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• Page 3
  EB000000 FZS600 SERVICE MANUAL 1997 by Yamaha Motor Co., Ltd. First edition, December 1997 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

• Page 4: Important Information

  It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha scooter has a basic understanding of the mechanical ideas and the procedures of scooter repair.

• Page 5: Periodic Inspections And

  YP002000 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 inspection procedures are laid out with the individual steps in sequential order. 1 The manual is divided into chapters.

• Page 6
  EB003000 SYMBOLS The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter. General information Specifications Periodic inspection and adjustment Engine Cooling system Carburetor(-s) Chassis Electrical system Troubleshooting Symbols indicate the following. Serviceable with engine mounted Filling fluid Lubricant…
• Page 7
  INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE COOLING SYSTEM COOL CARBURETORS CARB CHASSIS CHAS ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG…
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  INFO…

• Page 10: Table Of Contents

  INFO CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ……… . VEHICLE IDENTIFICATION NUMBER .

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  INFO…

• Page 12: Motorcycle Identification

  MOTORCYCLE IDENTIFICATION 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. EB100020 MODEL CODE The model code label 1 is affixed to the frame. This information will be needed to order spare parts.

• Page 13: Important Information

  5. Keep all parts away from any source of fire. EB102010 REPLACEMENT PARTS 1. Use only genuine Yamaha parts for all re- placements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in-function and appearance, but inferior in quality.

• Page 14: Lock Washers/Plates And Cotter Pins

  IMPORTANT INFORMATION INFO EB102030 LOCK WASHERS/PLATES AND COTTER PINS 1. After removal, replace all lock washers/ plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EB102040 BEARINGS AND OIL SEALS 1.

• Page 15: Checking The Connections

  CHECKING THE CONNECTIONS INFO EB103000 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector 2. Check: S lead S coupler S connector Moisture !Dry with an air blower. Rust/stains ! Connect and disconnect several times.

• Page 16: Special Tools

  SPECIAL TOOLS 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.

• Page 17
  SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration 90890-01399 Special thickness gauge This tool is used to measure the valve clearance. 90890-01401 Spark plug wrench This tool is used for removing or installing the spark plug. 90890-01403 Ring nut wrench This tool is used to tighten the steering ring nut.
• Page 18
  SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration 90890-03141 Timing light This tool is necessary for checking ignition timing. 90890-04044 Piston ring compressor This tool is used to compress piston rings when installing the cylinder. 90890-03158 Carburetor angle driver This tool is used to adjust the pilot screw. 90890-04086 Clutch holding tool This tool is used for holding the clutch boss.
• Page 19
  SPECIAL TOOLS INFO Tool No. Tool name/Usage Illustration 90890-85505 Yamaha bond No.1215 This sealant (bond) is used for crankcase mating surface, etc.
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  SPEC…
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  SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS ……….MAINTENANCE SPECIFICATIONS .
• Page 22
  SPEC…

• Page 23: Specifications

  SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model FZS600 Model code: 5DM1 Dimensions: Overall length 2,080 mm Overall width 710 mm Overall height 1,170 mm Seat height 790 mm Wheelbase 1,415 mm Minimum ground clearance 130 mm Minimum turning radius 2,900 mm Basic weight: With oil and full fuel tank 210 kg…

• Page 24
  SPEC GENERAL SPECIFICATIONS Model FZS600 Carburetor: Type/quantity BSR 33/4 Manufacturer MIKUNI Spark plug: Type CR9E, CR8E/U27ESR-NU24ESR-N Manufacturer NGK/DENSO 0.7 X 0.8 mm Spark plug gap Clutch type: Wet, multiple-disc Transmission: Primary reduction system Spur gear Primary reduction ratio 82/48 (1.708) Secondary reduction system Chain drive Secondary reduction ratio…
• Page 25
  SPEC GENERAL SPECIFICATIONS Model FZS600 Brake: Front brake type Dual disc brake operation Right hand operation Rear brake type Single disc brake operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link suspension) Shock absorber: Front shock absorber Coil spring/Oil damper Rear shock absorber Coil spring/Gas-oil damper…

• Page 26: Maintenance Specifications

  SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit 0.05 mm Cylinder: 62.00 X 62.01 mm Bore size 62.1 mm Taper limit 0.09 mm Out of round limit 0.07 mm Camshaft: Drive method Chain drive (center) 23.000 X 23.021 mm Cam cap inside dia.

• Page 27
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit 0.010 X 0.037 mm Stem-to-guide clearance 0.08 mm 0.025 X 0.052 mm 0.1 mm Stem runout limit 0.04 mm 0.9 X 1.1 mm Valve seat width 1.6 mm 0.9 X 1.1 mm 1.6 mm Valve spring: Free length IN/EX…
• Page 28
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: 2.94 X 3.06 mm Friction plate thickness Quantity 8 pcs Wear limit 2.8 mm 2.94 X 3.06 mm Friction plate thickness Quantity 1 pcs 1.9 X 2.1 mm Clutch plate thickness Quantity 8 pcs Warp limit 0.1 mm Clutch spring free length…
• Page 29
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type Oil pump type Trochoid type 0.03 X 0.09 mm Tip clearance “A” or “B” 0.15 mm 0.03 X 0.08 mm Side clearance 0.15 mm 80 X 120 kPa (0.8 X 1.2 kg/cm Bypass valve setting pressure 450 X 550 kPa (4.5 X 5.5 kg/cm Relief valve operating pressure…
• Page 30
  SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES ENGINE Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Camshaft cap Bolt Cylinder head Spark plug – Cylinder head cover Bolt Cylinder head side cover Bolt Connecting rod cap See NOTE Camshaft sprocket Bolt…
• Page 31
  SPEC MAINTENANCE SPECIFICATIONS Tightening Thread torque Part to be tightened Part name Q’ty Remarks size size mSkg Starter cover Bolt Oil gallery – Clutch cover Bolt Clamp (A.C magneto cover) Screw Starter clutch assembly Bolt Starter clutch outer Bolt Pressure plate Screw Clutch boss Bolt…
• Page 32
  SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Angular bearing Steering bearing type Front suspension: Front fork travel 120 mm Fork spring free length 323 mm 319 mm Fitting length 315.9 mm Collar length 200 mm Spring Rate (K1) 7.5 N/mm (0.75 kg/mm) (K2) 14 N/mm (1.4 kg/mm)
• Page 33
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Type Dual Disc outside dia. thickness 4 mm Disc deflection limit 0.2 mm Pad thickness Inner 5.5 mm 0.5 mm Pad thickness Outer 5.5 mm 0.5 mm Master cylinder inside dia. 14 mm Caliper cylinder inside dia.
• Page 34
  SPEC MAINTENANCE SPECIFICATIONS TIGHTENING TORQUES CHASSIS Tightening Remarks torque Part to be tightened Thread size mSkg Upper bracket and inner tube 1.25 Upper bracket and steering stem 11.0 Handlebar under holder 1.25 Handlebar upper holder 1.25 Under bracket and inner tube 1.25 Ring nut (steering stem) –…
• Page 35
  SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Remarks mSkg Side cover and frame Garb bar 1.25 Front wheel axle Front wheel axle pinch bolt Front brake caliper 1.25 Front brake disc 1.25 Front brake caliper bleed screw Compression bar 1.25 Rear wheel sprocket…
• Page 36
  SPEC MAINTENANCE SPECIFICATIONS ELECTRICAL Item Standard Limit Voltage 12 V Ignition system: Ignition timing (B.T.D.C.) 10_/1,250 r/min Advanced timing (B.T.D.C.) 50_/4,500 r/min Advance type TPS and electrical type T.C.I.: 189 X 231 Ω Y-L Pickup coil resistance T.C.I. unit model/manufacturer J4T085/MITSUBISHI Ignition coil: Model/manufacturer…
• Page 37
  SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Starter motor: Model/manufacturer SM-13/MITSUBA I.D. number SM-13 Output 0.7 kW 0.0015 X 0.0025 Ω at 20_C Armature coil resistance Brush overall length 10 mm 4 mm 7.8 X 10.2 N (780 X 1.020 gf) Brush spring pressure Commutator dia.
• Page 38
  SPEC MAINTENANCE SPECIFICATIONS Item Standard limit Amperage for individual circuit: Main 30 A Headlight 20 A Signal 20 A Ignition 20 A 10 A Back up Reserve 30 A 20 A 10 A 2-16…

• Page 39: General Tightening Torque Specifications

  SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EB201000 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tight- ening torque specifications for special components or assemblies are provided for each chapter of this manual.

• Page 40
  Starter idrer gear shaft 1 Neutral switch O-ring Push rod Push rod 1 O-ring Shift pedal Shift shaft Water pump O-ring Cylinder head cover gasket Yamaha bond No. 1215 Shift cam plug Breather plate Crankcase Yamaha bond No. 1215 Taper plug Bearing plate 2-18…
• Page 41
  SPEC LUBRICATION POINT AND LUBRICATION TYPES CHASSIS Lubrication Point Symbol Steering bearing and bearing race (upper and lower) Pivot shaft Rear arm bearing Rear arm oil seal Rear arm cover oil seal lips Relay arm bearing Relay arm oil seal Rear shock absorber (upper/lower) Front wheel oil seal Speed sensor oil seal…
• Page 42
  SPEC COOLING SYSTEM DIAGRAMS EB203000 COOLING SYSTEM DIAGRAMS 1 Engine outlet hose 8 Radiator outlet hose 2 Engine outlet hose 9 Radiator 3 Carburetor inlet hose 10 Radiator inlet hose 4 Carburetor outlet hose 5 Water pump 6 Coolant drain bolt 7 Water pump outlet hose 2-20…
• Page 43
  SPEC COOLING SYSTEM DIAGRAMS 1 Radiator 2 Water pump outlet hose 3 Oil cooler inlet hose 4 Oil cooler outlet hose 5 Carburetor outlet hose 2-21…
• Page 44
  SPEC LUBRICATION DIAGRAMS EB204000 LUBRICATION DIAGRAMS 1 Oil nozzle (main nozzle) 2 Oil nozzle (drive axle) 3 Projection 4 Oil filter 5 Relief valve 6 Oil strainer 7 Oil pump 2-22…
• Page 45
  SPEC LUBRICATION DIAGRAMS 1 Main axle 2 Drive axle 3 Camshaft 4 Oil delivery pipe 2-23…
• Page 46
  SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Crankshaft 2-24…
• Page 47
  SPEC CABLE ROUTING EB205000 CABLE ROUTING 1 Throttle cable 9 Handlebar switch (left) 2 Clutch cable A Use a plastic clamp to fasten 3 Handlebar switch (right) together the handlebar switch 4 Starter cable lead (left), clutch cable and 5 Main switch starter cable.
• Page 48
  SPEC CABLE ROUTING 1 Main switch lead 11 Battery 21 Speed sensor lead 2 Starter cable 12 Starting circuit cut-off relay 22 Horn 3 Handlebar switch lead (left) 13 Battery positive (+) lead 23 Starter relay 14 Seat lock cable 24 Fuse box 4 Clutch cable 5 Rectifier/ regulator…
• Page 49
  SPEC CABLE ROUTING A Use a plastic clamp to fasten Position the band end to out side of D Use a steel holder to fasten the handlebar switch lead (left), chassis. together the AC magneto lead, main switch lead, clutch cable C Use a plastic locking tie to sidestand lead and oil and starter cable to the frame.

• Page 50: Cable Routing

  SPEC CABLE ROUTING 1 Battery negative (–) lead 10 Throttle cable A Use a plastic clamp to fasten 2 Rear brake switch lead 11 Brake hose together the throttle cables, 3 Battery 12 Headlight lead headlight lead handlebar switch 13 Speed sensor lead 4 Reservoir tank hose (right) and speed sensor lead.

