harness) • Disconnect the EXUP cables from the EXUP servomotor pulley. • Disconnect the EXUP servomotor coupler from the wire harness. • Connect the battery leads to the EXUP servomotor coupler (servomotor side) as shown. • Measure the EXUP servomotor resistance. Battery positive terminal → black/yellow 1 Battery negative terminal → black/red 2 EXUP servomotor resistance 5.3 ~ 9.
EXUP SYSTEM ELEC – + EB802411 EB811404 5.Wiring 3.Main switch • Check the entire EXUP system’s wiring. Refer to “CIRCUIT DIAGRAM”. • Is the EXUP system’s wiring properly connected and without defects? • Check the main switch for continuity. Refer to “CHECKING THE SWITCHES”. • Is the main switch OK? YES NO YES Replace the ignitor unit. NO Replace the main switch. Properly connect or repair the EXUP system’s wiring. EB802412 4.Engine stop switch • Check the engine stop switch for continuity.
SELF-DIAGNOSIS ELEC – + EB812000 SELF-DIAGNOSIS The YZF-R1 features a self-diagnosing system for the following circuit(-s): • throttle position sensor • EXUP • fuel level indicator light If any of these circuits are defective, their respective condition codes will be displayed on the tachometer when the main switch is set to “ON” (irrespective of whether the engine is running or not) Circuit Throttle position sensor Defect(-s) • Disconnected • Short-circuit • Locked • • EXUP • Improper connection •
SELF-DIAGNOSIS ELEC – + EB812010 1.Wire harness TROUBLESHOOTING • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? The tachometer starts to display the selfdiagnosis sequence. Check: 1. throttle position sensor 2. Exup 3. fuel level indicator light Repair or replace the wire harness. NOTE: • Before troubleshooting, remove the following part(-s): 1) rider seat 2) fuel tank 3) air filter case • Troubleshoot with the following special tool(-s).
SELF-DIAGNOSIS EB812030 ELEC – + EB812402 2. EXUP CIRCUIT DIAGRAM 2.EXUP servomotor R/B B/L B/R B Y/B O G/Y Sb B/Y R/W L/R Gy Gy W W/R Y B • Check the EXUP servomotor for continuity. Refer to “EXUP SYSTEM”. • Is the EXUP servomotor OK? R/B R/W B L O B L/R G/Y B/R L B/Y B/L L E Y Gy B Replace the ignitor unit. G G L W/R B/L B/L F L YES L Y B/L Y Gy G B B/L B Y/B Sb W B E EXUP servomotor G Ignitor unit EB812400 1.Wire harness • Check the wire harness for continuity.
SELF-DIAGNOSIS EB812040 – ELEC + EB812403 3. Fuel level indicator light CIRCUIT DIAGRAM 1.Fuel level indicator light LED • Check the LED of the fuel level indicator light. Refer to “CHECKING THE LEDs”.
SELF-DIAGNOSIS EB812405 3.Wire harness • Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. • Is the wire harness OK? YES Replace the ignitor unit. NO Replace or replace the wire harness.
ELEC 8 - 62 – +
TRBL SHTG 9
TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING PROBLEMS ................................................................................9-1 ENGINE .................................................................................................9-1 FUEL SYSTEM ......................................................................................9-1 ELECTRICAL SYSTEMS .......................................................................9-1 INCORRECT ENGINE IDLING SPEED .......................................
TRBL SHTG UNSTABLE HANDLING ................................................................................9-4 FAULTY LIGHTING AND SIGNALING SYSTEMS ......................................9-5 HEADLIGHT DOES NOT LIGHT ...........................................................9-5 HEADLIGHT BULB BURNT OUT ..........................................................9-5 TAIL/BRAKE LIGHT DOES NOT LIGHT ...............................................9-5 TAIL/BRAKE LIGHT BULB BURNT OUT ..............................
STARTING PROBLEMS TRBL SHTG EB900000 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-ANDHIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING TRBL SHTG EB901000 INCORRECT ENGINE IDLING SPEED ENGINE Cylinders and cylinder head • Incorrect valve clearance • Damaged valve train components Air filter • Clogged air filter element ELECTRICAL SYSTEMS Battery • Faulty battery • Discharged battery Spark plugs • Incorrect spark plug gap • Incorrect spark plug heat range • Fouled spark plug • Worn or damaged electrode • Worn or damaged insulator • Faulty spark plug
FAULTY CLUTCH/OVERHEATING/OVERCOOLING TRBL SHTG EB904000 FAULTY CLUTCH CLUTCH SLIPS Clutch • Incorrectly assembled clutch • Incorrectly adjusted clutch cable • Loose or fatigued clutch spring • Worn friction plate • Worn clutch plate Engine oil • Incorrect oil level • Incorrect oil viscosity (low) • Deteriorated oil CLUTCH DRAGS Clutch • Unevenly tensioned clutch spring plate • Warped pressure plate • Bent clutch plate • Swollen friction plate • Bent clutch pull rod • Damaged clutch boss • Burnt primary
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK LEGS/UNSTABLE HANDLING TRBL SHTG EB907000 POOR BRAKING PERFORMANCE • • • • • Worn brake pad Worn brake disc Air in hydraulic brake system Leaking brake fluid Faulty brake caliper piston seal • • • • • Loose union bolt Damaged brake hose Oil or grease on the brake disc Oil or grease on the brake pad Incorrect brake fluid level EB908001 FAULTY FRONT FORK LEGS MALFUNCTION • Bent or damaged inner tube • Bent or damaged outer tube • Damaged fork spring • Worn or
FAULTY LIGHTING AND SIGNALING SYSTEMS TRBL SHTG EB910000 FAULTY LIGHTING AND SIGNALING SYSTEMS TURN SIGNAL BLINKS SLOWLY • Faulty turn signal relay • Faulty main switch • Faulty turn signal switch • Wrong turn signal bulb HEADLIGHT DOES NOT LIGHT • Wrong headlight bulb • Too many electrical accessories • Hard charging • Incorrect connection • Incorrectly grounded circuit • Poor contacts (main or light switch) • Burnt-out headlight bulb TURN SIGNAL REMAINS LIT • Faulty turn signal relay • Burnt-out turn
TRBL SHTG 9-6
YZF-R1 WIRING DIAGRAM A 2 R/G R/G R R B R/Y W/Y W Br G/W Dg R/G L G/R R/Y W/G L/Y B G/Y R/L Y/B Ch Sb L/R Br/L G/R L R/G Dg G/W Br W W/Y R/Y Br/L L/R Sb Ch Y/B B/R G/Y B L/Y W/G R/Y WIRE HARNESS HEADLIGHT SUB-WIRE HARNESS R/B O Gy R/B O Gy WIRE HARNESS IGNITION COIL SUB-WIRE HARNESS R R L/W R/W R R R R/B B R/B R/B W W W R W W W R 6 5 9 B B R W W W R 3 P OFF ON L/Y L/B L L/R B L/Y L/R L R Br/L R Br/L W W W W 4 B 1 W W 7 B B B/L B/R B Y/B O G/Y Sb B/Y R/W L/R Gy L/W
