Yamaha warrior xv1700 мануал - RukovodstvoRus.ru - инструкции пользования и руководства

Материал из BikesWiki — энциклопедия японских мотоциклов

Перейти к: навигация, поиск

Ниже представлены прямые ссылки на скачку сервисной документации.

Для Yamaha XV1700A/P (Road Star, Warrior)

Руководство пользователя (Owners Manual) на Yamaha XV1700A (XV17AV, XV17AWV, XV17AMV, XV17ATV, XV17ATMV)
Дополнение к сервисному мануалу (Supplementary Service Manual) на Yamaha XV1700A (XV17AS, XV17ASS, XV17ATS)
Сервисный мануал (Service Manual) на Yamaha XV1700P/PC Warrior (оригинальный, 2001, на английском)
Сервисный мануал (Service Manual) на Yamaha XV1700P/PC Warrior (русский перевод, 2001)

Обзор модели

Yamaha XV1700

Источник

Contents
Table of Contents
Troubleshooting
Bookmarks

Related Manuals for Yamaha XV1700PCRC

Summary of Contents for Yamaha XV1700PCRC

Page 1
XV1700PCR XV1700PCRC SUPPLEMENTARY SERVICE MANUAL LIT-11616-16-36 5PX-28197-11…
Page 2
FOREWORD This Supplementary Service Manual has been prepared to introduce new service and data for the XV1700PCR/XV1700PCRC. For complete service information procedures it is necessary to use this Supplementary Service Manual together with the following manual. XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10)
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
EAS00009 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 8 indicate the INFO subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting TRBL…
Page 6: Table Of Contents

CONTENTS SPECIFICATIONS ………………. 1 GENERAL SPECIFICATIONS …………..1 ENGINE SPECIFICATIONS …………..1 CHASSIS SPECIFICATIONS …………..1 ELECTRICAL SPECIFICATIONS …………2 TIGHTENING TORQUES …………….. 2 CHASSIS TIGHTENING TORQUES ………… 2 CABLE ROUTING ………………3 PERIODIC CHECKS AND ADJUSTMENTS ……….11 INTRODUCTION ………………11 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ……….
Page 7: Specifications

GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS/CHASSIS SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PX4 (USA) —- 5PX5 (California) —- 5PX6 (CDN) —- ENGINE SPECIFICATIONS Item Standard Limit Electronic fuel injection Model (manufacturer) INP-732 (NIPPON INJECTOR) —- Quantity —- Crankshaft Width A 132.8 ~ 133.2 mm (5.228 ~ 5.244 in) —-…
Page 8: Electrical Specifications

—- Secondary coil resistance 12 ~ 18 kΩ —- Charging system System type AC magneto —- Model (manufacturer) F5PX (YAMAHA) —- Nominal output 14 V/31 A at 5,000 r/min —- 0.13 ~ 0.19 Ω/W–W Stator coil resistance/color —- TIGHTENING TORQUES…
Page 9: Cable Routing

SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Brake hose È Fasten the rectifier/regulator Ê Fasten the rear brake light 2 Clutch cable lead, horn lead, and rear brake switch lead, horn lead, and 3 Rectifier/regulator light switch lead with a plastic stator coil assembly lead with 4 Rectifier/regulator lead locking tie to the frame.
Page 10
SPEC CABLE ROUTING 1 Tachometer couplers È Secure the wire harness in the holder at the 2 Right handlebar switch coupler and speedome- white tape on the harness. É Route each lead behind the headlight assembly ter couplers 3 Main switch coupler bracket bolts.
Page 11
SPEC CABLE ROUTING 1 Throttle cable 1 and throttle cable 2 È Pass throttle cable 1 and throttle cable 2 through 2 Clutch cable the cable guide, and then fasten them with a 3 Atmospheric pressure sensor plastic holder. 4 Spark plug cap (ignition coil 1-L spark plug lead) É…
Page 12
SPEC CABLE ROUTING Ë Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking tie. Ì Fasten the starter motor lead and side stand switch lead with a plastic locking tie to the frame. Í…
Page 13
SPEC CABLE ROUTING 1 Ignition coil 1 È To the rectifier/regulator, horn 1, and rear brake 2 Atmospheric pressure sensor lead light switch. 3 Ignition coil 2 É 30 ~ 50 degrees 4 Ignition coil 2 lead Ê 40 ~ 60 degrees 5 Rear brake light switch coupler 6 Rectifier/regulator lead and horn lead 7 Linear control valve lead…
Page 14
SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 H Ignition coil 1-R spark plug lead 2 Fuel hose 0 Throttle cables I Lean angle cut-off switch lead 3 Spark plug cap (ignition coil 1-R A Brake hose J Crankshaft position sensor lead B Spark plug cap (ignition coil 2-R K Sidestand switch lead…
Page 15
SPEC CABLE ROUTING È To the battery box. Í Fasten the main wire harness, intake air pres- É Fasten the main wire harness and fuel hose with sure sensor lead #2, ignition coil 1-R spark plug a plastic locking tie to the frame. lead, and intake air temperature sensor coupler Ê…
Page 16
SPEC CABLE ROUTING Ð To the injector sub lead. × To the speed sensor. Ñ To the engine temperature sensor. Ø Fasten the crankshaft position sensor lead, side- Ò 10 30 mm (0.4 1.2 in) stand switch lead, lean angle cut-off switch lead, Ó…
Page 17: Periodic Checks And Adjustments

Evaporative Emission control • Check control system for damage. √ √ system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. – 11 –…
Page 18: General Maintenance And Lubrication Chart

√ √ √ √ — ing and cable free play if necessary. • Lubricate the throttle grip housing and cable. Yamaha Chain and • Apply chain lube thor- Cable Lube or √ √ √ √ √ √ 9 * Control cables oughly.
Page 19
Every 2,500 mi (4,000 km) • Adjust if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
Page 20: Chassis

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHASSIS 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 mini- mum adjustment positions. 1.
Page 21: Adjusting The Rear Shock Absorber

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Rebound damping CAUTION: Never go beyond the maximum or mini- mum adjustment positions. 1. Adjust: • rebound damping M MMM M MMM M MMM M MMM M MMM a. Turn the adjusting knob 1 in direction a or Rebound damping is Direction a increased (suspension…
Page 22
CHAS FRONT AND REAR BRAKES CHASSIS FRONT AND REAR BRAKES REAR BRAKE MASTER CYLINDER 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • •…
Page 23
CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •…
Page 24: Rear Shock Absorber And Swingarm

CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 25
CHAS REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 26
CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
Page 27
CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Swingarm Dust cover Spacer Bearing For installation, reverse the removal…
Page 28: Engine

ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ENGINE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft •…
Page 29
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 30: Generator And Starter Clutch

GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH STATOR COIL ASSEMBLY 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 31
GENERATOR AND STARTER CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 48 Nm (4.8 m kg, 35 ft •…
Page 32
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
Page 33
XV1700P XV1700PC SERVICEMANUAL LIT-11616-15-37 5PX-28197-10…
Page 34
EAS00001 XV1700P/XV1700PC SERVICE MANUAL ©2001 by Yamaha Motor Corporation, U.S.A. First edition, October 2001 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-11616-15-37…
Page 35
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 36
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 37
EAS00009 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 8 indicate the INFO subject of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments CHAS 4 Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting TRBL…
Page 38
EAS00013 TABLE OF CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECKS AND ADJUSTMENTS CHASSIS CHAS ENGINE FUEL INJECTION SYSTEM – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG…
Page 39: Table Of Contents

CONTENTS CHAPTER 1 GENERAL INFORMATION MOTORCYCLE IDENTIFICATION …………..1-1 VEHICLE IDENTIFICATION NUMBER ………….1-1 MODEL LABEL………………1-1 FEATURES ………………….1-2 OUTLINE ………………..1-2 FI SYSTEM ………………..1-3 COMPONENTS ………………1-5 FUEL INJECTION SYSTEM …………..1-17 FIRST IDLE CONTROL SYSTEM …………1-28 COMPONENTS ………………1-29 IMPORTANT INFORMATION…………….1-32 PREPARATION FOR REMOVAL AND DISASSEMBLY ……1-32 REPLACEMENT PARTS ……………..1-32 GASKETS, OIL SEALS AND O-RINGS ……….1-32 LOCK WASHERS/PLATES AND COTTER PINS ……..1-33…
Page 40: Table Of Contents

TIGHTENING TORQUES …………….2-21 ENGINE TIGHTENING TORQUES …………2-21 CHASSIS TIGHTENING TORQUES …………2-24 LUBRICATION POINTS AND LUBRICANT TYPES……..2-27 ENGINE ………………..2-27 CHASSIS ………………..2-28 ENGINE OIL LUBRICATION CHART …………2-29 ENGINE OIL FLOW DIAGRAMS …………..2-30 TRANSFER GEAR OIL FLOW DIAGRAMS ……….2-34 CABLE ROUTING ………………2-36 CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION………………..3-1 PERIODIC MAINTENANCE CHART…
Page 41
ENGINE………………….3-11 ADJUSTING THE VALVE CLEARANCE……….3-11 SYNCHRONIZING THE THROTTLE BODIES ……..3-15 ADJUSTING THE ENGINE IDLING SPEED ………..3-17 ADJUSTING THE THROTTLE CABLE FREE PLAY…….3-18 CHECKING THE SPARK PLUGS …………3-20 CHECKING THE IGNITION TIMING …………3-22 MEASURING THE COMPRESSION PRESSURE ……..3-23 CHECKING THE ENGINE OIL LEVEL …………3-26 CHANGING THE ENGINE OIL…………..3-27 MEASURING THE ENGINE OIL PRESSURE ……..3-31 CHECKING THE TRANSFER GEAR OIL LEVEL ……..3-32…
Page 42
INSTRUMENT FUNCTIONS…………….3-70 ODOMETER AND TRIPMETER…………..3-70 ADJUSTING THE METER LIGHT …………3-71 ADJUSTING THE CLOCK ……………3-71 CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISCS …………4-1 REMOVING THE FRONT WHEEL …………4-4 CHECKING THE FRONT WHEEL …………4-4 CHECKING THE BRAKE DISCS …………..4-6 INSTALLING THE FRONT WHEEL …………4-7 ADJUSTING THE FRONT WHEEL STATIC BALANCE……4-9 REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY…..4-11 REMOVING THE REAR WHEEL …………4-17…
Page 43
FRONT FORK………………..4-55 REMOVING THE FRONT FORK LEGS ……….4-58 DISASSEMBLING THE FRONT FORK LEGS ……..4-58 CHECKING THE FRONT FORK LEGS………..4-60 ASSEMBLING THE FRONT FORK LEGS ……….4-62 INSTALLING THE FRONT FORK LEGS……….4-67 HANDLEBAR………………..4-69 REMOVING THE HANDLEBAR …………..4-71 CHECKING THE HANDLEBAR……………4-71 INSTALLING THE HANDLEBAR………….4-71 STEERING HEAD………………4-75 REMOVING THE LOWER BRACKET ………….4-77 CHECKING THE STEERING HEAD …………4-77…
Page 44
CHAPTER 5 ENGINE ENGINE………………….5-1 INSTALLING THE ENGINE ……………5-9 INSTALLING THE MUFFLER AND EXHAUST PIPES……5-10 ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ……5-11 REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS………………5-16 CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS..5-16 CHECKING THE ROCKER ARM BASES ……….5-18 CHECKING THE PUSH RODS ……………5-18 CHECKING THE VALVE LIFTERS AND VALVE LIFTER CASES..5-18 BLEEDING A VALVE LIFTER …………..5-19…
Page 45
CLUTCH………………….5-56 CLUTCH COVER ………………5-56 CLUTCH ………………..5-59 REMOVING THE CLUTCH …………..5-61 REMOVING THE PRIMARY DRIVE GEAR ……….5-62 CHECKING THE FRICTION PLATES ………….5-62 CHECKING THE CLUTCH PLATES …………5-62 CHECKING THE CLUTCH PLATE SPRING ………..5-63 CHECKING THE CLUTCH HOUSING …………5-63 CHECKING THE CLUTCH BOSS …………5-63 CHECKING THE PRESSURE PLATE …………5-64 CHECKING THE PULL LEVER SHAFT AND PULL ROD…….5-64 CHECKING THE PRIMARY DRIVE …………5-64…
Page 46
CRANKCASE ………………..5-93 DISASSEMBLING THE CRANKCASE …………5-96 CHECKING THE CRANKCASE …………..5-97 CHECKING THE BEARINGS AND OIL SEALS ……..5-98 CHECKING THE OIL DELIVERY PIPE ………..5-98 CHECKING THE ENGINE OIL PUMP DRIVE………5-98 ASSEMBLING THE CRANKCASE …………5-99 ENGINE OIL PUMP ………………5-102 CHECKING THE OIL PUMP …………..5-105 CHECKING THE RELIEF VALVE …………5-105 CHECKING THE OIL STRAINER…………5-106 ASSEMBLING THE OIL PUMP ………….5-106…
Page 47
AIR INDUCTION SYSTEM …………….6-43 AIR INJECTION ………………6-43 AIR CUT-OFF VALVE …………….6-43 AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES…………6-44 REED VALVES………………6-45 CHECKING THE PRESSURE REGULATOR……….6-46 CHECKING THE AIR INDUCTION SYSTEM ……….6-46 CHAPTER 7 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS…………….7-1 ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS ………………..7-3 CHECKING SWITCH CONTINUITY …………..7-8 CHECKING THE SWITCHES …………….7-10…
Page 48
LIGHTING SYSTEM ………………7-38 CIRCUIT DIAGRAM …………….7-38 TROUBLESHOOTING…………….7-39 CHECKING THE LIGHTING SYSTEM …………7-40 SIGNALING SYSTEM………………7-44 CIRCUIT DIAGRAM …………….7-44 TROUBLESHOOTING…………….7-46 CHECKING THE SIGNALING SYSTEM ……….7-47 FUEL INJECTION SYSTEM …………….7-54 CIRCUIT DIAGRAM …………….7-54 TROUBLESHOOTING…………….7-56 CHECKING THE FUEL PUMP …………..7-64 CHECKING AND ADJUSTING THE THROTTLE POSITION SENSOR ……….7-64 CHAPTER 8 TROUBLESHOOTING STARTING FAILURES ………………8-1…
Page 49
OVERHEATING ………………..8-4 ENGINE …………………8-4 FUEL SYSTEM ………………8-4 CHASSIS ………………..8-4 ELECTRICAL SYSTEMS …………….8-4 POOR BRAKING PERFORMANCE…………..8-4 FAULTY FRONT FORK LEGS…………….8-4 LEAKING OIL ………………..8-4 MALFUNCTION ………………8-4 UNSTABLE HANDLING………………8-5 FAULTY LIGHTING OR SIGNALING SYSTEM……….8-6 HEADLIGHT DOES NOT COME ON …………8-6 HEADLIGHT BULB BURNT OUT …………..8-6 TAIL/BRAKE LIGHT DOES NOT COME ON ……….8-6 TAIL/BRAKE LIGHT LED BURNT OUT …………8-6 TURN SIGNAL DOES NOT COME ON………….8-6…
Page 50: General Information

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 51
FEATURES INFO FEATURES OUTLINE The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti- mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera- ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the com- bustion chamber is created by the volume of the intake air and the fuel that is metered by the jet that is used in the respective chamber.
Page 52
FEATURES INFO 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 2.55 kg/cm higher than the intake manifold pres- sure. 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 53
FEATURES INFO Fuel control block The fuel control block consists of the following main components: Component Function Control block Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure adjustment Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Engine temperature sensor…
Page 54
FEATURES INFO COMPONENTS ECU (Electronic Control Unit) The ECU is mounted underneath the seat, above the battery box. The main functions of the ECU are ignition control, fuel control, self-diagnosis, and load control. • ECU’s internal construction and functions The main components and functions of the ECU can be broadly divided into the following four items: A.
Page 55
FEATURES INFO • Ignition control The ignition timing control uses the signals from the throttle position sensor (to detect the angle of the throttle), and the crankshaft position sensor (to detect the speed of the engine) and the speed sensor. This control establishes an ignition timing that suits the operating condition of the engine through compensations made to the basic ignition timing control map.
Page 56
FEATURES INFO • Self-diagnosis function The ECU is equipped with a self-diagnosis function to ensure that the engine control system is operating normally. The ECU mode functions include a diagnosis mode in addition to the normal mode. Normal mode • To check for any blown bulbs, this mode illuminates a warning light while the main switch is turned ON, and while the starter switch is being pressed.
Page 57
FEATURES INFO Fuel pump The fuel pump, which is mounted in the fuel tank, draws the fuel directly from the tank and pumps it to the injector. A filter that is provided in the fuel pump prevents any debris in the fuel tank from entering the fuel system downstream of the pump.
Page 58
FEATURES INFO Pressure regulator It regulates the fuel pressure that is applied to the injectors that supply fuel to the cylinders in order to maintain a constant pressure. The fuel that is delivered by the fuel pump fills the fuel chamber through the fuel inlet of the regulator and exerts pressure on the diaphragm in the direction for opening the valve.
Page 59
FEATURES INFO Fuel injector Upon receiving injection signals from the ECU, the fuel injector injects fuel. In the normal state, the core is pressed downward by the force of the spring, as illustrated. The needle that is integrated with the bottom of the core keeps the fuel passage closed. When the current flows to the coil in accordance with the signal from the ECU, the core is drawn upward, allowing the flange that is integrated with the needle to move to the spacer.
Page 60
FEATURES INFO Crankshaft position sensor The crankshaft position sensor uses the signals of the crankshaft position sensor that is mounted on the left side of the crankshaft. When the rotation of the pickup rotor that is attached to the crankshaft causes the projections on the rotor to pass by the crankshaft position sensor, an electromotive force is generated in the coil.
Page 61
FEATURES INFO Cylinder identification sensor The cylinder identification sensor is installed on the camshaft drive gear cover. When the cam of cyl- inder #1 rotates, the pickup rotor installed on the cam also rotates. When the pickup rotor passes by the sensor, trigger poles on the rotor generate a signal and send it to the ECU.
Page 62
FEATURES INFO Throttle position sensor The throttle position sensor measures the intake air volume by detecting the position of the throttle valve. It detects the mechanical angle of the throttle valve through the positional relationship between the moving contact that moves in unison with the throttle shaft and the resistor board. In actual operation, the ECU supplies 5 V power to both ends of the resistor board and the voltage that is output by the throttle position sensor is used to determine the angle of the throttle valve.
Page 63
FEATURES INFO Intake air pressure sensor and atmospheric pressure sensor • Intake air pressure sensor The intake air pressure sensor is used for measuring the intake air volume. The intake air volume of every intake stroke is proportionate to the intake air pressure. Therefore, the intake air volume can be measured by measuring the intake air pressure.
Page 64
FEATURES INFO Engine temperature sensor The signals from the engine temperature sensor are used primarily for making fuel volume compen- sations during starting and warm-up. The engine temperature sensor converts the temperature of the engine into electrical signals and sends them to the ECU. È…
Page 65
FEATURES INFO Lean angle cut-off switch The lean angle cut-off switch stops the supply of fuel to the engine in case the motorcycle overturns. When the motorcycle is in the normal state, the cut-off switch outputs a constant voltage of approxi- mately 1.0 V (low level).
Page 66
FEATURES INFO FUEL INJECTION SYSTEM Operation and control The fuel injection timing, injection duration, ignition timing, and the coil energizing duration are con- trolled by the ECU. To determine the basic injection timing, the ECU calculates the intake air volume through the signals from the intake air pressure sensor, throttle position sensor, cylinder identifica- tion sensor, and crankshaft position sensor.
Page 67
FEATURES INFO Fuel injection duration during linear control valve operation The linear control valve supplies air to the intake manifold when starting or during engine warm up. The intake air volume determines the basic injection duration. As the intake air increases through the linear control valve, the intake air volume corrects the basic injection duration.
Page 68
FEATURES INFO Determining the final injection duration The intake air volume determines the basic injection duration. However, at a given intake air vol- ume, the volume of fuel that is required varies by the engine operating conditions such as accelera- tion or deceleration, or by weather conditions.
Page 69
FEATURES INFO Reactive injection duration: A lag is created between the time the ECU outputs a fuel injection signal to the injector and the time the injector actually opens. Therefore, the ECU calculates this lag in advance before sending the actuation signal to the injector.
Page 70
FEATURES INFO Fuel control during normal driving In synchronous injection during normal driving, fuel is injected on a cylinder-by-cylinder basis when all of the conditions below are met: 1 Other than the stop mode 2 Cylinder identification completed 3 Other than overrun To determine the injection timing, the ECU calculates the injection timing through the use of the 3D control map provided in the ECU, which is based on the throttle position and the engine speed.
Page 71
FEATURES INFO • Fuel injection control during normal driving È É Ê Ë È #1 cylinder fuel injection timing É Basic injection duration Ê Various types of fuel injection duration compensations Ë Final injection duration (É + Ê) 1 — 22…
Page 72
FEATURES INFO Fuel injection compensation control • Starting injection control The engine temperature is used for determining the injection duration in order to ensure proper start ability. To suit the engine’s operating conditions, the starting injection duration is determined by applying a starting compensation coefficient to the basic injection duration, which forms the basis of the injection duration.
Page 73
FEATURES INFO • After-start enrichment After-start enrichment provides enrichment compensation during a prescribed duration following the starting (firing) of the engine. While the amount of fuel enrichment is determined by the after-start enrichment coefficient, the coefficient varies by the engine temperature. Although the engine tem- perature determines the initial starting enrichment coefficient, the coefficient subsequently changes in accordance with the damping factor.
Page 74
FEATURES INFO • Warm-up enrichment When the engine temperature is low, a warm-up coefficient is applied in accordance with the signals from the engine temperature sensor in order to effect fuel enrichment. Because the engine temper- ature determines the coefficient, the coefficient changes with the fluctuations in the engine tempera- ture.
Page 75
FEATURES INFO • Acceleration enrichment Acceleration enrichment is provided in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to accelerate the motorcycle from a constant speed, the throt- tle position sensor actuates in unison with the accelerator. The ECU interprets that acceleration has taken place through the throttle position sensor signal and executes acceleration enrichment.
Page 76
FEATURES INFO • Deceleration control Deceleration control is effected in accordance with the signals from the throttle position sensor. As the rider operates the accelerator to decelerate the motorcycle that is in motion, the throttle position sensor actuates in unison with the accelerator. When the engine speed is greater than a prescribed value with the throttle fully closed (thus applying engine braking), the ECU executes a deceleration fuel cut-off.
Page 77
FEATURES INFO FIRST IDLE CONTROL SYSTEM This system temporarily increases the fuel injection volume of the injectors when starting a cold engine and until the engine is warm. The system improves startability and stabilizes engine speed during engine warm up. Basic operation The ECU receives a signal from the engine temperature sensor and determines the temperature of the engine with the collected data.
Page 78
FEATURES INFO COMPONENTS Linear control valve The linear control valve sends air from the silencer box to the intake manifold to increase the intake air volume. The linear control valve consists of a stepper motor that operates the valve, a valve unit that is attached to the motor, and a main body that distributes the intake air.
Page 79
FEATURES INFO Instrument panel Function indication The indications of the self-diagnosis function can be checked and inspection operations can be per- formed through the use of the tachometer on the instrument panel. Based on the signals received from the sensors, the ECU inputs the signals into the tachometer. Then, the conditions of the sensors appear on the clock and trip/odometer display of the tachome- ter.
Page 80
FEATURES INFO 2. DIAG mode inspection and adjustment (multi-function meter) Mode Selection (Make sure to disconnect the coupler from the fuel pump.) DIAG mode Normal mode 1. While keeping both the SELECT and Turn “ON” the main switch. RESET buttons pressed, turn “ON” the * The self-diagnostic function starts a sys- main switch.
Page 81: Important Information

