Yamaha fz6 2006 мануал

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  OWNER’S MANUAL FZ6-N 1B3-28199-E3…
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  EAU26943 DECLARATION of CONFORMITY Company: MORIC CO., LTD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.1(2001-6), EN60950-1(2001) Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC) Place of issue: Shizuoka, Japan Date of issue: 1 Aug.
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  Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your FZ6-N. The owner’s manual does not only instruct you in how to operate, inspect and maintain your motorcycle, but also in how to safeguard yourself and oth- ers from trouble and injury.

• Page 4: Important Manual Information

  This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual.

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  IMPORTANT MANUAL INFORMATION EAU10200 FZ6-N OWNER’S MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st edition, July 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

• Page 6: Table Of Contents

  TABLE OF CONTENTS SAFETY INFORMATION ….1-1 PRE-OPERATION CHECKS ….. 4-1 Adjusting the clutch lever free Pre-operation check list ….4-2 play ……….. 6-19 DESCRIPTION ……..2-1 Rear brake light switch ….6-20 Left view ……….2-1 OPERATION AND IMPORTANT Checking the front and rear brake Right view ……..2-2 RIDING POINTS………

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  TABLE OF CONTENTS Replacing a turn signal light bulb ………..6-33 Replacing the license plate light bulb ………..6-33 Replacing the auxiliary light bulb ………..6-34 Supporting the motorcycle ….6-34 Front wheel ……..6-35 Rear wheel ……..6-36 Troubleshooting ……6-38 Troubleshooting charts ….6-39 MOTORCYCLE CARE AND STORAGE ……….7-1 Matte color caution ……7-1 Care ……….7-1…

• Page 8: Safety Information

  SAFETY INFORMATION EAU10281 AND/OR WHEN MADE NECES- • Ride where other motorists can SARY BY MECHANICAL CONDI- see you. Avoid riding in another MOTORCYCLES SINGLE TIONS. motorist’s blind spot. TRACK VEHICLES. THEIR SAFE USE Many accidents involve inexperi- AND OPERATION ARE DEPENDENT Safe riding enced operators.

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  Modifications made to this motorcycle other motorists can see you. the single most critical factor in the pre- not approved by Yamaha, or the re- The posture of the operator and vention or reduction of head injuries. moval of original equipment, may ren- passenger is important for proper Always wear an approved helmet.
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  Maximum load: been specifically designed for use on create instability due to improper 196 kg (432 lb) this motorcycle. Since Yamaha cannot weight distribution or aerody- test all other accessories that may be namic changes. If accessories When loading within this weight limit,…
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  SAFETY INFORMATION tor and may limit control ability, Always turn the engine off before or clothing, immediately wash the therefore, such accessories are leaving the motorcycle unattended affected area with soap and water not recommended. and remove the key from the main and change your clothes.

• Page 12: Description

  DESCRIPTION EAU10410 Left view 1. Main fuse (page 6-30) 9. Engine oil drain bolt (page 6-7) 2. Battery (page 6-28) 10.Engine oil filter cartridge (page 6-7) 3. Air filter element (page 6-13) 4. Idle adjusting screw (page 6-15) 5. Shock absorber assembly spring preload adjusting ring (page 3-16) 6.

• Page 13: Right View

  DESCRIPTION EAU10420 Right view 1. Fuse box (page 6-30) 2. Rear brake fluid reservoir (page 6-21) 3. Engine oil filler cap (page 6-7) 4. Front brake fluid reservoir (page 6-21) 5. Radiator cap (page 6-10) 6. Coolant reservoir (page 6-10) 7.

• Page 14: Controls And Instruments

  DESCRIPTION EAU10430 Controls and instruments 1. Clutch lever (page 3-11) 2. Left handlebar switches (page 3-10) 3. LCD tachometer (page 3-5) 4. Multi-function display (page 3-5) 5. Right handlebar switches (page 3-10) 6. Brake lever (page 3-12) 7. Throttle grip (page 6-15) 8.

• Page 15: Instrument And Control Functions

  Do not expose any key to exces- a Yamaha dealer to have them re-reg- sively high temperatures. istered. Do not use the key with the red Do not place any key close to bow for driving.

• Page 16: Main Switch/Steering Lock

  INSTRUMENT AND CONTROL FUNCTIONS EAU10471 EAU38530 To lock the steering Main switch/steering lock All electrical circuits are supplied with power; the meter lighting, taillight, li- cense plate light and auxiliary light come on, and the engine can be start- ed. The key cannot be removed. NOTE: The headlight comes on automatically when the engine is started and stays on…

• Page 17: Indicator And Warning Lights

  INSTRUMENT AND CONTROL FUNCTIONS To unlock the steering EAU34341 EAU11003 (Parking) Indicator and warning lights The steering is locked, and the taillight, license plate light and auxiliary light are on. The hazard lights and turn signal lights can be turned on, but all other electrical systems are off.

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  When this occurs, can be checked by turning the key to lizer system is still enabled. have a Yamaha dealer check the self- “ON”. diagnosis system. (See page 3-5 for an This model is also equipped with a self-…

• Page 19: Lcd Tachometer

  INSTRUMENT AND CONTROL FUNCTIONS EAU32922 ECA10031 EAU32978 LCD tachometer Multi-function display CAUTION: EWA12311 Do not operate the engine in the ta- WARNING chometer red zone. Be sure to stop the vehicle before Red zone: 14000 r/min and above making any setting changes to the multi-function display.

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  INSTRUMENT AND CONTROL FUNCTIONS two tachometers, one LCD and Odometer, tripmeter and digital ta- distance traveled from that point. In that one digital (which show engine chometer modes case, pushing the “SELECT” button r/min) switches the display between the vari- an odometer (which shows the to- ous tripmeter and odometer modes in tal distance traveled)
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  INSTRUMENT AND CONTROL FUNCTIONS To switch the air intake temperature Air intake temperature mode Fuel meter display to the clock, first set the display to the odometer or tachometer mode, and then push the “RESET” button for at least two seconds. NOTE: The clock is automatically displayed when the key is turned to “OFF”.
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  (e.g., 51, 52, 53). and then go off for 3 seconds. If this oc- NOTE: curs, have a Yamaha dealer check the electrical circuit. If the multi-function display indicates er- ror code 52 (all segments of the coolant…

• Page 23: Anti-Theft Alarm (Optional)

  Yamaha If the multi-function display indicates dealer. Contact a Yamaha dealer for any error code, note the code number, more information. and then have a Yamaha dealer check the vehicle. ECA11590 CAUTION: If the display indicates an error 1.

• Page 24: Handlebar Switches

  INSTRUMENT AND CONTROL FUNCTIONS EAU12347 Right position. To cancel the turn signal Handlebar switches lights, push the switch in after it has re- turned to the center position. Left EAU12500 Horn switch “ ” Press this switch to sound the horn. EAU12660 Engine stop switch “…

• Page 25: Clutch Lever

  INSTRUMENT AND CONTROL FUNCTIONS EAU12733 EAU12820 EAU12870 Hazard switch “ ” Clutch lever Shift pedal With the key in the “ON” or “ ” posi- tion, use this switch to turn on the haz- ard lights (simultaneous flashing of all turn signal lights).

• Page 26: Brake Lever

  INSTRUMENT AND CONTROL FUNCTIONS EAU26822 EAU12941 EAU13070 Brake lever Brake pedal Fuel tank cap The brake lever is located at the right handlebar grip. To apply the front brake, pull the lever toward the handle- bar grip. 1. Brake pedal 1.

• Page 27: Fuel

  Avoid spilling fuel on the hot en- Your Yamaha engine has been de- gine. signed to use regular unleaded gaso- line with a research octane number of 91 or higher.

• Page 28: Fuel Tank Breather Hose

  INSTRUMENT AND CONTROL FUNCTIONS or premium unleaded fuel. Use of un- EAU13411 EAU13441 Fuel tank breather hose Catalytic converter leaded fuel will extend spark plug life This vehicle is equipped with catalytic and reduce maintenance costs. converters in the exhaust system. EWA10860 WARNING The exhaust system is hot after op-…

• Page 29: Seat

  INSTRUMENT AND CONTROL FUNCTIONS EAU32980 EAU14281 Seat Helmet holder To remove the seat 1. Insert the key into the seat lock, and then turn it counterclockwise. 1. Projection 2. Seat holder 1. Helmet holder 2. Push the rear of the seat down to 2.

• Page 30: Storage Compartment

  Adjusting the shock absorber load of 196 kg (432 lb) for the ve- assembly hicle. 1. CYCLELOK bar (optional) 2. Yamaha CYCLELOK (optional) 1. Spring preload adjusting ring 3. Strap 2. Special wrench 3. Position indicator This storage compartment is designed…

• Page 31: Sidestand

  Spring preload setting: formance. stand cannot be properly moved up Minimum (soft): Always have a Yamaha dealer (or does not stay up), otherwise the service the shock absorber. Standard: sidestand could contact the ground…

• Page 32: Ignition Circuit Cut-Off System

  INSTRUMENT AND CONTROL FUNCTIONS below and have a Yamaha dealer re- EAU15311 Ignition circuit cut-off system pair it if it does not function proper- The ignition circuit cut-off system (com- prising the sidestand switch, clutch switch and neutral switch) has the fol- lowing functions.

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  5. Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. 7. Keep the clutch lever pulled.

• Page 34: Pre-Operation Checks

  PRE-OPERATION CHECKS EAU15591 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.

• Page 35: Pre-Operation Check List

  • If necessary, add recommended coolant to specified level. 6-10 • Check cooling system for leakage. • Check operation. • If soft or spongy, have Yamaha dealer bleed hydraulic system. • Check brake pads for wear. Front brake • Replace if necessary.

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  • Make sure that operation is smooth. • Check cable free play. Throttle grip 6-15, 6-24 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing. • Make sure that operation is smooth. Control cables 6-24 •…

• Page 37: Operation And Important Riding Points

  Exhaust fumes check the function of the igni- Yamaha dealer check the electrical cir- are poisonous, and inhaling tion circuit cut-off system ac- cuit. them can cause loss of con-…

• Page 38: Shifting

  OPERATION AND IMPORTANT RIDING POINTS ECA11040 EAU16671 ECA10260 Shifting CAUTION: CAUTION: For maximum engine life, never ac- Even with the transmission in celerate hard when the engine is the neutral position, do not cold! coast for long periods of time with the engine off, and do not NOTE: tow the motorcycle for long dis-…

• Page 39: Tips For Reducing Fuel Consumption

  If any engine trouble should oc- result in engine overheating must be lights or at railroad crossings). cur during the engine break-in avoided. period, immediately have a Yamaha dealer check the vehi- EAU17091 cle. 0–1000 km (0–600 mi) Avoid prolonged operation above 7000 r/min.

• Page 40: Parking

  OPERATION AND IMPORTANT RIDING POINTS EAU17212 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 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.

• Page 41: Periodic Maintenance And Minor Repair

  Yamaha dealer certain maintenance work correctly. do it for you. NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you.

• Page 42: Periodic Maintenance And Lubrication Chart

  The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)

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  PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK • Check tread depth and for damage. • Replace if necessary. √ √ √ √ √ 10 * Tires • Check air pressure. •…
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  PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ • Check coolant level and vehicle for coolant leakage. 23 * Cooling system • Change. Every 3 years Front and rear brake √…
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  PERIODIC MAINTENANCE AND MINOR REPAIR • Every two years replace the internal components of the brake master cylinders and calipers, and change the brake fluid. • Replace the brake hoses every four years and if cracked or damaged.

• Page 46: Removing And Installing The Panel

  Panel A properly. Do not attempt to diagnose such problems yourself. Instead, have To remove the panel a Yamaha dealer check the vehicle. 1. Remove the seat. (See page If a spark plug shows signs of electrode 3-15.) erosion and excessive carbon or other 2.

• Page 47: Engine Oil And Oil Filter Cartridge

  PERIODIC MAINTENANCE AND MINOR REPAIR Before installing a spark plug, the spark EAU32852 NOTE: Engine oil and oil filter car- plug gap should be measured with a If a torque wrench is not available when tridge wire thickness gauge and, if necessary, installing a spark plug, a good estimate The engine oil level should be checked adjusted to specification.

• Page 48: Changing Engine Oil

  PERIODIC MAINTENANCE AND MINOR REPAIR 4. Remove the engine oil dipstick and wipe it clean, insert it back into the hole (without screwing it in), and then remove it again to check the oil level. 1. Engine oil filler cap 1.

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  Recommended engine oil: NOTE: See page 8-1. An oil filter wrench is available at a Oil quantity: Yamaha dealer. Without oil filter cartridge replace- ment: 5. Apply a thin coat of engine oil to 2.50 L (2.64 US qt) (2.20 Imp.qt)

• Page 50: Coolant

  If the oil level warning light flickers EAU20091 or remains on, immediately turn the To check the coolant level engine off and have a Yamaha dealer 1. Place the vehicle on a level sur- 1. Coolant reservoir check the vehicle.

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  3. Remove the radiator cap retaining If water has been added to the bolt, radiator cap retainer and radi- coolant, have a Yamaha dealer ator cap. check the antifreeze content of EWA10380 1. Coolant reservoir cap…
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  10 Nm (1.0 m·kgf, 7.2 ft·lbf) corrosion. 11. Pour the specified amount of the If water has been added to the recommended coolant into the ra- coolant, have a Yamaha dealer diator and reservoir. check the antifreeze content of 6-12…

• Page 53: Replacing The Air Filter Element

  If taining bolt. usually wet or dusty areas. coolant is leaking, have a Yamaha 1. Remove the seat. (See page dealer check the cooling system. 3-15.) 2. Remove the fuel tank bolts, and then lift the fuel tank away from the air filter case.

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  5. Insert a new air filter element into If any hose is damaged, have a 1. Original position (paint mark) the air filter case. Yamaha dealer replace the hose 8. Install the seat. before starting the engine, oth- erwise fuel may leak.

• Page 55: Adjusting The Engine Idling Speed

  Yamaha dealer make the adjustment. sary, have a Yamaha dealer adjust it. screw in direction (a). To decrease the engine idling speed, turn the screw in direction (b).

• Page 56: Valve Clearance

  225 kPa (33 psi) (2.25 kgf/cm²) Rear: from occurring, the valve clearance regarding the specified tires. 250 kPa (36 psi) (2.50 kgf/cm²) must be adjusted by a Yamaha dealer 90–196 kg (198–432 lb): at the intervals specified in the periodic Tire air pressure Front: maintenance and lubrication chart.

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  Tire information glass fragments in it, or if the sidewall is weight evenly on both sides. cracked, have a Yamaha dealer re- Adjust the suspension and tire place the tire immediately. air pressure with regard to the load.
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  DUNLOP/D252 tires listed below have been ap- FRONT and REAR: proved this model Tire air valve: Yamaha Motor Co., Ltd. TR412 Valve core: Always make sure that the valve #9100 (original) caps are securely installed to prevent air pressure leakage.

• Page 59: Cast Wheels

  Yamaha dealer check the internal specified wheels. clutch mechanism. The wheel rims should be checked for cracks, bends or warpage be- fore each ride.

• Page 60: Rear Brake Light Switch

  EAU22390 indicator groove has almost disap- Rear brake light switch Checking the front and rear peared, have a Yamaha dealer replace brake pads the brake pads as a set. The front and rear brake pads must be checked for wear at the intervals spec-…

• Page 61: Checking The Brake Fluid Level

  However, if the Use only the recommended quality brake fluid level goes down sud- 1. Minimum level mark brake fluid, otherwise the rubber denly, have a Yamaha dealer Rear brake seals may deteriorate, causing check the cause. leakage and poor braking perfor- mance.

• Page 62: Changing The Brake Fluid

  EAU22730 EAU22760 Changing the brake fluid Drive chain slack Have a Yamaha dealer change the The drive chain slack should be brake fluid at the intervals specified in checked before each ride and adjusted the NOTE after the periodic mainte- if necessary.

