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Summary of Contents for Yamaha 2009 XP500Y TMAX

  • Page 1: Service Manual

    2009 SERVICE MANUAL XP500Y LIT-11616-22-08 4B5-28197-10…

  • Page 2
    EAS20050 XP500Y SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, March 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-22-08…
  • Page 3
    If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
  • Page 4
    EAS20090 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. •…
  • Page 5
    EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

  • Page 7: Table Of Contents

    EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING…

  • Page 9: General Information

    GENERAL INFORMATION IDENTIFICATION ……………….. 1-1 VEHICLE IDENTIFICATION NUMBER ………….1-1 MODEL LABEL………………1-1 FEATURES…………………. 1-2 OUTLINE OF FI SYSTEM …………….. 1-2 FI SYSTEM………………..1-3 MULTI-FUNCTION DISPLAY…………..1-4 IMPORTANT INFORMATION …………….. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY……1-7 REPLACEMENT PARTS…………….1-7 GASKETS, OIL SEALS AND O-RINGS ………… 1-7 LOCK WASHERS/PLATES AND COTTER PINS ……..

  • Page 10: Identification

    IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.

  • Page 11: Features

    FEATURES EAS20170 FEATURES EAS4B51038 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. In a conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective chamber.

  • Page 12: Fi System

    FEATURES EAS4B51039 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 240–260 kPa (2.40–2.60 kg/cm², 34.1– 37.0 psi) higher than the intake manifold pressure.

  • Page 13: Multi-Function Display

    FEATURES • an odometer (which shows the total distance EAS4B51037 MULTI-FUNCTION DISPLAY traveled) EWA4B54001 • two tripmeters (which show the distance trav- WARNING eled since they were last set to zero) Be sure to stop the vehicle before making • a fuel reserve tripmeter (which shows the dis- any setting changes to the multi-function tance traveled when the remaining fuel in the display.

  • Page 14
    FEATURES Odometer and tripmeter modes 1. Fuel reserve tripmeter 1. Odometer/tripmeters To reset a tripmeter, select it by pushing the “SE- LECT” button until “F Trip”, “Trip-A” or “Trip-B” is displayed. While “F Trip”, “Trip-A” or “Trip-B” is displayed, push the “RESET” button for at least one second.
  • Page 15
    FEATURES “OIL” must be reset after the oil change for the Self-diagnosis device next periodic oil change to be indicated at the correct time. The electrical circuit of the indicator can be checked according to the following procedure. 1. Set the engine stop switch to “ ”…

  • Page 16: Important Information

    5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but…

  • Page 17: Bearings And Oil Seals

    IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

  • Page 18: Checking The Connections

    CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •…

  • Page 19: Special Tools

    SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

  • Page 20
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-12, 6-6 90890-01469 YM-01469 66.8 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter B 3-13 90890-03124 Pressure gauge 3-13, 7-4 90890-03153 YU-03153 Steering nut wrench…
  • Page 21
    Fork seal driver weight 4-54, 4-55 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 4-54 90890-01374 Replacement 43 mm YM-A5142-3 Yamaha bond No. 1215 5-14, 5-44, 90890-85505 5-52, 5-69, (Three Bond No.1215®) 6-12 Valve spring compressor 5-19, 5-24 90890-04019 YM-04019…
  • Page 22
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø4) 5-21 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-21 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Piston pin puller set 5-27 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder…
  • Page 23
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave spring compressor 5-41, 5-44 90890-04134 YM-04134 Sheave fixed block 5-41, 5-44 90890-04135 Sheave fixed bracket YM-04135 Oil seal guide (ø41) 5-43 90890-01396 Sheave holder 5-50, 5-51, 90890-01701 5-52 Primary clutch holder YS-01880-A Flywheel puller 5-50…
  • Page 24
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Clutch spring compressor 5-57, 5-60 90890-01482 Universal clutch holder 5-57, 5-60 90890-04086 YM-91042 Plane bearing installer 5-73, 5-76 90890-04139 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984…
  • Page 25
    SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Mechanical seal installer 6-12 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Bearing driver 40 mm YM-04058 Fuel pressure adapter 90890-03181 Ignition checker 8-72 90890-06754 Opama pet-4000 spark checker YM-34487 1-16…
  • Page 26
    SPECIAL TOOLS 1-17…

  • Page 27: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS ……………. 2-1 ENGINE SPECIFICATIONS …………….2-2 CHASSIS SPECIFICATIONS …………….2-10 ELECTRICAL SPECIFICATIONS …………..2-13 TIGHTENING TORQUES …………….2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS……2-16 ENGINE TIGHTENING TORQUES…………2-17 CHASSIS TIGHTENING TORQUES…………2-21 LUBRICATION POINTS AND LUBRICANT TYPES ……..2-24 ENGINE………………..2-24 CHASSIS………………..2-26 LUBRICATION SYSTEM DIAGRAMS …………

  • Page 28: General Specifications

    GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 4B54 (USA) Dimensions Overall length 2195 mm (86.4 in) Overall width 775 mm (30.5 in) Overall height 1445 mm (56.9 in) Seat height 800 mm (31.5 in) Wheelbase 1580 mm (62.2 in) Ground clearance 125 mm (4.92 in) Minimum turning radius 2800 mm (110.2 in)

  • Page 29: Engine Specifications

    ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 499.0 cm³ Cylinder arrangement Forward-inclined parallel 2-cylinder Bore × stroke 66.0 × 73.0 mm (2.60 × 2.87 in) Compression ratio 11.00 :1 Standard compression pressure (at sea level) 1400 kPa/360 r/min (199.1 psi/360 r/min) (14.0 kgf/cm²/360 r/min) Minimum–maximum…

  • Page 30
    ENGINE SPECIFICATIONS Pressure check location MAIN GALLERY Cooling system Radiator capacity (including all routes) 1.48 L (1.56 US qt) (1.30 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 107.9–137.3 kPa (15.6–19.9 psi) (1.08–1.37 kgf/cm²) Thermostat…
  • Page 31
    ENGINE SPECIFICATIONS Limit 24.856 mm (0.9786 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links SCR-0409 SV/132 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.20 mm (0.0059–0.0079 in) Exhaust 0.25–0.30 mm (0.0098–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
  • Page 32
    ENGINE SPECIFICATIONS Valve margin thickness D (exhaust) 0.60–0.80 mm (0.0236–0.0315 in) Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in) Limit 3.945 mm (0.1553 in) Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in) Limit 3.930 mm (0.1547 in) Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.050 mm (0.1594 in)
  • Page 33
    ENGINE SPECIFICATIONS Winding direction (exhaust) Clockwise Valve lifter Valve lifter outside diameter (intake) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Valve lifter outside diameter (exhaust) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Cylinder Bore 66.000–66.010 mm (2.5984–2.5988 in) Wear limit 66.100 mm (2.6024 in) Taper limit…
  • Page 34
    ENGINE SPECIFICATIONS Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.40–0.50 mm (0.0157–0.0197 in) Limit 0.75 mm (0.0295 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.100 mm (0.0039 in) Oil ring Dimensions (B ×…
  • Page 35
    ENGINE SPECIFICATIONS Plate quantity 4 pcs Warpage limit 0.10 mm (0.0039 in) Clutch plate 2 thickness 1.80–2.00 mm (0.071–0.079 in) Plate quantity 2 pcs Warpage limit 0.20 mm (0.0079 in) Clutch spring free length 25.80 mm (1.02 in) Minimum length 20.40 mm (0.80 in) Spring quantity 6 pcs…
  • Page 36
    ENGINE SPECIFICATIONS Intake air pressure sensor output voltage 3.15–4.15 V Intake air temperature sensor resistance 2.21–2.69 kΩ at 20 °C (68 °F) Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F) 310–326 Ω at 80 °C (176 °F) Idling condition Engine idling speed 1100–1300 r/min…

  • Page 37: Chassis Specifications

    CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00° Trail 92.0 mm (3.62 in) Front wheel Wheel type Cast wheel 15M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)

  • Page 38
    Inner tube outer diameter 43.0 mm (1.69 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) Level 87.0 mm (3.43 in) Rear suspension…
  • Page 39
    CHASSIS SPECIFICATIONS Installed length 180.0 mm (7.09 in) Spring rate K1 225.60 N/mm (1288.18 lb/in) (23.00 kgf/mm) Spring rate K2 294.00 N/mm (1678.74 lb/in) (29.98 kgf/mm) Spring stroke K1 0.0–28.8 mm (0.00–1.13 in) Spring stroke K2 28.8–43.0 mm (1.13–1.69 in) Optional spring available Enclosed gas/air pressure (STD) 4900 kPa (696.9 psi) (49.0 kgf/cm²)

  • Page 40: Electrical Specifications

    ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Digital Ignition timing (B.T.D.C.) 10.0°/1200 r/min Engine control unit Model/manufacturer TBDF81/DENSO Ignition coil Model/manufacturer JO313/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) 1.87–2.53 Ω…

  • Page 41
    ELECTRICAL SPECIFICATIONS Meter lighting Indicator light LED × 2 Turn signal indicator light High beam indicator light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM-18/MITSUBA Power output 0.70 kW 0.0100–0.0200 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 12.0 mm (0.47 in)
  • Page 42
    ELECTRICAL SPECIFICATIONS Fuel injection system relay Model/manufacturer 5JJ/MATSUSHITA Fuses Main fuse 30.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 15.0 A Ignition fuse 10.0 A Radiator fan fuse 15.0 A Fuel injection system fuse 10.0 A Backup fuse 10.0 A Spare fuse…

  • Page 43: Tightening Torques

    TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

  • Page 44: Engine Tightening Torques

    TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft cap 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil check bolt 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe stud bolt 15 Nm (1.5 m·kg, 11 ft·lb) Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) Cylinder head nut…

  • Page 45
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Muffler nut 31 Nm (3.1 m·kg, 22 ft·lb) Muffler end protector bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Exhaust pipe protector bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler end protector cover bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler protector (side) bolt 8 Nm (0.8 m·kg, 5.8 ft·lb)
  • Page 46
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size BEL-RAY Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) assem- bly lube® Crankshaft right end bearing re- 11 Nm (1.1 m·kg, 8.0 ft·lb) tainer screw Secondary shaft bearing retainer 12 Nm (1.2 m·kg, 8.7 ft·lb) bolt Stator coil bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
  • Page 47
    TIGHTENING TORQUES Cylinder head tightening sequence: 2-20…

  • Page 48: Chassis Tightening Torques

    TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front upper 88 Nm (8.8 m·kg, 64 ft·lb) side) Engine mounting bolt (front right 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting bolt (front left 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting nut (rear side)

  • Page 49
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Pivot shaft 7 Nm (0.7 m·kg, 5.1 ft·lb) Pivot shaft nut 100 Nm (10.0 m·kg, 72 ft·lb) Swingarm bolt 40 Nm (4.0 m·kg, 29 ft·lb) Swingarm damper nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear shock absorber assembly 53 Nm (5.3 m·kg, 38 ft·lb) rear nut…
  • Page 50
    TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) Rear wheel drive hub bolt 69 Nm (6.9 m·kg, 50 ft·lb) Front brake hose joint bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front brake hose holder bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake hose holder bolt…

  • Page 51: Lubrication Points And Lubricant Types

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nut seats and washers Camshaft cap bolt seats Big end bearings and crank pins Connecting rod big end contact surfaces (to crank) Balancer big end bearings and crank pin Balancer connecting rod big end contact surface (to crank) Pistons, ring grooves, and piston rings…

  • Page 52
    BEL-RAY assembly Secondary sheave nut seats lube® Outer V-belt case crankshaft right end point Pivot shaft taper roller bearing Yamaha bond Cylinder head cover inner gaskets mating surface No.1215 (Three bond No.1215®) Yamaha bond Timing chain guide (upper side) mating surface No.1215 (Three bond…

  • Page 53: Chassis

    LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings (upper and lower) Upper bearing cover seal lip and lower bearing dust seal lip Steering bearing races (inner and outer) Tube guide (throttle grip) inner surface and throttle cables Rear brake lock cable end (lever end) Brake lever pivoting point and metal-to-metal moving parts Drive axle spline…

  • Page 54: Lubrication System Diagrams

    LUBRICATION SYSTEM DIAGRAMS EAS4B51021 LUBRICATION SYSTEM DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27…

  • Page 55
    LUBRICATION SYSTEM DIAGRAMS 1. Oil delivery pipe 2. Oil pump 3. Oil cooler 4. Oil filter cartridge 5. Oil pipe 6. Oil strainer 2-28…
  • Page 56
    LUBRICATION SYSTEM DIAGRAMS 2-29…
  • Page 57
    LUBRICATION SYSTEM DIAGRAMS 1. Secondary shaft 2. Drive axle 3. Clutch 4. Crankshaft 2-30…

  • Page 58: Cooling System Diagrams

    COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-31…

  • Page 59
    COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator filler hose 3. Radiator inlet hose 4. Coolant reservoir 5. Coolant pipe 6. Thermostat outlet hose 7. Oil cooler outlet hose 8. Thermostat 9. Oil cooler 10. Coolant hose 11. Water pump inlet pipe 12.
  • Page 60
    COOLING SYSTEM DIAGRAMS 2-33…
  • Page 61
    COOLING SYSTEM DIAGRAMS 1. Thermostat outlet hose 2. Cooling system air bleed hose 3. Radiator cap 4. Radiator filler pipe 5. Radiator filler hose 6. Coolant reservoir hose 7. Radiator 8. Radiator inlet hose 9. Coolant reservoir 10. Coolant reservoir breather hose 11.

