Yzf-R6 1999

EAS00001
YZF-R6L /YZF-R6CL
SERVICE MANUAL
 1999 by Yamaha Motor Corporation,
U.S.A.
First edition, February 1999
All rights reserved. Any reproduction or
unauthorized use without the written
permission of Yamaha Motor
Corporation, U.S.A. is expressly
prohibited.
Printed in U.S.A.
P/N LIT-11616-12-62
EAS00003
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 manu-
al. 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 ve-
hicle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools in necessary to ensure that the ve-
hicle will operate as designed. If there is any question about a service procedure, it is imperative that
you contact a Yamaha dealer for any service information changes that apply to this model. This policy
is intended to provide the customer with the most satisfaction from his vehicle and to conform with fed-
eral environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and signifi-
cant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where paalicable.
NOTE:
This Service Manual contains information regarding periodic maintenance to the emission control
system. Please read this material carefully.
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 mo-
torcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

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) ap-
pears.
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 sequen-
tially.
6 2 1
3
4
7
EB004000
1 2 SYMBOLS
GEN The following symbols are not relevant to every
SPEC vehicle.
INFO Symbols 1 to 9 indicate the subject of each
3 4 chapter.
1 General information
CHK 2 Specifications
ADJ ENG Periodic checks and adjustments
3
4 Engine
5 6 5 Cooling system
6 Carburetor(-s)
COOL CARB 7 Chassis
8 Electrical system
9 Troubleshooting
7 8
CHAS ELEC
Symbols 10 to 17 indicate the following.
9 10
10 Serviceable with engine mounted
TRBL 11 Filling fluid
SHTG 12 Lubricant
13 Special tool
11 12 14 Tightening torque
15 Wear limit, clearance
16 Engine speed
17 Electrical data
13 14
15 16 17
18 19 20
Symbols 18 to 23 in the exploded diagrams indi-
cate the types of lubricants and lubrication
points.
18 Engine oil
19 Gear oil
21 22 23 20 Molybdenum disulfide oil
21 Wheel bearing grease
22 Lithium soap base grease
23 Molybdenum disulfide grease
24 25 Symbols 24 to 25 in the exploded diagrams indi-
cate the following.
24 Apply locking agent (LOCTITE)
25 Replace the part
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE OVERHAUL ENG
4
COOLING SYSTEM COOL
5
CARBURETORS CARB
6
CHASSIS CHAS
7
ELECTRICAL ELEC
8
TROUBLESHOOTING TRBL
SHTG 9
GEN
INFO
CHAPTER 1.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . 1-2
USING A DYNAMOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . . 1-3
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

GEN
INFO
GEN
MOTORCYCLE IDENTIFICATION INFO
EB100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
EB100010
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped
into the right side of the steering head 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
GEN
IMPORTANT INFORMATION INFO
EB102000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DIS-
ASSEMBLY
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, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an as-
sembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disas-
sembly. This will speed up assembly and al-
low 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 replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs.
Other brands may be similar in function and ap-
pearance, 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 sur-
faces, 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
GEN
IMPORTANT INFORMATION INFO
USING A DYNAMOMETER
The YZF-R6L/YZF-R6CL has a carbon muffler
that may change color when exposed to high
temperatures. Therefore, when using a dy-
namometer 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
manufacturer’s marks or numbers are vis-
ible. 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 sur-
faces.
1 Bearing
EB102050
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways 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
GEN
CHECKING THE CONNECTIONS INFO
EB103000
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
lead
coupler
connector
2. Check:
lead
coupler
connector
Moisture Dry with an air blower.
Rust/stains Connect and disconnect sev-
eral times.
3. Check:
all connections
Loose connection Connect properly.
NOTE:
If the pin 1 on the terminal is flattened, bend it
up.
4. Connect:
lead
coupler
connector
NOTE:
Make sure that all connections are tight.
5. Check:
continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
If there is no continuity, clean the terminals.
When checking the wire harness, perform
steps (1) to (3).
As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
GEN
FEATURES 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 Time
1-5
GEN
FEATURES INFO
Flow control operation 1) 2)
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 4)
3)
The 3rd lip 3 seals the coolant.
The coolant flows through the notch depend-
ing 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.
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 CDI unit 5 Spark plug 9 Speed sensor 13 Stator coil