5. Keep all parts away from any source of fire. EAS00021 REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recom- mended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.
Page 82
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 manu-…
Page 83: Checking The Connections

CHECKING THE CONNECTIONS INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust/stains →…
Page 84: 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 inappropri- ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country.
Page 85
SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Valve spring compressor set YM-04019 This tool is used to remove or install the valve assemblies. Bearing driver YM-04058 This tool is needed when installing the crankshaft journal bearing. Valve guide remover (ø6) YM-04064-A This tool is used to remove or install the valve guides.
Page 86
SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Dynamic spark tester YM-34487 This tool is used to check the ignition system components. Valve adjuster YM-8035 This tool is used to adjust the valve clearance. Universal clutch holder YM-91042 This tool is used to hold the clutch boss when removing or installing the clutch boss nut.
Page 87
SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Carburetor synchronizer YU-08030 This gauge is needed for throttle bodies synchronization. Compression gauge set 14/18 mm Compression gauge Compression gauge adapter 12 mm YU-33223 Compression gauge adapter These tools are used to measure YU-33223-3 engine compression.
Page 88
SPECIAL TOOLS INFO Tool No. Tool name/Function Illustration Pivot shaft wrench YM-01485 This tool is needed to loosen or tighten the spacer bolt. 1 — 39…
Page 89: General Specifications

SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 5PX1 (USA) —- 5PX2 (California) —- 5PX3 (CDN) —- Dimensions Overall length 2,385 mm (93.9 in) —- Overall width 955 mm (37.6 in) —- Overall height 1,120 mm (44.1 in) —- Seat height 725 mm (28.5 in)
Page 90: Engine Specifications

SPEC ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Item Standard Limit Engine Engine type Air-cooled, 4-stroke, OHV —- Displacement 1,670 cm (101.9 cu.in) —- Cylinder arrangement V-type 2-cylinder —- Bore × stroke 97 × 113 mm (3.82 × 4.45 in) —- Compression ratio 8.36 : 1 —- Engine idling speed…
Page 91
SPEC ENGINE SPECIFICATIONS Item Standard Limit Transfer gear oil Recommended oil SAE 80 API “GL-4” hypoid gear oil —- Total amount 0.49 L (0.43 Imp qt, 0.52 US qt) —- Periodic oil replacement 0.4 L (0.35 Imp qt, 0.42 US qt) —- Oil filter Oil filter type…
Page 92
SPEC ENGINE SPECIFICATIONS Item Standard Limit Camshafts Drive system Gear drive —- Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) —- Camshaft cover hole inside diameter 28.000 ~ 28.021 mm (1.1024 ~ 1.1032 in) —- Camshaft journal diameter 24.937 ~ 24.950 mm (0.9818 ~ 0.9823 in) —- (crankcase side)
Page 93
SPEC ENGINE SPECIFICATIONS Item Standard Limit Rocker arms, Rocker arm shafts Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 18.036 mm (0.7101 in) Rocker arm shaft outside diameter 17.976 ~ 17.991 mm (0.7077 ~ 0.7083 in) 14.970 mm (0.5894 in) Rocker arm to rocker arm shaft clear- 0.009 ~ 0.042 mm (0.0004 ~ 0.0017 in)
Page 94
SPEC ENGINE SPECIFICATIONS Item Standard Limit Valve stem diameter Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm (0.2341 in) Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.920 mm (0.2331 in) Valve guide inside diameter Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.05 mm (0.2382 in)
Page 95
SPEC ENGINE SPECIFICATIONS Item Standard Limit Compressed spring force (installed) Intake 63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb) —- Exhaust 63 ~ 73 N (6.3 ~ 7.3 kg, 13.9 ~ 16.1 lb) —- Spring tilt Intake —- 2.5°/2.4 mm…
Page 96
SPEC ENGINE SPECIFICATIONS Item Standard Limit Spring tilt Intake —- 2.5°/2.4 mm (2.5°/0.094 in) Exhaust —- 2.5°/2.4 mm (2.5°/0.094 in) Winding direction (top view) Intake Clockwise —- Exhaust Clockwise —- Valve lifters Valve lifter outside diameter 22.9680 ~ 22.9744 mm —- (0.9043 ~ 0.9045 in) Valve lifter case inside diameter…
Page 97
SPEC ENGINE SPECIFICATIONS Item Standard Limit Pistons Piston-to-cylinder clearance 0.025 ~ 0.050 mm (0.001 ~ 0.002 in) 0.15 mm (0.006 in) Diameter D 96.960 ~ 96.975 mm (3.8173 ~ 3.8179 in) —- Height H 5 mm (0.20 in) —- Piston pin bore (in the piston) Diameter 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm (0.8679 in)
Page 98
SPEC ENGINE SPECIFICATIONS Item Standard Limit 2nd ring Ring type Taper —- Dimensions (B × T) 1.2 × 3.8 mm (0.047 × 0.150 in) —- End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.8 mm (0.031 in) Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm…
Page 99
SPEC ENGINE SPECIFICATIONS Item Standard Limit Clutch Clutch type Wet, multiple disc —- Clutch release method Outer pull, rack and pinion (pull rod type) —- Clutch release method operation Cable operation —- Operation Left-hand operation —- Clutch cable free play (at the end of 10 ~ 15 mm (0.39 ~ 0.59 in) —- the clutch lever)
Page 100
SPEC ENGINE SPECIFICATIONS Item Standard Limit Transmission Transmission type Constant mesh, 5-speed —- Primary reduction system Spur gear —- Primary reduction ratio 72/47 (1.532) —- Secondary reduction system Belt drive —- 35/32 × 70/32 (2.393) Secondary reduction ratio —- Operation Left-foot operation —- Gear ratios…
Page 101: Chassis Specifications

SPEC CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Frame Frame type Double cradle —- Caster angle 29.5° —- Trail 130 mm (5.12 in) —- Front wheel Wheel type Cast wheel —- 18 M/C × MT 3.50 Size —- 18 × MT 3.50 Material Aluminum —-…
Page 102
SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear tire Tire type Tubeless —- Size 200/50 ZR 17 M/C (75 W) —- 200/50 ZR 17 (75 W) Model (manufacturer) D220ST (DUNLOP)/ —- BT020R (BRIDGESTONE) Tire pressure (cold) 0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kgf/cm , 36 psi) —-…
Page 103
SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Single-disc brake —- Operation Right-foot operation —- Brake pedal free play (P) 0 mm (0 in) —- Brake pedal position 80 mm (3.2 in) —- (from the top of the rider footrest to the top of the brake pedal) Recommended fluid DOT 4…
Page 104
SPEC CHASSIS SPECIFICATIONS Item Standard Limit Rear suspension Suspension type Swingarm (link suspension) —- Rear shock absorber assembly type Coil spring/gas-oil damper —- Rear shock absorber assembly travel 50 mm (1.97 in) —- Spring Free length 188 mm (7.4 in) 183 mm (7.2 in) Installed length…
Page 105
Resin —- Resistance 10 kΩ —- Charging system System type AC magneto —- Model (manufacturer) F5PX/YAMAHA —- Nominal output 14 V/31 A at 5,000 r/min —- 0.12 ~ 0.20 Ω/W–W Stator coil resistance/color —- Rectifier/regulator Regulator type Semiconductor, short circuit…
Page 106
—- LED × 1 Tachometer light —- Electric starting system System type Constant mesh —- Starter motor Model (manufacturer) 5PX (YAMAHA) —- Power output 0.9 kW —- 0.0081 ~ 0.0099 Ω Armature coil resistance —- Brushes Overall length 9.8 mm (0.39 in) 5 mm (0.2 in)
Page 107
SPEC ELECTRICAL SPECIFICATIONS Item Standard Limit Headlight relay Model/manufacturer ACM33211 M04/MATSUSHITA —- 86.4 ~ 105.6 Ω Coil resistance —- Fuel injection system relay Model/manufacturer G8R-30Y-S/OMRON —- 162 ~ 198 Ω Coil resistance —- Throttle position sensor Resistance 4 ~ 6 kΩ/L-B —- Output voltage (at idle) 0.605 ~ 0.755 V…
Page 108: General Tightening Torque Specifications

CONVERSION TABLE/ SPEC GENERAL TIGHTENING TORQUE SPECIFICATIONS EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE All specification data in this manual are listed SPECIFICATIONS in SI and METRIC UNITS. This chart specifies tightening torques for stan- Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread IMPERIAL unit data.
Page 109: Tightening Torques

SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Spark plug — Front cylinder head cover Bolt Rear cylinder head cover Bolt Front rocker arm base Bolt Front rocker arm base Bolt Rear rocker arm base Bolt…
Page 110
SPEC TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Intake manifold Bolt Throttle body joint Screw Pressure regulator Bolt Intake vacuum hose bracket Bolt Intake air pressure sensor bracket 2 Bolt A.I.S. bracket Bolt Resonator Screw Air cut-off valve assembly Bolt Air cut-off valve assembly…
Page 111
SPEC TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Cover Bolt Cover Bolt Oil tank left cover Bolt Oil tank left cover Bolt Oil strainer Bolt Transfer gear case Bolt Transfer gear case cover Transfer gear oil checking bolt Bolt Transfer gear oil pump cover Bolt…
Page 112
SPEC TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering shaft 11.5 Handlebar holder (lower) and handlebar holder (upper) Ring nut (steering shaft) 2.9 See NOTE.
Page 113
SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Rear fender bracket and frame Rear fender bracket and rear fender Fuel tank and fuel filter Fuel tank bracket and frame Fuel tank and frame Sub fuel tank and frame Seat bracket and frame Side cover and side cover bracket Side cover bracket and frame…
Page 114
SPEC TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Damper rod assembly bolt — Reflector bracket (front) Footrest bracket and rear brake bracket Footrest bracket and shift rod bracket Rear brake bracket and brake pedal Shift shaft and shift pedal NOTE: 1.
Page 115: Lubrication Points And Lubricant Types

SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Connecting rod bolts and nuts Connecting rod small end and big end Crankshaft pins Crankshaft journals Piston surfaces Piston pins Camshaft cam lobes and camshaft journals Valve push rods Valve push rod end balls…
Page 116
SPEC LUBRICATION POINTS AND LUBRICANT TYPES EAS00032 CHASSIS Lubrication point Lubricant Steering bearings and bearing races (upper and lower) Steering bearing cover Steering head pipe lower oil seal Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub mating surface Rear brake pedal shaft Shift pedal Rear footrest pivot…
Page 117: Engine Oil Lubrication Chart

SPEC ENGINE OIL LUBRICATION CHART ENGINE OIL LUBRICATION CHART Pressure feed Rear cylinder intake valve Front cylinder intake valve Rear cylinder Crankshaft journal Piston Connecting rod Crank pin (left) Valve stem Rocker Push Valve Rear lifter camshaft Front cylinder Valve stem Rocker Push Valve…
Page 118: Engine Oil Flow Diagrams

SPEC ENGINE OIL FLOW DIAGRAMS ENGINE OIL FLOW DIAGRAMS 1 Oil tank 2 Dipstick 3 Oil delivery pipe 4 Push rod 5 Oil filter cartridge 2 — 30…
Page 119
SPEC ENGINE OIL FLOW DIAGRAMS 1 Valve lifter 2 Push rod 3 Rocker arm shaft 4 Crankshaft 2 — 31…
Page 120
SPEC ENGINE OIL FLOW DIAGRAMS 1 Engine oil pump 2 Oil strainer 3 Engine oil drain bolt (engine) 2 — 32…
Page 121
SPEC ENGINE OIL FLOW DIAGRAMS 1 Main axle È To oil filter cartridge 2 Drive axle 3 Engine oil pump 4 Oil strainer È 2 — 33…
Page 122: Transfer Gear Oil Flow Diagrams

SPEC TRANSFER GEAR OIL FLOW DIAGRAMS TRANSFER GEAR OIL FLOW DIAGRAMS 1 Middle driven shaft 2 Transfer gear oil pump 2 — 34…
Page 123
SPEC TRANSFER GEAR OIL FLOW DIAGRAMS 1 Transfer gear oil pump 2 Middle driven shaft 2 — 35…
Page 124
SPEC CABLE ROUTING EB206000 CABLE ROUTING 1 Brake hose È Fasten Ê Fasten the rear brake light rectifier/regulator 2 Clutch cable lead, horn lead, and rear brake switch lead, horn lead, and sta- 3 Rectifier/regulator light switch lead with a plastic tor coil assembly lead with a 4 Rectifier/regulator lead locking tie to the frame.
Page 125
SPEC CABLE ROUTING 1 Clutch cable È Fasten the left handlebar switch lead with a plas- 2 Left handlebar switch lead tic holder. 3 Right handlebar switch lead É Fasten the right handlebar switch lead with a 4 Throttle cable 1 plastic holder.
Page 126
SPEC CABLE ROUTING 1 Throttle cables È Pass throttle cable 1 and throttle cable 2 through 2 Clutch cable the cable guide, and then fasten them with a 3 Atmospheric pressure sensor plastic holder. 4 Spark plug cap (ignition coil 1-L spark plug lead) É…
Page 127
SPEC CABLE ROUTING Ë Fasten the engine stop switch lead, crankshaft position sensor lead, and horn lead with a plastic locking tie. Ì Fasten the starter motor lead, and side stand switch lead with a plastic locking tie to the frame. Í…
Page 128
SPEC CABLE ROUTING 1 Ignition coil 1 È To the rectifier/regulator, horn 1 and rear brake 2 Atmospheric pressure sensor lead light switch. 3 Ignition coil 2 É 30 ~ 50 degrees 4 Ignition coil 2 lead Ê 40 ~ 60 degrees 5 Rear brake light switch coupler 6 Rectifier/regulator lead and horn lead 7 Linear control valve lead…
Page 129
SPEC CABLE ROUTING 1 Tail/brake light lead È Be sure to position the ECU leads and sensor 2 Fuel pump lead leads toward the left side of the frame, and then 3 Sidestand switch lead fasten the wire harness protector with a plastic 4 Starter motor lead locking tie.
Page 130
SPEC CABLE ROUTING Ë Fasten the decompression solenoid lead, speed sensor lead, cylinder identification sensor lead, sidestand switch lead, crankshaft position sensor lead, neutral switch lead, and fuel pump lead with a plastic band. Ì Position the gray mark on the starter motor lead at the center of the bolt. Fit the starter motor lead and sid- estand switch lead into the groove in the frame, and then fasten them with a plastic locking tie.
Page 131
SPEC CABLE ROUTING 1 Fuse box A Cut-off relay 2 ECU lead B Turn signal relay 3 Battery C Headlight relay 4 Starter motor lead 5 ECU ground lead È Clamp the fuel tank/air filter breather hose, and 6 Fuel tank/air filter breather hose fuel tank/air filter drain hose with a plastic clamp.
Page 132
SPEC CABLE ROUTING 1 Roll over valve A Fuel tank drain hose 2 Fuel tank breather hose B Fuel tank/air filter breather hose 3 Fuel hose joint 1 C Ignition coil 1 4 Fuel hose 5 Fuel inlet hose È Make sure that the white paint mark is facing for- 6 Fuel outlet hose ward.
Page 133
SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 H Ignition coil 1-R spark plug lead 2 Fuel hose 0 Throttle cables I Lean angle cut-off switch lead 3 Spark plug cap (ignition coil 1-R A Brake hose J Crankshaft position sensor lead B Spark plug cap (ignition coil 2-R K Sidestand switch lead…
Page 134
SPEC CABLE ROUTING È To the battery box. Í Fasten the main wire harness, intake air pres- É Fasten the main wire harness, and fuel hose sure sensor lead #2, ignition coil 1-R spark plug with a plastic locking tie to the frame. lead, and intake air temperature sensor coupler Ê…
Page 135
SPEC CABLE ROUTING Ð To the injector sub lead. × To the speed sensor. Ñ To the engine temperature sensor. Ø Fasten the crankshaft position sensor lead, side- Ò 10 30 mm (0.4 1.2 in) stand switch lead, lean angle cut-off switch lead, Ó…
Page 136
SPEC CABLE ROUTING 1 Ignition coil 2-R spark plug lead 8 ECU 2 Ignition coil 1-R spark plug lead 9 Fuel hose 3 Main wire harness 0 Ignition coil 1-L spark plug lead 4 Negative battery ground lead A Ignition coil 2-L spark plug lead 5 Fuse box 6 Main fuse coupler È…
Page 137
SPEC CABLE ROUTING 1 Canister (California only) 0 Pressure regulator 2 Canister purge hose (California only) A A.I.S. vacuum hose 3 Intake vacuum hose B Silencer air filter case drain hose 4 Liner control valve inlet hose 5 Liner control valve outlet hose 6 Throttle position sensor 7 Fuel hose 8 Throttle stop screw…
Page 138
SPEC CABLE ROUTING Canister (California only) 1 Canister charge hose È To the fuel tank. 2 Canister purge hose É To the silencer air filter case. 3 Starter motor lead Ê To the throttle bodies. 4 Canister 5 Fuel tank drain hose 6 Regulator lead 7 Horn lead 8 Rear brake light switch lead…
Page 139: For The Emission Control System

Evaporative Emission control • Check control system for damage. √ √ system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. 3 — 1…
Page 140
SAE 80 API “GL-4” • Replace every Change. Check. Change. (See page 3-32.) hypoid gear oil 16,000 mi (25,000 km) or 24 months. Yamaha chain and Control cables • Apply chain lube thor- √ √ √ √ √ √ cable lube or (See page 3-58.)
Page 141
(See page 3-47.) • Adjust if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
Page 142: Seat And Side Covers

SEAT AND SIDE COVERS EAS00038 SEAT AND SIDE COVERS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 143: Headlight And Meter Assemblies

HEADLIGHT AND METER ASSEMBLIES HEADLIGHT AND METER ASSEMBLIES 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 144
BATTERY BATTERY Order Job/Part Q’ty Remarks Removing the battery Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS”. Battery cover Negative battery lead Positive battery lead Battery Belt For installation, reverse the removal procedure. 3 — 6…
Page 145: Fuel Tank

FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS”. Air induction system cover Air duct Fuel hose joint 1…
Page 146: Air Filter Case

AIR FILTER CASE EAS00043 AIR FILTER CASE 3 Nm (0.3 m kg, 2.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the air filter case Remove the parts in the order listed. Fuel tank Refer to “FUEL TANK”.
Page 147
SILENCER AIR FILTER CASE EAS00043 SILENCER AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the silencer air filter case Remove the parts in the order listed.
Page 148
SILENCER AIR FILTER CASE 10 Nm (1.0 m kg, 7.2 ft • • 15 Nm (1.5 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Intake air pressure sensor 1 coupler Disconnect.
Page 149
ADJUSTING THE VALVE CLEARANCE EAS00047 ENGINE ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: • The valve clearance automatically adjusted by the hydraulic valve lifter. How- ever, there are times that the valve clearance is needed to be adjusted manually.
Page 150: Adjusting The Valve Clearance

ADJUSTING THE VALVE CLEARANCE 4. Remove: • engine left side cover 1 5. Remove: • timing mark accessing screw 1 • crankshaft end cover 2 6. Remove: • decompression solenoid cover 1 • camshaft sprocket cover 2 7. Measure: • valve clearance Out of specification →…
Page 151
ADJUSTING THE VALVE CLEARANCE M MMM M MMM M MMM M MMM M MMM Piston #1 TDC (rear cylinder) a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on the compres- sion stroke, align the TDC mark a on the crankshaft position sensor rotor with the pointer b on the clutch/crankshaft position sensor rotor cover.
Page 152
ADJUSTING THE VALVE CLEARANCE 8. Adjust: • valve clearance M MMM M MMM M MMM M MMM M MMM a. Loosen the locknut 1. b. Insert a thickness gauge 2 between the end of the adjusting screw and the valve tip. c.
Page 153
SYNCHRONIZING THE THROTTLE BODIES EAS00051 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 timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand.
Page 154
SYNCHRONIZING THE THROTTLE BODIES 7. Adjust: • throttle body synchronization M MMM M MMM M MMM M MMM M MMM a. With throttle body #1 as standard, adjust throttle body #2 using the air screw 1. NOTE: Rev the engine two or three times, each time for less than a second, and check the synchro- nization again.
Page 155
ADJUSTING THE ENGINE IDLING SPEED EAS00053 ADJUSTING THE ENGINE IDLING SPEED NOTE: Prior to adjusting the engine idling speed, the throttle bodies synchronization should be adjusted properly, the air filter element should be clean, and the engine should have ade- quate compression.
Page 156
ADJUSTING THE THROTTLE CABLE FREE PLAY EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • throttle cable free play a Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 4 ~ 6 mm (0.16 ~ 0.24 in)
Page 157
ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: ® Apply locking agend (LOCKTITE ) to the threads of the locknut 2. e. Loosen the locknut 4 on the accelerator cable. f. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained.
Page 158
CHECKING THE SPARK PLUGS EAS00059 CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”.
Page 159
CHECKING THE SPARK PLUGS 5. Check: • electrode 1 Damage/wear → Replace the spark plug. • insulator 2 Abnormal color → Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: • spark plug (with a spark plug cleaner or wire brush) 7.
Page 160
CHECKING THE IGNITION TIMING EAS00061 CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition sys- tem. Make sure all connections are tight and free of corrosion. 1. Remove: • engine left side cover 1 2.
Page 161
CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE 5. Install: • timing mark accessing screw 6. Install: • engine left side cover EAS00065 MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance.
Page 162: Measuring The Compression Pressure