  • Page 62: Cable Routing

    CABLE ROUTING EAS20430 CABLE ROUTING A B C 2-35…

  • Page 63
    CABLE ROUTING 1. Rear brake hose 2. Left handlebar switch lead 3. Right handlebar switch lead 4. Front brake hose 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Rear brake lock cable 8. Front brake light switch connectors A.
  • Page 64
    CABLE ROUTING 2-37…
  • Page 65
    CABLE ROUTING 1. Front brake pipe 2. Wire harness (to horn) 3. Front brake hose (to left front brake caliper) 4. Front brake hose (to right front brake caliper) 5. Horn 6. Speed sensor lead 7. Speed sensor A. Fasten the wire harness (to horn) and front brake pipe with plastic locking ties, making sure to –…
  • Page 66
    CABLE ROUTING 26 27 2-39…
  • Page 67
    CABLE ROUTING 1. Left handlebar switch lead P. Route the starter motor lead and generator lead to the outside of the wire harness. 2. Right handlebar switch lead Q. To meter assembly 3. Rectifier/regulator R. Route the wire harness (to starter relay) behind 4.
  • Page 68
    CABLE ROUTING 22 23 2-41…
  • Page 69
    CABLE ROUTING 1. Positive battery lead L. Fasten the main switch lead with the holder, making sure that the plastic locking tie is 2. Fuse box positioned to the inside of the holder. Face the 3. Negative battery lead catch of the holder forward. 4.
  • Page 70
    CABLE ROUTING 2-43…
  • Page 71
    CABLE ROUTING 1. Intake air temperature sensor coupler P. Pass the wire harness (to storage box light switch) between the rear frame and the tail/brake light 2. Cylinder head breather hose assembly. 3. Fast idle plunger intake hose Q. Pass the plastic band through the holes in the 4.
  • Page 72
    CABLE ROUTING 2-45…
  • Page 73
    CABLE ROUTING 1. Rear brake hose 2. Rear brake pipe 3. Rear brake lock cable 4. Ribs (bottom of storage box) A. Install the rear brake hose holder to the front cowling stay, making sure to fit the projection on the holder into the hole in the stay.
  • Page 74
    CABLE ROUTING H I J 2-47…
  • Page 75
    CABLE ROUTING 1. Fast idle plunger intake hose 2. Cylinder head breather hose 3. Intake air pressure sensor hose 4. Fuel hose 5. Fast idle plunger inlet coolant hose 6. Fast idle plunger outlet coolant hose 7. Fuel injector #2 8.
  • Page 76
    CABLE ROUTING 2-49…
  • Page 77
    CABLE ROUTING 1. Rollover valve U. Route the canister purge hose (3-way joint to canister) over the frame cross member. 2. Fuel tank breather hose (fuel tank to rollover valve) 3. Fuel tank breather hose (rollover valve to canister) 4. Canister purge hose (throttle body #2 to 3-way joint) 5.
  • Page 78
    CABLE ROUTING 2-51…

  • Page 79: Periodic Checks And Adjustments

    PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE …………….3-1 INTRODUCTION ………………3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ………………..3-1 GENERAL MAINTENANCE AND LUBRICATION CHART …….3-1 ENGINE ………………….3-4 ADJUSTING THE VALVE CLEARANCE ……….3-4 SYNCHRONIZING THE THROTTLE BODY ……….3-7 ADJUSTING THE ENGINE IDLING SPEED ……….3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY ……..3-9 CHECKING THE SPARK PLUGS ………….

  • Page 80
    ELECTRICAL SYSTEM…………….. 3-30 CHECKING AND CHARGING THE BATTERY……..3-30 CHECKING THE FUSES …………….3-30 REPLACING THE HEADLIGHT BULBS ……….3-30 ADJUSTING THE HEADLIGHT BEAMS……….3-30…

  • Page 82: Periodic Maintenance

    • Check control system for √ sion control sys- damage. • Replace if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32185 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS…

  • Page 83
    • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi…
  • Page 84
    PERIODIC MAINTENANCE EAU38260 • The air filter and V-belt filter need more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

  • Page 85: Engine

    ENGINE 6. Measure: EAS20471 ENGINE • Valve clearance Out of specification → Adjust. EAS20490 ADJUSTING THE VALVE CLEARANCE Valve clearance (cold) The following procedure applies to all of the Intake valves. 0.15–0.20 mm (0.0059–0.0079 in) Exhaust • Valve clearance adjustment should be made 0.25–0.30 mm (0.0098–0.0118 in) on a cold engine, at room temperature.

  • Page 86
    ENGINE 0˚ 360˚ 720˚ A. Degrees that the crankshaft is turned c. Measure the valve clearance with a thickness clockwise gauge “1”. B. Cylinder C. Combustion cycle Cylinder #2 360° L LLL L LLL L LLL L LLL L LLL 7.
  • Page 87
    ENGINE Last digit Rounded value 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available valve pads. Valve pad range Nos. 120–240 1.20–2.40 mm b. Calculate the difference between the speci- Valve pad thickness (0.0472–0.0945 in) fied valve clearance and the measured valve clearance.

  • Page 88: Synchronizing The Throttle Body

    ENGINE • Turn the crankshaft clockwise several full turns Vacuum gauge to seat the parts. 90890-03094 h. Measure the valve clearance again. Carburetor synchronizer i. If the valve clearance is still out of specifica- YU-44456 Digital tachometer tion, repeat all of the valve clearance adjust- 90890-06760 ment steps until the specified clearance is YU-39951-B…

  • Page 89: Adjusting The Engine Idling Speed

    ENGINE 3. Install: ECA14900 NOTICE • Digital tachometer Do not use the throttle valve adjusting (onto the spark plug lead of cylinder #1) screws to adjust the throttle body syncroni- Digital tachometer zation. 90890-06760 YU-39951-B Carburetor angle driver 90890-03158 4. Check: •…

  • Page 90: Adjusting The Throttle Cable Free Play

    ENGINE EAS20630 EAS20680 ADJUSTING THE THROTTLE CABLE FREE CHECKING THE SPARK PLUGS PLAY The following procedure applies to all of the spark plugs. 1. Remove: Prior to adjusting the throttle cable free play, the • Bottom cowling engine idling speed and throttle body synchroni- Refer to “GENERAL CHASSIS”…

  • Page 91: Measuring The Compression Pressure

    ENGINE Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • Spark plug 10.Remove: • Bottom cowling 7. Measure: Refer to “GENERAL CHASSIS” on page 4-1. • Compression pressure Out of specification →…

  • Page 92: Checking The Engine Oil Level

    ENGINE Compression pressure (with oil applied into Type the cylinder) YAMALUBE 4 (10W-40) or SAE Reading Diagnosis 10W-40, YAMALUBE 4 (20W-50) or SAE 20W-50 Higher than without Piston ring(s) wear or Recommended engine oil grade damage → Repair. API service SG type or higher, Piston, valves, cylin- JASO standard MA der head gasket or…

  • Page 93: Changing The Engine Oil

    ENGINE b. Lubricate the O-ring “3” of the new oil filter EAS20780 CHANGING THE ENGINE OIL cartridge with a thin coat of engine oil. 1. Start the engine, warm it up for several min- ECA13390 utes, and then turn it off. NOTICE 2.

  • Page 94: Measuring The Engine Oil Pressure

    ENGINE 10.Start the engine, warm it up for several min- 2. Start the engine, warm it up for several min- utes, and then turn it off. utes, and then turn it off. 11.Check: ECA13410 NOTICE • Engine When the engine is cold, the engine oil will (for engine oil leaks) have a higher viscosity, causing the engine 12.Check:…

  • Page 95: Replacing The Air Filter Element

    ENGINE Oil pressure (hot) 150.0 kPa/1200 r/min (21.8 psi/1200 r/min) (1.50 kgf/cm²/1200 r/min) Oil temperature 70.0 °C (158.00 °F) Out of specification → Adjust. Engine oil pressure Possible causes 4. Install: • Faulty oil pump • Clogged oil filter • Air filter case cover Below specification •…

  • Page 96: Cleaning The V-Belt Case Air Filter Element

    ENGINE EAS20980 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: • Footrest boards Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • V-belt case air filter element (left) “1” 3. Remove: • V-belt case air filter case cover “1” •…

  • Page 97: Checking The Fuel Line

    ENGINE 2. Check: 2. Check: • Throttle body joints “1” • Cylinder head breather hose “1” Cracks/damage → Replace the intake mani- Cracks/damage → Replace. Loose connection → Connect properly. folds. ECA14920 NOTICE Make sure the cylinder head breather hose is routed correctly.

  • Page 98: Checking The Canister

    ENGINE Below the minimum level mark → Add the 4. Install: • Bottom cowling recommended coolant to the proper level. Refer to “GENERAL CHASSIS” on page 4-1. EAS21090 CHECKING THE CANISTER 1. Remove: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. •…

  • Page 99: Changing The Coolant

    ENGINE 3. Install: • Footrest boards • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. EAS21130 CHANGING THE COOLANT 1. Remove: • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: • Coolant reservoir hose “1” 3. Drain: •…

  • Page 100
    ENGINE be blown out, which could cause serious in- Recommended antifreeze jury. When the engine has cooled, open the High-quality ethylene glycol an- radiator cap as follows: tifreeze containing corrosion in- Place a thick rag or a towel over the radiator hibitors for aluminum engines cap and slowly turn the radiator cap counter- Mixing ratio…
  • Page 101
    ENGINE 12.Install: • Coolant reservoir cap 13.Start the engine, warm it up for several min- utes, and then stop it. 14.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-17. Before checking the coolant level, wait a few minutes until the coolant has settled.

  • Page 102: Chassis

    CHASSIS EAS21140 M MMM M MMM M MMM M MMM M MMM CHASSIS a. While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in EAS21160 the desired position. ADJUSTING THE FRONT DISC BRAKE 1.

  • Page 103: Checking The Front Brake Pads

    CHASSIS 1. Operate the brake. 2. Check: • Front brake pad Wear indicator groove “a” has almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-18. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads.

  • Page 104: Checking The Rear Brake Hose

    CHASSIS 2. Check: Rear brake lock cable length • Brake hose holders 45–47 mm (1.77–1.85 in) Loose → Tighten the holder bolt. 3. Hold the vehicle upright and apply the brake 2. Adjust: several times. • Rear brake lock cable length “a” 4.

  • Page 105: Checking The Chain Drive Oil Level

    CHASSIS caution could allow air to enter the hydraulic i. Repeat steps (e) to (h) until all of the air bub- brake system, considerably lengthening the bles have disappeared from the brake fluid in bleeding procedure. the plastic hose. • If bleeding is difficult, it may be necessary to let j.

  • Page 106: Changing The Chain Drive Oil

    CHASSIS 3. Check: • Chain drive oil level Wipe the dipstick clean, insert it into the oil fill- er hole (without screw it in), and then remove it to check the oil level. The chain drive oil level should be between the minimum level mark “a”…

  • Page 107
    CHASSIS 2. Check: EWA13140 WARNING • Steering head Do not overtighten the lower ring nut. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering Lower ring nut (final tightening torque) head.

  • Page 108: Checking The Front Fork

    CHASSIS 2. Check: • Inner tube Damage/scratches → Replace. • Oil seal Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds d.

  • Page 109
    No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. 1. Tire tread depth Front tire 2. Side wall Size 3.

  • Page 110: Checking The Wheels

    CHASSIS 1. Check: EWA13210 WARNING • Outer cable Damage → Replace. New tires have a relatively low grip on the road surface until they have been slightly 2. Check: worn. Therefore, approximately 100 km • Cable operation Rough movement → Lubricate. should be traveled at normal speed before any high-speed riding is done.