• Page 63: Cleaning And Lubricating The Drive Chain

  PERIODIC MAINTENANCE AND MINOR REPAIR 3. Tighten the locknuts, and then EAU23022 NOTE: Cleaning and lubricating the tighten the axle nut to the specified Using the alignment marks on each drive chain torque. side of the swingarm, make sure that The drive chain must be cleaned and both adjusting nuts are in the same po- lubricated at the intervals specified in…

• Page 64: Checking And Lubricating The Cables

  If a cable is damaged maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. Recommended lubricant: Engine oil EWA10720 WARNING…

• Page 65: Checking And Lubricating The Brake And Shift Pedals

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU23131 EAU23140 Recommended lubricant: Checking and lubricating the Checking and lubricating the Lithium-soap-based grease (all-pur- brake and shift pedals brake and clutch levers pose grease) Brake lever Clutch lever The operation of the brake and shift pedals should be checked before each The operation of the brake and clutch ride, and the pedal pivots should be lu-…

• Page 66: Checking And Lubricating The Sidestand

  EWA10730 WARNING If the sidestand does not move up and down smoothly, have a Yamaha dealer check or repair it. Recommended lubricant: Lithium-soap-based grease (all-pur- pose grease) 6-26…

• Page 67: Checking The Front Fork

  Securely support the vehicle so that fork does not operate smoothly, damage and excessive oil leakage. there is no danger of it falling over. have a Yamaha dealer check or re- pair it. To check the operation 2. Hold the lower ends of the front 1.

• Page 68: Checking The Wheel Bearings

  To charge the battery Have a Yamaha dealer charge the bat- tery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories.

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  IES OUT OF THE REACH OF If you do not have access to a Electrolyte is poisonous and CHILDREN. sealed-type (MF) battery charg- have a Yamaha dealer dangerous since it contains sul- charge your battery. furic acid, which causes severe To store the battery burns.

• Page 70: Replacing The Fuses

  3. Turn the key to “ON” and turn on the electrical circuit in question to check if the device operates. 4. If the fuse immediately blows 1. Fuse box again, have a Yamaha dealer check the electrical system. 6-30…

• Page 71: Replacing The Headlight Bulb

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU34380 EWA10790 Replacing the headlight bulb WARNING This model is equipped with a quartz Headlight bulbs get very hot. There- bulb headlight. If the headlight bulb fore, keep flammable products away burns out, replace it as follows. from a lit headlight bulb, and do not 1.

• Page 72: Replacing The Tail/Brake Light Bulb

  5. Install the headlight bulb cover, and then connect the coupler. 6. Install the headlight unit by install- ing the bolts. 7. Have a Yamaha dealer adjust the headlight beam if necessary. 1. Tail/brake light bulb socket 2. Muffler bracket cover…

• Page 73: Replacing A Turn Signal Light Bulb

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU24202 EAU24310 Replacing a turn signal light Replacing the license plate bulb light bulb 1. Remove the turn signal light lens 1. Remove the license plate light unit by removing the screw. by removing the screws. 1.

• Page 74: Replacing The Auxiliary Light Bulb

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU34401 EAU24350 a jack either under each side of the Replacing the auxiliary light Supporting the motorcycle frame in front of the rear wheel or under bulb Since this model is not equipped with a each side of the swingarm.

• Page 75: Front Wheel

  2. Insert the wheel axle. EWA10820 3. Lower the front wheel so that it is WARNING on the ground. It is advisable to have a Yamaha 4. Install the brake calipers by install- dealer service the wheel. ing the bolts. Securely support the motor-…

• Page 76: Rear Wheel

  EAU34411 To remove the rear wheel EWA10820 WARNING It is advisable to have a Yamaha dealer service the wheel. Securely support the motor- cycle so that there is no danger 1. Axle nut of it falling over.

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  PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: NOTE: If the drive chain is difficult to re- A rubber mallet may be useful to tap the move, remove the wheel axle first, wheel axle out. and then lift the wheel upward 7. Remove the wheel. enough to remove the drive chain ECA11070 from the rear sprocket.

• Page 78: Troubleshooting

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

• Page 79: Troubleshooting Charts

  Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.

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  Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: 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 81: Motorcycle Care And Storage

  Rust and corrosion can develop matte colored finished parts. Be Cleaning even if high-quality components are sure to consult a Yamaha dealer for ECA10770 advice on what products to use be- used. A rusty exhaust pipe may go un- CAUTION: fore cleaning the vehicle.

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  MOTORCYCLE CARE AND STORAGE cleaning products, solvent or After normal use ECA10790 CAUTION: thinner, fuel (gasoline), rust re- Remove dirt with warm water, a mild movers or inhibitors, brake flu- detergent, and a soft, clean sponge, Do not use warm water since it in- id, antifreeze or electrolyte.

• Page 83: Storage

  WARNING NOTE: To prevent corrosion, avoid Make sure that there is no oil or Consult a Yamaha dealer for advice on damp cellars, stables (because what products to use. wax on the brakes or tires. of the presence of ammonia)

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  MOTORCYCLE CARE AND STORAGE 3. Perform the following steps to pro- 4. Lubricate all control cables and the tect the cylinders, piston rings, etc. pivoting points of all levers and from corrosion. pedals as well as of the side- a. Remove the spark plug caps stand/centerstand.

• Page 85: Specifications

  SPECIFICATIONS Dimensions: Engine oil: Fuel: Overall length: Type: Recommended fuel: 2095 mm (82.5 in) SAE10W30, SAE10W40, SAE15W40, Regular unleaded gasoline only Overall width: SAE20W40 or SAE20W50 Fuel tank capacity: 755 mm (29.7 in) 19.4 L (5.13 US gal) (4.27 Imp.gal) Overall height: Fuel reserve amount: -20 -10…

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  SPECIFICATIONS Gear ratio: Manufacturer/model: Rear wheel: 1st: BRIDGESTONE/BT020R GG Wheel type: 37/13 (2.846) Manufacturer/model: Cast wheel 2nd: DUNLOP/D252 Rim size: 37/19 (1.947) Loading: 17M/C x MT5.50 3rd: Maximum load: Front brake: 28/18 (1.556) 196 kg (432 lb) Type: 4th: (Total weight of rider, passenger, cargo and Dual disc brake 32/24 (1.333) accessories)
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  SPECIFICATIONS Electrical system: Turn signal indicator light: Ignition system: Engine trouble warning light: Transistorized coil ignition (digital) Charging system: Immobilizer system indicator light: AC magneto Battery: Fuses: Model: Main fuse: GT12B-4 30.0 A Voltage, capacity: Headlight fuse: 12 V, 10.0 Ah 20.0 A Headlight: Taillight fuse:…

• Page 88: Consumer Information

  Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.

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  1. Model label The model label is affixed to the frame under the seat. (See page 3-15.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
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  INDEX Front fork, checking ……6-27 Parking …………5-4 Fuel…………3-13 Part locations ………. 2-1 Air filter element, replacing ….6-13 Fuel consumption, tips for reducing..5-3 Pass switch ……….. 3-10 Anti-theft alarm (optional)……3-9 Fuel tank breather hose……3-14 Periodic maintenance and lubrication Auxiliary light bulb, replacing ….
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  INDEX Turn signal indicator lights …… 3-3 Turn signal light bulb, replacing…. 6-33 Turn signal switch……… 3-10 Valve clearance ……..6-16 Vehicle identification number….9-1 Wheel bearings, checking ….6-28 Wheel (front) ……… 6-35 Wheel (rear)………. 6-36 Wheels……….6-19…
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  YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2006.07-0.3×1 CR…

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  EAS00010 FZ6-SS/FZ6-SSC SERVICE MANUAL 2003 by Yamaha Motor Corporation, U.S.A. First edition, November 2003 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-11616-17-50…

• Page 3: Important Manual Information

  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: How To Use This Manual

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

• Page 5: Specifications

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

• Page 6: Table Of Contents

  EAS00012 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE COOLING SYSTEM COOL FUEL INJECTION SYSTEM ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG…

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  CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION ……VEHICLE IDENTIFICATION NUMBER ……MODEL LABEL .
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  ENGINE OIL LUBRICATION CHART ……2-29 LUBRICATION DIAGRAMS ……..2-30 CABLE ROUTING .
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  CHASSIS ……….. . 3-41 ADJUSTING THE FRONT BRAKE .
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  FRONT AND REAR BRAKES ……..4-16 FRONT BRAKE PADS .
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  SWINGARM AND DRIVE CHAIN ……. 4-68 REMOVING THE SWINGARM ……. 4-70 REMOVING THE DRIVE CHAIN .
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  SHIFT SHAFT ……….5-39 SHIFT SHAFT AND STOPPER LEVER .
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  CONNECTING RODS AND PISTONS ……5-67 REMOVING THE CONNECTING RODS AND PISTONS ..5-68 REMOVING THE CRANKSHAFT ASSEMBLY .
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  CHAPTER 7 FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM ……..WIRING DIAGRAM .

• Page 15: Troubleshooting

  ELECTRIC STARTING SYSTEM ……. . 8-14 CIRCUIT DIAGRAM ……..8-14 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .

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  POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE … . ENGINE ……….FUEL SYSTEM .

• Page 17: Gen Info

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

• Page 18: Features

  FEATURES INFO EAS00896 FEATURES 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 and the atmospheric temperature. In the 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 carburetor.

• Page 19: Fi System

  FEATURES INFO EAS00897 FI SYSTEM The fuel pump delivers fuel to the injector via the fuel filter. The pressure regulator maintains the fuel pressure that is applied to the injector at only 250 kPa (2.5 kg/cm ). Accordingly, when the energizing signal from the ECU energizes the injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open.

• Page 20: Instrument Function

  FEATURES INFO INSTRUMENT FUNCTION Multi-function display The multi-function display is equipped with the following: S a speedometer (which shows the riding speed) S an odometer (which shows the total distance traveled) S two tripmeters (which show the distance traveled since they were last set to zero) S a fuel reserve tripmeter (which shows the 1 Multi-function display distance traveled since the bottom segment…

• Page 21
  FEATURES INFO Clock mode To set the clock: 1. Push the “SELECT” button and “RESET” button together for at least two seconds. 2. When the hour digits start flashing, push the “RESET” button to set the hours. 3. Push the “SELECT” button, and the minute digits will start flashing. 4.

• Page 22: Important Information

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

• Page 23: Lock Washers/Plates And Cotter Pins

  IMPORTANT INFORMATION INFO EAS00023 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the…

• Page 24: Checking The Connections

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

• Page 25: Special Tools

  SPECIAL TOOLS INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

• Page 26
  SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Oil filter wrench 90890-01426 YU-38411 This tool is needed to loosen or tighten the oil filter cartridge. Fork seal driver Fork seal driver weight 90890-01367 Fork seal driver attachment YM-33963 Fork seal driver attachment This tool is used to install the front fork’s oil 90890-01374…
• Page 27
  This tool is used to check the ignition system components. Vacuum/pressure pump gauge set 90890-06756 YB-35956 This tool used to measure the vacuum pres- sure. Yamaha bond No. 1215 90890-85505 ACC-11001- 05-01 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces). 1-11…

• Page 28: Spec

  SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5VX3 (USA except for CAL) 5VX4 (CAL) Dimensions Overall length 2,095 mm (82.5 in) Overall width 750 mm (29.5 in) Overall height 1,215 mm (47.8 in) Seat height 795 mm (31.3 in) Wheelbase 1,440 mm (56.7 in) Minimum ground clearance…

• Page 29: Engine Specifications

  SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Liquid-cooled, 4-stroke, DOHC Displacement 600 cm (36.61 cu.in) Cylinder arrangement Forward-inclined parallel 4-cylinder Bore stroke 65.5 44.5 mm (2.58 1.75 in) Compression ratio 12.2 : 1 1,250 X 1,350 r/min Engine idling speed Vacuum pressure at engine idling 29 kPa (218 mmHg, 8.6 inHg)

• Page 30
  SPEC ENGINE SPECIFICATIONS Item Standard Limit Oil filter Oil filter type Formed 80 X 120 kPa (0.8 X 1.2 kg/cm Bypass valve opening pressure 0.8 X 1.2 bar, 11.6 X 17.4 psi) Oil pump Oil pump type Trochoid 0.03 X 0.09 mm Inner-rotor-to-outer-rotor-tip 0.15 mm (0.0012 X 0.0035 in)
• Page 31
  SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Chain drive (right) 23.008 X 23.029 mm (0.9058 X 0.9067 in) Camshaft cap inside diameter 22.967 X 22.980 mm (0.9042 X 0.9047 in) Camshaft journal diameter 0.028 X 0.062 mm (0.0011 X 0.0024 in) Camshaft-journal-to-camshaft- 0.08 mm cap clearance…
• Page 32
  SPEC ENGINE SPECIFICATIONS Item Standard Limit Timing chain Model/number of links 92RH2015 /120 Tensioning system Automatic Valves, valve seats, valve guides Valve clearance (cold) 0.13 X 0.20 mm (0.0051 X 0.0079 in) Intake 0.23 X 0.30 mm (0.0091 X 0.0118 in) Exhaust Valve dimensions Head Diameter…
• Page 33
  SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve springs Free length Intake (inner) 37.0 mm (1.46 in) 35.2 mm (1.39 in) Intake (outer) 38.4 mm (1.51 in) 36.5 mm (1.44 in) Exhaust 41.8 mm (1.65 in) 39.7 mm (1.56 in) Installed length (valve closed) Intake (inner) 30 mm (1.18 in) Intake…
• Page 34
  SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston 0.010 X 0.035 mm (0.0004 X 0.0014 in) Piston-to-cylinder clearance 0.055 mm (0.0022 in) 65.475 X 65.490 mm (2.5778 X 2.5783 in) Diameter D Height H 4 mm (0.16 in) Piston pin bore (in the piston) 16.002 X 16.013 mm Diameter 16.043 mm…
• Page 35
  SPEC ENGINE SPECIFICATIONS Item Standard Limit Connecting rods 0.028 X 0.052 mm (0.0011 X 0.0020 in) Crankshaft-pin-to-big-end-bearing 0.08 mm clearance (0.0032 in) Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green Crankshaft 51.85 X 52.55 mm (2.04 X 2.06 in) Width A 268.8 X 270.0 mm (10.58 X 10.63 in) Width B…
• Page 36
  SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 6-speed Primary reduction system Spur gear Primary reduction ratio 86/44 (1.955) Secondary reduction system Chain drive Secondary reduction ratio 46/16 (2.875) Operation Left-foot operation Gear ratios 1st gear 37/13 (2.846) 2nd gear 37/19 (1.947) 3rd gear…

• Page 37: Chassis Specifications

  SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Diamond Caster angle Trail 97.5 mm (3.84 in) Front wheel Wheel type Cast wheel Size 17 M/C MT3.50 Material Aluminum Wheel travel 130 mm (5.12 in) Wheel runout Max. radial wheel runout 1 mm (0.04 in) Max.

• Page 38
  SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless Size 180/55 ZR17 M/C (73W) Model (manufacturer) BT020R GG (BRIDGESTONE) D252 (DUNLOP) Tire pressure (cold) 0 X 90 kg (0 X 198 lb) 250 kPa (2.5 kgf/cm , 2.5 bar, 35.6 psi) 90 X 190 kg (198 X 419 lb) 290 kPa (2.9 kgf/cm , 2.9 bar, 41.3 psi)
• Page 39
  SPEC CHASSIS SPECIFICATIONS Item Standard Limit Front suspension Suspension type Telescopic fork Front fork type Coil spring/oil damper Front fork travel 130 mm (5.12 in) Spring Free length 354.0 mm (13.94 in) 347 mm (13.66 in) Spacer length 131.5 mm (5.18 in) Installed length 347.0 mm (13.66 in) Spring rate (K1)
• Page 40
  SPEC CHASSIS SPECIFICATIONS Item Standard Limit Steering Steering bearing type Angular bearing Rear suspension Suspension type Swingarm (monocross) Rear shock absorber assembly Coil spring/gas-oil damper type Rear shock absorber assembly 50 mm (1.97 in) travel Spring Free length 185.0 mm (7.28 in) Installed length 172.0 mm (6.77 in) Spring rate (K1)

• Page 41: Electrical Specifications

  SPEC ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Item Standard Limit System voltage 12 V Ignition system Ignition system type DC. T.C.I. Ignition timing 5_ BTDC at 1,300 r/min Advancer type Digital 248 X 372 Ω at 20_C (68_F)/Gy-B Crankshaft position sensor resistance/color T.C.I.