• Page 51
  SPEC CABLE ROUTING C Pass the main switch lead under E Pass the battery negative (–) the throttle cables, headlight lead inside of the reservoir lead, handlebar switch lead hose. (right) and speed sensor lead, then insert it right side of the box. D Pass the reservoir tank over flow hose, fuel tank breather hose and fuel tank drain hose…
• Page 52
  SPEC CABLE ROUTING 1 Throttle cable 11 Battery negative (–) lead 21 Starter relay 2 Handlebar switch lead (right) 12 Battery 22 Starting circuit cut-off relay 3 Headlight lead 13 Rear brake reservoir tank 23 Flasher relay 14 Rear brake switch lead 24 Fuel pump lead coupler 4 Speed sensor lead 5 Carburetor heater hose…
• Page 53
  SPEC CABLE ROUTING 31 Starter cable B Pass the rectifier / regulator turn signal light lead and clamp 32 Clutch cable lead, fan motor lead, handlebar 33 Handlebar switch lead (left) switch lead (left), main switch D Pass the reservoir hose left side 34 Main switch lead lead, headlight lead, handlebar of thermo stat housing.
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  SPEC…
• Page 56
  CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION …………PERIODIC MAINTENANCE/LUBRICATION INTERVALS .

• Page 58: Periodic Inspections And Adjustments

  INTRODUCTION / PERIODIC MAINTENANCE/LUBRICATION INTERVALS EB300000 PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and adjust- ments. If followed, these preventive maintenance procedures will ensure more reliable vehicle opera- tion, a longer service life and reduce the need for costly overhaul work. This information applies to ve- hicles already in service as well as to new vehicles that are being prepared for sale.

• Page 59: Brake Fluid Replacement

  S Change coolant every 24,000 km or 24 months (whichever comes first). *Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. NOTE: S The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

• Page 60: Front Cowling/Seat/Side Cover/Fuel Tank

  FRONT COWLING/ SEAT/SIDE COVER/FUEL TANK FRONT COWLING/SEAT/SIDE COVER/FUEL TANK FRONT COWLING 33 Nm (3.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the front cowling Remove the parts in the order listed. View mirror (left/right) Inner panel (left/right) Cowling stay (left/right) Head light lead NOTE: Front flasher light lead (left/right)

• Page 61
  FRONT COWLING/ SEAT/SIDE COVER/FUEL TANK SEAT, SIDE COVER AND FUEL TANK 19 Nm (1.9 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 4 Nm (0.4 mSkg) Order Job name/Part name Q’ty Remarks Removing the seat, side cover Remove the parts in the order listed. and fuel tank Seat Fuel tank…

• Page 62: Engine

  ADJUSTING THE VALVE CLEARANCE EB303001 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room tempera- ture. S When the valve clearance is to be mea- sured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

• Page 63
  ADJUSTING THE VALVE CLEARANCE a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the com- pression stroke, align the TDC mark a on the generator rotor with the mark b on the crankcase. NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other.
• Page 64
  ADJUSTING THE VALVE CLEARANCE 7. Remove: S timing chain tensioner bolt 1 S timing chain tensioner assembly 2 8. Remove: S timing chain guide 1 S timing chain guide (upper) 2 S camshaft cap 3 9. Remove: S camshaft 1 NOTE: S Refer to “DISASSEMBLING THE ENGINE –…
• Page 65
  ADJUSTING THE VALVE CLEARANCE NOTE: S The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. S Since valve pads of various sizes are origi- nally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original.
• Page 66
  ADJUSTING THE VALVE CLEARANCE VALVE PAD SELECTION TABLE INTAKE Measured INSTALLED PAD NUMBER clearance 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230…
• Page 67
  ADJUSTING THE VALVE CLEARANCE e. Install the new valve pad 1 and the valve lifter 2 . NOTE: S Apply molybdenum disulfide grease to the valve pad. S Lubricate the valve lifter with molybdenum disulfide oil. S The valve lifter must turn smoothly when rotated by hand.

• Page 68: Synchronizing The Carburetors

  ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS 14. Install: S cylinder head cover S spark plugs Bolt (cylinder head cover): 10 Nm (1.0 mSkg) Spark plug: 13 Nm (1.3 mSkg) EB303010 SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked.

• Page 69
  SYNCHRONIZING THE CARBURETORS 6. Adjust: S carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same. NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again.

• Page 70: Adjusting The Engine Idling Speed

  ADJUSTING THE ENGINE IDLING SPEED EB303020 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean, and the engine should have adequate compression. 1. Start the engine and let it warm up for sever- al minutes.

• Page 71: Adjusting The Throttle Cable Free Play

  ADJUSTING THE THROTTLE CABLE FREE PLAY EB303032 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor syn- chronization should be adjusted properly. 1. Check: S throttle cable free play a Out of specification ! Adjust.

• Page 72: Checking The Spark Plugs

  ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHECKING THE SPARK PLUGS After adjusting the throttle cable free play, turn the handlebar to the right and to the left to ensure that this does not cause the engine idling speed to change. 4.

• Page 73: Checking The Ignition Timing

  CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING 8. Connect: S spark plug cap EB303053 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.

• Page 74: Measuring The Compression Pressure

  MEASURING THE COMPRESSION PRESSURE EB303060 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cyl- inders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Check: S valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEARANCE”.

• Page 75: Checking The Engine Oil Level

  MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL Compression pressure (at sea level) Standard 1,500 kPa (15.0 kg/cm Minimum 1,200 kPa (12.0 kg/cm a. Turn the main switch to “ON”. b. With the throttle wide open, crank the en- gine until the reading on the compression gauge stabilizes.

• Page 76: Changing The Engine Oil

  CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL Recommended engine oil Refer to the chart for the TEMP engine oil grade which is best suited for certain atmospheric SAE 10W-30 temperatures. API standard ! SAE 10W-30 SE or higher grade SAE 10W-30 ACEA standard ! G4 or G5 CAUTION:…

• Page 77
  CHANGING THE ENGINE OIL a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01469 b. Apply a thin coat of engine oil onto the O- ring 3 of the new oil filter cartridge. CAUTION: Make sure that the O-ring 3 is positioned correctly in the groove of the oil filter car-…

• Page 78: Measuring The Engine Oil Pressure

  MEASURING THE ENGINE OIL PRESSURE EB303090 MEASURING THE ENGINE OIL PRESSURE 1. Check: S engine oil level Below the minimum level mark ! Add the recommended engine oil to the proper lev- 2. Start the engine, warm it up for several min- utes, and then turn it off.

• Page 79: Adjusting The Clutch Cable Free Play

  MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH CABLE FREE PLAY 6. Install: S oil gallery bolt 8 Nm (0.8 mSkg) EB303100 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm…

• Page 80: Cleaning The Air Filter Element

  CLEANING THE AIR FILTER ELEMENT EB303130 CLEANING THE AIR FILTER ELEMENT 1. Remove: S Seat S Fuel tank S Cover 1 2. Remove: S air filter case cover 1 S air filter element 2 3. Clean: S air filter element Apply compressed air to the outer surface of the air filter element.

• Page 81: Checking The Carburetor Joints And Intake Manifolds

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

• Page 82: Checking The Crankcase Breather Hose

  CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM EB303190 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: S seat S fuel tank S carburetor 2. Check: S crankcase breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly. CAUTION: Make sure that the crankcase breather hose is routed correctly.

• Page 83: Checking The Coolant Level

  CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM EB303220 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Remove: S side cover (right) 3.

• Page 84: Changing The Coolant

  CHANGING THE COOLANT EB303240 CHANGING THE COOLANT 1. Remove: S seat S fuel tank 2. Disconnect: S coolant reservoir hose 1 3. Drain: S coolant (from the coolant reservoir) 4. Remove: S radiator cap A hot radiator is under pressure. There- fore, do not remove the radiator cap when the engine is hot.

• Page 85
  CHANGING THE COOLANT 9. Coonect: S coolant reservoir hose 10. Fill: S cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol anti- freeze containing corrosion inhibi- tors for aluminum engines Mix ratio 50% antifreeze/50 % water Quantity Total amount 1.95 L…
• Page 86
  CHANGING THE COOLANT 12. Fill: S coolant reservoir (with the recommended coolant to the maximum level mark a ) 13. Install: S coolant reservoir cap 14. Start the engine, warm it up for several min- utes, and then turn if off. 15.

• Page 87: Chassis

  ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE EB304001 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position.

• Page 88: Checking The Brake Fluid Level

  ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL After adjusting the brake pedal position, check that the end of the adjusting bolt 2 is visible through the hole c . c. Tighten the locknut 1 to specification. A soft or spongy feeling in the brake ped- al can indicate the presence of air in the brake system.

• Page 89: Adjusting The Rear Brake Light Switch

  CHECKING THE BRAKE FLUID LEVEL / ADJUSTING THE REAR BRAKE LIGHT SWITCH S Use only the designated brake fluid. Other brake fluids may cause the rub- ber seals to deteriorate, causing leak- age and poor brake performance. S Refill with the same type of brake fluid that is already in the system.

• Page 90: Checking The Brake Hoses

  CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM EB304062 CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and clamps. 1. Check: S brake hose Cracks/damage/wear ! Replace. 2. Check: S brake hose clamp Loose connection ! Tighten.

• Page 91: Adjusting The Shift Pedal

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

• Page 92: Adjusting The Drive Chain Slack

  ADJUSTING THE DRIVE CHAIN SLACK EB304090 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will over- load the engine and other vital parts, and one that is too loose can skip and dam- age the swingarm or cause an accident.

• Page 93: Lubricating The Drive Chain

  ADJUSTING THE DRIVE CHAIN SLACK/LUBRICATING THE DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEAD c. Tighten the wheel axle nut to specifica- tion. Wheel axle nut 117 Nm (11.7 mSkg) Locknut 16 Nm (1.6 mSkg) EB304100 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.

• Page 94: Checking And Adjusting The Steering Head

  CHECKING AND ADJUSTING THE STEERING HEAD 4. Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the rubber washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 .

• Page 95: Checking The Front Fork

  CHECKING ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK/ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY 5. Install: S upper bracket S handlebar Steering stem nut 110 Nm (11.0 mSkg) Upper bracket pinch bolt 30 Nm (3.0 mSkg) Handlebar upper holder bolt 23 Nm (2.3 mSkg) EB304140 CHECKING THE FRONT FORK 1.

• Page 96
  ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY/CHECKING THE TIRES a. Turn the adjusting ring 1 in direction a or adjusting position b. Align the desired position on the adjusting ring with the stopper. ! Spring preload is Direction increased (suspension is harder). ! Spring preload is Direction decreased (suspension…

• Page 97: Checking The Tires

  CHECKING THE TIRES Basic weight (with oil and a 210 kg full fuel tank) Maximum load 187 kg Cold tire Front tire Rear tire pressure 225 kPa 250 kPa Up to 90 kg load* (2.25 (2.50 kg / cm kg / cm 225 kPa 280 kPa 90 kg maximum…

• Page 98: Checking The Wheels

  No guarantee concerning han- dling characteristics can be given if a tire combination other than one ap- proved by Yamaha is used on this mo- torcycle. Front tire Manufacturer Size…

• Page 99: Checking And Lubricating The Cables

  CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTER STAND/ LUBRICATING THE REAR SUSPENSION EB304200 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables. Damaged cable sheaths may cause the cable to corrode and interfere with its movement.

• Page 100: Electrical System

  CHECKING AND CHARGING THE BATTERY EB305020 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preven- tive measures: S Wear protective eye gear when han- dling or working near batteries.

• Page 101
  CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not pos- sible to check the charge state of the battery by measuring the specific gravity of the elec- trolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
• Page 102
  CHECKING AND CHARGING THE BATTERY Do not quick charge a battery. S Make sure that the battery vent is free of obstructions. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
• Page 103
  CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) type charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
• Page 104
  CHECKING AND CHARGING THE BATTERY Charging method using a constant-voltage type charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.

• Page 105: Checking The Fuses

  CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1 , then the negative lead 2 . 8. Check: S battery terminals Dirt ! Clean with a wire brush.

• Page 106
  CHECKING THE FUSES/ REPLACING THE HEADLIGHT BLUBS 3. Replace: S blown fuse a. Turn off the ignition. b. Install a new fuse of the correct amperage rating. c. Turn on the switches to verify if the electri- cal circuit is operational. d.