  • Page 111
    ELECTRICAL SYSTEM 6. Install: EAS21750 ELECTRICAL SYSTEM • Headlight bulb Secure the new headlight bulb with the head- EAS21760 CHECKING AND CHARGING THE BATTERY light bulb holder. Refer to “ELECTRICAL COMPONENTS” on ECA13690 NOTICE page 8-57. Avoid touching the glass part of the head- EAS21770 light bulb to keep it free from oil, otherwise CHECKING THE FUSES…
  • Page 112
    ELECTRICAL SYSTEM Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. L LLL L LLL L LLL L LLL L LLL…
  • Page 113
    CHASSIS GENERAL CHASSIS………………4-1 REMOVING THE FUEL HOSE …………..4-7 INSTALLING THE FUEL HOSE …………..4-7 FRONT WHEEL………………..4-8 REMOVING THE FRONT WHEEL…………4-11 DISASSEMBLING THE FRONT WHEEL……….4-11 CHECKING THE FRONT WHEEL …………4-11 ASSEMBLING THE FRONT WHEEL…………4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE ……4-12 INSTALLING THE FRONT WHEEL (DISC) ……….4-13 REAR WHEEL ………………..4-15 REMOVING THE REAR WHEEL (DISC) ……….
  • Page 114
    HANDLEBAR ………………..4-44 REMOVING THE HANDLEBAR…………..4-46 CHECKING THE HANDLEBAR …………..4-46 INSTALLING THE HANDLEBAR …………4-46 FRONT FORK………………..4-49 REMOVING THE FRONT FORK LEGS……….4-52 DISASSEMBLING THE FRONT FORK LEGS ……..4-52 CHECKING THE FRONT FORK LEGS ……….4-53 ASSEMBLING THE FRONT FORK LEGS ……….4-53 INSTALLING THE FRONT FORK LEGS ……….
  • Page 116
    GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the battery and windshield 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rear view mirror…
  • Page 117
    GENERAL CHASSIS Removing the bottom cowling 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Footrest board mat Footrest board cover Side panel Left side cowling Bottom panel Right side cowling Wire harness (to ignition coil) Unhook.
  • Page 118
    GENERAL CHASSIS Removing the footrest boards 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Front lower outer panel Front lower inner panel Center panel Fuel tank overflow hose Unhook. Rear brake pipe Unhook. Left footrest board Fuel tank breather hose Unhook.
  • Page 119
    GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Windshield bracket lower cover Meter ring Meter assembly cover Meter assembly coupler Disconnect. Meter assembly Storage compartment Headlight sub-wire harness coupler Disconnect.
  • Page 120
    GENERAL CHASSIS Removing the rear cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

  • Page 121: General Chassis

    GENERAL CHASSIS Removing the storage box 10 Nm (1.0 m kg, 7.2 ft 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 10 Nm (1.0 m kg, 7.2 ft •…

  • Page 122: Removing The Fuel Hose

    GENERAL CHASSIS EAS4B51010 ECA4B51021 REMOVING THE FUEL HOSE NOTICE 1. Remove: When installing the fuel hose, make sure that • Fuel hose connector cover “1” it is securely connected, and that the fuel 2. Disconnect: hose connector cover is in the correct posi- •…

  • Page 123: Front Wheel

    FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •…

  • Page 124
    FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •…
  • Page 125
    FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Collar For assembly, reverse the disassembly pro- cedure. 4-10…

  • Page 126: Removing The Front Wheel

    FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake calipers Do not apply the brake lever when removing the L LLL L LLL L LLL…

  • Page 127: Assembling The Front Wheel

    FRONT WHEEL 4. Check: L LLL L LLL L LLL L LLL L LLL • Wheel bearings EAS21970 Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings. BALANCE • Oil seal Damage/wear →…

  • Page 128: Installing The Front Wheel (Disc)

    FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.

  • Page 129
    FRONT WHEEL Be sure to fit the two projections on the speed sensor in between the projections on the wheel hub. 5. Install: • Front wheel Make sure the slot “a” in the speed sensor fits over the stopper “b” on the outer tube. 6.

  • Page 130: Rear Wheel

    REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel and brake disc 40 Nm (4.0 m kg, 29 ft • • 17 Nm (1.7 m kg, 12 ft • • 105 Nm (10.5 m kg, 75 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

  • Page 131
    REAR WHEEL Disassembling the rear wheel 69 Nm (6.9 m • kg, 50 ft • Ib) Order Job/Parts to remove Q’ty Remarks Rear wheel drive hub O-ring Oil seal Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-16…

  • Page 132: Removing The Rear Wheel (Disc)

    REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on the centerstand so that the rear wheel is elevated.

  • Page 133: Front Brake

    FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of…

  • Page 134
    FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
  • Page 135
    FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-20…
  • Page 136
    FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
  • Page 137
    FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston Brake caliper piston dust seal…

  • Page 138: Introduction

    FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA4B51008 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

  • Page 139: Replacing The Front Brake Pads

    FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Front brake pads steps until the brake disc deflection is within • Brake pad spring specification. f. If the brake disc deflection cannot be brought Always install new brake pads and a new brake within specification, replace the brake disc.

  • Page 140: Removing The Front Brake Calipers

    FRONT BRAKE Put the end of the brake hose into a container and pump out the brake fluid carefully. e. Install the brake pad pin and brake pad clips. L LLL L LLL L LLL L LLL L LLL 3. Install: •…

  • Page 141: Checking The Front Brake Calipers

    FRONT BRAKE EWA4B51006 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and piston seals. EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA4B51007 WARNING • Before installation, all internal brake com- b. Remove the brake caliper piston dust seals ponents should be cleaned and lubricated and piston seals.

  • Page 142: Removing The Front Brake Master Cylinder

    FRONT BRAKE • When refilling, be careful that water does ECA14170 NOTICE not enter the brake fluid reservoir. Water When installing the brake hose onto the will significantly lower the boiling point of brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.

  • Page 143: Checking The Front Brake Master Cylinder

    FRONT BRAKE • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the end of the brake master cylinder hold- er with the punch mark “b” on the handlebar. • First, tighten the upper bolt, then the lower bolt. EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER…

  • Page 144
    FRONT BRAKE 3. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

  • Page 145: Rear Brake

    REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt (rear) Rear brake caliper bolt Rear brake caliper Rear brake pad…

  • Page 146
    REAR BRAKE Removing the rear brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
  • Page 147
    REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32…
  • Page 148
    REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •…
  • Page 149
    REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •…
  • Page 150
    REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper body For assembly, reverse the disassembly pro- cedure.

  • Page 151: Introduction

    REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA4B51008 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •…

  • Page 152
    REAR BRAKE 3. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake pad lining thickness (in- ner) 8.0 mm (0.31 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (out- M MMM M MMM M MMM…

  • Page 153: Removing The Rear Brake Caliper

    REAR BRAKE 7. Install: • Rear brake caliper bolts Rear brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) 8. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”…

  • Page 154: Disassembling The Rear Brake Caliper

    REAR BRAKE Recommended brake component replace- ment schedule Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1. Check: • Brake caliper piston “1” Rust/scratches/wear → Replace the brake caliper piston. EAS22630 DISASSEMBLING THE REAR BRAKE •…

  • Page 155: Assembling The Rear Brake Caliper

    REAR BRAKE • Rear brake caliper “1” EAS22660 ASSEMBLING THE REAR BRAKE CALIPER (temporarily) EWA4B51010 WARNING • Brake hose gaskets • Rear brake hose “2” • Before installation, all internal brake com- • Brake hose union bolt “3” ponents should be cleaned and lubricated with clean or new brake fluid.

  • Page 156: Removing The Rear Brake Master Cylinder

    REAR BRAKE 4. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- 8. Install: mended brake fluid) • Rear brake lock cable holder • Spring Recommended fluid •…

  • Page 157: Assembling The Rear Brake Master Cylinder

    REAR BRAKE 2. Check: • Rear brake hose “2” • Brake master cylinder kit • Brake hose union bolt “3” Damage/scratches/wear → Replace. Brake hose union bolt 3. Check: 30 Nm (3.0 m·kg, 22 ft·lb) • Brake master cylinder reservoir •…

  • Page 158
    REAR BRAKE • When refilling, be careful that water does not enter the brake master cylinder reser- voir. Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.

  • Page 159: Handlebar

    HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft •…

  • Page 160
    HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft • • 40 Nm (4.0 m kg, 29 ft •…

  • Page 161: Removing The Handlebar

    HANDLEBAR EAS4B51014 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” 3. Install: Blow compressed air between the left end of the •…

  • Page 162
    HANDLEBAR 6. Connect: 9. Install: • Rear brake lock cable • Throttle grip “1” (to rear brake lock lever) • Throttle cables “2” Lubricate the inside of the rear brake lock cable Lubricate the inside of the throttle grip with a thin and rear brake lock lever with a thin coat of lithi- coat of lithium-soap-based grease and install it um-soap-based grease.
  • Page 163
    HANDLEBAR Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 12.Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-23. 4-48…

  • Page 164: Front Fork

    FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

  • Page 165
    FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring seat Fork spring Dust seal Oil seal clip…
  • Page 166
    FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure. 4-51…

  • Page 167: Removing The Front Fork Legs

    FRONT FORK EAS22960 EAS22980 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. 1.

  • Page 168: Checking The Front Fork Legs

    FRONT FORK • Outer tube Damper rod holder Bends/damage/scratches → Replace. 90890-01460 EWA13650 T-handle WARNING 90890-01326 Do not attempt to straighten a bent inner T-handle 3/8″ drive 60 cm long tube as this may dangerously weaken it. YM-01326 2. Measure: •…

  • Page 169
    3. Lubricate: (with the fork seal driver weight “3” and fork • Inner tube’s outer surface “2” seal driver attachment “4”) Recommended oil Fork seal driver weight Yamaha fork oil 10WT 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 90890-01374…
  • Page 170
    10.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil.

  • Page 171: Installing The Front Fork Legs

    FRONT FORK 11.After filling the front fork leg, slowly stroke the • Temporarily tighten the cap bolt. inner tube “1” up and down (at least ten times) to distribute the fork oil. EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the Be sure to stroke the inner tube slowly because front fork legs.

  • Page 172
    FRONT FORK 4-57…

  • Page 173: Steering Head

    STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

  • Page 174
    STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Dust seal Lower bearing inner race…

  • Page 175: Removing The Lower Bracket

    STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut • Rubber washer •…

  • Page 176: Installing The Steering Head

    STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: •…

  • Page 177: Rear Shock Absorber Assembly

    REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 53 Nm (5.3 m kg, 38 ft • • 68 Nm (6.8 m kg, 49 ft • • Order Job/Parts to remove Q’ty Remarks Exhaust assembly Refer to “ENGINE REMOVAL”…

  • Page 178: Handling The Rear Shock Absorber

    REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly bolts “1” the rear shock absorber, read and make sure you understand the following information.

  • Page 179
    REAR SHOCK ABSORBER ASSEMBLY • Lubricate the rear shock absorber assembly front bolt seats with lithium-soap-based grease. 3. Tighten: • Rear shock absorber assembly rear nut Rear shock absorber assembly rear nut 53 Nm (5.3 m·kg, 38 ft·lb) 4. Tighten: •…

  • Page 180: Swingarm And Transmission Chain Drive

    SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51015 SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •…

  • Page 181
    SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
  • Page 182
    SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Outer chain drive case Secondary drive gear Secondary drive chain Secondary driven gear Chain drive case gasket Dowel pin Middle shaft…
  • Page 183
    SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Bearing retainer For assembly, reverse the disassembly pro- cedure. * Apply chain drive oil. 4-68…

  • Page 184: Checking The Swingarm

    SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51017 CHECKING THE SWINGARM 1. Check: • Swingarm “1” Damage/wear → Replace. EAS4B51018 ASSEMBLING THE TRANSMISSION CHAIN DRIVE ASSEMBLY 1. Install: • Outer chain drive case 2. Check: • Pivot shaft Chain drive case bolt •…

  • Page 185
    SWINGARM AND TRANSMISSION CHAIN DRIVE 5. Fill: • Transmission chain drive case Refer to “CHANGING THE CHAIN DRIVE OIL” on page 3-25. 6. Check: • Chain drive oil level Refer to “CHECKING THE CHAIN DRIVE OIL LEVEL” on page 3-24. 2.
  • Page 186
    SWINGARM AND TRANSMISSION CHAIN DRIVE 4-71…

  • Page 187: Engine

    ENGINE ENGINE REMOVAL ………………5-1 INSTALLING THE ENGINE…………… 5-5 CAMSHAFTS………………..5-6 REMOVING THE CAMSHAFTS…………..5-9 CHECKING THE CAMSHAFTS …………..5-10 CHECKING THE CAMSHAFT SPROCKETS ………5-11 CHECKING THE TIMING CHAIN GUIDES……….5-11 CHECKING THE TIMING CHAIN TENSIONER……..5-12 INSTALLING THE CAMSHAFTS …………5-12 CYLINDER HEAD………………5-15 REMOVING THE CYLINDER HEAD…………5-16 CHECKING THE CYLINDER HEAD …………5-16 INSTALLING THE CYLINDER HEAD ………….5-16…

  • Page 188
    V-BELT AUTOMATIC TRANSMISSION …………5-35 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE..5-41 DISASSEMBLING THE SECONDARY SHEAVE……..5-41 CHECKING THE V-BELT…………….5-42 CHECKING THE PRIMARY SHEAVE …………5-42 CHECKING THE V-BELT CASE AIR DUCT ………..5-42 CHECKING THE PRIMARY SHEAVE WEIGHTS……..5-42 CHECKING THE SLIDERS …………..5-42 CHECKING THE SECONDARY SHEAVE ……….
  • Page 189
    CRANKSHAFT ………………..5-71 REMOVING THE CONNECTING RODS ……….5-73 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ……5-73 CHECKING THE CRANKSHAFT AND CONNECTING RODS….5-73 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS…..5-76 INSTALLING THE CONNECTING RODS……….5-77 INSTALLING THE CRANKSHAFT ASSEMBLY……..5-78 TRANSMISSION……………….. 5-79 CHECKING THE TRANSMISSION …………5-80…

  • Page 190: Engine Removal

    ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust assembly 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 45 Nm (4.5 m kg, 32 ft • • 8 Nm (0.8 m kg, 5.8 ft •…

  • Page 191
    ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front cowling/Storage box 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”…
  • Page 192
    ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “SWINGARM AND TRANSMIS- Transmission chain drive holder assembly SION CHAIN DRIVE” on page 4-65. Refer to “ELECTRIC STARTER”…
  • Page 193
    ENGINE REMOVAL Removing the engine 83 Nm (8.3 m kg, 60 ft • • 105 Nm (10.5 m kg, 75 ft • • 45 Nm (4.5 m kg, 32 ft • • 88 Nm (8.8 m kg, 64 ft • •…

  • Page 194: Installing The Engine

    ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolts (front right lower side) “1”, en- gine mounting bolts (front left lower side) “2”, and rear frame bolts “3”. •…

  • Page 195: Camshafts

    CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •…

  • Page 196
    CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •…
  • Page 197
    CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Timing chain tensioner rod accessing plug Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap…

  • Page 198: Removing The Camshafts

    CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. L LLL L LLL L LLL…

  • Page 199: Checking The Camshafts

    CAMSHAFTS 3. Measure: • Camshaft runout EAS23850 Out of specification → Replace. CHECKING THE CAMSHAFTS 1. Check: Camshaft runout limit • Camshaft lobes 0.030 mm (0.0012 in) Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →…

  • Page 200: Checking The Camshaft Sprockets

    CAMSHAFTS EAS4B51035 c. Install the dowel pins and camshaft caps. CHECKING THE CAMSHAFT SPROCKETS The following procedure applies to both of the • Tighten the camshaft cap bolts in stages and in camshaft sprockets. a crisscross pattern, working from the inner 1.