MEASURING THE COMPRESSION PRESSURE 7. Remove: • spark plug 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. 8. Install: •…
Page 163
MEASURING THE COMPRESSION PRESSURE c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces and piston crown for carbon deposits. d. Carbon deposits → Eliminate. e. If the compression pressure is below the minimum specification, pour a teaspoonful of engine oil into the spark plug bore and measure again.
Page 164
CHECKING THE ENGINE OIL LEVEL EAS00071 CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: • Place the motorcycle on a suitable stand. • Make sure the motorcycle is upright. 2. Start the engine, warm it up for several min- utes, and then turn it off.
Page 165
CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL 6. Install: • dipstick 7. Start the engine, warm it up for several min- utes, and then turn it off. 8. Check the engine oil level again. NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.
Page 166
CHANGING THE ENGINE OIL 5. If the oil filter cartridge is also to be replaced, perform the following procedure. M MMM M MMM M MMM M MMM M MMM a. Remove the oil filter cartridge 1 with an oil filter wrench 2. Oil filter wrench YU-38411 b.
Page 167
CHANGING THE ENGINE OIL 8. Fill: • oil tank (with the specified amount of the recom- mended engine oil) Quantity Total amount 5.0 L (4.40 Imp qt, 5.29 US qt) Without oil filter cartridge replacement 3.7 L (3.26 Imp qt, 3.91 US qt) With oil filter cartridge replacement 4.1 L (3.61 Imp qt, 4.33 US qt)
Page 168
CHANGING THE ENGINE OIL 10.Install: • dipstick 11.Start the engine, warm it up for several min- utes, and then turn it off. 12.Check: • engine (for engine oil leaks) 13.Check: • engine oil level Refer to “CHECKING THE ENGINE OIL LEVEL”.
Page 169
MEASURING THE ENGINE OIL PRESSURE EAS00077 MEASURING THE ENGINE OIL PRESSURE 1. Check: • engine oil level Below the minimum level mark → Add the recommended engine oil to the proper level. 2. Start the engine, warm it up for several min- utes, and then turn it off.
Page 170
MEASURING THE ENGINE OIL PRESSURE/ CHECKING THE TRANSFER GEAR OIL LEVEL 5. Measure: • engine oil pressure (at the following conditions) Engine oil pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm 5.688 ~ 11.376 psi) Engine speed Approx. 900 r/min Engine oil temperature 70 ~ 90 °C (158 ~ 194 °F) Engine oil pressure…
Page 171
CHECKING THE TRANSFER GEAR OIL LEVEL/ CHANGING THE TRANSFER GEAR OIL 4. Check: • transfer gear oil level The transfer gear oil level should be up to the brim 2 of the hole. Below the brim → Add the recommended transfer gear oil to the proper level.
Page 172
CHECKING THE TRANSFER GEAR OIL LEVEL 6. Install: • transfer gear oil drain bolt 18 Nm (1.8 m • kg, 13 ft • lb) 7. Fill: • transfer gear case (with the specified amount of the recom- mended transfer gear oil) Quantity Total amount 0.49 L (0.43 Imp qt, 0.52 US qt)
Page 173
ADJUSTING THE CLUTCH CABLE FREE PLAY EAS00078 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play a Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10 ~ 15 mm (0.39 ~ 0.59 in) 2.
Page 174
CLEANING THE AIR FILTER ELEMENTS EAS00088 CLEANING THE AIR FILTER ELEMENTS The following procedure applies to both air fil- ter elements. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. • air filter case Refer to “AIR FILTER CASE”.
Page 175
CHECKING THE THROTTLE BODY JOINTS/ CHECKING THE FUEL HOSES EAS00094 CHECKING THE THROTTLE BODY JOINTS The following procedure applies to all of the throttle body joint. 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. • fuel tank Refer to “FUEL TANK”. •…
Page 176
CHECKING THE FUEL HOSES/ CHECKING THE CYLINDER HEAD BREATHER HOSE AND OIL TANK BREATHER HOSE 2. Check: • fuel hose 1 Cracks/damage → Replace. Loose connection → Connect properly. 3. Install: • air induction system cover Refer to “FUEL TANK”. EAS00098 CHECKING THE CYLINDER HEAD BREATHER HOSE AND OIL TANK…
Page 177
CHECKING THE EXHAUST SYSTEM EAS00099 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Check: • exhaust pipe 1 • muffler 2 Cracks/damage → Replace. • gasket 3 Exhaust gas leaks → Replace. 2.
Page 178
ADJUSTING THE FRONT BRAKE EAS00108 CHASSIS ADJUSTING THE FRONT BRAKE 1. Check: • brake lever free play a Out of specification → Adjust. Brake lever free play (at the end of the brake lever) 2 ~ 5 mm (0.08 ~ 0.20 in) 2.
Page 179
ADJUSTING THE REAR BRAKE EAS00110 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal position (distance a from the top of the rider foot- rest to the top of the brake pedal) Out of specification → Adjust. Brake pedal position (from the top of the rider footrest to the top of the brake pedal) 80 mm (3.2 in)
Page 180
ADJUSTING THE REAR BRAKE/ CHECKING THE BRAKE FLUID LEVEL CAUTION: After adjusting the brake pedal position, make sure there is no brake drag. L LLL L LLL L LLL L LLL L LLL 3. Adjust: • rear brake light switch Refer to “ADJUSTING THE REAR BRAKE LIGHT SWITCH”.
Page 181
CHECKING THE BRAKE FLUID LEVEL/ CHECKING THE FRONT BRAKE PADS/ CHECKING THE 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 182
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 movement 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 183
CHECKING THE FRONT AND REAR BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM È 4. Check: • brake hose Brake fluid leakage → Replace the dam- aged hose. Refer to “FRONT AND REAR BRAKES” in chapter 4. È Front É Rear É…
Page 184
BLEEDING THE HYDRAULIC BRAKE SYSTEM È 1. Bleed: • hydraulic brake system M MMM M MMM M MMM M MMM M MMM a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir).
Page 185
ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE BELT SLACK EAS00137 ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed shift rod length a. 1. Measure: • installed shift rod length a Incorrect → Adjust. Installed shift rod length 368 ~ 372 mm (14.49 ~ 14.65 in) 2.
Page 186
ADJUSTING THE DRIVE BELT SLACK 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 the sidestand and or on a suitable stand so that the rear wheel is elevated.
Page 187
ADJUSTING THE DRIVE BELT SLACK 4. Adjust: • drive belt slack M MMM M MMM M MMM M MMM M MMM NOTE: Place the motorcycle on the suitable stand so that the rear wheel is elevated. a. Loosen the brake caliper bracket bolt 1. b.
Page 188
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 189
CHECKING AND ADJUSTING THE STEERING HEAD 6. Adjust: • steering head M MMM M MMM M MMM M MMM M MMM a. Remove the lock washer 1, the upper ring nut 2, and the rubber washer 3. b. Loosen the lower ring nut 4 and then tighten it to specification with a spanner wrench 5.
Page 190
CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK 7. Install: • upper bracket • washer • steering stem nut 115 Nm (11.5 m • kg, 85 ft • lb) 8. Tighten: • upper bracket pinch bolt 26 Nm (2.6 m • kg, 19 ft • lb) 9.
Page 191
ADJUSTING THE FRONT FORK LEGS EAS00152 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. •…
Page 192
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 mini- mum adjustment positions. 1.
Page 193
CHECKING THE TIRES EAS00166 CHECKING THE TIRES The following procedure applies to both of the tires. 1. Check: • tire pressure Out of specification → Regulate. WARNING • The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature.
Page 194
Tube or tubeless Tubeless wheel tire • After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design.
Page 195: Checking The Tires

CHECKING THE TIRES Front tire Manufacturer Model Size 120/70 ZR 18 M/C (59 W) BRIDGESTONE BT020FG 120/70 ZR 18 (59 W) 120/70 ZR 18 M/C (59 W) DUNLOP D220FST 120/70 ZR 18 (59 W) Rear tire Manufacturer Model Size 200/50 ZR 17 M/C (75 W) BRIDGESTONE BT020R…
Page 196: Checking The Wheels

CHECKING THE WHEELS/ CHECKING AND LUBRICATING THE CABLES EAS00168 CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: • wheel Damage/out-of-round → Replace. WARNING Never attempt to make any repairs to the wheel. NOTE: After a tire or wheel has been changed or replaced, always balance the wheel.
Page 197
LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/ LUBRICATING THE REAR SUSPENSION EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium-soap-based grease EAS00172 LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand.
Page 198: 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 poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
Page 199
CHECKING AND CHARGING THE BATTERY NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 200
CHECKING AND CHARGING THE BATTERY 5. Charge: Charging Ambient temperature 20 °C (68 °F) • battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. Time (minutes) Check the open-circuit voltage. CAUTION: • Never remove the MF battery sealing caps.
Page 201
CHECKING AND CHARGING THE BATTERY Charging method using a variable-current (voltage) charger NOTE: Leave the battery unused for Measure the open-circuit more than 30 minutes before measuring its open-circuit voltage. voltage prior to charging. Charger Ammeter NOTE: Set the charging voltage to Connect a charger and 16 ~ 17 V.
Page 202
CHECKING AND CHARGING THE BATTERY Charging method using a constant voltage charger NOTE: Measure the open-circuit Leave the battery unused for voltage prior to charging. more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging.
Page 203
CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES 6. Install: • battery Refer to “BATTERY”. 7. Connect: • battery leads (to the battery terminals) CAUTION: First, connect the positive battery lead 1, and then the negative battery lead 2. 8. Check: •…
Page 204
CHECKING THE FUSES 1. Remove: • seat Refer to “SEAT AND SIDE COVERS”. 2. Check: • fuse M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω…
Page 205
CHECKING THE FUSES 3. Replace: • blown fuse M MMM M MMM M MMM M MMM M MMM a. Set the main switch to “OFF”. b. Install a new fuse of the correct amperage rating. c. Set on the switches to verify if the electrical circuit is operational.
Page 206
REPLACING THE HEADLIGHT BULB EAS00182 REPLACING THE HEADLIGHT BULB 1. Remove: • screws 1 • headlight lens unit 2 2. Disconnect: • headlight coupler 1 3. Remove: • headlight bulb holder cover 2 4. Detach: • headlight bulb holder 1 5.
Page 207
REPLACING THE HEADLIGHT BULB/ ADJUSTING THE HEADLIGHT BEAM 7. Attach: • headlight bulb holder 8. Install: • headlight bulb holder cover 9. Connect: • headlight coupler 10.Install: • headlight lens unit • screws EAS00184 ADJUSTING THE HEADLIGHT BEAM 1. Adjust: •…
Page 208: Instrument Functions

INSTRUMENT FUNCTIONS INSTRUMENT FUNCTIONS ODOMETER AND TRIPMETER 1 Tachometer 2 Clock 3 Odometer/trip meter/fuel reserve trip meter 4 “RESET” button 5 “SELECT” button Pushing the “SELECT” button switches the dis- play between the odometer mode “ODO” and the tripmeter modes “TRIP 1” and “TRIP 2” in the following order: “ODO”…
Page 209
INSTRUMENT FUNCTIONS ADJUSTING THE METER LIGHT 1. Adjust: • meter light M MMM M MMM M MMM M MMM M MMM a. Turn the key to “OFF”. b. Push and hold the “SELECT” button. c. Turn the key to “ON”, and then after five seconds, release the “SELECT”…
Page 210: Front Wheel And Brake Discs

CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 40 Nm (4.0 m kg, 29 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •…
Page 211
CHAS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 40 Nm (4.0 m kg, 29 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •…
Page 212
CHAS FRONT WHEEL AND BRAKE DISCS Order Job/Part Q’ty Remarks Disassembling the front wheel Remove the parts in the order listed. Oil seal (left and right) Wheel bearing (left and right) Spacer For assembly, reverse the disassembly procedure. 4 — 3…
Page 213
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 214
CHAS FRONT WHEEL AND BRAKE DISCS 3. Measure: • radial wheel runout 1 • lateral wheel runout 2 Over the specified limits → Replace. Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4.
Page 215
CHAS FRONT WHEEL AND BRAKE DISCS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: • brake disc Damage/galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc.
Page 216
CHAS FRONT WHEEL AND BRAKE DISCS 4. Adjust: • brake disc deflection M MMM M MMM M MMM M MMM M MMM a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. c. Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern.
Page 217
CHAS FRONT WHEEL AND BRAKE DISCS 2. Lubricate: • wheel axle • oil seal lips Recommended lubricant Lithium-soap-based grease 3. Install: • collars • front wheel • front wheel axle 4. Tighten: • front wheel axle 1 72 Nm (7.2 m • kg, 52 ft • lb) •…
Page 218
CHAS FRONT WHEEL AND BRAKE DISCS EAS00549 ADJUSTING THE FRONT WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the front wheel static balance should adjusted. • Adjust the front wheel static balance with the brake discs installed. 1.
Page 219
CHAS FRONT WHEEL AND BRAKE DISCS 3. Adjust: • front wheel static balance M MMM M MMM M MMM M MMM M MMM a. Install a balancing weight 1 onto the rim exactly opposite the heavy spot “X”. NOTE: Start with the lightest weight. b.
Page 220
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00550 REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY 40 Nm (4.0 m kg, 29 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft •…
Page 221
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •…
Page 222
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 27 Nm (2.7 m kg, 19 ft • • 30 Nm (3.0 m kg, 22 ft • • 150 Nm (15.0 m kg, 110 ft • • 16 Nm (1.6 m kg, 11 ft •…
Page 223
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00556 Order Job/Part Q’ty Remarks Removing the brake disc and rear Remove the parts in the order listed. wheel pulley Brake disc cover Brake disc Rear wheel pulley Refer to “INSTALLING THE REAR WHEEL”.
Page 224
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY Order Job/Part Q’ty Remarks Collar Bearing Collar Bearing Rear wheel drive hub damper Rear wheel For installation, reverse the removal procedure. 4 — 15…
Page 225
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00560 Order Job/Part Q’ty Remarks Disassembling the rear wheel Remove the parts in the order listed. Oil seal Bearing Refer to “ASSEMBLING THE REAR WHEEL”. Spacer Bearing Rear wheel For assembly, reverse the disassembly procedure.
Page 226
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 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 227
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00567 CHECKING THE REAR WHEEL DRIVE HUB 1. Check: • rear wheel drive hub 1 Cracks/damage → Replace. • rear wheel drive hub dampers 2 Damage/wear → Replace. EAS00568 CHECKING AND REPLACING THE REAR WHEEL PULLEY 1.
Page 228
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00572 INSTALLING THE REAR WHEEL 1. Lubricate: • oil seal lips Recommended lubricant Lithium-soap-based grease 2. Install: • rear wheel drive hub dampers 1 3. Install: • rear wheel drive hub assembly 1 4.
Page 229
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 6. Install: • brake caliper bracket 1 • washer • brake caliper bracket bolt 2 NOTE: Temporarily tighten the brake caliper bracket bolt. 7. Install: • collars • rear wheel • adjusting plates •…
Page 230
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY 12.Install: • upper drive belt cover plate 1 7 Nm (0.7 m • kg, 5.1 ft • lb) • upper drive belt cover 2 7 Nm (0.7 m • kg, 5.1 ft • lb) 13.Install: •…
Page 231
REAR WHEEL, BRAKE DISC, AND REAR WHEEL CHAS PULLEY EAS00575 ADJUSTING THE REAR WHEEL STATIC BALANCE NOTE: • After replacing the tire, wheel or both, the rear wheel static balance should be adjusted. • Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed.
Page 232
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 40 Nm (4.0 m kg, 29 ft • • 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.
Page 233
CHAS FRONT AND REAR BRAKES EAS00578 REAR BRAKE PADS 6 Nm (0.6 m kg, 4.3 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake pads Remove the parts in the order listed. Brake caliper retaining bolt Brake caliper Brake pad…
Page 234
CHAS FRONT AND REAR BRAKES EAS00579 CAUTION: Disc brake components rarely require dis- assembly. Therefore, always follow these preventive measures: • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly.
Page 235
CHAS FRONT AND REAR BRAKES 2. Remove: • brake pad clips 1 • brake pad pin 2 • brake pad spring 3 3. Remove: • brake pads 1 (along with the brake pad shims) • brake pad shims 4. Measure: •…
Page 236
CHAS FRONT AND REAR BRAKES d. Install new brake pads and a new brake pad spring. NOTE: The arrow a on the brake pad spring must point in the direction of disc rotation. L LLL L LLL L LLL L LLL L LLL 6.
Page 237
CHAS FRONT AND REAR BRAKES 2. Remove: • brake pads 1 (along with the brake pad shims) • brake pad springs 3. Measure: • brake pad wear limit a Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4.
Page 238
CHAS FRONT AND REAR BRAKES 5. Install: • brake caliper retaining bolt 1 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”…
Page 239
CHAS FRONT AND REAR BRAKES EAS00584 FRONT BRAKE MASTER CYLINDER Order Job/Part Q’ty Remarks Removing the front brake master Remove the parts in the order listed. cylinder Brake fluid Drain. Rear view mirror (right) Brake master cylinder reservoir cap Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm…
Page 240: Front And Rear Brakes

CHAS FRONT AND REAR BRAKES Order Job/Part Q’ty Remarks Front brake light switch connector Disconnect. Refer to “REMOVING THE Union bolt FRONT BRAKE MASTER Brake hose Disconnect. CYLINDER” and “ASSEM- BLING AND INSTALLING Copper washer THE FRONT BRAKE MAS- Brake master cylinder holder TER CYLINDER”.
Page 241
CHAS FRONT AND REAR BRAKES EAS00585 Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. master cylinder Dust boot Refer to “ASSEMBLING AND INSTALL- Circlip ING THE FRONT BRAKE MASTER CYL- Brake master cylinder kit INDER”.
Page 242
CHAS FRONT AND REAR BRAKES EAS00586 REAR BRAKE MASTER CYLINDER 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the brake fluid reservoir Remove the parts in the order listed. Brake fluid Drain. Brake fluid reservoir cover Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm…
Page 243
CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •…
Page 244
CHAS FRONT AND REAR BRAKES 48 Nm (4.8 m kg, 35 ft • • 23 Nm (2.3 m kg, 17 ft • • 16 Nm (1.6 m kg, 11 ft • • 30 Nm (3.0 m kg, 22 ft • •…
Page 245
CHAS FRONT AND REAR BRAKES EAS00587 Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. master cylinder Dust boot Circlip Brake master cylinder kit Circlip Brake hose joint O-ring Brake master cylinder For assembly, reverse the disassembly procedure.
Page 246
CHAS FRONT AND REAR BRAKES EAS00588 REMOVING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the…
Page 247
CHAS FRONT AND REAR BRAKES É 2. Check: È • brake master cylinder kit Damage/scratches/wear → Replace. È Front É Rear 3. Check: • rear brake fluid reservoir 1 Cracks/damage → Replace. • rear brake fluid reservoir diaphragm 2 Cracks/damage → Replace. 4.
Page 248
CHAS FRONT AND REAR BRAKES 1. Install: • brake master cylinder • brake master cylinder holder 1 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. •…
Page 249
CHAS FRONT AND REAR BRAKES WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
Page 250
CHAS FRONT AND REAR BRAKES EAS00608 ASSEMBLING AND INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • copper washers 1 • brake hoses 2 • union bolt 3 30 Nm (3.0 m • kg, 22 ft • lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
Page 251
CHAS FRONT AND REAR BRAKES 3. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level.
Page 252
CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 40 Nm (4.0 m kg, 29 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
Page 253
CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring…
Page 254
CHAS FRONT AND REAR BRAKES EAS00616 REAR BRAKE CALIPER 30 Nm (3.0 m kg, 22 ft • • 27 Nm (2.7 m kg, 19 ft • • Order Job/Part Q’ty Remarks Removing the rear brake caliper Remove the parts in the order listed. Union bolt Refer to “DISASSEM- BLING THE REAR BRAKE…
Page 255
CHAS FRONT AND REAR BRAKES EAS00617 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the rear brake Remove the parts in the order listed. caliper Brake caliper piston Refer to “DISASSEMBLING THE REAR BRAKE CALIPER”. Brake caliper piston seal Bleed screw For assembly, reverse the disassembly…
Page 256
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: • union bolt 1 •…
Page 257
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: • union bolt 1 • copper washers 2 • brake hose 3 NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully.
Page 258
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 Every years and whenever the Brake fluid brake is disassem- bled È…
Page 259
CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •…
Page 260
CHAS FRONT AND REAR BRAKES 3. Install: • brake pads • brake pad spring • brake caliper bolt 40 Nm (4.0 m • kg, 29 ft • lb) • brake hose holder 8 Nm (0.8 m • kg, 5.8 ft • lb) 4.
Page 261
CHAS FRONT AND REAR BRAKES 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 7. Check: • brake lever operation Soft or spongy feeling →…
Page 262
CHAS FRONT AND REAR BRAKES 1. Install: • brake caliper 1 (temporarily) • copper washers 2 • brake hose 3 • union bolt 4 30 Nm (3.0 m • kg, 22 ft • lb) WARNING Proper brake hose routing is essential to insure safe motorcycle operation.
Page 263
CHAS FRONT AND REAR BRAKES 4. Fill: • brake fluid reservoir (with the specified amount of the recom- mended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.
Page 264: Front Fork

CHAS FRONT FORK EAS00647 FRONT FORK 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 265
CHAS FRONT FORK EAS00648 Order Job/Part Q’ty Remarks Disassembling the front fork legs Remove the parts in the order listed. The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Refer to “DISASSEMBLING THE FRONT FORK LEGS”…
Page 266
CHAS FRONT FORK Order Job/Part Q’ty Remarks Oil seal clip Oil seal Washer Refer to “DISASSEMBLING THE FRONT Damper rod assembly bolt FORK LEGS” and “ASSEMBLING THE FRONT FORK LEGS”. Copper washer Damper rod assembly Inner tube For assembly, reverse the disassembly procedure.
Page 267
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. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated.
Page 268
CHAS FRONT FORK NOTE: Use the side of the rod holder that is marked “B”. c. Loosen the nut. d. Remove the cap bolt. e. Remove the rod holder and fork spring com- pressor. WARNING The fork spring is compressed. f.
Page 269
CHAS FRONT FORK 4. Remove: • damper rod assembly bolt • copper washer NOTE: While holding the damper rod with the damper rod holder 1, loosen the damper rod assem- bly bolt. Damper rod holder YM-01423 EAS00657 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
Page 270
CHAS FRONT FORK 3. Check: • damper rod 1 Damage/wear → Replace. Obstruction → Blow out all of the oil pas- sages with compressed air. CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particu- larly sensitive to foreign material.
Page 271
CHAS FRONT FORK EAS00660 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. WARNING • Make sure the oil levels in both front fork legs are equal. • Uneven oil levels can result in poor han- dling and a loss of stability.
Page 272
CHAS FRONT FORK 3. Install: • dust seal 1 • oil seal clip 2 • oil seal 3 • washer 4 CAUTION: Make sure the numbered side of the oil seal faces down. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease.
Page 273
Quantity (each front fork leg) 476 cm (16.8 Imp qt, 16.1 US qt) Recommended oil Yamaha suspension oil “01” CAUTION: • Be sure to use the recommended fork oil. Other oils may have an adverse effect on front fork performance.
Page 274
CHAS FRONT FORK 12.Slowly stroke the outer tube 1 up and down to distribute the fork oil once more (1 stroke = about 150 mm (8.12 in)). NOTE: Be careful not to stroke the outer tube over 150 mm (8.12 in) as this will cause air to enter. If the outer tube is stroke more than 150 mm (8.12 in), repeat steps (11) and (12).
Page 275
CHAS FRONT FORK 15.Install: • nut 1 • fork spring 2 • spring seat 3 • spacer 4 • cap bolt 5 M MMM M MMM M MMM M MMM M MMM a. Remove the rod puller. b. Install the nut 1. c.
Page 276: Front Fork

CHAS FRONT FORK k. Remove the rod holder and fork spring com- pressor. CAUTION: The fork spring is compressed. Always use a new cap bolt O-ring. L LLL L LLL L LLL L LLL L LLL 16.Install: • cap bolt (onto the outer tube) NOTE: Temporary tighten the cap bolt.
Page 277
CHAS FRONT FORK 3. Adjust: • spring preload Refer to “ADJUSTING THE FRONT FORK LEGS” in chapter 3. 4 — 68…
Page 278
CHAS HANDLEBAR EAS00664 HANDLEBAR Order Job/Part Q’ty Remarks Removing the handlebar Remove the parts in the order listed. Rear view mirror (left and right) Plastic clamp Front brake light switch connector Disconnect. Brake master cylinder holder Brake master cylinder Refer to “INSTALLING THE Right handlebar switch HANDLEBAR”.
Page 279
CHAS HANDLEBAR Order Job/Part Q’ty Remarks Left handlebar switch Handlebar grip Refer to “REMOV- ING THE HANDLE- BAR”. Refer to “INSTALL- Clutch cable Disconnect. ING THE HANDLE- Clutch lever holder BAR”. Upper handlebar holder Handlebar Lower handlebar holder For installation, reverse the removal procedure.
Page 280
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: • handlebar grip 1 NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar.
Page 281
CHAS HANDLEBAR 3. Install: • handlebar 1 • upper handlebar holders 2 28 Nm (2.8 m • kg, 20 ft • lb) CAUTION: • First, tighten the bolts on the front side of the handlebar holder, and then on the rear side.
Page 282
CHAS HANDLEBAR 7. Install: • left handlebar switch NOTE: Align the end a of the left handlebar switch with the punch mark b on the handlebar. 8. Connect: • clutch switch coupler 9. Install: • handlebar grip M MMM M MMM M MMM M MMM M MMM…
Page 283
CHAS HANDLEBAR 13.Install: • brake master cylinder • brake master cylinder holder 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. • Align the end of the brake master cylinder holder with the punch mark a in the handle- bar.
Page 284: Steering Head

