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EB000000

YZF-R6 SERVICE MANUAL 1998 by Yamaha Motor Co., Ltd. First edition, August 1998 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.

EB001000

NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. it is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable. NOTE: Designs and specifications are subject to change without notice.

EB002000

IMPORTANT MANUAL INFORMATION


Particularly important information is distinguished in this manual by the following.

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

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the motorcycle operator, a bystander or a person checking or repairing the motorcycle. A CAUTION indicates special precautions that must be taken to avoid damage to the motorcycle. A NOTE provides key information to make procedures easier or clearer.

CAUTION:
NOTE:

EB003000

HOW TO USE THIS MANUAL


This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order.
1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to SYMBOLS. 2 Each chapter is divided into sections. The current section title is shown at the top of each page, except in Chapter 3 (PERIODIC CHECKS AND ADJUSTMENTS), where the sub-section title(-s) appears. 3 Sub-section titles appear in smaller print than the section title. 4 To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a disassembly step. 6 Symbols indicate parts to be lubricated or replaced. Refer to SYMBOLS. 7 A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 8 Jobs requiring more information (such as special tools and technical data) are described sequentially.

3 4 5 8

EB004000

SYMBOLS
The following symbols are not relevant to every vehicle. Symbols 1 to 9 indicate the subject of each chapter.
1 2 3 4 5 6 7 8 9
General information Specifications Periodic checks and adjustments Engine Cooling system Carburetor(-s) Chassis Electrical system Troubleshooting

GEN INFO
3

SPEC
4

CHK ADJ
5 6

ENG

COOL
7

CARB
8

CHAS
9

ELEC
10

Symbols 10 to 17 indicate the following.


10 11 12 13 14 15 16 17

TRBL SHTG
11 12

Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit, clearance Engine speed Electrical data

13

14

15

16

17

18

19

20

Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.
18 19 20 21 22 23

21

22

23

Engine oil Gear oil Molybdenum disulfide oil Wheel bearing grease Lithium soap base grease Molybdenum disulfide grease

24

25

Symbols 24 to 25 in the exploded diagrams indicate the following.


24 Apply locking agent (LOCTITE) 25 Replace the part

INDEX
GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL COOLING SYSTEM CARBURETORS CHASSIS ELECTRICAL TROUBLESHOOTING
GEN INFO

1 2 3 4 5 6 7 8 9

SPEC

CHK ADJ

ENG

COOL

CARB

CHAS

ELEC

TRBL SHTG

GEN INFO
CHAPTER 1. GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . USING A DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1-2 1-2 1-2 1-3 1-3 1-3 1-3

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 1-5 1-5 1-6

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

GEN INFO

MOTORCYCLE IDENTIFICATION
EB100000

GEN INFO

GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010

VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the steering head pipe.

EB100020

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

1-1

IMPORTANT INFORMATION
EB102000

GEN INFO

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust, and foreign material.

2. Use only the proper tools and cleaning equipment. Refer to SPECIAL TOOLS. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been mated through normal wear. Mated parts must always be reused or replaced as an assembly. 4. During disassembly, clean all of the parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fire.

EB102010

REPLACEMENT PARTS Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality.

EB102020

GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals, and O-rings. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. During reassembly, properly oil all mating parts and bearings and lubricate the oil seal lips with grease.

1-2

IMPORTANT INFORMATION

GEN INFO

USING A DYNAMOMETER The YZF-R6 has a carbon muffler that may change color when exposed to high temperatures. Therefore, when using a dynamometer always use a fan to cool the muffler.

EB102030

LOCK WASHERS/PLATES AND COTTER PINS After removal, replace all lock washers/plates 1 and cotter pins. After the bolt or nut has been tightened to specification, bend the lock washer tabs and the cotter pin ends along a flat of the bolt or nut.

EB102040

BEARINGS AND OIL SEALS 1. Install bearings and oil seals so that the manufacturers marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium soap base grease. Oil bearings liberally when installing, if appropriate. 1 Oil seal

CAUTION:
Do not spin the bearing with compressed air because this will damage the bearing surfaces.
1 Bearing

EB102050

CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip 1 , make sure that the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives. 4 Shaft

1-3

CHECKING THE CONNECTIONS


EB103000

GEN INFO

CHECKING THE CONNECTIONS


Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: S lead S coupler S connector

2. Check: S lead S coupler S connector Moisture ! Dry with an air blower. Rust/stains ! Connect and disconnect several times.

3. Check: S all connections Loose connection ! Connect properly. NOTE: If the pin 1 on the terminal is flattened, bend it up.

4. Connect: S lead S coupler S connector NOTE: Make sure that all connections are tight. 5. Check: S continuity (with the pocket tester) Pocket tester 90890-03112 NOTE: S If there is no continuity, clean the terminals. S When checking the wire harness, perform steps (1) to (3). S As a quick remedy, use a contact revitalizer available at most part stores.
1-4

FEATURES

GEN INFO

FEATURES
AIR INTAKE SYSTEM System diagram

This system is designed to improve the power while riding a motorcycle at a high speed by increasing the air intake efficiency by means of pressurizing the air filter case 2 where the air is taken in via the air duct 1 from the air intake port located under the headlight. The system also delivers air pressure from the air filter case to the carburetor side. The air pressure is operated to the fuel level in the carburetor to supply the appropriate fuel to increase the power. The air chamber 3 is also installed between the air filter case and carburetor for delivery of stabilized air pressure to the carburetor. THERMOSTAT Coolant flow is controlled by the thermostat of which flow control valve 1 is newly developed for avoiding quick temperature change. (Refer to the graphs) 2 Notch groove

Former thermostat

New thermostat

Temperature

Temperature

Time 1-5

Time

FEATURES
Flow control operation 1) When valve is closed The lip 1 seals the coolant. 2) When valve is set as low-lift The 2nd lip 2 seals the coolant. To reduce the water temperature change, the coolant starts flowing through the notch depending on its area at a section. 3) When the valve is set as middle-lift The 3rd lip 3 seals the coolant. The coolant flows through the notch depending on its area at b section. This flow rate is larger than the case of 2). 4) When the valve is set as high-lift In the same way as the regular thermostat control, the coolant flows through clearance c between the valve and flange. 1) 2)

GEN INFO

3)

4)

IGNITION SYSTEM 1. DC CDI 1) Features * Battery is used as the power source. * Stabilized spark performance is provided in the range from a low speed to high speed since the battery is used as the power source. * Compact AC magneto design is possible since the source coil is unnecessary. * Compact ignition coil design is possible since the condenser stores electricity. Plug top ignition coil is equipped in which the plug cap and ignition coil are integrated. * Stator coil can supply power even if the battery is running out. 2) Circuit diagram

1 2 3 4

CDI unit Voltage converter Condenser Ignition coil

5 6 7 8

Spark plug Ignition timing controller Pickup coil T. P. S.

9 Speed sensor
10 Battery 11 Rectifier/ regulator 12 AC magneto

13 Stator coil

1-6

FEATURES
2. Ignition coil Compact and right weight design is provided since the plug top ignition coil is equipped in which the plug cap ignition coil are integrated. High tension cord was cut an end to use and ignition energy loss has become lower.

GEN INFO

3. Spark plug The 2-pole spark plug is applied to improve the ignition quality and combustion efficiency.

1-7

SPECIAL TOOLS
EB104000

GEN INFO

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. When placing an order, refer to the list provided below to avoid any mistakes. Tool name/Function Illustration Tool No. Flywheel puller 90890-01362 Adapter 90890-04089 Flywheel puller Adapter This tool is used to remove the generator rotor. Sheave holder 90890-01701 This tool is used to hold the generator rotor when removing or installing the generator rotor bolt or pickup coil rotor bolt. Piston pin puller 90890-01304 This tool is used to remove the piston pins. Fuel level gauge 90890-01312 This tool is used to measure the fuel level in the float chamber. Radiator cap tester 90890-01325 Adapter 90890-01352 Radiator cap tester Adapter These tools are used to check the cooling system. Steering nut wrench 90890-01403 This tool is used to loosen or tighten the steering stem ring nuts. Damper rod holder 90890-01425 This tool is used to hold the damper rod assembly when loosening or tightening the damper rod assembly bolt. Pivot shaft wrench 90890-01471 This tool is used to loosen or tighten the pivot adjust bolt and engine mount adjust bolt.

1-8

SPECIAL TOOLS
Tool No. Tool name/Function Oil filter wrench

GEN INFO
Illustration

90890-01426 This tool is needed to loosen or tighten the oil filter cartridge. Rod holder 90890-01434 This tool is used to support the damper adjusting rod. Rod puller Rod puller attachment These tools are used to pull up the front fork damper rod. Fork spring compressor

Rod puller 90890-01437 Rod puller attachment 90890-01436

90890-01441 This tool is used to disassemble or assemble the front fork legs. Fork seal driver Fork seal driver weight 90890-01376 Fork seal driver attachment Fork seal driver attachment This tool is used to install the front forks oil 90890-01374 seal and dust seal. Micrometer 90890-03008 This tool is used to measure the piston skirt diameter. Cylinder bore gauge (50~100mm) 90890-03017 This gauge is used to measure cylinder bore. Vacuum gauge Vacuum gauge attachment

Vacuum gauge 90890-03094 Valve gauge attachment 90890-03060 Compression gauge 90890-03081 Adapter 90890-04136

This gauge is used to synchronize the carburetors. Compression gauge Adapter These tools are used to measure engine compression. Pocket tester

90890-03112 This tool is used to check the electrical system.


1-9

SPECIAL TOOLS
Tool No. Tool name/Function Engine tachometer

GEN INFO
Illustration

90793-80009 This tool is used to check engine speed. Timing light 90890-03141 This tool is used to check the ignition timing. Oil pressure gauge Adapter These tools are used to measure engine oil pressure. Piston ring compressor

Oil pressure gauge 90890-03153 Adapter 90890-03139

90890-04044 This tool is used to compress piston rings when installing the cylinder. Carburetor angle driver 90890-03158 This tool is used to turn the pilot screw when adjusting the engine idling speed. Valve spring compressor Attachment These tools are used to remove or install the valve assemblies. Middle driven shaft bearing driver Mechanical seal installer These tools are used to install the water pump seal. Clutch holding tool 90890-04086 This tool is used to hold the clutch boss when removing or installing the clutch boss nut. Valve guide remover

Valve spring compressor 90890-04019 Attachment 90890-04108


Middle driven shaft bearing driver 90890-04058 Mechanical seal installer 90890-04078

90890-04111 This tool is used to remove or install the valve guides.

1-10

SPECIAL TOOLS
Tool No. Tool name/Function Valve guide installer 90890-04112 This tool is used to install the valve guides. Valve guide reamer 90890-04113 This tool is used to rebore the new valve guides. Ignition checker 90890-06754 This tool is used to check the ignition system components. Yamaha bond No. 1215 90890-85505 This bond is used to seal two mating surfaces (e.g., crankcase mating surfaces).

GEN INFO
Illustration

1-11

GEN INFO

SPEC
CHAPTER 2. SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 2-18 2-19 2-22

LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23 ENGINE LUBRICATION POINTS AND LUBRICANT TYPES . . . . . 2-23 CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES . . . . 2-24 OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25 COOLANT FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29 CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

SPEC

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Minimum turning radius Weight Wet (with oil and a full fuel tank) Dry (without oil and fuel) Standard 2025 mm (except for NOR, SWE, FIN, AUS NZL) 2075 mm (for NOR, SWE, FIN, AUS, NZL) 690 mm 1105 mm 820 mm 1380 mm 135 mm 3400 mm 188 kg 169 kg Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

Maximum load (total of cargo, rider, 375 kg passenger, and accessories)

2-1

ENGINE SPECIFICATIONS

SPEC

ENGINE SPECIFICATIONS
Item Engine Engine tipe Displacement Cylinder arrangement Bore stroke Compression ratio Engine idling speed Vacuum pressure at engine idling speed Standard compression pressure (at sea level) Fuel Recommended fuel Fuel tank capacity Total (including reserve) Reserve only Engine oil Lubrication system Recommended oil
Temp.