2 Voltage converter 6 Ignition timing controller 10 Battery
3 Condenser 7 Pickup coil 11 Rectifier/ regulator
4 Ignition coil 8 T. P. S. 12 AC magneto
1-6
GEN
FEATURES INFO
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 inte-
grated.
High tension cord was cut an end to use and
ignition energy loss has become lower.
3. Spark plug
The 2-pole spark plug is applied to improve
the ignition quality and combustion efficien-
cy.
1-7
GEN
SPECIAL TOOLS INFO
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration
Flywheel puller
Flywheel puller
YU-33270
Adapter
90890-01362
Adapter
This tool is used to remove the generator ro-
YM-33282
tor.
90890-04089
Sheave holder
YS-01880
This tool is used to hold the generator rotor
90890-01701
when removing or installing the generator ro-
tor bolt or pickup coil rotor bolt.
Piston pin puller
YU-01304
90890-01304
This tool is used to remove the piston pins.
Fuel level gauge
YM-01312-A
90890-01312
This tool is used to measure the fuel level in
the float chamber.
Radiator cap
tester Radiator cap tester
YU-24460-01 Adapter
90890-01325
Adapter These tools are used to check the cooling
YU-33984 system.
90890-01352
Steering nut wrench
YU-33975
90890-01403
This tool is used to loosen or tighten the steer-
ing stem ring nuts.
Damper rod holder
YM-01425
This tool is used to hold the damper rod as-
90890-01425
sembly when loosening or tightening the
damper rod assembly bolt.
Pivot shaft wrench
YM-01471
90890-01471
This tool is used to loosen or tighten the pivot
adjust bolt and engine mount adjust bolt.
1-8
GEN
SPECIAL TOOLS INFO
Oil filter wrench
YU-38411
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 ad-
justing rod.
Rod puller
YM-01437 Rod puller
90890-01437 Rod puller attachment
Rod puller
attachment These tools are used to pull up the front fork
90890-01436 damper rod.
Fork spring compressor
90890-01441
This tool is used to disassemble or assemble
the front fork legs.
Fork seal driver
YM-33963 Fork seal driver weight
90890-01367 Fork seal driver attachment
Fork seal driver
attachment This tool is used to install the front fork’s oil
YM-8020 seal and dust seal.
90890-01374
Micrometer
YU-03008
90890-03008
This tool is used to measure the piston skirt
diameter.
Cylinder bore gauge (50~100mm)
YU-03017
90890-03017
This gauge is used to measure cylinder bore.
Vacuum gauge Vacuum gauge
YU-08030-A Vacuum gauge attachment
90890-03094
Valve gauge
attachment This gauge is used to synchronize the carbu-
90890-03060 retors.
Compression
gauge Compression gauge
YU-33223 Adapter
90890-03081
Adapter These tools are used to measure engine
90890-04136 compression.
Pocket tester
YU-03112
90890-03112
This tool is used to check the electrical sys-
tem.
1-9
GEN
SPECIAL TOOLS INFO
Engine tachometer
90793-80009
This tool is used to check engine speed.

Timing light
YU-33277-A
90890-03141
This tool is used to check the ignition timing.
Oil pressure Oil pressure gauge
gauge Adapter
90890-03153
Adapter These tools are used to measure engine oil
90890-03139 pressure.
Piston ring compressor
YM-04044
90890-04044
This tool is used to compress piston rings
when installing the cylinder.
Valve spring
compressor Valve spring compressor
YM-04019 Attachment
90890-04019
Attachment These tools are used to remove or install the
YM-01253-1 valve assemblies.
90890-04108
Middle driven shaft
bearing driver Middle driven shaft bearing driver
YM-04058-1 Mechanical seal installer
90890-04058
Mechanical seal in-
staller These tools are used to install the water pump
YM-33221 seal.
90890-04078
Clutch holding tool
YM-91042
This tool is used to hold the clutch boss
90890-04086
when removing or installing the clutch boss
nut.
Valve guide remover
YM-4111
90890-04111
This tool is used to remove or install the valve
guides.
1-10
GEN
SPECIAL TOOLS INFO
Ignition checker
YM-34487
90890-06754
This tool is used to check the ignition system
components.
Yamaha bond No. 1215
ACC-1100-15-01
90890-85505
This bond is used to seal two mating surfaces
(e.g., crankcase mating surfaces).
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