• Page 107: Replacing The Headlight Bulbs

  REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAMS 2. Remove: S headlight bulb holder 1 3. Remove: S headlight bulb 2 Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down.

• Page 108
  ADJUSTING THE HEADLIGHT BEAMS 2. Adjust: S headlight beam (horizontally) a. Turn the adjusting knob 2 4 in direction a or b . Left headlight 2 ! Headlight beam Direction moves to the right. ! Headlight beam Direction moves to the left. Right headlight 4 ! Headlight beam Direction…
• Page 111
  CHAPTER 4 OVERHAULING THE ENGINE REMOVING THE ENGINE ……….DRIVE SPROCKET AND EXHAUST PIPE .
• Page 112
  AC MAGNETO AND STARTER CLUTCH ……..4-41 STATOR COIL .

• Page 113: Overhauling The Engine

  REMOVING THE ENGINE OVERHAULING THE ENGINE REMOVING THE ENGINE DRIVE SPROCKET AND EXHAUST PIPE 25 Nm (2.5 mSkg) 70 Nm (7.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 17 Nm (1.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the drive sprocket and…

• Page 114
  REMOVING THE ENGINE 25 Nm (2.5 mSkg) 70 Nm (7.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 17 Nm (1.7 mSkg) Order Job name/Part name Q’ty Remarks Shift arm Refer to “INSTALLING THE ENGINE” Drive sprocket cover section.

• Page 115: Leads And Hoses

  REMOVING THE ENGINE LEADS AND HOSES Engine right side Engine left side 12 Nm (1.2 mSkg) 12 Nm (1.2 mSkg) Order Job name/Part name Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Magneto/sidestand/neutral/engine oil 1/1/1/1 level switch lead Ground lead…

• Page 116: Engine Bracket And Engine

  REMOVING THE ENGINE ENGINE BRACKET AND ENGINE 33 Nm (3.3 mSkg) 55 Nm (5.5 mSkg) 33 Nm (3.3 mSkg) 55 Nm (5.5 mSkg) 33 Nm (3.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the engine bracket and Remove the parts in the order listed. engine Engine mounting bolt (front left) Engine mounting bolt (front right)

• Page 117: Installing The Engine

  REMOVING THE ENGINE EB400700 INSTALLING THE ENGINE 1. Install: S bolt 1 S bolt 2 S bolt 3 S bolt 4 S engine bracket 5 S engine bracket 6 NOTE: Do not fully tighten the bolts. 2. Tighten the bolts in the following order. Bolt 1 55 Nm (5.5 mSkg) Bolt 2…

• Page 118: Camshaft

  CAMSHAFT CAMSHAFT CYLINDER HEAD COVERS 10 Nm (1.0 mSkg) 9 Nm (0.9 mSkg) Order Job name/Part name Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Front cowling Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section Seat and fuel tank in chapter 3.

• Page 119: Camshafts

  CAMSHAFT CAMSHAFT 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) 20 Nm (2.0 mSkg) 13 Nm (1.3 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the camshafts Remove the parts in the order listed. Spark plug Magneto cover Timing chain guide (upper) Timing chain tensioner assembly…

• Page 120: Removing The Camshafts

  CAMSHAFT EB401102 REMOVING THE CAMSHAFTS 1. Remove: S magneto cover 2. Align: S “T” mark on the magneto rotor (with the stationary pointer on the crank- case) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the com- pression stroke, align the “T”…

• Page 121: Checking The Camshafts

  CAMSHAFT CAUTION: To prevent damage to the cylinder head, camshafts or camshaft caps, loosen the camshaft cap bolts in stages and in a crisscross pattern, working from the out- side in. 8. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire 3 .

• Page 122: Checking The Timing Chain, Camshaft Sprockets, And Timing Chain Guides

  CAMSHAFT 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ! Measure the cam- shaft journal diameter. Camshaft-journal-to- camshaft-cap clearance 0.08 mm a. Install the camshaft into the cylinder head (without the dowel pins and camshaft caps). b. Position a strip of Plastigauge 1 onto the camshaft journal as shown.

• Page 123: Checking The Timing Chain Tensioner

  CAMSHAFT EB401430 CHECKING THE TIMING CHAIN TENSIONER 1. Check: S timing chain tensioner Cracks/damage ! Replace. 2. Check: S one-way cam operation Rough movement ! Replace the timing chain tensioner housing. 3. Check: S cap bolt 1 S copper washer 2 S ball 3 S spring 4 S ball 5…

• Page 124
  CAMSHAFT CAUTION: The camshaft cap bolts must be tight- ened evenly or damage to the cylinder head, camshaft caps, and camshafts will result. Camshaft cap bolt 10 Nm (1.0 mSkg) 4. Install: S intake camshaft sprocket S exhaust camshaft sprocket a.
• Page 125
  CAMSHAFT Always use a new gasket. Timing chain tensioner bolt 10 Nm (1.0 mSkg) d. Install the springs 3 , washer 2 , and cap bolt 1 . Cap bolt 20 Nm (2.0 mSkg) 7. Turn: S crankshaft (several full turns counterclockwise) 8.

• Page 126: Cylinder Head

  CYLINDER HEAD CYLINDER HEAD 35 Nm (3.5 mSkg) 20 Nm (2.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Camshaft Refer to “CAMSHAFT”section. Union bolt Copper washer Oil delivery pipe Cylinder head Refer to “REMOVING/INSTALLING THE Cylinder head gasket…

• Page 127: Removing The Cylinder Heads

  CYLINDER HEAD EB402101 REMOVING THE CYLINDER HEADS 1. Remove: S cylinder head nuts NOTE: S Loosen the nuts in the proper sequence as shown. S Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, re- move them.

• Page 128: Installing The Cylinder Head

  CYLINDER HEAD EB402702 INSTALLING THE CYLINDER HEAD 1. Install: S gasket (New) 1 S dowel pins 2 NOTE: The “UP” mark a on the gasket must face 2. Install: S cylinder head NOTE: S Apply engine oil onto the threads of the cyl- inder head nuts.

• Page 129: Valves And Valve Springs

  VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Order Job name/Part name Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs Camshaft Refer to “CAMSHAFT” section. Cylinder head Refer to “CYLINDER HEAD” section. Valve lifter Adjusting pad Valve cotters Upper spring seat…

• Page 130: Removing The Valves

  VALVES AND VALVE SPRINGS 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.

• Page 131: Checking The Valves And Valve Guides

  VALVES AND VALVE SPRINGS EB403400 CHECKING THE VALVES AND VALVE GUIDES The following procedure applies to all of the valves and valve guides. 1. Measure: S valve-stem-to-valve-guide clearance Valve-stem-to-valve-guide clearance = Valve guide inside diameter – Valve stem diameter Out of specification ! Replace the valve guide.

• Page 132: Checking The Valve Seats

  VALVES AND VALVE SPRINGS 4. Check: S valve face Pitting/wear ! Grind the valve face. S valve stem end Mushroom shape of diameter larger than the body of the valve stem ! Replace the valve. 5. Measure: S valve margin thickness a Out of specification ! Replace the valve.

• Page 133
  VALVES AND VALVE SPRINGS a. Apply Mechanic’s blueing dye (Dykem) b onto the valve face. b. Install the valve into the cylinder head. c. Press the valve through the valve guide and onto the valve seat to make a clear pattern.

• Page 134: Checking The Valve Springs

  VALVES AND VALVE SPRINGS EB403420 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: S valve spring free length a Out of specification ! Replace the valve spring. Valve spring free length (intake and exhaust) Spring 40.09 mm (Limit 37.5 mm) 2.

• Page 135: Checking The Camshaft Cap

  VALVES AND VALVE SPRINGS EB403440 CHECKING THE CAMSHAFT CAP 1. Check: S camshaft case S camshaft caps 1 Cracks/damage ! Replace th camshaft case and camshaft caps as a set, and check the camshafts (Refer to “CHECK- ING THE CAMSHAFTS”.). S camshaft bearing surfaces 2 Damage/pitting/scratches ! Replace the camshaft case and camshaft caps as a…

• Page 136
  VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019 Attachment 90890-04114 5. To secure the valve cotters 1 onto the a valve stem, lightly tap the valve tip with a soft-face hammer. CAUTION: Hitting the valve tip with excessive force could damage the valve. 6.

• Page 137: Cylinder And Piston

  CYLINDER AND PISTON CYLINDER AND PISTON 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the cylinder and pistons Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD” section. Water jacket joint O-ring Cylinder Cylinder gasket Refer to “INSTALLING THE PISTON AND Dowel pin…

• Page 138: Removing The Cylinders And Pistons

  CYLINDER AND PISTON EB404101 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cyl- inders and pistons. 1. Remove: S piston pin clip 1 S piston pin 2 S piston 3 CAUTION: Do not use a hammer to drive the piston pin out.

• Page 139: Checking The Piston Rings

  CYLINDER AND PISTON Standard Wear limit Cylinder 62.00 X 62.01 62.1 mm bore “C” X + Y “C” = b. If out of specification, replace the cylin- der, piston and piston rings as a set. c. Measure piston skirt diameter “P” with the micrometer.

• Page 140: Checking The Piston Pins

  CYLINDER AND PISTON 2. Install: S piston ring 1 (into the cylinder) NOTE: Level the piston ring in the cylinder with the piston crown as shown. 20 mm 3. Measure: S piston ring end gap Out of specification ! Replace the piston ring.

• Page 141: Installing The Piston And Cylinder

  CYLINDER AND PISTON 3. Calculate: S piston-pin-to-piston clearance Out of specification ! Replace the piston pin. Piston-pin-to-piston clearance = Piston pin bore size b – Piston pin outside diameter a Piston-pin-to-piston clearance 0.011 X 0.013 mm <Limit>: 0.023 mm EB404701 INSTALLING THE PISTON AND CYLINDER The following procedure applies to all of the pis- tons and cylinders.

• Page 142
  CYLINDER AND PISTON 5. Offset: S piston ring end gaps Top ring Lower oil ring rail Upper oil ring rail 2nd ringe Oil ring expander 6. Install: S cylinder 1 S O-ring 2 NOTE: S First, install pistons #2 and #3. S Pass the timing chain and timing chain guide (exhaust side) through the timing chain cavity.

• Page 143: Clutch

  CLUTCH CLUTCH CLUTCH COVER 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Drain the engine oil Refer to “CHANGING THE ENGINE OIL” section in chapter 3. Clutch cover Clutch cover gasket Dowel pin…

• Page 144: Clutch

  CLUTCH CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job name/Part name Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate Short clutch push rod O-ring Ball Long clutch push rod Refer to “INSTALLING THE CLUTCH”…

• Page 145
  CLUTCH 70 Nm (7.0 mSkg) 8 Nm (0.8 mSkg) Order Job name/Part name Q’ty Remarks Lock washer Refer to “REMOVING/INSTALLING Clutch boss THE CLUTCH” section. Thrust washer Refer to “INSTALLING THE CLUTCH” section. Spacer Refer to “REMOVING/INSTALLING Bearing THE CLUTCH” section. Clutch housing Refer to “INSTALLING THE CLUTCH”…

• Page 146: Removing The Clutch

  CLUTCH EB405100 REMOVING THE CLUTCH 1. Straighten the lock washer tab. 2. Loosen: S clutch boss nut 1 NOTE: While holding the clutch boss 2 with the uni- versal clutch holder 3 , loosen the clutch boss nut. Universal clutch holder 3 90890-04086 3.

• Page 147: Checking The Clutch Springs

  CLUTCH EB405420 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: S clutch spring Damage ! Replace the clutch springs as a set. 2. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set.

• Page 148: Checking The Clutch Boss

  CLUTCH EB405450 CHECKING THE CLUTCH BOSS 1. Check: S clutch boss splines 1 Damage/pitting/wear ! Replace the clutch boss. NOTE: Pitting on the clutch boss splines will cause erratic clutch operation. EB405450 CHECKING THE PRESSURE PLATE 1. Check: S pressure plate 1 Cracks/damage ! Replace.