Standard Liquid-cooled, 4-stroke, DOHC 600 cm3 Forward-inclined parallel 4-cylinder 65.5 44.5 mm 12.4 : 1 1,250 X 1,350 r/min 24.0 kPa (0.24 kg/cm2) 1550 kPa (15.5 kgf/cm2) at 400 r/min SSS SSS SSS SSS SSS SSS SSS SSS

Limit

Regular gasoline 17 L 3.5 L Wet sump

SSS SSS SSS SSS SSS

SAE20W40SE or SAE10W30SE

Quantity Total amount Without oil filter cartridge replacement With oil filter cartridge replacement Oil pressure (hot) Relief valve opening pressure

3.5 L 2.5 L 2.7 L 80 kPa at 1300 r/min (0.80 kgf/cm2 at 1300 r/min) 450 X 550 kPa (4.5 X 5.5 kgf/cm2)

SSS SSS SSS SSS SSS

2-2

ENGINE SPECIFICATIONS
Item Oil filter Oil filter type Bypass valve opening pressure Oil pump Oil pump type Inner-rotor-to-outer-rotor-tip clearance Outer-rotor-to-oil-pump-housing clearance Cooling system Radiator capacity Radiator cap opening pressure Radiator core Width Height Depth Coolant reservoir Capacity Water pump Water pump type Reduction ratio Starting system type Spark plugs Model (manufacturer) Spark plug gap Cylinder head Max. warpage quantity Standard Cartridge (paper) 80 X 120 kPa (0.8 X 1.2 kgf/cm2) Trochoidal 0.03 X 0.09 mm 0.03 X 0.08 mm

SPEC
Limit SSS SSS SSS 0.15 mm 0.15 mm

2.15 L 110 X 140 kPa (1.10 X 1.40 kgf/cm2) 320 mm 258 mm 24 mm 0.44 L Single-suction centrifugal pump 86/44 31/31 (1.955) Electric starter CR10EK/NGK 0.6 X 0.7 mm SSS 4

SSS SSS SSS SSS SSS SSS SSS

SSS SSS 0.05 mm

2-3

ENGINE SPECIFICATIONS
Item Camshafts Drive system Camshaft cap inside diameter Camshaft journal diameter Camshaft-journal-to-camshaftcap clearance Intake camshaft lobe dimensions Standard Chain drive (right) 23.000 X 23.021 mm 22.967 X 22.980 mm 0.020 X 0.054 mm

SPEC
Limit SSS SSS SSS 0.08 mm

Measurement A Measurement B Measurement C Exhaust camshaft lobe dimensions

33.05 X 33.15 mm 25.14 X 25.24 mm 7.81 X 8.01 mm

33.0 mm 25.09 mm SSS

Measurement A Measurement B Measurement C Max. camshaft runout

32.55 X 32.65 mm 25.07 X 25.17 mm 7.38 X 7.58 mm SSS

32.50 mm 25.02 mm SSS 0.06 mm

2-4

ENGINE SPECIFICATIONS
Item Timing chain Model/number of links Tensioning system Valves, valve seats, valve guides Valve clearance (cold) Intake Exhaust Valve dimensions RH2015/120 Automatic Standard

SPEC
Limit SSS SSS

0.11 X 0.20 mm 0.21 X 0.30 mm

SSS SSS

Head Diameter

Face Width

Seat Width

Margin Thickness

Valve head diameter A Intake Exhaust Valve face width B Intake Exhaust Valve seat width C Intake Exhaust Valve margin thickness D Intake Exhaust Valve stem diameter Intake Exhaust Valve guide inside diameter Intake Exhaust Valve-stem-to-valve-guide clearance Intake Exhaust Valve stem runout

24.9 X 25.1 mm 21.9 X 22.1 mm 1.14 X 1.98 mm 1.14 X 1.98 mm 0.9 X 1.1 mm 0.9 X 1.1 mm 0.6 X 0.8 mm 0.6 X 0.8 mm 3.975 X 3.990 mm 3.960 X 3.975 mm 4.000 X 4.012 mm 4.000 X 4.012 mm 0.010 X 0.037 mm 0.025 X 0.052 mm SSS

SSS SSS SSS SSS 1.6 mm 1.6 mm 0.5 mm 0.5 mm 3.950 mm 3.935 mm 4.042 mm 4.042 mm 0.08 mm 0.1 mm 0.04 mm

Valve seat width Intake Exhaust

0.9 X 1.1 mm 0.9 X 1.1 mm

1.6 mm 1.6 mm

2-5

ENGINE SPECIFICATIONS
Item Valve springs Free length Intake (inner) (outer) Exhaust Installed length (valve closed) Intake (inner) (outer) Exhaust Compressed spring force (installed) Intake (inner) (outer) Exhaust Spring tilt Standard

SPEC
Limit

37.0 mm 38.4 mm 41.7 mm 30.0 mm 32.5 mm 36.1 mm 69 X 79 N (7.0 X 8.0 kgf) 114 X 132 N (11.6 X 13.4 kgf) 160 X 184 N (16.3 X 18.7 kgf)

35 mm 36.5 mm 39.5 mm SSS SSS SSS SSS

Intake (inner) (outer) Exhaust Winding direction (top view) Intake Exhaust

SSS SSS Clockwise Clockwise

2.5_/1.6 mm 2.5_/1.7 mm 2.5_/1.8 mm SSS SSS

Cylinders Cylinder arrangement Bore stroke Compression ratio Bore Max. taper Max. out-of-round

Forward-inclined, parallel 4-cylinder 65.5 45.5 mm 12.4 : 1 65.50 X 65.51 mm SSS SSS

SSS SSS SSS SSS 0.05 mm 0.05 mm

2-6

ENGINE SPECIFICATIONS
Item Pistons Piston-to-cylinder clearance Diameter D Standard 0.025 X 0.050 mm 65.460 X 65.475 mm

SPEC
Limit 0.07 mm SSS

Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pins Outside diameter Piston-pin-to-piston-pin-bore clearance Piston rings Top ring

4 mm 16.002 X 16.013 mm 0.35 X 0.65 mm Intake side 0.5 mm 15.991 X 16.000 mm 0.002 X 0.022 mm

SSS SSS SSS SSS SSS 0.072 mm

Ring type Dimensions (B T) End gap (installed) Ring side clearance 2nd ring

Barrel 0.80 2.45 mm 0.15 X 0.25 mm 0.030 X 0.065 mm

SSS SSS 0.50 mm 0.115 mm

Ring type Dimensions (B T) End gap (installed) Ring side clearance Oil ring

Taper 0.8 2.5 mm 0.40 X 0.50 mm 0.020 X 0.055 mm

SSS SSS 0.85 mm 0.115 mm

Dimensions (B T) End gap (installed)

1.5 2.3 mm 0.10 X 0.35 mm

SSS SSS

2-7

ENGINE SPECIFICATIONS
Item Connecting rods Crankshaft-pin-to-big-end-bearing clearance Bearing color code Crankshaft Standard 0.028 X 0.052 mm

SPEC
Limit SSS SSS

1 = Blue 2 = Black 3 = Brown 4 = Green

Width B Max. runout C Big end side clearance D Crankshaft-journal-to-crankshaftjournal-bearing clearance Bearing color code

268.8 X 270.0 mm 0.160 X 0.262 mm 0.034 X 0.058 mm 0 = White 1 = Blue 2 = Black 3 = Brown 4 = Green Wet, multiple disc Rack and pinion (pull rod type) Cable operation Left hand operation 10 X 15 mm 2.9 X 3.1 mm 8 1.9 X 2.1 mm 7 SSS 2.2 X 2.4 mm 1 SSS 55 mm 6

SSS SSS 0.03 mm SSS SSS SSS

Clutch Clutch type Clutch release method Clutch release method operation Operation Clutch cable free play (at the end of the clutch lever) Friction plates Thickness Plate quantity Clutch plates Thickness Plate quantity Max. warpage Clutch plate Thickness Plate quantity Max. warpage Clutch springs Free length Spring quantity

SSS SSS SSS SSS SSS 2.8 mm SSS SSS SSS 0.1 mm

0.1 mm 54 mm SSS

2-8

ENGINE SPECIFICATIONS
Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Max. main axle runout Max. drive axle runout Shifting mechanism Shift mechanism type Max. shift fork guide bar bending installed shift rod length Air filter type Fuel pump Pump type Model (manufacturer) Output pressure Carburetors Model (manufacturer) quantity Throttle cable free play (at the flange of the throttle grip) ID mark Main jet Main air jet Jet needle Needle jet Pilot air jet Pilot outlet Pilot jet Bypass 1 Bypass 2 Bypass 3 Pilot screw turns out Valve seat size Standard Constant mesh, 6-speed Spur gear 86/44 (1.9545) Chain drive 48/16 (3.000) Left-foot operation 37/13 (2.846) 37/19 (1.947) 28/18 (1.555) 32/24 (1.333) 25/21 (1.190) 26/24 (1.083) SSS SSS Cam drum SSS 242 mm Dry element Electrical 5EB (MITSUBISHI) 15 X 20 kPa (0.15 X 0.2 kgf/cm2) CVRD37 (MIKUNI) 6 X 8 mm 4

SPEC
Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS 0.02 mm 0.02 mm SSS 0.05 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

5EB00, 5EB200 (G), 5EB300 (F) Carburetors 1 and 4: #152 Carburetors 2 and 3: #148 #110 N7RA 2.6 #110 0.9 #38 0.8 0.8 0.8 2 1.2

2-9

ENGINE SPECIFICATIONS
Item Starter jet 1 Starter jet 2 Butterfly valve size Fuel level (below the line on the float chamber) Standard #50 0.6 #110 17.5 X 18.5 mm

SPEC
Limit SSS SSS SSS SSS

2-10

CHASSIS SPECIFICATIONS

SPEC

CHASSIS SPECIFICATIONS
Item Frame Frame type Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Rear wheel Wheel type Rim Size Material Wheel travel Wheel runout Max. radial wheel runout Max. lateral wheel runout Front tire Tire type Size Model (manufacturer) Diamond 24_ 81 mm Cast wheel 17 MT3.50 Aluminum 130 mm SSS SSS Cast wheel 17 MT5.50 Aluminum 120 mm SSS SSS Tubeless 120/60ZR17 (55W) BRIDGESTON BT56F.E DUNLOP D207F.J 250 kPa (2.5 kg/cm2, 2.5 bar) 250 kPa (2.5 kg/cm2, 2.5 bar) 250 kPa (2.5 kg/cm2, 2.5 bar) SSS Standard SSS SSS SSS SSS SSS SSS SSS 1 mm 0.5 mm SSS SSS SSS SSS 1 mm 0.5 mm SSS SSS SSS Limit

Tire pressure (cold) 0 X 90 kg 90 X 197 kg High-speed riding Min. tire tread depth

SSS SSS SSS 1.6 mm

2-11

CHASSIS SPECIFICATIONS
Item Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) 0 X 90 kg 90 X 197 kg High-speed riding Min. tire tread depth Front brakes Brake type Operation Recommended fluid Brake discs Diameter thickness Min. thickness Max. deflection Brake pad lining thickness Standard Tubeless 180/55 ZR17 (73 W) BRIDGESTON BT56R.E DUNLOP D207.N 250 kPa (2.5 kg/cm2, 2.5 bar) 290 kPa (2.9 kg/cm2, 2.9 bar) 250 kPa (2.5 kg/cm2, 2.5 bar)

SPEC
Limit SSS SSS SSS SSS SSS SSS 1.6 mm SSS SSS SSS SSS 4.5 mm 0.1 mm 0.5 mm

Dual-disc brake Right-hand operation DOT 4 298 5 mm SSS SSS 5.5 mm

Master cylinder inside diameter Caliper cylinder inside diameter Rear brake Brake type Operation Brake pedal position (from the top of the brake pedal to the bottom of the rider footrest bracket bolt center.) Recommended fluid Brake discs Diameter thickness Min. thickness Max. deflection Brake pad lining thickness

14 mm 30.2 mm and 27 mm Single-disc brake Right-foot operation 4.3 X 9.3 mm DOT 4 220 5 mm SSS SSS 5 mm

SSS SSS SSS SSS SSS SSS SSS 4.5 mm 0.1 mm 0.8 mm

Master cylinder inside diameter Caliper cylinder inside diameter

12.7 mm 27.0 mm and 22.2 mm

SSS SSS

2-12

CHASSIS SPECIFICATION
Item Front suspension Suspension type Front fork type Front fork travel Spring Free length Spacer length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the innertube, with the inner tube fullycompressed, and without thefork spring) Damper adjusting rod locknut distance Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *from the fully turned-in position Standard Telescopic fork Coil spring/oil damper 130 mm 251.8 mm 125 mm 247.8 mm 7.5 N/mm (0.75 kgf/mm) 0 X 130 mm No Suspension oil 01 or equivalent 476 cm3 107 mm

SPEC
Limit SSS SSS SSS 246 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

25 mm 8 5 1 11 6 1

12 6 1

2-13

CHASSIS SPECIFICATIONS
Item Steering Steering bearing type Rear suspension Suspension type Rear shock absorber assemblytype Rear shock absorber assemblytravel Spring Free length Installed length Spring rate (K1) Spring stroke (K1) Optional spring available Standard spring preload gas/air pressure Spring preload adjusting positions Minimum Standard Maximum Rebound damping adjusting positions Minimum* Standard* Maximum* Compression damping adjusting positions Minimum* Standard* Maximum* *from the fully turned-in position Swingarm Free play (at the end of the swingarm) Radial Axial Drive chain Model (manufacturer) Link quantity Drive chain slack Maximum ten-link section Standard Angular ball bearings Swingarm (link suspension) Coil spring/gas-oil damper 60 mm

SPEC
Limit SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

169.5 mm 159 mm 95.1 N/mm (9.51 kgf/mm) 0 X 60 mm No 1,200 kPa (12 kgf/cm2) 1 4 9 25 9 1