GENERAL TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Standard Limit
Model code YZF-R6L: 5GV1 (U.S.A.)
YZF-R6CL: 5GV2 (California)
YZF-R6L: 5GV3 (Canada)
Dimensions
Overall length 2025 mm (79.7 in)
Overall width 690 mm (27.2 in)
Overall height 1105 mm (43.5 in)
Seat height 820 mm (32.3 in)
Wheelbase 1380 mm (54.3 in)
1385 mm (54.5 in) (California)
Minimum ground clearance 135 mm (5.3 in)
Minimum turning radius 3400 mm (133.9 in)
Weight
Wet (with oil and a full fuel tank) 188 kg (415 lb)
189 kg (417 lb) (California)
Dry (without oil and fuel) 169 kg (373 lb)
170 kg (375 lb) (California)
Maximum load (total of cargo, rider, 375 kg (827 lb)
passenger, and accessories)
2-1
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine tipe Liquid-cooled, 4-stroke, DOHC SSS
Displacement 600 cm3 (36.61 cu.in) SSS
Cylinder arrangement Forward-inclined parallel 4-cylinder SSS
Bore stroke 65.5 44.5 mm (2.58 1.75 in) SSS
Compression ratio 12.4 : 1 SSS
Engine idling speed 1,250 1,350 r/min SSS
Vacuum pressure at engine idling 24.0 kPa (180 mmHg, 7.0866 in Hg) SSS
speed
Standard compression pressure 1550 kPa (15.5 kg/cm2, 224.75 psi) at SSS
(at sea level) 400 r/min
Fuel
Recommended fuel Regular gasoline SSS
Fuel tank capacity
Total (including reserve) 17 L (3.74 Imp gal, 4.49 US gal) SSS
Reserve only 3.5 L (0.77 Imp gal, 0.93 US gal) SSS
Engine oil
Lubrication system Wet sump SSS
Recommended oil SSS
A : Yamalube 4 (10 W 30) or SAE 10 W

30 type SE motor oil (–10_C (10_F)
or higher)
B Yamalube 4 (20 W 40) or SAE 20 W
:
40 type SE motor oil (5_C (40_F) or
higher)
Quantity
Total amount 3.5 L (3.08 Imp qt, 3.70 US qt) SSS
Without oil filter cartridge 2.5 L (2.20 Imp qt, 2.64 US qt) SSS
replacement
With oil filter cartridge replacement 2.7 L (2.38 Imp qt, 2.85 US qt) SSS
Oil pressure (hot) 80 kPa (0.8 kg/cm2, 11.6 psi) at 1300 SSS
r/min
Relief valve opening pressure 450 550 kPa (4.5 5.5 kg/cm2, 65.3 SSS
79.8 psi)
2-2
Item Standard Limit

Oil filter
Oil filter type Cartridge (paper)
Bypass valve opening pressure 80 120 kPa (0.8 1.2 kg/cm2, 11.6
17.4 psi)
Oil pump
Oil pump type Trochoidal
Inner-rotor-to-outer-rotor-tip 0.03 0.09 mm (0.0012 0.0035 in) 0.15 mm
clearance (0.0059 in)
Outer-rotor-to-oil-pump-housing 0.03 0.08 mm (0.0012 0.0031 in) 0.15 mm
Cooling system
Radiator capacity 2.15 L (2.27 US qt)
Radiator cap opening pressure 110 140 kPa (1.10 1.40 kg/cm2,
16.0 20.3 psi)
Radiator core
Width 320 mm (12.6 in)
Height 258 mm (10.2 in)
Depth 24 mm (0.94 in)
Coolant reservoir
Capacity 0.44 L (0.47 US qt)
Water pump
Water pump type Single-suction centrifugal pump
Reduction ratio 86/44 31/31 (1.955)
Starting system type Electric starter
Spark plugs
Model (manufacturer) quantity CR10EK/NGK 4
CR9EK/NGK 4 (California)
Spark plug gap 0.6 0.7 mm (0.02 0.03 in)
Cylinder head
Max. warpage 0.05 mm
(0.002 in)
2-3
Item Standard Limit