• Page 42
  SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Indicator light (voltage /wattage quantity) Neutral indicator light High beam indicator light Oil level warning light Turn signal indicator light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model (manufacturer) SM-14 (MITSUBA) Power output 0.6 kW…
• Page 43
  SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Fuses (amperage quantity) Main fuse 30 A Fuel injection system fuse 10 A Headlight fuse 20 A Signaling system fuse 10 A Ignition fuse 10 A Radiator fan motor fuse 20 A Backup fuse (odometer and clock) 10 A Taillight fuse 10 A…

• Page 44: Conversion Table

  CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are SPECIFICATIONS listed in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC dard fasteners with a standard ISO thread unit data to IMPERIAL unit data.

• Page 45: Tightening Torques

  Bolt Camshaft caps Bolt Cylinder head cover Bolt Camshaft cap oil check bolt Bolt Air indication system reed valve Bolt Yamaha bond No.1215 cover Air-cut valve stay Bolt Camshaft sprockets Bolt Connecting rod caps (except for CAL) 15 + 150_ 1.5 + 150_…

• Page 46
  Crankcase Bolt Crankcase Bolt Crankcase Bolt Generator rotor cover Bolt Clutch cover Bolt Clutch cover Bolt Yamaha bond No.1215 Pickup coil rotor cover Bolt Clutch cable holder Bolt Pickup coil rotor cover Bolt Shift shaft cover Bolt Breather plate Screw…
• Page 47
  SPEC TIGHTENING TORQUES Cylinder head tightening sequence: Crankcase tightening sequence. 2-20…

• Page 48: Chassis Tightening Torques

  SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Upper bracket pinch bolt Steering stem nut Upper bracket and upper handlebar holder Under bracket pinch bolt – Lower ring nut See NOTE 1 Front fork cap bolt Damper rod assembly bolt Pinch bolt (front wheel axle) Front brake master cylinder and master cylinder…

• Page 49
  SPEC TIGHTENING TORQUES Tightening Thread Item Item Remarks Remarks size mSkg ftSlb Side cover and rear frame Rear mud guard and rear frame Engine stop switch and frame Coolant reserver tank bracket and stay 1, 2 Stay 1, 2 and frame Coolant reserver tank bracket and coolant reserver tank Canister and canister bracket (for CAL)

• Page 50: Lubrication Points And Lubricant Types

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

• Page 51: Chassis

  SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Sidestand pivoting point and metal-to-metal moving parts Link and sidestand switch contact point…

• Page 52: Cooling System Diagrams

  SPEC COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS Radiator Oil cooler 2-25…

• Page 53
  SPEC COOLING SYSTEM DIAGRAMS Water pump Oil cooler Radiator 2-26…
• Page 54
  SPEC COOLING SYSTEM DIAGRAMS Oil cooler Water pump 2-27…
• Page 55
  SPEC COOLING SYSTEM DIAGRAMS Radiator Thermostat 2-28…

• Page 56: Engine Oil Lubrication Chart

  SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART 2-29…

• Page 57: Lubrication Diagrams

  SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil level switch Oil cooler Relief valve 2-30…

• Page 58
  SPEC LUBRICATION DIAGRAMS Oil pump Exhaust camshaft Intake camshaft Oil strainer 2-31…
• Page 59
  SPEC LUBRICATION DIAGRAMS Oil cooler Oil strainer Oil level switch Oil pump 2-32…
• Page 60
  SPEC LUBRICATION DIAGRAMS Main axle Oil pump Relief valve 2-33…
• Page 61
  SPEC LUBRICATION DIAGRAMS Cylinder head Intake camshaft Exhaust camshaft Crankshaft 2-34…
• Page 62
  SPEC LUBRICATION DIAGRAMS Main axle Drive axle 2-35…

• Page 63: Cable Routing

  SPEC CABLE ROUTING CABLE ROUTING Left handlebar switch lead A Clamp the right and left handlebar switch leads and Main switch lead handlebars. Point the tip of the clamp downward in Clutch cable front of the handlebars. Throttle cables B Clamp the horn lead and main switch lead to the in- Right handlebar switch lead ner tube.

• Page 64
  SPEC CABLE ROUTING F Clamp the brake hose to the inner tube. Point the binding section to the outside of the vehicle body and cut the tip down to the length of 1 to 5 mm (0.04 to 0.20 in). G Pass the throttle cables through the wire guide.
• Page 65
  SPEC CABLE ROUTING Right handlebar switch lead D Route the radiator hoses (2 pieces) under the cover Rear brake light switch lead Neutral switch lead E Route the crank shaft position sensor lead inner Fuel tank breather hose side of the radiator hose. Crankshaft position sensor lead F Pull down the mark-painted sections of the fuel tank breather hose, fuel tank drain hose and coolant res-…
• Page 66
  SPEC CABLE ROUTING I Pass the neutral switch lead between the engine and coolant reservoir tank bracket. J To the starter motor. K Install the right handlebar switch lead coupler through the hole of the bracket 2 from the downside. L Route the starter motor lead by the inner side of the air cut-off valve hose.
• Page 67
  SPEC CABLE ROUTING Main switch lead License plate light lead Stay assembly Rear turn signal light lead (right) Left handlebar switch lead Rear turn signal light lead (left) Clutch cable Speed sensor lead Throttle cables Side stand switch lead Battery negative lead coupler Oil level switch lead Starter relay lead A.C.
• Page 68
  SPEC CABLE ROUTING A Route the throttle cables above the stay assy 1. K Clamp the rear turn signal lead and license plate B Route the main switch lead above the clutch cable. light lead to the frame. Hook the clamp to the brack- C Line up the left handlebar switch lead coupler and et.
• Page 69
  SPEC CABLE ROUTING R To the rear turn signal light (left) X Make sure to pass the neutral switch lead through S Pass the fuel tank drain hose through the clamp lo- the hole of the flap. cated under the coolant reservoir tank. Y Clamp the seat lock wire to the frame as shown in T Route it behind the starter motor lead.
• Page 70
  SPEC CABLE ROUTING Right handlebar switch lead Seat lock cable Throttle cables Rectifier/regulator Battery positive lead E.C.U Coolant reservoir tank hose Fuel tank drain hose Battery cover Cover Connecter cover Starter relay lead Fuel tank breather hose Battery negative lead Brake fluid reservoir hose Battery negative lead coupler Lean angle cut-off switch…
• Page 71
  SPEC CABLE ROUTING A Either right or left side arrangement for the left han- H Set the 4-pin coupler in the connector cover after dlebar switch lead coupler and radiator fan motor wiring it. coupler can be accepted. I To the sidestand switch. B Point the L-shape terminal to the front side of the ve- J To the speed sensor.
• Page 72
  SPEC CABLE ROUTING S To the license plate light. AD Press the battery negative lead into the space be- T To the tail/brake light. tween the ribs of the frame. U Insert the enwinding clamp of the wire harness into AE Pass the spark plug leads #1 and #4 through the the hole of the rear frame.
• Page 73
  SPEC CABLE ROUTING AL Route the spark plug lead #4 by the front side of the spark plug leads #2 and #3. AM Route the spark plug leads #2 and #3 behind the air cut-off valve hose. 2-46…
• Page 74
  SPEC CABLE ROUTING Fuel pump assembly a Fuel piping connector attachment directions. (fuel Fuel tank breather hose (except for CAL) pump side) Fuel tank drain hose 1. It is inserted until it makes a click sound the connec- Fuel hose tor, and it checks that a connector does not fail out.
• Page 75
  SPEC CABLE ROUTING except for CAL A Front side. Coolant breather hose B Pass the coolant reservoir tank hose hangs down Coolant reservoir tank downward from back of the bolt. Coolant reservoir tank hose C Insert this portion securely. Clamp D Spittle is turned back.
• Page 76
  SPEC CABLE ROUTING for CAL A Front side. Clip B Point the paint marking upward. Roll over valve C Pass the canister hose and balance hose behind Canister hoes the bolt. Balance hose D Pass the canister hose outside, pass the balance Coolant reservoir tank hose inside.
• Page 77
  SPEC CABLE ROUTING K Insert the clamp certainly. L It may open and close to direction of which. All notches gear at the time of attachment. M Pass the coolant reservoir tank hose and the fuel tank drain hose inside of the clamp. N Point the knob of clamp downward.

• Page 78: Chk Adj

  Air induction system hose for damage. (See page 7-32) S Replace any damaged parts if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL…

• Page 79
  (See page 3-20) Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi (13000 km) or 12 months.

• Page 80: Seat

  SEAT EAS00038 SEAT Order Job/Part Q’ty Remarks Removing the seat Remove the parts in the order listed. Seat For installation, reverse the removal procedure.

• Page 81: Fuel Tank

  FUEL TANK EAS00040 FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Disconnect. Seat Refer to “SEAT”. Front cowling inner panel (left and Refer to “COWLINGS”.

• Page 82
  FUEL TANK 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Roll over valve (for CAL) For installation, reverse the removal procedure. Refer to the CABLE ROUTING for how to attach a hose.

• Page 83: Removing The Fuel Tank

  FUEL TANK REMOVING THE FUEL TANK 1. Extract the fuel in the fuel tank through the fuel tank cap with a pump. 2. Remove: S fuel hose CAUTION: S Be sure to disconnect the fuel hose by hand. Do not forcefully disconnect the hose with tools.

• Page 84: Installing The Fuel Pump

  FUEL TANK INSTALLING THE FUEL PUMP 1. Install: S fuel pump 4 Nm (0.4 mSkg, 2.9 ftSlb) NOTE: S Do not damage the installation surfaces of the fuel tank when installing the fuel pump. S Always use a new fuel pump gasket. S Install the fuel pump as shown in the illustra- tion.

• Page 85: Cowlings

  COWLINGS COWLINGS 23 Nm (2.3 mSkg, 17 ftSlb) 33 Nm (3.3 mSkg, 24 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Removing the cowlings Remove the parts in the order listed. Seat Refer to “SEAT”.

• Page 86: Air Filter Case

  AIR FILTER CASE EAS00043 AIR FILTER CASE 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Seat Refer to “SEAT”. Front cowling inner panel (left and Refer to “COWLINGS”. right) Fuel tank Refer to “FUEL TANK”.

• Page 87: Battery Box And Battery Box Bracket

  BATTERY BOX AND BATTERY BOX BRACKET BATTERY BOX AND BATTERY BOX BRACKET 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Remove the parts in the order listed. Battery box NOTE: This part has to be set properly.

• Page 88: Engine

  ADJUSTING THE VALVE CLEARANCE EAS00045 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke.

• Page 89
  ADJUSTING THE VALVE CLEARANCE 4. Measure: S valve clearance Out of specification ! Adjust. Valve clearance (cold) Intake valve 0.13 X 0.20 mm (0.0051 X 0.0079 in) Exhaust valve 0.23 X 0.30 mm (0.0091 X 0.0118 in) a. Turn the crankshaft counterclockwise. b.
• Page 90
  ADJUSTING THE VALVE CLEARANCE 5. Remove: S camshafts NOTE: S Refer to “CAMSHAFTS” in chapter 5. S When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re- trieve it if it falls into the crankcase. 6.
• Page 91
  ADJUSTING THE VALVE CLEARANCE c. Round off the original valve pad number ac- cording to the following table. Last digit Rounded value 0 or 2 EXAMPLE: Original valve pad number = 148 (thickness =1.48 mm (0.058 in)) Rounded value = 150 d.
• Page 92
  ADJUSTING THE VALVE CLEARANCE NOTE: S Refer to “CAMSHAFTS” in chapter 5. S Lubricate the camshaft bearings, camshaft lobes and camshaft journals. S First, install the exhaust camshaft. S Align the camshaft marks with the camshaft cap marks. S Turn the crankshaft counterclockwise several full turns to seat the parts.
• Page 93
  ADJUSTING THE VALVE CLEARANCE INTAKE INSTALLED PAD NUMBER MEASURED 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 CLEARANCE 0.00 X 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.03 X 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.08 X 0.12…

• Page 94: Synchronizing The Throttle Bodies

  ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE THROTTLE BODIES 7. Install: S all removed parts NOTE: For installation, reverse the removal procedure. SYNCHRONIZING THE THROTTLE BODIES NOTE: Prior to synchronizing the throttle bodies, the valve clearance and the engine idling speed should be properly adjusted and the ignition tim- ing should be checked.

• Page 95
  SYNCHRONIZING THE THROTTLE BODIES 6. Measure: S engine idling speed Out of specification ! Adjust. Refer to “ADJUSTING THE ENGINE IDLING SPEED”. Engine idling speed 1,250 X 1,350 r/min 7. Adjust: S throttle body synchronization a. With throttle body #1 as standard, adjust throttle bodies #2, #3, and #4 using the air screws 1 .

• Page 96: Adjusting The Engine Idling Speed

  ADJUSTING THE ENGINE IDLING SPEED EAS00052 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be ad- justed properly, the air filter element should be clean, and the engine should have adequate compression.

• Page 97: Adjusting The Throttle Cable Free Play

  ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00055 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and throttle bodies synchro- nization should be adjusted properly. 1. Check: S throttle cable free play a Out of specification ! Adjust.

• Page 98
  ADJUSTING THE THROTTLE CABLE FREE PLAY Handlebar side a. Loosen the locknut 1 . b. Turn the adjusting nut 2 in direction a or b until the specified throttle cable free play is obtained. Throttle cable free play is Direction increased.

• Page 99: Checking The Spark Plugs

  CHECKING THE SPARK PLUGS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S radiator lower bolt 1 S radiator lower hose bracket bolt 2 2. Remove: S spark plug caps S spark plugs A Right side #1 and #2 and #3 B Left side #4 CAUTION:…

• Page 100: Measuring The Compression Pressure

  CHECKING THE SPARK PLUGS/ MEASURING THE COMPRESSION PRESSURE 7. Install: S spark plug 18 Nm (1.8 mSkg, 13 ftSlb) S spark plug caps NOTE: Before installing the spark plug, clean the spark plug and gasket surface. 8. Install: S radiator lower hose bracket bolt S radiator lower bolt EAS00065 MEASURING THE COMPRESSION…

• Page 101
  MEASURING THE COMPRESSION PRESSURE CAUTION: Before removing the spark plugs, use com- pressed air to blow away any dirt accumu- lated in the spark plug wells to prevent it from falling into the cylinders. 5. Install: S compression gauge 1 S adapter Compression gauge 90890-03081, YU-33223…
• Page 102
  MEASURING THE COMPRESSION PRESSURE d. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and mea- sure again. Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Diagnosis Higher than…

• Page 103: Checking The Engine Oil Level

  CHECKING THE ENGINE OIL LEVEL EAS00069 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.

• Page 104: Changing The Engine Oil

  CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled. 4. Start the engine, warm it up for several min- utes, and then turn it off. 5.

• Page 105
  CHANGING THE ENGINE OIL 5. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01426, YU-38411 b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil.

• Page 106: Measuring The Engine Oil Pressure

  CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE 9. Install: S engine oil filler cap 10. Start the engine, warm it up for several min- utes, and then turn it off. 11. Check: S engine (for engine oil leaks) 12.

• Page 107
  MEASURING THE ENGINE OIL PRESSURE 5. Measure: S engine oil pressure (at the following conditions) Engine oil pressure 240 kPa (2.4 kg/cm , 2.4 bar, 34.1 psi) Engine speed Approx. 6,600 r/min Engine oil temperature 96_C (205_F) NOTE: Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity, the oil pressure may fluctuate when measuring.

• Page 108: Adjusting The Clutch Cable Free Play

  ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm (0.39 X 0.59 in) 2.

• Page 109: Cleaning The Air Filter Element

  ADJUSTING THE CLUTCH CABLE FREE PLAY/ CLEANING THE AIR FILTER ELEMENT 4. Install: S air filter case Refer to “AIR FILTER CASE”. S fuel tank Refer to “FUEL TANK”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S seat Refer to “SEAT”.

• Page 110: Checking The Throttle Body Joints

  CLEANING THE AIR FILTER ELEMENT/ CHECKING THE THROTTLE BODY JOINTS NOTE: When installing the air filter element into the air filter case cover, make sure their sealing sur- faces are aligned to prevent any air leaks. 6. Install: S fuel tank Refer to “FUEL TANK”.

• Page 111: Checking The Fuel And Breather Hoses

  CHECKING THE FUEL AND BREATHER HOSES/ CHECKING THE CRANKCASE BREATHER HOSE EAS00096 CHECKING THE FUEL AND BREATHER HOSES The following procedure applies to all of the fuel and breather hoses. 1. Remove: S rider seat Refer to “SEAT”. S front cowling inner panel (left and right) Refer to “COWLINGS”…

• Page 112: Checking The Exhaust System

  CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM 3. Install: S fuel tank Refer to “FUEL TANK”. S front cowling inner panel (left and right) Refer to “COWLINGS”. S rider seat Refer to “SEAT”. EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the ex- haust pipes and gaskets.