13 7 1

SSS SSS 532ZLV KAI (DID) 116 40 X 50 mm 149 mm

1 mm 1 mm SSS SSS SSS SSS

2-14

ELECTRICAL SPECIFICATIONS

SPEC

ELECTRICAL SPECIFICATIONS
Item System voltage Ignition system Ignition system type Ignition timing Advanced timing Advancer type Pickup coil resistance/color Transistorized coil ignition unit model (manufacturer) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Throttle position sensor standard resistance Charging system System type Model (manufacturer) Nominal output Stator coil resistance Voltage regulator Regulator type Model (manufacturer) No-load regulated voltage Rectifier Model Rectifier capacity Withstand voltage Battery Battery type Battery voltage/capacity Headlight type Indicator light type quantity quantity) 12 V 60 W/55 W 12 V 5 W 2 12 V 5 W/21 W 12 V 21 W 4 2 2 SSS SSS SSS SSS Bulbs (voltage/wattage Headlight Auxiliary light Tail/brake light Turn signal light 12 V C.D.I. 10_ BTDC at 1700 r/min 55_ BTDC at 5250 r/min Throttle position sensor and electrical 248 X 372 /Gy-B F8T354 (MITSUBISHI) Standard SSS SSS SSS SSS SSS SSS SSS Limit

F6T549 (MITSUBISHI) 6 mm 0.238 X 0.322 8.16 X 11.04 k 4 X 6 k

SSS SSS SSS SSS SSS

AC magneto F4T366 (MITSUBISHI) 14 V/320W at 5,000 r/min 0.27 X 0.33 at 20_C Semiconductor, short circuit type SH650A-12 (SHINDENGEN) 14.1 X 14.9 V SH650A-12 18 A 200 V GT12B-4 12 V/10 AH Halogen bulb LED 5

SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

2-15

ELECTRICAL SPECIFICATIONS
Item License plate light Meter light Electric starting system System type Starter motor Model (manufacturer) Power output Brushes Overall length Spring force Commutator resistance Commutator diameter Mica undercut Starter relay Model (manufacturer) Amperage Coil resistance Horn Horn type Model (manufacturer) Max. amperage Standard 12 V 5 W 2 12 V 1.4 W 2 Constant mesh SM-14 (MITSUBA) 0.6 kW 10 mm 7.16 X 9.52 N (730 X 970 gf) 0.012 X 0.022 28 mm 0.7 mm MS5F-631 (JIDECO) 180 A 4.18 X 4.62 Plain YF-12 (NIKKO) 3A

SPEC
Limit SSS SSS SSS SSS SSS 3.5 mm SSS SSS 27 mm SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS SSS

quantity

Flasher relay Relay type Model (manufacturer) Self-cancelling device built-in Turn signal blinking frequency Wattage Oil level switch model (manufacturer) Fuel sender Model (manufacturer) Resistance Sidestand relay Model Coil resistance Fuel pump maximum amperage Fuel pump relay model (manufacturer) Resistance Radiator fan model (manufacturer) Thermo switch model (manufacturer) Headlight relay (manufacturer) Resistance

Full-transistor FE246BH (DENSO) No 75 X 95 cycles/min. 21 W 2 + 3.4 W 4XV (DENSO) 1UF (NIPPON SEIKI) 0.7 X 1.1 k GW-B G8R-30Y-K 162 X 198 1A G8R-30Y-K (OMRON) 162 X 198 4XV (TOYO RADIATOR) 5EB (NIPPON THERMOSTAT) ACA12115 (MATSUSHITA) 72 X 88

2-16

ELECTRICAL SPECIFICATIONS
Item Temperature sender Model (manufacturer) Resistance Fuses (amperage quantity) Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan fuse Backup fuse (odometer) Standard 11H (NIPPON SEIKI) 50.6 X 64.2 at 80_C 16.1 X 17.3 at 120_C 30 A 20 A 20 A 15 A 7.5 A 7.5 A 1 1 1 1 1 1

SPEC
Limit SSS SSS

SSS SSS SSS SSS SSS SSS

2-17

CONVERSION TABLE/TIGHTENING TORQUES


EB201000 EB202001

SPEC

CONVERSION TABLE
All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC **mm 2 mm MULTIPLIER 0.03937 0.03937 = = IMPERIAL **in 0.08 in

TIGHTENING TORQUES
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature.

CONVERSION TABLE
METRIC TO IMPERIAL Metric unit Tightening torque Weight Speed mSkg mSkg cmSkg cmSkg kg g km / hr km m m cm mm cc (cm3) cc (cm3) ( lt (liter) lt (liter) kg / mm kg / cm2 Centigrade (_C) Multiplier 7.233 86.794 0.0723 0.8679 2.205 0.03527 0.6214 0.6214 3.281 1.094 0.3937 0.03937 0.03527 0.06102 0.8799 0.2199 55.997 14.2234 9 / 5 + 32 Imperial unit ftSlb inSlb ftSlb inSlb lb oz mph mi ft yd in in oz (IMP liq.) cuSin qt (IMP liq.) gal (IMP liq.) lb / in psi (lb / in2) Fahrenheit (_F)

A: Width across flats B: Thread diameter

Distance

Volume / Capacity

A (nut) 10 mm 12 mm 14 mm 18 mm 19 mm 22 mm

B (bolt) 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm

General tightening torques Nm 6 15 30 55 85 130 mSkg 0.6 1.5 3.0 5.5 8.5 13.0 ftSlb 4.3 11 22 40 61 94

Misc.

2-18

TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES Item Spark plugs Cylinder head Cylinder head Camshaft caps Cylinder head cover Oil passage check bolt Cylinder head (exhaust pipe) Connecting rod caps Generator rotor Pickup rotor Cap bolt (timing chain tensioner) Timing chain tensioner bolt Camshaft sprocket Oil pump Oil cooler Engine oil drain bolt Oil pump assembly driven sprocket cover Oil pipe Oil filter bolt Oil filter cartridge Exhaust pipes Muffler clamp Exhaust pipe emission check bolts Exhaust pipe bracket Crankcase Crankcase Crankcase Generator rotor cover Drive sprocket cover Fastener Bolt Bolt Bolt Bolt Bolt Stud bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Nut Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Thread size M10 M10 M6 M6 M6 M8 M8 M7 M12 M8 M6 M6 M7 M6 M20 M14 M6 M6 M20 M20 M8 M8 M6 M8 M6 M6 M8 M6 M6 Qty y 4 10 2 20 6 1 8 1 1 1 2 4 3 1 1 2 2 1 1 8 1 4 1 2 12 12 9 5

SPEC

Tightening torque Nm nSkgf

Remarks

13 1.3 51 5.1 10 1.0 10 1.0 10 1.0 20 2.0 15 1.5 See NOTE 65 6.5 35 3.5 10 1.0 12 1.2 24 2.4 12 1.2 63 6.3 43 4.3 10 1,0 15 80 17 20 20 10 20 14 12 24 12 10 1.5 8.0 1.7 2.0 2.0 1.0 2.0 1.4 1.2 2.4 1.2 1.0

NOTE: After tightening to 15 Nm (1.5mSkg), tighten another 90_

2-19

TIGHTENING TORQUES

SPEC

Item Clutch cover Pickup coil rotor cover Shift shaft cover Breather plate 2 Starter clutch Clutch boss Clutch springs Drive sprocket Main axle bearing housing Shift bar stopper Shift shaft spring stopper Shift rod locknut Oil level switch Shift arm Stator coil Ignitor unit Neutral switch Pickup coil Thermo unit Thermo switch

Fastener Bolt Bolt Bolt Bolt Nut Bolt Nut Screw Bolt Bolt Nut Bolt Bolt Bolt Bolt Screw Bolt

Thread size M6 M6 M6 M6 M8 M20 M6 M18 M6 M6 M8 M6 M8 M6 M6 M6 M6 M6 M5 PT1/8 M18 1.5

Qty y 10 5 6 3 3 1 6 1 3 2 1 1 1 2 1 3 1 2 2 1 1

Tightening torque Nm 12 12 12 12 32 70 8 70 12 10 22 7 10 10 10 10 10 4.0 10 15 28 mSkgf 1.2 1.2 1.2 1.2 3.2 7.0 0.8 7.0 1.2 1.0 2.2 0.7 1.0 1.0 1.0 1.0 1.0 0.4 1.0 1.5 2.8

Remarks

Use a lock washer. Use a lock washer.

2-20

TIGHTENING TORQUES
Crankcase tightening sequence:

SPEC

2-21

TIGHTENING TORQUES
CHASSIS TIGHTENING TORQUES Item Upper bracket pinch bolts Steering stem nut Handlebar pinch bolts Lower ring nut Lower bracket pinch bolts Brake fluid reservoir cap stopper Front brake hose union bolts Front brake master cylinder Engine mounting Front mounting bolts Rear mounting bolts Pinch bolts Button head bolt Exhaust pipe bracket Pivot shaft nut Connecting arms Relay arm and connecting arms Relay arm Rear shock absorber and relay arm Fuel cock Fuel sender and fuel tank Coolant reservoir and radiator Rider footrest bracket Passenger footrest bracket Rear master cylinder Rear brake hose union bolts Sidestand Front wheel axle Rear wheel axle nut Front brake caliper and front fork Rear brake caliper and bracket Brake disc and wheel Rear wheel sprocket and rear wheel drive hub Brake caliper and bleed screw Pinch bolt (front wheel axle) Thread size M8 M28 M8 M30 M8 M4 M10 M6 M12 M12 M10 M8 M6 M10 M8 M18 M10 M10 M10 M10 M6 M6 M6 M8 M8 M8 M10 M10 M18 M24 M10 M10 M6 M10 M8 M8

SPEC

Tightening torque Nm 25 115 33 9 23 12 30 13 55 55 45 24 13 39 20 95 40 40 40 40 7 7 5 28 28 23 30 60 72 150 40 27 18 69 6 23 mSkgf 2.5 11.5 3.3 0.9 2.3 1.2 3.0 1.3 5.5 5.5 4.5 2.4 1.3 3.9 2.0 9.5 4.0 4.0 4.0 4.0 0.7 0.7 0.5 2.8 2.8 2.3 3.0 6.0 7.2 15.0 4.0 2.7 1.8 6.9 0.6 2.3

Remarks

See NOTE.

NOTE: 1. First, tighten the ring nut to approximately 17 Nm (1.7 mSkg) with a torque wrench, then loosen the ring nut completely. 2. Retighten the ring nut to specification.

2-22

LUBRICATION POINTS AND LUBRICANT TYPES


EB202000

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES


ENGINE LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Connecting rod bolts and nuts Crankshaft journals Camshaft lobes Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Water pump impeller shaft Oil pump rotors (inner and outer) Oil pump housing Oil strainer Starter clutch idle gear inner surface Starter clutch assembly Primary driven gear Transmission gears (wheel and pinion) Main axle and drive axle Shift drum Shift forks and shift fork guide bars Shift shaft Shift shaft boss Engine mounting bolts (rear) Cylinder head cover mating surface Crankcase mating surface Clutch cover (crankcase mating surface) Generator rotor cover (crankcase mating surface) Cylinder head cover Yamaha bond No.1215 Yamaha bond No.1215 Yamaha bond No.1215 Yamaha bond No.1215 Yamaha bond No.1215 Lubricant

2-23

LUBRICATION POINTS AND LUBRICANT TYPES


EB202010

SPEC

CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES Lubrication Steering bearings and bearing races (upper and lower) Front wheel oil seal (right and left) Rear wheel oil seal Rear wheel drive hub oil seal Rear wheel drive hub mating surface Rear brake pedal Sidestand pivoting point and metal-to-metal moving parts Throttle grip inner surface Brake lever pivoting point and metal-to-metal moving parts Clutch lever pivoting point and metal-to-metal moving parts Rear shock absorber assembly oil seal Rear shock absorber assembly bearing Rear shock absorber assembly spacer Pivot shaft Connecting arm bearing (left and right) Spacer (relay arm and connecting arm) Oil seal (relay arm and connecting arm) Lubricant

2-24

OIL FLOW DIAGRAMS

SPEC

OIL FLOW DIAGRAMS


1 2 3 4 5 6 Intake camshaft Exhaust camshaft Crankshaft Oil pipe Oil strainer Oil pump

2-25

OIL FLOW DIAGRAMS


1 2 3 4 Exhaust camshaft Intake camshaft Oil filter Oil cooler

SPEC

2-26

OIL FLOW DIAGRAMS


1 Cylinder head 2 Crankshaft

SPEC

2-27

OIL FLOW DIAGRAMS


1 Main axle 2 Oil delivery pipe 3 driveaxle

SPEC

2-28

COOLANT FLOW DIAGRAMS

SPEC

COOLANT FLOW DIAGRAMS


1 Radiator 2 Radiator fan 3 Oil cooler

2-29

COOLANT FLOW DIAGRAMS


1 2 3 4 Thermostat housing Thermostat Radiator Therm

SPEC

2-30

COOLANT FLOW DIAGRAMS


1 2 3 4 5 Radiator cap Radiator Oil cooler Water jacket joint Water pump

SPEC

2-31

COOLANT FLOW DIAGRAMS


1 Radiator 2 Radiator fan switch 3 Radiator fan

SPEC

2-32

CABLE ROUTING
EB206000

SPEC

CABLE ROUTING
1 2 3 4 5 6 7 Throttle cables Front brake hose Clutch cable Starter cable Left handlebar switch lead Main switch lead Right handlebar switch lead A Install the headlight relays onto the headlight housing bridge. B Route the headlight lead through the plastic guide. C Route the right handlebar switch lead in front of the front fork inner tube. D Route the throttle cables between the brake hose and right handlebar switch lead. E Route the wire harness through under the left handlebar switch lead and starter cable. F Fasten the left handlebar switch lead to the front fork with a plastic locking tie and cut the end of locking tie.