• Page 149
  CLUTCH 2. Tighten: S clutch boss nut 1 70 Nm (7.0 mSkg) NOTE: While holding the clutch boss with the uni- versal clutch holder 2 , tighten the clutch boss nut. Universal clutch holder 90890-04086 3. Bend the lock washer 3 tab along a flat side of the nut.
• Page 150
  CLUTCH 9. Install: S clutch cover 1 12 Nm (1.2 mSkg) NOTE: Tighten the clutch cover bolts in stages and in a crisscross pattern. 4-38…

• Page 151: Shift Shaft

  SHIFT SHAFT SHIFT SHAFT Order Job name/Part name Q’ty Remarks Removing the shift shaft Remove the parts in the order listed. Oil pump Refer to “OIL PUMP” section. Drive sprocket cover Refer to “REMOVING THE ENGINE” section. Collar Shift shaft Shift lever spring Refer to “INSTALLING THE SHIFT Stopper lever…

• Page 152: Checking The Shift Shaft

  SHIFT SHAFT EB408400 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 S shift lever 2 Bends/damage/wear ! Replace. S shift lever spring 3 S stopper lever spring 4 Damage/wear ! Replace. EB408700 INSTALLING THE SHIFT SHAFT 1. Install: S stopper lever 1 S stopper lever spring 2 S shift shaft lever…

• Page 153: Stator Coil

  AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH STATOR COIL 5 Nm (0.5 mSkg) 10 Nm (1.0 mSkg) 12 Nm (1.2 mSkg) Order Job name/Part name Q’ty Remarks Removing the stator coil Remove the parts in the order listed. Seat Refer to “FRONT COWLING/SEAT/ Fuel tank…

• Page 154: Starter Clutch

  AC MAGNETO AND STARTER CLUTCH STARTER CLUTCH 12 Nm (1.2 mSkg) 80 Nm (8.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the starter clutch Remove the parts in the order listed. Generator cover Starter clutch cover Dowel pin Gasket Starter clutch assembly Refer to “REMOVING/INSTALLING THE STARTER CLUTCH”…

• Page 155: Ac Magneto Rotor

  AC MAGNETO AND STARTER CLUTCH AC MAGNETO ROTOR 130 Nm (13.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the generator roter Remove the parts in the order listed. Bolt/washer Refer to “REMOVING/INSTALLING Rotor THE AC MAGNETO” section. Woodruff key For installation, reverse the removal procedure.

• Page 156: Removing The Starter Clutch

  AC MAGNETO AND STARTER CLUTCH EB410100 REMOVING THE STARTER CLUTCH 1. Remove: S starter 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.

• Page 157: Checking The Starter Clutch

  AC MAGNETO AND STARTER CLUTCH 2. Remove: S AC magneto rotor 1 S Woodruff key NOTE: Use a flywheel puller 2 to remove the AC magneto rotor 1 . Flywheel puller: 90890-01362 EB410401 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 S starter clutch gear 3 Burrs/chips/roughness/wear ! Replace…

• Page 158: Installing The Ac Magneto

  AC MAGNETO AND STARTER CLUTCH INSTALLING THE AC MAGNETO 1. Install: S Woodruff key 1 S AC magneto rotor 2 S Bolt (AC magneto rotor) NOTE: S Clean the tapered portion of the crankshaft and the AC magneto rotor. S When installing the AC magneto rotor, make sure that the woodruff key is properly seated in the key way of the crankshaft.

• Page 159: Oil Pan And Oil Strainer

  OIL PAN AND OIL STRAINER OIL PAN AND OIL STRAINER OIL STRAINER 7 Nm (0.7 mSkg) 43 Nm (4.3 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 63 Nm (6.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the oil strainer Remove the parts in the order listed.

• Page 160: Oil Pump

  OIL PAN AND OIL STRAINER OIL PUMP 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the oil pump Remove the parts in the order listed. Clutch Refer to “CLUTCH” section. Oil pump assembly Refer to “INSTALLING THE OIL PUMP” Oil pump gasket section.

• Page 161
  OIL PAN AND OIL STRAINER Order Job name/Part name Q’ty Remarks Disassembling the oil pump Disassembly the parts in the order listed. Oil pump rotor housing Dowel pin Inner rotor/outer rotor Refer to “ASSEMBLING THE OIL PUMP” Dowel pin section. Oil pump shaft assembly Oil pump cover Washer…

• Page 162: Removing The Oil Pan

  OIL PAN AND OIL STRAINER EB411100 REMOVING THE OIL PAN 1. Remove: S oil level switch 1 S oil pan 2 S gasket S 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.

• Page 163: Checking The Oil Strainer

  OIL PAN AND OIL STRAINER EB411430 CHECKING THE OIL STRAINER 1. Check: S oil strainer 1 Damage ! Replace. Contaminants ! Clean with engine oil. EB411470 CHECKING THE OIL NOZZLE 1. Check: S oil nozzle 1 S check ball 2 Damage/wear ! Replace the oil nozzle.

• Page 164: Installing The Oil Pump

  OIL PAN AND OIL STRAINER EB411710 INSTALLING THE OIL PUMP Install: S oil pump 1 10 Nm (1.0 mSkg) CAUTION: After tightening the bolts, make sure that the oil pump turns smoothly. NOTE: Align the projection a on the oil pump shaft with the slot b on the water pump shaft.

• Page 165
  OIL PAN AND OIL STRAINER NOTE: S Tighten the oil pan bolts in stages and in a crisscross pattern. S Lubricate the oil level switch’s O-ring with engine oil. Oil pan bolt 12 Nm (1.2 mSkg) Oil level switch bolt 7 Nm (0.7 mSkg) 4-53…

• Page 166: Crankcase

  CRANKCASE CRANKCASE 24 Nm (2.4 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the crankcase Disassembly the parts in the order listed. Engine Refer to “REMOVING THE ENGINE” section.

• Page 167: Assembling The Crankcase

  CRANKCASE 24 Nm (2.4 mSkg) 12 Nm (1.2 mSkg) 10 Nm (1.0 mSkg) 24 Nm (2.4 mSkg) Order Job name/Part name Q’ty Remarks O-ring Upper crankcase Refer to “DISASSEMBLING/ Dowel pin ASSEMBLING THE CRANKCASE” Oil seal section. Oil jet O-ring For assembly, reverse the disassembly procedure.

• Page 168
  CRANKCASE EB412100 DISASSEMBLING THE CRANKCASE 1. Remove: S crankcase bolts 1 X A Upper crankcase NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.
• Page 169
  Recommended lubricant Engine oil 2. Apply: S sealant (onto the crankcase mating surfaces) Yamaha bond No. 1215 90890-85505 NOTE: Do not allow any sealant to come into con- tact with the oil gallery or crankshaft journal bearings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings.
• Page 170
  CRANKCASE 7. Install: S upper crankcase bolts S lower crankcase bolts NOTE: S Lubricate the bolt threads with engine oil. S Tighten the bolts in increasing numerical order. S Install washers on bolts 1 X S Install the cable holder on bolt #35. A Upper crankcase B Lower crankcase M8 bolt…

• Page 171: Crankshaft

  CRANKSHAFT CRANKSHAFT 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Disassembly the crankcase Refer to “CRANKCASE” section. Timing chain guide (intake side) Crankshaft assembly Refer to “REMOVING/INSTALLING THE Oil seal CRANKSHAFT ASSEMBLY”…

• Page 172: Connecting Rod

  CRANKSHAFT CONNECTING ROD 15 Nm (1.5 mSkg) + 90_ Order Job name/Part name Q’ty Remarks Removing the connecting rod Remove the parts in the order listed. Refer to “INSTALLING THE Connecting rod bolt CONNECTING RODS” section. Connecting rod Refer to “REMOVING/INSTALLING Connecting rod cap THE CONNECTING RODS”…

• Page 173: Removing The Crankshaft Assembly

  CRANKSHAFT EB412110 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly 1 S crankshaft journal upper bearing 2 (from the upper crankcase) S timing chain guide (intake side) NOTE: Identify the position of each crankshaft jour- nal upper bearing so that it can be reinstalled in its original place.

• Page 174
  CRANKSHAFT Crankshaft-journal-to-crank- shaft-journal-bearing clearance 0.025 X 0.043 mm Limit 0.08 mm CAUTION: Do not interchange the crankshaft jour- nal bearings. To obtain the correct crank- shaft journal-to-crankshaft-journal-bear- clearance prevent engine damage, the crankshaft journal bearings must be installed in their original posi- tion.
• Page 175
  CRANKSHAFT f. Tighten the bolts to specification in the tightening sequence cast on the crank- case. Crankcase bolt 24 Nm (2.4 mSkg) 12 Nm (1.2 mSkg) A Upper crankcase B Lower crankcase NOTE: Lubricate the crankcase bolt threads (M8) and (M6) with engine oil. g.
• Page 176
  CRANKSHAFT For example, if the crankcase “J ” and crankshaft web “J1” numbers are “6” and “2” respectively, then the bearing size for “J1” is: Bearing size for J1: (crankcase) – J1 (crankshaft web) + 1 = 6 – 2 + 1 = 5 (yellow) CRANKSHAFT JOURNAL BEARING…
• Page 177
  CRANKSHAFT NOTE: S Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. S Apply molybdenum disulfide grease onto the bolts, threads, and nut seats. S Make sure that the “Y” mark c on the con- necting rod faces towards the left side of the crankshaft.

• Page 178: Installing The Connecting Rods

  CRANKSHAFT For example, if the connecting rod “P ” and the crankshaft web “P1” numbers are “4” and “1” respectively, then the bearing size for “P ” is: Bearing size for P (connecting rod) – P1 (crankshaft- web) = 4 – 1 = 3 (brown) BIG END BEARING COLOR CODE…

• Page 179
  CRANKSHAFT 4. Align: S bolt heads 1 (with the connecting rod caps) 5. Tighten: S Nuts (connecting rod) Nut (connecting rod): 15 Nm (1.5 mSkg) + (turn the nut another 90_) a. Replace the connecting rod bolts and nuts with new ones. CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle meth-…

• Page 180: Installing The Crankshaft

  CRANKSHAFT EB412720 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft journal upper bearings with the notches b in the crankcase. S Be sure to install each crankshaft journal upper bearing in its original place.

• Page 181: Transmission

  TRANSMISSION TRANSMISSION Order Job name/Part name Q’ty Remarks Removing the transmission Remove the parts in the order listed. Disassembly the crankcase Refer to “CRANKCASE” section. Main axle assembly Refer to “INSTALLING THE Circlip TRANSMISSION” section. Bearing Bearing Drive axle assembly Refer to “INSTALLING THE Circlip TRANSMISSION”…

• Page 182
  TRANSMISSION Order Job name/Part name Q’ty Remarks Disassembling the transmission Disassembly the parts in the order listed. 1st wheel gear 5th wheel gear Circlip Washer 4th wheel gear 3rd wheel gear 6th wheel gear 2nd wheel gear Washer Circlip Drive axle 2nd pinion gear 6th pinion gear 4-70…
• Page 183
  TRANSMISSION Order Job name/Part name Q’ty Remarks 3rd/4th pinion gear Circlip Washer Main axle For assembly, reverse the disassembly procedure. 4-71…

• Page 184: Checking The Transmission

  TRANSMISSION EB413422 CHECKING THE TRANSMISSION 1. Measure: S main axle runout (with a centering device and dial gauge Out of specification ! Replace the main axle. Main axle runout limit 0.02 mm 2. Measure: S drive axle runout (with a centering device and dial gauge Out of specification ! Replace the drive axle.

• Page 185: Installing The Transmission

  TRANSMISSION EB413710 INSTALLING THE TRANSMISSION 1. Install: S oil baffle plate 1 S crankcase breather hose 2 NOTE: Insert the metal clamp 3 on the crankcase breather hose into the slots 4 in the crank- case. 2. Install: S main axle assembly 1 S drive axle assembly 2 S oil seals S circlips…

• Page 186: Shift Drum And Shift Forks

  SHIFT DRUM AND SHIFT FORKS SHIFT DRUM AND SHIFT FORKS 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the shift drum and Remove the parts in the order listed. shift forks Disassembly the crankcase Refer to “CRANKCASE”…

• Page 187: Checking The Shift Forks

  SHIFT DRUM AND SHIFT FORKS EB413400 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks and related components. 1. Check: S shift fork cam follower 1 S shift fork pawl 2 Bends/damage/scoring/wear ! Replace the shift fork. 2.