Camshafts
Drive system Chain drive (right)
Camshaft cap inside diameter 23.000 23.021 mm (0.9055 0.9063 in)
Camshaft journal diameter 22.967 22.980 mm (0.9042 0.9047 in)
Camshaft-journal-to-camshaftcap 0.020 0.054 mm (0.0008 0.0021 in) 0.08 mm
Intake camshaft lobe dimensions
Measurement A 33.05 33.15 mm (1.3012 1.3051 in) 33.0 mm

(1.3 in)
Measurement B 25.14 25.24 mm (0.9898 0.9937 in) 25.09 mm
(0.99 in)
Measurement C 7.81 8.01 mm (0.3075 0.3154 in)
Exhaust camshaft lobe dimensions
Measurement A 32.55 32.65 mm (1.2815 1.2854 in) 32.50 mm

(1.28 in)
Measurement B 25.07 25.17 mm (0.9870 0.9909 in) 25.02 mm
(0.99 in)
Measurement C 7.38 7.58 mm (0.2906 0.2984 in)
Max. camshaft runout 0.06 mm
(0.0024 in)
2-4
Item Standard Limit

Timing chain
Model/number of links RH2015/120
Tensioning system Automatic
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.11 0.20 mm (0.0043 0.0079 in)
Exhaust 0.21 0.30 mm (0.0083 0.0118 in)
Valve dimensions
Head Diameter Face Width Seat Width Margin Thickness

Valve head diameter A
Intake 24.9 25.1 mm (0.9803 0.9882 in)
Exhaust 21.9 22.1 mm (0.8622 0.8701 in)
Valve face width B
Intake 1.14 1.98 mm (0.0449 0.0780 in)
Exhaust 1.14 1.98 mm (0.0449 0.0780 in)
Valve seat width C
Intake 0.9 1.1 mm (0.0354 0.0433 in) 1.6 mm
(0.06 in)
Exhaust 0.9 1.1 mm (0.0354 0.0433 in) 1.6 mm
(0.06 in)
Valve margin thickness D
Intake 0.6 0.8 mm (0.0236 0.0315 in) 0.5 mm
(0.02 in)
Exhaust 0.6 0.8 mm (0.0236 0.0315 in) 0.5 mm
(0.02 in)
Valve stem diameter
Intake 3.975 3.990 mm (0.1565 0.1571 in) 3.950 mm
(0.1555 in)
Exhaust 3.960 3.975 mm (0.1559 0.1565 in) 3.935 mm
(0.1549 in)
Valve guide inside diameter
Intake 4.000 4.012 mm (0.1575 0.1580 in) 4.042 mm
(0.1591 in)
Exhaust 4.000 4.012 mm (0.1575 0.1580 in) 4.042 mm
(0.1591 in)
Valve-stem-to-valve-guide clearance
Intake 0.010 0.037 mm (0.0004 0.0015 in) 0.08 mm
(0.0031 in)
Exhaust 0.025 0.052 mm (0.001 0.002 in) 0.1 mm
(0.0039 in)
Valve stem runout 0.04 mm
(0.0016 in)
Valve seat width

Intake 0.9 1.1 mm (0.0354 0.0433 in) 1.6 mm
(0.06 in)
Exhaust 0.9 1.1 mm (0.0354 0.0433 in) 1.6 mm
(0.06 in)
2-5
Item Standard Limit

Valve springs
Free length
Intake (inner) 37.0 mm (1.46 in) 35 mm
(1.38 in)
(outer) 38.4 mm (1.51 in) 36.5 mm
(1.44 in)
Exhaust 41.7 mm (1.64 in) 39.5 mm
(1.56 in)
Installed length (valve closed)
Intake (inner) 30.0 mm (1.18 in) SSS
(outer) 32.5 mm (1.28 in) SSS
Exhaust 36.1 mm (1.42 in) SSS
Compressed spring force
(installed)
Intake (inner) 69 79 N (15.51 17.76 lb, SSS
7.04 8.06 kg)
(outer) 114 132 N (25.63 29.67 lb,
11.62 13.46 kg)
Exhaust 160 184 N (35.97 41.36 lb, SSS
16.32 18.76 kg)
Spring tilt
Intake (inner) SSS 2.5_/1.6 mm