2-33

CABLE ROUTING
G Fasten the throttle cables and starter cable with a band. Locate the end of band to forward. H Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie. Cut the end of locking tie. And then, route the horn lead under the brake hose and clamp it to the under cover.

SPEC

2-34

CABLE ROUTING
1 2 3 4 Fuel pump lead Pickup coil lead Clutch cable Rear brake switch lead

SPEC

A Route the ignition coil lead over the heat protector plate. B Position the face of steel clip up ward. C Route the clutch cable through the guide on the frame. D Route the coolant hose under the heat protector plate.

E Route the clutch cable through the guide on the radiator. F Fasten the clutch cable to the coolant hose protector with a plastic band. G Fasten the rear brake switch lead to the footrest bracket with a plastic locking tie and cut the end of locking tie. H Fasten the fuel pump lead and rear brake switch lead with a plastic band on the fuel pump bracket.

2-35

CABLE ROUTING
1 2 3 4 5 6 7 8 9 A AC magneto lead Sidestand switch lead Oil lever switch lead Reservoir tank breather hose Fuel tank breather hose Fuel tank drain hose Speed sensor lead Neutral switch lead Fuel pump lead Route the throttle cable through inside of the radiator bracket and outside of the wireharness. B Fasten the wireharness, radiator hose and fan motor lead with a plastic band.

SPEC

C Do not touch the wireharness with the throttle cable pully. Route the wireharness under the radiator hose. D Route the wireharness through the slit of rear fender. E Route the rear turn signal light leads (left and right) through the hole of rear fender. F Route the seat lock cable outside of the wireharness. G Fasten the sidestand switch lead and oil level sensor lead with a band. H Route the fuel tank drain hose, fuel tank breather hose, reservoir tank breather hose, oil level switch lead and sidestand switch lead through the guide on the frame. I Route the starter cable between the main switch lead and left randlebar switch lead.

2-36

CABLE ROUTING
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15

SPEC

Throttle cable Handlebar switch lead (right) Coolant reservoir breather hose Carburetor idle adjusting cable Pickup coil connector Neutral switch connector Rear brake switch connector Handlebar switch (right) connectors Main switch connectors Throttle position sensor connector Handlebar switch (left) connectors Neutral switch lead Fuel pump connector Rear brake switch lead Starter motor lead

16 17 18 19 20 21 22 23 24 25

Battery negative () cable Fuel sender connector Coolant reservoir tank cap Crankcase breather hose Therm unit lead Fan motor lead connector Clutch cable Handlebar switch lead (left) Stater cable Main switch lead

A To headlight lead B Route the clutch cable through the guide.

2-37

CABLE ROUTING

SPEC

C Fasten the handlebar switch leads (left and right) H Route the starter motor lead under the wireharness. and main switch lead with a band. I Fasten the starter motor to the rear fender with a D Route the ignition coil lead and handlebar switch band. leads (left and right) over the heat protection plate. J Fasten the battery positive (+) cable and starter E Route the reservoir tank hose, carburetor heater motor cable with a plastic band. hoses under the heat protector plate. K Position the rear turn signal light connectors (left F Fasten the neutral switch lead, right handlebar and right) and taillight connector between the rear switch lead, main switch lead, TPS lead, left hanfender and taillight bracket. dlebar switch lead, pickup coil lead and throttle L Install the seat lock cable to the frame bracket with stop screw cable with a band. protector side. G Insert the projection of the band to the hole of the frame and fasten the wireharness, neutral switch M Fasten the wireharness, oil level sensor lead, ground lead and alarm leads (3 lines) with a band. lead, handlebar switch leads (left and right), main N Fasten the starter relay lead and battery negative switch lead, throttle position sensor lead, rear brake switch lead and pickup coil lead with them. () lead to the wireharness with a plastic band. O Fasten the battery negative () lead and wireharness with a plastic band.

2-38

CABLE ROUTING
P Insert the projection of the band (wireharness) into U the hole of the frame. V Q 1: Speed sensor connector 2: AC magneto connector 3: Sidestand switch connector W 4: Oil level switch connector 5: Meter ground lead R Fasten the leads (above 1 5) and starter motor lead with a steel band on the engine. S Route the fuel tank breather hose and fuel tank drain hose over the wireharness. T Route the starter cable with slot of the heat protection plate.

SPEC

Route the starter cable and wireharness through the guide of the heat protection plate. Route the fan motor lead under the throttle cable and then, fasten the fan motor lead and throttle cable with a band. To radiator fan motor

2-39

SPEC

CHK ADJ
CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . 3-1 RIDER AND PASSENGER SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 COWLINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 AIR FILTER CASE AND IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . 3-8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR JOINTS . . . . . . . . . . . . . . . . . . . . . CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . . CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 3-11 3-16 3-18 3-20 3-22 3-23 3-24 3-26 3-27 3-29 3-30 3-31 3-32 3-32 3-33 3-33 3-34 3-35 3-35 3-36 3-39 3-39 3-39 3-41 3-42

CHK ADJ
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . . . 3-42 3-43 3-43 3-45 3-45 3-47 3-47 3-50 3-51 3-53 3-55 3-57 3-58 3-58 3-58 3-58 3-59 3-59 3-64 3-66 3-67

INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION INTERVALS


EB300000

CHK ADJ

PERIODIC CHECKS AND ADJUSTMENTS


INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter.
EB301000

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS


EVERY INITIAL (1,000 km) 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first)

No.

ITEM

CHECKS AND MAINTENANCE JOBS

1 2 3 4 5 6

* *

Fuel line Fuel filter Spark plugs

S Check fuel hoses for cracks or damage. S Replace if necessary. S Check condition. S Replace if necessary. S Check condition. S Clean, regap or replace if necessary. S Check valve clearance. S Adjust if necessary. S Clean or replace if necessary. S Check operation. S Adjust or replace cable. S Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 3-2.) S Correct accordingly. S Replace brake pads if necessary. S Check operation, fluid level and vehicle for fluid leakage. (See NOTE on page 3-2.) S Correct accordingly. S Replace brake pads if necessary. S Check balance, runout and for damage. S Rebalance or replace if necessary. S S S S Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

Valves Air filter element Clutch

Every 42,000 km or 42 months (whichever comes first)

Front brake

Rear brake

Wheels

10 *

Tires

11 *

Wheel bearings

S Check bearing for looseness or damage. S Replace if necessary. S Check swingarm pivoting point for play. S Correct if necessary. S Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first). S Check chain slack. S Adjust if necessary. Make sure that the rear wheel is properly aligned. S Clean and lubricate. S Check bearing play and steering for roughness. S Correct accordingly. S Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first).

12 *

Swingarm

13

Drive chain

Every 1,000 km and after washing the motorcycle or riding in rain

14 *

Steering bearings

3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHK ADJ
EVERY 6,000 km or 6 months (whichever comes first) 12,000 km or 12 months (whichever comes first)

No.

ITEM

CHECKS AND MAINTENANCE JOBS

INITIAL (1,000 km)

15 *

Chassis fasteners

S Make sure that all nuts, bolts and screws are properly tightened. S Tighten if necessary. S Check operation. S Lubricate and repair if necessary. S Check operation. S Replace if necessary. S Check operation and for oil leakage. S Correct accordingly. S Check operation and shock absorber for oil leakage. S Replace shock absorber assembly if necessary. S Check operation. S Lubricate with lithium soap base grease every 24,000 km or 24 months (whichever comes first). S Check engine idling speed, synchronization and starter operation. S Adjust if necessary. S Check oil level and vehicle for oil leakage. S Correct if necessary. S Change. (Warm engine before draining.) S Replace. S Check coolant level and vehicle for coolant leakage. S Correct if necessary. S Change coolant every 24,000 km or 24 months (whichever comes first).

16 17 * 18 * 19 *

Sidestand Sidestand switch Front fork Rear shock absorber assembly Rear suspension relay arm and connecting arm pivoting points Carburetors

20 *

21 *

22

Engine oil Engine oil filter cartridge

23

24 *

Cooling system

* Since these items require special tools, data and technical skills, they should be serviced by a Yamaha dealer. NOTE: S The air filter element needs more frequent service if you are riding in unusually wet or dusty areas. S Hydraulic brake system. Replace the brake fluid after disassembling the master cylinder or caliper cylinder. Check the brake fluid level and add fluid as required. Replace the master cylinder and caliper cylinder oil seals every two years. Replace the brake hoses every four years, or if cracked or damaged.

3-2

RIDER AND PASSENGER SEATS


EB302000

CHK ADJ

RIDER AND PASSENGER SEATS


7Nm (0.7 mSkg)

Order

Job/Part Removing the rider and passenger seats Passenger seat Rider seat

Qty

Remarks Remove the parts in the order listed.

1 2

1 1 For installation, reverse the removal procedure.

3-3

FUEL TANK

CHK ADJ

FUEL TANK

10 Nm (1.0 mSkg) 10 Nm (1.0 mSkg)

7 Nm (0.7 mSkg) 7 Nm (0.7 mSkg)

Order

Job/Part Removing the fuel tank Rider seat Bolt Bolts Fuel sender coupler Fuel hose

Qty

Remarks Remove the parts in the order listed Refer to SEATS.

1 2 3 4

1 2 1 1

Disconnect. NOTE: Before disconnecting the fuel hose, set the fuel cock OFF.

5 6 7

Fuel tank overflow hose Fuel tank breather hose Fuel tank

1 1 1 For installation reverse the removal procedure.

3-4

COWLINGS

CHK ADJ

COWLINGS

5 Nm (0.5 mSkg)

5 Nm (0.5 mSkg)

Order

Job/Part Removing the cowlings Rider and passenger seats Rear cowling Bottom cowling (left) Bottom cowling (right) Front cowling inner panel (left) Front cowling inner panel (right) Side cowling inner panel (left) Side cowling inner panel (right)

Qty

Remarks Remove the parts in the order listed Refer to SEATS.

1 2 3 4 5 6 7

1 1 1 1 1 1 1

3-5

COWLINGS

CHK ADJ

COWLINGS

5 Nm (0.5 mSkg)

5 Nm (0.5 mSkg)

Order 8 9 10 11 12

Job/Part Left side cowling Right side cowling Windshield Rear view mirror Front cowling

Qty 1 1 1 2 1

Remarks

For installation, reverse the removal procedure.

3-6

COWLINGS
REMOVAL 1. Remove: S rear cowling S side cowlings

CHK ADJ

NOTE: To remove the quick fastener, turn its center to 90_ with a screwdriver, then pull the fastener out.

INSTALLATION 1. Install: S side cowlings S rear cowling NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the cowling and push the pin a in with a screwdriver. Make sure that the pin is flush with the fasteners head.

3-7

AIR FILTER CASE AND IGNITION COILS

CHK ADJ

AIR FILTER CASE AND IGNITION COILS

Order

Job/Part Removing the air filter case and ignition coils Rider seat and fuel tank Front cowling inner panel (left) Front cowling inner panel (right) Crankcase breather hose Air vent hose Hoses Drain cup Air filter case balance hose Clamp screw Bolt Surge tank joint (left) Surge tank joint (right) Air filter case Clamp Quick fastener

Qty

Remarks Remove the parts in the order listed. Refer to SEATS and FUEL TANK. Refer to COWLINGS.

1 2 3 4 5 6 7 8 9 10 11 12

1 1 2 1 2 4 1 1 1 1 2 2

Loosen.

3-8

AIR FILTER CASE AND IGNITION COILS

CHK ADJ

Order 13 14 15

Job/Part Heat protector plate Ignition coil coupler Ignition coil

Qty 1 4 4

Remarks

For installation, reverse the removal procedure.

3-9

AIR FILTER CASE AND IGNITION COIL PLATE


REMOVAL 1. Remove: S heat protector plate

CHK ADJ

NOTE: To remove the quick fastener, push its center in with a screwdriver, then pull the fastener out.

INSTALLATION 1. Install: S heat protector plate NOTE: To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastener into the rubber baffle and push the pin a in with a screwdriver. Make sure that the pin is flush with the fasteners head.

3-10

ADJUSTING THE VALVE CLEARANCE


EB303001

CHK ADJ

ENGINE
ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. NOTE: S Valve clearance adjustment should be made on a cold engine, at room temperature. S When the valve clearance is to be measured or adjusted, the piston must be at top dead center (TDC) on the compression stroke. 1. Remove: S rider seat S fuel tank Refer to SEATS and FUEL TANK. S air filter case S heat protector plate Refer to AIR FILTER CASE AND IGNITION COILS. S bottom cowling S side cowlings Refer to COWLINGS. S carburetor assembly Refer to CARBURETORS in chapter 6. S radiator assembly Refer to RADIATOR in chapter 5.