• Page 188
  SHIFT DRUM AND SHIFT FORKS 2. Install: S shift fork guide bars 1 S shift fork “L” 2 S shift fork “C” 3 S shift fork “R” 4 NOTE: S The embossed marks on the shift forks should face towards the left side of the en- gine and be in the following sequence: “L”, “C”, “R”.
• Page 189
  COOL…
• Page 190
  COOL CHAPTER 5 COOLING SYSTEM RADIATOR …………. . . CHECKING THE RADIATOR .
• Page 191
  COOL…

• Page 192: Cooling System

  COOL RADIATOR COOLING SYSTEM RADIATOR 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the radiator Remove the parts in the order listed. Seat Refer to “FRONT COWLING/SEAT/SIDE Fuel tank COVER/FUEL TANK” section in chapter Drain the coolant Refer to “CHANGING THE COOLANT”…

• Page 193
  COOL RADIATOR EB500010 CHECKING THE RADIATOR 1. Check: S radiator fins Obstruction ! Clean. Apply compressed air to the rear of the ra- diator. Damage ! Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. 2.
• Page 194
  COOL RADIATOR EB500020 INSTALLING THE RADIATOR 1. Fill: S cooling system (with the specified amount of the recom- mended coolant) Refer to “CHANGING THE COOLANT” in chapter 3. 2. Check: S cooling system Leaks ! Repair or replace any faulty part. a.
• Page 195
  COOL THERMOSTAT THERMOSTAT 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Seat Refer to “FRONT COWLING/SEAT/ Fuel tank SIDE COVER/FUEL TANK” section in chapter 3. Drain the coolant Refer to “CHANGING THE COOLANT”…
• Page 196
  COOL THERMOSTAT 23 Nm (2.3 mSkg) 8 Nm (0.8 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the thermostat Disassembly the parts in the order listed. Thermo switch (fan motor) Thermo switch (engine temperature) Thermostat housing cover Refer to “ASSEMBLING THE O-ring THERMOSTAT”…
• Page 197
  COOL THERMOSTAT EB502021 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 80.5 X 83.5_C ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.
• Page 198
  COOL THERMOSTAT EB502030 ASSEMBLING THE THERMOSTAT 1. Install: S thermostat housing 1 S thermostat 2 S O-ring (New) 3 S thermostat housing cover 4 NOTE: Install the thermostat with its breather hole a facing up. 2. Install: S thermo switch (fan motor) 1 23 Nm (2.3 mSkg) S thermo switch (engine temperature) 2 8 Nm (0.8 mSkg)

• Page 199: Water Pump

  COOL WATER PUMP WATER PUMP 10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the water pump Remove the parts in the order listed. Drain the coolant Refer to “CHANGING THE COOLANT” section in chapter 3. Shift arm, drive chain cover Refer to “REMOVING THE ENGINE”…

• Page 200
  COOL WATER PUMP EB503020 REMOVING THE WATER PUMP 1. Remove: S water pump housing 1 NOTE: Tap out the water pump seal from the inside of the water pump housing. EB503032 CHECKING THE WATER PUMP 1. Check: S water pump housing cover S water pump housing 1 S impeller 2 2.
• Page 201
  COOL WATER PUMP NOTE: S Align the slot a on the impeller shaft with the projection b on the oil pump shaft. S Before installing the water pump housing, apply a thin coat of lithium soap base grease onto the O-ring. 2.
• Page 202
  CARB…
• Page 203
  CARB CHAPTER 6 CARBURETORS CARBURETORS …………AIR FILTER CASE .
• Page 204
  CARB…
• Page 205
  CARB CARBURETORS CARBURETORS CARBURETORS AIR FILTER CASE Order Job name/Part name Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seat, fueltank and sidecovers Refer to “FRONT COWLING/SEAT/ SIDE COVER/FUEL TANK” section in chapter 3. Drain the coolant Refer to “CHANGING THE COOLANT”…
• Page 206
  CARB CARBURETORS CARBURETORS Order Job name/Part name Q’ty Remarks Removing the carburetors Remove the parts in the order listed. NOTE: Throttle position sensor lead Air filter joint screw Disconnect the coupler. Carburetors joint screw Carburetor inlet/outlet hose Carburetors assembly Starter cable Throttle cable For installation, reverse the removal procedure.
• Page 207
  CARB CARBURETORS Order Job name/Part name Q’ty Remarks Disassembling the carburetors Disassembly the parts in the order listed. Starter plunger link Carburetors assembly #1, #2, #3, #4 Vacuum chamber cover Refer to “ASSEMBLING THE Piston valve spring CARBURETERS” section. Piston valve Needle kit Float chamber Float chamber gasket…
• Page 208
  CARB CARBURETORS Order Job name/Part name Q’ty Remarks Main jet holder Needle jet Pilot jet Pilot screw set Refer to “ASSEMBLING THE CARBURETORS” section. Starter plunger kit For assembly, reverse the disassembly procedure.
• Page 209
  CARB CARBURETORS EB600031 CHECKING THE CARBURETORS The following procedure applies to all of the car- buretors. 1. Check: S carburetor body S float chamber S main jet holder Cracks/damage ! Replace. 2. Check: S fuel passages Obstruction ! Clean. a. Wash the carburetor in a petroleumbased solvent.
• Page 210
  CARB CARBURETORS 8. Check: S piston valve 1 Damage/scratches/wear ! Replace. S rubber diaphragm 2 Cracks/tears ! Replace. 9. Check: S vacuum chamber cover 1 S piston valve spring 2 S jet needle holder 3 Cracks/damage ! Replace. 10. Check: S jet needle kit 1 S needle jet 2 S main jet 3…
• Page 211
  CARB CARBURETORS EB600041 ASSEMBLING THE CARBURETORS The following procedure applies to all of the car- buretors. CAUTION: S Before assembling the carburetors, wash all of the parts in a petroleum- based solvent. S Always use a new gasket. 1. Install: S O-ring (New) S washer S pilot screw spring…
• Page 212
  CARB CARBURETORS 4. Install: S fuel feed joints 1 S hose joints 2 S spacer 3 S connecting bolt 4 S starter plunger link 5 S throttle cable holder 6 S spacer 7 S connecting bolt 8 NOTE: S Do not tighten the connecting bolts yet. S Install the throttle arm 9 onto carburetors #1, #2, and #4 between the spring synchronizing screw…
• Page 213
  CARB CARBURETORS EB600062 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: S fuel level a Out of specification ! Adjust Fuel level (above the float chamber mating surface) 4.5 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.
• Page 214
  CARB CARBURETORS EB600070 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: S Before adjusting the throttle position sen- sor, the engine idling speed should be properly adjusted. S When installing the throttle position sen- sor, adjust its angle according to the RPM which is displayed on the tachometer.
• Page 215
  CARB CARBURETORS b. Disconnect the throttle position sensor coupler. c. Reconnect the throttle position sensor coupler. NOTE: After reconnecting the throttle position sen- sor coupler, the tachometer switches to the throttle position sensor adjustment mode. d. Loosen the throttle position sensor screws 1 .
• Page 216
  CARB 6-12…
• Page 217
  CHAS…
• Page 218
  CHAS CHAPTER 7 CHASSIS FRONT WHEEL AND BRAKE DISCS ……..FRONT WHEEL .
• Page 219
  CHAS STEERING HEAD …………7-53 LOWER BRACKET .

• Page 220: Front Wheel And Brake Discs

  CHAS FRONT WHEEL AND BRAKE DISC CHASSIS FRONT WHEEL AND BRAKE DISC 40 Nm(4.0 mSkg) 67 Nm (6.7 mSkg) 20 Nm (2.0 mSkg) 23 Nm(2.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the flont wheel and brake Remove the parts in the order listed. discs Wheel axle pinch bolt NOTE:…

• Page 221: Front Wheel

  CHAS FRONT WHEEL AND BRAKE DISC FRONT WHEEL Order Job name/Part name Q’ty Remarks Disassembling the front wheel Disassembly the parts in the order listed. Oil seal Bearing Spacer Bearing For assembly, reverse the disassembly prodedure.

• Page 222: Removing The Front Wheel

  CHAS FRONT WHEEL AND BRAKE DISC EB700102 REMOVING THE FRONT WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

• Page 223
  CHAS FRONT WHEEL AND BRAKE DISC 3. Measure: S front wheel radial runout 1 S front wheel lateral runout 2 Over the specified limits ! Replace. Front wheel radial runout limit 1.0 mm Front wheel lateral runout limit 0.5 mm 4.

• Page 224: Checking The Brake Discs

  CHAS FRONT WHEEL AND BRAKE DISC EB700414 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: S brake disc Damage/galling ! Replace. 2. Measure: S brake disc deflection a Out of specification ! Correct the brake disc deflection or replace the brake disc.

• Page 225: Installing The Front Wheel

  CHAS FRONT WHEEL AND BRAKE DISC EB700722 INSTALLING THE FRONT WHEEL 1. Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2. Install: S Speed sensor unit NOTE: Make sure that the speed sensor unit and the wheel hud are installed with the two pro- jections a meshed into the two slots b re- spectively.

• Page 226: Adjusting The Front Wheel Static Balance

  CHAS FRONT WHEEL AND BRAKE DISC EB700901 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: S After replacing the tire. wheel or both, the front wheel static balance should be ad- justed. S Adjust the front wheel static balance with the brake discs installed. 1.

• Page 227: Rear Wheel, Brake Disc And Rear Wheel Sprocket

  REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET REAR WHEEL 117 Nm (11.7 mSkg) 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear wheel Remove the parts in the order listed. Brake caliper Washer Wheel axle…

• Page 228: Brake Disc And Rear Wheel Sprocket

  REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET BRAKE DISC AND REAR WHEEL SPROCKET 60 Nm (6.0 mSkg) 23 Nm (2.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the brake disk and rear Remove the parts in the order listed. wheel sprocket Collar (left/right) Brake disc…

• Page 229
  REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET DIASSEMBLY THE REAR WHEEL Order Job name/Part name Q’ty Remarks Disassembling the rear wheel Disassembly the parts in the order listed. Oil seal Bearing Collar Bearing For assembly, reverse the disassembly procedure.

• Page 230: Removing The Rear Wheel

  REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET EB701100 REMOVING THE REAR WHEEL 1. Stand the motorcycle on a level surface. Securely support the motorcycle so. that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

• Page 231: Checking And Replacing The Rear Wheel Sprocket

  REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET 3. Measure: S rear wheel radial runout S rear wheel lateral runout Refer to “FRONT WHEEL AND BRAKE DISC”. EB701440 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: S rear wheel sprocket More than 1/4 tooth a wear ! Replace the rear wheel sprocket.

• Page 232: Adjusting The Rear Wheel Static Balance

  REAR WHEEL, BRAKE DISC CHAS AND REAR WHEEL SPROCKET EB701900 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be ad- justed. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.

• Page 233: Front And Rear Brakes

  CHAS FRONT AND REAR BRAKES FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the front brake pads Remove the parts in the order listed. Brake caliper Brake pads clip Brake pad pin Refer to “REPLACING THE FRONT Brake pad spring BRAKE PADS”…

• Page 234: Rear Brake Pads

  CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 10 Nm (1.0 mSkg) 40 Nm (4.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Caliper Brake pad pin Refer to “REPLACING THE REAR Brake pad/shim BRAKE PADS”…

• Page 235: Replacing The Front Brake Pads

  CHAS FRONT AND REAR BRAKES EB702100 CAUTION: Disc brake componets rarely require dis- assembly. Tehrefore, always follow these preven- tive measures: S Never disassemble brake components unless absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the en- tire brake system must be disas- sembled, drained, cleaned, properly filled, and bled after reassembly.