• Page 113: Checking The Coolant Level

  CHECKING THE COOLANT LEVEL EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure the motorcycle is upright. 2. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level mark b .

• Page 114: Checking The Cooling System

  CHECKING THE COOLING SYSTEM/ CHANGING THE COOLANT EAS00104 CHECKING THE COOLING SYSTEM 1. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water jacket outlet joint 7 S water jacket hose 8 S water pump outlet pipe 9…

• Page 115: Changing The Coolant

  CHANGING THE COOLANT 3. Disconnect: S coolant reservoir cap 1 4. Drain: S coolant (from the coolant reservoir tank) 5. Remove: S radiator cap lock bolt 1 S radiator cap 2 CAUTION: A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot.

• Page 116
  CHANGING THE COOLANT 10. Install: S coolant reservoir tank 11. Connect: S coolant reservoir hose 12. Fill: S cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity…
• Page 117
  CHANGING THE COOLANT S Use only distilled water. However, if dis- tilled water is not available, soft water may be used. S If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. S Do not mix different types of antifreeze. 13.

• Page 118: Chassis

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

• Page 119: Adjusting The Rear Brake

  ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: S brake pedal position (distance a from the top of the rider footrest to the top of the brake pedal) Out of specification ! Adjust. Brake pedal position (below the top of the rider footrest) 25.8 mm (1.02 in) 2.

• Page 120: Checking The Brake Fluid Level

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

• Page 121: Checking The Front And Rear Brake Pads

  CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT AND REAR BRAKE PADS CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. NOTE: In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal.

• Page 122: Adjusting The Rear Brake Light Switch

  ADJUSTING THE REAR BRAKE LIGHT SWITCH/ CHECKING THE FRONT AND REAR BRAKE HOSES EAS00128 ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts.

• Page 123
  BLEEDING THE HYDRAULIC BRAKE SYSTEM EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenev- S the system is disassembled. S a brake hose is loosened, disconnected or replaced. S the brake fluid level is very low. S brake operation is faulty.

• Page 124: Bleeding The Hydraulic Brake System

  BLEEDING THE HYDRAULIC BRAKE SYSTEM/ ADJUSTING THE SHIFT PEDAL h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose.

• Page 125: Adjusting The Drive Chain Slack

  ADJUSTING THE DRIVE CHAIN SLACK EAS00140 ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain. CAUTION: A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swin- garm or cause an accident.

• Page 126: Lubricating The Drive Chain

  ADJUSTING THE DRIVE CHAIN SLACK/ LUBRICATING THE DRIVE CHAIN f. Tighten both locknuts to specification. Locknut 16 Nm (1.6 mSkg, 12 ftSlb) g. Tighten the wheel axle nut to specification. Wheel axle nut 120 Nm (12 mSkg, 87 ftSlb) EAS00142 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts.

• Page 127: Checking And Adjusting The Steering Head

  CHECKING AND ADJUSTING THE STEERING HEAD EAS00146 CHECKING AND ADJUSTING THE STEERING HEAD 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.

• Page 128
  CHECKING AND ADJUSTING THE STEERING HEAD c. Loosen the lower ring nut 6 completely, then tighten it to specification. WARNING Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 mSkg, 13 ftSlb) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions.

• Page 129: Checking The Front Fork

  CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK Steering head tension 200 X 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specifi- cation (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut.

• Page 130: Adjusting The Rear Shock Absorber Assembly

  ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY EAS00156 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the motorcycle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1.

• Page 131: Checking The Tires

  CHECKING THE TIRES WARNING S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. S The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed.

• Page 132
  Ltd. for this model. The front and rear tires should always be by the same manufactur- er and of the same design. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle. 3-55…
• Page 133
  CHECKING THE TIRES/CHECKING THE WHEELS Front tire Manufacturer Size Model BRIDGESTONE 120/70ZR 17 BT020F M/C (58W) DUNLOP 120/70ZR 17 D252F M/C (58W) Rear tire Manufacturer Size Model BRIDGESTONE 180/55ZR 17 BT020R M/C (73W) DUNLOP 180/55ZR 17 D252 M/C (73W) WARNING New tires and wheels have a relatively low grip on the road surface until they have been slightly worn.

• Page 134: Checking And Lubricating The Cables

  CHECKING AND LUBRICATING THE CABLES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE SIDESTAND/ LUBRICATING THE CENTERSTAND EAS00170 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement.

• Page 135: Lubricating The Rear Suspension

  LUBRICATING THE REAR SUSPENSION EAS00174 LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Molybdenum disulfide grease 3-58…

• Page 136: Electrical System

  CHECKING AND CHARGING THE BATTERY EAS00178 ELECTRICAL SYSTEM CHECKING AND CHARGING THE BATTERY WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poi- sonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: S Wear protective eye gear when handling or working near batteries.

• Page 137
  CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by mea- suring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
• Page 138
  CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20_C S battery (refer to the appropriate charging method il- lustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit CAUTION: voltage. S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause bat-…
• Page 139
  CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charged and NOTE: AMP meter to the battery Set the charging voltage at 16 X 17 V.
• Page 140
  CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger Measure the open-circuit NOTE: voltage prior to charging. Voltage should be measured 30 minutes after the machine is stopped. Connect a charger and AMP meter to the battery and start charging.
• Page 141
  CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger Charging method using a constant voltage charger 6. Install: S battery 7. Connect: S battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1 , and then the negative battery lead 2 .

• Page 142: Checking The Fuses

  CHECKING THE FUSES EAS00181 CHECKING THE FUSES The following procedure applies to all of the fuses. CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. 1. Remove: S right side cover Refer to “COWLINGS”.

• Page 143
  CHECKING THE FUSES WARNING Never use a fuse with an amperage rating other than that specified. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire.

• Page 144: Replacing The Headlight Bulbs

  REPLACING THE HEADLIGHT BULBS EAS00183 REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: S front cowling inner panels Refer to “COWLINGS”. 2. Disconnect: S headlight bulb cover S headlight coupler 1 3. Remove: S headlight bulb holder 1 4.

• Page 145: Adjusting The Headlight Beams

  ADJUSTING THE HEADLIGHT BEAMS EAS00185 ADJUSTING THE HEADLIGHT BEAMS The following procedure applies to both of the headlights. 1. Adjust: S headlight beam (vertically) a. Turn the adjusting screw 1 in direction a or Direction Headlight beam is raised. Headlight beam is Direction lowered.

• Page 146: Chas

  CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 6 Nm (0.6 mSkg, 4.3 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 4 Nm (0.4 mSkg, 2.9 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) 72 Nm (7.2 mSkg, 52 ftSlb)

• Page 147
  CHAS FRONT WHEEL AND BRAKE DISCS EAS00518 Order Job/Part Q’ty Remarks Disassembling the front wheel Disassemble the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure.

• Page 148: Removing The Front Wheel

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

• Page 149
  CHAS FRONT WHEEL AND BRAKE DISCS 2. Check: S tire S front wheel Damage/wear ! Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Measure: S radial wheel runout 1 S lateral wheel runout 2 Over the specified limits ! Replace.

• Page 150: Checking The Brake Discs

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

• Page 151: Installing The Front Wheel

  CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: S brake disc thickness Measure the brake disc thickness at a few different locations. Out of specification ! Replace. Brake disc thickness limit (minimum) Front: 4.5 mm (0.18 in) Rear: 4.5 mm (0.18 in) 4.

• Page 152: Adjusting The Front Wheel Static Balance

  CHAS FRONT WHEEL AND BRAKE DISCS 3. Insert the wheel axle. NOTE: Install the tire and wheel with the mark 1 point- ing in the direction of wheel rotation. 4. Lower the front wheel so that it is on the ground.

• Page 153
  CHAS FRONT WHEEL AND BRAKE DISCS a. Spin the front wheel. b. When the front wheel stops, put an “X ” mark at the bottom of the wheel. c. Turn the front wheel 90_ so that the “X ” mark is positioned as shown.

• Page 154: Rear Wheel And Brake Disc

  CHAS REAR WHEEL AND BRAKE DISC EAS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 22 Nm (2.2 mSkg, 16 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order Job/Part Q’ty Remarks Removing the rear wheel Remove the parts in the order listed.

• Page 155: Rear Brake Disc And Rear Wheel Sprocket

  CHAS REAR WHEEL AND BRAKE DISC EAS00556 REAR BRAKE DISC AND REAR WHEEL SPROCKET 30 Nm (3.0 mSkg, 22 ftSlb) 100 Nm (10 mSkg, 72 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake disc and Remove the parts in the order listed. rear wheel sprocket Rear brake disc Rear wheel sprocket…

• Page 156
  CHAS REAR WHEEL AND BRAKE DISC EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed. Collar Bearing Spacer Oil seal Circlip Bearing For assembly, reverse the disassembly procedure. 4-11…

• Page 157: Removing The Rear Wheel

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

• Page 158: Checking The Rear Wheel

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

• Page 159: Installing The Rear Wheel

  CHAS REAR WHEEL AND BRAKE DISC 2. Replace: S rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c.

• Page 160: Adjusting The Rear Wheel Static Balance

  CHAS REAR WHEEL AND BRAKE DISC EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: S After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. S Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1.

• Page 161: Front And Rear Brakes

  CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 10 Nm (1.0 mSkg, 7.2 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.

• Page 162
  CHAS FRONT AND REAR BRAKES REAR BRAKE PADS 3 Nm (0.3 mSkg, 2.2 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) 22 Nm (2.2 mSkg, 16 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake pads.
• Page 163
  CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: WARNING S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly.

• Page 164: Replacing The Front Brake Pads

  CHAS FRONT AND REAR BRAKES EAS00582 REPLACING THE FRONT BRAKE PADS The following procedure applies to both brake calipers. NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1.

• Page 165
  CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose 1 tightly to the bleed screw 2 . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.

• Page 166: Replacing The Rear Brake Pads

  CHAS FRONT AND REAR BRAKES EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not neces- sary to disconnect the brake hose or disas- semble the brake caliper. 1. Remove: S screw plug 1 S brake pad pin 2 S brake caliper 3 S brake pad spring 4 2.

• Page 167
  CHAS FRONT AND REAR BRAKES b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 mSkg, 4.3 ftSlb) d. Install a new brake pad shim 3 onto each new brake pad 4 .

• Page 168: Front Brake Master Cylinder

  CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER 2 Nm (0.2 mSkg, 1.4 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain.

• Page 169
  CHAS FRONT AND REAR BRAKES 2 Nm (0.2 mSkg, 1.4 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Master cylinder assembly For installation, reverse the removal procedure. 4-24…

• Page 170: Disassembling The Front Brake Master Cylinder

  CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. master cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder Push rod For assembly, reverse the disassembly procedure. 4-25…

• Page 171
  CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 30 Nm (3.0 mSkg, 22 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake master Remove the parts in the order listed. cylinder Brake fluid Drain.

• Page 172: Disassembling The Rear Brake Master Cylinder

  CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake master Disassemble the parts in the order listed. cylinder Dust boot Circlip Master cylinder kit Spring Master cylinder body For assembly, reverse the disassembly procedure. 4-27…

• Page 173: Master Cylinder

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

• Page 174
  CHAS FRONT AND REAR BRAKES 3. Check: S rear brake fluid reservoir 1 Cracks/damage ! Replace. S rear brake fluid reservoir diaphragm 2 Cracks/damage ! Replace. 4. Check: S front brake master cylinder reservoir 1 Cracks/damage ! Replace. S front brake master cylinder reservoir dia- phragm 2 Damage/wear ! Replace.
• Page 175
  CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents.
• Page 176
  CHAS FRONT AND REAR BRAKES NOTE: S While holding the brake hose, tighten the union bolt as shown. S Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary.
• Page 177
  CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: S brake master cylinder kit S circlip S dust boot 2. Install: S copper washers S brake hoses S union bolt 30 Nm (3.0 mSkg, 22 ftSlb) WARNING Proper brake hose routing is essential to in- sure safe motorcycle operation.
• Page 178
  CHAS FRONT AND REAR BRAKES CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: S brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level.
• Page 179
  CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 4 Nm (0.4 mSkg, 2.9 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 10 Nm (1.0 mSkg, 72 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks…
• Page 180
  CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 mSkg, 4.3 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front brake Disassemble the parts in the order listed. calipers NOTE: The following procedure applies to both of the front brake calipers. Brake pad Brake caliper piston Brake caliper piston seal…
• Page 181
  CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 22 Nm (2.2 mSkg, 16 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 27 Nm (2.7 mSkg, 20 ftSlb) Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Brake fluid Drain.

• Page 182: Disassembling The Rear Brake Caliper

  CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 mSkg, 4.3 ftSlb) 17 Nm (1.7 mSkg, 12 ftSlb) 3 Nm (0.3 mSkg, 2.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the rear brake caliper Disassemble the parts in the order listed. Screw plug Brake pad pin Brake pad…

• Page 183: Calipers

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

• Page 184: Caliper

  CHAS FRONT AND REAR BRAKES EAS00627 DISASSEMBLING THE REAR BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: S union bolt 1 S copper washers 2 S brake hose 3 S brake caliper 4 NOTE: Put the end of the brake hose into a container…

• Page 185
  CHAS FRONT AND REAR BRAKES EAS00633 CHECKING THE FRONT AND REAR BRAKE CALIPERS Recommended brake component replacement schedule Brake pads If necessary Piston seals Every two years Brake hoses Every four years Brake fluid Every two years and whenever the brake is disas- sembled 1.
• Page 186
  CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
• Page 187
  CHAS FRONT AND REAR BRAKES 2. Fill: S brake master cylinder reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
• Page 188
  CHAS FRONT AND REAR BRAKES EAS00642 ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER WARNING S Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. S Never use solvents on internal brake com- ponents as they will cause the piston seals to swell and distort.
• Page 189
  CHAS FRONT AND REAR BRAKES WARNING S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake perfor- mance.

• Page 190: Front Fork

  CHAS FRONT FORK EAS00647 FRONT FORK FRONT FORK LEGS 30 Nm (3.0 mSkg, 22 ftSlb) 6 Nm (0.6 mSkg, 4.3 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the front fork legs Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.

• Page 191
  CHAS FRONT FORK EAS00648 24 Nm (2.4 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Disassembling the front fork legs Disassemble the parts in the order listed. NOTE: The following the procedure applies to both of the front fork legs. Cap bolt O-ring Spacer…
• Page 192
  CHAS FRONT FORK 24 Nm (2.4 mSkg, 17 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Inner tube Outer tube bushing Inner tube bushing Oil flow stopper Outer tube For assembly, reverse the disassembly procedure. 4-47…

• Page 193: Removing The Front Fork Legs

  CHAS FRONT FORK EAS00649 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. Place the motorcycle on a suitable stand so that the front wheel is elevated.

• Page 194
  CHAS FRONT FORK 3. Remove: S dust seal 1 S oil seal clip 2 (with a flat-head screwdriver) CAUTION: Do not scratch the inner tube. 4. Remove: S damper rod assembly bolt NOTE: While holding the damper rod assembly with the damper rod holder 1 and T-handle 2 , loosen the damper rod assembly bolt.

• Page 195: Checking The Front Fork Legs

  CHAS FRONT FORK EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: S inner tube 1 S outer tube 2 Bends/damage/scratches ! Replace. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it.

• Page 196: Assembling The Front Fork Legs

  CHAS FRONT FORK EAS00659 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING S Make sure the oil levels in both front fork legs are equal. S Uneven oil levels can result in poor han- dling and a loss of stability.

• Page 197
  CHAS FRONT FORK Damper rod holder 90890-01294 T-handle 90890-01326 4. Install: S outer tube bushing 1 (with the fork seal driver weight 2 and fork seal driver attachment 3 ) Fork seal driver weight 90890-01367 Fork seal driver attachment 90890-01374 5.
• Page 198
  CHAS FRONT FORK 7. Install: S dust seal 1 (with the fork seal driver weight) Fork seal driver weight 90890-01367 8. Fill: S front fork leg (with the specified amount of the recom- mended fork oil) Quantity (each front fork leg) 0.467 L (0.41 Imp qt, 0.49 US qt) Recommended oil Suspension oil “01”…

• Page 199: Installing The Front Fork Legs

  CHAS FRONT FORK 10. Install: S spring 1 S spring seat 2 S spacer 3 S cap bolt NOTE: S Install the spring with the smaller pitch a fac- ing up. S Before installing the cap bolt, lubricate its O- ring with grease.