2. Remove: S ignition coils S spark plugs S cylinder head cover 1 S cylinder head cover gasket

3. Remove: S pickup coil rotor cover 1

3-11

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

4. Measure: S valve clearance Out of specification ! Adjust Valve clearance (cold) Intake valve 0.11 X 0.20 mm Exhaust valve 0.21 X 0.30 mm a. Turn the crankshaft clockwise. b. When piston #1 is at TDC on the compression stroke, align the TDC mark a on the pickup coil rotor with the crankcase mating surface b . NOTE: TDC on the compression stroke can be found when the camshaft lobes are turned away from each other. c. Measure the valve clearance with a thickness gauge 1 . NOTE: S If the valve clearance is incorrect, record the measured reading. S Measure the valve clearance in the following sequence. Valve clearance measuring sequence Cylinder #1 ! #2 ! #4 ! #3
A Front d. To measure the valve clearances of the other cylinders, starting with cylinder #1 at TDC, turn the crankshaft counterclockwise as specified in the following table. B Degrees that the crankshaft is turned counterclockwise C Cylinder D Combustion cycle

Cylinder #2 Cylinder #4 Cylinder #3

180_ 360_ 540_

3-12

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

5. Remove: S timing chain tensioner S timing chain guide (exhaust side) S camshaft cap S timing chain (from the camshaft sprockets) S intake camshaft S exhaust camshaft NOTE: S Refer to CAMSHAFTS in chapter 4. S When removing the timing chain from camshafts, fasten the timing chain with a wire to retrieve it if it falls into the crankcase.

6. Adjust: S valve clearance a. Remove the valve lifter 1 and the valve pad 2. NOTE: S Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. S Make a note of the position of each valve lifter 1 and valve pad 2 so that they can be installed in the correct place. b. Select the proper valve pad from the following table. Valve pad thickness range Nos. 120 X 240 1.20 X 2.40 mm Available valve pads 25 thicknesses in 0.05 mm increments

NOTE: S The thickness a of each valve pad is marked in hundredths of millimeters on the side that touches the valve lifter. S Since valve pads of various sizes are originally installed, the valve pad number must be rounded in order to reach the closest equivalent to the original.

3-13

ADJUSTING THE VALVE CLEARANCE

CHK ADJ

c. Round off the original valve pad number according to the following table. Last digit 0 or 2 5 8 Rounded value 0 5 10

EXAMPLE: Original valve pad number = 148 (thickness = 1.48 mm) Rounded value = 150 d. Locate the rounded number of the original valve pad and the measured valve clearance in the valve pad selection table. The point where the column and row intersect is the new valve pad number. NOTE: The new valve pad number is only an approximation. The valve clearance must be measured again and the above steps should be repeated if the measurement is still incorrect. e. Install the new valve pad 1 and the valve lifter 2 . NOTE: S Lubricate the valve pad with molybdenum disulfide grease. S Lubricate the valve lifter with molybdenum disulfide oil. S The valve lifter must turn smoothly when rotated by hand. S Install the valve lifter and the valve pad in the correct place. f. Install the exhaust and intake camshafts, timing chain and camshaft caps. Camshaft cap bolt 10 Nm (1.0 mSkg) NOTE: S Refer to CAMSHAFTS in chapter 4. S Lubricate the camshaft lobes and camshaft journals. S First, install the exhaust camshaft. S Align the camshaft marks with the camshaft cap marks. S Turn the crankshaft counterclockwise several full turns to seat the parts.

3-14

ADJUSTING THE VALVE CLEARANCE


VALVE PAD SELECTION TABLE INTAKE
B
MEASURED

CHK ADJ

A ORIGINAL VALVE PAD NUMBER

VALVE CLEARANCE

0.00 X 0.02 0.03 X 0.07 0.08 X 0.10 0.11 X 0.20 0.21 X 0.22 0.23 X 0.27 0.28 X 0.32 0.33 X 0.37 0.38 X 0.42 0.43 X 0.47 0.48 X 0.52 0.53 X 0.57 0.58 X 0.62 0.63 X 0.67 0.68 X 0.72 0.73 X 0.77 0.78 X 0.82 0.83 X 0.87 0.88 X 0.92 0.93 X 0.97 0.98 X 1.02 1.03 X 1.07 1.08 X 1.12 1.13 X 1.17 1.18 X 1.22 1.23 X 1.27 1.28 X 1.32 1.33 X 1.37

120 125 130 135 120 120 125 120 125 130 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

140 125 130 135 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

145 130 135 140 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

150 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

155 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

160 145 150 155 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

165 170 175 180 185 190 195 200 205 210 215 150 155 160 165 170 175 180 185 190 195 200 155 160 165 170 175 180 185 190 195 200 205 160 165 170 175 180 185 190 195 200 205 210 C STANDARD CLEARANCE 170 175 180 185 190 195 200 205 210 215 220 175 180 185 190 195 200 205 210 215 220 225 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 235 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 Example: 230 235 240 Valve Clearance (cold) 235 240 240 0.11 X 0.20 mm

220 205 210 215

225 210 215 220

230 215 220 225

235 240 220 225 225 230 230 235

225 230 235 240 230 235 240 235 240 240

Rounded value 150 Measured valve clearance is 0.24 mm Replace pad 150 with pad 160 Pad No. 150 = 1.50 mm Pad No. 160 = 1.60 mm Always install the valve pad with the number facing down.

EXHAUST
B
MEASURED

A ORIGINAL VALVE PAD NUMBER

VALVE CLEARANCE

0.00 X 0.02 0.03 X 0.07 0.08 X 0.12 0.13 X 0.17 0.18 X 0.20 0.21 X 0.30 0.31 X 0.32 0.33 X 0.37 0.38 X 0.42 0.43 X 0.47 0.48 X 0.52 0.53 X 0.57 0.58 X 0.62 0.63 X 0.67 0.68 X 0.72 0.73 X 0.77 0.78 X 0.82 0.83 X 0.87 0.88 X 0.92 0.93 X 0.97 0.98 X 1.02 1.03 X 1.07 1.08 X 1.12 1.13 X 1.17 1.18 X 1.22 1.23 X 1.27 1.28 X 1.32 1.33 X 1.37 1.38 X 1.42 1.43 X 1.47

120 125 130 135 140 145 120 120 125 120 125 130 120 125 130 135 120 125 130 135 140 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

150 125 130 135 140 145 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

155 130 135 140 145 150 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

160 135 140 145 150 155 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240

165 170 175 180 185 190 195 200 205 210 215 140 145 150 155 160 165 170 175 180 185 190 145 150 155 160 165 170 175 180 185 190 195 150 155 160 165 170 175 180 185 190 195 200 155 160 165 170 175 180 185 190 195 200 205 160 165 170 175 180 185 190 195 200 205 210 C STANDARD CLEARANCE 170 175 180 185 190 195 200 205 210 215 220 175 180 185 190 195 200 205 210 215 220 225 180 185 190 195 200 205 210 215 220 225 230 185 190 195 200 205 210 215 220 225 230 235 190 195 200 205 210 215 220 225 230 235 240 195 200 205 210 215 220 225 230 235 240 200 205 210 215 220 225 230 235 240 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 Example: 230 235 240 235 240 Valve Clearance (cold) 240 0.21 X 0.30 mm

220 195 200 205 210 215

225 200 205 210 215 220

230 205 210 215 220 225

235 240 210 215 215 220 220 225 225 230 230 235

225 230 235 240 230 235 240 235 240 240

Rounded value 175 Measured valve clearance is 0.35 mm Replace pad 150 with pad 185 Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm Always install the valve pad with the number facing down.

3-15

ADJUSTING THE VALVE CLEARANCE/ SYNCHRONIZING THE CARBURETORS

CHK ADJ

g. Measure the valve clearance again. h. If the valve clearance is still out of specification, repeat all of the valve clearance adjustment steps until the specified clearance is obtained.

7. Install: S all removed parts NOTE: For installation, reverse the removal procedure. Note the following points.

8. Install: S timing chain guide (exhaust side) S timing chain tensioner S pickup coil rotor cover S cylinder head cover S spark plugs S ignition coils Refer to CAMSHAFTS in chapter 4.

EB303010

SYNCHRONIZING THE CARBURETORS NOTE: Prior to synchronizing the carburetors, the valve clearance and the engine idling speed should be properly adjusted and the ignition timing should be checked. 1. Stand the motorcycle on a level surface. NOTE: Place the motorcycle on a suitable stand. 2. Remove: S rider seat S fuel tank Refer to SEATS and FUEL TANK.

3-16

SYNCHRONIZING THE CARBURETORS


3. Remove: S hose 1

CHK ADJ

4. Install: S vacuum gauge attachments (into the bolt holes) S vacuum gauge 1 (onto the vacuum gauge attachments) S engine tachometer 2 (onto the ignition coil of cylinder #1) Vacuum gauge 90890-03094 Vacuum gauge attachment 90890-03060 Engine tachometer 90793-80009 5. Start the engine and let it warm up for several minutes.

6. Measure: S engine idling speed Out of specification ! Adjust. Refer to ADJUSTING THE ENGINE IDLING SPEED. Engine idling speed 1,250 X 1,350 r/min

7. Adjust: S carburetor synchronization a. Synchronize carburetor #1 to carburetor #2 by turning the synchronizing screw 1 in either direction until both gauges read the same.

3-17

SYNCHRONIZING THE CARBURETORS/ ADJUSTING THE ENGINE IDLING SPEED

CHK ADJ

NOTE: After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. b. Synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw 2 in either direction until both gauges read the same. c. Synchronize carburetor #2 to carburetor #3 by turning the synchronizing screw 3 in either direction until both gauges read the same. Vacuum pressure at engine idling speed 24.0 kPa (0.24 kg/cm2) NOTE: The difference in vacuum pressure between two carburetors should not exceed 1.33 kPa (10 mm Hg).

8. Measure: S engine idling speed Out of specification ! Adjust. 9. Stop the engine and remove the measuring equipment. 10. Adjust: S throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 6 X 8 mm
EB303020

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

3-18

ADJUSTING THE ENGINE IDLING SPEED

CHK ADJ

2. Remove: S air filter case S quick fasteners 1 S band 2 Refer to AIR FILTER CASE AND IGNITION COILS.

3. Install: S engine tachometer (onto the ignition coil of cylinder #1) Engine tachometer 90793-80009 4. Install: S air filter case Refer to AIR FILTER CASE AND IGNITION COILS. 5. Measure: S engine idling speed Out of specification ! Adjust. Engine idling speed 1,250 X 1,350 r/min 6. Adjust: S engine idling speed a. Turn the pilot screw 1 in until it is lightly seated. b. Turn the pilot screw out the specified number of turns. Carburetor angle driver 90890-03158 Pilot screw setting 2 turns out c. Turn the throttle stop screw 2 in direction a or b until the specified engine idling speed is obtained. Direction a Direction b Engine idling speed is decreased. Engine idling speed is increased.

3-19

ADJUSTING THE ENGINE IDLING SPEED/ ADJUSTING THE THROTTLE CABLE FREE PLAY

CHK ADJ

7. Adjust: S throttle cable free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY. Throttle cable free play (at the flange of the throttle grip) 6 X 8 mm

EB303031

ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed and carburetor synchronization should be adjusted properly.

1. Measure: S throttle cable free play a Out of specification ! Adjust. Throttle cable free play (at the flange of the throttle grip) 6 X 8 mm

2. Remove: S rider seat S fuel tank Refer to SEATS and FUEL TANK. S air filter case S heat protector plate Refer to AIR FILTER CASE AND IGNITION COILS.

3-20

ADJUSTING THE THROTTLE CABLE FREE PLAY


3. Adjust: S throttle cable free play

CHK ADJ

NOTE: When the throttle is opened, the accelerator cable 1 is pulled. Carburetor side a. Loosen the locknut 2 on the decelerator cable. b. Turn the adjusting nut 3 in direction a or b to take up any slack on the decelerator cable. c. Loosen the locknut 4 on the accelerator cable. d. Turn the adjusting nut 5 in direction a or b until the specified throttle cable free play is obtained. Direction a Direction b Throttle cable free play in increased. Throttle cable free play is decreased.

e. Tighten the locknuts. NOTE: If the specified throttle cable free play cannot be obtained on the carburetor side of the cable, use the adjusting nut on the handlebar side.

Handlebar side a. Loosen the locknut 6 . b. Turn the adjusting nut 7 in direction c or d until the specified throttle cable free play is obtained. Direction c Direction d Throttle cable free play is increased. Throttle cable free play is decreased.

d. Tighten the locknut.

WARNING
After adjusting the throttle cable free play, start the engine and turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.

3-21

CHECKING THE SPARK PLUGS


EB303040

CHK ADJ

CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: S rider seat S fuel tank Refer to SEATS and FUEL TANK. S air filter case S heat protector plate Refer to AIR FILTER CASE AND IGNITION COILS. 2. Disconnect: S Ignition coils 3. Remove: S spark plug NOTE: a. Remove the coupler. b. Turn the coil counterdockwise. (5 to 6 turns would be adequate.) c. Pull out the coil upward. Never pry the coupler with a screw driver. d. Press the coil in the plug hole by hand as faras it will go. e. Turn the coil clockwise and screw it in, 5 to 6 turns would be adequate. f. Reins tall the coupler. Do not strike on the coil with a hammer or the like.