• Page 236
  CHAS FRONT AND REAR BRAKES 3. Remove: S brake pads 1 (along with the brake pad shims) 4. Measure: S brake pad wear limit a Out of specification ! Replace the brake pads as a set. Brake pad wear limit 0.5 mm 5.

• Page 237: Replacing The Rear Brake Pads

  CHAS FRONT AND REAR BRAKES EB702113 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not nec- essary to disconnect the brake hose or dis- assemble the brake caliper. 1. Remove: S brake caliper 1 2. Remove: S brake pad pins 1 3.

• Page 238
  CHAS FRONT AND REAR BRAKES 6. Install: S brake pad pins 1 10 Nm (1.0 mSkg) S brake caliper 40 Nm (4.0 mSkg) 7. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

• Page 239: Front Brake Master Cylinder

  CHAS FRONT AND REAR BRAKES FRONT BRAKE MASTER CYLINDER 10 Nm(1.0 mSkg) 30 Nm(3.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Drain the brake fluid Brake lever Brake switch lead Brake switch Union bolt…

• Page 240
  CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake Disassembly the parts in the order listed. master cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 7-21…
• Page 241
  CHAS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER 30 Nm(3.0 mSkg) 4 Nm(0.4 mSkg) 23 Nm(2.3 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Side cover (right) Drain the brake fluid Master cylinder bolt Union bolt…
• Page 242
  CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the rear brake master Disassembly the parts in the order listed. cylinder Master cylinder boot Circlip Master cylinder kit Spring For assembly, reverse the disassembly procedure. 7-23…
• Page 243
  CHAS FRONT AND REAR BRAKES EB702210 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Befor disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Disconnect: S brake switch coupler 1 (from the brake switch) 2.

• Page 244: Checking The Front And Rear Brake Master Cylinders

  CHAS FRONT AND REAR BRAKES EB702242 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: S brake master cylinder Damage/scratches/wea ! Replace. S brake fluid delivery passages (brake master cylinder body) Obstruction ! Blow out with compressed air.

• Page 245: Assembling And Installing The Front Brake Master Cylinder

  CHAS FRONT AND REAR BRAKES EB702270 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER S Before installation, all internal brake components should be cleaned and lu- bricated with clean or new brake fluid. S Never use solvents on internal brake components.

• Page 246: Assembling And Installing The Rear Brake Master Cylinder

  CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 3. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper…

• Page 247
  CHAS FRONT AND REAR BRAKES S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.

• Page 248: Front Brake Calipers

  CHAS FRONT AND REAR BRAKES FRONT BRAKE CALIPERS 40 Nm(4.0 mSkg) 30 Nm(3.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. Drain the brake fluid Union bolt Refer to “ASSEMBLING AND Copper washer INSTALLING THE FRONT BRAKE Brake hose…

• Page 249: Disassembling The Front Brake Caliper

  CHAS FRONT AND REAR BRAKES Order Job name/Part name Q’ty Remarks Disassembling the front brake Disassembly the parts in the order listed. calipers Clip Pad pin Refer to “REPLACING THE FRONT Brake pad spring BRAKE PADS” section. Brake pad Bleed screw kit Brake caliper piston Refer to “DISASSEMBLING THE FRONT Dust seal…

• Page 250
  CHAS FRONT AND REAR BRAKES REAR BRAKE CALIPER 30 Nm(3.0 mSkg) 40 Nm(4.0 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Drain the brake fluid Union bolt Refer to “ASSEMBLING AND Copper washer INSTALLING THE REAR BRAKE Brake hose…
• Page 251
  CHAS FRONT AND REAR BRAKES 10 Nm (1.0 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the rear brake caliper Disassembly the parts in the order listed. Pad pin Pad spring Refer to “REPLACING THE REAR Brake pad assembly/shim BRAKE PAD” section. Bleed screw kit Brake caliper piston Refer to “DISASSEMBLING THE REAR…
• Page 252
  CHAS FRONT AND REAR BRAKES 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: S union bolt 1 S copper washers 2 S brake hose 3 NOTE:…

• Page 253: Disassembling The Rear Brake Caliper

  CHAS FRONT AND REAR BRAKES EB702322 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 NOTE: Put the end of the brake hose into a contain- er and pump out the brake fluid carefully.

• Page 254: Assembling And Installing The Front Brake Calipers

  CHAS FRONT AND REAR BRAKES 1. Check: S brake caliper pistons 1 Rust/scratches/wear Replace brake caliper. S brake caliper cylinders 2 Scratches/wear ! Replace the brake cali- per. S brake calipers 3 Cracks/damage ! Replace. S brake fluid delivery passages (brake caliper body) Obstruction ! Blow out with compressed air.

• Page 255
  CHAS FRONT AND REAR BRAKES CAUTION: When installing the brake hose onto the brake caliper, make sure that the brake pipe a touches the projection a on the brake caliper. 2. Remove: S brake caliper 3. Install: S brake pads S brake spring S brake caliper pins S brake caliper clips…

• Page 256: Assembling And Installing The Rear Brake Caliper

  CHAS FRONT AND REAR BRAKES 5. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.

• Page 257
  CHAS FRONT AND REAR BRAKES 2. Remove: S brake caliper 3. Install: S brake pad spring S brake pads S brake pad pins S brake caliper S brake hose holder Refer to “REPLACING THE BRAKE PADS”. Brake caliper pad pin 10 Nm (1.0 mSkg) Brake caliper bolt 40 Nm (4.0 mSkg)
• Page 258
  CHAS FRONT AND REAR BRAKES 6. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: S brake pedal operation Soft or spongy feeling ! Bleed the brake system.

• Page 259: Front Fork

  CHAS FRONT FORK FRONT FORK 30 Nm (3.0 mSkg) 30 Nm (3.0 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the front fork Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”…

• Page 260
  CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Disassembling the front fork Disassembly the parts in the order listed. Cap bolt O-ring Spacer Washer Front fork spring Refer to “ASSEMBLING THE FRONT Dust seal FORK LEGS”…
• Page 261
  CHAS FRONT FORK 23 Nm (2.3 mSkg) 30 Nm (3.0 mSkg) Order Job name/Part name Q’ty Remarks Outer tube bushing Refer to “ASSEMBLING THE FRONT Oil flow stopper FORK LEGS” section. For assembly, reverse the disassembly procedure. 7-42…

• Page 262: Removing The Front Fork Legs

  CHAS FRONT FORK 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. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

• Page 263: Checking The Front Fork Legs

  CHAS FRONT FORK 3. Remove: S inner tube a. Hold the front fork leg horizontally. b. Securely clamp the brake caliper bracket in a vise with soft jaws. c. Separate the inner tube from the outer tube by pulling the inner tube forcefully but carefully.

• Page 264: Assembling The Front Fork Legs

  CHAS FRONT FORK 4. Check: S cap bolt O-ring Damage/wear ! Replace. EB703700 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. S Make sure that the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor handling and a loss of stability.

• Page 265
  (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.475 L Yamaha fork and shock oil 10 W or equivalent. Front fork leg oil level a (from the top of the inner tube, with…

• Page 266: Installing The Front Fork Legs

  CHAS FRONT FORK NOTE: S While filling the front fork leg, keep it up- right. S After filling, slowly pump the front fork leg up and down to distribute the fork oil. 9. Install: S spring 1 S spring seat 2 S spacer 3 S cap bolt NOTE:…

• Page 267: Handlebar

  CHAS HANDLEBAR HANDLEBAR 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the handle bar Remove the parts in the order listed. Master cylinder bracket Master cylinder assembly Throttle cable housing cover Handle bar switch (right) Throttle cable housing…

• Page 268
  CHAS HANDLEBAR 10 Nm (1.0 mSkg) 7 Nm (0.7 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Grip (left) Refer to “REMOVING THE HANDLEBAR” Clutch lever holder section. Upper handlebar holder Refer to “INSTALLING THE Handle bar HANDLEBAR”…

• Page 269: Removing The Handlebar

  CHAS HANDLEBAR EB704100 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S throttle cable housing 1 S throttle grip 2 NOTE: While removing the throttle cable housing, pull back the rubber cover 3 .

• Page 270: Installing The Handlebar

  CHAS HANDLEBAR EB704701 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Install: S handlebar 1 S upper handlebar holders 2 23 Nm (2.3 mSkg) CAUTION: S First, tighten the bolts on the front side a of the handlebar holder, then on the…

• Page 271
  CHAS HANDLEBAR 6. Install: S throttle grip 1 S throttle cable housing 2 S throttle cables 3 NOTE: Apply a thin coat of lithium soap base grease onto the inside of the throttle grip and install it onto the handlebar. NOTE: S Align the projection a on the throttle cable housing with the hole b in the handlebar.

• Page 272: Steering Head

  CHAS STEERING HEAD STEERING HEAD LOWER BRACKET 110 Nm (11.0 mSkg) 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) Order Job name/Part name Q’ty Remarks Removing the lower bracket Remove the parts in the order listed. Front cowling Refer to “FRONT COWUNG/SEAT/ SIDE COVER/FUEL TANK”…

• Page 273
  CHAS STEERING HEAD 110 Nm (11.0 mSkg) 52 Nm (5.2 mSkg) 18 Nm (1.8 mSkg) Order Job name/Part name Q’ty Remarks Lower bracket Ball race cover Ball bearing Refer to “INSTALLING THE STEERING Rubber washer 1 HEAD” section. Ball bearing For installation, reverse the removal procedure.

• Page 274: Removing The Lower Bracket

  CHAS STEERING HEAD EB705102 REMOVING THE LOWER BRACKET 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S upper ring nut S lower ring nut 1 NOTE: Hold the lower ring nut with the exhaust and steering nut wrench 2 , then remove the up-…

• Page 275: Installing The Steering Head

  CHAS STEERING HEAD 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: If the bearing race is not installed proper- ly, the steering head pipe could be dam- aged.

• Page 276: Rear Shock Absorber And Relay Arm

  CHAS REAR SHOCK ABSORBER AND RELAY ARM REAR SHOCK ABSORBER AND RELAY ARM 48 Nm (4.8 mSkg) 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) 48 Nm (4.8 mSkg) Order Job name/Part name Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.

• Page 277
  CHAS REAR SHOCK ABSORBER AND RELAY ARM 48 Nm (4.8 mSkg) 40 Nm (4.0 mSkg) 40 Nm (4.0 mSkg) 48 Nm (4.8 mSkg) Order Job name/Part name Q’ty Remarks Bolt = 80 mm Relay arm Self-locking nut/washer Bolt = 120 mm Connecting plate Spacer Spacer…

• Page 278: Handling The Rear Shock Absorber

  CHAS REAR SHOCK ABSORBER AND RELAY ARM EB706101 HANDLING THE REAR SHOCK ABSORBER This rear shock absorber contain highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may re- sult from improper handling of the rear shock absorber.

• Page 279: Removing The Rear Shock Absorber Assembly

  CHAS REAR SHOCK ABSORBER AND RELAY ARM EB706204 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the rear wheel is elevated.

• Page 280: Checking The Rear Shock Absorber Assembly

  CHAS REAR SHOCK ABSORBER AND RELAY ARM EB706401 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 1. Check: S rear shock absorber rod Bends/damage ! Replace the rear shock absorber assembly. S rear shock absorber oil leaks ! Replace the rear shock absorb- er assembly.

• Page 281: Swingarm And Drive Chain

  CHAS SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN 115 Nm (11.5 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Removing the swingarm and drive Removing the parts in the order listed. chain Rear wheel Refer to “REAR WHEEL, BRAKE DISC AND REAR WHEEL SPROCKET”…

• Page 282
  CHAS SWINGARM AND DRIVE CHAIN 115 Nm (11.5 mSkg) 23 Nm (2.3 mSkg) 7 Nm (0.7 mSkg) Order Job name/Part name Q’ty Remarks Spacer Bearing Washer For installation, reverse the removal procedure. 7-63…

• Page 283: Removing The Swingarm

  CHAS SWINGARM AND DRIVE CHAIN EB707100 NOTE: Before removing the drive sprocket, drive chain, and rear wheel, measure the drive chain slack and the length of a ten-link sec- tion of the drive chain. EB707111 REMOVING THE SWINGARM 1. Stand the motorcycle on a level surface. Securely support the motorcycle so that there is no danger of it falling over.