  • Page 201: Checking The Timing Chain Tensioner

    CAMSHAFTS EAS23960 EAS24000 CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS 1. Check: 1. Install: • Timing chain tensioner • Exhaust camshaft “1” Cracks/damage → Replace. • Intake camshaft “2” M MMM M MMM M MMM M MMM M MMM a.

  • Page 202
    CAMSHAFTS hole “d” on the exhaust camshaft sprocket ECA13730 NOTICE align with the cylinder head mating surface, as The camshaft cap bolts must be tightened shown in the illustration. evenly or damage to the cylinder head, cam- ECA4B51015 shaft caps, and camshafts will result. NOTICE 4.
  • Page 203
    • Timing chain guide (upper side) • Gaskets (to the cylinder head cover) ECA4B51014 • Apply Yamaha bond No.1215 “1” onto the mat- NOTICE ing surface of the cylinder head cover and tim- Do not push up the timing chain. Push up “c”…

  • Page 204: Cylinder Head

    CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kg, 7.2 ft • • 46 Nm (4.6 m kg, 33 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks Camshafts…

  • Page 205: Removing The Cylinder Head

    CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.03 mm (0.0012 in) • Cylinder head bolts • Cylinder head nuts • Loosen the bolts and nuts in the proper se- quence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

  • Page 206
    CYLINDER HEAD Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) • Cylinder head nuts “2” Cylinder head nut 46 Nm (4.6 m·kg, 33 ft·lb) • Cylinder head bolts “3” Cylinder head bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Lubricate the cylinder head nuts and washers with engine oil.
  • Page 207
    VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Valve lifter Valve pad Valve cotter Valve retainer Valve spring Intake valve Exhaust valve Valve stem seal…

  • Page 208: Valves And Valve Springs

    VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “2” and the valve spring compressor attachment “3”.

  • Page 209
    VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” — Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”…

  • Page 210: Checking The Valve Seats

    VALVES AND VALVE SPRINGS Valve guide remover (ø4) Valve stem runout 90890-04111 0.040 mm (0.0016 in) Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 L LLL L LLL…

  • Page 211
    VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. c. Install the valve into the cylinder head. c. Press the valve through the valve guide and d. Turn the valve until the valve face and valve onto the valve seat to make a clear impres- seat are evenly polished, then clean off all of sion.

  • Page 212: Checking The Valve Springs

    VALVES AND VALVE SPRINGS j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. L LLL L LLL L LLL L LLL L LLL EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.

  • Page 213
    VALVES AND VALVE SPRINGS 1. Deburr: • Valve stem end (with an oil stone) 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil b. Smaller pitch 4. Install: • Valve cotters “1” Install the valve cotters by compressing the valve spring with the valve spring compressor “2”…
  • Page 214
    VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil…
  • Page 215
    CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin…

  • Page 216: Cylinder And Pistons

    CYLINDER AND PISTONS • 2nd ring EAS24380 REMOVING THE PISTONS • Oil ring The following procedure applies to all of the pis- ton. When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring •…

  • Page 217: Checking The Piston Rings

    CYLINDER AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

  • Page 218: Checking The Piston Pins

    CYLINDER AND PISTONS 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. The oil ring expander spacer end gap cannot be measured. If the oil ring rail gap is excessive, re- place all three piston rings. Piston ring 3.

  • Page 219
    CYLINDER AND PISTONS 3. Install: • Dowel pins Be sure to install the top and 2nd rings so that the manufacturer marks or numbers face up. • Cylinder gasket 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5.

  • Page 220: Electric Starter

    ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Negative battery lead Starter motor lead Starter motor…

  • Page 221
    ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover Bearing Oil seal Circlip Armature assembly Starter motor yoke O-ring Insulator Brush Brush spring Brush holder Starter motor rear cover For assembly, reverse the disassembly pro- cedure.

  • Page 222: Checking The Starter Motor

    ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. L LLL L LLL L LLL…

  • Page 223: Installing The Starter Motor

    ELECTRIC STARTER 2. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers.

  • Page 224
    V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •…

  • Page 225: V-Belt Automatic Transmission

    V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •…

  • Page 226
    V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •…
  • Page 227
    V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •…
  • Page 228
    V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave Order Job/Parts to remove Q’ty Remarks Slider Primary sheave weight Primary sliding sheave Collar Oil seal For assembly, reverse the disassembly pro- cedure. * Apply BEL-RAY assembly lube®. 5-39…
  • Page 229
    V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 90 Nm (9.0 m kg, 65 ft • • Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat Secondary sheave compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave…

  • Page 230: Removing The Primary Sheave And Secondary Sheave

    V-BELT AUTOMATIC TRANSMISSION EAS4B51022 EAS24640 REMOVING THE PRIMARY SHEAVE AND DISASSEMBLING THE SECONDARY SECONDARY SHEAVE SHEAVE 1. Remove: 1. Loosen: • Primary sheave nut “1” • Secondary sheave spring seat nut “1” • Secondary sheave nut “2” • While holding the secondary fixed sheave “2” While holding the primary and secondary with the sheave holder “3”, loosen the second- sheave with the sheave holder “3”, loosen the…

  • Page 231: Checking The V-Belt

    V-BELT AUTOMATIC TRANSMISSION EAS24690 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear → Replace. 2. Measure: • Primary sheave weight outside diameter Out of specification → Replace. EAS24670 CHECKING THE V-BELT Primary sheave weight outside…

  • Page 232: Assembling The Primary Sheave

    V-BELT AUTOMATIC TRANSMISSION 2. Install: EAS24720 • Secondary sliding sheave “1” ASSEMBLING THE PRIMARY SHEAVE 1. Clean: Install the secondary sliding sheave onto the • Primary fixed sheave secondary fixed sheave “2” with the oil seal • Primary sliding sheave guide “3”.

  • Page 233: Installing The Primary Sheave Assembly, Secondary Sheave Assembly And V-Belt

    INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1. Apply: • Sealant (onto the inner V-belt case seal) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 2. Install: • V-belt case air duct joint clamp “1” 6. Tighten: •…

  • Page 234
    V-BELT AUTOMATIC TRANSMISSION While holding the secondary sheave with the sheave holder “2”, tighten the secondary sheave nut. Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) Sheave holder 90890-01481 3. Install: • Primary fixed sheave “1” • V-belt “2” •…

  • Page 235: Installing The V-Belt Case

    V-BELT AUTOMATIC TRANSMISSION EAS4B51025 INSTALLING THE V-BELT CASE 1. Install: • Oil seal “1” (into outer V-belt case) Installed depth of oil seal “a” 4.0–4.3 mm (0.16–0.17 in) 2. Fill the space “b” shown in the illustration with 10 g or more of lithium-soap-based grease. 3.

  • Page 236
    GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft •…

  • Page 237: Generator And Starter Clutch

    GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft • • 30 Nm (3.0 m kg, 22 ft 10 Nm (1.0 m…

  • Page 238
    GENERATOR AND STARTER CLUTCH Removing the stator coil and oil tank 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil tank…

  • Page 239: Removing The Generator

    GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator cover Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

  • Page 240: Checking The Starter Clutch

    GENERATOR AND STARTER CLUTCH c. When turning the starter clutch gear clock- wise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced. EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” L LLL L LLL L LLL…

  • Page 241: Installing The Generator

    • While holding the generator rotor “2” with the (onto the crankshaft position sensor lead sheave holder “3”, tighten the generator rotor grommet) nut. Yamaha bond No. 1215 • Do not allow the sheave holder to touch the 90890-85505 projection on the generator rotor. (Three Bond No.1215®)

  • Page 242
    GENERATOR AND STARTER CLUTCH Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Tighten the generator cover bolts in stages and in a crisscross pattern. 5-53…

  • Page 243: Clutch

    CLUTCH EAS25061 CLUTCH Removing the clutch 65 Nm (6.5 m kg, 47 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator cover CLUTCH” on page 5-47. Clutch assembly nut Clutch assembly Washer For installation, reverse the removal proce- dure.

  • Page 244
    CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Circlip Spring stopper plate Clutch spring plate Pressure plate Clutch plate 2 Clutch damper spring Friction plate Clutch plate 1 Clutch spring Clutch boss nut Primary drive gear…
  • Page 245
    CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Clutch housing For assembly, reverse the disassembly pro- cedure. 5-56…

  • Page 246: Removing The Clutch

    CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch assembly nut “1” • Clutch assembly “2” • Before removal, put alignment marks “a” and “b” as shown. • While holding the clutch assembly with the ro- tor holding tool “3”, loosen the clutch assembly nut.

  • Page 247: Checking The Friction Plates

    CLUTCH EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: • Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: • Friction plate thickness Out of specification → Replace the friction EAS4B51027 plates as a set.

  • Page 248: Checking The Clutch Springs

    CLUTCH EAS25140 EAS25160 CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH BOSS The following procedure applies to all of the 1. Check: clutch springs. • Clutch boss splines 1. Check: Damage/pitting/wear → Replace the clutch • Clutch spring boss. Damage → Replace the clutch springs as a set.

  • Page 249: Installing The Clutch

    CLUTCH • Friction plates “4” Recommended lubricant • Clutch plates 1 “5” Engine oil • Pressure plate “6” • Clutch spring plate “7” 2. Install: • Clutch boss • Primary drive gear • Clutch boss nut 3. Tighten: • Clutch boss nut “1” Clutch boss nut 130 Nm (13.0 m·kg, 94 ft·lb) While holding the clutch boss “2”…

  • Page 250
    CLUTCH Clutch assembly nut 65 Nm (6.5 m·kg, 47 ft·lb) • Align the “a” and “b” during reassembly. • While holding the clutch assembly with the ro- tor holding tool “3”, tighten the clutch assembly nut. Rotor holding tool 90890-01235 Universal magneto &…

  • Page 251: Oil Pump

    OIL PUMP EAS24901 OIL PUMP Removing the oil pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Starter clutch gear CLUTCH”…

  • Page 252
    OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing 1 Dowel pin Oil pump outer rotor 1 Oil pump inner rotor 1 Washer Oil pump housing center Oil pump outer rotor 2 Oil pump inner rotor 2 Oil pump driven gear Oil pump housing 2 For assembly, reverse the disassembly pro-…

  • Page 253: Checking The Oil Pump

    OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven gear “1” 0.040–0.120 mm (0.0016–0.0047 • Oil pump housing 2 “2” Limit • Oil pump housing 1 “3” Cracks/damage/wear → Replace the defec- 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing tive part(s).

  • Page 254: Assembling The Oil Pump

    OIL PUMP ECA13890 NOTICE After tightening the bolts, make sure the oil pump turns smoothly. EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.

  • Page 255: Crankcase

    CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft •…

  • Page 256
    CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft • • 24 Nm (2.4 m kg, 17 ft •…
  • Page 257
    CRANKCASE Removing the oil seals and bearings 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-71. Transmission Refer to “TRANSMISSION” on page 5-79. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.

  • Page 258: Disassembling The Crankcase

    (onto the crankcase mating surfaces) es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Yamaha bond No. 1215 • M8 × 110 mm bolts “1” 90890-85505 • M6 × 50 mm bolts “2”…

  • Page 259
    CRANKCASE • M6 × 35 mm bolts “3” 5. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-70…

  • Page 260: Crankshaft

    CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft assembly 58 Nm (5.8 m kg, 42 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Dowel pin Crankshaft assembly Balancer cylinder Oil seal Crankshaft journal bearing For installation, reverse the removal proce- dure.

  • Page 261
    CRANKSHAFT Removing the connecting rods 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ 60 Nm (6.0 m kg, 43 ft • • 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ Order Job/Parts to remove Q’ty…

  • Page 262: Removing The Connecting Rods

    CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod cap • Connecting rod “1” • Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place.

  • Page 263
    CRANKSHAFT 3. Measure: • Crankshaft-pin-to-big-end-bearing clearance • Do not move the connecting rod or crankshaft Out of specification → Replace the big end until the clearance measurement has been bearings. completed. • Lubricate the bolts threads and nut seats with Oil clearance (using plasti- molybdenum disulfide grease.
  • Page 264
    CRANKSHAFT • P –P refer to the bearings shown in the crank- Journal oil clearance (using plas- shaft illustration. tigauge®) 0.040–0.082 mm (0.0016–0.0032 The following procedure applies to all of the crankshaft journal bearings. ECA13920 NOTICE Do not interchange the crankshaft journal bearings.