• Page 200: Handlebar

  CHAS HANDLEBAR EAS00664 HANDLEBAR 26 Nm (2.6 mSkg, 19 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 11 Nm (1.1 mSkg, 8.0 ftSlb) 23 Nm (2.3 mSkg, 17 ftSlb) Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Grip end Handlebar grip (left) Clutch switch connector…

• Page 201: Removing The Handlebar

  CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S grip end S handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.

• Page 202: Installing The Handlebar

  CHAS HANDLEBAR EAS00672 INSTALLING THE HANDLEBAR 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Install: S handlebar 1 S upper handlebar holders 2 23 Nm (2.3 mSkg, 17 ftSlb) S upper handlebar holder caps 3 CAUTION: S First, tighten the bolts on the front side of…

• Page 203
  CHAS HANDLEBAR 5. Install: S grip end 26 Nm (2.6 mSkg, 19 ftSlb) 6. Adjust: S throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. Throttle cable free play (at the flange of the throttle grip) 3 X 5 mm (0.12 X 0.20 in) 7.

• Page 204: Steering Head

  CHAS STEERING HEAD EAS00676 STEERING HEAD UNDER BRACKET 110 Nm (11 mSkg, 80 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Removing the under bracket Remove the parts in the order listed. Front wheel Refer to “FRONT WHEEL AND BRAKE DISCS”.

• Page 205
  CHAS STEERING HEAD 110 Nm (11 mSkg, 80 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) 30 Nm (3.0 mSkg, 22 ftSlb) Order Job/Part Q’ty Remarks Upper ring nut Rubber washer Lower ring nut Under bracket Bearing cover Bearing inner race Upper bearing Lower bearing Dust seal…

• Page 206: Removing The Under Bracket

  CHAS STEERING HEAD EAS00677 REMOVING THE UNDER BRACKET 1. Stand the motorcycle on a level surface. WARNING Securely support the motorcycle so that there is no danger of it falling over. 2. Remove: S steering stem nut S washer S upper bracket S lock washer S rubber washer S ring nut 1…

• Page 207: Installing The Steering Head

  CHAS STEERING HEAD 3. Replace: S bearing balls S bearing races a. Remove the bearing races 1 from the steer- ing head pipe with a long rod 2 and hammer. b. Remove the bearing race 3 from the lower bracket with a floor chisel 4 and hammer. c.

• Page 208
  CHAS STEERING HEAD 3. Install: S upper bracket S washer S steering stem nut 110 Nm (11 mSkg, 80 ftSlb) 4. Install: S front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”. 4-63…

• Page 209: Rear Shock Absorber Assembly

  CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00685 REAR SHOCK ABSORBER ASSEMBLY 40 Nm (4.0 mSkg, 29 ftSlb) 40 Nm (4.0 mSkg, 29 ftSlb) Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed. assembly Rear wheel Refer to “REAR WHEEL AND BRAKE DISC”.

• Page 210: Removing The Rear Shock Absorber Assembly

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

• Page 211: Handling The Rear Shock Absorber

  CHAS REAR SHOCK ABSORBER ASSEMBLY EAS00686 HANDLING THE REAR SHOCK ABSORBER WARNING This rear shock absorber contains highly compressed nitrogen gas. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsi- ble for property damage or personal injury that may result from improper handling of the rear shock absorber.

• Page 212: Installing The Rear Shock Absorber Assembly

  CHAS REAR SHOCK ABSORBER ASSEMBLY S spring Damage/wear ! Replace the rear shock ab- sorber assembly. S bushings Damage/wear ! Replace. S dust seals Damage/wear ! Replace. S bolts Bends/damage/wear ! Replace. EAS00697 INSTALLING THE REAR SHOCK ABSORB- ER ASSEMBLY 1.

• Page 213: Swingarm And Drive Chain

  CHAS SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order Job/Part Q’ty Remarks Removing the swingarm and drive Remove the parts in the order listed. chain Muffler assembly Catalyst assembly…

• Page 214
  CHAS SWINGARM AND DRIVE CHAIN 16 Nm (1.6 mSkg, 12 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 120 Nm (12 mSkg, 87 ftSlb) Order Job/Part Q’ty Remarks Drive chain guide Dust cover Bearing Spacer For installation, reverse the removal procedure. 4-69…

• Page 215: Removing The Swingarm

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

• Page 216: Removing The Drive Chain

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

• Page 217: Installing The Swingarm

  CHAS SWINGARM AND DRIVE CHAIN 4. Check: S dust covers 1 S spacer 2 Damage/wear ! Replace. S bearings Damage/pitting ! Replace. AS00711 INSTALLING THE SWINGARM 1. Lubricate: S bearings S spacer S dust covers S pivot shaft Recommended lubricant Lithium-soap-based grease 2.

• Page 218: Checking The Drive Chain

  CHAS SWINGARM AND DRIVE CHAIN EAS00709 CHECKING THE DRIVE CHAIN 1. Measure: S ten-link section a of the drive chain Out of specification ! Replace the drive chain. Ten-link drive chain section limit (maximum) 150.1 mm (5.91 in) NOTE: S While measuring the ten-link section, push down on the drive chain to increase its tension.

• Page 219
  CHAS SWINGARM AND DRIVE CHAIN 4. Check: S O-rings 1 Damage ! Replace the drive chain. S drive chain rollers 2 Damage/wear ! Replace the drive chain. S drive chain side plates 3 Damage/wear ! Replace the drive chain. Cracks ! Replace the drive chain and make sure that the battery breather hose is proper- ly routed away from the drive chain and be- low the swingarm.

• Page 220: Eng

  ENGINE EAS00188 ENGINE ENGINE DRIVE SPROCKET 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) 90 Nm (9.0 mSkg, 65 ftSlb) Order Job/Part Q’ty Remarks Removing the drive sprocket Drive chain Loosen.

• Page 221: Exhaust Pipe

  ENGINE EAS00189 EXHAUST PIPE 20 Nm (2.0 mSkg, 15 ftSlb) 9 Nm (0.9 mSkg, 6.5 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 34 Nm (3.4 mSkg, 26 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 16 Nm (1.6 mSkg, 11.6 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb)

• Page 222: Leads And Hoses

  ENGINE EAS00191 LEADS AND HOSES Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. Fuel tank Refer to “FUEL TANK”…

• Page 223
  ENGINE Order Job/Part Q’ty Remarks Radiator Refer to “COOLING SYSTEM” in chapter 6. Starter motor Refer to “STARTER MOTOR” in chapter 8. Battery negative lead Battery positive lead Clutch cable Ground lead Stator coil assembly coupler Disconnect. Crankshaft position sensor coupler Disconnect.
• Page 224
  ENGINE EAS00191 ENGINE 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) 55 Nm (5.5 mSkg, 40 ftSlb) Order Job/Part Q’ty Remarks Removing the engine Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine.

• Page 225: Installing The Engine

  ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: S rear engine mounting bolts 1 NOTE: Lubricate the rear engine mounting bolt threads with lithium-soap-based grease. 2. Install: S right front engine mounting bolt 2 S left front engine mounting bolts 3 NOTE: Do not fully tighten the bolts.

• Page 226
  ENGINE 5. Tighten S right front engine mounting bolts 6 55 Nm (5.5 mSkg, 40 ftSlb) 6. Install: S shift arm 7 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Align the punch mark a in the shift shaft with the slot in the shift arm.

• Page 227: Camshafts

  CAMSHAFTS EAS00194 CAMSHAFTS CYLINDER HEAD COVER 12 Nm (1.2 mSkg, 8.7 ftSlb) 18 Nm (1.8 mSkg, 13 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head cover Remove the parts in the order listed. Battery Refer to “CHECKING AND CHARGING THE BATTERY”…

• Page 228
  CAMSHAFTS EAS00196 CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the camshafts Remove the parts in the order listed.
• Page 229
  CAMSHAFTS 10 Nm (1.0 mSkg, 7.2 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 20 Nm (2.0 mSkg, 15 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Exhaust camshaft Timing chain guide (intake side) Cam sprocket For installation, reverse the removal procedure.

• Page 230: Removing The Camshafts

  CAMSHAFTS EAS00198 REMOVING THE CAMSHAFTS 1. Remove: S pickup rotor cover Refer to “CRANKSHAFT POSITION SEN- SOR AND PICKUP ROTOR”. 2. Align: S “T” mark a on the pickup rotor (with the crankcase mating surface b ) a. Turn the crankshaft clockwise. b.

• Page 231: Checking The Camshafts

  CAMSHAFTS 7. Remove: S intake camshaft 1 S exhaust camshaft 2 NOTE: To prevent the timing chain from falling into the crankcase, fasten it with a wire a . 8. Remove: S camshaft sprockets EAS00204 CHECKING THE CAMSHAFTS 1. Check: S camshaft lobes Blue discoloration/pitting/scratches ! Re- place the camshaft.

• Page 232
  CAMSHAFTS 3. Measure: S camshaft runout Out of specification ! Replace. Camshaft runout limit 0.06 mm (0.0024 in) 4. Measure: S camshaft-journal-to-camshaft-cap clear- ance Out of specification ! Measure the camshaft journal diameter. Camshaft-journal-to-camshaft- cap clearance 0.028 X 0.062 mm (0.0011 X 0.0024 in) <Limit>: 0.08 mm (0.0032 in) a.

• Page 233: Checking The Timing Chain, Camshaft Sprockets

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

• Page 234: Installing The Camshafts

  CAMSHAFTS b. Remove the screwdriver and slowly release the timing chain tensioner rod. c. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. If there is rough move- ment, replace the timing chain tensioner. 3.

• Page 235
  CAMSHAFTS 3. Install: S dowel pins S exhaust camshaft caps S intake camshaft caps NOTE: S Make sure each camshaft cap is installed in its original place. S Make sure the arrow mark a on each cam- shaft cap points towards the right side of the engine.
• Page 236
  CAMSHAFTS 6. Install: S timing chain tensioner a. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod ful- ly clockwise with a thin screwdriver 1 . b. With the timing chain tensioner rod turned all the way into the timing chain tensioner hous- ing (with the thin screwdriver still installed), install the gasket and the timing chain ten-…
• Page 237
  CAMSHAFTS 10. Measure: S valve clearance Out of specification ! Adjust. Refer to “ADJUSTING THE VALVE CLEAR- ANCE” in chapter 3. 5-18…

• Page 238: Cylinder Head

  CYLINDER HEAD EAS00221 CYLINDER HEAD 19 Nm (1.9 mSkg, 14 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the cylinder head Remove the parts in the order listed. Intake and exhaust camshaft Refer to “CAMSHAFTS”.

• Page 239: Removing The Cylinder Head

  CYLINDER HEAD EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: S cylinder head bolts NOTE: S Loosen the bolts in the proper sequence as shown. S Loosen each bolt 1/2 of a turn at a time. After all of the bolts are fully loosened, remove them.

• Page 240: Installing The Cylinder Head

  CYLINDER HEAD EAS00233 INSTALLING THE CYLINDER HEAD 1. Install: S gasket S dowel pins 2 2. Install: S cylinder head NOTE: Pass the timing chain through the timing chain cavity. 3. Tighten: S cylinder head bolts 1 X 19 Nm (1.9 mSkg, 14 ftSlb) 50 Nm (5.0 mSkg, 36 ftSlb) S cylinder head bolts 12 Nm (1.2 mSkg, 8.7 ftSlb)

• Page 241: Valves And Valve Springs

  VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Remove the valves and valve springs Remove the parts in the order listed. Cylinder head Refer to “CYLINDER HEAD”. Intake valve lifter Intake valve pad Intake valve cotter Intake valve upper spring seat Intake valve spring outer Intake valve spring inner…

• Page 242
  VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Exhaust valve upper spring seat Exhaust valve spring Refer to “REMOVING/INSTALLING Exhaust valve stem seal THE VALVES”. Exhaust valve lower spring seat Exhaust valve Exhaust valve guide For installation, reverse the removal procedure.

• Page 243: Removing The Valves

  VALVES AND VALVE SPRINGS EAS00238 REMOVING THE VALVES The following procedure applies to all of the valves and related components. NOTE: Before removing the internal parts of the cylin- der head (e.g., valves, valve springs, valve seats), make sure the valves properly seal. 1.

• Page 244: Checking The Valves And Valve Guides

  VALVES AND VALVE SPRINGS Valve spring compressor 90890-04019, YM-04019 Valve spring compressor attachment 90890-04108, YM-01253 4. Remove: S upper spring seat 1 S valve spring outer 2 S valve spring inner (intake only) 3 S valve 4 S valve stem seal 5 S lower spring seat 6 NOTE: Identify the position of each part very carefully…

• Page 245
  VALVES AND VALVE SPRINGS 2. Replace: S valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100_C (212_F) in an oven. a. Remove the valve guide with the valve guide remover 1 .

• Page 246: Checking The Valve Seats

  VALVES AND VALVE SPRINGS 5. Measure: S valve margin thickness a Out of specification ! Replace the valve. Valve margin thickness 0.6 X 0.8 mm (0.0236 X 0.0315 in) <Limit>: 0.5 mm (0.02 in) 6. Measure: S valve stem runout Out of specification ! Replace the valve.

• Page 247
  VALVES AND VALVE SPRINGS NOTE: Where the valve seat and valve face contacted one another, the blueing will have been re- moved. 4. Lap: S valve face S valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped.

• Page 248: Checking The Valve Springs

  VALVES AND VALVE SPRINGS j. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.

• Page 249
  VALVES AND VALVE SPRINGS 3. Measure: S valve spring tilt a Out of specification ! Replace the valve spring. Spring tilt limit Intake valve spring (inner) 2.5_/1.6 mm (0.06 in) (outer) 2.5_/1.7 mm (0.07 in) Exhaust valve spring 2.5_/1.8 mm (0.07 in) EAS00242 CHECKING THE VALVE LIFTERS The following procedure applies to all of the…
• Page 250
  VALVES AND VALVE SPRINGS NOTE: S Make sure that each valve is installed in its original place. S Install the valve springs with the larger pitch a facing up. b Smaller pitch 4. Install: S valve cotters 1 NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor 2 and the valve spring compressor attachment Valve spring compressor…

• Page 251: Starter Clutch And Generator

  STARTER CLUTCH AND GENERATOR EAS00341 STARTER CLUTCH AND GENERATOR STATOR COIL ASSEMBLY 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty…

• Page 252
  STARTER CLUTCH AND GENERATOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 32 Nm (3.2 mSkg, 23 ftSlb) 75 Nm (7.5 mSkg, 54 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Stator coil assembly Generator rotor bolt Refer to “REMOVING/INSTALLING Washer…

• Page 253: Removing The Generator

  STARTER CLUTCH AND GENERATOR EAS00347 REMOVING THE GENERATOR 1. Remove: S seat Refer to “SEAT” in chapter 3. S front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. S fuel tank Refer to “FUEL TANK” in chapter 3. 2.

• Page 254: Removing The Starter Clutch

  STARTER CLUTCH AND GENERATOR 5. Remove: S generator rotor 1 (with the flywheel puller 2 and flywheel pull- er attachment) S woodruff key CAUTION: To protect the end of the crankshaft, place an appropriate sized socket between the fly- wheel puller set’s center bolt and the crank- shaft.

• Page 255: Checking The Starter Clutch

  STARTER CLUTCH AND GENERATOR EAS00351 CHECKING THE STARTER CLUTCH 1. Check: S starter clutch rollers 1 Damage/wear ! Replace. 2. Check: S starter clutch idle gear 1 S starter clutch drive gear 2 Burrs/chips/roughness/wear ! Replace the defective part(s). 3. Check: S starter clutch gear’s contacting surfaces a Damage/pitting/wear ! Replace the starter clutch gear.

• Page 256: Installing The Generator

  Sheave holder 90890-01701, YS-01880-A 3. Apply: S sealant (onto the stator coil assembly lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-05-01 4. Install: S stator coil 5. Install: S generator rotor cover 12 Nm (1.2 mSkg, 8.7 ftSlb)

• Page 257
  STARTER CLUTCH AND GENERATOR NOTE: Tighten the generator rotor cover bolts in stages and in a crisscross pattern. 6. Fill: S engine oil Refer to “CHANGING THE ENGINE OIL” in chapter 3. S coolant Refer to “CHANGING THE COOLANT” in chapter 3.