CHAS STEERING HEAD EAS00676 STEERING HEAD 23 Nm (2.3 m kg, 17 ft 1st 52 Nm (5.2 m kg, 37 ft • • • • 2nd 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 285
CHAS STEERING HEAD 23 Nm (2.3 m kg, 17 ft 1st 52 Nm (5.2 m kg, 37 ft • • • • 2nd 4 Nm (0.4 m kg, 2.9 ft • • 7 Nm (0.7 m kg, 5.1 ft • •…
Page 286
CHAS STEERING HEAD EAS00677 REMOVING THE LOWER 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: • ring nut 1 (with the spanner wrench 2) Spanner wrench YU-33975 WARNING…
Page 287
CHAS STEERING HEAD 3. Replace: • bearings • bearing races M MMM M MMM M MMM M MMM M MMM a. Remove the bearing races from the steering head pipe with a long rod 1 and hammer. b. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer.
Page 288
CHAS STEERING HEAD 3. Install: • upper bracket • steering stem nut NOTE: Temporarily tighten the steering stem nut. 4. Install: • front fork legs Refer to “FRONT FORK”. NOTE: Temporarily tighten the lower bracket pinch bolts. 5. Tighten: • steering stem nut 115 Nm (11.5 m •…
Page 289
CHAS REAR SHOCK ABSORBER AND SWINGARM REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 290
CHAS REAR SHOCK ABSORBER AND SWINGARM 10 Nm (1.0 m kg, 7.2 ft • • 16 Nm (1.6 m kg, 11 ft • • 59 Nm (5.9 m kg, 43 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
Page 291
CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Removing the rear shock absorber Remove the parts in the order listed.
Page 292
CHAS REAR SHOCK ABSORBER AND SWINGARM 59 Nm (5.9 m kg, 43 ft • • 40 Nm (4.0 m kg, 29 ft • • 59 Nm (5.9 m kg, 43 ft • • Order Job/Part Q’ty Remarks Swingarm Dust cover Spacer Bearing For installation, reverse the removal…
Page 293
CHAS REAR SHOCK ABSORBER AND SWINGARM 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 informa- tion. The manufacturer cannot be held responsible for property damage or per- sonal injury that may result from improper handling of the rear shock absorber.
Page 294
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00703 REMOVING THE REAR SHOCK ABSORBER AND 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 295
CHAS REAR SHOCK ABSORBER AND SWINGARM EAS00696 CHECKING THE REAR SHOCK ABSORBER 1. Check: • rear shock absorber rod Bends/damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks/oil leaks → Replace the rear shock absorber assembly. •…
Page 296
CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Wash: • pivot shaft • dust covers • spacer • bearings Recommended cleaning solvent Kerosine 4. Check: • dust covers • spacer • oil seals Damage/wear → Replace. • bearings Damage/pitting → Replace. EAS00711 INSTALLING THE REAR SHOCK ABSORBER AND SWINGARM…
Page 297: Rear Shock Absorber And Swingarm

CHAS REAR SHOCK ABSORBER AND SWINGARM 3. Install: • bolt (shock absorber-connecting arm- frame) 1 NOTE: When installing the bolt (shock absorber-con- necting arm-frame), hold the swingarm so that it does not drop down. 4. Adjust: • drive belt slack Refer to “ADJUSTING THE DRIVE BELT SLACK”…
Page 298
CHAS DRIVE BELT AND DRIVE SPROCKET DRIVE BELT AND DRIVE SPROCKET Order Job/Part Q’ty Remarks Removing the drive belt and drive Remove the parts in the order listed. sprocket Rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY”. Rear shock absorber and swingarm Refer to “REAR SHOCK ABSORBER assembly…
Page 299
CHAS DRIVE BELT AND DRIVE SPROCKET REMOVING THE DRIVE BELT AND DRIVE SPROCKET NOTE: Loosen the drive sprocket nut before remove the rear wheel. 1. Straighten the lock washer tab. 2. Loosen: • drive sprocket nut 1 NOTE: When loosening the drive sprocket nut, press down on the brake pedal so the drive sprocket does not move.
Page 300
CHAS DRIVE BELT AND DRIVE SPROCKET 3. Check: • drive sprocket • rear wheel pulley Bent teeth → Replace the drive belt and pulleys as a set. INSTALLING THE DRIVE BELT AND DRIVE SPROCKET 1. Install: • drive sprocket 1 •…
Page 301
ENGINE EAS00188 ENGINE ENGINE 24 Nm (2.4 m kg, 17 ft • • 20 Nm (2.0 m kg, 14 ft • • 20 Nm (2.0 m kg, 14 ft • • 53 Nm (5.3 m kg, 38 ft • • 12 Nm (1.2 m kg, 8.7 ft •…
Page 302
ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the oil filter bracket and Remove the parts in the order listed.
Page 303
ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Engine oil/oil filter cartridge Drain.
Page 304
ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 70 Nm (7.0 m kg, 50 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Rectifier/regulator coupler Disconnect.
Page 305
ENGINE 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • Order Job/Part Q’ty Remarks Disconnecting the leads and hoses Disconnect the parts in the order listed. Spark plug caps Cylinder head breather hose Oil tank breather hose Clutch cable Plastic clamp…
Page 306
ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the ignition coil and Remove the parts in the order listed. linear control valve Hose bracket Wire harness bracket Ignition coil connector Disconnect.
Page 307
ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •…
Page 308
ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •…
Page 309
ENGINE EAS00192 INSTALLING THE ENGINE 1. Install: • spacer bolt 1 • lower front mounting bolt 2 • lower rear mounting bolt 3 2. Tighten: • spacer bolt 1 18 Nm (1.8 m • kg, 13 ft • lb) NOTE: •…
Page 310
ENGINE 6. Connect: • oil tank breather hose 1 • cylinder head breather hose 2 • spark plug caps 3 NOTE: Refer to “CABLE ROUTING” in chapter 2. INSTALLING THE MUFFLER AND EXHAUST PIPES 1. Install: • gaskets • exhaust pipes NOTE: Finger tighten the exhaust pipe nuts and bolts.
Page 311
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • •…
Page 312
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 313
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing cylinder head covers Remove the parts in the order listed. Ignition coil/rectifier/regulator/ Refer to “ENGINE”. liner control valve Cylinder head breather hose Oil tank breather hose Bolt = 60 mm (2.36 in)
Page 314
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 20 Nm (2.0 m kg, 14 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the push rods and rocker Remove the parts in the order listed.
Page 315
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the valve lifters Remove the parts in the order listed. Push rod cover O-ring Seal…
Page 316
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS REMOVING THE ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Align: • TDC mark a on the crankshaft position sensor rotor (with the pointer b on the clutch/crankshaft position sensor rotor cover) M MMM M MMM M MMM M MMM…
Page 317
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Check: • rocker arm shaft Blue discoloration/excessive wear/pitting/ scratches → Replace or check the lubrica- tion system. 3. Measure: • rocker arm inside diameter a Out of specification → Replace. Rocker arm inside diameter 18.000 ~ 18.018 mm (0.7087 ~ 0.7094 in) 4.
Page 318
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS CHECKING THE ROCKER ARM BASES 1. Check: • rocker arm base Cracks/damage → Replace. CHECKING THE PUSH RODS 1. Check: • push rod • push rod end Bends/damage → Replace. 2. Measure: • push rod runout Out of specification →…
Page 319
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 3. Measure: • valve lifter outside diameter a Out of specification → Replace. Valve lifter outside diameter 22.9680 ~ 22.9744 mm (0.9043 ~ 0.9045 in) 4. Measure: • valve lifter case inside diameter a Out of specification →…
Page 320
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 1. Bleed: • valve lifter M MMM M MMM M MMM M MMM M MMM a. Fill a container with kerosene and place the valve lifter into the container as shown. Pump the plunger side of the valve lifter with a press a number of times to let in kero- sene.
Page 321
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS h. Rotate the crankshaft unit the mark (on the camshaft driven gear) for the valve lifter to be bled aligns with the camshaft drive gear as shown. Example: For bleeding the cylinder #2 intake valve lifter, align mark 2 as shown.
Page 322
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS INSTALLING THE ROCKER ARMS AND PUSH RODS The following procedure applies to both cylin- ders. 1. Install: • rocker arms 1 • rocker arm shafts 2 (onto rocker arm base) NOTE: The thread hole a of the rocker arm shaft must face to the outside.
Page 323
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS c. Install the rocker arm base bolts. NOTE: Tighten the rocker arm base bolts in stages and in a crisscross pattern. Rocker arm base bolt 1 10 Nm (1.0 m • kg, 7.2 ft • lb) Rocker arm base bolt 2 24 Nm (2.4 m •…
Page 324
ROCKER ARMS, PUSH RODS AND VALVE LIFTERS 2. Install: • canister (for California only) NOTE: Refer to “CABLE ROUTING” in chapter 2. 3. Install: • spark plugs 4. Connect: • spark plug caps NOTE: Refer to “CABLE ROUTING” in chapter 2. È…
Page 325
CAMSHAFTS EAS00196 CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 52 Nm (5.2 m kg, 37 ft • • Order Job/Part Q’ty Remarks…
Page 326
CAMSHAFTS 10 Nm (1.0 m kg, 7.2 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 52 Nm (5.2 m kg, 37 ft • • Order Job/Part Q’ty Remarks Camshaft driven gear Straight key…
Page 327
CAMSHAFTS REMOVING THE CAMSHAFTS 1. Loosen: • front cylinder camshaft end cover bolts 1 • camshaft drive gear bolt 2 NOTE: • Place a folded copper washer 3 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. •…
Page 328
CAMSHAFTS EAS00204 CHECKING THE CAMSHAFTS 1. Check: • cam Blue discoloration/pitting/scratches → Replace the camshaft. 2. Measure: • cam dimensions a and b Out of specification → Replace the cam- shaft. Camshaft lobe dimension limit Intake camshaft a 38.231 ~ 38.331 mm (1.5052 ~ 1.5091 in) b 32.013 ~ 32.113 mm (1.2604 ~ 1.2643 in)
Page 329
CAMSHAFTS 5. Measure: • crankcase hole inside diameter c Out of specification → Replace the crank- case. Crankcase hole inside diameter 25.000 ~ 25.021 mm (0.9843 ~ 0.9851 in) 6. Measure: • camshaft cover hole inside diameter d Out of specification → Replace the cam- shaft cover.
Page 330
CAMSHAFTS 9. Check: • camshaft drive gears • camshaft driven gears Chips/pitting/roughness/wear → Replace the defective part(s). CHECKING THE DECOMPRESSION SYSTEM 1. Check: • decompression system NOTE: • Check the decompression system while the decompression push rod is installed in the camshaft.
Page 331
CAMSHAFTS INSTALLING THE CAMSHAFTS 1. Install: • camshafts (to the camshaft cover) • front cylinder camshaft end cover NOTE: • Lubricate molybdenum disulfide oil onto the camshaft journals and lobes. • Align the punch mark a on the rear cylinder camshaft with the punch mark b on the front cylinder camshaft.
Page 332
CAMSHAFTS 4. Install: • front cylinder camshaft end cover 1 NOTE: • Align the projection a on the front cylinder camshaft end cover with the hole b on the front cylinder camshaft. • Finger tighten the place bolts. 5. Install: •…
Page 333
CAMSHAFTS 6. Tighten: • camshaft driven gear nut 1 52 Nm (5.2 m • kg, 37 ft • lb) NOTE: • Place a folded copper washer 2 between the teeth of the camshaft drive gear and camshaft driven gear in order to lock them. •…
Page 334
CYLINDER HEADS EAS00221 CYLINDER HEADS 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 39 Nm (3.9 m kg, 28 ft • • 60 Nm (6.0 m kg, 43 ft • •…
Page 335
CYLINDER HEADS 20 Nm (2.0 m kg, 14 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 39 Nm (3.9 m kg, 28 ft • • 60 Nm (6.0 m kg, 43 ft • • 21 Nm (2.1 m kg, 15 ft •…
Page 336
CYLINDER HEADS REMOVING THE CYLINDER HEADS 1. Remove: • cylinder head NOTE: • Loosen the nuts in the proper sequence. • Follow the numerical order shown in the illus- tration. Loosen each bolt 1/4 of a turn at a time until all of the nuts are loose. EAS00228 CHECKING THE CYLINDER HEADS The following procedure applies to each cylin-…
Page 337
CYLINDER HEADS CHECKING THE OIL DELIVERY PIPE 1. Check: • oil delivery pipe 1 Damage → Replace. Obstruction → Wash and blow out with compressed air. EAS00232 INSTALLING THE CYLINDER HEAD 1. Install: • cylinder head gasket 1 • dowel pins 2 2.
Page 338
CYLINDER HEADS 6. Install: • washer • engine temperature sensor 1 20 Nm (2.0 m • kg, 14 ft • lb) 5 — 38…
Page 339: Valves And Valve Springs

VALVES AND VALVE SPRINGS EAS00236 VALVES AND VALVE SPRINGS Order Job/Part Q’ty Remarks Removing the valves and valve Remove the parts in the order listed. springs The following procedure applies to both cylinders. Cylinder head Refer to “CYLINDER HEADS”. Valve cotter Upper spring seat Outer valve spring Inner valve spring…
Page 340
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 341
VALVES AND VALVE SPRINGS 3. Remove: • upper spring seat 1 • outer valve spring 2 • inner valve spring 3 • valve 4 • valve stem seal 5 • lower spring seat 6 NOTE: Identify the position of each part very carefully so that it can be reinstalled in its original place.
Page 342
VALVES AND VALVE SPRINGS 2. Replace: • valve guide NOTE: To ease valve guide removal and installation, and to maintain the correct fit, heat the cylinder head to 100 °C (212 °F) in an oven. M MMM M MMM M MMM M MMM M MMM a.
Page 343
VALVES AND VALVE SPRINGS 5. Measure: • valve margin thickness a Out of specification → Replace the valve. Valve margin thickness 0.7 ~ 1.3 mm (0.0276 ~ 0.0512 in) 6. Measure: • valve stem runout Out of specification → Replace the valve. NOTE: •…
Page 344
VALVES AND VALVE SPRINGS 3. Measure: • valve seat width a Out of specification → Replace the cylinder head. Valve seat width Intake 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) Exhaust 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) M MMM M MMM M MMM…
Page 345
VALVES AND VALVE SPRINGS 4. Lap: • valve face • valve seat NOTE: After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. M MMM M MMM M MMM M MMM M MMM a.
Page 346
VALVES AND VALVE SPRINGS EAS00241 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs. 1. Measure: • valve spring free length a Out of specification → Replace the valve spring. Valve spring free length Intake valve spring 38.26 mm (1.51 in) <Limit>: 36.26 mm (1.43 in) Exhaust valve spring…
Page 347
VALVES AND VALVE SPRINGS EAS00246 INSTALLING THE VALVES The following procedure applies to all of the valves and related components. 1. Deburr: • valve stem end (with an oil stone) 2. Lubricate: • valve stem 1 • oil seal 2 (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil…
Page 348
VALVES AND VALVE SPRINGS 4. Install: • valve cotters 1 NOTE: Install the valve cotters by compressing the valve springs with the valve spring compressor set 1. Valve spring compressor set YM-04019 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer.
Page 349
CYLINDERS AND PISTONS EAS00252 CYLINDERS AND PISTONS Order Job/Part Q’ty Remarks Removing the cylinders and pistons Remove the parts in the order listed. Cylinder heads Refer to “CYLINDER HEADS”. Front cylinder Rear cylinder Cylinder gasket Dowel pin Refer to “INSTALL- Piston pin clip ING THE PIS- Refer to “REMOV-…
Page 350
CYLINDERS AND PISTONS EAS00254 REMOVING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Remove: • piston pin clips 1 • piston pin 2 • piston 3 CAUTION: Do not use a hammer to drive the piston pin out.
Page 351
CYLINDERS AND PISTONS EAS00258 CHECKING THE CYLINDERS AND PISTONS The following procedure applies to all of the cylinders and pistons. 1. Check: • piston wall • cylinder wall Vertical scratches → Replace the cylinder, and the piston and piston rings as a set. 2.
Page 352
CYLINDERS AND PISTONS Piston size “P” 96.960 ~ 96.975 mm Standard (3.8173 ~ 3.8179 in) d. If out of specification, replace the piston and piston rings as a set. e. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance = Cylinder bore “C”…
Page 353
CYLINDERS AND PISTONS 2. Install: • piston ring (into the cylinder) NOTE: Level the piston ring into the cylinder with the piston crown. a 10 mm (0.39 in) 3. Measure: • piston ring end gap Out of specification → Replace the piston ring.
Page 354
CYLINDERS AND PISTONS 3. Measure: • piston pin bore diameter (in the piston) b Out of specification → Replace the piston pin. Piston pin bore diameter (in the piston) 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) <Limit>: 22.045 mm (0.8679 in) 4.
Page 355
CYLINDERS AND PISTONS 2. Install: • piston 1 • piston pin 2 • piston pin clips 3 NOTE: • Apply engine oil onto the piston pin. • Make sure the “arrow” mark a on the piston faces towards the front of the motorcycle. •…
Page 356
CLUTCH EAS00273 CLUTCH CLUTCH COVER 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the clutch cover Remove the parts in the order listed. Left side cover Refer to “SEAT AND SIDE COVERS”…
Page 357
CLUTCH 12 Nm (1.2 m kg, 8.7 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Shift arm Clutch cable holder Refer to “REMOV- Refer to “INSTALL- Clutch cover ING THE CLUTCH”. ING THE CLUTCH”. Clutch cover gasket Dowel pin For installation, reverse the removal…
Page 358
CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the pull lever shaft and Remove the parts in the order listed. crankshaft position sensor Pull lever Pull lever spring Circlip Pull lever shaft Oil seal Bearing Crankshaft position sensor lead holder Refer to “INSTALLING THE CRANK-…
Page 359
CLUTCH EAS00274 CLUTCH 18 19 80 Nm (8.0 m kg, 58 ft • • 9 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Removing the clutch Remove the parts in the order listed.
Page 360
CLUTCH 18 19 80 Nm (8.0 m kg, 58 ft • • 9 12 100 Nm (10.0 m kg, 72 ft • • 8 Nm (0.8 m kg, 5.8 ft • • Order Job/Part Q’ty Remarks Clutch damper spring Refer to “REMOV- Clutch damper spring seat ING THE CLUTCH”.
Page 361
CLUTCH EAS00277 REMOVING THE CLUTCH 1. Remove: • clutch cable holder 1 • clutch cover 2 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 362
CLUTCH EAS00279 REMOVING THE PRIMARY DRIVE GEAR 1. Remove: • crankshaft position sensor rotor bolt 1 NOTE: While holding the generator rotor 2 with the sheave holder 3, loosen the crankshaft posi- tion sensor rotor bolt. Primary sheave holder YS-01880-A EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the…
Page 363
CLUTCH 2. Measure: • clutch plate warpage (with a surface plate and thickness gauge Out of specification → Replace the clutch plates as a set. Clutch plate warpage limit 0.2 mm (0.008 in) EAS00283 CHECKING THE CLUTCH PLATE SPRING 1. Check: •…
Page 364
CLUTCH EAS00286 CHECKING THE PRESSURE PLATE 1. Check: • pressure plate 1 Cracks/damage → Replace. • bearing 2 Damage/wear → Replace. EAS00287 CHECKING THE PULL LEVER SHAFT AND PULL ROD 1. Check: • pull lever shaft pinion gear teeth a •…
Page 365
CLUTCH 2. Install: • crankshaft position sensor 7 Nm (0.7 m • kg, 5.1 ft • lb) • crankshaft position sensor lead holder 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: ® Apply locking agent (LOCTITE ) to the threads of the crankshaft position sensor bolts and crankshaft position sensor lead holder bolts.
Page 366
CLUTCH EAS00293 INSTALLING THE CLUTCH 1. Install: • dowel pin 1 • oil pump drive gear 2 • plate 3 • circlip 4 2. Install: • clutch housing 1 • thrust washer 2 NOTE: • Lubricate the clutch housing bearings with engine oil.
Page 367
CLUTCH 4. Install: • clutch boss 1 • lock washer • clutch boss nut 2 80 Nm (8.0 m • kg, 58 ft • lb) NOTE: While holding the clutch boss with the univer- sal clutch holder 3, tighten the clutch boss nut.
Page 368
CLUTCH 8. Install: • pressure plate 1 NOTE: Align the punch mark a in the pressure plate with the punch mark b in the clutch boss. 9. Install: • clutch spring plate seat 1 • clutch spring plate 2 • clutch spring plate retainer 3 8 Nm (0.8 m •…
Page 369
CLUTCH 13.Install: • shift arm 1 12 Nm (1.2 m • kg, 8.7 ft • lb) NOTE: Align the mark a in the shift shaft with the slot in the shift arm. 14.Install: • pull lever spring • pull lever 12 Nm (1.2 m •…
Page 370
SHIFT SHAFT AND STOPPER LEVER EAS00327 SHIFT SHAFT AND STOPPER LEVER 22 Nm (2.2 m kg, 16 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the shift shaft and Remove the parts in the order listed. stopper lever Engine oil Drain.
Page 371
SHIFT SHAFT AND STOPPER LEVER EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft 1 • shift lever spring 2 Damage/wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever 1 Bends/damage → Replace. Roller turns roughly → Replace the stopper lever.
Page 372
SHIFT SHAFT AND STOPPER LEVER 3. Install: • shift shaft spring • circlips • shift shaft 1 NOTE: Install the end of the shift shaft spring onto the shift shaft spring stopper 2. 5 — 72…
Page 373
GENERATOR AND STARTER CLUTCH EAS00341 GENERATOR AND STARTER CLUTCH STATOR COIL ASSEMBLY 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 374
GENERATOR AND STARTER CLUTCH 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 48 Nm (4.8 m kg, 35 ft •…
Page 375
GENERATOR AND STARTER CLUTCH EAS00343 GENERATOR AND STARTER CLUTCH Order Job/Part Q’ty Remarks Removing the generator rotor Remove the parts in the order listed. Starter clutch idle gear shaft #2 Starter clutch idle gear shaft #1 Starter clutch idle gear #2 Starter clutch idle gear #1 Generator rotor Woodruff key…
Page 376
GENERATOR AND STARTER CLUTCH EAS00347 REMOVING THE GENERATOR 1. Remove: • generator 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 377
GENERATOR AND STARTER CLUTCH 2. Check: • starter clutch operation M MMM M MMM M MMM M MMM M MMM a. Install the starter clutch gear 1 onto the starter clutch and hold the starter clutch. b. When turning the starter clutch gear clock- wise È, the starter clutch and the starter clutch gear should engage, otherwise the starter clutch is faulty and must be…
Page 378
GENERATOR AND STARTER CLUTCH 3. Apply: • sealant (onto the stator coil assembly lead grom- met) ® Quick Gasket ACC-11001-05-01 4. Install: • stator coil assembly 1 7 Nm (0.7 m • kg, 5.2 ft • lb) • stator coil assembly lead holder 10 Nm (1.0 m •…
Page 379
TRANSFER GEAR CASE TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •…
Page 380
TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 381
TRANSFER GEAR CASE Order Job/Part Q’ty Remarks Disassembling the transfer gear Remove the parts in the order listed. case oil pump Oil pump cover Oil pump shaft Oil pump inner rotor Oil pump outer rotor Oil pump housing For assembly, reverse the disassembly procedure.
Page 382
TRANSFER GEAR CASE FUEL PUMP 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the fuel pump Remove the parts in the order listed. Seat/cover Refer to “SEAT AND SIDE COVERS” in chapter 3. Fuel tank Refer to “FUEL TANK”…
Page 383
TRANSFER GEAR CASE REMOVING THE FUEL PUMP 1. Remove: • fuel pump CAUTION: • Do not drop the fuel pump or give it a strong shock. • Do not touch the base section of the fuel sender. INSTALL THE FUEL PUMP 1.
Page 384
TRANSFER GEAR CASE SUB FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 28 Nm (2.8 m kg, 20 ft • • Order Job/Part Q’ty Remarks Removing the sub fuel tank Remove the parts in the order listed. Fuel pump Refer to “FUEL PUMP”.
Page 385
TRANSFER GEAR CASE 50 Nm (5.0 m kg, 36 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the transfer gear case Remove the parts in the order listed. Seat/right side cover Refer to “SEAT AND SIDE COVERS”…
Page 386
TRANSFER GEAR CASE 50 Nm (5.0 m kg, 36 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Oil seal Transfer gear case Dowel pin Bearing Bearing housing For installation, reverse the removal procedure.
Page 387
TRANSFER GEAR CASE 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Disassembling the oil tank Remove the parts in the order listed. Oil temperature sensor Oil tank left cover Oil tank left cover gasket…
Page 388
TRANSFER GEAR CASE REMOVING THE MIDDLE DRIVEN SHAFT NOTE: Loosen the middle drive gear nut before remove the drive sprocket. 1. Straighten the lock washer tab. 2. Loosen: • middle drive gear nut 1 NOTE: When loosening the middle drive gear nut, press down on the brake pedal so the middle drive gear does not move.
Page 389
TRANSFER GEAR CASE CHECKING THE OIL STRAINER 1. Check: • oil strainer Damage → Replace. Contaminants → Clean with engine oil. CHECKING THE OIL PUMP 1. Check: • oil pump housing 1 • oil pump cover 2 Cracks/damage/wear → Replace the defec- tive part(-s).
Page 390
TRANSFER GEAR CASE CHECKING THE OIL PIPE 1. Check: • oil pipe Damage → Replace. EAS00375 ASSEMBLING THE OIL PUMP 1. Lubricate: • inner rotor • outer rotor • oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.
Page 391
TRANSFER GEAR CASE 4. Check: • oil pump operation Refer to “CHECKING THE OIL PUMP”. INSTALLING THE TRANSFER GEAR CASE 1. Install: • middle driven shaft 1 • middle drive gear 2 • primary chain 3 (into the transfer gear case) •…
Page 392
TRANSFER GEAR CASE 4. Install: • lock washer • middle drive gear nut 1 100 Nm (10.0 m • kg, 72 ft • lb) 5. Bend the lock washer tab along a flat side of the nut. 6. Remove: • drive sprocket nut 7.
Page 393
CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Separating the crankcase Remove the parts in the order listed. Engine Refer to “ENGINE”. Camshafts Refer to “CAMSHAFTS”. Pistons Refer to “CYLINDERS AND PISTONS”. Shift shaft Refer to “SHIFT SHAFT AND STOPPER LEVER”. Generator rotor Refer to “GENERATOR AND STARTER CLUTCH”.
Page 394
CRANKCASE Order Job/Part Q’ty Remarks Engine oil pump driven gear Left crankcase Dowel Joint pipe Right crankcase For installation, reverse the removal procedure. 5 — 94…
Page 395
CRANKCASE Order Job/Part Q’ty Remarks Removing the baffle plate and Remove the parts in the order listed. bearings Crankshaft Refer to “CRANKSHAFT AND CON- NECTING RODS”. Transmission Refer to “TRANSMISSION”. Baffle plate Oil seal Bearing For installation, reverse the removal procedure.
Page 396
CRANKCASE EAS00386 DISASSEMBLING THE CRANKCASE NOTE: Loosen the generator shaft bolt before remov- ing the generator rotor. 1. Remove: • generator shaft bolt 1 NOTE: While the holding the generator rotor 2 with the primary sheave holder 3, loosen the gen- erator shaft bolt.
Page 397
CRANKCASE 3. Turn: • shift drum segment NOTE: Turn the shift drum segment 1 to the position shown in the illustration. In this position, the shift drum segment’s teeth will not contact the crankcase during crankcase separation. 4. Remove: • right crankcase CAUTION: •…
Page 398
CRANKCASE EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1. Check: • bearings Clean and lubricate the bearings, then rotate the inner race with your finger. Rough movement → Replace. 2. Check: • oil seals Damage/wear → Replace. CHECKING THE OIL DELIVERY PIPE 1.
Page 399
CRANKCASE EAS00416 ASSEMBLING THE CRANKCASE 1. Apply: • sealant (onto the crankcase mating surfaces) ® Quick Gasket ACC-11001-05-01 NOTE: Do not allow any sealant to come into contact with the oil gallery. 2. Install: • dowel pins 1 • joint pipe 2 3.
Page 400
CRANKCASE È 4. Install: • holder • crankcase bolts NOTE: • Lubricate the bolt threads with engine oil. • Tighten each bolt 1/4 of a turn at a time, in stages and in a crisscross pattern. • Tighten the bolts in numerical order (refer to the numbers in the illustration).
Page 401
CRANKCASE 9. Install: • washer • generator shaft bolt 1 28 Nm (2.8 m • kg, 20 ft • lb) NOTE: ® • Apply locking agent (LOCTITE ) to the threads of the generator shaft bolt. • While holding the generator rotor 2 with the primary sheave holder 3, tighten the gener- ator shaft bolt.
Page 402
ENGINE OIL PUMP EAS00356 ENGINE OIL PUMP Order Job/Part Q’ty Remarks Removing the engine oil pump Remove the parts in the order listed. Crankcase Separate. Refer to “CRANKCASE” Oil strainer Engine oil pump assembly For installation, reverse the removal procedure. 5 — 102…
Page 403
ENGINE OIL PUMP Order Job/Part Q’ty Remarks Disassembling the engine oil pump Remove the parts in the order listed. Spring retainer Spring Relief valve Oil pump housing cover 1 Spring Collar Ball Oil pump outer rotor 1 Oil pump inner rotor 1 5 — 103…
Page 404
ENGINE OIL PUMP Order Job/Part Q’ty Remarks Oil pump housing cover 2 Oil pump shaft Oil pump inner rotor 2 Oil pump outer rotor 2 Oil seal Oil pump housing For assembly, reverse the disassembly procedure. 5 — 104…
Page 405
ENGINE OIL PUMP EAS00363 CHECKING THE OIL PUMP 1. Check: • oil pump housing 1 • oil pump housing covers 2 Cracks/damage/wear → Replace the defec- tive part(s). 2. Measure: • inner-rotor-to-outer-rotor-tip clearance a • outer-rotor-to-oil-pump-housing clearance Out of specification → Replace the oil pump.
Page 406
ENGINE OIL PUMP 2. Check: • ball 1 • collar 2 • spring 3 • oil seal 4 Damage/wear → Replace the defective part(s). EAS00368 CHECKING THE OIL STRAINER 1. Check: • oil strainer 1 Damage → Replace. Contaminants → Clean with solvent. EAS00375 ASSEMBLING THE OIL PUMP 1.
Page 407
ENGINE OIL PUMP 2. Install: • oil pump housing 1 • oil seals 2 • oil pump outer rotor 2 3 • oil pump inner rotor 2 4 • pin 5 • oil pump shaft 6 • pins 7 • oil pump housing cover 2 8 2 Nm (0.2 m •…
Page 408
ENGINE OIL PUMP EAS00378 INSTALLING THE OIL STRAINER 1. Install: • oil strainer 1 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: The arrow mark on the oil strainer cover must point towards the rear of the engine. 5 — 108…
Page 409: Crankshaft And Connecting Rods