  • Page 265: Installing The Crankshaft Journal Bearings

    CRANKSHAFT d. Measure the crankshaft journal bearing in- side diameter “b” of each crankshaft journal bearing at two places. e. If crankshaft journal bearing inside diameter is “45.03” and crankshaft journal diameter is “44.98”, then the journal oil clearance is: Journal oil clearance: Crankshaft journal bearing inside diameter — Crankshaft journal diameter…

  • Page 266: Installing The Connecting Rods

    CRANKSHAFT • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. EAS26150 INSTALLING THE CONNECTING RODS 1. Lubricate: • Bolt threads • Nut seats 4. Tighten: (with the recommended lubricant) • Connecting rod nuts M MMM M MMM M MMM…

  • Page 267: Installing The Crankshaft Assembly

    CRANKSHAFT c. Tighten the connecting rod nuts further to (6.0 m·kg, 43 ft·lb), loosen the nut to less reach the specified angle 90°. than 30 Nm (3.0 m·kg, 22 ft·lb) and start again. Connecting rod nut (final) Specified angle 90° EAS4B51033 INSTALLING THE CRANKSHAFT ASSEMBLY…

  • Page 268: Transmission

    TRANSMISSION EAS26240 TRANSMISSION Removing the transmission Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Secondary shaft Collar Primary driven gear Main axle 1st pinion gear Drive axle 1st wheel gear Circlip For installation, reverse the removal proce- dure.

  • Page 269: Checking The Transmission

    TRANSMISSION EAS26300 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 4. Check: • Transmission gear movement Rough movement →…

  • Page 270
    TRANSMISSION 5-81…

  • Page 271: Cooling System

    COOLING SYSTEM RADIATOR …………………. 6-1 CHECKING THE RADIATOR…………..6-3 INSTALLING THE RADIATOR…………..6-3 OIL COOLER………………..6-4 CHECKING THE OIL COOLER …………..6-6 INSTALLING THE OIL COOLER ………….. 6-6 THERMOSTAT ………………..6-7 CHECKING THE THERMOSTAT………….. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ……..6-8 WATER PUMP………………..6-9 DISASSEMBLING THE WATER PUMP……….6-11 CHECKING THE WATER PUMP …………

  • Page 272
    RADIATOR EAS26380 RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Footrest boards 4-1.
  • Page 273
    RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Radiator fan Radiator bracket For installation, reverse the removal proce- dure.

  • Page 274: Radiator

    RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

  • Page 275: Oil Cooler

    OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

  • Page 276
    OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Oil cooler For installation, reverse the removal proce- dure.

  • Page 277: Checking The Oil Cooler

    OIL COOLER 4. Fill: EAS26420 CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-18. • Oil cooler inlet hose •…

  • Page 278: Thermostat

    THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK”…

  • Page 279: Checking The Thermostat

    THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 71–85 °C (159.8–185.0 °F) EAS26480 INSTALLING THE THERMOSTAT → Replace. ASSEMBLY 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing forward.

  • Page 280: Water Pump

    WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Left footrest board 4-1.

  • Page 281
    WATER PUMP Disassembling the water pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil.

  • Page 282: Disassembling The Water Pump

    WATER PUMP EAS26510 EAS26550 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Rubber damper holder “1” • Water pump housing cover • Rubber damper “2” • Water pump housing (from the impeller, with a thin, flat-head •…

  • Page 283: Installing The Water Pump

    WATER PUMP • Before installing the water pump seal, apply ECA14090 NOTICE Yamaha bond No.1215 “2” to the water pump Make sure the rubber damper and rubber housing “3”. damper holder are flush with the impeller. Mechanical seal installer Impeller shaft tilt limit 90890-04078 0.15 mm (0.0059 in)

  • Page 284
    WATER PUMP 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3. 6-13…

  • Page 285: Fuel System

    FUEL SYSTEM FUEL TANK………………… 7-1 REMOVING THE FUEL TANK …………..7-3 REMOVING THE FUEL PUMP …………..7-3 CHECKING THE FUEL PUMP BODY…………7-3 CHECKING THE ROLLOVER VALVE …………7-3 INSTALLING THE FUEL PUMP…………..7-3 CHECKING THE FUEL PRESSURE …………7-3 THROTTLE BODY………………. 7-5 CHECKING THE INJECTORS …………..7-8 CHECKING THE THROTTLE BODY …………7-8 ADJUSTING THE THROTTLE POSITION SENSOR……..7-8…

  • Page 286
    FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1.
  • Page 287
    FUEL TANK Removing the canister 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel tank breather hose Canister purge hose (3-way joint to canister) Canister purge hose (throttle body to 3-way joint)

  • Page 288: Fuel Tank

    FUEL TANK EAS26630 REMOVING THE FUEL TANK • Do not damage the installation surfaces of the 1. Extract the fuel in the fuel tank through the fuel tank when installing the fuel pump. fuel tank cap with a pump. • Always use a new fuel pump gasket. 2.

  • Page 289
    FUEL TANK b. Connect the pressure gauge “1” and fuel pressure adapter “2” to the fuel pump and the fuel hose “3”. Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03181 c. Start the engine. d. Measure the fuel pressure. Faulty → Replace the fuel pump. Output pressure 246.0–254.0 kPa (35.7–36.8 psi) (2.46–2.54 kgf/cm²)

  • Page 290: Throttle Body

    THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

  • Page 291
    THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Throttle body assembly Plastic band Coupler cover…
  • Page 292
    THROTTLE BODY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Before disassembling the throttle body as- sembly, make sure to note the number of times the air screw is turned out from the seated position to its set position. Throttle position sensor Fast idle plunger Idling speed adjusting screw…
  • Page 293
    THROTTLE BODY EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. EAS26990 CHECKING THE THROTTLE BODY 1. Check: B/L Y • Throttle body Cracks/damage → Replace the throttle body. 2. Check: d. Measure the throttle position sensor output •…
  • Page 294
    THROTTLE BODY…

  • Page 295: Electrical System

    ELECTRICAL SYSTEM IGNITION SYSTEM ………………8-1 CIRCUIT DIAGRAM ……………… 8-1 TROUBLESHOOTING …………….8-3 ELECTRIC STARTING SYSTEM …………..8-5 CIRCUIT DIAGRAM ……………… 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ……8-7 TROUBLESHOOTING …………….8-9 CHARGING SYSTEM………………8-11 CIRCUIT DIAGRAM …………….8-11 TROUBLESHOOTING …………….8-13 LIGHTING SYSTEM ………………8-15 CIRCUIT DIAGRAM …………….

  • Page 296
    ELECTRICAL COMPONENTS…………..8-57 CHECKING THE SWITCHES …………..8-61 CHECKING THE BULBS AND BULB SOCKETS ……..8-64 CHECKING THE FUSES …………….8-65 CHECKING AND CHARGING THE BATTERY……..8-66 CHECKING THE RELAYS …………..8-69 CHECKING THE TURN SIGNAL RELAY ……….8-70 CHECKING THE DIODE ……………..8-71 CHECKING THE SPARK PLUG CAPS………..8-71 CHECKING THE IGNITION COIL …………

  • Page 298: Ignition System

    IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM…

  • Page 299
    IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug 39.Lean angle sensor…

  • Page 300: Troubleshooting

    IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Footrest boards 2. Front cowling assembly NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

  • Page 301
    IGNITION SYSTEM NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-61. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch.

  • Page 302: Electric Starting System

    ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM…

  • Page 303
    ELECTRIC STARTING SYSTEM 4. Main switch 9. Signaling system fuse 11.Ignition fuse 14.Battery 15.Main fuse 16.Starter relay 17.Starter motor 18.Diode 1 20.Engine stop switch 21.Start switch 22.Front brake light switch 23.Diode 2 24.Starting circuit cut-off relay 28.Sidestand switch 57.Rear brake light switch…

  • Page 304: Starting Circuit Cut-Off System Operation

    ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •…

  • Page 305
    ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Diode 2 7. Starting circuit cut-off relay 8. Sidestand switch 9. Signaling system fuse 10. Front brake light switch 11. Rear brake light switch 12.

  • Page 306: Troubleshooting

    ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).

  • Page 307
    ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-61. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch.

  • Page 308: Charging System

    CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11…

  • Page 309
    CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 14.Battery 15.Main fuse 8-12…

  • Page 310: Troubleshooting

    CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-65. OK ↓…

  • Page 311
    CHARGING SYSTEM 8-14…

  • Page 312: Lighting System

    LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15…

  • Page 313
    LIGHTING SYSTEM 4. Main switch 5. Storage box light switch 6. Storage box light 8. Backup fuse (odometer and clock) 10.Headlight fuse 13.Taillight fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 47.License plate light 51.Tail/brake light 54.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 61.Headlight relay 62.Headlight (high beam)

  • Page 314: Troubleshooting

    LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position lights, or meter light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Mudguard NG → 1.

  • Page 315
    LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-15. OK ↓ Replace the ECU (engine control unit) or meter assembly. 8-18…

  • Page 316: Signaling System

    SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19…

  • Page 317
    SIGNALING SYSTEM 4. Main switch 8. Backup fuse (odometer and clock) 9. Signaling system fuse 11.Ignition fuse 13.Taillight fuse 14.Battery 15.Main fuse 22.Front brake light switch 27.Fuel sender 29.ECU (engine control unit) 40.Speed sensor 49.Rear left turn signal light 50.Rear right turn signal light 51.Tail/brake light 52.Turn signal relay 55.Horn switch…

  • Page 318: Troubleshooting

    SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •…

  • Page 319
    SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. OK ↓ This circuit is OK. The tail/brake light fails to come on. NG → 1.
  • Page 320
    SIGNALING SYSTEM NG → 3. Check the turn signal relay. Refer to “CHECKING THE TURN Replace the turn signal relay. SIGNAL RELAY” on page 8-70. OK ↓ NG → 4. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”…
  • Page 321
    SIGNALING SYSTEM 8-24…

  • Page 322: Cooling System

    COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25…

  • Page 323
    COOLING SYSTEM 4. Main switch 11.Ignition fuse 12.Radiator fan fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 34.Coolant temperature sensor 45.Radiator fan motor relay 46.Radiator fan motor 65.Multi-function meter 66.Coolant temperature meter 8-26…

  • Page 324: Troubleshooting

    COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and radiator fan) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

  • Page 325
    COOLING SYSTEM 8-28…

  • Page 326: Fuel Injection System

    FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29…

  • Page 327
    FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 7. Fuel injection system fuse 9. Signaling system fuse 10.Headlight fuse 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 23.Diode 2 24.Starting circuit cut-off relay 25.Fuel injection system relay 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug…

  • Page 328: Ecu Self-Diagnostic Function

    FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU (engine control unit) is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

  • Page 329: Self-Diagnostic Function Table

    FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS4B51034 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU (engine control unit) detects an abnormal signal from a sensor while the vehicle is being driv- en, the ECU (engine control unit) illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.

  • Page 330
    FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Coolant temperature Coolant temperature sensor-open Able Able sensor or short circuit detected. Intake air tempera- Intake air temperature sensor- Able Able ture sensor open or short circuit detected.

  • Page 331: Troubleshooting Method

    FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive ECU (engine control unit) internal malfunc- Non-registered data has been re- Er-4 Unable Unable tion ceived from the meter. (input signal error) EAS27400 5.

  • Page 332: Diagnostic Mode

    FUEL INJECTION SYSTEM EAS27431 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

  • Page 333
    FUEL INJECTION SYSTEM 8. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. No normal signals are re- •…
  • Page 334
    FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Stuck fast idle plunger (in fully open posi- Engine speed is high when tion). the engine is idling. • Malfunction in ECU (engine control unit). • Open or short circuit in wire harness. Lean angle sensor: open or •…
  • Page 335
    FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code Throttle angle • Fully closed position (15–16) Check with throttle fully closed. • Fully opened position (97–102) Check with throttle fully open. Pressure difference Displays the intake air pres- Set the engine stop switch (atmospheric pressure and sure.
  • Page 336
    FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code — display • No history • History exists Fault codes 12–50 • (If more than one code number is detected, the dis- play alternates every two seconds to show all the de- tected code numbers.

  • Page 337: Troubleshooting Details

    FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the fuel injection system relay five times at one-second intervals. Illuminates the engine trou- Check the operating sound ble warning light. Fuel injection system relay of the fuel injection system (The engine trouble warning relay five times.