• Page 284: Checking The Swingarm

  CHAS SWINGARM AND DRIVE CHAIN EB707400 CHECKING THE SWINGARM 1. Check: S swingarm Bends/cracks/damage ! Replace. 2. Check: S pivot shaft Roll the pivot shaft on a flat surface. Bends ! Replace. Do not attempt to straighten a bent pivot shaft.

• Page 285: Checking The Drive Chain

  CHAS SWINGARM AND DRIVE CHAIN EB707410 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Ten-link drive chain section limit (maximum) 150 mm NOTE: S While measuring the ten-link section, push down on the drive chain to increase its ten- sion.

• Page 286: Installing The Swingarm

  CHAS SWINGARM AND DRIVE CHAIN 5. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 6. Check: S drive sprocket S rear wheel sprocket More than 1/4 tooth a wear ! Replace the drive chain sprockets as a set. Bent teeth ! Replace the drive chain sprockets as a set.

• Page 287: Installing The Drive Chain

  CHAS SWINGARM AND DRIVE CHAIN 4. Adjust: S drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Drive chain slack 30 X 45 mm EB707710 INSTALLING THE DRIVE CHAIN 1. Lubricate: S drive chain Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains 2.

• Page 288
  – ELEC…
• Page 289
  ELEC CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS ……….CIRCUIT DIAGRAM .
• Page 290
  ELEC…
• Page 291
  ELEC ELECTRICAL COMPONENTS EB800000 ELECTRICAL ELECTRICAL COMPONENTS Main switch Starting circuit cut-off relay Rectifier/ Regulator Fuel sender Flasher relay Thermo switch (warning light) Rear brake switch Sidestand switch Thermo switch (fan motor) Battery Neutral switch Horn Ignitor unit Oil level gauge Diode Starter relay Ignition coil…
• Page 292
  ELEC CIRCUIT DIAGRAM CIRCUIT DIAGRAM…

• Page 293: Circuit Diagram

  ELEC CIRCUIT DIAGRAM 1 A.C. magneto High beam indicator light 2 Rectifier regulator Turn indicator lights 3 Main switch Meter lights 4 Battery Clutch switch 5 Fuse (back up) Oil level switch 6 Fuse (main) Flasher relay 7 Starter relay Horn 8 Starter motor Pass switch…

• Page 294
  ELEC CHECKING SWITCHES YP-N CHECKING SWITCHES CHECKING STEPS Using pocket tester, check switches for continu- ity between their terminals to determine whether they are correctly connected. Replace the switch component if any of the com- binations does not produce the correct reading. Pocket tester: 90890-03112 NOTE:…
• Page 295
  ELEC CHECKING SWITCHES YP****** SWITCH POSITION AND TERMINAL CONNECTION Before checking a switch refer to the checking switches as shown in the left page and check for the correct terminal connections (closed circuit) according to the color combinations shown in the chart. Poor connection, fault ! Repair or replace.
• Page 296
  ELEC IGNITION SYSTEM EB802000 IGNITION SYSTEM CIRCUIT DIAGRAM…
• Page 297
  ELEC IGNITION SYSTEM EB802010 TROUBLESHOOTING IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK): Procedure Check: 1. Fuses (main and ignition) 8. Engine stop switch 2. Battery 9. Neutral switch 3. Spark plugs 10. SIdestand switch 4. Ignition spark gap 11.
• Page 298
  ELEC IGNITION SYSTEM EB802013 3. Spark plugs Standard spark plug: CR9E, CR8E/U27ESR-N, U24ESR-N S Check the spark plug condition. NGK/NIPPONDENSO S Check the spark plug type. S Check the spark plug gap. Refer to “SPARK LUG INSPECTION” in CHAPTER 3. INCORRECT Spark plug gap: 0.7 X 0.8 mm…
• Page 299
  ELEC IGNITION SYSTEM EB802015 5. Spark plug cap resistance S Remove the spark plug cap. S Connect the pocket tester (Ω 1k) to the spark plug cap. S Check if the spark plug cap has the speci- OUT OF SPECIFICATION fied resistance.
• Page 300
  ELEC IGNITION SYSTEM EB802017 7. Main switch S Disconnect the main switch couplers from the wire harness. S Check for continuity as follows: – Brown/Blue NO CONTINUITY Replace the main switch. CONTINUITY EB802018 8. Engine stop switch S Disconnect the right handlebar switch cou- pler from the wire harness.
• Page 301
  ELEC IGNITION SYSTEM NO CONTINUITY Replace the main switch. CONTINUITY EB80201A 10. Sidestand switch S Disconnect the sidestand switch coupler from the wire harness. S Check for continuity as follows: Black – Black NO CONTINUITY Replace the sidestand switch. CONTINUITY 11.
• Page 302
  ELEC IGNITION SYSTEM Tester lead!Blue/Yellow INCORRECT Continuity Tester lead!Light green Tester lead!Blue/Yellow Tester lead!Light green Continuity Replace the relay unit. CORRECT EB80201C 12. Pickup coil resistance S Disconnect the pickup coil coupler from the wire harness. S Connect the pocket tester (Ω…
• Page 303
  ELEC ELECTRIC STARTING SYSTEM EB803000 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 8-13…
• Page 304
  ELEC ELECTRIC STARTING SYSTEM EB803010 STARTING CIRCUIT OPERATION The starting circuit on this model consists of the starter motor, starter relay, and the starting cir- cuit cut-off relay. If the engine stop switch is on “RUN” and the main switch is on “ON” (both switches are closed), the starter motor can op- erate only if.

• Page 305: Electric Starting System

  ELEC ELECTRIC STARTING SYSTEM EB803020 TROUBLESHOOTING IF THE STARTER MOTOR FAILS TO OPERATE: Procedure Check: 1. Fuses (main and ignition) 8. Neutral switch 2. Battery 9. Sidestand switch 3. Starter motor 10. Clutch switch 4. Starting circuit cut-off relay 11. Start switch 5.

• Page 306
  ELEC ELECTRIC STARTING SYSTEM EB803021 3. Starter motor S A wire that is used as a jumper lead must S Connect the battery positive terminal have the equivalent capacity or more as starter motor cable using a jumper lead that of the battery lead, otherwise the jumper lead may burn.
• Page 307
  ELEC ELECTRIC STARTING SYSTEM EB803024 5. Starter relay S Disconnect the relay unit coupler from the wire harness. S Connect the pocket tester (Ω X 1) and bat- tery (12 V) to the relay unit coupler termi- nals. Battery (+) terminal ! Red/White terminal Battery (–) terminal ! NO CONTINUITY…
• Page 308
  ELEC ELECTRIC STARTING SYSTEM EB802018 7.Engine stop switch S Disconnect the right handlebar switch cou- pler from the wire harness. S Check for continuity as follows: Red/White – Red/White NO CONTINUITY Replace the right handlebar switch. CONTINUITY EB802019 8. Neutral switch S Disconnect the neutral switch/lead from the neutral switch.
• Page 309
  ELEC ELECTRIC STARTING SYSTEM EB80201A 9. Sidestand switch S Disconnect the sidestand switch coupler from the wire harness. S Check for continuity as follows: Black – Black NO CONTINUITY Replace the sidestand switch. CONTINUITY EB803025 10. Clutch switch S Disconnect the clutch switch coupler from the wire harness.
• Page 310
  ELEC ELECTRIC STARTING SYSTEM EB803027 11. Start switch S Disconnect the right handlebar switch cou- pler from the wire harness. S Check for continuity as follows: Blue/White – Black NO CONTINUITY Replace the right handlebar switch. CONTINUITY EB803026 12. Diode (starting circuit cut-off relay) S Remove the relay unit from the wire har- ness.
• Page 311
  ELEC ELECTRIC STARTING SYSTEM EB803028 13. Wiring connection POOR CONNECTION S Check the connections of the entire starting system. Refer to “CIRCUIT DIAGRAM”. Properly connect the starting system. 8-21…
• Page 312
  ELEC ELECTRIC STARTING SYSTEM EB803030 STARTER MOTOR Order Job name/Part name Q’ty Remarks Starter motor removal Remove the parts in order. Starter motor Starter motor lead Reverse the removal procedure for installation. Starter motor disassembly Disassembly the parts in order. Front bracket Washers Rear bracket…
• Page 313
  ELEC ELECTRIC STARTING SYSTEM CHECKING THE STARTER MOTOR 1. Measure: S Brush length a Out of specification ! Replace. Brush length wear limit: 4 mm 2. Measure: S Brush spring force Fatigue/out of specification ! Replace as a set. Brush spring force: 780 X 1,020 g 3.
• Page 314
  ELEC ELECTRIC STARTING SYSTEM 5. Measure: S Commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit: 27 mm 6. Measure: S Mica undercut a Out of specification ! Scrape the mica to the proper measurement using a hacksaw blade which has been grounded to fit the commutator.
• Page 315
  ELEC CHARGING SYSTEM EB804000 CHARGING SYSTEM CIRCUIT DIAGRAM 8-25…

• Page 316: Charging System

  ELEC CHARGING SYSTEM EB803020 TROUBLESHOOTING IF THE BATTERY IS NOT CHARGED: Procedure Check: 1. Fuse (main) 4. Stator coil resistance 2. Battery 5. Wiring connections (the entire charging 3. Charging voltage system) NOTE: S Remove the following part(s) before trouble- Engine tachometer: shooting: 90890-03113…

• Page 317
  ELEC CHARGING SYSTEM EB804011 3. Charging voltage S Connect the engine tachometer to the spark plug lead. S Connect the pocket tester (DC 20 V) to the battery. Tester (+) lead ! Battery (+) terminal Tester (–) lead ! Battery (–) terminal S Measure the battery terminal voltage.
• Page 318
  ELEC CHARGING SYSTEM EB804015 5. Wiring connections POOR CONNECTION S Check the connections of the entire charg- ing system. Refer to “CIRCUIT DIAGRAM”. Properly connect the charging system. CORRECT Replace the rectifier/regulator. 8-28…
• Page 319
  ELEC LIGHTING SYSTEM EB805000 LIGHTING SYSTEM CIRCUIT DIAGRAM 8-29…
• Page 320
  ELEC LIGHTING SYSTEM EB803020 TROUBLESHOOTING IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHTS, TAILLIGHT, AUXILIARY LIGHT AND/OR METER LIGHT FAIL TO COME ON: Procedure Check: 1. Fuses (main and head) 5. Dimmer switch 2. Battery 6. Pass switch (for Europe and Australia) 3.
• Page 321
  ELEC LIGHTING SYSTEM EB802017 3. Main switch S Disconnect the main switch couplers from the wire harness. S Check for continuity as follows: – Brown/Blue Blue/Red – Blue NO CONTINUITY Replace the main switch. CONTINUITY EB805011 4. Lights switch S Disconnect the right handlebar switch cou- pler from the wire harness.
• Page 322
  ELEC LIGHTING SYSTEM 5. Dimmer switch S Disconnect the left handlebar switch cou- plers from the wire harness. S Turn the dimmer switch to “HI”. S Check for continuity as follows: NO CONTINUITY Blue/Black – Yellow CONTINUITY The dimmer switch is faulty. Replace the left handlebar switch.

• Page 323: Lighting System

  ELEC LIGHTING SYSTEM EB805020 LIGHTING SYSTEM CHECK 1. If the headlight and the high beam indicator light fail to come on: 1. Bulb and bulb socket. NO CONTINUITY S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY Headlight: 2.

• Page 324
  ELEC LIGHTING SYSTEM EB805021 2. If the meter light fails to come on: 1. Bulb and bulb socket NO CONTINUITY S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2. Voltage S Connect the pocket tester (20 V) to the bulb socket coupler.
• Page 325
  ELEC LIGHTING SYSTEM S Turn the main switch to “ON”. OUT OF SPECIFICATION S Turn the lights switch to “ON” or “PO”. S Check the voltage (12 V) of the “Blue” lead on the bulb socket connector. The wiring circuit from the main switch to the MEETS bulb socket connector is faulty, repair it.