CRANKSHAFT AND CONNECTING RODS CRANKSHAFT AND CONNECTING RODS Order Job/Part Q’ty Remarks Removing the crankshaft and Remove the parts in the order listed. connecting rods Crankcase Separate. Refer to “CRANKCASE”. Crankshaft Generator shaft Connecting rod cap Big end lower bearing Connecting rod Big end upper bearing For installation, reverse the removal…
Page 410
CRANKSHAFT AND CONNECTING RODS EAS00385 REMOVING THE CRANKSHAFT 1. Remove: • crankshaft journal bearing 1 NOTE: • Remove the crankshaft journal bearing with the bearing remover and installer 2 and bearing driver 3. Bearing remover and installer YM-28898 Bearing driver YM-04058 EAS00391 REMOVING THE CONNECTING RODS…
Page 411
CRANKSHAFT AND CONNECTING RODS 2. Check: • crankshaft journal surfaces • crankshaft pin surfaces • bearing surfaces Scratches/wear → Replace the crankshaft. • generator shaft drive gear 1 Damage/wear → Replace the crankshaft. 3. Measure: • crankshaft-pin-to-big-end-bearing clear- ance Out of specification → Replace the big end bearings.
Page 412
CRANKSHAFT AND CONNECTING RODS d. Assemble the connecting rod halves. NOTE: • Do not move the connecting rod or crank- shaft until the clearance measurement has been completed. • Lubricate the bolts threads and nut seats with molybdenum disulfide grease. •…
Page 413
CRANKSHAFT AND CONNECTING RODS CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle. • Tighten the bolt until it is the specified angle. NOTE: When using a hexagonal bolt note that the angle from one corner to another is 60°. h.
Page 414
CRANKSHAFT AND CONNECTING RODS 4. Select: • big end bearings (P NOTE: • The numbers a stamped into the crankshaft web and the numbers b on the connecting rods are used to determine the replacement big end bearing sizes. • “P ”…
Page 415
CRANKSHAFT AND CONNECTING RODS 5. Measure: • crankshaft journal diameter a Out of specification → Replace the crank- shaft. Crankshaft journal diameter 49.968 ~ 49.980 mm (1.9672 ~ 1.9677 in) NOTE: Measure the diameter of each crankshaft jour- nal at two places. 6.
Page 416
CRANKSHAFT AND CONNECTING RODS 7. Calculate: • crankshaft journal-to-crankshaft journal bearing clearance Out of specification → Replace the crank- shaft and crankshaft journal bearings as a set. NOTE: Calculate the clearance by subtracting the crankshaft journal diameter from the crank- shaft journal bearing inside diameter.
Page 417
CRANKSHAFT AND CONNECTING RODS 3. Install: • big end bearings • connecting rods • connecting rod caps (onto the crankshaft pins) NOTE: • Align the projections a on the big end bear- ings with the notches b in the connecting rods and connecting rod caps.
Page 418
CRANKSHAFT AND CONNECTING RODS WARNING When the bolts are tightened more than the specified angle, do not loosen the bolt and then retighten it. Replace the bolt with a new one and per- form the procedure again. CAUTION: • Do not use a torque wrench to tighten the bolt to the specified angle.
Page 419
TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE”. Shift fork guide bar Shift fork “L” Shift fork “R” Shift fork “C” Shift drum assembly Drive axle assembly Main axle assembly…
Page 420
TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. assembly Circlip Washer 5th pinion gear 2nd/3rd pinon gear Circlip Washer 4th pinon gear Main axle/1st pinon gear For assembly, reverse the disassembly procedure. 5 — 120…
Page 421
TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly 5th wheel gear Circlip Washer 2nd wheel gear Circlip Washer 1st wheel gear 4th wheel gear Circlip Washer 3rd wheel gear Drive axle For assembly, reverse the disassembly procedure.
Page 422
TRANSMISSION EAS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1. Check: • shift fork cam follower 1 • shift fork pawl 2 Bends/damage/scoring/wear → Replace the shift fork. 2. Check: • shift fork guide bar Roll the shift fork guide bar on a flat surface.
Page 423
TRANSMISSION EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage/scratches/wear → Replace the shift drum assembly. • shift drum segment 1 Damage/wear → Replace the shift drum assembly. • shift drum bearing 2 Damage/pitting → Replace the shift drum assembly.
Page 424
TRANSMISSION 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • circlips Bends/damage/looseness → Replace. EAS00428 INSTALLING THE TRANSMISSION 1.
Page 425
TRANSMISSION 2. Check: • transmission Rough movement → Repair. NOTE: Oil each gear, shaft, and bearing thoroughly. 5 — 125…
Page 426
FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM 1 Linear control valve 8 Spark plug E Decompression solenoid 2 Intake air pressure sensor 2 9 Relay unit F Crankshaft position sensor 3 Intake air temperature sensor 0 ECU G Cylinder identification sensor 4 Intake air pressure sensor 1 A Battery H Ignition coil…
Page 427
FUEL INJECTION SYSTEM WIRING DIAGRAM 6 — 2…
Page 428
FUEL INJECTION SYSTEM 3 Main switch 4 Battery 6 Main fuse A Fuel injection system relay B Fuel pump E Crankshaft position sensor F Throttle position sensor G Intake air pressure sensor 1 H Intake air pressure sensor 2 I Atmospheric pressure sensor J Cylinder identification sensor K Lean angle cut-off switch L Speed sensor…
Page 429
FUEL INJECTION SYSTEM ECU’S SELF-DIAGNOSTIC FUNCTION The ECU is equipped with a self-diagnostic function in order to ensure that the engine control sys- tem is operating normally. If this function detects a malfunction in the system, it immediately oper- ates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Page 430: Fuel Injection System

FUEL INJECTION SYSTEM Engine trouble warning light indication and FI system operating conditions (normal mode) Warning light ECU’s operating FI operating condition Starting and driving indication condition ON and OFF *1 Self-diagnostic func- FI function in operation Able tion in operation Blinking *2 Warning control when Operation stopped…
Page 431
FUEL INJECTION SYSTEM Function to check for blown warning light bulb The engine trouble warning light illuminates 1 for 1.4 seconds after the main switch has been turned “ON” and while the starter switch is being pressed. If the warning light does not illuminate under these conditions, a problem may have possibly occurred, such as a blown warning light bulb.
Page 432
FUEL INJECTION SYSTEM * Table of self-diagnostic fault code numbers displayed on meter Able/ Able/ Able/ Able/ Symptom unable to unable to Symptom unable to unable to start drive start drive No normal signals are received Faulty intake air pressure sensor from the cylinder identification pipe system 2;…
Page 433
FUEL INJECTION SYSTEM SUBSTITUTE CHARACTERISTICS OPERATION CONTROL (FAIL-SAFE ACTION) If the ECU detects an abnormal signal from a sensor while the motorcycle is being driven, the ECU illuminates the engine trouble warning light and provides the engine with substitute characteristic operation instructions that are appropriate for the type of the malfunction.
Page 434
FUEL INJECTION SYSTEM TROUBLESHOOTING Diagnosis mode troubleshooting 1 (self-diagnostic malfunction detected) By entering a diagnostic code in the ECU through the use of the “SELECT” and “RESET” buttons on the tachometer, the sensor output values can be displayed and the actuators can be operated in accordance with the code that has been entered.
Page 435
FUEL INJECTION SYSTEM Verifying the operation of various sensors and actuators 1. Disconnect the wiring harness coupler from the fuel pump. 2. Turn the engine stop switch “OFF”. TRIP mile · Turn the engine stop switch “ON” if diag- nostic code numbers 03 and 09 are shown.
Page 436
FUEL INJECTION SYSTEM Erase the codes appearing on the meter upon the completion of the operation (reinstating the ECU). * Verify reinstatement procedures detailed in the troubleshooting details in order to carry out the reinstatement opera- tion that is applicable to the malfunctioning item.
Page 437
FUEL INJECTION SYSTEM Self-diagnostic fault codes, symptoms, and probable causes Diagnostic code indication Code No. Symptom Probable cause of malfunction Diagnostic code No normal signals are received from • Open or short circuit in wiring sub lead. the cylinder identification sensor. •…
Page 438
FUEL INJECTION SYSTEM Code No. Symptom Probable cause of malfunction Diagnostic code Atmospheric pressure sensor — open • Open or short circuit in wiring harness. or short circuit detected. • Defective atmospheric pressure sensor. • Improperly installed sensor. • Malfunction in ECU. Intake air pressure sensor 2 — open or •…
Page 439
FUEL INJECTION SYSTEM Sensor operation data display verification table NOTE: • Check the intake temperature, engine temperature, and oil temperature as close as possible to the area in which the respective sensor is mounted. • If it is not possible to check it with an atmospheric pressure gauge, judge it by using 760 mmHg as the standard.
Page 440
FUEL INJECTION SYSTEM Data displayed on meter Diag code Item Description of action (reference value) Malfunction history • Displays the total number of codes that are being detected 00 ~ 21 code erasure through self diagnosis and the fault codes in the past his- (00) Displays when there is no tory.
Page 441
FUEL INJECTION SYSTEM Actuator operation verification table Data displayed on meter Diag code Item Description of action (reference value) Ignition coil #1 After 1 second has elapsed from the time the engine stop Check that spark is generated, switch has been turned from OFF to ON, it actuates ignition 5 times with the engine stop coils #1 for five times every second and illuminates the engine switch ON.
Page 442: Troubleshooting

FUEL INJECTION SYSTEM Troubleshooting The condition of the engine is poor or the engine trouble warning light comes on. * The engine trouble warning light may not come on even if the condition of the engine is poor. The engine trouble warning light comes on. The engine trouble warning light does not come on.
Page 443
FUEL INJECTION SYSTEM Troubleshooting details Troubleshooting the self-diagnostic fault code Code No. Symptom No normal signals are received from the cylinder identification sensor. Used diagnostic code No. 1.Inspection operation item Operation item and countermeasure Reinstatement method 2.Defective cylinder identification sensor. Replace if defective.
Page 444
FUEL INJECTION SYSTEM Code No. Symptom Intake air pressure sensor 1 — open or short circuit detected. Used diagnostic code No. 03 (intake air pressure sensor 1) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Open or short circuit in wiring harness or Repair or replace if there is an open or short Reinstated by turn- sub lead.
Page 445
FUEL INJECTION SYSTEM Code No. Symptom 1 Intake air pressure sensor 1 — pipe system malfunction (clogged or detached hose). 2 Intake air pressure sensor 1 — open or short circuit detected. 3 Stuck throttle position sensor detected. Used diagnostic code No.
Page 446
FUEL INJECTION SYSTEM Code No. Symptom Throttle position sensor — open or short circuit detected. Used diagnostic code No. 01 (throttle position sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of throttle position sensor. Check the installed area for looseness or Reinstated by turn- pinching.
Page 447
FUEL INJECTION SYSTEM Code No. Symptom 1 Stuck throttle position sensor detected. 2 Intake air pressure sensor — pipe system malfunction (clogged or detached hose). Used diagnostic code No. 01 (throttle position sensor) No. 03 (intake air pressure sensor 1) No.
Page 448
FUEL INJECTION SYSTEM Code No. Symptom Open circuit is detected in the input line from the sidestand switch to the ECU. Used diagnostic code No. 20 (sidestand switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Open or short circuit in wiring harness or Repair or replace if there is an open or short If the transmission…
Page 449
FUEL INJECTION SYSTEM Code No. Symptom Open or short circuit detected from the atmospheric pressure sensor. Used diagnostic code No. 02 (atmospheric pressure sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of atmospheric pressure sen- Check the installed area for looseness or Reinstated by turn- pinching.
Page 450
FUEL INJECTION SYSTEM Code No. Symptom 1 Intake air pressure sensor 2 — pipe system malfunction (clogged or detached hose). 2 Intake air pressure sensor 2 — open or short circuit detected. 3 Stuck throttle position sensor detected. Used diagnostic code No.
Page 451
FUEL INJECTION SYSTEM Code No. Symptom Open or short circuit is detected from the oil temperature sensor. Used diagnostic code No. 10 (oil temperature sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of sensor Check the installed area for looseness or Reinstated by turn- pinching.
Page 452
FUEL INJECTION SYSTEM Code No. Symptom Electricity is not circulated to the decompression solenoid (open or short circuit in thermistor is detected) Used diagnostic code No. 55 (decompression solenoid) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Installed state of decompression solenoid Check the installed area for looseness or…
Page 453
FUEL INJECTION SYSTEM Code No. Symptom Faulty liner control valve or motor is detected. Used diagnostic code No. 54 (linear control valve) No. 10 (oil temperature sensor) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1-1.Defective linear control valve Replace if defective.
Page 454
FUEL INJECTION SYSTEM Code No. Symptom Open or short circuit detected in the lean angle cut-off switch. Used diagnostic code No. 08 (lean angle cut-off switch) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Open or short circuit in lead wire. Repair or replace if there is an open or short Reinstated by turn- circuit.
Page 455
FUEL INJECTION SYSTEM Code No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic code No. 50 (fuel injection system relay) Inspection operation item and probable cause Operation item and countermeasure Reinstatement method 1.Malfunction in ECU Fuel injection system relay is on. Reinstated by starting the engine 2.Open or short circuit in the wiring harness.
Page 456
FUEL INJECTION SYSTEM Diagnosis mode troubleshooting 2 (self-diagnostic malfunction not detected) Troubleshooting the sensors and actuator with no malfunctions detected, and special indications Even if the malfunctions of some of the sensors do not appear on the meter because they are not detected by the self-diagnostic function, they can be inspected in the diagnosis mode.
Page 457
FUEL INJECTION SYSTEM Symptom Engine cannot be started or difficult to start. (Fuel is not supplied to the cylinder.) Probable mal- • Open or short circuit in injector function area • Open or short circuit in wiring harness Inspection method 1 Inspection method 2 Inspection by diagnosis mode Inspection of a malfunction that cannot be identified in the…
Page 458
FUEL INJECTION SYSTEM Symptom The headlight does not turn ON or OFF. Probable mal- • Malfunction in the headlight relay function area • Malfunction in the headlight • Open or short circuit in the headlight wiring harness • Malfunction in the handlebar switch •…
Page 459
FUEL INJECTION SYSTEM Symptom Clock LCD displays “Er-2”. (No signals are received from the ECU within the specified duration.) Probable mal- • Improper operation of communication line function area • Malfunction in meter • Malfunction in ECU Inspection method 1 Inspection method 2 Inspection by diagnosis mode Inspection of a malfunction that cannot be identified in the…
Page 460
FUEL INJECTION SYSTEM Symptom Sidestand switch does not function (the engine does not stop when the stand is extended). Probable mal- • Short circuit in the input line to ECU function area • Malfunction in the starter circuit cut-off relay Inspection method 1 Inspection method 2 Inspection by diagnosis mode…
Page 461
FUEL INJECTION SYSTEM Symptom Engine trouble warning light blinks while the start switch is being pressed (to warn that the engine is unable to start). Probable mal- • Malfunction in Fuel injection system relay function area • Open circuit in wiring harness •…
Page 462
FUEL INJECTION SYSTEM THROTTLE BODIES 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the throttle bodies Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS” in chapter 3. Fuel tank/Air induction system cover/ Refer to “FUEL TANK”…
Page 463
FUEL INJECTION SYSTEM 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Throttle stop screw Throttle body joint screw Throttle bodies Throttle cable Disconnect. Throttle position sensor Refer to “FUEL INJECTION SYSTEM” in chapter 7. For installation, reverse the removal procedure.
Page 464
FUEL INJECTION SYSTEM 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Removing the intake manifolds Remove the parts in the order listed. Engine temperature sensor coupler Disconnect. Injection sub-wire harness coupler Disconnect. Fuel hose Disconnect. Linear control valve outlet hose Disconnect.
Page 465
FUEL INJECTION SYSTEM 30 Nm (3.0 m kg, 22 ft • • Order Job/Part Q’ty Remarks Removing the injectors Remove the parts in the order listed. Cylinder #1-injector coupler Disconnect. Cylinder #2-injector coupler Disconnect. Injector sub-wire harness Fuel pipe Injector joint 1 Injector joint 2 Injector For installation, reverse the removal…
Page 466
FUEL INJECTION SYSTEM CAUTION: The throttle bodies should not be disas- sembled unnecessarily. CHECKING THE INJECTOR 1. Check: • injector Damage → Replace. CHECKING THE THROTTLE BODY 1. Check: • throttle body Cracks/damage → Replace the throttle bodies. 2. Check: •…
Page 467
FUEL INJECTION SYSTEM CHECKING THE FUEL PUMP AND PRESSURE REGULATOR OPERATION 1. Check: • pressure regulator operation M MMM M MMM M MMM M MMM M MMM a. Remove the air duct. Refer to “FUEL TANK” in chapter 3. b. Remove the fuel hose end clamp 1. c.
Page 468: Air Induction System