  • Page 338
    FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check the installed area for Cranking the tion sensor.
  • Page 339
    FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Cranking the •…
  • Page 340
    FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose •…
  • Page 341
    FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
  • Page 342
    FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Reinstated by sensor.
  • Page 343
    FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor: open or short circuit detect- Diagnostic code No. Coolant temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of coolant tempera- Check for looseness or pinching. Turning the ture sensor.
  • Page 344
    FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air tem- Check for looseness or pinching.
  • Page 345
    FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of O sensor. Check for looseness or pinching. Starting and warming up the Connections •…
  • Page 346
    FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the ignition coil. Diagnostic code No. Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •…
  • Page 347
    FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Reinstated im- •…
  • Page 348
    FUEL INJECTION SYSTEM Fault code No. Symptom The ECU (engine control unit) is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel injection system relay Order Item/components and probable Check or maintenance job Reinstatement cause…
  • Page 349
    FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connection. • Check the coupler for any pins Starting the en- •…

  • Page 350: Fuel Pump System

    FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-53…

  • Page 351
    FUEL PUMP SYSTEM 4. Main switch 7. Fuel injection system fuse 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 25.Fuel injection system relay 26.Fuel pump 29.ECU (engine control unit) 8-54…

  • Page 352: Troubleshooting

    FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

  • Page 353
    FUEL PUMP SYSTEM 8-56…

  • Page 354: Electrical Components

    ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS 8-57…

  • Page 355
    ELECTRICAL COMPONENTS 1. Front brake light switch 2. Rear brake light switch 3. Battery 4. Main fuse 5. Starter relay 6. Diode 2 7. Diode 1 8. Rectifier/regulator 9. Ignition coil 10.Speed sensor 11.Turn signal relay 12.Horn 13.ECU (electronic control unit) 14.Lean angle sensor 15.Starting circuit cut-off relay 16.Headlight relay…
  • Page 356
    ELECTRICAL COMPONENTS 8-59…
  • Page 357
    ELECTRICAL COMPONENTS 1. Main switch 2. Intake air temperature sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Coolant temperature sensor 6. Fuel pump 7. O sensor 8. Crankshaft position sensor 9. Stator coil 10.Sidestand switch 11.Radiator fan 8-60…

  • Page 358: Checking The Switches

    ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES B/Y B/W Br/W Y Br/W Ch Dg Br B/Y L/B L/Y B (BLACK) B L/W R/W R/B R/W L/W R Br/L L/G L/B R L/G ( BLUE ) Br/L 8-61…

  • Page 359
    ELECTRICAL COMPONENTS 1. Dimmer switch 2. Horn switch 3. Turn signal switch 4. Rear brake light switch 5. Engine stop switch 6. Start switch 7. Front brake light switch 8. Main switch 9. Sidestand switch 10. Storage box light switch 8-62…
  • Page 360
    ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

  • Page 361: Checking The Bulbs And Bulb Sockets

    ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB • Bulb SOCKETS EWA4B51012 WARNING Do not check any of the lights that use LEDs. Since the headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continuity down.

  • Page 362: Checking The Fuses

    ELECTRICAL COMPONENTS Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL Checking the condition of the bulb sockets 3.

  • Page 363: Checking And Charging The Battery

    ELECTRICAL COMPONENTS 4. Install: • Battery cover Since VRLA (Valve Regulated Lead Acid) bat- Refer to “GENERAL CHASSIS” on page 4-1. teries are sealed, it is not possible to check the charge state of the battery by measuring the EAS28030 CHECKING AND CHARGING THE BATTERY specific gravity of the electrolyte.

  • Page 364
    ELECTRICAL COMPONENTS • When charging a battery, be sure to remove Example it from the vehicle. (If charging has to be Open-circuit voltage = 12.0 V done with the battery mounted on the vehi- Charging time = 6.5 hours Charge of the battery = 20–30% cle, disconnect the negative battery lead from the battery terminal.) •…
  • Page 365
    ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is turned off. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.

  • Page 366: Checking The Relays

    ELECTRICAL COMPONENTS • Battery cover 4. Negative tester probe Refer to “GENERAL CHASSIS” on page 4-1. Result EAS28040 Continuity CHECKING THE RELAYS (between “3” and “4”) Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay.

  • Page 367: Checking The Turn Signal Relay

    ELECTRICAL COMPONENTS Fuel injection system relay M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C L/ R •…

  • Page 368: Checking The Diode

    ELECTRICAL COMPONENTS c. Check the diode 1 for continuity. d. Check the diode 1 for no continuity. L LLL L LLL L LLL L LLL L LLL EAS28070 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps.

  • Page 369: Checking The Ignition Spark Gap

    ELECTRICAL COMPONENTS c. Measure the secondary coil resistance. Pocket tester L LLL L LLL L LLL L LLL L LLL 90890-03112 EAS28930 Analog pocket tester CHECKING THE IGNITION SPARK GAP YU-03112-C 1. Check: • Ignition spark gap • Positive tester probe→ Out of specification →…

  • Page 370: Checking The Lean Angle Sensor

    ELECTRICAL COMPONENTS 2. Check: Pocket tester • Crankshaft position sensor resistance 90890-03112 Out of specification → Replace the crank- Analog pocket tester shaft position sensor/stator assembly. YU-03112-C Crankshaft position sensor resis- • Positive tester probe → tance 189–231 Ω at 20 °C (68 °F) yellow/green “1”…

  • Page 371: Checking The Stator Coil

    ELECTRICAL COMPONENTS b. Check the starter motor operation. b. Measure the stator coil resistance. L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL EAS28150 EAS28170 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1.

  • Page 372: Checking The Horn

    ELECTRICAL COMPONENTS EAS28180 EAS28230 CHECKING THE HORN CHECKING THE FUEL SENDER 1. Check: 1. Disconnect: • Horn resistance • Fuel pump coupler Out of specification → Replace. • Fuel hose (from the fuel pump) Coil resistance Refer to “GENERAL CHASSIS” on page 4-1. 1.06–1.11 Ω…

  • Page 373: Checking The Speed Sensor

    ELECTRICAL COMPONENTS c. Elevate the front wheel and slowly rotate it. d. Measure the voltage of white and black/blue. With each full rotation of the front wheel, the voltage reading should cycle from 0 V to 5.0 V to 0 V to 5.0 V. L LLL L LLL L LLL…

  • Page 374: Checking The Throttle Position Sensor

    ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the Pocket tester 90890-03112 coolant temperature sensor terminals as Analog pocket tester shown. YU-03112-C Pocket tester • Tester positive lead → 90890-03112 Analog pocket tester blue “1”…

  • Page 375: Checking The Intake Air Temperature Sensor

    ELECTRICAL COMPONENTS • Positive tester probe → blue “1” • Negative tester probe → pink/white “2” B/L P/W L b. Measure the intake air temperature sensor resistance. L LLL L LLL L LLL L LLL L LLL b. Turn the main switch to “ON”. c.

  • Page 376
    ELECTRICAL COMPONENTS 8-79…

  • Page 377: Troubleshooting

    TROUBLESHOOTING TROUBLESHOOTING………………9-1 GENERAL INFORMATION …………… 9-1 STARTING FAILURE/HARD STARTING……….9-1 INCORRECT ENGINE IDLING SPEED ………… 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……9-2 FAULTY CLUTCH ………………9-2 OVERHEATING ………………9-2 OVERCOOLING………………9-3 POOR BRAKING PERFORMANCE…………9-3 FAULTY FRONT FORK LEGS…………..9-3 UNSTABLE HANDLING …………….9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ……..9-4…

  • Page 378: Troubleshooting

    TROUBLESHOOTING • Sucked-in air EAS28450 TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •…

  • Page 379: Poor Medium-And-High-Speed Performance

    TROUBLESHOOTING • Improper throttle cable free play 2. Engine oil • Flooded throttle body • Incorrect oil level • Incorrect oil viscosity (low) Electrical system • Deteriorated oil 1. Battery 3. Primary sliding sheave • Discharged battery • Seized primary sliding sheave •…

  • Page 380: Overcooling

    TROUBLESHOOTING • Thermostat • Damaged oil seal lip • Thermostat stays closed • Incorrect oil level (high) • Oil cooler • Loose damper rod bolt • Clogged or damaged oil cooler • Damaged damper rod bolt copper washer • Hose(s) and pipe(s) •…

  • Page 381: Faulty Lighting Or Signaling System

    TROUBLESHOOTING Turn signal flashes quickly EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM • Incorrect turn signal bulb • Faulty turn signal relay Headlight does not come on • Burnt-out turn signal bulb • Wrong headlight bulb • Too many electrical accessories Horn does not sound •…

  • Page 382: Wiring Diagram

    EAS28740 57. Rear brake light switch EAS28750 WIRING DIAGRAM COLOR CODE 58. Horn Black 59. Front right turn signal/position XP500Y 2009 Brown light 1. Crankshaft position sensor Chocolate 60. Front left turn signal/position 2. AC magneto Dark green light 3. Rectifier/regulator Green 61.

  • Page 384
    YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN…
  • Page 385
    XP500Y 2009 WIRING DIAGRAM HEADLIGHT HEADLIGHT GRIP WARMER STORAGE BOX WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS LIGHT SUB-WIRE HARNESS HARNESS HARNESS HARNESS W/Y Y/R L/Y B/L P/W Br/W G/R R/B R/W B/W B/Y W Gy/G Y/G Y/L (BLACK) W W W W W W…
  • Page 386
    XP500Y 2009 WIRING DIAGRAM HEADLIGHT HEADLIGHT GRIP WARMER STORAGE BOX WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS LIGHT SUB-WIRE HARNESS HARNESS HARNESS HARNESS (BLACK) (BLACK) (GREEN) (BLACK) (GREEN) ( GREEN ) ( GREEN ) (DARK BLUE) ( BLACK ) ( BLUE ) ( BLACK )

Источник

МОТОСЕРВИС

Диагностика от 700р

Полировка от 1000р

Сварка аргонная от 110р

Шиномонтаж от 1500р

Балансировка от 300р

ДВИГАТЕЛЬ  

С/У двигателя от 6000р

Переборка двигателя от 10000р

Замена ремня вариатора от 2000р

Замена цепи (ремня) ГРМ от 10000р

Замена натяжителя цепи ГРМ от 2500р

Замена дисков сцепления от 2500р

Регулировка клапанов от 5000р

Замена распредвалов от 4000р

Замена гидрокампенсаторов от 4000р

Замена масла в двигателе или трансмиссии от 300р

Измерение компрессии от 1000р

Замена свечей от 800р

СИСТЕМА ОХЛАЖДЕНИЯ

Замена антифриза от 900

С/У радиатора от 1500

Диагностика системы охлаждения от 500

Промывка системы охлаждения от 500

Замена помпы от 1500  

Замена термостата от 2000  

Замена датчика температуры от 500  

  ТОПЛИВНАЯ СИСТЕМА  

Диагностика топливной системы от 800

Коплекс по карбюраторам от 2500

Промывка инжектора от 2700  

Промывка бензобака от 1500

Синхронизация от 1500

Замена бензонасоса от 1000

Замена топливного фильтра от 500

Замена воздушного фильтра от 500

Очиска системы впуска от 2000

  ЭЛЕКТРООБОРУДОВАНИЕ  

Диагностика электрики от 800

Ремонт электрики от 500

Установка сигнализации/иммобилайзера от 1000

Замена АКБ от 400

Зарядка АКБ от 500  

  ТОРМОЗНАЯ СИСТЕМА

Диагностика тормозной системы от 400

Замена тормозных колодок (за суппорт) от 250

Замена тормозных дисков (за колесо) от 700  

Замена тормозной жидкости (за суппорт) от 400

Переборка суппорта от 1500  

С/У суппорта от 350  

Переборка тормозной  машинки от 1000  

  ПЕРЕДНЯЯ ПОДВЕСКА  

С/У колеса от 350  

Замена подшипников ступицы (за колесо.) от 1500  

Переборка вилки от 2500

C/У верхней траверсы от 3500  

Замена подшипников рулевой колонки от 3500  

  ЗАДНЯЯ ПОДВЕСКА  

С/у колеса от 350  

Замена подшипника (за 1 шт.) от 750  

Замена амортизатора (за 1 шт.) от 1500  

Замена масла в заднем редукторе от 350  

С/у маятника от 4000

Источник

Yamaha Tmax XP500 2016 Owner's Manual

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OWNER’S MANUAL

XP500

MOTORCYCLE

Read this manual carefully before oper-

ating this vehicle.

XP500

XP500A

2PW-28199-E1

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Related Manuals for Yamaha Tmax XP500 2016

Summary of Contents for Yamaha Tmax XP500 2016

  • Page 1
    OWNER’S MANUAL XP500 MOTORCYCLE Read this manual carefully before oper- ating this vehicle. XP500 XP500A 2PW-28199-E1…
  • Page 2
    EAU72660 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3
    If you have any further questions, do not hesitate to con- tact your Yamaha dealer. The Yamaha team wishes you many safe and pleasant rides. So, remember to put safety first! Yamaha continually seeks advancements in product design and quality. There-…

  • Page 4: Important Manual Information

    *Product and specifications are subject to change without notice. EAU10201 XP500/XP500A OWNER’S MANUAL ©2015 by Yamaha Motor Co., Ltd. 1st edition, August 2015 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd.

  • Page 5: Table Of Contents

    Table of contents Safety information ……1-1 For your safety – pre-operation checks ……….5-1 Further safe-riding points ….1-5 Description ……..2-1 Operation and important riding points……….6-1 Left view ………. 2-1 Right view……..2-2 Starting the engine……6-2 Controls and instruments ….

  • Page 6
    Table of contents Checking and lubricating the throttle grip and cable….7-25 Lubricating the front and rear brake levers……..7-25 Checking and lubricating the centerstand and sidestand ..7-26 Checking the front fork ….7-26 Checking the steering….7-27 Checking the wheel bearings ..7-27 Battery ………..7-28 Replacing the fuses …….7-29 Headlights……..7-31 Auxiliary lights……..7-32…

  • Page 7: Safety Information

    Safety information for a list of pre-operation checks. EAU1026B  This scooter is designed to carry the operator and a passenger. Be a Responsible Owner  The failure of motorists to detect As the vehicle’s owner, you are respon- and recognize scooters in traffic is sible for the safe and proper operation the predominating cause of auto- of your scooter.

  • Page 8
    Safety information Protective Apparel help you to avoid an accident. • We recommend that you prac- The majority of fatalities from scooter tice riding your scooter where accidents are the result of head inju- ries. The use of a safety helmet is the there is no traffic until you have become thoroughly familiar with single most critical factor in the preven-…
  • Page 9
    Genuine senger, accessories and cargo must Yamaha accessories, which are avail- not exceed the maximum load limit. able only from a Yamaha dealer, have Operation of an overloaded vehicle been designed, tested, and approved could cause an accident.
  • Page 10
    Yamaha or should be kept to a minimum. modifications not specifically recom- • Bulky or large accessories may mended by Yamaha, even if sold and seriously affect the stability of installed by a Yamaha dealer. the scooter due to aerodynamic effects.