• Page 258: Shift Shaft

  SHIFT SHAFT EAS00327 SHIFT SHAFT SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the shift shaft and stopper Remove the parts in the order listed. lever Drain.

• Page 259
  SHIFT SHAFT 22 Nm (2.2 mSkg, 16 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Stopper lever Collar Washer Shift shaft spring stopper For installation, reverse the removal procedure. 5-40…

• Page 260: Checking The Shift Shaft

  SHIFT SHAFT EAS00328 CHECKING THE SHIFT SHAFT 1. Check: S shift shaft 1 Bends/damage/wear ! Replace. S shift shaft spring 2 Damage/wear ! Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: S stopper lever 1 Bends/damage ! Replace. Roller turns roughly ! Replace the stopper lever.

• Page 261: Crankshaft Position Sensor And Pickup Rotor

  CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) Order Job/Part Q’ty Remarks Removing the crankshaft position Remove the parts in the order listed.

• Page 262
  CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 15 Nm (1.5 mSkg, 11 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 35 Nm (3.5 mSkg, 25 ftSlb) Order Job/Part Q’ty Remarks Crankshaft position sensor Pickup rotor Plug screw For installation, reverse the removal procedure.

• Page 263: Removing The Pickup Rotor

  CRANKSHAFT POSITION SENSOR AND PICKUP ROTOR REMOVING THE PICKUP ROTOR 1. Remove: S pickup rotor cover 1 NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2.

• Page 264
  3 , tighten the pickup rotor bolt. Sheave holder 90890-01701, YS-01880-A 3. Apply: S sealant (onto the crankshaft position sensor lead grommet) Yamaha bond No.1215 90890-85505, ACC-11001-5-01 4. Install: S pickup rotor cover S gasket NOTE: S When installing the pickup rotor cover, align the timing chain guide (intake side) pin 1 with the hole 2 in the pickup rotor cover.

• Page 265: Clutch

  CLUTCH EAS00273 CLUTCH CLUTCH COVER : YAMAHA BOND No. 1215 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Engine oil Drain.

• Page 266
  CLUTCH Order Job/Part Q’ty Remarks Disassembling the clutch cover Disassemble the parts in the order listed. Circlip Washer Pull lever Pull lever spring Washer Oil seal Bearing Pull lever shaft Washer For assembly, reverse the disassembly procedure. 5-47…
• Page 267
  CLUTCH EAS00274 CLUTCH 90 Nm (9.0 mSkg, 65 ftSlb) 8 Nm (0.8 mSkg, 5.8 ftSlb) Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed. Compression spring Pressure plate Pull rod Bearing Friction plate (Brown) Clutch plate (t=2.0 mm, 0.08 in) Friction plate Clutch plate (t=2.3 mm, 0.09 in) Clutch boss nut…
• Page 268
  CLUTCH EAS00276 REMOVING THE CLUTCH 1. Remove: S clutch cable holder 1 S clutch cover 2 S gasket NOTE: Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

• Page 269: Checking The Clutch Plates

  CLUTCH 2. Measure: S friction plate thickness Out of specification ! Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 X 3.1 mm (0.114 X 0.122 in) <Limit>: 2.8 mm (0.110 in) EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the…

• Page 270: Checking The Clutch Housing

  CLUTCH 2. Measure: S clutch spring free length a Out of specification ! Replace the clutch springs as a set. Clutch spring free length 55 mm (2.17 in) <Limit>: 52.3 mm (2.06 in) EAS00284 CHECKING THE CLUTCH HOUSING 1. Check: S clutch housing dogs Damage/pitting/wear ! Deburr the clutch housing dogs or replace the clutch housing.

• Page 271: Checking The Pull Lever Shaft And Pull Rod

  CLUTCH EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: S pull lever shaft pinion gear teeth a S pull rod teeth b Damage/wear ! Replace the pull rod and pull lever shaft pinion gear as a set. 2.

• Page 272
  CLUTCH 4. Install: S friction plates S clutch plates NOTE: First, install a clutch plate and then alternate be- tween a friction plate and a friction plate. a. Install the clutch plate and friction plate as shown in the illustration. Clutch plate 1 : t=2.3 mm (0.09 in) Clutch plate 2 : t=2.0 mm (0.08 in) Friction plate 3…
• Page 273
  CLUTCH 8. Install: S clutch cover S gasket S clutch cable holder NOTE: S Install the pull rod so that the teeth a face to- wards the rear of the motorcycle. Then, install the clutch cover. S Apply oil onto the bearing. S Apply molybdenum disulfide grease onto the pull rod.

• Page 274: Oil Pan And Oil Pump

  OIL PAN AND OIL PUMP EAS00356 OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order…

• Page 275
  OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 43 Nm (4.3 mSkg, 31 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part…
• Page 276
  OIL PAN AND OIL PUMP 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Disassembling the oil pump Disassemble the parts in the order listed. assembly Oil pump cover Oil pump inner rotor Oil pump outer rotor Washer Oil pump rotor housing Oil pump driver sprocket For assembly, reverse the disassembly procedure.

• Page 277: Removing The Oil Pan

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

• Page 278
  OIL PAN AND OIL PUMP 3. Check: S oil pump operation Rough movement ! Repeat steps (1) and (2) or replace the defective part(s). EAS00365 CHECKING THE RELIEF VALVE 1. Check: S relief valve body 1 S relief valve 2 S spring 3 S O-ring 4 Damage/wear ! Replace the defective…
• Page 279
  OIL PAN AND OIL PUMP EAS00374 ASSEMBLING THE OIL PUMP 1. Lubricate: S inner rotor S outer rotor S oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2. Install: S oil pump housing 1 S oil pump shaft 2 S washer 3 S pin 4 S inner rotor 5…

• Page 280: Installing The Oil Strainer

  OIL PAN AND OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: S oil strainer 1 S relief valve 2 NOTE: Make sure to check the arrow mark a located on the oil strainer housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine.

• Page 281: Crankcase

  CRANKCASE CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Cylinder head Refer to “CYLINDER HEAD”. Starter clutch and generator Refer to “STARTER CLUTCH AND GENERATOR”.

• Page 282
  CRANKCASE 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Thrust plate Washer Plate For installation, reverse the removal procedure. 5-63…
• Page 283
  CRANKCASE EAS00384 DISASSEMBLING THE CRANKCASE 1. Place the engine upside down. 2. Remove: S crankcase bolts NOTE: S Loosen each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. S Loosen the bolts in decreasing numerical or- der (refer to the numbers in the illustration).

• Page 284: Checking The Crankcase

  ASSEMBLING THE CRANKCASE 1. Lubricate: S crankshaft journal bearings (with the recommended lubricant) Recommended lubricant Engine oil 2. Apply: S sealant Yamaha bond No. 1215 90890-85505, ACC-1109-05-01 5-65…

• Page 285
  CRANKCASE NOTE: Do not allow any sealant to come into contact with the oil gallery or crankshaft journal bear- ings. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. 3. Install: S dowel pin 4.

• Page 286: Connecting Rods And Pistons

  CONNECTING RODS AND PISTONS EAS00252 CONNECTING RODS AND PISTONS 15 Nm (1.5 mSkg, 11 ftSlb) +120_ 15 Nm (1.5 mSkg, 11 ftSlb) +150_ Order Job/Part Q’ty Remarks Removing the connecting rods and Remove the parts in the order listed. pistons Lower crankcase Refer to “CRANKCASE”.

• Page 287: Removing The Connecting Rods And Pistons

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

• Page 288: Removing The Crankshaft Assembly

  CONNECTING RODS AND PISTONS EAS00387 REMOVING THE CRANKSHAFT ASSEMBLY 1. Remove: S crankshaft assembly S crankshaft journal upper bearings (from the upper crankcase) Refer to “CRANKSHAFT”. NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place.

• Page 289: Checking The Piston Rings

  CONNECTING RODS AND PISTONS 65.50 X 65.51 mm Cylinder bore “C” (2.5787 X 2.5791 in) 65.56 mm Wear limit (2.5811 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = maximum of D “T”…

• Page 290: Checking The Piston Pins

  CONNECTING RODS AND PISTONS Piston ring side clearance Top ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.115 mm (0.0045 in) 2nd ring 0.030 X 0.065 mm (0.0012 X 0.0026 in) <Limit>: 0.125 mm (0.0049 in) 2. Install: S piston ring (into the cylinder) NOTE:…

• Page 291
  CONNECTING RODS AND PISTONS 2. Measure: S piston pin outside diameter a Out of specification ! Replace the piston pin. Piston pin outside diameter 15.991 X 16.000 mm (0.6296 X 0.6299 in) <Limit>: 15.971 mm (0.6288 in) 3. Measure: S piston pin bore inside diameter b Out of specification ! Replace the piston.

• Page 292: Checking The Big End Bearings (Except For Cal)

  CONNECTING RODS AND PISTONS CHECKING THE BIG END BEARINGS (except for CAL) 1. Measure: S crankshaft-pin-to-big-end-bearing clear- ance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.028 X 0.052 mm (0.0011 X 0.0020 in) The following procedure applies to all of the connecting rods.

• Page 293
  CONNECTING RODS AND PISTONS e. Tighten the connecting rod nuts. Connecting rod nut 15 Nm (1.5 mSkg, 11 ftSlb) + 150_ f. Replace the connecting rod bolts with new ones. CAUTION: Tighten the connecting rod nuts using the plastic-region tightening angle method. Always install new bolts and nuts.
• Page 294
  CONNECTING RODS AND PISTONS 2. Select: S big end bearings (P1 X P4) NOTE: S The numbers A stamped into the crankshaft web and the numbers 1 on the connecting rods are used to determine the replacement big end bearing sizes. S “P1”…

• Page 295: Checking The Big End Bearings (For Cal)

  CONNECTING RODS AND PISTONS CHECKING THE BIG END BEARINGS (for CAL) 1. Measure: S crankshaft-pin-to-big-end-bearing clear- ance Out of specification ! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0.028 X 0.052 mm (0.0011 X 0.0020 in) The following procedure applies to all of the connecting rods.

• Page 296
  CONNECTING RODS AND PISTONS e. Tighten the connecting rod bolts. NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts Connecting rod bolt 24.5 Nm (2.5 mSkg, 17.7 ftSlb) f.
• Page 297
  CONNECTING RODS AND PISTONS k. Tighten the connecting rod bolts. Connecting rod bolt 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. Always install new bolts. l. Clean the connecting rod bolts. m.
• Page 298
  CONNECTING RODS AND PISTONS q. Remove the connecting rod and big end bearings. Refer to “REMOVING THE CONNECTING RODS AND PISTONS”.  r. Measure the compressed Plastigauge width on the crankshaft pin. crankshaft-pin-to-big-end-bearing clearance is out of specification, select re- placement big end bearings.
• Page 299
  CONNECTING RODS AND PISTONS INSTALLING THE CONNECTING ROD AND PISTON (except for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: S top ring 1 S 2nd ring 2 S upper oil ring rail 3 S oil ring expander 4 S lower oil ring rail 5 NOTE:…
• Page 300
  CONNECTING RODS AND PISTONS 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant…
• Page 301
  CONNECTING RODS AND PISTONS b. Clean the connecting rod bolts and nuts. c. Tighten the connecting rod nuts. d. Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod cap 3 . e. Tighten the nut further to reach the specified angle (150_).
• Page 302
  CONNECTING RODS AND PISTONS INSTALLING THE CONNECTING ROD AND PISTON (for CAL) The following procedure applies to all of the connecting rods and pistons. 1. Install: S top ring 1 S 2nd ring 2 S upper oil ring rail 3 S oil ring expander 4 S lower oil ring rail 5 NOTE:…
• Page 303
  CONNECTING RODS AND PISTONS 4. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5. Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface (with the recommended lubricant) Recommended lubricant…
• Page 304
  CONNECTING RODS AND PISTONS 7. Tighten: NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts. 24.5 Nm (2.5 mSkg, 17.7 ftSlb) a. Replace the connecting rod bolts with new ones.
• Page 305
  CONNECTING RODS AND PISTONS 9. Tighten: S connecting rod bolts 15 Nm (1.5 mSkg, 11 ftSlb) + 120_ CAUTION: Tighten the connecting rod bolts using the plastic-region tightening angle method. a. Clean the connecting rod bolts. b. Tighten the connecting rod bolts. c.

• Page 306: Crankshaft

  CRANKSHAFT EAS00381 CRANKSHAFT Order Job/Part Q’ty Remarks Removing the crankshaft Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE”. Connecting rod caps Refer to “CONNECTING RODS AND PISTONS”. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal procedure.

• Page 307: Checking The Crankshaft

  CRANKSHAFT EAS00395 CHECKING THE CRANKSHAFT 1. Measure: S crankshaft runout Out of specification ! Replace the crank- shaft. Crankshaft runout Less than 0.03 mm (0.0012 in) 2. Check: S crankshaft journal surfaces S crankshaft pin surfaces S bearing surfaces Scratches/wear ! Replace the crankshaft. CHECKING THE CRANKSHAFT JOURNAL BEARINGS 1.

• Page 308
  CRANKSHAFT c. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. NOTE: Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the up- per crankcase.  d. Put a piece of Plastigauge 2 on each crankshaft journal.
• Page 309
  CRANKSHAFT g. Remove the lower crankcase and the crank- shaft journal lower bearings.  h. Measure the compressed Plastigauge width c on each crankshaft journal. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. 2.

• Page 310: Installing The Crankshaft

  CRANKSHAFT EAS00407 INSTALLING THE CRANKSHAFT 1. Install: S crankshaft journal upper bearings 1 (into the upper crankcase) NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase. S Be sure to install each crankshaft journal up- per bearing in its original place.

• Page 311: Transmission

  TRANSMISSION EAS00419 TRANSMISSION TRANSMISSION, SHIFT DRUM ASSEMBLY AND SHIFT FORKS 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the part in the order listed.

• Page 312
  TRANSMISSION 12 Nm (1.2 mSkg, 8.7 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Main axle assembly Oil pipe Oil baffle plate Thrust plate Washer For installation, reverse the removal procedure.
• Page 313
  TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Disassemble the parts in the order listed. assembly Bearing 2nd pinion gear Toothed lock washer Toothed lock washer retainer 6th pinion gear Collar Washer Circlip 3rd pinion gear Circlip Washer 5th pinion gear Collar Main axle 5-94…
• Page 314
  TRANSMISSION Order Job/Part Q’ty Remarks Bearing housing Bearing For installation, reverse the removal procedure. 5-95…
• Page 315
  TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Disassemble the parts in the order listed. assembly Washer 1st wheel gear Collar 5th wheel gear Circlip Washer Collar 3rd wheel gear Toothed lock washer Toothed lock washer retainer 4th wheel gear Collar Washer Circlip…
• Page 316
  TRANSMISSION Order Job/Part Q’ty Remarks 6th wheel gear Circlip Washer 2nd wheel gear Collar Collar Oil seal Bearing Circlip Drive axle For installation, reverse the removal procedure. 5-97…

• Page 317: Removing The Transmission

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

• Page 318: Checking The Shift Drum Assembly

  TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: S shift drum grooves Damage/scratches/wear ! Replace the shift drum assembly. S shift drum segment 1 Damage/wear ! Replace the shift drum as- sembly. S shift drum bearing 2 Damage/pitting ! Replace the shift drum assembly.

• Page 319: Installing The Transmission

  TRANSMISSION 4. Check: S transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect ! Reassemble the transmission axle assemblies. 5. Check: S transmission gear movement Rough movement ! Replace the defective part(s). 6. Check: S circlips Bends/damage/looseness ! Replace. EAS00430 INSTALLING THE TRANSMISSION 1.

• Page 320
  TRANSMISSION 3. Install: S shift fork “R” 1 and “L” 2 S drive axle 3 S shift fork guide bar S shift drum retainer 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: S Install shift fork “L” into the groove in the 6th wheel gear and shift fork “R”…

• Page 321: Cool

  COOL RADIATOR EAS00454 COOLING SYSTEM RADIATOR 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Removing the radiator Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS”…

• Page 322
  COOL RADIATOR 7 Nm (0.7 mSkg, 5.1 ftSlb) 10 Nm (1.0 mSkg, 7.2 ftSlb) 7 Nm (0.7 mSkg, 5.1 ftSlb) Order Job/Part Q’ty Remarks Radiator fan For installation, reverse the removal procedure.