AIR INDUCTION SYSTEM EAS00507 AIR INDUCTION SYSTEM AIR INJECTION The air induction system burns unburned exhaust gases by injecting fresh air (second- ary 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 469
AIR INDUCTION SYSTEM AIR CUT-OFF VALVE ASSEMBLY AND AIR INDUCTION SYSTEM HOSES 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • Order Job/Part Q’ty Remarks Removing the air cut-off valve Remove the parts in the order listed. assembly and hoses Fuel hose joint 1/air duct Refer to “FUEL TANK”…
Page 470
AIR INDUCTION SYSTEM REED VALVES 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the reed valves Remove the parts in the order listed. Air cut-off valve assembly/hoses A.I.S. vacuum hose Reed valve cover Reed valve assembly Reed valve case Pressure regulator A.I.S.
Page 471
AIR INDUCTION SYSTEM CHECKING THE PRESSURE REGULATOR 1. Check: • pressure regulator Damage → Replace. EAS00510 CHECKING THE AIR INDUCTION SYSTEM 1. Check: • hoses Loose connection → Connect properly. Cracks/damage → Replace. • pipes Cracks/damage → Replace. 2. Check: •…
Page 472
– ELEC ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 1 Ignition coil 2 7 Clutch switch C Decompression solenoid 2 Ignition coil 1 8 Atmospheric pressure sensor D Sidestand switch 3 Intake air pressure sensor 2 9 ECU E Crankshaft position sensor 4 Front brake light switch 0 Battery F Starter motor…
Page 473
– ELEC ELECTRICAL COMPONENTS 1 Intake air temperature sensor A Relay unit 2 Linear control valve B Speed sensor 3 Throttle position sensor C Lean angle cut-off switch 4 Engine temperature sensor D Oil temperature sensor 5 Spark plugs E Neutral switch 6 Fuse box F Stator coil assembly 7 Main fuse…
Page 474
ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS ARRANGEMENT OF THE ELECTRICAL COMPONENTS AND COUPLERS 1 Speedometer coupler, tachometer couplers, right handlebar switch coupler and front turn signal/position connectors 2 Speedometer coupler, main switch coupler and left handlebar switch couplers 3 Headlight coupler 1 Rear turn signal light (left) connectors and license plate light connectors 2 Rear turn signal light (right) connectors…
Page 475
ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 Linear control valve 9 Starter motor 2 Ignition coil 1 (rear cylinder) 0 Starter motor lead 3 Atmospheric pressure sensor A Rectifier/regulator coupler 4 Atmospheric pressure sensor coupler B Stator coil assembly coupler 5 Spark plug cap (ignition coil 2 — L spark plug lead) C Horn 1 connectors 6 Spark plug cap (ignition coil 1 — L spark plug lead)
Page 476
ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 ECU coupler 2 ECU 3 Tail sub-wire harness coupler, decompression solenoid couplers, cylinder identification coupler, crankshaft position sensor coupler, speed sensor coupler, neutral switch connector and sidestand switch coupler 4 Fuel pump coupler 5 Horn 2 6 Horn 2 coupler 7 Lean angle cut-off switch coupler…
Page 477
ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 ECU fuse 8 Battery positive lead 2 Fuse box 9 Headlight relay 3 Starter relay coupler 0 Battery negative lead 4 Main fuse A Horn 2 5 Starter relay B Startr motor lead 6 Turn signal relay C Relay unit 7 Battery…
Page 478
ARRANGEMENT OF THE ELECTRICAL COMPONENTS – ELEC AND COUPLERS 1 Spark plug cap (ignition coil 1 — R spark plug lead) 0 Rear brake light switch 2 Throttle position sensor A Stator coil 3 Intake air pressure sensor 1 coupler B Cylinder identification sensor 4 Engine temperature sensor coupler C Decompression solenoid…
Page 479: 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 incor- rect, check the wiring connections and if nec- essary, replace the switch. CAUTION: Never insert the tester probes into the cou- pler terminal slots 1.
Page 480: 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 ter- minals. Refer to “CHECKING SWITCH CONTINUITY”. Damage/wear → Repair or replace the switch. Improperly connected → Properly connect. Incorrect continuity reading →…
Page 481
– ELEC CHECKING THE SWITCHES 1 Dimmer switch 2 Horn switch 3 Turn signal switch 4 Clutch switch 5 Engine stop switch 6 Start switch 7 Front brake light switch 8 Main switch 9 Fuse 0 Rear brake light switch A Neutral switch B Sidestand switch 7 — 11…
Page 482: 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 con- tinuity between the terminals. Damage/wear → Repair or replace the bulb, bulb socket or both.
Page 483
– ELEC CHECKING THE BULBS AND BULB SOCKETS WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. CAUTION: • Be sure to hold the socket firmly when removing the bulb.
Page 484
– ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE CONDITION OF THE BULB SOCKETS The following procedure applies to all of the bulb sockets. 1. Check: • bulb socket (for continuity) (with the pocket tester) No continuity → Replace. Pocket tester YU-03112 NOTE:…
Page 485
– ELEC CHECKING THE BULBS AND BULB SOCKETS CHECKING THE LEDs The following procedures applies to all of the LEDs. 1. Check: Dg Lg B • LED (for proper operation) Ch Y Improper operation → Replace. M MMM M MMM M MMM M MMM M MMM…
Page 486
– ELEC IGNITION SYSTEM EAS00735 IGNITION SYSTEM CIRCUIT DIAGRAM 7 — 16…
Page 487
– ELEC IGNITION SYSTEM EAS00737 EAS00738 TROUBLESHOOTING 1. Main and ignition fuses The ignition system fails to operate (no • Check the main and ignition fuses for con- spark or intermittent spark). tinuity. Refer to “CHECKING THE FUSES” in Check: chapter 3.
Page 488
– ELEC IGNITION SYSTEM EAS00745 • Is the spark plug in good condition, is it of 5. Spark plug cap resistance the correct type, and is its gap within spec- ification? The following procedure applies to all of the spark plug caps. •…
Page 489
– ELEC IGNITION SYSTEM EAS00747 • Is the ignition coil OK? 6. Ignition coil resistance The following procedure applies to all of the ignition coils. • Disconnect the ignition coil leads from the Replace the ignition wire harness. coil. • Connect the pocket tester (Ω × 1) to the EAS00748 ignition coil as shown.
Page 490: Ignition System

– ELEC IGNITION SYSTEM EAS00749 12.Lean angle cut-off switch voltage 8. Main switch • Remove the lean angle cut-off switch. • Check the main switch for continuity. • Connect the pocket tester (Ω × 1) to the Refer to “CHECKING THE SWITCHES”. lean angle cut-off switch terminals as •…
Page 491
– ELEC IGNITION SYSTEM EAS00760 EAS00754 13.Relay unit (diode) 14.Wiring • Remove the relay unit from the wire har- • Check the entire ignition system’s wiring. ness. Refer to “CIRCUIT DIAGRAM”. • Connect the pocket tester (Ω × 1) to the •…
Page 492
– ELEC ELECTRIC STARTING SYSTEM EAS00755 ELECTRIC STARTING SYSTEM CIRCUIT DIAGRAM 7 — 22…
Page 493
– 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: •…
Page 494: Electric Starting System

– ELEC ELECTRIC STARTING SYSTEM EAS00757 EAS00739 TROUBLESHOOTING 2. Battery The starter motor fails to turn. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main, ignition and decompression solenoid fuses Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F)
Page 495
– ELEC ELECTRIC STARTING SYSTEM EAS00759 Positive tester probe → 4. Relay unit (starting circuit cut-off relay) sky blue 1 Negative tester probe → • Remove the relay unit from the wire har- black/yellow 2 ness. • Connect the pocket tester (Ω × 1) and bat- Positive tester probe →…
Page 496
– ELEC ELECTRIC STARTING SYSTEM EAS00761 EAS00750 6. Starter relay 8. Engine stop switch • Remove the starter relay. • Check the engine stop switch for continu- • Connect the pocket tester (Ω × 1) and bat- ity. tery (12 V) to the starter relay terminals as Refer to “CHECKING THE SWITCHES”.
Page 497
– ELEC ELECTRIC STARTING SYSTEM EAS00764 Decompression solenoid 12.Start switch resistance 1.2 Ω at 20 °C (68 °F) • Check the start switch for continuity. Refer to “CHECKING THE SWITCHES”. • Check the decompression solenoid for • Is the start switch OK? continuity.
Page 498: Starter Motor

– ELEC STARTER MOTOR EAS00767 STARTER MOTOR 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Part Q’ty Remarks Removing the starter motor Remove the parts in the order listed. Starter motor lead Starter motor assembly For installation, reverse the removal procedure.
Page 499
– ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Disassembling the starter motor Remove the parts in the order listed. Circlip Starter motor gear Starter motor rear cover Lock washer Washer set Refer to “ASSEMBLING THE STARTER Oil seal MOTOR”. Bearing Circlip Starter motor front cover Brush…
Page 500
– ELEC STARTER MOTOR Order Job/Part Q’ty Remarks Brush holder (along with the brushes) Brush seat (along with the brushes) Bearing Refer to “ASSEMBLING THE STARTER MOTOR”. Gasket Armature assembly Starter motor yoke For assembly, reverse the disassembly procedure. 7 — 30…
Page 501
– ELEC STARTER MOTOR EAS00770 CHECKING THE STARTER MOTOR 1. Check: • commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • commutator diameter a Out of specification → Replace the starter motor. Commutator wear limit 27.5 mm (1.08 in) 3.
Page 502
– ELEC STARTER MOTOR 4. Measure: • armature assembly resistances (commuta- tor and insulation) Out of specification → Replace the starter motor. M MMM M MMM M MMM M MMM M MMM a. Measure the armature assembly resis- tances with the pocket tester. Pocket tester YU-03112 Armature coil…
Page 503
– ELEC STARTER MOTOR EAS00772 ASSEMBLING THE STARTER MOTOR 1. Install: • bearing • brush seat 1 NOTE: Align the slot a on the brush seat with the tab b in the starter motor front cover. 2. Install: • brush holder (along with the brushes) 1 3.
Page 504
– ELEC STARTER MOTOR 6. Install: • gasket 1 • starter motor cover 2 • bolts NOTE: Align the match marks a on the starter motor yoke with the match marks b on the starter motor rear cover. 7. Install: •…
Page 505: Charging System

– ELEC CHARGING SYSTEM EAS00773 CHARGING SYSTEM CIRCUIT DIAGRAM Br/B Br/B (BLACK) (BLACK) L/W1 WIREHARNESS TAIL SUB-WIREHARNESS WIREHARNESS INJECTION SUB-WIREHARNESS (BLACK) (GRAY) L W/Y (BLACK) Br/L Br/L (BLACK) Br/L (GRAY) B/L Br/W (BLACK) (BLA å (BLACK) Br/B Br B L W/B (BLACK) (BLACK) (BLACK)
Page 506
– ELEC CHARGING SYSTEM EAS00774 EAS00739 TROUBLESHOOTING 2. Battery The battery is not being charged. • Check the condition of the battery. Refer to “CHECKING AND CHARGING Check: THE BATTERY” in chapter 3. 1. main fuse 2. battery Minimum open-circuit voltage 12.8 V or more at 20 °C (68 °F) 3.
Page 507
– ELEC CHARGING SYSTEM EAS00779 • Is the charging voltage within specifica- 5. Wiring tion? • Check the wiring connections of the entire charging system. Refer to “CIRCUIT DIAGRAM”. • Is the charging system’s wiring properly The charging circuit connected and without defects? is OK.
Page 508
– ELEC LIGHTING SYSTEM EAS00780 LIGHTING SYSTEM CIRCUIT DIAGRAM 7 — 38…
Page 509
– ELEC LIGHTING SYSTEM EAS00781 EAS00739 TROUBLESHOOTING 2. Battery Any of the following fail to light: head- • Check the condition of the battery. light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING position light, license plate light or meter THE BATTERY”…
Page 510: Lighting System

– ELEC LIGHTING SYSTEM EAS00788 5. Headlight relay CHECKING THE LIGHTING SYSTEM 1. The headlight and the high beam indicator • Remove the headlight relay from the wire light fail to come on. harness. • Connect the pocket tester (Ω × 1) and bat- 1.
Page 511
– ELEC LIGHTING SYSTEM EAS00789 Headlight 2. The tachometer and speedometer light fails Positive tester probe → to come on. yellow 1 or green 2 1. Tachometer and speedometer light LED Negative tester probe → black 3 • Check the LED of the tachometer and High beam indicator light speedometer light.
Page 512
– ELEC LIGHTING SYSTEM Speedometer assembly coupler 2. Voltage • Connect the pocket tester (DC 20 V) to the tail/brake light assembly coupler (tail sub- wire harness side) as shown. Positive tester probe → blue 1 Dg Lg B Negative tester probe → black 2 Ch Y Br Ch Y Dg Lg B…
Page 513
– ELEC LIGHTING SYSTEM • Check the front turn signal/position light 2. Voltage bulb and socket for continuity. • Connect the pocket tester (DC 20 V) to the Refer to “CHECKING THE BULBS AND license plate light connectors (wire har- BULB SOCKETS”.
Page 514
– ELEC SIGNALING SYSTEM EAS00793 SIGNALING SYSTEM CIRCUIT DIAGRAM 7 — 44…
Page 515
– ELEC SIGNALING SYSTEM 3 Main switch 4 Battery 5 Backup fuse (odometer and clock) 6 Main fuse 9 Relay unit B Fuel pump C Neutral switch P ECU X Tachometer [ Engine trouble warning light Neutral indicator light ] Speedometer _ Fuel level warning light a Left turn signal indicator light…
Page 516
– ELEC SIGNALING SYSTEM EAS00794 EAS00739 TROUBLESHOOTING 2. Battery • Any of the following fail to light: turn • Check the condition of the battery. signal light, brake light or an indicator Refer to “CHECKING AND CHARGING light. THE BATTERY” in chapter 3. •…
Page 517: Signaling System

– ELEC SIGNALING SYSTEM EAS00796 3. Horn 1 CHECKING THE SIGNALING SYSTEM 1. The horn 1 fails to sound. • Disconnect the black connector at the horn 1 terminal. 1. Horn switch • Connect a jumper lead 1 to the horn 1 ter- •…
Page 518
– ELEC SIGNALING SYSTEM EAS00796 3. Horn 2 2. The horn 2 fails to sound. • Disconnect the horn 2 coupler at the horn 1. Horn switch • Check the horn switch for continuity. • Connect a jumper lead 1 to the brown ter- Refer to “CHECKING THE SWITCHES”.
Page 519
– ELEC SIGNALING SYSTEM EAS00799 2. Brake light switches 4. The turn signal light, turn signal indicator light or both fail to blink. • Check the brake light switches for continu- ity. 1. Turn signal light bulb and socket Refer to “CHECKING THE SWITCHES”. •…
Page 520
– ELEC SIGNALING SYSTEM 4. Voltage 5. Voltage • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the turn signal relay coupler (wire harness turn signal relay coupler (wire harness side) as shown.
Page 521
– ELEC SIGNALING SYSTEM • Set the main switch to “ON”. 6. Voltage • Set the turn signal switch to “ ” or “ ”. • Connect the pocket tester (DC 20 V) to the • Measure the voltage (DC 12 V) of the turn signal light connectors or speedome- chocolate 1 or dark green 2 at the turn ter assembly coupler (wire harness side)
Page 522
– ELEC SIGNALING SYSTEM EAS00803 3. Voltage 6. The fuel level indicator light fails to come • Connect the pocket tester (DC 20 V) to the speedometer assembly coupler (wire har- 1. Fuel level indicator light LED ness side) as shown. •…
Page 523
– ELEC SIGNALING SYSTEM 3. Voltage 2. Voltage • Connect the pocket tester (DC V 20) to the • Connect the pocket tester (DC 20 V) to the speedometer assembly coupler (wire har- speedometer assembly coupler (wire har- ness side) as shown. ness side) as shown.
Page 524
– ELEC FUEL INJECTION SYSTEM FUEL INJECTION SYSTEM CIRCUIT DIAGRAM 7 — 54…
Page 525
– ELEC FUEL INJECTION SYSTEM 3 Main switch 4 Battery 6 Main fuse A Fuel injection system relay B Fuel pump E Crankshaft position sensor F Throttle position sensor G Intake air pressure sensor 1 H Intake air pressure sensor 2 I Atmospheric pressure sensor J Cylinder identification sensor K Lean angle cut-off switch…
Page 526
– ELEC FUEL INJECTION SYSTEM EAS00821 EAS00738 TROUBLESHOOTING 1. Main, ignition, ECU and fuel injection sys- tem fuses If the fuel injection system fails to oper- ate. • Check the main, ignition, ECU and fuel injection system fuses for continuity. Check: Refer to “CHECKING THE FUSES”…
Page 527
– ELEC FUEL INJECTION SYSTEM EAS00750 6. Cylinder #1-injector resistance 4. Engine stop switch • Disconnect the injection sub-wire harness • Check the engine stop switch for continu- coupler from the cylinder #1-injector. ity. • Connect the pocket tester (Ω × 1) to the Refer to “CHECKING THE SWITCHES”.
Page 528
– ELEC FUEL INJECTION SYSTEM EAS00817 7. Cylinder #2-injector resistance 8. Fuel pump resistance • Disconnect the injection sub-wire harness • Disconnect the fuel pump coupler from the coupler from the cylinder #2-injector. fuel pump. • Connect the pocket tester (Ω × 1) to the •…
Page 529
– ELEC FUEL INJECTION SYSTEM EAS00748 10.Cylinder identification sensor output volt- 9. Crankshaft position sensor resistance • Disconnect the crankshaft position sensor • Connect the pocket tester (DC 20 V) to the coupler from the wire harness. cylinder identification sensor coupler as •…
Page 530
– ELEC FUEL INJECTION SYSTEM 11.Speed sensor output voltage • Measure the speed sensor output voltage. • Connect the pocket tester (DC 20 V) to the speed sensor coupler as shown. Positive tester probe → white 1 Negative tester probe → black 2 •…
Page 531
– ELEC FUEL INJECTION SYSTEM 13.Intake air pressure sensor 1 output volt- 14.Intake air pressure sensor 2 output volt- • Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the intake air intake air pressure sensor 1 cou- intake air intake air pressure sensor 2 cou- pler as shown.
Page 532
– ELEC FUEL INJECTION SYSTEM Positive tester probe → blue 1 Negative tester probe → black/blue 2 P B/L L • Measure the engine temperature sensor resistance. • Set the main switch to “ON”. Engine temperature sensor • Measure the atmospheric pressure sensor resistance 898 ~ 1,098 Ω…
Page 533
– ELEC FUEL INJECTION SYSTEM EAS00818 17.Oil temperature sensor resistance 18.Wiring • Remove the oil temperature sensor from • Check the entire fuel injection system’s the oil tank. wiring. • Connect the pocket tester (Ω × 100) to the Refer to “CIRCUIT DIAGRAM”. oil temperature sensor terminal as shown.
Page 534
– ELEC FUEL INJECTION SYSTEM EAS00819 CHECKING THE FUEL PUMP WARNING Gasoline is extremely flammable and under certain circumstances there can be a dan- ger of an explosion or fire. Be extremely careful and note the following points: • Stop the engine before refueling. •…
Page 535
– ELEC FUEL INJECTION SYSTEM 1. Check: • throttle position sensor (installed on the throttle body) M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor.
Page 536
– ELEC FUEL INJECTION SYSTEM 2. Check: • throttle position sensor (removed from the throttle body) M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. b. Remove the throttle position sensor from the throttle body.
Page 537
– ELEC FUEL INJECTION SYSTEM 3. Adjust: • throttle position sensor angle M MMM M MMM M MMM M MMM M MMM a. Disconnect the throttle position sensor cou- pler from the throttle position sensor. b. Connect the pocket tester (Ω × 1k) to the throttle position sensor.
Page 538
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 man- ual for checks, adjustments, and replacement of parts.
Page 539: Incorrect Engine Idling Speed

STARTING FAILURES/ TRBL INCORRECT ENGINE IDLING SPEED SHTG ELECTRICAL SYSTEMS Battery Ignition system • Discharged battery • Faulty ECU • Faulty battery • Faulty crankshaft position sensor Fuse(s) • Broken generator rotor woodruff key • Blown, damaged or incorrect fuse Switches and wiring •…
Page 540: Faulty Gear Shifting

POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE/ TRBL FAULTY GEAR SHIFTING/FAULTY CLUTCH SHTG EAS00848 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE Refer to “STARTING FAILURES”. ENGINE FUEL SYSTEM Air filter Fuel pump • Clogged air filter element • Faulty fuel pump EAS00850 FAULTY GEAR SHIFTING SHIFTING IS DIFFICULT JUMPS OUT OF GEAR Refer to “CLUTCH DRAGS”.
Page 541: Poor Braking Performance

OVERHEATING/POOR BRAKING PERFORMANCE/ TRBL FAULTY FRONT FORK LEGS SHTG EAS00854 OVERHEATING ENGINE CHASSIS Cylinder head(s) and piston(s) Brake(s) • Heavy carbon buildup • Dragging brake Engine oil ELECTRICAL SYSTEMS • Incorrect oil level Spark plug(s) • Incorrect oil viscosity • Incorrect spark plug gap •…
Page 542: Unstable Handling

TRBL UNSTABLE HANDLING SHTG EAS00862 UNSTABLE HANDLING Handlebar Rear shock absorber assembly(-ies) • Bent or improperly installed handlebar • Faulty rear shock absorber spring Steering head components • Leaking oil or gas • Improperly installed upper bracket Tire(s) • Improperly installed lower bracket •…
Page 543: 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 • Wrong headlight bulb • Faulty turn signal switch • Too many electrical accessories • Faulty turn signal relay •…
Page 544
XV1700P/XV1700PC WIRING DIAGRAM 1 Generator | Signaling system fuse 2 Rectifier/regulator } Decompression solenoid fuse 3 Main switch ~ ECU fuse 4 Battery å Fuel injection system fuse 5 Backup fuse (odometer and clock) 6 Main fuse 7 Starter relay 8 Starter motor 9 Relay unit 0 Starting circuit cut-off relay…
Page 545
XV1700P/XV1700PC WIRING DIAGRAM (For USA) (BLACK) (BLACK) WIRE HARNESS TAIL SUB-WIRE HARNESS WIRE HARNESS INJECTION SUB-WIRE HARNESS (BLUE) (BLUE) (BLACK) (GRAY) (BLACK) (BLACK) (BLACK) (GRAY) (BLACK) (BLACK) å (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (BLACK) (DARK GRAY) (GRAY) (BLACK) (BLACK) (BLACK) (BLUE) (BLUE)
Page 546
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.
Page 547
XV17PCV(C) XV17PCMV(C) SUPPLEMENTARY SERVICE MANUAL LIT-11616-19-46 5PX-28197-12…
Page 548
XV1700P/XV1700PC SERVICE MANUAL: LIT-11616-15-37 (5PX-28197-10) XV1700PCR/XV1700PCRC SUPPLEMENTARY SERVICE MANUAL: LIT-11616-16-36 (5PX-28197-11) XV17PCV(C)/XV17PCMV(C) SUPPLEMENTARY SERVICE MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. First edition, June 2005 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A.
Page 549
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 550
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 551
EAS00009 SYMBOLS The following symbols are not relevant to SPEC every vehicle. Symbols 1 to 8 indicate the INFO subject of each chapter. 1 General information 2 Specifications CHAS 3 Periodic checks and adjustments 4 Chassis 5 Engine 6 Fuel injection system 7 Electrical system 8 Troubleshooting TRBL…
Page 552: Table Of Contents