  • Page 11: Further Safe-Riding Points

    Safety information Transporting the Scooter EAU57600 Further safe-riding points Be sure to observe following instruc-  Be sure to signal clearly when tions before transporting the scooter in making turns. another vehicle.  Braking can be extremely difficult  Remove all loose items from the on a wet road.

  • Page 12: Description

    Description EAU63371 Left view 8 7 6 1. Battery (page 7-28) 2. Helmet holder (page 4-17) 3. Rear storage compartment (page 4-18) 4. Grab bar (page 6-3) 5. Engine oil filler cap (page 7-10) 6. Sidestand (page 4-22) 7. Engine oil drain bolt (page 7-10) 8.

  • Page 13: Right View

    Description EAU63391 Right view 1. Owner’s tool kit (page 7-2) 2. Fuel tank cap (page 4-14) 3. Air filter element (page 7-15) 4. Windshield (page 4-19) 5. Fuses (page 7-29) 6. Centerstand (page 7-26)

  • Page 14: Controls And Instruments

    Description EAU63401 Controls and instruments 1. Rear brake lever (page 4-12) 2. Left handlebar switches (page 4-10) 3. Rear brake lock lever (page 4-12) 4. Speedometer (page 4-2) 5. Multi-function display (page 4-3) 6. Tachometer (page 4-3) 7. Right handlebar switches (page 4-10) 8.

  • Page 15: Smart Key System

    Smart key system EAU61663 Smart key system The smart key system enables the ve- hicle to be operated without using a mechanical key. EWA14704 WARNING Keep implanted pacemakers or  cardiac defibrillators, as well as other electric medical devices away from the vehicle mounted 1.

  • Page 16: Operating Range Of The Smart Key

    Smart key system EAU61582 Operating range of the smart key system The operating range of the smart key system is about 80 cm (31.5 in) from the center of the handlebars. 1. “SEAT OPEN/ ” switch 2. “OFF/LOCK” switch ECA15763 NOTICE The smart key system uses weak ra- dio waves.

  • Page 17: Handling Of The Smart Key And Mechanical Key

    Smart key system or cannot communicate with the EAU61643 Handling of the smart key and vehicle, all switches will be tempo- mechanical key rarily disabled.  EWA17952 Placing the smart key in the front WARNING or rear storage compartment may The smart key should be carried …

  • Page 18
    Do not leave the smart key in a  smart key system still does not operate, place exposed to direct sun- have a Yamaha dealer check the vehi- light, high temperature or high cle. humidity. Do not grind or attempt to mod-…

  • Page 19: Smart Key

    Smart key system EAU61673 Smart key You can register up to six smart keys for the same vehicle. See a Yamaha dealer regarding spare smart keys. 1. “ON/OFF” switch 2. Smart key indicator light When the smart key is turned on and…

  • Page 20: Replacing The Smart Key Battery

    Smart key system EAU61603 Replacing the smart key battery Replace the battery in the following sit- uations.  The smart key system indicator light flashes for about 20 seconds when the power of the vehicle is turned on.  When the smart key indicator light 1.

  • Page 21
    Smart key system damaged or contaminated by dirt. Dispose of the removed battery in ac- Do not touch the internal cir-  cordance with local regulations. cuits and terminals. This may cause malfunctions. 5. Install a new battery as shown. Do not apply excessive force to Note the polarity of the battery.

  • Page 22: Vehicle Power On And Steering Lock Release

    1. With the smart key on and in oper- and the smart key system indicator ating range, press the “ON/ ” light is flashing, have a Yamaha switch for one second. dealer check the smart key system. 3. The power of the vehicle is turned on once the steering lock is com- pletely released.

  • Page 23: Powering Off The Vehicle

    Smart key system Be sure to stop the vehicle in a EAU61693 Powering off the vehicle safe place when turning off the To turn the vehicle power off (and stop power. the engine if it is running), with the  Without the smart key, the vehicle smart key on and within operating power can be turned off by press-…

  • Page 24: How To Lock The Steering

    Smart key system EAU61612 EAU61683 How to lock the steering Seat opening and closing After moving the vehicle to a safe park- To open the seat ing place, turn off the power of the vehi- cle. Turn the handlebars fully to the left 1.

  • Page 25: Parking Mode

    Smart key system EAU61593 Parking mode  Make sure the seat is properly The steering is locked, and the hazard closed before starting off. lights and turn signal lights can be  In case of an emergency, the seat turned on, but all other electrical sys- can be opened with a mechanical tems are off.

  • Page 26: Instrument And Control Functions

    Yamaha dealer check the electrical circuit. This warning light will come on when the vehicle power is on and the “ON/ ”…

  • Page 27: Speedometer

    When the start switch is pushed, the in- dicator light will come on for about one second and then go off. If the indicator light does not come on or go off as nor- mal, have a Yamaha dealer check the vehicle.

  • Page 28: Tachometer

    Instrument and control functions EAU63551 EAU63564 Tachometer Multi-function display EWA12313 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. Changing settings while riding can distract the operator and increase the risk of an accident.

  • Page 29
    Instrument and control functions Clock 1. Clock 1. Clock The multi-function display is equipped with the following: The clock uses a 24-hour time system.  a fuel meter The clock displays when the key is  a coolant temperature meter turned to “ON”.
  • Page 30
    Instrument and control functions the display between the odometer mode and the tripmeter modes in the following order: Odo  Trip 1  Trip 2  V-Belt Trip  Oil Trip  Odo When approximately 3.0 L (0.79 US gal, 0.66 Imp.gal) of fuel remains in the fuel tank, the display will automatically change to the fuel reserve tripmeter mode “Trip F”…
  • Page 31
    Instrument and control functions been reset. ECA10022 NOTICE Do not continue to operate the en- Fuel meter gine if it is overheating. The fuel meter indicates the amount of fuel in the fuel tank. The display seg- Oil change indicator “Oil” ments of the fuel meter disappear to- wards “E”…
  • Page 32
    “V-Belt” onds and then goes off. 3. If the V-belt replacement indicator does not come on, have a Yamaha dealer check the electrical circuit. Ambient temperature display, aver- age fuel consumption, and instan- taneous fuel consumption modes 1.
  • Page 33
    Instrument and control functions For the UK: Average fuel consumption mode Push the “RESET” button to switch the display between the ambient tempera- ture display “Air”, the average fuel con- sumption mode “AVE_ _._ MPG” and the instantaneous fuel consumption mode “MPG”…
  • Page 34
     When the display is set to “km/L”, note the code number, and then have a the distance that can be traveled Yamaha dealer check the vehicle. on 1.0 L of fuel under the current ECA11591 NOTICE riding conditions is shown.

  • Page 35: Handlebar Switches

    Instrument and control functions turn, push this switch to “ ”. When re- EAU1234H Handlebar switches leased, the switch returns to the center Left position. To cancel the turn signal lights, push the switch in after it has re- turned to the center position. EAU12501 Horn switch “…

  • Page 36: Front Brake Lever

    Instrument and control functions an emergency or to warn other drivers EAU44912 Front brake lever when your vehicle is stopped where it might be a traffic hazard. ECA10062 NOTICE Do not use the hazard lights for an extended length of time with the en- gine not running, otherwise the bat- tery may discharge.

  • Page 37: Rear Brake Lever

    Instrument and control functions EAU44922 EAU63230 Rear brake lever Rear brake lock lever 1. Rear brake lever 1. Rear brake lock lever 2. Brake lever position adjusting dial This vehicle is equipped with a rear 3. “ ” mark brake lock lever to prevent the rear 4.

  • Page 38: Abs (For Abs Models)

    ABS is operating. However, EAU63591 ABS (for ABS models) special tools are required, so The Yamaha ABS (Anti-lock Brake please consult your Yamaha deal- System) features a dual electronic con- trol system, which acts on the front and ECA20100 rear brakes independently.

  • Page 39: Fuel Tank Cap

    Instrument and control functions EAU63691 Fuel tank cap To remove the fuel tank cap 1. Open the lid by pulling the lever up. 1. Match marks 2. Turn the key counterclockwise to the original position, and then re- move it. 3.

  • Page 40: Fuel

    Your Yamaha engine has been de- 1. Fuel tank filler tube signed to use regular unleaded gaso- 2. Maximum fuel level line with a research octane number of 3.

  • Page 41: Catalytic Converter

    10% (E10). Gas- possible fire hazards such as ohol containing methanol grass or other materials that recommended by Yamaha because it easily burn. can cause damage to the fuel system Park the vehicle in a place  or vehicle performance problems.

  • Page 42: Adjusting The Rider Backrest

    Instrument and control functions EAU63600 EAU63640 Adjusting the rider backrest Helmet holder The rider backrest can be adjusted to the three different positions shown. 1. Shaded projection 2. Helmet holding cable 3. Helmet holder 1. Rider backrest The helmet holder is located under the Adjust the backrest as follows.

  • Page 43: Storage Compartments

    Instrument and control functions Rear storage compartment EAU63510 Storage compartments A helmet can be stored in the rear stor- age compartment under the seat. (See Front storage compartment page 3-10 for seat opening and closing To open the storage compartment information.) To store a helmet in the when it is locked, insert the mechanical rear storage compartment, place the…

  • Page 44: Windshield

    Instrument and control functions locked inside and the smart key EAU52212 Windshield system may not operate normally. To suit the rider’s preference, the wind- ECA15963 shield height can be changed to one of NOTICE two positions. Do not leave the seat open for …

  • Page 45
    Instrument and control functions 1. Screw 1. Screw 3. Remove the rubber caps. 6. Tighten the screws to the specified torque. WARNING! A loose wind- shield could cause an accident. Be sure to tighten the screws to the specified torque. [EWA15511] Tightening torque: Windshield screw:…

  • Page 46: Rear View Mirrors

    Be sure to fold the rear view mirrors Do not dispose of a damaged or  back to their original position before worn-out shock absorber as- riding. sembly yourself. Take the shock absorber assembly to a Yamaha dealer for any service. 4-21…

  • Page 47: Sidestand

    Therefore, check this system regularly and have a Yamaha dealer repair it if it does not function properly. 4-22…

  • Page 48
    • If a malfunction is noted, have a 3. Turn the vehicle power on. Yamaha dealer check the system 4. Keep the front or rear brake applied. before riding. 5. Push the “ON/ ”…

  • Page 49: Auxiliary Dc Jack

    Instrument and control functions EAU49453 Auxiliary DC jack EWA14361 WARNING To prevent electrical shock or short- circuiting, make sure that the cap is installed when the auxiliary DC jack is not being used. ECA15432 NOTICE 1. Auxiliary DC jack The accessory connected to the 5.

  • Page 50: For Your Safety — Pre-Operation Checks

    Do not operate the vehicle if you find any problem. If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points:…

  • Page 51
    • Tighten if necessary. Instruments, lights, • Check operation. — signals and switches • Correct if necessary. • Check operation of ignition circuit cut-off system. Sidestand switch • If system is not working correctly, have Yamaha dealer 4-22 check vehicle.

  • Page 52: Operation And Important Riding Points

    This model is equipped with: there is a control or function you do not  a lean angle sensor to stop the en- understand, ask your Yamaha dealer. gine in case of a turnover. In this EWA10272 case, the display will indicate error…

  • Page 53: Starting The Engine

    Operation and important riding points EAU61552 ECA21980 Starting the engine NOTICE ECA10251 If the engine warning light or the NOTICE warning light (for ABS- See page 6-5 for engine break-in in- equipped models) does not come on structions prior to operating the ve- and then go off as explained above, hicle for the first time.

  • Page 54: Starting Off

    Operation and important riding points EAU45093 EAU16782 Starting off Acceleration and deceleration 1. While pulling the rear brake lever with your left hand and holding the grab bar with your right hand, push the scooter off the centerstand. The speed can be adjusted by opening and closing the throttle.

  • Page 55: Braking

    Operation and important riding points Rear EAU16794 Braking EWA10301 WARNING Avoid braking hard or suddenly  (especially when leaning over to one side), otherwise the scooter may skid or overturn. Railroad crossings, streetcar  rails, iron plates on road con- struction sites, and manhole covers become extremely slip- pery when wet.

  • Page 56: Tips For Reducing Fuel Consumption

    The vehicle can now be operated nor- mally. ECA10311 NOTICE Keep the engine speed out of  the tachometer red zone. If any engine trouble should oc-  cur during the engine break-in period, immediately have a Yamaha dealer check the vehi- cle.

  • Page 57: Parking

    Operation and important riding points EAU63740 Parking When parking, turn the vehicle power off, and then turn the smart key off. EWA10312 WARNING Since the engine and exhaust  system can become very hot, park in a place where pedestri- ans or children are not likely to touch them and be burned.

  • Page 58: Periodic Maintenance And Adjustment

    If you are not familiar with vehicle ser- vice, have a Yamaha dealer perform service. EWA15123 WARNING Turn off the engine when performing…

  • Page 59: Owner’s Tool Kit

    If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.