CAUTION:
Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to prevent it from falling into the cylinders. 4. Check: S spark plug type Incorrect ! Change. Spark plugs type (manufacturer) CR10EK (NGK)

3-22

CHECKING THE SPARK PLUGS/ CHECKING THE IGNITION TIMING

CHK ADJ

5. Check: S electrodes 1 Damage/wear ! Replace the spark plug. S insulator 2 Abnormal color ! Replace the spark plug. Normal color is medium-to-light tan. 6. Clean: S spark plug (with a spark plug cleaner or wire brush) 7. Measure: S spark plug gap a (with a wire gauge) Out of specification ! Regap. Spark plug gap 0.6 X 0.7 mm

8. Install: S spark plug

13 Nm (1.3 mSkg)

NOTE: Before installing the spark plug, clean the spark plug and gasket surface.

EB303050

CHECKING THE IGNITION TIMING NOTE: Prior to checking the ignition timing, check the wiring connections of the entire ignition system. Make sure that all connections are tight and free of corrosion.

1. Remove: S bottom cowling Refer to COWLINGS. S rider seat S fuel tank Refer to SEATS and FUEL TANK. S air filter case Refer to AIR FILTER CASE AND IGNITION COILS. S timing mark accessing screw 1
3-23

CHECKING THE IGNITION TIMING/ MEASURING THE COMPRESSION PRESSURE

CHK ADJ

2. Install: S timing light 1 S engine tachometer (onto the ignition coil of cylinder #1) Timing light 90890-03141 Engine tachometer 90793-80009 3. Check: S ignition timing a. Start the engine, warm it up for several minutes, and then let it run at the specified engine idling speed. Engine idling speed 1,250 X 1,350 r/min b. Check that the mark a is within the required firing range b on the pickup coil rotor. Incorrect firing range ! Check the ignition system. NOTE: The ignition timing is not adjustable.
EB303060

MEASURING THE COMPRESSION PRESSURE The following procedure applies to all of the cylinders. NOTE: Insufficient compression pressure will result in a loss of performance. 1. Measure: S valve clearance Out of specification ! Adjust. Refer to ADJUSTING THE VALVE CLEARANCE. 2. Start the engine, warm it up for several minutes, and then stop it. 3. Remove: S rider seat S fuel tank Refer to SEATS and FUEL TANK. S air filter case S heat protector plate S ignition coils Refer to AIR FILTER CASE AND IGNITION COILS.
3-24

MEASURING THE COMPRESSION PRESSURE


4. Remove: S spark plug

CHK ADJ

CAUTION:
Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells to prevent it from falling into the cylinders.

5. Install: S compression gauge 1 Compression gauge 90890-03081 Adapter 90890-04136

6. Measure: S compression pressure Out of specification ! Refer to steps (c) and (d). Compression pressure (at sea level) Minimum 1300 kPa (13.0 kg/cm2, 13.0 bar) Standard 1550 kPa (15.5 kg/cm2, 15.5 bar) Maximum 1600 kPa (16.0 kg/cm2, 16.0 bar) a. Set the main switch to ON. b. With the throttle wide open, crank the engine until the reading on the compression gauge stabilizes.

WARNING
To prevent sparking, ground all spark plug leads before cranking the engine. NOTE: The difference in compression pressure between cylinders should not exceed 100 kPa (1 kg/cm2, 1 bar).
3-25

MEASURING THE COMPRESSION PRESSURE/ CHECKING THE ENGINE OIL LEVEL

CHK ADJ

c. If the compression pressure is above the maximum specification, check the cylinder head, valve surfaces, and piston crown for carbon deposits. Carbon deposits ! Eliminate. d. If the compression pressure is below the minimum specification, squirt a few drops of oil into the cylinder and measure again.

Refer to the following table. Compression pressure (with oil applied into the cylinder) Reading Higher than without oil Diagnosis Piston wear or damage ! Repair. Piston ring(-s), valve(-s), cylinder head gasket or piston possibly defective ! Repair.

Same as without oil

7. Install: S spark plug

13 Nm (1.3 mSkg)

EB303070

CHECKING THE ENGINE OIL LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Start the engine, let it idle for several minutes, and then stop it. 3. Check: S engine oil level The engine oil level should be between the minimum level mark a and maximum level mark b . Below the minimum level mark ! Add the recommended engine oil to the proper level.

3-26

CHECKING THE ENGINE OIL LEVEL/ CHANGING THE ENGINE OIL

CHK ADJ

Recommended oil Refer to the chart for the engine oil grade which is best suited for certain atmospheric temperatures. API standard SE or higher grade (Non-Friction modified) ACEA standard G4 or G5

CAUTION:
S Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of CD c or higher and do not use oils labeled ENERGY CONSERVING II d or higher. S Do not allow foreign materials to enter the crankcase. 4. Start the engine, warm it up for several minutes, and then turn it off. 5. Check: S engine oil level NOTE: Before checking the engine oil level, wait a few minutes until the oil has settled.

EB303081

CHANGING THE ENGINE OIL 1. Remove: S bottom cowling Refer to COWLINGS. 2. Start the engine, warm it up for several minutes, and then turn it off. 3. Place a container under the engine oil drain bolt. 4. Remove: S engine oil filler cap 1 S engine oil drain bolt 2 (along with the washer) 5. Drain: S engine oil (completely from the crankcase)

3-27

CHANGING THE ENGINE OIL

CHK ADJ

6. If the oil filter cartridge is also to be replaced, perform the following procedure. a. Remove the oil filter cartridge 1 with an oil filter wrench 2 . Oil filter wrench 90890-01426 b. Lubricate the O-ring 3 of the new oil filter cartridge with a thin coat of engine oil.

CAUTION:
Make sure theat the O-ring 3 is positioned correctly in the groove of the oil filter cartridge. c. Tighten the new oil filter cartridge to specification with an oil filter wrench. Oil filter cartridge 17 Nm (1.7 mSkg) 7. Check: S engine oil drain bolt washer Damage ! Replace. 8. Install: S engine oil drain bolt 43 Nm (4.3 mSkg) 9. Fill: S crankcase (with the specified amount of the recommended engine oil) Quantity Total amount 3.5 L Without oil filter cartridge replacement 2.5 L With oil filter cartridge replacement 2.7 L 10. Install: S engine oil filler cap 11. Start the engine, warm it up for several minutes, and then turn it off. 12. Check: S engine (for engine oil leaks)

3-28

CHANGING THE ENGINE OIL/ MEASURING THE ENGINE OIL PRESSURE

CHK ADJ

13. Check: S engine oil level Refer to CHECKING THE ENGINE OIL LEVEL. 14. Install: S bottom cowling Refer to COWLINGS.
EB303090

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

CAUTION:
When the engine is cold, the engine oil will have a higher viscosity, causing the engine oil pressure to increase. Therefore, be sure to measure the engine oil pressure after warming up the engine. 3. Remove: S oil gallery bolt 1

WARNING
The engine, muffler and engine oil are extremely hot. 4. Install: S oil pressure gauge 1 S adapter 2 Oil pressure gauge 90890-03153 Adapter 90890-03139 5. Measure: S engine oil pressure (at the following conditions) Engine oil pressure 240 kpa (2.4 kg/cm2) Engine speed Approx. 6000 r/min Engine oil temperature 96_C

3-29

MEASURING THE ENGINE OIL PRESSURE/ ADJUSTING THE CLUTCH CABLE FREE PLAY

CHK ADJ

NOTE: Regarding the oil pressure as its own data may fluctuate depending on the oil temperature and viscosity, the oil pressure may fluctuate when measuring. The following data should be used only as a reference when measuring the engine oil pressure. Out of specification ! Adjust.
Engine oil pressure Possible cause Faulty oil pump Clogged oil filter Leaking oil passapage Broken or damaged oil seal Leaking oil passage Faulty oil filter Oil viscosity too high
20 Nm (2.0 mSkg)
EB303100

Below specification

Above specification

6. Tighten the oil gallery bolt ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Measure: S clutch cable free play a Out of specification ! Adjust. Clutch cable free play (at the end of the clutch lever) 10 X 15 mm 2. Adjust: S clutch cable free play Handlebar side a. Turn the adjusting bolt 1 in direction a or b until the specified clutch cable free play is obtained.
Direction a Direction b Clutch cable free play is increased. Clutch cable free play is decreased.

NOTE: If the specified clutch cable free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. Engine side a. Loosen the locknut 2 . b. Turn the adjusting nut 3 in direction c or d until the specified clutch cable free play is obtained.
Direction c Direction d Clutch cable free play is increased. Clutch cable free play is decreased.

c. Tighten the locknut.

3-30

CLEANING THE AIR FILTER ELEMENT/ ADJUSTING THE CLUTCH CABLE FREE PLAY
EB303130

CHK ADJ

CLEANING THE AIR FILTER ELEMENT 1. Remove: S fuel tank Refer to FUEL TANK. S air filter case cover 1 S air filter element

2. Clean: S air filter element Use solvent to clean the air filter element. After cleaning the air filter element, remove the solvent from the air filter element. 3. Apply the engine oil to the entire surface of the filter and remove the excess oil. The air filter should be wet but not dripping. 4. Check: S air filter element Damage ! Replace. 5. Install: S air filter element S air filter case cover

CAUTION:
Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating. NOTE: When installing the air filter element into the air filter case cover, make sure that their sealing surfaces are aligned to prevent any air leaks. 6. Install: S fuel tank Refer to FUEL TANK.

3-31

CHECKING THE CARBURETOR JOINTS/ CHECKING THE FUEL HOSES AND FUEL FILTER/
EB303171

CHK ADJ

CHECKING THE CARBURETOR JOINTS The following procedure applies to all of the carburetor joints and intake manifolds. 1. Remove: S carburetor assembly Refer to CARBURETORS in chapter 6. 2. Check: S carburetor joint 1 Cracks/damage ! Replace. Refer to CARBURETORS in chapter 6. 3. Install: S carburetor assembly Refer to CARBURETORS in chapter 6.

EB303181

CHECKING THE FUEL HOSES AND FUEL FILTER The following procedure applies to all of the fuel hoses. 1. Remove: S fuel tank Refer to FUEL TANK.

2. Check: S fuel hose 1 Cracks/damage ! Replace. S fuel filter 2 Contaminants/damage ! Replace. NOTE: S Drain and flush the fuel tank if abrasive damage to any components of the fuel line is evident. S The arrow mark on the fuel filter must point towards the fuel pump as shown. 3. Install: S fuel tank Refer to FUEL TANK.

3-32

CHECKING THE EXHAUST SYSTEM/ CLEANING THE AIR INTAKE SYSTEM


EB303190

CHK ADJ

CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: S fuel tank Refer to FUEL TANK. 2. Check: S crankcase breather hose 1 Cranks/damage ! Replace. Loose connection ! Connect properly.

CAUTION:
Make sure that the crankcase breather hose is routed correctly. 3. Install: S fuel tank Refer to FUEL TANK.

EAS00092

CLEANING THE AIR INTAKE SYSTEM The following procedure applies to both air intake system. 1. Remove: S side cowling inner covers S side cowlings S front cowling inner covers S front cowling S fuel tank 2. Loosen: S clamps (on the inside of the front cowling) 3. Remove: S air intake system air ducts 1 4. Clean: S air intake system air ducts a. Thoroughly flush out the air intake system air ducts with clean water. b. Hold the air intake system air ducts upside down to allow the water to drain out. c. Repeat the flushing steps until the excess water is clear and free of debris. d. Place the air intake system air ducts in an upright position to allow any remaining water to drain out of the lower drain tube. e. Keep the air intake system air ducts upright to allow it to dry sufficiently. 5. Install: S air intake system air ducts S fuel tank S front cowling S front cowling inner covers S side cowlings S side cowlings inner covers
3-33

CHECKING THE CRANKCASE BREATHER HOSE/ CHECKING THE EXHAUST SYSTEM

CHK ADJ

2. Check: S crankcase breather hose 1 Cracks/damage ! Replace. Loose connection ! Connect properly.

CAUTION:
Make sure that the crankcase breather hose is routed correctly.

3. Install: S fuel tank Refer to FUEL TANK.

EB303200

CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes and gaskets. 1. Remove: S radiator assembly Refer to RADIATOR in chapter 5. 2. Check: S exhaust pipe 1 S muffler 2 Cracks/damage ! Replace. S gasket 3 Exhaust gas leaks ! Replace. 3. Measure: S tightening torque Exhaust pipe nut 4 20 Nm (2.0 mSkg) Muffler clamp bolt 5 20 Nm (2.0 mSkg) Exhaust pipe bolt 6 20 Nm (2.0 mSkg) Muffler bolt 7 38 Nm (3.8 mSkg) 4. Install: S radiator assembly Refer to RADIATOR in chapter 5.

3-34

CHECKING THE COOLANT LEVEL/ CHECKING THE COOLING SYSTEM


EB303220

CHK ADJ

CHECKING THE COOLANT LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright. 2. Check: S coolant level The coolant level should be between the maximum level mark a and minimum level marks b . Below the minimum level mark ! Add the recommended coolant to the proper level.