CONTENTS SPECIFICATIONS ………………..1 GENERAL SPECIFICATIONS …………..1 ENGINE SPECIFICATIONS ……………. 1 CHASSIS SPECIFICATIONS…………… 4 ELECTRICAL SPECIFICATIONS …………..4 TIGHTENING TORQUES…………….5 ENGINE TIGHTENING TORQUES …………5 CHASSIS TIGHTENING TORQUES …………. 6 LUBRICATION POINTS AND LUBRICANT TYPES ……..6 ENGINE ………………..6 CABLE ROUTING ………………
Page 553
GENERAL SPECIFICATIONS/ SPEC ENGINE SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Limit Model code 2D84 (XV17PCMV for USA) —- 2D85 (XV17PCMV(C) for California) —- 5PXG (XV17PCV for USA) —- 5PXH (XV17PCV(C) for California) —- ENGINE SPECIFICATIONS Item Standard Limit Engine oil Lubrication system Dry sump —-…
Page 554
SPEC ENGINE SPECIFICATIONS Item Standard Limit Piston pin bore (in the piston) Diameter 22.004 ~ 22.015 mm (0.8663 ~ 0.8667 in) 22.045 mm (0.8679 in) Offset 1.0 mm (0.0394 in) —- Piston pins Outside diameter 21.991 ~ 22.000 mm (0.8658 ~ 0.8661 in) 21.971 mm (0.8650 in) Piston pin-to-piston pin bore clear- 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) 0.074 mm…
Page 555
SPEC ENGINE SPECIFICATIONS Item Standard Limit Crankshaft Width A 105.8 ~ 106.2 mm (4.165 ~ 4.181 in) —- Max. runout C —- 0.04 mm (0.0016 in) Big end side clearance D 0.320 ~ 0.474 mm (0.0126 ~ 0.0187 in) —- Big end radial clearance E 0.037 ~ 0.074 mm (0.0015 ~ 0.0029 in) 0.09 mm…
Page 556
CHASSIS SPECIFICATIONS/ SPEC ELECTRICAL SPECIFICATIONS CHASSIS SPECIFICATIONS Item Standard Limit Rear brake Brake type Single-disc brake —- Operation Right-foot operation —- Brake pedal free play 0 mm (0 in) —- Brake pedal position 86 mm (3.4 in) —- (from the top of the rider footrest to the top of the brake pedal) Recommended fluid DOT 4…
Page 557
SPEC TIGHTENING TORQUES TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Tightening torque Thread Item Fastener Q’ty Remarks size m·kg ft·lb Front cylinder camshaft end cover Bolt Oil filter bracket Bolt A.I.S. bracket Bolt Crankshaft position sensor Bolt Stator coil assembly Screw Generator rotor Bolt Use a lock Clutch boss…
Page 558
TIGHTENING TORQUES/ SPEC LUBRICATION POINTS AND LUBRICANT TYPES CHASSIS TIGHTENING TORQUES Tightening torque Item Thread size Remarks m·kg ft·lb Throttle stop screw bracket and seat bracket Throttle stop screw bracket and frame Left side cover 1 and left side cover 2 Lean angle sensor bracket and frame Sidestand bracket and frame Front brake caliper…
Page 559
SPEC CABLE ROUTING È Fasten the left handlebar switch lead with the CABLE ROUTING plastic holders. 1 Clutch cable É Fasten the right handlebar switch lead with the 2 Left handlebar switch lead plastic holders. 3 Right handlebar switch lead Ê…
Page 560
SPEC CABLE ROUTING È Be sure to position the ECU leads and sensor 1 Negative battery lead 2 Tail/brake light lead leads toward the left side of the vehicle, and 3 Seat lock cable then fasten the wire harness protector with a 4 Fuel pump lead plastic locking tie.
Page 561
SPEC CABLE ROUTING Ê Place the couplers (crankshaft position sensor Î Fasten the decompression solenoid lead, speed coupler, sidestand switch coupler, decompres- sensor lead, cylinder identification sensor lead, sion solenoid couplers, tail/brake light coupler, sidestand switch lead, crankshaft position sen- cylinder identification sensor coupler and speed sor lead, neutral switch lead, and fuel pump lead sensor coupler) in the tray.
Page 562
SPEC CABLE ROUTING Ï Position the gray mark on the starter motor lead at the center of the bolt. Fit the starter motor lead and sidestand switch lead into the groove in the frame, and then fasten them with a plastic lock- ing tie.
Page 563
SPEC CABLE ROUTING 1 Oil temperature sensor 9 Intake air pressure sensor 2 G Neutral switch lead 2 Fuel hose 0 Throttle cables H Speed sensor lead 3 Spark plug cap (ignition coil A Brake hose I Ignition coil 1-R spark plug lead B Main wire harness J Oil temperature sensor lead 1-R spark plug lead)
Page 564
SPEC CABLE ROUTING È To the battery box. Ë Route the throttle position sensor lead, engine É Fasten the oil temperature sensor lead with the temperature sensor lead, injector lead, and igni- lead holder. tion coil 1-R spark plug lead in the order listed Ê…
Page 565
SPEC CABLE ROUTING Ì Fasten the main wire harness and ignition coil 1- Í Fasten the throttle position sensor lead, engine R spark plug lead to the frame between the air temperature sensor lead, and injector lead with filter case joint and the fuel hose with a plastic a plastic locking tie to the fuel delivery pipe.
Page 566
SPEC CABLE ROUTING Î Fasten the main wire harness and ignition coil 1- Ï Fasten the main wire harness, intake air pres- R spark plug lead to the frame between the sure sensor 2 lead, ignition coil 1-R spark plug intake air pressure sensor 1 and the fuel hose lead, and intake air temperature sensor coupler with a plastic locking tie, making sure to install…
Page 567
SPEC CABLE ROUTING Ò Fasten the rear brake light switch lead and igni- Ó Fasten the main wire harness and intake vac- tion coil 2-R spark plug lead to the pipe section uum hose with a plastic locking tie. Ô To the engine temperature sensor. of the linear control valve bracket with a plastic Õ…
Page 568
SPEC CABLE ROUTING Ù Position the gray mark on the stator coil lead at Þ Route the oil temperature sensor lead under the the center of the bolt, and then fasten it with a rear engine bracket (right). ß Position the buckle of the plastic locking tie so plastic locking tie.
Page 569
SPEC CABLE ROUTING Fasten the crankshaft position sensor lead, Fasten the corrugated tube with the plastic sidestand switch lead, lean angle sensor lead, locking tie. Face the end of the plastic locking starter motor lead, and horn 2 lead with a plas- tie outward, and then cut off the excess end of tic locking tie.
Page 570
• Check control system for damage. √ √ • Replace if necessary. tem (For California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. – 18 –…
Page 571
GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS 600 mi 4000 mi 8000 mi 12000 mi 16000 mi 20000 mi ITEM ROUTINE (1000 km) (7000 km) (13000 km) (19000 km) (25000 km) (31000 km) 1 month 6 months 12 months 18 months…
Page 572
• Adjust the headlight beam. * 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 573
SEAT AND SIDE COVERS EAS00038 SEAT AND SIDE COVERS 16 Nm (1.6 m kg, 11 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft •…
Page 574
FUEL TANK FUEL TANK 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Part Q’ty Remarks Removing the fuel tank Remove the parts in the order listed. Seat Refer to “SEAT AND SIDE COVERS”. Air induction system cover Air duct Fuel hose joint 1…
Page 575
FUEL TANK INSTALLING THE FUEL HOSE JOINT 2 1. Install: • fuel hose joint 2 1 • hose joint cover 2 NOTE: Install the hose joint cover completely onto fuel hose joint 2. – 23 –…
Page 576
CHAS FRONT WHEEL AND BRAKE DISCS EAS00514 CHASSIS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 35 Nm (3.5 m kg, 25 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •…
Page 577
CHAS FRONT WHEEL AND BRAKE DISCS 8 Nm (0.8 m kg, 5.8 ft • • 35 Nm (3.5 m kg, 25 ft • • 16 Nm (1.6 m kg, 11 ft • • 13 Nm (1.3 m kg, 9.4 ft •…
Page 578
CHAS FRONT AND REAR BRAKES EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 35 Nm (3.5 m kg, 25 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Part Q’ty Remarks Removing the front brake pads Remove the parts in the order listed.
Page 579
CHAS FRONT AND REAR BRAKES EAS00613 FRONT BRAKE CALIPERS 35 Nm (3.5 m kg, 25 ft • • 32 Nm (3.2 m kg, 23 ft • • Order Job/Part Q’ty Remarks Removing the front brake calipers Remove the parts in the order listed. The following procedure applies to both of the front brake calipers.
Page 580
CHAS FRONT AND REAR BRAKES EAS00615 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Part Q’ty Remarks Disassembling the front brake Remove the parts in the order listed. calipers The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring…
Page 581
CHAS FRONT AND REAR BRAKES EAS00638 ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPERS The following procedure applies to both of the brake calipers. WARNING • Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. •…
Page 582
CHAS FRONT AND REAR BRAKES 3. Install: • brake pads • brake pad spring • brake caliper bolts 35 Nm (3.5 m · kg, 25 ft · lb) • brake hose holders 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: The arrow a on the brake pad spring must point in the direction of rotation.
Page 583
CHAS FRONT AND REAR BRAKES 6. Check: • brake fluid level Below the minimum level mark a → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. (Manual No.: 5PX-28197-10) 7.
Page 584
CHAS FRONT FORK EAS00647 FRONT FORK 26 Nm (2.6 m kg, 19 ft • • 23 Nm (2.3 m kg, 17 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 23 Nm (2.3 m kg, 17 ft •…
Page 585
CHAS DRIVE BELT AND DRIVE PULLEY DRIVE BELT AND DRIVE PULLEY Order Job/Part Q’ty Remarks Removing the drive belt and drive Remove the parts in the order listed. pulley Rear wheel Refer to “REAR WHEEL, BRAKE DISC, AND REAR WHEEL PULLEY” in chapter 4.
Page 586
CHAS DRIVE BELT AND DRIVE PULLEY Order Job/Part Q’ty Remarks Drive pulley For installation, reverse the removal procedure. – 34 –…
Page 587
CHAS DRIVE BELT AND DRIVE PULLEY INSTALLING THE DRIVE BELT AND DRIVE PULLEY 1. Install: • drive pulley 1 • conical spring washer 2 • drive pulley nut 3 NOTE: • Lubricate the drive pulley nut threads and conical spring washer mating surface with engine oil.
Page 588
ENGINE ENGINE ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks…
Page 589
ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Engine oil/oil filter cartridge Drain.
Page 590
ENGINE 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Part Q’ty Remarks Oil filter bracket Rectifier/regulator coupler…
Page 591
ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •…
Page 592
ENGINE 88 Nm (8.8 m kg, 64 ft • • 48 Nm (4.8 m kg, 35 ft • • 98 Nm (9.8 m kg, 71 ft • • 53 Nm (5.3 m kg, 38 ft • • 88 Nm (8.8 m kg, 64 ft •…
Page 593
TRANSFER GEAR CASE TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •…
Page 594
TRANSFER GEAR CASE 18 Nm (1.8 m kg, 13 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 10 Nm (1.0 m kg, 7.2 ft •…
Page 595
TRANSFER GEAR CASE INSTALLING THE TRANSFER GEAR CASE 1. Install: • middle driven shaft 1 • middle drive gear 2 • primary chain 3 (into the transfer gear case) • drive pulley nut 4 NOTE: • Install the middle driven shaft, middle drive gear and primary chain at the same time.
Page 596
TRANSFER GEAR CASE 5. Tighten: • middle driven gear nut 1 100 Nm (10.0 m · kg, 72 ft · lb) NOTE: Stake the middle driven gear nut 1 at a cutout a in the drive axle. 6. Remove: • drive pulley nut 7.
Page 597
CRANKCASE CRANKCASE Order Job/Part Q’ty Remarks Removing the baffle plate and Remove the parts in the order listed. bearings Crankshaft Refer to “CRANKSHAFT AND CON- NECTING RODS” in chapter 5. (Manual No.: 5PX-28197-10) Transmission Refer to “TRANSMISSION”. Baffle plate Bearing retainer Bearing retainer Oil seal Bearing…
Page 598
CRANKCASE INSTALLING THE BEARING RETAINER 1. Install: • Bearing retainer 1 NOTE: • Install the bearing retainer 1 with its “OUT” mark a facing outward. ® • Apply locking agent (LOCTITE ) to the threads of the bearing retainer bolt. –…
Page 599
TRANSMISSION EAS00419 TRANSMISSION Order Job/Part Q’ty Remarks Removing the transmission, shift Remove the parts in the order listed. drum assembly, and shift forks Crankcase Separate. Refer to “CRANKCASE” in chapter 5. (Manual No.: 5PX-28197-10) Shift fork guide bar Shift drum assembly Shift fork “L”…
Page 600
TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the main axle Remove the parts in the order listed. assembly Circlip Washer 5th pinion gear Spacer Washer 2nd/3rd pinion gear Circlip Washer 4th pinion gear Spacer Main axle/1st pinion gear For assembly, reverse the disassembly procedure.
Page 601
TRANSMISSION Order Job/Part Q’ty Remarks Disassembling the drive axle Remove the parts in the order listed. assembly 5th wheel gear Circlip Washer 2nd wheel gear Spacer Circlip Washer 1st wheel gear Spacer Washer 4th wheel gear Circlip – 49 –…
Page 602
TRANSMISSION Order Job/Part Q’ty Remarks Washer 3rd wheel gear Spacer Drive axle For assembly, reverse the disassembly procedure. – 50 –…
Page 603: Xv17Pcv(C)/Xv17Pcmv(C) 2006 Wiring Diagram

XV17PCV(C)/XV17PCMV(C) 2006 WIRING DIAGRAM Br/B Lg BR L LG LY Sb BY LW/1 Br/B (BLACK) (BLACK) WIREHARNESS TAIL SUB-WIREHARNESS WIREHARNESS INJECTION SUB-WIREHARNESS L/W1 (BLUE) (BLUE) Y W/Y Br/W (BLACK) Br/L Y/R R/L Y/R L/W (GRAY) (BLACK) L W/Y (BLACK) Br/L Br/L Br/L Br/L…
Page 604
XV17PCV(C)/XV17PCMV(C) 2006 WIRING DIAGRAM 1 Generator o Front turn signal/position light COLOR CODE 2 Rectifier/regulator (right) B…. Black 3 Main switch p Rear turn signal light (right) B3..Black 3 4 Battery q Rear turn signal light (left) Br ..Brown 5 Backup fuse (odometer and r Headlight Ch ..
Page 605
YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.

Источник

Manuals
Brands
Yamaha Manuals
Motorcycle
XV1700PCR Road Star Warrior
Owner’s manual

Contents
Table of Contents
Troubleshooting
Bookmarks

Related Manuals for Yamaha XV1700PCR Road Star Warrior

Summary of Contents for Yamaha XV1700PCR Road Star Warrior

Page 1
OWNER’S MANUAL XV1700PCR XV1700PCRC LIT-11626-16-36 5PX-28199-11…
Page 2
EAU03438…
Page 3
EAU00002 Congratulations on your purchase of the Yamaha XV1700PC/XV1700PCC. This model is the result of Yamaha’s vast experience in the production of fine sporting, touring, and pacesetting racing machines. It represents the high degree of crafts- manship and reliability that have made Yamaha a leader in these fields.
Page 4
● 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…
Page 5: Important Manual Information

IMPORTANT MANUAL INFORMATION EW000000 WARNING PLEASE READ THIS MANUAL AND THE “YOU AND YOUR MOTORCYCLE: RIDING TIPS” BOOKLET CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MOTOR- CYCLE. DO NOT ATTEMPT TO OPERATE THIS MOTORCYCLE UNTIL YOU HAVE AT- TAINED ADEQUATE KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES.
Page 6
IMPORTANT MANUAL INFORMATION AFFIX DEALER LABEL HERE EAU04247 XV1700PCR/XV1700PCRC OWNER’S MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st edition, June 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.
Page 7: Table Of Contents

TABLE OF CONTENTS EAU00009 1 SAFETY INFORMATION 2 DESCRIPTION 3 INSTRUMENT AND CONTROL FUNCTIONS 4 PRE-OPERATION CHECKS 5 OPERATION AND IMPORTANT RIDING POINTS 6 PERIODIC MAINTENANCE AND MINOR REPAIR 7 MOTORCYCLE CARE AND STORAGE 8 SPECIFICATIONS 9 CONSUMER INFORMATION INDEX…
Page 9: Safety Information

SAFETY INFORMATION Safe riding ………………1-1 Protective apparel …………….1-3 Modifications ………………1-3 Loading and accessories …………..1-3 Gasoline and exhaust gas…………..1-5 Location of important labels ………….. 1-7…
Page 10: Safe Riding

S AFETY INFORMATION EAU04193 MOTORCYCLES ARE SINGLE TRACK VEHICLES. THEIR SAFE USE AND OPERATION ARE DEPENDENT UPON THE USE OF PROPER RIDING TECHNIQUES AS WELL AS THE EXPERTISE OF THE OPERATOR. EVERY OPERATOR SHOULD KNOW THE FOLLOWING REQUIREMENTS BEFORE RIDING THIS MOTORCYCLE. HE OR SHE SHOULD: 1.
Page 11: Safety Information

SAFETY INFORMATION 4. Many accidents involve inexperienced operators. In fact, many operators who have been involved in accidents do not even have a current motorcycle license. a. Make sure that you are qualified and that you only lend your motorcycle to other qualified opera- tors.
Page 12: Protective Apparel

6. A passenger should also observe the above precautions. Modifications Modifications made to this motorcycle not approved by Yamaha, or the removal of original equipment, may render the motorcycle unsafe for use and may cause severe personal injury. Modifications may also make your motorcycle illegal to use.
Page 13
Genuine Yamaha accessories have been specifically designed for use on this motorcycle. Since Yamaha cannot test all other accessories that may be available, you must personally be responsible for the proper selection, installation and use of non-Yamaha accessories. Use extreme caution when selecting and installing any accessories.
Page 14: Gasoline And Exhaust Gas

SAFETY INFORMATION a. Accessories fitted to the handlebar or the front fork area can create instability due to improper weight distribution or aerodynamic changes. If accessories are added to the handlebar or front fork area, they must be as lightweight as possible and should be kept to a minimum. b.
Page 15
SAFETY INFORMATION a. The engine and exhaust system may be hot, therefore, park the motorcycle in a place where pe- destrians or children are not likely to touch these hot areas. b. Do not park the motorcycle on a slope or soft ground, otherwise it may fall over. c.
Page 16: Location Of Important Labels

SAFETY INFORMATION EAU02977 Location of important labels Please read the following important labels carefully before operating this motorcycle.
Page 17
SAFETY INFORMATION California only California only…
Page 19: Description

DESCRIPTION Left view ………………… 2-1 Right view………………. 2-2 Controls and instruments …………..2-3…
Page 20: Left View

D ESCRIPTION EAU00026 Left view 1. Engine oil drain bolt (crankcase) (page 6-11) 4. Helmet holder (page 3-11) 2. Shift pedal (page 3-7) 5. Fuses (page 6-37) 3. Fuel tank cap (page 3-9) 6. Owner’s tool kit (page 6-2)
Page 21: Right View

DESCRIPTION Right view 7. Battery (page 6-35) 11. Brake pedal (page 3-8) 8. Engine oil filler cap (page 6-9) 12. Engine oil drain bolt (oil tank) (page 6-10) 9. Front fork spring preload adjusting bolt (page 3-12) 13. Shock absorber assembly spring 10.
Page 22: Controls And Instruments

DESCRIPTION Controls and instruments 1. Clutch lever (page 3-7) 6. Right handlebar switches (page 3-7) 2. Left handlebar switches (page 3-6) 7. Throttle grip (page 6-18) 3. Speedometer (page 3-3) 8. Brake lever (page 3-8) 4. Tachometer unit (page 3-4) 5.
Page 23: Instrument And Control Functions

INSTRUMENT AND CONTROL FUNCTIONS Main switch/steering lock …………..3-1 Indicator and warning lights …………. 3-2 Speedometer ………………3-3 Tachometer unit …………….. 3-4 Handlebar switches …………….3-6 Clutch lever ………………3-7 Shift pedal ………………3-7 Brake lever ………………3-8 Brake pedal ………………3-8 Fuel tank cap ………………
Page 24: Main Switch/Steering Lock

I NSTRUMENT AND CONTROL FUNCTIONS EAU00027 EAU04437 All electrical circuits are supplied with power, and the meter lighting, taillight, license plate light and position lights 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 EAU00029…
Page 25: Instrument And Control Functions

EAU00063 may result in loss of control or an High beam indicator light “ ” Yamaha dealer check the electrical cir- accident. Make sure that the motor- This indicator light comes on when the cuit. cycle is stopped before turning the high beam of the headlight is switched key to “OFF”…
Page 26: Speedometer

The electrical circuit of the warning light can be checked by turning the key to “ON”. If the warning light does not come on for a few seconds, then go off, have a Yamaha dealer check the elec- trical circuit. EAU00061 Neutral indicator light “…
Page 27: Tachometer Unit

INSTRUMENT AND CONTROL FUNCTIONS ● a fuel reserve tripmeter (which shows the distance traveled since the fuel level warning light came ● a meter lighting control ● a clock ● a self diagnosis device NOTE: ● Be sure to turn the key to “ON” 1.
Page 28
INSTRUMENT AND CONTROL FUNCTIONS Odometer and tripmeter modes To reset a tripmeter, select it by push- Clock mode Pushing the “SELECT” button switches ing the “SELECT” button, and then To set the clock: the display between the odometer push the “RESET” button for at least 1.
Page 29: Handlebar Switches

1. Dimmer switch “ ” then have a Yamaha dealer check the 2. Turn signal switch “ ” cycle has traveled both about 490 ft motorcycle.
Page 30: Clutch Lever

INSTRUMENT AND CONTROL FUNCTIONS 1. Engine stop switch “ ” 1. Clutch lever 1. Shift pedal 2. Start switch “ ” EAU00152 EAU00157 Clutch lever Shift pedal EAU03890 Engine stop switch “ ” The clutch lever is located at the left The shift pedal is located on the left Set this switch to “…
Page 31: Brake Lever

INSTRUMENT AND CONTROL FUNCTIONS 1. Brake lever 1. Brake pedal EAU00158 EAU00162 Brake lever Brake pedal The brake lever is located at the right The brake pedal is on the right side of handlebar grip. To apply the front the motorcycle. To apply the rear brake, pull the lever toward the handle- brake, press down on the brake pedal.
Page 32: Fuel Tank Cap

INSTRUMENT AND CONTROL FUNCTIONS To close the fuel tank cap 1. Push the fuel tank cap into posi- tion with the key inserted in the lock. 2. Turn the key counterclockwise to the original position, remove it, and then close the lock cover. NOTE: The fuel tank cap cannot be closed un- 1.
Page 33
INSTRUMENT AND CONTROL FUNCTIONS Your Yamaha engine has been de- EAU00185 CAUTION: signed to use regular unleaded gaso- Immediately wipe off spilled fuel line with a pump octane number with a clean, dry, soft cloth, since [(R+M)/2] of 86 or higher, or a research fuel may deteriorate painted surfac- octane number of 91 or higher.
Page 34: Seat

INSTRUMENT AND CONTROL FUNCTIONS 1. Seat lock 1. Projection 1. Helmet holder 2. Unlock. 2. Seat holder EAU00263* Helmet holder To install the seat EAU01319 Seat The helmet holder is located under the 1. Insert the projection on the rear of seat.
Page 35: Adjusting The Front Fork

INSTRUMENT AND CONTROL FUNCTIONS EW000030 WARNING Never ride with a helmet attached to the helmet holder, since the helmet may hit objects, causing loss of control and possibly an accident. To release the helmet from the helmet holder 1. Spring preload adjusting bolt 1.
Page 36: Adjusting The Shock Absorber Assembly