(0.06 in)
(outer) 2.5_/1.7 mm
(0.07 in)
Exhaust SSS 2.5_/1.8 mm
(0.07 in)
Winding direction (top view)

Intake (inner) Counter clockwise SSS
(outer) Clockwise SSS
Exhaust Clockwise SSS
Cylinders
Cylinder arrangement Forward-inclined, parallel 4-cylinder SSS
Bore stroke 65.5 45.5 mm (2.58 1.75 in) SSS
Compression ratio 12.4 : 1 SSS
Bore 65.50 65.51 mm (2.5787 2.5791 in) SSS
Max. taper SSS 0.05 mm
(0.002 in)
Max. out-of-round SSS 0.05 mm
(0.002 in)
2-6
Item Standard Limit

Pistons
Piston-to-cylinder clearance 0.025 0.050 mm (0.001 0.002 in) 0.07 mm
(0.0028 in)
Diameter D 65.460 65.475 mm (2.5772 2.5778 in)
Height H 4 mm (0.16 in)

Piston pin bore (in the piston)
Diameter 16.002 16.013 mm (0.6300 0.6304 in)
Offset 0.5 mm (0.0197 in)
Offset direction Intake side
Piston pins
Outside diameter 15.991 16.000 mm (0.6296 0.6299 in)
Piston-pin-to-piston-pin-bore 0.002 0.022 mm (0.00008 0.0009 0.072 mm
clearance in) (0.0028 in)
Piston rings
Top ring
Ring type

Dimensions (B T) Barrel
End gap (installed) 0.80 2.45 mm (0.03 0.10 in) 0.50 mm
0.15 0.25 mm (0.006 0.009 in) (0.02 in)
Ring side clearance 0.115 mm
2nd ring 0.030 0.065 mm (0.0012 0.0026 in) (0.05 in)
Ring type

Dimensions (B T) Taper
End gap (installed) 0.8 2.5 mm (0.03 0.10 in) 0.85 mm
0.40 0.50 mm (0.016 0.020 in) (0.033 in)
Ring side clearance 0.115 mm
Oil ring 0.020 0.055 mm (0.0008 0.0022 in) (0.05 in)
Dimensions (B T)
End gap (installed) 1.5 2.3 mm (0.06 0.09 in)
0.10 0.35 mm (0.004 0.014 in)
2-7
Item Standard Limit

Connecting rods
Crankshaft-pin-to-big-end-bearing 0.028 0.052 mm (0.0011 0.0020 in)
clearance
Bearing color code 1 = Blue 2 = Black 3 = Brown 4 = Green
Crankshaft

Width B 268.8 270.0 mm (10.58 10.63 in)
Max. runout C 0.03 mm
(0.0012 in)
Big end side clearance D 0.160 0.262 mm (0.0063 0.0103 in)
Crankshaft-journal-to-crankshaft- 0.034 0.058 mm (0.0013 0.0023 in)
journal-bearing clearance
Bearing color code 0 = White 1 = Blue
2 = Black 3 = Brown
4 = Green
Clutch
Clutch type Wet, multiple disc
Clutch release method Rack and pinion (pull rod type)
Clutch release method operation Cable operation
Operation Left hand operation
Clutch cable free play (at the end 10 15 mm (0.39 0.59 in)
of the clutch lever)
Friction plates
Thickness 2.9 3.1 mm (0.11 0.12 in) 2.8 mm
(0.1102 in)
Plate quantity 8
Clutch plates
Thickness 1.9 2.1 mm (0.07 0.08 in)
Plate quantity 7
Max. warpage 0.1 mm
(0.0039 in)
Clutch plate
Thickness 2.2 2.4 mm (0.087 0.094 in)
Plate quantity 1
Max. warpage 0.1 mm
(0.0039 in)
Clutch springs
Free length 55 mm (2.17 in) 54 mm
(2.13 in)
Spring quantity 6
2-8
Item Standard Limit