• Page 323: Checking The Radiator

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

• Page 324: Installing The Radiator

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

• Page 325: Oil Cooler

  COOL OIL COOLER EAS00457 OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) Order Job/Part Q’ty Remarks Removing the oil cooler Remove the parts in the order listed. Radiator assembly Refer to “RADIATOR”. Engine oil Drain.

• Page 326
  COOL OIL COOLER 10 Nm (1.0 mSkg, 7.2 ftSlb) 63 Nm (6.3 mSkg, 46 ftSlb) Order Job/Part Q’ty Remarks O-ring Water pump outlet hose Radiator outlet hose For installation, reverse the removal procedure.

• Page 327: Checking The Oil Cooler

  COOL OIL COOLER EAS00458 CHECKING THE OIL COOLER 1. Check: S oil cooler Cracks/damage ! Replace. 2. Check: S oil cooler inlet hose S oil cooler outlet hose Cracks/damage/wear ! Replace. EAS00459 INSTALLING THE OIL COOLER 1. Clean: S mating surfaces of the oil cooler and the crankcase (with a cloth dampened with lacquer thinner) 2.

• Page 328: Thermostat

  COOL THERMOSTAT EAS00460 THERMOSTAT 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the thermostat Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS” Fuel tank Refer to “FUEL TANK”…

• Page 329: Checking The Thermostat

  COOL THERMOSTAT EAS00462 CHECKING THE THERMOSTAT 1. Check: S thermostat 1 Does not open at 71 X 85_C (160 X 185_F) ! Replace. a. Suspend the thermostat in a container filled with water. b. Slowly heat the water. c. Place a thermometer in the water. d.

• Page 330: Installing The Thermostat

  COOL THERMOSTAT EAS00466 INSTALLING THE THERMOSTAT 1. Install: S thermostat NOTE: Install the thermostat with its breather hole a facing up. 2. Install: S thermostat cover 12 Nm (1.2 mSkg, 8.7 ftSlb) NOTE: Before installing the thermostat cover to the cyl- inder head, lubricate the O-ring with a thin coat of lithium soap based grease.

• Page 331: Water Pump

  COOL WATER PUMP EAS00468 WATER PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) 12 Nm (1.2 mSkg, 8.7 ftSlb) Order Job/Part Q’ty Remarks Removing the water pump Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil.

• Page 332
  COOL WATER PUMP 10 Nm (1.0 mSkg, 7.2 ftSlb) Order Job/Part Q’ty Remarks Disassembling the water pump Disassemble the parts in the order listed. Water pump cover O-ring Impeller shaft Circlip Water pump seal Oil seal Bearing Water pump housing O-ring Copper washer For assembly, reverse the disassembly…

• Page 333: Disassembling The Water Pump

  COOL WATER PUMP EAS00471 DISASSEMBLING THE WATER PUMP 1. Remove: S water pump cover S O-ring S circlip S impeller shaft 2. Remove: S water pump seal 1 NOTE: Remove the water pump seal from the outside of the water pump housing. 2 Water pump housing 3.

• Page 334: Checking The Water Pump

  Never lubricate the water pump seal surface with oil or grease. NOTE: S Install the water pump seal with the special tools. S Before installing the water pump seal, apply Yamaha bond No.1215 or Quick Gasket 2 to the water pump housing 3 . 6-14…

• Page 335
  WATER PUMP Mechanical seal installer 90890-04078, YM-33221 4 Middle driven shaft bearing driver 90890-04058, YM-04058 5 Quick Gasket ACC-11001-05-01 Yamaha bond #1215 90890-85505 A Push down. 3. Install: S rubber damper S rubber damper holder NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface.

• Page 336: Installing The Water Pump

  COOL WATER PUMP INSTALLING THE WATER PUMP 1. Install: S O-ring S copper washer S water pump assembly 10 Nm (1.0 mSkg, 7.2 ftSlb) NOTE: Align the projection a at the oil pump shaft and water pump shaft groove b . 2.

• Page 337: Fuel Injection System

  FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM Ignition coil Throttle position sensor Battery Air filter case Fuel injector Intake air temperature sensor Catalytic converter Fuel injection system relay Fuel delivery hose Crankshaft position sensor Engine trouble warning light Fuel tank Coolant temperature sensor Lean angle cut-off switch…

• Page 338: Wiring Diagram

  FUEL INJECTION SYSTEM WIRING DIAGRAM Main switch Fuse (fuel injection) Fuse (main) Battery Starting circuit cut-off relay Sidestand switch Neutral switch Fuel pump Throttle position sensor Intake air pressure sensor Lean angle cut-off switch Crankshaft position sensor Intake air temperature sensor Coolant temperature sensor Cylinder #1-injector Cylinder #2-injector…

• Page 339: Ecu’s Self-Diagnostic Function

  FUEL INJECTION SYSTEM EAS00899 ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control system is operating normally. If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

• Page 340: Fail-Safe Action

  FUEL INJECTION SYSTEM EAS00902 ALTERNATE INSTRUCTIONS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the vehicle is being driven, the ECU illumi- nates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.

• Page 341
  FUEL INJECTION SYSTEM Communication error with the meter ECU internal malfunction No signals are received from Er-1 – Unable Unable (output signal error) the ECU. No signals are received from ECU internal malfunction Er-2 the ECU within the specified – Unable Unable (output signal error)

• Page 342: Troubleshooting Chart

  FUEL INJECTION SYSTEM EAS00904 TROUBLESHOOTING CHART Engine operation is not normal or the engine trouble warning light is on. * Engine trouble warning light may not come on even if the engine operation is not normal. The engine trouble warning light does not come The engine trouble warning light comes on.

• Page 343: Diagnostic Mode

  FUEL INJECTION SYSTEM EAS00905 DIAGNOSTIC MODE It is possible to monitor the sensor output data or check the activation of actuators without con- necting the measurement equipment by simply switching the meter indication from the normal mode to the diagnostic monitoring mode. Setting the diagnostic mode 1.

• Page 344
  FUEL INJECTION SYSTEM 7. Verify the operation of the sensor or actuator. S Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. S Actuator operation Set the engine stop switch to “ON” to operate the actuator.
• Page 345
  FUEL INJECTION SYSTEM Fault code table Fault Diagnostic Symptom Probable cause of malfunction code No. code S Open or short circuit in wiring harness. No normal signals are received from S Defective crankshaft position sensor. the crankshaft position sensor. S Malfunction in pickup rotor. —…
• Page 346
  FUEL INJECTION SYSTEM Fault Diagnostic Symptom Probable cause of malfunction code No. code S Malfunction in ECU. (The program and data are not Faulty ECU memory. When this malfunction is detected, the code properly written on or read from the internal memory.) —…
• Page 347
  FUEL INJECTION SYSTEM EAS00907 Diagnostic mode table Switch the meter display from the regular mode to the diagnostic mode. To switch the display, refer to “DIAGNOSTIC MODE”. NOTE: S Check the intake air temperature and coolant temperature as close as possible to the intake air tem- perature sensor and the coolant temperature sensor respectively.
• Page 348
  FUEL INJECTION SYSTEM Diagnostic Data displayed on meter Item Description of action code (reference value) AI system solenoid After 1 second has elapsed from the time the engine stop Check the operating sound of switch has been turned from OFF to ON, it actuates the AI the AI system solenoid 5 times system solenoid five times every second and illuminates the with the engine stop…

• Page 349: Troubleshooting Details

  FUEL INJECTION SYSTEM EAS00908 TROUBLESHOOTING DETAILS This section describes the countermeasures per fault code number displayed on the meter. Check and service the items or components that are the probable cause of the malfunction following the order. After the check and service of the malfunctioned part has been completed, reset the meter display ac- cording to the “Reinstatement method”.

• Page 350
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor — open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it Reinstated by Inspect the coupler for any pins that…
• Page 351
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor — hose system malfunction (clogged or detached hose). Used diagnostic code No. 03 (intake air pressure sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Intake air pressure sensor hose de-…
• Page 352
  FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Used diagnostic code No. 01 (throttle position sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Installed condition of throttle position Check the installed area for looseness or pinching. Reinstated by sensor.
• Page 353
  FUEL INJECTION SYSTEM Fault code No. Symptom Open or short circuit detected from the intake air temperature sensor. Used diagnostic code No. 05 (intake air temperature sensor) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Installed condition of sensor Check the installed area for looseness or Reinstated by…
• Page 354
  FUEL INJECTION SYSTEM Fault code No. Symptom The motorcycle has overturned. Used diagnostic code No. 08 (lean angle cut-off switch) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by The motorcycle has overturned. Raise the motorcycle upright. turning the Installed condition of the lean angle cut- Check the installed area for looseness or…
• Page 355
  FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary lead of the ignition coil (#1, #4). Used diagnostic code No. 30 (ignition coil #1, #4) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Connected condition of connector If there is a malfunction, repair it and connect it…
• Page 356
  FUEL INJECTION SYSTEM Fault code No. Symptom 1 No normal signals are received from the speed sensor. 2 Open or short circuit is detected in the neutral switch. Used diagnostic code No. 07 (speed sensor) ! A1 X A4 No. 21 (neutral switch) ! B1 X B4 Order Inspection operation item and probable Operation item and countermeasure Reinstatement…
• Page 357
  FUEL INJECTION SYSTEM Fault code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 09 (fuel system voltage) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.
• Page 358
  FUEL INJECTION SYSTEM Fault code No. Symptom Error is detected while reading or writing on EEP-ROM (CO adjustment value). Used diagnostic No. 60 (EEP-ROM improper cylinder indication) Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Malfunction in ECU Execute diagnostic code 60 Reinstated by…
• Page 359
  FUEL INJECTION SYSTEM Fault code No. Er-1 Symptom No signals are received from the ECU. Used diagnostic code No. – – Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.
• Page 360
  FUEL INJECTION SYSTEM Fault code No. Er-4 Symptom Non-registered data has been received from the meter. Used diagnostic code No. – – Order Inspection operation item and probable Operation item and countermeasure Reinstatement cause method Reinstated by Connected condition of connector If there is a malfunction, repair it and connect it Inspect the coupler for any pins that securely.

• Page 361: Throttle Bodies

  THROTTLE BODIES EAS00909 THROTTLE BODIES Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS” in chapter 3. Fuel tank Refer to “FUEL TANK”…

• Page 362
  THROTTLE BODIES Order Job/Part Q’ty Remarks Plunger control unit hose Disconnect For installation, reverse the removal procedure. 7-26…

• Page 363: Injectors

  THROTTLE BODIES EAS00910 INJECTORS Order Job/Part Q’ty Remarks Removing the injectors Remove the parts in the order listed. Throttle position sensor coupler Disconnect Intake air pressure sensor coupler Disconnect Cylinder #1-injector coupler Cylinder #2-injector coupler Cylinder #3-injector coupler Cylinder #4-injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor…

• Page 364: Checking The Injectors

  THROTTLE BODIES EAS00911 CAUTION: The throttle bodies should not be disas- sembled. EAS00912 CHECKING THE INJECTORS 1. Check: S injectors Damage ! Replace. EAS00913 CHECKING THE THROTTLE BODIES 1. Check: S throttle bodies Cracks/damage ! Replace the throttle bo- dies as a set. 2.

• Page 365: Checking The Fuel Pump And Pressure Regulator Operation

  THROTTLE BODIES CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: S fuel pump operation Refer to “FUEL TANK” in chapter 3. a. Remove the seat fuel tank. Refer to “SEAT AND FUEL TANK” in chapter b. Connect the pressure gauge 1 and adapter 2 onto the fuel injection pipe.

• Page 366: Checking And Adjusting The Throttle Position Sensor

  THROTTLE BODIES EAS00916 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR NOTE: Before adjusting the throttle position sensor, the engine idling speed should be properly ad- justed. 1. Check: S throttle position sensor a. Disconnect the throttle position sensor cou- pler. b.

• Page 367
  THROTTLE BODIES f. While slowly opening the throttle, check that the throttle position sensor resistance is with- in the specified range. The resistance does not change or it changes abruptly ! Replace the throttle position sensor. The slot is worn or broken ! Replace the throttle position sensor.

• Page 368: Air Induction System

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

• Page 369: Air Induction System Diagrams

  AIR INDUCTION SYSTEM EAS00509 AIR INDUCTION SYSTEM DIAGRAMS 1 Air cut-off valve A To cylinder #1 and #2 2 Reed valve B To cylinder #3 and #4 3 To air filter case 7-33…

• Page 370: Checking The Air Induction System

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

• Page 371
  AIR INDUCTION SYSTEM 5. Check S AI system solenoid a. Remove the AI system solenoid coupler from the wire harness. b. Connect the pocket tester (Ω 1) to the AI system solenoid terminal as shown. Tester positive probe ! brown/red 1 Tester negative probe ! red/white 2 c.

• Page 372: Elec

  ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Main switch Oil level switch Front brake light switch Radiator fan motor Starter relay Horn Battery Ignition coil Fuse box Rear brake light switch Neutral switch Sidestand switch…

• Page 373
  ELEC ELECTRICAL COMPONENTS Coolant temperature sensor Radiator fan motor relay Intake air temperature sensor Turn signal relay Intake air pressure sensor Rectifier/ regulator Fuel pump Throttle position sensor Lean angle cut-off switch Starting circuit cut-off relay Dimmer relay…

• Page 374: Checking Switch Continuity

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

• Page 375: Checking The Switches

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

• Page 376: Checking The Bulbs And Bulb Sockets

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

• Page 377: Checking The Condition Of The Bulb Sockets

  ELEC CHECKING THE BULBS AND BULB SOCKETS CAUTION: S Be sure to hold the socket firmly when re- moving the bulb. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler. S Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb, and the luminous flux will be adverse-…

• Page 378: Checking The Leds

  ELEC CHECKING THE BULBS AND BULB SOCKETS Pocket tester 90890-03112, YU-3112 NOTE: Check each bulb socket for continuity in the same manner as described in the bulb section; however, note the following. a. Install a good bulb into the bulb socket. b.

• Page 379: Ignition System

  ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Ignition coil #1 and #4 Battery ignition coil #2 and #3 Starting circuit cut-off relay Spark plug Sidestand switch Engine stop switch Neutral switch Fuse (ignition) Lean angle cut-off switch Clutch switch Crankshaft position sensor…

• Page 380: Troubleshooting

  ELEC IGNITION SYSTEM EAS00737 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The ignition system fails to operate (no Refer to “CHECKING AND CHARGING spark or intermittent spark). THE BATTERY” in chapter 3. Check: Minimum open-circuit voltage 1.

• Page 381
  ELEC IGNITION SYSTEM EAS00743 4. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker and spark plug cap as shown. S Set the main switch to “ON”. S Measure the ignition spark gap Spark plug cap resistance S Crank the engine by pushing the starter…
• Page 382
  ELEC IGNITION SYSTEM Negative tester probe ! Crankshaft position sensor resis- spark plug lead tance Positive tester probe ! 248 X 372 Ω at 20_C (68_F) spark lug lead (between gray and black) S Is the crankshaft position sensor OK? Replace the crank- shaft position sen- sor.
• Page 383
  ELEC IGNITION SYSTEM EAS00752 Positive tester probe ! 11. Sidestand switch sky blue S Check the sidestand switch for continuity. Negative tester probe ! Refer to “CHECKING THE SWITCHES”. black/red S Is the sidestand switch OK? Positive tester probe ! continuity blue/green Negative tester probe !
• Page 384
  ELEC IGNITION SYSTEM EAS00754 15. Wiring S Check the entire ignition system’s wiring. Refer to “CIRCUIT DIAGRAM”. S Is the ignition system’s wiring properly con- nected and without defects? Replace the ECU. Properly connect or repair the ignition system’s wiring. 8-13…

• Page 385: Electric Starting System

  ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM Main switch Sidestand switch Fuse (main) Neutral switch Starter relay Engine stop switch Starter motor Start switch Battery Fuse (ignition) Starting circuit cut-off relay Clutch switch 8-14…

• Page 386: Starting Circuit Cut-Off System Operation

  ELEC ELECTRIC STARTING SYSTEM EAS00756 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: S The transmission is in neutral (the neutral switch is closed).

• Page 387: Troubleshooting

  ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. The starter motor fails to turn. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main and ignition fuses Minimum open-circuit voltage 2.