INSTRUMENT AND CONTROL FUNCTIONS 1. Locknut 1. Special wrench A. Distance A 2. Spring preload adjusting nut 2. To increase the spring preload NOTE: EAU04873 and thereby harden the suspen- ● Use the special wrench included in Adjusting the shock absorber sion, turn the adjusting nut in di- the owner’s tool kit to make the ad- assembly…
Page 37
INSTRUMENT AND CONTROL FUNCTIONS NOTE: Spring preload: Although the total number of clicks of Minimum (soft): the damping force adjusting mecha- Distance A = 2.05 in (52 mm) nism may not exactly match the above Standard: specifications due to small differences Distance A = 2.13 in (54 mm) in production, the actual number of Maximum (hard):…
Page 38: Sidestand

Therefore, sorber to an open flame or other check this system regularly as de- high heat sources, otherwise it scribed below and have a Yamaha may explode due to excessive dealer repair it if it does not function gas pressure.
Page 39: Ignition Circuit Cut-Off System

Periodically check the operation of the ignition circuit cut-off system according to the following procedure. EW000045 WARNING If a malfunction is noted, have a Yamaha dealer check the system before riding. 3-16…
Page 40
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 41: Pre-Operation Checks

PRE-OPERATION CHECKS Pre-operation check list …………..4-1…
Page 42: Pre-Operation Check List

• Check lever free play. • Adjust if necessary. • Make sure that operation is smooth. • Check cable free play. Throttle grip 6-18, 6-31 • If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.
Page 43
• Check operation of ignition circuit cut-off system. Sidestand switch 3-15 • If system is defective, have Yamaha dealer check vehicle. NOTE: Pre-operation checks should be made each time the motorcycle is used. Such an inspection can be accomplished in a very short time;…
Page 45: Operation And Important Riding Points

OPERATION AND IMPORTANT RIDING POINTS Starting and warming up a cold engine ……….5-1 Shifting ………………..5-3 Engine break-in …………….. 5-5 Parking ………………..5-5…
Page 46
● Make sure not to put anything Consult a Yamaha dealer re- tion circuit cut-off system ac- near the battery and its termi- garding any control or function cording…
Page 47: Operation And Important Riding Points

NOTE: Yamaha dealer check the electrical cir- The engine is warm when it quickly re- cuit. sponds to the throttle. 3. Start the engine by pushing the…
Page 48
OPERATION AND IMPORTANT RIDING POINTS EC000048 EAU02988 To start out and accelerate CAUTION: 1. Pull the clutch lever to disengage ● Even with the transmission in the clutch. the neutral position, do not 2. Shift the transmission into first coast for long periods of time gear.
Page 49
OPERATION AND IMPORTANT RIDING POINTS EAU00427 EAU02974 To decelerate Recommended shift points 1. Apply both the front and the rear The recommended shift points during brakes to slow the motorcycle. acceleration and deceleration are 2. Shift the transmission into first shown in the table below.
Page 50: Engine Break-In

CAUTION: other flammable materials. ● Keep the engine speed out of the tachometer red zone. ● If any engine trouble should oc- cur during the engine break-in period, immediately have a Yamaha dealer check the vehi- cle.
Page 51: Periodic Maintenance And Minor Repair

PERIODIC MAINTENANCE AND MINOR REPAIR Periodic maintenance ……….6-1 Drive belt slack ……….6-29 Owner’s tool kit …………6-2 Checking and lubricating the cables ….6-31 Periodic maintenance chart for the emission Checking and lubricating the throttle grip and control system ………..6-3 cable ……………
Page 52: Periodic Maintenance

SERVICE. ESPE- If you are not familiar with motor- CIALLY IMPORTANT cycle maintenance work, have a MAINTENANCE SERVICES RELAT- Yamaha dealer do it for you. EMISSIONS CONTROL. THESE CONTROLS ONLY FUNCTION TO ENSURE CLEANER AIR, BUT ARE ALSO VITAL TO PROPER ENGINE OPERATION AND MAXIMUM PERFORMANCE.
Page 53: Owner’s Tool Kit

PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EW000062 WARNING Modifications approved Yamaha may cause loss of perfor- mance, excessive emissions, and 1.
Page 54: Periodic Maintenance Chart For The Emission Control System

• Adjust cable free play. Evaporative Emission control • Check control system for damage. √ √ system (For • Replace if necessary. California only) * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 55: General Maintenance And Lubrication Chart

• Adjust the throttle cable housing and √ √ √ √ √ free play if necessary. cable • Lubricate the throttle grip housing and cable. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 56
√ √ √ √ Wheel bearings smooth rotation. Rear suspen- • Lubricate. Lithium-soap-based √ sion link pivots • Apply grease lightly. grease * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
Page 57
√ Every 2,500 mi (4,000 km) • Adjust if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU03907 NOTE: From 24,000 mi (37,000 km) or 36 months, repeat the maintenance intervals starting from 4,000 mi (7,000 km) or 6 months.
Page 58: Checking The Spark Plugs

The spark plugs are important engine deposits, it should be replaced. components, which should be checked periodically, preferably by a Yamaha Specified spark plug: dealer. Since heat and deposits will DPR7EA-9/NGK or cause any spark plug to slowly erode,…
Page 59: Canister (For California Only)

PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: If a torque wrench is not available when installing a spark plug, a good estimate of the correct torque is 1/4–1/2 turn past finger tight. However, the spark plug should be tightened to the speci- fied torque as soon as possible.
Page 60: Engine Oil And Oil Filter Cartridge

PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: Make sure that the motorcycle is posi- tioned straight up when checking the oil level. A slight tilt to the side can result in a false reading. 2. Remove the seat. (See page 3-11 for seat removal and installation procedures.) 3.
Page 61
PERIODIC MAINTENANCE AND MINOR REPAIR NOTE: NOTE: When adding oil, be careful not to over- Skip steps 5–9 if the oil filter cartridge is fill the engine oil tank; the oil level rises not being replaced. faster starting from the half level por- tion on the dipstick.
Page 62
6. Remove the engine oil drain bolt to tridge. drain the oil from the crankcase. NOTE: NOTE: An oil filter wrench is available at a Make sure that the O-ring is properly Yamaha dealer. seated. 6-11…
Page 63
PERIODIC MAINTENANCE AND MINOR REPAIR 11. Pour only 2.6 US qt (2.2 Imp qt, ECA00133 CAUTION: 2.5 L) of the specified amount of ● In order to prevent clutch slip- recommended engine oil through the filler hole, insert the dipstick, page (since the engine oil also lubricates the clutch), do not and then tighten the oil filler cap.
Page 64: Transfer Case Oil

This motorcycle is equipped with two Yamaha dealer at the intervals speci- air filter elements, one of which is locat- fied in the periodic maintenance and lu- ed in the air filter case, the other is lo- brication chart.
Page 65
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Fuel hose A 1. Nut (× 2) 1. Fuel hose B 3. Remove the fuel tank as follows. b. Remove the nuts. c. Disconnect fuel hose B from the a. Disconnect fuel hose A from the joint as shown.
Page 66
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Hose (× 2) 1. Air filter case 1. Air filter joint clamp screw 2. Bolt (× 2) d. Remove the hoses as shown, and 5. Loosen the air filter joint clamp 4. Remove the air filter case bolts. then remove the fuel tank by pull- screw, and then pull off the air filter ing it upward.
Page 67
PERIODIC MAINTENANCE AND MINOR REPAIR 1. Screw (× 3) 1. Air filter element 1. Air filter check hose 2. Screw (× 4) 6. Remove the air filter case cover by 9. Remove the clamp from the check 7. Remove the air filter element by removing the screws.
Page 68
Before installing the fuel tank, make sure that the fuel hoses are not damaged. If any fuel hose is damaged, do not start the engine but have a Yamaha dealer replace the hose, other- wise fuel may leak. ● Make sure that the fuel hoses are properly connected and routed, and not pinched.
Page 69: Adjusting The Throttle Cable Free Play

Periodically check the throttle cable free play and, if neces- ● Make sure that the air filter ele- sary, have a Yamaha dealer adjust it. ment is properly seated in the air filter case. ● The engine should never be op-…
Page 70: Adjusting The Valve Clearance

250 kPa) 250 kPa) from occurring, the valve clearance regarding the specified tires. 36 psi 42 psi must be adjusted by a Yamaha dealer 198 lb (90 kg)– (2.50 kgf/cm (2.90 kgf/cm maximum at the intervals specified in the periodic…
Page 71
(cowling, sad- tact a Yamaha dealer immediately and dlebags, etc. if approved for this have the tire replaced. model) does not exceed the maxi- CE-09E mum load of the motorcycle.
Page 72
BT020R 1. Tire air valve proved this model 200/50 ZR17 M/C (75W) 2. Tire air valve core Yamaha Motor Co., Ltd. 200/50 ZR17 (75W) 3. Tire air valve cap with seal Dunlop D220 ST ● 200/50 ZR17 M/C (75W) Always make sure that the valve…
Page 73: Cast Wheels

Other tires may run fore each ride. If any damage is the danger of bursting at super found, have a Yamaha dealer re- high speeds. place the wheel. Do not attempt ●…
Page 74: Accessories And Replacement Parts

EW000098 Yamaha cannot be held liable for WARNING any consequences caused by the This motorcycle is not designed to use of items which have not been pull a trailer or to be attached to a approved by Yamaha.
Page 75: Adjusting The Brake Lever Free Play

2. Brake lever free play adjusting bolt system. If there is air in the hy- c. Brake lever free play 3. If the specified clutch lever free draulic system, have a Yamaha EAU00696 play could be obtained as de- Adjusting the brake lever free…
Page 76: Adjusting The Brake Pedal Position

Periodically check the brake pedal posi- on just before braking takes effect. If tion and, if necessary, have a Yamaha necessary, adjust the brake light switch dealer adjust it. as follows.
Page 77: Checking The Front And Rear Brake Pads

To check the brake pad wear, check the wear indicator groove. If a brake pad has worn to the point that the wear indicator groove has almost disap- peared, have a Yamaha dealer replace the brake pads as a set. 6-26…
Page 78: Checking The Brake Fluid Level

0.03 in fluid reservoir is level. ing it to become ineffective. ● (0.8 mm), have a Yamaha dealer Use only the recommended quali- Before riding, check that the brake fluid replace the brake pads as a set.
Page 79: Changing The Brake Fluid

Be careful that water does not en- EAU03976 Changing the brake fluid ter the brake fluid reservoir when Have a Yamaha dealer change the refilling. Water will significantly brake fluid at the intervals specified in lower the boiling point of the fluid the NOTE after the periodic mainte- and may result in vapor lock.
Page 80: Drive Belt Slack

NOTE: in the periodic maintenance and lubri- A belt tension gauge is available at a cation chart. Yamaha dealer. 4. Calculate the drive belt slack by To check the drive belt slack subtracting the measurement not- 1. Place the motorcycle on the side- ed in step 2 from the measure- stand.
Page 81
PERIODIC MAINTENANCE AND MINOR REPAIR ECA00025 CAUTION: Improper drive belt slack will over- load the engine. Keep the drive belt slack within the specified range. 4. Tighten the locknuts, the axle nut and the brake caliper bracket bolt to the specified torques. 1.
Page 82: Checking And Lubricating The Cables

If a cable is damaged the periodic maintenance chart. or does not move smoothly, have a Yamaha dealer check or replace it. EAU03370 Checking and lubricating the Recommended lubricant: brake and shift pedals…
Page 83: Checking And Lubricating The Brake And Clutch Levers

PERIODIC MAINTENANCE AND MINOR REPAIR EAU03164 Checking and lubricating the brake and clutch levers The operation of the brake and clutch levers should be checked before each ride, and the lever pivots should be lu- bricated if necessary. Recommended lubricant: Lithium-soap-based grease (all-purpose grease) 6-32…
Page 84: Checking And Lubricating The Sidestand

Recommended lubricant: EW000113 WARNING Lithium-soap-based grease 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-purpose grease) 6-33…
Page 85: Checking The Steering

If any free Securely support the motorcycle so position. play can be felt, have a Yamaha that there is no danger of it falling 2. While applying the front brake, dealer check or repair the steer- over.
Page 86: Checking The Wheel Bearings

Avoid any contact with hub or if the wheel does not turn skin, eyes or clothing and al- ways shield your eyes when smoothly, have a Yamaha dealer working near batteries. In case check the wheel bearings. of contact, administer the fol- 1.
Page 87
PERIODIC MAINTENANCE AND MINOR REPAIR To charge the battery EC000102 CAUTION: Have a Yamaha dealer charge the bat- ● Always keep battery tery as soon as possible if it seems to have discharged. Keep in mind that the charged. Storing a discharged…
Page 88: Replacing The Fuses

PERIODIC MAINTENANCE AND MINOR REPAIR 1. Battery band 1. Headlight fuse 1. Main fuse 2. Battery cover 2. Signaling system fuse 2. Spare main fuse 3. Ignition fuse EAU04874 4. Electronic fuel injection fuse Replacing the fuses Specified fuses: 5. Odometer and clock fuse (backup fuse) Main fuse: 30 A The main fuse and the fuse box, which…
Page 89: Replacing The Headlight Bulb

EAU04189 5. If the fuse immediately blows Replacing the headlight bulb 2. Disconnect the headlight coupler, again, have a Yamaha dealer This motorcycle is equipped with a and then remove the bulb cover. check the electrical system. quartz bulb headlight. If the headlight 6.
Page 90
6. Install the headlight unit by install- from a lit headlight bulb, and do not ing the screws. touch the bulb until it has cooled 7. Have a Yamaha dealer adjust the down. headlight beam if necessary. 4. Place a new headlight bulb into position, and then secure it with the bulb holder.
Page 91: Tail/Brake Light

Tail/brake light This motorcycle is equipped with an LED type of tail/brake light. If the tail/brake light does not come on, have a Yamaha dealer check it. 1. Screw (× 2) 1. Turn signal light bulb EAU03218 2. Remove the defective bulb by…
Page 92: Replacing A License Plate Light Bulb

PERIODIC MAINTENANCE AND MINOR REPAIR ECA00107 CAUTION: Do not overtighten the nuts, other- wise the lens may break. 1. Nut (× 2) 1. Nut (× 2) 2. Washer (× 2) 2. Washer (× 2) 3. Rubber damper (× 2) 3. Bulb (× 2) 4.
Page 93: Supporting The Motorcycle

However, should your motorcycle To service the front wheel require any repair, take it to a Yamaha 1. Stabilize the rear of the motorcycle dealer, whose skilled technicians have by using a motorcycle stand or, if…
Page 94: Troubleshooting Chart

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.
Page 95: Motorcycle Care And Storage

MOTORCYCLE CARE AND STORAGE Care ………………..7-1 Storage ………………..7-4…
Page 96
M OTORCYCLE CARE AND STORAGE EAU04449 Before cleaning Cleaning 1. Cover the muffler outlet with a ECA00010 CAUTION: plastic bag after the engine has ● cooled down. Avoid using strong acidic wheel cleaners, especially on spoked 2. Make sure that all caps and covers wheels.
Page 97: Motorcycle Care And Storage

MOTORCYCLE CARE AND STORAGE thinner, fuel (gasoline), rust re- shield is scratched, use a quali- 1. Clean the motorcycle with cold movers or inhibitors, brake flu- ty plastic polishing compound water and a mild detergent, after id, antifreeze or electrolyte. after washing.
Page 98
NOTE: 4. Use spray oil as a universal clean- Consult a Yamaha dealer for advice on er to remove any remaining dirt. what products to use. 5. Touch up minor paint damage caused by stones, etc.
Page 99
MOTORCYCLE CARE AND STORAGE Long-term a. Remove the spark plug caps Before storing your motorcycle for and spark plugs. several months: b. Pour a teaspoonful of engine 1. Follow all the instructions in the oil into each spark plug bore. “Care”…
Page 100
MOTORCYCLE CARE AND STORAGE 4. Lubricate all control cables and NOTE: Make any necessary repairs before the pivoting points of all levers and storing the motorcycle. pedals as well as of the sidestand/ centerstand. 5. Check and, if necessary, correct the tire air pressure, and then lift the motorcycle so that both of its wheels are off the ground.
Page 101: Specifications

SPECIFICATIONS Specifications ………………8-1…
Page 102
S PECIFICATIONS EAU01038 Specifications CS-01E Model XV1700PC(C) Engine oil Dimensions Type YAMALUBE 4 (20W-40) or SAE 20W-40 Overall length 93.9 in (2,385 mm) Recommended engine oil Overall width 37.6 in (955 mm) classification API Service SE, SF, SG or Overall height 44.1 in (1,120 mm) higher Seat height…
Page 103
SPECIFICATIONS Transfer case oil Operation Left foot Type SAE80 API “GL-4” hypoid gear Gear ratio 2.375 Quantity 0.42 US qt (0.35 lmp qt, 0.4 L) 1.579 Air filters Oil-coated paper element 1.160 Fuel 0.935 Type UNLEADED GASOLINE ONLY 0.800 Fuel tank capacity 4.0 US gal (3.3 lmp gal, 15.0 L) Chassis Amount remaining when the…
Page 104
SPECIFICATIONS Manufacturer/ Brakes model Dunlop / D220 ST Front Bridgestone / BT020R Type Dual disc brake Maximum load* 408 lb (185 kg) Operation Right hand Tire air pressure Fluid DOT 4 (measured on cold tires) Rear Up to 198 lb (90 kg)* Type Single disc brake Front…
Page 105
SPECIFICATIONS Battery Auto-decompression fuse 15 A Model GT14B-4 Odometer and clock fuse (backup fuse) 7.5 A Voltage, capacity 12 V, 12 Ah Headlight type Halogen bulb Bulb voltage, wattage × quantity Headlight 12 V, 60/55 W × 1 Tail/brake light License plate light 12 V, 5 W ×…
Page 107: Consumer Information

Vehicle identification number …………. 9-1 Model label ………………9-2 Reporting safety defects …………..9-3 Motorcycle noise regulation ………….. 9-4 Maintenance record …………….9-5 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY ……9-7 YAMAHA EXTENDED SERVICE (Y.E.S.) ……… 9-9…
Page 108: Identification Numbers

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. 1. Key identification number 1.
Page 109: Model Label

The model label is affixed to the frame under the seat. (See page 3-11 for seat removal and installation procedures.) Record the information on this label in the space provided. This information will be needed when ordering spare parts from a Yamaha dealer.
Page 110: Reporting Safety Defects

If you believe that your vehicle has a defect which could cause a crash or could cause injury or death, you should immedi- ately inform the National Highway Traffic Safety Administration (NHTSA) in addition to notifying Yamaha Motor Corporation, U.S.A. If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign.
Page 111: Motorcycle Noise Regulation

CONSUMER INFORMATION EAU01053 Motorcycle noise regulation TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new ve- hicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2) the use of the vehicle after such device or element of design has been removed or rendered inoperative by any person.
Page 112: Maintenance Record

CONSUMER INFORMATION EAU01325 Maintenance record Copies of work orders and/or receipts for parts purchased and installed on your motorcycle will be required to document that maintenance has been completed in accordance with the emissions warranty. The chart below is printed only as a reminder that maintenance work is required.
Page 113
CONSUMER INFORMATION Maintenance Date of Servicing dealer Mileage Remarks interval service name and address 28,000 mi (43,000 km) or 42 months 32,000 mi (49,000 km) or 48 months 36,000 mi (55,000 km) or 54 months 40,000 mi (61,000 km) or 60 months…
Page 114: Yamaha Motor Corporation, U.s.a. Street And Enduro Motorcycle Limited Warranty

CONSUMER INFORMATION EAU02918 YAMAHA MOTOR CORPORATION, U.S.A. STREET AND ENDURO MOTORCYCLE LIMITED WARRANTY…
Page 115
CONSUMER INFORMATION…
Page 116: Yamaha Extended Service (Y.e.s.)

CONSUMER INFORMATION EAU01063 YAMAHA EXTENDED SERVICE (Y.E.S.)
Page 117
CONSUMER INFORMATION 9-10…
Page 118
INDEX Accessories and replacement parts ..6-23 Engine break-in ……..5-5 Main switch/steering lock ……3-1 Air filter elements, replacing ….6-13 Engine oil and oil filter cartridge ….6-9 Maintenance and lubrication, periodic ..6-4 Engine stop switch……..3-7 Maintenance, emission control system..6-3 Engine trouble warning light ….
Page 119
INDEX Spark plugs, checking ……6-7 Specifications ………. 8-1 Speedometer……….. 3-3 Starting and warming up a cold engine..5-1 Start switch……….3-7 Steering, checking ……… 6-34 Storage………… 7-4 Supporting the motorcycle ….. 6-42 Tachometer unit ……..3-4 Tail/brake light ……..6-40 Throttle cable free play, adjusting ..
Page 122
YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2002.07-0.5×2 CR…

Источник

Работает на WP – Разработан в Тема Customizr

Источник

Для Yamaha XV1700A/P (Road Star, Warrior)

Обзор модели

Related Manuals for Yamaha XV1700PCRC

Summary of Contents for Yamaha XV1700PCRC

Page 3: Important Manual Information

Page 4: How To Use This Manual

Page 6: Table Of Contents

Page 7: Specifications

Page 8: Electrical Specifications

Page 9: Cable Routing

Page 17: Periodic Checks And Adjustments

Page 18: General Maintenance And Lubrication Chart

Page 20: Chassis

Page 21: Adjusting The Rear Shock Absorber

Page 24: Rear Shock Absorber And Swingarm

Page 28: Engine

Page 30: Generator And Starter Clutch

Page 39: Table Of Contents

Page 40: Table Of Contents

Page 50: General Information

Page 81: Important Information

Page 83: Checking The Connections

Page 84: Special Tools

Page 89: General Specifications

Page 90: Engine Specifications

Page 101: Chassis Specifications

Page 108: General Tightening Torque Specifications

Page 109: Tightening Torques

Page 115: Lubrication Points And Lubricant Types

Page 117: Engine Oil Lubrication Chart

Page 118: Engine Oil Flow Diagrams

Page 122: Transfer Gear Oil Flow Diagrams

Page 139: For The Emission Control System

Page 142: Seat And Side Covers

Page 143: Headlight And Meter Assemblies

Page 145: Fuel Tank

Page 146: Air Filter Case

Page 150: Adjusting The Valve Clearance

Page 162: Measuring The Compression Pressure

Page 195: Checking The Tires

Page 196: Checking The Wheels

Page 198: Electrical System

Page 208: Instrument Functions

Page 210: Front Wheel And Brake Discs

Page 240: Front And Rear Brakes

Page 264: Front Fork

Page 276: Front Fork

Page 284: Steering Head

Page 297: Rear Shock Absorber And Swingarm

Page 339: Valves And Valve Springs

Page 409: Crankshaft And Connecting Rods

Page 430: Fuel Injection System

Page 442: Troubleshooting

Page 468: Air Induction System

Page 479: Checking Switch Continuity

Page 480: Checking The Switches

Page 482: Checking The Bulbs And Bulb Sockets

Page 490: Ignition System

Page 494: Electric Starting System

Page 498: Starter Motor

Page 505: Charging System

Page 510: Lighting System

Page 517: Signaling System

Page 539: Incorrect Engine Idling Speed

Page 540: Faulty Gear Shifting

Page 541: Poor Braking Performance

Page 542: Unstable Handling

Page 543: Faulty Lighting Or Signaling System

Page 552: Table Of Contents

Page 603: Xv17Pcv(C)/Xv17Pcmv(C) 2006 Wiring Diagram

Related Manuals for Yamaha XV1700PCR Road Star Warrior

Summary of Contents for Yamaha XV1700PCR Road Star Warrior

Page 5: Important Manual Information

Page 7: Table Of Contents

Page 9: Safety Information

Page 10: Safe Riding

Page 11: Safety Information

Page 12: Protective Apparel

Page 14: Gasoline And Exhaust Gas

Page 16: Location Of Important Labels