• Page 326: Signal System

  ELEC SIGNAL SYSTEM EB806000 SIGNAL SYSTEM CIRCUIT DIAGRAM 8-36…

• Page 327
  ELEC SIGNAL SYSTEM 3 Main switch 4 Battery 6 Fuse (main) 16 Neutral switch 18 Fuel sender 20 Diode 25 Fuel meter 26 Fuel level warning light 28 Neutral indicator light 29 Oil level warning light 31 Turn indicator light 34 Oil level switch 35 Flasher relay 36 Horn…
• Page 328
  ELEC SIGNAL SYSTEM B806010 TROUBLESHOOTING IF THE TURN SIGNAL LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT FAIL TO COME ON: IF THE HORN FAILS TO SOUND: Procedure Check: 1. Fuses (main and signal) 2. Battery 3. Main switch 4. Wiring connection (the entire signal system) NOTE: S Remove the following part(s) before trouble- Pocket tester:…
• Page 329
  ELEC SIGNAL SYSTEM EB802017 3. Main switch S Disconnect the main switch coupler from the wire harness. S Check for continuity as follows: – Brown/Blue NO CONTINUITY Replace the main switch. CONTINUITY EB806011 POOR CONNECTION 4. Wiring connections S Check the connections of the entire signal system.
• Page 330
  ELEC SIGNAL SYSTEM EB806020 SIGNAL SYSTEM CHECK 1. If the horn fails to sound: 1. Horn switch S Disconnect the left handlebar switch cou- NO CONTINUITY pler from the wire harness. S Disconnect the “Black/White” lead at the horn terminal. S Check for continuity as follows: Replace the left handlebar switch.
• Page 331
  ELEC SIGNAL SYSTEM HORN SOUNDS The horn is not faulty. HORN DOES NOT SOUND 4. Voltage S Connect the pocket tester (DC 20 V) to the horn at the “Pink” terminal. Tester (+) lead ! Brown lead Tester (–) lead ! Pink S Turn the main switch to “ON”.
• Page 332
  ELEC SIGNAL SYSTEM 2. Brake switch S Disconnect the front brake switch leads. S Disconnect the rear brake switch coupler from the wire harness. S Check for continuity as follows: Brown – Green/Yellow Black – Black NO CONTINUITY Front brake switch Rear brake switch CONTINUITY Replace the brake switch.
• Page 333
  ELEC SIGNAL SYSTEM EB806023 3. If the turn signal light and/or turn indicator light fails to blink: 1. Bulb and bulb socket NO CONTINUITY S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2.
• Page 334
  ELEC SIGNAL SYSTEM 4. Voltage S Connect the pocket tester (DC 20 V) to the flasher relay coupler. Tester (+) lead ! Brown/White terminal Tester (–) lead ! Frame ground S Turn the main switch to “ON”. OUT OF SPECIFICATION S Turn the turn switch to “L”…
• Page 335
  ELEC SIGNAL SYSTEM EB806024 4. If the neutral indicator light fails to come on: 1. Bulb and bulb socket NO CONTINUITY S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2. Neutral switch S Disconnect the neutral switch lead from the neutral switch.
• Page 336
  ELEC SIGNAL SYSTEM 4. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket coupler. Tester (+) lead ! Brown terminal Tester (–) lead ! Frame ground OUT OF SPECIFICATION S Turn the main switch to “ON”. S Check the voltage (12 V).
• Page 337
  ELEC SIGNAL SYSTEM 3. Oil level switch S Drain the engine oil and remove the oil level switch from the oil pan. S Connect the pocket tester (Ω 1) to the oil level switch. Tester (+) lead ! Black/Red terminal Tester (–) lead ! Frame ground NO CONTINUITY S Check the oil level switch for continuity.
• Page 338
  ELEC SIGNAL SYSTEM 5. Start switch S Disconnect the right handlebar switch cou- pler from the wire harness. S Check for continuity as follows: Blue/White – Black NO CONTINUITY Replace the right handlebar switch. CONTINUITY 6. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector.
• Page 339
  ELEC SIGNAL SYSTEM 6. If the fuel level warning light fails to come on or the fuel meter fails to operate: 1. Bulb and bulb socket NO CONTINUITY S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 2.
• Page 340
  ELEC SIGNAL SYSTEM 3. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. Tester (+) lead ! Brown terminal Tester (–) lead ! Green/Red terminal OUT OF SPECIFICATION S Drain the fuel. S Turn the main switch to “ON”. S Check the voltage (12 V).
• Page 341
  ELEC COOLING SYSTEM EB807000 COOLING SYSTEM CIRCUIT DIAGRAM 8-51…
• Page 342
  ELEC COOLING SYSTEM EB807010 TROUBLESHOOTING IF THE FAN MOTOR FAILS TO TURN: IF THE WATER TEMPERTATURE METER FAILS TO MOVE, WHEN THE ENGINE IS WARM: Procedure Check: 1. Fuses (main, signal and fan) 6. Engine temperature warning light 2. Battery 7.
• Page 343
  ELEC COOLING SYSTEM EB802017 3. Main switch S Disconnect the main switch coupler from the wire harness. S Check for continuity as follows: – Brown/Blue NO CONTINUITY Replace the main switch. CONTINUITY EB807011 4. Fan motor S Disconnect the fan motor coupler. S Connect the battery (12 V) as shown.
• Page 344
  ELEC COOLING SYSTEM EB802017 5. Thermo switch (fan, engine temperature) Handle the thermo switch with special care. S Remove the thermo switch from the thermo- Never subjct it to strong shocks or allow it to static valve housing. be dropped. Should it be dropped, it must be S Connect the pocket tester (Ω…
• Page 345
  ELEC COOLING SYSTEM 6. Engine temperature warning light NO CONTINUITY S Check the bulb and bulb socket for continu- ity. Replace the bulb and/or bulb socket. CONTINUITY 7. Voltage S Connect the pocket tester (DC 20 V) to the bulb socket connector. Tester (+) lead ! Brown lead Tester (–) lead ! Green/White lead OUT OF SPECIFICATION…
• Page 346
  ELEC FUEL PUMP SYSTEM EB808000 FUEL PUMP SYSTEM CIRCUIT DIAGRAM 8-56…
• Page 347
  ELEC FUEL PUMP SYSTEM EB808010 1 Battery FUEL PUMP CIRCUIT OPERATION 2 Fuse (main) The fuel pump circuit consists of the fuel pump 3 Main switch relay, fuel pump, engine stop switch and ignitor 4 Fuse (ignition) unit. 5 Engine stop switch The ignitor unit includes the control unit for the 6 Ignitor unit fuel pump.
• Page 348
  ELEC COOLING SYSTEM EB808020 TROUBLESHOOTING IF THE FUEL PUMP FAILS TO OPERATE: Procedure Check: 1. Fuses (main and ignition) 5. Fuel pump relay (starting circuit cut-off relay) 2. Battery 6. Fuel pump resistance 3. Main switch 7. Wiring connections (the entire fuel system) 4.

• Page 349: Fuel Pump System

  ELEC FUEL PUMP SYSTEM EB802017 3. Main switch S Disconnect the main switch coupler from the wire harness. S Check for continuity as follows: – Brown/Blue NO CONTINUITY Replace the main switch. CONTINUITY EB802018 4. Engine stop switch S Disconnect the right handlebar switch cou- pler from the wire harness.

• Page 350
  ELEC FUEL PUMP SYSTEM Battery (+) terminal ! Red/Black terminal Battery (–) terminal ! Blue/Red terminal NO CONTINUITY Tester (+) lead ! Red/Black terminal Tester (–) lead ! Blue/Black terminal S Check the fuel pump relay for continuity. Replace the starting circuit cut-off relay. CONTINUITY EB808021 6.
• Page 351
  ELEC FUEL PUMP SYSTEM EB808030 FUEL PUMP TEST Gasoline is extremely flammable and un- der certain circumstances there can be danger of an explosion or combustion. Be extremely careful and note the follow- ing points: S Stop the engine before refuelling. S Do not smoke and keep away from open flames, sparks, or any other source of fire.
• Page 352
  ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The YZF600R features self-diagnosis. When the main switch is turned to “ON”, the following items are monitored and the condition codes are displayed on the tachometer (irrespective of whether the engine is running or not). Display condition Item Condition Response…
• Page 353
  ELEC SELF-DIAGNOSIS TROUBLESHOOTING The tachometer starts to display the self-diagnosis sequence. NOTE: Use the following special tool in this trouble- Pocket tester: shooting. 90890-03112 1. Throttle position sensor (TPS) CIRCUIT DIAGRAM Ignitor unit Throttle position sensor (TPS) 1. Wire harness NO CONTINUITY S Check the wire harness for continuity.
• Page 354
  ELEC SELF-DIAGNOSIS 2. Speed sensor CIRCUIT DIAGRAM 11 Ignitor unit 17 Speed sensor 1. Wire harness NO CONTINUITY S Check the wire harness for continuity. Refer to “CIRCUIT DIAGRAM”. Repair or replace the wire harness. CONTINUITY Replace the speed sensor. 8-64…
• Page 355
  TRBL SHTG…
• Page 356
  TRBL SHTG CHAPTER 9. TROUBLESHOOTING STARTING FAILURE/HARD STARTING ……..FUEL SYSTEM .
• Page 357
  TRBL SHTG…

• Page 358: Troubleshooting

  TRBL STARTING FAILURE/HARD STARTING SHTG EB900000 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of problems. It should be helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection, adjustment and replacement of parts. STARTING FAILURE/HARD STARTING FUEL SYSTEM Fuel tank…

• Page 359
  STARTING FAILURE/HARD STARTING/POOR ENGINE IDLE SPEED TRBL PERFORMANCE/POOR MEDIUM-AND HIGH-SPEED PERFORMANCE SHTG COMPRESSION SYSTEM Cylinder and cylinder head Piston and piston ring S Loose spark plug S Improperly installed piston ring S Loose cylinder head or cylinder S Worn, fatigued or broken piston ring S Faulty cylinder head gasket S Seized piston ring S Worn, damaged or seized cylinder…

• Page 360: Faulty Gear Shifting

  FAULTY GEAR SHIFTING/ TRBL FAULTY CLUTCH PERFORMANCE SHTG EB903000 FAULTY GEAR SHIFTING HARD SHIFTING Refer to “CLUTCH DRAGGING”. SHIFT PEDAL DOES NOT MOVE Shift shaft Transmission S Improperly adjusted shift pedal link S Seized transmission gear S Bent shift shaft S Jammed impurities S Incorrectly assembled transmission Shift cam, shift fork…

• Page 361
  OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING/FAULTY FRONT FORK LEGS SHTG EB905000 OVERHEATING OVERHEATING Ignition system Compression system S Improper spark plug gap S Heavy carbon build-up S Improper spark plug heat range Engine oil S Faulty ignitor unit S Improper oil level S Improper oil viscosity Fuel system S Improper carburetor main jet setting…

• Page 362: Unstable Handling

  UNSTABLE HANDLING/ TRBL FAULTY LIGHTING AND SIGNAL SYSTEMS SHTG EB908000 UNSTABLE HANDLING UNSTABLE HANDLING Handlebar Front fork S Improperly installed or bent S Uneven oil levels on both sides S Uneven spring tension Steering S Broken spring S Improperly installed handlebar crown S Twisted front fork S Bent steering stem S Improperly installed steering shaft…

• Page 363
  TRBL SHTG…
• Page 364
  FZS600 ’98 WIRING DIAGRAM 1 A.C. magneto 2 Rectifier/ regulator 3 Main switch 4 Battery 5 Fuse (back up) 6 Fuse (main) 7 Starter relay 8 Starter motor 9 Starting circuit cut-off relay 10 Fuel pump relay 11 Ignitor unit 12 Ignition coil 13 Spark plug 14 Pick up coil…