  • Page 60: Periodic Maintenance Chart For The Emission Control System

    From 50000 km (30000 mi), repeat the maintenance intervals starting from 10000 km (6000 mi).  Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. EAU63321 Periodic maintenance chart for the emission control system…

  • Page 61: General Maintenance And Lubrication Chart

    Periodic maintenance and adjustment EAU64031 General maintenance and lubrication chart ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi Air filter element   • Replace.   • Clean. V-belt case air filter elements  …

  • Page 62
    Periodic maintenance and adjustment ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi Drive pulley and 13 *   • Lubricate. drive axle • Check bearing play and      steering for roughness. 14 * Steering bearings •…
  • Page 63
    Periodic maintenance and adjustment ODOMETER CHECK OR READINGS MAINTENANCE JOB ITEM X 1000 km X 1000 mi Moving parts and      • Lubricate. cables • Check operation. • Check throttle grip free play, 28 * Throttle grip …

  • Page 64: Removing And Installing Panels

    Periodic maintenance and adjustment EAU18773 Removing and installing panels The panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a panel needs to be removed and installed. 1.

  • Page 65
    Periodic maintenance and adjustment 3. Remove the panel as shown. 3. Install the quick fastener. Panel C To remove the panel Remove the screws, and then pull the panel backward and upward. To install the panel 1. Insert the tabs on the upper left and right sides of the panel.

  • Page 66: Checking The Spark Plugs

    Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. If a spark plug shows signs of electrode erosion and excessive carbon or other deposits, it should be replaced.

  • Page 67: Engine Oil And Oil Filter Cartridge

    Periodic maintenance and adjustment EAU1985E Engine oil and oil filter cartridge The engine oil level should be checked before each ride. In addition, the oil must be changed and the oil filter car- tridge replaced at the intervals speci- fied in the periodic maintenance and lubrication chart.

  • Page 68
    Periodic maintenance and adjustment 1. Engine oil level check window 1. Engine oil drain bolt 2. Maximum level mark 2. O-ring 3. Minimum level mark 3. Gasket 4. If the engine oil is below the mini- 5. Check the O-ring for damage and mum level mark, add sufficient oil replace it if necessary.
  • Page 69
    Oil filter cartridge: 17 Nm (1.7 m·kgf, 12 ft·lbf) An oil filter wrench is available at a Yamaha dealer. 9. Install the engine oil drain bolt and its new gasket, and then tighten 7. Apply a thin coat of clean engine the bolt to the specified torque.

  • Page 70: Coolant

    Periodic maintenance and adjustment lubricates the clutch), do not EAU20071 Coolant mix any chemical additives. Do The coolant level should be checked not use oils with a diesel speci- before each ride. In addition, the cool- fication of “CD” or oils of a high- ant must be changed at the intervals er quality than specified.

  • Page 71
    Periodic maintenance and adjustment corrosion. If water has been added to the coolant, have a Yamaha dealer check the anti- freeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. [ECA10473] 1. Floorboard mat 4.

  • Page 72: Replacing The Air Filter Element

    Periodic maintenance and adjustment element installed, otherwise the EAU52031 Replacing the air filter element piston(s) and/or cylinder(s) may The air filter element should be re- become excessively worn. [ECA10482] placed at the intervals specified in the 5. Install the air filter case cover by in- periodic maintenance and lubrication stalling the screws.

  • Page 73: Adjusting The Engine Idling Speed

    (a). To decrease the en- gine idling speed, turn the screw in 3.0–5.0 mm (0.12–0.20 in) direction (b). Periodically check the throttle grip free play and, if necessary, have a Yamaha dealer adjust it. 1. Idle adjusting screw Engine idling speed: 1100–1300 r/min…

  • Page 74: Valve Clearance

    Therefore, it must be adjusted by a Yamaha dealer is essential to maintain the tires in good at the intervals specified in the periodic condition at all times and replace them maintenance and lubrication chart.

  • Page 75
    Old and aged tires shall be glass fragments in it, or if the sidewall is checked by tire specialists to ascertain cracked, have a Yamaha dealer re- their suitability for further use. place the tire immediately. 7-18…

  • Page 76: Cast Wheels

    If any Always make sure that the valve  damage is found, have a Yamaha caps are securely installed to dealer replace the wheel. Do not prevent air pressure leakage. attempt even the smallest repair to Use only the tire valves and …

  • Page 77: Checking The Front And Rear Brake Lever Free Play

    Rear 1. No brake lever free play There should be no free play at the brake lever ends. If there is free play, have a Yamaha dealer inspect the brake system. EWA14212 WARNING A soft or spongy feeling in the brake lever can indicate the presence of air in the hydraulic system.

  • Page 78: Adjusting The Rear Brake Lock Cable

    (b). WARNING! If proper adjustment cannot be obtained as described, 1. Wear indicator groove have a Yamaha dealer make this ad- 2. Wear indicator justment. [EWA16151] 3. Rubber boot…

  • Page 79: Checking The Front And Rear Brake Pads

    Insufficient brake fluid may al-  have a Yamaha dealer replace the low air to enter the brake sys- brake pads as a set. tem, reducing braking performance.

  • Page 80: Changing The Brake Fluid

    Clean the filler cap before re-  EAU22733 Changing the brake fluid moving. Use only DOT 4 brake Have a Yamaha dealer change the fluid from a sealed container. brake fluid at the intervals specified in Use only the specified brake flu- …

  • Page 81: Drive Belt Slack

    Drive belt slack Checking and lubricating the cables The drive belt slack should be checked and adjusted by a Yamaha dealer at The operation of all control cables and the intervals specified in the periodic the condition of the cables should be maintenance and lubrication chart.

  • Page 82: Checking And Lubricating The Throttle Grip And Cable

    Front brake lever be checked before each ride. In addi- tion, the cable should be lubricated by a Yamaha dealer at the intervals speci- fied in the periodic maintenance chart. The throttle cable is equipped with a rubber cover. Make sure that the cover is securely installed.

  • Page 83: Checking The Front Fork

    EWA10742 WARNING If the centerstand or sidestand does not move up and down smoothly, have a Yamaha dealer check or re- pair it. Otherwise, the centerstand or ECA10591 sidestand could contact the ground NOTICE and distract the operator, resulting If any damage is found or the front in a possible loss of control.

  • Page 84: Checking The Steering

    If there is play in the wheel ward and backward. If any free hub or if the wheel does not turn play can be felt, have a Yamaha smoothly, have a Yamaha dealer check dealer check or repair the steering.

  • Page 85: Battery

    IES OUT OF THE REACH OF CHILDREN. To charge the battery 1. Negative battery lead (black) Have a Yamaha dealer charge the bat- 2. Positive battery lead (red) tery as soon as possible if it seems to 3. Battery have discharged. Keep in mind that the…

  • Page 86: Replacing The Fuses

    Periodic maintenance and adjustment ing the battery, connect the EAU54025 Replacing the fuses positive lead before connecting The main fuse box and the fuse box, the negative lead. [ECA21910] which contains the fuses for the individ- 4. After installation, make sure that ual circuits, are located under panel B.

  • Page 87
    Periodic maintenance and adjustment For XP500 For XP500A 1. Signaling system fuse 1. Spare fuse 2. Ignition fuse 2. ABS solenoid fuse 3. Parking lighting fuse 3. ABS motor fuse 4. Radiator fan motor fuse 4. Headlight fuse 5. Fuel injection system fuse 5.

  • Page 88: Headlights

    Headlights check the electrical system. This model is equipped with LED-type headlights. If a headlight does not come on, have a Yamaha dealer check its electrical cir- cuit. ECA16581 NOTICE Do not affix any type of tinted film or stickers to the headlight lens.

  • Page 89: Auxiliary Lights

    This model is equipped with an LED- auxiliary lights. type tail/brake light. If an auxiliary light does not come on, If the tail/brake light does not come on, have a Yamaha dealer check it. have a Yamaha dealer check it. 7-32…

  • Page 90: Replacing A Front Turn Signal Light Bulb

    Replacing a front turn signal Rear turn signal light bulb light bulb If a rear turn signal light does not come on, have a Yamaha dealer check the 1. Place the scooter on the center- electrical circuit or replace the bulb. stand.

  • Page 91: Replacing The License Plate Light Bulb

    The following troubleshooting charts represent quick and easy procedures for checking these vital systems your- self. However, should your scooter re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have 1. Screw the necessary tools, experience, and know-how to service the scooter prop- 2.

  • Page 92
    (See page 7-28.) If the smart key system does not work after checking the above-mentioned items, have a Yamaha dealer check the smart key system. Refer to emergency mode on page 7-38 on how to start the engine without using the smart key.

  • Page 93: Troubleshooting Charts

    Check the vehicle. compression. 4. Compression The engine does not start. There is compression. Have a Yamaha dealer check the vehicle. Operate the electric starter. There is no Have a Yamaha dealer check the vehicle. compression. 7-36…

  • Page 94: Engine Overheating

    Start the engine. If the engine overheats again, The coolant level is have a Yamaha dealer check and repair the cooling system. If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

  • Page 95: Emergency Mode

    Periodic maintenance and adjustment The smart key system indicator EAU61545 Emergency mode light on the speedometer will come When the smart key is lost, damaged, on for three seconds to indicate or its battery has discharged, the vehi- the transition to emergency mode. cle can still be turned on and the engine started.

  • Page 96
    Periodic maintenance and adjustment light will start to flash. 10 seconds during the identifica-  tion number input process.  When the smart key system indi- cator light is allowed to flash 10 or more times. 8. Press the “ON/ ” switch while the smart key system indicator light is Release the “SEAT OPEN/ ”…

  • Page 97: Scooter Care And Storage

    Be Rust and corrosion can develop even if sure to consult a Yamaha dealer for high-quality components are used. A advice on what products to use be- rusty exhaust pipe may go unnoticed fore cleaning the vehicle.

  • Page 98
    Scooter care and storage structed. Also, thoroughly rinse pounds for plastic may leave the area off with water, immedi- scratches on the windshield. ately dry it, and then apply a cor- Test the product on a small hid- rosion protection spray. den part of the windshield to Improper cleaning can damage make sure that it does not leave…
  • Page 99
     Consult a Yamaha dealer for ad- 3. To prevent corrosion, it is recom- vice on what products to use. mended to apply a corrosion pro- …

  • Page 100: Storage

    Scooter care and storage head so that the electrodes are EAU36554 Storage grounded. (This will limit spark- ing during the next step.) Short-term d. Turn the engine over several Always store your scooter in a cool, dry times with the starter. (This will place and, if necessary, protect it coat the cylinder walls with oil.) against dust with a porous cover.

  • Page 101
    Scooter care and storage storing the scooter.

  • Page 102: Specifications

    Specifications Dimensions: Engine oil quantity: EAU69993 Oil change: Overall length: 2.70 L (2.85 US qt, 2.38 Imp.qt) 2200 mm (86.6 in) With oil filter removal: Overall width: 2.90 L (3.07 US qt, 2.55 Imp.qt) 775 mm (30.5 in) Coolant quantity: Overall height: 1420/1475 mm (55.9/58.1 in) Coolant reservoir (up to the maximum level…

  • Page 103
    Specifications Front tire: Specified brake fluid: DOT 4 Type: Front suspension: Tubeless Size: Type: 120/70R15M/C 56H Telescopic fork Manufacturer/model: Spring: DUNLOP/GPR-100F M Coil spring Rear tire: Shock absorber: Hydraulic damper Type: Wheel travel: Tubeless 120 mm (4.7 in) Size: Rear suspension: 160/60R15M/C 67H Manufacturer/model: Type:…
  • Page 104
    Specifications Turn signal indicator light: Engine trouble warning light: ABS warning light: LED (XP500A) Smart key system indicator light: Fuse(s): Main fuse: 40.0 A Headlight fuse: 10.0 A Signaling system fuse: 15.0 A Ignition fuse: 7.5 A Parking lighting fuse: 10.0 A Radiator fan motor fuse: 15.0 A…

  • Page 105: Consumer Information

    These identification numbers are needed when registering the vehicle with the authorities in your EAU26442 Engine serial number area and when ordering spare parts from a Yamaha dealer. VEHICLE IDENTIFICATION NUM- BER: ENGINE SERIAL NUMBER: 1. Engine serial number The engine serial number is stamped into the crankcase.

  • Page 106
    The model label is affixed to the inside of the rear storage compartment. (See page 4-18.) Record the information on this label in the space provided. This in- formation will be needed when ordering spare parts from a Yamaha dealer. 10-2…

  • Page 107: Index

    Index ABS (for ABS models)……4-13 Identification numbers……10-1 ABS warning light (for ABS models)..4-1 Ignition circuit cut-off system….4-22 Acceleration and deceleration ….6-3 Indicator lights and warning lights… 4-1 Air filter element, replacing….7-15 Auxiliary DC jack ……..4-24 Key, handling of smart and mechanical Auxiliary lights ……..7-32 key …………

  • Page 108
    Index Tachometer……….4-3 Tail/brake light……..7-32 Throttle grip and cable, checking and lubricating ……….. 7-25 Throttle grip free play, checking…. 7-16 Tires …………7-17 Tool kit ………… 7-2 Troubleshooting ……..7-34 Troubleshooting charts ……7-36 Turn signal indicator lights …… 4-1 Turn signal light bulb (front), replacing ……….
  • Page 110
    Original instructions PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2015.10–0.5×1 !

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Каталог оригинальных запчастей Yamaha на максискутер Yamaha T-Max XP-500 2-е поколение (5VU).
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Каталог оригинальных запчастей Yamaha на максискутер Yamaha T-Max XP-500 1-е поколение.
Yamaha T-Max XP-500 год выпуска 2000-2003
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