CAUTION:
S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check and correct the antifreeze concentration of the coolant. S Use only distilled water. Soft water may be used if distilled water is not available. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check: S coolant level NOTE: Before checking the coolant level, wait a few minutes until it settles.
EB303230

CHECKING THE COOLING SYSTEM 1. Remove: S bottom cowling S side cowlings Refer to COWLINGS. 2. Check: S radiator 1 S radiator inlet hose 2 S radiator outlet hose 3 S oil cooler 4 S oil cooler inlet hose 5 S oil cooler outlet hose 6 S water pump outlet hose 7 Cracks/damage ! Replace. Refer to COOLING SYSTEM in chapter 5. 3. Install: S side cowlings S bottom cowling Refer to Cowlings.
3-35

CHANGING THE COOLANT


EB303240

CHK ADJ

CHANGING THE COOLANT 1. Remove: S bottom cowling S left side cowling Refer to COWLINGS. S reservoir hose clamps 1 2. Remove: S coolant reservoir bolts 2 S coolant reservoir cap 3 NOTE: When draining the coolant from the coolant reservoir, be sure to tilt the reservoir so that coolant cannot flow through the coolant reservoir breather hose 4 . 3. Drain: S coolant (from the coolant reservoir) 4. Install: S coolant reservoir bolts S reservoir cover

5. Remove: S radiator cap 1

WARNING
A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury. When the engine has cooled, open the radiator cap as follows: Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counterclockwise toward the detent to allow any residual pressure to escape. When the hissing sound has stopped, turn the radiator cap counterclockwise while pressing down on it and then remove it.

3-36

CHANGING THE COOLANT

CHK ADJ

6. Remove: S coolant drain bolt 1 (along with the copper washer) 7. Drain: S coolant 8. Check: S coper washer 1 S coolant drain bolt 2 Damage ! Replace 9. Install: S coolant drain bolt

7 Nm (0.7 mSkg)

10. Fill: S cooling system (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze: water) Quantity Total amount 2.15 L Coolant reservoir capacity 0.44 L Handling notes for coolant Coolant is potentially harmful and should be handled with special care.

WARNING
S If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor. S If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. S If coolant is swallowed, induce vomiting and get immediate medical attention.

3-37

CHANGING THE COOLANT CAUTION:

CHK ADJ

S Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant, check, and if necessary, correct the antifreeze concentration of the coolant. S Use only distilled water. However, soft water may be used if distilled water is not available. S If coolant comes into contact with painted surfaces, immediately wash them with water. S Do not mix different types of antifreeze. 11. Install: S radiator cap

12. Fill: S coolant reservoir (with the recommended coolant to the maximum level mark a ) 13. Install: S coolant reservoir cap 14. Start the engine, warm it up for several minutes, and then turn it off.

15. Check: S coolant level Refer to CHECKING THE COOLANT LEVEL. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. 16. Install: S left side cowling S bottom cowling Refer to COWLINGS.

3-38

ADJUSTING THE FRONT BRAKE/ ADJUSTING THE REAR BRAKE


EB304001

CHK ADJ

CHASSIS
ADJUSTING THE FRONT BRAKE 1. Adjust: S brake lever position (distance a from the throttle grip to the brake lever) a. While pushing the brake lever forward, turn the adjusting dial 1 until the brake lever is in the desired position. NOTE: Be sure to align the setting on the adjusting dial with the arrow mark 2 on the brake lever holder. Position #1 Position #5 Distance a is the largest. Distance a is the smallest.

WARNING
After adjusting the brake lever position, make sure that the pin on the brake lever holder is firmly inserted in the hole in the adjusting dial.

EB304010

ADJUSTING THE REAR BRAKE 1. Measure: S brake pedal position (distance a from the top of the brake pedal to the bottom of the rider footrest bracket bolt center) Out of specification ! Adjust. Brake pedal position (from the top of the brake pedal to the bottom of the rider footrest bracket bolt center) 4.3 X 9.3 mm
b :

11mm

3-39

ADJUSTING THE REAR BRAKE


2. Adjust: S brake pedal position

CHK ADJ

a. Loosen the locknut 1 . b. Turn the adjusting bolt 2 in direction a or b until the specified brake pedal position is obtained. Direction a Direction b Brake pedal is raised. Brake pedal is lowered.

WARNING
After adjusting the brake pedal position, check that the end of the adjusting bolt c is visible through the hole d . c. Tighten the locknut 1 to specification. Locknut 16 Nm (1.6 mSkg)

WARNING
A soft or spongy feeling in the brake pedal can indicate the presence of air in the brake system. Before the vehicle is operated, the air must be removed by bleeding the brake system. Air in the brake system will considerably reduce braking performance and could result in loss of control and possibly an accident. Therefore, check and, if necessary, bleed the brake system.

CAUTION:
After adjusting the brake pedal position, make sure that there is no brake drag.

3. Adjust: S rear brake light switch Refer to ADJUSTING THE REAR BRAKE LIGHT SWITCH.

3-40

CHECKING THE BRAKE FLUID LEVEL


EB304020

CHK ADJ

CHECKING THE BRAKE FLUID LEVEL 1. Stand the motorcycle on a level surface. NOTE: S Place the motorcycle on a suitable stand. S Make sure that the motorcycle is upright.

2. Check: S brake fluid level Below the minimum level mark a ! Add the recommended brake fluid to the proper level. Recommended brake fluid DOT 4
A Front brake B Rear brake

WARNING
S Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. S Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. S When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock.

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 that the top of the brake fluid reservoir is horizontal.

3-41

CHECKING THE BRAKE PADS/ ADJUSTING THE REAR BRAKE LIGHT SWITCH
A
EB304032

CHK ADJ

CHECKING THE BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: S front brake pad S rear brake pad Brake pad wear limit a Wear limit reached ! Replace the brake pads as a set. Refer to FRONT AND REAR BRAKES in chapter 7. Brake pad wear limit a 0.5 mm b 0.8 mm
A Front brake B Rear brake

EB304050

ADJUSTING THE REAR BRAKE LIGHT SWITCH NOTE: S The rear brake light switch is operated by movement of the brake pedal. S The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts. 1. Check: S rear brake light operation timing Incorrect ! Adjust. 2. Adjust: S rear brake light operation timing a. Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 in direction a or b until the rear brake light comes on at the proper time. Direction a Direction b Brake light comes on sooner. Brake light comes on later.

3-42

CHECKING THE BRAKE HOSES/ BLEEDING THE HYDRAULIC BRAKE SYSTEM


EB304062

CHK ADJ

CHECKING THE BRAKE HOSES The following procedure applies to all of the brake hoses and brake hose clamps. 1. Check: S brake hose 1 Cracks/damage/wear ! Replace. 2. Check: S brake hose clamp Loose ! Tighten the clamp bolt. 3. Hold the motorcycle upright and apply the brake several times. 4. Check: S brake hose Brake fluid leakage ! Replace the damaged hose. Refer to FRONT AND REAR BRAKES in chapter 7.

EB304072

BLEEDING THE HYDRAULIC BRAKE SYSTEM

WARNING
Bleed the hydraulic brake system whenever: S the brake system was disassembled, S a brake hose was loosened, disconnected or replaced, S the brake fluid level is very low, S brake operation is faulty. NOTE: S Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow. S When bleeding the hydraulic brake system, make sure that there is always enough brake fluid before applying the brake. Ignoring this precaution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. S If bleeding is difficult, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared.

3-43

BLEEDING THE HYDRAULIC BRAKE SYSTEM


A

CHK ADJ

5. Bleed: S hydraulic brake system a. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. b. Install the brake fluid reservoir diaphragm. c. Connect a clear plastic hose 1 tightly to the bleed screw 2 . A Front brake B Rear brake d. Place the other end of the hose into a container. e. Slowly apply the brake several times. f. Fully squeeze the brake lever or fully depress the brake pedal and hold it in position. g. Loosen the bleed screw. NOTE: Loosening the bleed screw will release the pressure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. h. Tighten the bleed screw and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 mSkg) k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to CHECKING THE BRAKE FLUID LEVEL.

WARNING
After bleeding the hydraulic brake system, check the brake operation.

3-44

ADJUSTING THE SHIFT PEDAL/ ADJUSTING THE DRIVE CHAIN SLACK


EB304081

CHK ADJ

ADJUSTING THE SHIFT PEDAL NOTE: The shift pedal position is determined by the installed. 1. Measure: S incorrect ! Adjust. The top of sift pedal should be aligned with the lower part of the bracket. (from the horizontal view) 2. Adjust: S installed shift rod length a. Loosen both locknuts 1 . b. Turn the shift rod 2 in direction b or c to obtain the correct shift pedal position. Direction b Direction c Installed shift rod length increases. Installed shift rod length decreases.

c. Tighten both locknuts. d. Make sure that the installed shift rod length is within specification.
EB304092

ADJUSTING THE DRIVE CHAIN SLACK NOTE: The drive chain slack must be checked at the tightest point on the chain.

CAUTION:
A drive chain that is too tight will overload the engine and other vital parts, and one that is too loose can skip and damage the swingarm or cause an accident. Therefore, keep the drive chain slack within the specified limits. 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.
3-45

ADJUSTING THE DRIVE CHAIN SLACK

CHK ADJ

2. Rotate the rear wheel several times and check the drive chain to locate its tightest point. 3. Measure: S drive chain slack a Out of specification ! Adjust. Drive chain slack 40 X 50 mm

4. Adjust: S drive chain slack a. Loosen the wheel axle nut 1 . b. Loosen both locknuts 2 . c. Turn both adjusting bolts 3 in direction a or b until the specified drive chain slack is obtained. Direction a Direction b Drive chain slack is reduced. Drive chain slack is increased.

NOTE: To maintain the proper wheel alignment, adjust both sides evenly. d. Tighten both locknuts to specification. Locknut 16 Nm (1.6 mSkg) e. Tighten the wheel axle nut to specification. Wheel axle nut 150 Nm (15.0 mSkg)

3-46

LUBRICATING THE DRIVE CHAIN/ CHECKING AND ADJUSTING THE STEERING HEAD
EB304100

CHK ADJ

LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out rapidly. Therefore, the drive chain should be serviced, especially when the motorcycle is used in dusty areas. This motorcycle has a drive chain with small rubber Orings between each side plate. Steam cleaning, high-pressure washing, certain solvents, and the use of a coarse brush can damage these Orings. Therefore, use only kerosine to clean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. Recommended lubricant Engine oil or chain lubricant suitable for O-ring chains

EB304130

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. 2. Check: S steering head Grasp the bottom of the front fork legs and gently rock the front fork. Looseness/binding ! Adjust the steering head.

3-47

CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

3. Remove: S upper bracket bolts 1 S front brake fluid reservoir bolt 2

4. Loosen: S upper bracket pinch bolts 1 S handlebar pinch bolts 2 S washer 3 5. Remove: S handlebars (from the upper bracket)

6. Remove: S steering stem nut 1 S washer 2 S upper bracket 3

7. Adjust: S steering head a. Remove the lock washer 1 , the upper ring nut 2 , and the washer 3 . b. Loosen the lower ring nut 4 and then tighten it to specification with a ring nut wrench 5 . NOTE: Set the torque wrench at a right angle to the steering nut wrench. Steering nut wrench 90890-01403 Lower ring nut (initial tightening torque) 17 Nm (1.7 mSkg)

3-48

CHECKING AND ADJUSTING THE STEERING HEAD

CHK ADJ

c. Loosen the lower ring nut completely, then tighten it to specification.

WARNING
Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 9 Nm (0.9 mSkg) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to STEERING HEAD in chapter 7. e. Install the washer 3 . f. Install the upper ring nut 2 . g. Finger tighten the upper ring nut 2 , then align the slots of both ring nuts. If necessary, hold the lower ring nut and tighten the upper ring nut until their slots are aligned. h. Install the lock washer 1 . NOTE: Make sure that the lock washer tabs a sit correctly in the ring nut slots b .

8. Install: S steering stem nut S upper bracket bolt S handlebar pinch bolt S upper bracket pinch bolt
115 Nm (11.5 mSkg) 13 Nm (1.3 mSkg) 13 Nm (1.3 mSkg) 23 Nm (2.3 mSkg)

9. Measure: S steering head tension (with the motorcycle still on the stand) NOTE: Make sure that all of the cables and wires are properly routed. a. Point the front wheel straight ahead. b. Install a plastic locking tie 1 loosely around the end of the handlebar as shown. c. Hook a spring gauge 2 onto the plastic locking tie.

3-49

CHECKING AND ADJUSTING THE STEERING HEAD/ CHECKING THE FRONT FORK

CHK ADJ

d. Hold the spring gauge at a 90_ angle from the handlebar, pull the spring gauge, and record the measurement when the handlebar starts to turn. Steering head tension 200 X 500 g e. Repeat the above procedure on the opposite handlebar. f. If the steering head tension is out of specification (both handlebars should be within specification), remove the upper bracket and loosen or tighten the upper ring nut. g. Reinstall the upper bracket and measure the steering head tension again as described above. h. Repeat the above procedure until the steering head tension is within specification. i. Grasp the bottom of the front fork legs and gently rock the front fork. Looseness or binding ! Adjust the steering head.