• Page 388
  ELEC ELECTRIC STARTING SYSTEM EAS00759 4. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the starting circuit cut-off relay coupler as shown.
• Page 389
  ELEC ELECTRIC STARTING SYSTEM EAS00752 EAS00766 9. Sidestand switch 12. Wiring S Check the sidestand switch for continuity. S Check the entire starting system’s wiring. Refer to “CHECKING THE SWITCHES”. Refer to “CIRCUIT DIAGRAM”. S Is the sidestand switch OK? S Is the starting system’s wiring properly con- nected and without defects? Replace the side-…

• Page 390: Starter Motor

  ELEC STARTER MOTOR EAS00767 STARTER MOTOR 10 Nm (1.0 mSkg, 7.2 ftSlb) 5 Nm (0.5 mSkg, 3.6 ftSlb) Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Seat Refer to “SEAT” in chapter 3. Front cowling inner panel (left and right) Refer to “COWLINGS”…

• Page 391
  ELEC STARTER MOTOR EAS00768 7.8 Nm (0.78 mSkg, 5.6 ftSlb) 3.4 Nm (0.34 mSkg, 2.5 ftSlb) Order Job/Part Q’ty Remarks Disassembling the starter motor Disassembly the parts in the order listed. O-ring Front cover Lock washer Oil seal Bearing Washer set Rear cover Washer set O-ring…

• Page 392: Checking The Starter Motor

  ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: S commutator Dirt ! Clean with 600 grit sandpaper. 2. Measure: S commutator diameter a Out of specification ! Replace the starter motor. Commutator wear limit 27 mm (1.06 in) 3.

• Page 393: Assembling The Starter Motor

  ELEC STARTER MOTOR 5. Measure: S brush length a . Out of specification ! Replace the brushes as a set. Brush length wear limit 3.5 mm (0.14 in) 6. Measure: S brush spring force Out of specification ! Replace the brush springs as a set.

• Page 394
  ELEC STARTER MOTOR 3. Install: S starter motor yoke 1 S O-ring 2 S front cover 3 Srear cover 4 S bolts 5 3.4 Nm (0.34 mSkg, 2.5 ftSlb) NOTE: Align the match marks a on the starter motor yoke with the match marks b on the front and starter motor rear covers.

• Page 395: Charging System

  ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM A.C. magneto Rectifier/ regulator Fuse (main) Battery 8-24…

• Page 396: Troubleshooting

  ELEC CHARGING SYSTEM EAS00774 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) The battery is not being charged. S Is the battery OK? Check: 1. main fuse 2. battery S Clean the battery 3. charging voltage 4. stator coil lead terminals.

• Page 397
  ELEC CHARGING SYSTEM EAS00776 4. Stator coil lead 5. Stator coil resistance S Disconnect stator coil lead coupler. S Remove the generator cover. S Connect the pocket tester (Ω S Connect the pocket tester (Ω 1) to the sta- 1) to the sta- tor coil lead coupler as shown.

• Page 398: Lighting System

  ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 8-27…

• Page 399
  ELEC LIGHTING SYSTEM Main switch Fuse (main) Battery High beam indicator light Fuse (headlight) Fuse (ignition) Fuse (tail) License plate light Tail / brake light Dimmer switch Dimmer relay Headlight (high beam) Headlight (low beam) Front turn signal/position light (right) Front turn signal/position light (left) 8-28…

• Page 400: Troubleshooting

  ELEC LIGHTING SYSTEM EAS00781 Minimum open-circuit voltage TROUBLESHOOTING 12.8 V or more at 20_C (68_F) Any of the following fail to light: headlight, S Is the battery OK? high beam indicator light, taillight, licence light or meter light. Check: S Clean the battery 1.

• Page 401
  ELEC LIGHTING SYSTEM 5. Dimmer relay S Disconnect the dimmer relay from the cou- pler. S Connect the pocket tester (Ω 1) and bat- tery (12 V) to the dimmer relay as shown. Positive battery lead ! red/yellow Negative battery lead ! yellow/black Positive tester probe ! red/yellow Negative tester probe ! green S Does the dimmer relay have continuity be-…

• Page 402: Checking The Lighting System

  ELEC LIGHTING SYSTEM EAS00788 Headlight CHECKING THE LIGHTING SYSTEM Positive tester probe ! black 1. The headlight and the high beam indicator Negative tester probe ! black/yellow light fail to come on. Headlight coupler (wire harness side) 1. Headlight bulb and socket High beam S Check the headlight bulb and socket for con- tinuity.

• Page 403
  ELEC LIGHTING SYSTEM EAS00792 2. The license plate light fails to come on. 1. License plate light bulb and socket S Check the license plate light bulb and socket for continuity. Refer to “CHECKING THE BULBS AND BULB SOCKETS”. S Are the license plate light bulb and socket Replace the license plate light bulb, sock- et or both.
• Page 404
  ELEC LIGHTING SYSTEM EAS00790 EAS00791 3. The tail/brake light fails to come on. 4. The turn signal/position light fails to come on. 1. Tail/brake light bulb and socket 1. Turn signal/position light and socket S Check the tail/brake light bulb and socket for S Check the turn signal/position light bulb and continuity.

• Page 405: Signaling System

  ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 8-34…

• Page 406
  ELEC SIGNALING SYSTEM Main switch Fuse (backup) Fuse (main) Battery Starting circuit cut-off relay Neutral switch Fuel pump Oil level waning light Neutral indicator light Multi-function meter Turn signal indicator light Oil level switch Front brake light switch Fuse (signal) Fuse (ignition) Fuse (tail) Turn signal relay…

• Page 407: Troubleshooting

  ELEC SIGNALING SYSTEM EAS00794 TROUBLESHOOTING S Any of the following fail to light: turn sig- nal light, brake light or an indicator light. S Clean the battery S The horn fails to sound. terminals. S Recharge or re- Check: place the battery. 1.

• Page 408
  ELEC SIGNALING SYSTEM EAS00797 2. Voltage 2. The tail/brake light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Tail/brake light bulb and socket horn connector at the horn terminal as S Check the tail/brake light bulb and socket for shown.
• Page 409
  ELEC SIGNALING SYSTEM S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) on brown/ green at the turn signal relay coupler (wire wiring circuit This circuit is OK. harness side). from the main switch S Is the voltage within specification? to the tail/brake light coupler is faulty and must be repaired.
• Page 410
  ELEC SIGNALING SYSTEM Left turn signal/position light Positive tester probe ! ground Negative tester probe ! chocolate Replace the meter Right turn signal/position light assembly. Positive tester probe ! ground Negative tester probe ! dark green 2. Neutral switch S Check the neutral switch for continuity. Refer to “CHECKING THE SWITCHES”.
• Page 411
  ELEC SIGNALING SYSTEM EAS00802 S Are the tester readings correct? 5. The oil level warning light fails to come on. 1. Oil level warning light (LEDs) S Check the oil level warning light for continu- ity. Replace the starting When the main switch is turn to “ON”, the oil circuit cut-off relay.
• Page 412
  ELEC SIGNALING SYSTEM EAS00803 3. Voltage 6. The fuel level warning light fails to come on. S Connect the pocket tester (DC 20 V) to the 1. Fuel sender meter assembly coupler (wire harness side) S Drain the fuel from the fuel tank and remove as shown.
• Page 413
  ELEC SIGNALING SYSTEM 2. Voltage S Connect the pocket tester (DC 20 V) to the meter assembly coupler (wire harness side) as shown. Positive tester probe ! green/white Negative tester probe ! black/white S Turn the main switch to “ON”. S Measure the voltage (DC 12 V) of green/white and black/white…

• Page 414: Cooling System

  ELEC COOLING SYSTEM EAS00807 COOLING SYSTEM CIRCUIT DIAGRAM Main switch Fuse (main) Battery Coolant temperature sensor Fuse (radiator fan motor) Radiator fan motor relay Radiator fan motor Fuse (ignition) 8-43…

• Page 415: Troubleshooting

  ELEC COOLING SYSTEM EAS00808 EAS00739 TROUBLESHOOTING 2. Battery S Check the condition of the battery. S The radiator fan motor fails to turn. S The coolant temperature indicator light Refer to “CHECKING AND CHARGING THE BATTERY” in chapter 3. fails to light when the engine is warm. Minimum open-circuit voltage Check: 12.8 V or more at 20_C (68_F)

• Page 416
  ELEC COOLING SYSTEM EAS00809 5. Radiator fan motor relay 4. Radiator fan motor S Disconnect the radiator fan motor coupler S Disconnect the radiator fan motor relay from the wire harness. form the wire harness. S Connect the battery (DC 12 V) as shown. S Connect the pocket tester (Ω…
• Page 417
  ELEC COOLING SYSTEM EAS00812 6. Coolant temperature sensor S Remove the coolant temperature sensor. S Connect the pocket tester (Ω 1k) to the coolant temperature sensor as shown. S Immerse the coolant temperature sensor in a container filled with coolant NOTE: Make sure the coolant temperature sensor terminals do not get wet.

• Page 418: Fuel Pump System

  ELEC FUEL PUMP SYSTEM EAS00814 FUEL PUMP SYSTEM CIRCUIT DIAGRAM Main switch Fuse (fuel injection) Fuse (main) Battery Starting circuit cut-off relay Fuel pump Engine stop switch Fuse (ignition) 8-47…

• Page 419
  ELEC FUEL PUMP SYSTEM EAS00815 FUEL PUMP SYSTEM Battery The ECU includes the control unit for the Fuse (main) fuel pump. Main switch Fuse (ignition) Engine stop switch Fuse (fuel injection) Starting circuit cut-off relay (fuel injection system relay) Fuel pump 8-48…

• Page 420: Troubleshooting

  ELEC FUEL PUMP SYSTEM EAS00816 EAS00739 TROUBLESHOOTING 2. Battery If the fuel pump fails to operate. S Check the condition of the battery Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition and fuel injection fuses Minimum open-circuit voltage 2.

• Page 421
  ELEC FUEL PUMP SYSTEM EAS00759 EAS00817 5 Starting circuit cut-off relay (fuel injection 6. Fuel pump resistance system relay) S Disconnect the fuel pump coupler from the S Disconnect the starting circuit cut-off relay wire harness. S Connect the pocket tester (Ω coupler from the wire harness.

• Page 422: Checking The Fuel Pump

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

• Page 423: Self-Diagnosis

  ELEC SELF-DIAGNOSIS SELF-DIAGNOSIS The FZ6-SS/FZ6-SSC features a self-diagnosing system for the following circuit(-s): S Fuel pump thermistor S Oil level switch If any of these circuits are defective, their respective condition codes will be displayed on the warning light when the main switch is turned “ON” (irrespective of whether the engine is running or not).

• Page 424
  ELEC SELF-DIAGNOSIS TROUBLESHOOTING 1. Wire harness The warning light starts to indicate the S Check the wire harness for continuity. self-diagnosis sequence. Refer to “CIRCUIT DIAGRAM”. S Is the wire harness OK? Check: 1. fuel pump thermistor 2. oil level switch NOTE: S Before troubleshooting, remove the following Repair or replace the…
• Page 425
  ELEC SELF-DIAGNOSIS 2. Oil level switch 2. Oil level switch CIRCUIT DIAGRAM S Check the oil level switch for continuity. Refer to “The oil level warning light fails to come on”. S Is the oil level switch OK? Replace the multi- Replace the oil level function meter.

• Page 426: Troubleshooting

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

• Page 427: Trbl Shtg

  STARTING FAILURE/INCORRECT ENGINE IDLING SPEED/ TRBL POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE SHTG Switches and wiring Starting system S Faulty main switch S Faulty starter motor S Faulty engine stop switch S Faulty starter relay S Broken or shorted wiring S Faulty starting circuit cut-off relay S Faulty neutral switch S Faulty starter clutch S Faulty start switch…

• Page 428: Faulty Gear Shifting

  TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”. Shift shaft S Incorrect shift pedal position SHIFT PEDAL DOES NOT MOVE S Improperly returned stopper lever Shift shaft S Improperly adjusted shift rod Shift forks S Bent shift shaft.

• Page 429: Overheating

  OVERHEATING/OVERCOOLING/ TRBL POOR BRAKING PERFORMANCE SHTG EAS00855 OVERHEATING ENGINE FUEL SYSTEM Clogged coolant passages Throttle body(-ies) S Cylinder head(s) and piston(s) S Damaged or loose carburetor joint S Heavy carbon buildup Air filter S Clogged air filter element Engine oil S Incorrect oil level CHASSIS S Incorrect oil viscosity…

• Page 430: Faulty Front Fork Legs

  TRBL FAULTY FRONT FORK LEGS/UNSTABLE HANDLING SHTG EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL S Bent, damaged or rusty inner tube S Cracked or damaged outer tube S Improperly installed oil seal S Damaged oil seal lip S Incorrect oil level (high) S Loose damper rod assembly bolt S Damaged damper rod assembly bolt copper washer S Cracked or damaged cap bolt O-ring…

• Page 431: Faulty Lighting Or Signaling System

  TRBL FAULTY LIGHTING OR SIGNALING SYSTEM SHTG EAS00866 FAULTY LIGHTING OR SIGNALING SYSTEM HEADLIGHT DOES NOT COME ON TURN SIGNAL DOES NOT COME ON S Wrong headlight bulb S Faulty turn signal switch S Too many electrical accessories S Faulty turn signal relay S Hard charging S Burnt-out turn signal bulb S Incorrect connection…

• Page 432
  FZ6-SS/FZ6-SSC WIRING DIAGRAM Br/W G/W Br/W Y R/B R/L R/W L/R Y Y/L R/G P/W B/L G/B L G/W W Ch Dg Lg B/W WIRE HARNESS SUB-WIRE HARNESS 2 WIRE HARNESS SUB-WIRE HARNESS 1 WIRE HARNESS HEADLIGHT SUB WIRE HARNESS 2…
• Page 433
  FZ6-SS/FZ6-SSC WIRING DIAGRAM…
• Page 434
  FZ6-SS/FZ6-SSC WIRING DIAGRAM Main switch Hazard switch A.C. magneto Turn signal switch Rectifier/ regulator Horn switch Fuse (backup) Horn Fuse (fuel injection) Dimmer relay Fuse (main) Headlight (high beam) Starter relay Headlight (low beam) Starter motor Rear turn signal light (right)

OWNER’S MANUAL

FZ6-NV

FZ6-NSV

EAU10151

Particularly important information is distinguished in this manual by the following notations:

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS

INVOLVED!

NOTE:

●This manual should be considered a permanent part of this motorcycle and should remain with it even if the motorcycle is subsequently sold.

●Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your motorcycle and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer.

EWA10030

WARNING

PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTORCYCLE.

*Product and specifications are subject to change without notice.

SAFETY INFORMATION

SAFETY INFORMATION

EAU10381

Location of important labels

Please read the following important labels carefully before operating this vehicle.

1

SAFETY INFORMATION

Before you operate this vehicle, read the owner’s manual.

Prima di usare il veicolo, leggete il manuale di istruzioni. 1

Lire le manuel du propriétaire avant d’utiliser ce véhicule.

Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.

Antes de conducir este vehículo, lea el Manual del Propietario.

5PA-21568-00

5

2

5VX-2117B-A1

3

DESCRIPTION

EAU10410

Left view

2

3.Air filter element (page 6-11)

4.Idle adjusting screw (page 6-12)

5.Shock absorber assembly spring preload adjusting ring (page 3-14)

6.Owner’s tool kit (page 6-1)

7.Storage compartment (page 3-13)

8.Shift pedal (page 3-10)

Right view

1.Fuse box (page 6-27)

2.Rear brake fluid reservoir (page 6-18)

3.Coolant reservoir cap (page 6-9)

4.Engine oil filler cap (page 6-6)

5.Front brake fluid reservoir (page 6-18)

6.Dipstick (page 6-6)

7.Brake pedal (page 3-10)

DESCRIPTION

EAU10430

Controls and instruments

2

1.Clutch lever (page 3-9)

2.Left handlebar switches (page 3-8)

3.LCD tachometer (page 3-5)

4.Multi-function display (page 3-5)

5.Right handlebar switches (page 3-8)

6.Brake lever (page 3-10)

7.Throttle grip (page 6-13)

8.Main switch/steering lock (page 3-2)

INSTRUMENT AND CONTROL FUNCTIONS

INSTRUMENT AND CONTROL FUNCTIONS

The fuel tank cap cannot be closed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly closed and locked.

EWA11090

WARNING