EB304141

CHECKING THE FRONT FORK 1. Stand the motorcycle on a level surface.

WARNING
Securely support the motorcycle so that there is no danger of it falling over. 2. Check: S inner tube 1 Damage/scratches ! Replace. S oil seal 2 Oil leakage ! Replace. 3. Hold the motorcycle upright and apply the front brake. 4. Check: S front fork operation Push down hard on the handlebars several times and check if the front fork rebounds smoothly. Rough movement ! Repair. Refer to FRONT FORK in chapter 7.
3-50

ADJUSTING THE FRONT FORK LEGS


EB304153

CHK ADJ

ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.

WARNING
S Always adjust both front fork legs evenly. Uneven adjustment can result in poor handling and loss of stability. S Securely support the motorcycle so that there is no danger of it falling over. Spring preload

CAUTION:
S Grooves are provided to indicate the adjustment position. S Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S spring preload a. Turn the adjusting bolt 1 in direction a or b. Direction a Spring preload is increased (suspension is harder). Spring preload is decreased (suspension is softer). STD 5 SOFT 6 7 8

Direction b

HARD 2 3

3-51

ADJUSTING THE FRONT FORK LEGS


Rebound damping

CHK ADJ

CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or b. Direction a Rebound damping is increased (suspension is harder). Rebound damping is decreased (suspension is softer).

Direction b

Adjusting positions Minimum: 12 clicks out* Standard: 6 clicks out* Maximum: 1 clicks out* * from the fully turned-in position Compression damping

CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S compression damping a. Turn the adjusting screw 1 in direction a or b. Direction a Compression damping is increased (suspension is harder). Compression damping is decreased (suspension is softer).

Direction b

Adjusting positions Minimum: 11 clicks out* Standard: 6 clicks out* Maximum: 1 clicks out* * from the fully turned-in position

3-52

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY


EB304162

CHK ADJ

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY

WARNING
Securely support the motorcycle so that there is no danger of it falling over. Spring preload

CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S spring preload NOTE: Adjust the spring preload with the special wrench and extension bar included in the owners tool kit.

a. Turn the adjusting ring 1 in direction a or b. b. Align the desired position on the adjusting ring with the position indicator 2 . Direction a Spring preload is increased (suspension is harder). Spring preload is decreased (suspension is softer).

Direction b

Adjusting positions Minimum: 1 Standard: 4 Maximum: 9

3-53

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY


Rebound damping

CHK ADJ

CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S rebound damping a. Turn the adjusting screw 1 in direction a or b. Direction a Rebound damping is increased (suspension is harder). Rebound damping is decreased (suspension is softer).

Direction b

Adjusting positions Minimum: 25 clicks out* Standard: 9 clicks out* Maximum: 1 click out* * from the fully turned-in position Compression damping

CAUTION:
Never go beyond the maximum or minimum adjustment positions. 1. Adjust: S compression damping a. Turn the adjusting screw 1 in direction a or b. Direction a Compression damping is increased (suspension is harder). Compression damping is decreased (suspension is softer).

Direction b

Adjusting positions Minimum: 13 clicks out* Standard: 7 clicks out* Maximum: 1 click out* * from the fully turned-in position

3-54

CHECKING THE TIRES


EB304170

CHK ADJ

CHECKING THE TIRES The following procedure applies to both of the tires. 1. Measure: S tire pressure Out of specification ! Regulate.

WARNING
S The tire pressure should only be checked and regulated when the tire temperature equals the ambient air temperature. S The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and accessories) and the anticipated riding speed. S Operation of an overloaded motorcycle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE MOTORCYCLE.
Basic weight (with oil and a full fuel tank) Maximum load* Cold tire pressure Up to 90 kg load* 90 kg Xmaximum load* High-speed riding Front

188 kg

187 kg Rear

250 kPa 250 kPa (2.5 kgf/cm2, (2.5 kgf/cm2, 2.5 bar) 2.5 bar) 250 kPa 290 kPa (2.5 kgf/cm2, (2.9 kgf/cm2, 2.5 bar) 2.9 bar) 250 kPa 250 kPa (2.5 kgf/cm2, (2.5 kgf/cm2, 2.5 bar) 2.5 bar)

* total of cargo, rider, passenger and accessories

WARNING
It is dangerous to ride with a worn-out tire. When the tire tread reaches the wear limit, replace the tire immediately.

3-55

CHECKING THE TIRES

CHK ADJ

2. Check: S tire surfaces Damage/wear ! Replace the tire. Minimum tire tread depth 1.6 mm 1 Tire tread depth 2 Side wall 3 Wear indicator

WARNING
A B S Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. S When using a tube tire, be sure to install the correct tube. S Always replace a new tube tire and a new tube as a set. S To avoid pinching the tube, make sure that the wheel rim band and tube are centered in the wheel groove. S Patching a punctured tube is not recommended. If it is absolutely necessary to do so, use great care and replace the tube as soon as possible with a good quality replacement. A Tire B Wheel Tube wheel Tubeless wheel Tube tire only Tube or tubeless tire

S 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. No guarantee concerning handling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle.

Front tire
Manufacturer
BRIDGESTONE DUNLOP

Size
120 / 60 ZR17 (55W) 120 / 60 ZR17 (55W)

Model
BT56FSE D207FSJ

3-56

CHECKING THE TIRES/CHECKING THE WHEELS


Rear tire
Manufacturer BRIDGESTONE DUNLOP

CHK ADJ
Size Model BT56RSE D207SN

180/55 ZR17 (73W) 180/55 ZR17 (73W)

WARNING
After mounting a new tire, ride conservatively for a while to become accustomed to the feel of the new tire and to allow the tire to seat itself properly in the rim. Failure to do so could lead to an accident with possible injury to the rider or damage to the motorcycle. NOTE: For tires with a direction of rotation mark 1 : S Install the tire with the mark pointing in the direction of wheel rotation. S Align the mark 2 with the valve installation point.
EB304180

CHECKING THE WHEELS The following procedure applies to both of the wheels. 1. Check: S 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.

3-57

CHECKING AND LUBRICATING THE CABLES/ LUBRICATING THE LEVERS AND PEDALS/ LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION
EB304200

CHK ADJ

CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the cable sheaths and cables.

WARNING
Damaged cable sheaths may cause the cable to corrode and interfere with its movement. Replace damaged cable sheaths and cables as soon as possible. 1. Check: S cable sheath Damage ! Replace. 2. Check: S cable operation Rough movement ! Lubricate. Recommended lubricant Engine oil or a suitable cable lubricant NOTE: Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubing device.
EB304210

LUBRICATING THE LEVERS AND PEDALS Lubricate the pivoting point and metal-to-metal moving parts of the levers and pedals. Recommended lubricant Lithium soap base grease
EB304220

LUBRICATING THE SIDESTAND Lubricate the pivoting point and metal-to-metal moving parts of the sidestand. Recommended lubricant Lithium soap base grease
EB304240

LUBRICATING THE REAR SUSPENSION Lubricate the pivoting point and metal-to-metal moving parts of the rear suspension. Recommended lubricant Lithium soap base grease

3-58

CHECKING AND CHARGING THE BATTERY


EB305020

CHK ADJ

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: S Wear protective eye gear when handling or working near batteries. S Charge batteries in a well-ventilated area. S Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). S DO NOT SMOKE when charging or handling batteries. S KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. S Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL S Skin Wash with water S Eyes Flush with water for 15 minutes and get immediate medical attention. INTERNAL S Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

CAUTION:
S This is a sealed battery. Never remove the sealing caps because the balance between cells will not be maintained and battery performance will deteriorate. S Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

3-59

CHECKING AND CHARGING THE BATTERY

CHK ADJ

NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: S rider seat Refer to SEATS. 2. Disconnect: S battery leads (from the battery terminals)

CAUTION:
First, disconnect the negative lead 2 , then the positive lead 1 . 3. Remove: S battery 4. Measure: S battery charge a. Connect a digital voltmeter to the battery terminals. Tester positive probe ! battery positive terminal Tester negative probe ! battery negative terminal
13.0 12.5 12.0 11.5 Relationship between the open-circuit voltage and the charging time at 20_C

NOTE: S The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). S No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V. b. Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20 X 30%

Open-circuit voltage (V)

5 6.5 10 Charging time (hours) These values vary with the temperature, the condition of the battery plates, and the electrolyte level.

3-60

CHECKING AND CHARGING THE BATTERY


Charging Ambient temperature 20_C Open-circuit voltage (V)

CHK ADJ

5. Charge: S battery (refer to the appropriate charging method illustration)

WARNING
Do not quick charge a battery.
Time (minutes) Check the open-circuit voltage.

CAUTION:
S Never remove the MF battery sealing caps. S Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. S If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. S When charging a battery, be sure to remove it from the motorcycle. (If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal.) S To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. S Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger. S Make sure that the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. S If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! S As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

Open-circuit voltage (V)

Ambient temperature 20_C

Charging condition of the battery (%)

3-61

CHECKING AND CHARGING THE BATTERY


Charging method using a variable-voltage charger
Charger Ammeter

CHK ADJ

Measure the open-circuit voltage prior to charging. Connect a charger and ammeter to the battery and start charging. Is the amperage higher than the standard charging amperage written on the battery?

NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage. NOTE: Set the charging voltage to 16 X 17 V. (If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged.)

YES

NO

Adjust the charging voltage to 20 X 25 V. Monitor the amperage for 3 X 5 minutes. Is the standard charging amperage exceeded? NO

Adjust the voltage to obtain the standard charging amperage.

YES

Set the timer to the charging time determined by the opencircuit voltage. Refer to CHECKING AND CHARGING THE BATTERY.

If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery.

If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. 12.8 V ! Charging is complete. 12.0 X 12.7 V ! Recharging is required. Under 12.0 V ! Replace the battery.

3-62

CHECKING AND CHARGING THE BATTERY


Charging method using a constant-voltage charger Measure the open-circuit voltage prior to charging.

CHK ADJ

NOTE: Leave the battery unused for more than 30 minutes before measuring its opencircuit voltage.

Connect a charger and ammeter to the battery and start charging.

YES

Is the amperage higher than the standard charging amperage written on the battery?

NO

Charge the battery until the charging voltage reaches 15 V.


NOTE: Set the charging time to a maximum of 20 hours.

This type of battery charger cannot charge an MF battery. A variablevoltage charger is recommended.

Charger

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. 12.8 V ! Charging is complete. 12.0 X 12.7 V ! Recharging is required. Under 12.0 V ! Replace the battery.
CAUTION: Constant amperage chargers are not suitable for charging MF batteries.

Ammeter Voltmeter

3-63

CHECKING AND CHARGING THE BATTERY/ CHECKING THE FUSES


6. Install: S battery 7. Connect: S battery leads (to the battery terminals)

CHK ADJ

CAUTION:
First, connect the positive lead 1 , then the negative lead 2 . 8. Check: S battery terminals Dirt ! Clean with a wire brush. Loose connection ! Connect properly. 9. Lubricate: S battery terminals Recommended lubricant Dielectric grease 10. Install: S rider seat Refer to SEATS.
EB305040

CHECKING THE FUSES The following procedure applies to all of the fuses.

CAUTION:
To avoid a short circuit, always set the main switch to OFF when checking or replacing a fuse. 1. Remove: S rider seat Refer to SEATS. 2. Check: S continuity a. Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to Pocket tester 90890-03112 b. If the pocket tester indicates , replace the fuse. 1.

3-64

CHECKING THE FUSES


3. Replace: S blown fuse

CHK ADJ

a. Set the main switch to OFF. b. Install a new fuse of the correct amperage. c. Set the main switch to ON and verify if the electrical circuit is operational. d. If the fuse immediately blows again, check the electrical circuit. Item Main fuse Headlight fuse Signaling system fuse Ignition fuse Radiator fan motor fuse Backup fuse (odometer) Amperage 30 A 20 A 20 A 15 A 7.5 A 7.5 A Qty 1 1 1 1 1 1

WARNING
Never use a fuse with an amperage other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. 4. Install: S rider seat Refer to SEATS.

3-65

REPLACING THE HEADLIGHT BULBS


EB305051

CHK ADJ

REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Disconnect: S headlight coupler 1 S headlight bulb holder cover 2

2. Detach: S headlight bulb holder 1 3. Remove: S headlight bulb 2

WARNING
Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 4. Install: S headlight bulb New Secure the new headlight bulb with the headlight bulb holder.

CAUTION:
Avoid touching the glass part of the headlight bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 5. Attach: S headlight bulb holder 6. Install: S headlight bulb holder cover 7. Connect: S headlight coupler

3-66

ADJUSTING THE HEADLIGHT BEAMS


EB305061

CHK ADJ

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

2. Adjust: S headlight beam (horizontally) a. Turn the adjusting knob 1 in direction a or b. Left headlight Direction a Direction b Right headlight Direction a Direction b Headlight beam moves to the left. Headlight beam moves to the right. Headlight beam moves to the right. Headlight beams moves to the left.

3-67

CHK ADJ