Transmission
Transmission type Constant mesh, 6-speed
Primary reduction system Spur gear
Primary reduction ratio 86/44 (1.9545)
Secondary reduction system Chain drive
Secondary reduction ratio 48/16 (3.000)
Operation Left-foot operation
Gear ratios
1st gear 37/13 (2.846)
2nd gear 37/19 (1.947)
3rd gear 28/18 (1.555)
4th gear 32/24 (1.333)
5th gear 25/21 (1.190)
6th gear 26/24 (1.083)
Max. main axle runout 0.02 mm
(0.0008 in)
Max. drive axle runout 0.02 mm
(0.0008 in)
Shifting mechanism
Shift mechanism type Cam drum
Max. shift fork guide bar bending 0.05 mm
(0.002 in)
installed shift rod length 242 mm (9.52 in)
Air filter type Wet element
Fuel pump
Pump type Electrical
Model (manufacturer) 5EB (MITSUBISHI)
Output pressure 15 20 kPa (0.15 0.2 kg/cm2,
2.2 2.9 psi)
Carburetors
Model (manufacturer) quantity CVRD37 (KEIHIN) 4
Throttle cable free play (at the 6 8 mm (0.24 0.31 in)
flange of the throttle grip)
ID mark 5GV101, 5GV210 (California)
Main jet Carburetors 1 and 4: #152, #148 (California)
Carburetors 2 and 3: #148
Main air jet #110
Jet needle Carburetors 1 and 4: N7SB
Carburetors 2 and 3: N7SA
Needle jet 2.6
Pilot air jet Carburetors 1 and 4: #105
Carburetors 2 and 3: #110
Pilot outlet 0.9
Pilot jet #38, #35 (California)
Bypass 1 0.8
Bypass 2 0.8
Bypass 3 0.8
Valve seat size 1.2
2-9
Item Standard Limit

Starter jet 1 #50
Starter jet 2 0.6
Butterfly valve size #110
Fuel level (below the line on the 17.5 18.5 mm (0.69 0.73 in)
float chamber)
2-10
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond SSS
Caster angle 24_ SSS
Trail 81 mm (3.19 in) SSS
Front wheel
Wheel type Cast wheel SSS
Rim
Size 17 MT3.50 SSS
Material Aluminum SSS
Wheel travel 130 mm (5.12 in) SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
(0.04 in)
Max. lateral wheel runout SSS 0.5 mm
(0.02 in)
Rear wheel
Wheel type Cast wheel SSS
Rim
Size 17 MT5.50 SSS
Material Aluminum SSS
Wheel travel 120 mm (4.72 in) SSS
Wheel runout
Max. radial wheel runout SSS 1 mm
(0.04 in)
Max. lateral wheel runout SSS 0.5 mm
(0.02 in)
Front tire
Tire type Tubeless SSS
Size 120/60ZR17 (55W) SSS
Model (manufacturer) BRIDGESTON BT56F.E SSS
DUNLOP D207F.J
Tire pressure (cold)

0 90 kg (0 198 lb) 250 kPa (2.5 kg/cm2, 36.3 psi) SSS
90 187 kg (198 412 lb) 250 kPa (2.5 kg/cm2, 36.3 psi) SSS
High-speed riding 250 kPa (2.5 kg/cm2, 36.3 psi) SSS
Min. tire tread depth SSS 1.6 mm
(0.06 in)
2-11
Item Standard Limit

Rear tire
Tire type Tubeless
Size 180/55 ZR17 (73 W)
Model (manufacturer) BRIDGESTON BT56R.E
DUNLOP D207.N
Tire pressure (cold)
0 90 kg (0 198 lb) 250 kPa (2.5 kg/cm2, 36.3 psi)
90 187 kg (198 412 lb) 290 kPa (2.9 kg/cm2, 42.1 psi)
High-speed riding 250 kPa (2.5 kg/cm2, 36.3 psi)
Min. tire tread depth 1.6 mm
(0.06 in)
Front brakes
Brake type Dual-disc brake
Operation Right-hand operation
Recommended fluid DOT 4
Brake discs
Diameter thickness 298 5 mm (11.73 0.20 in)
Min. thickness 4.5 mm
(0.18 in)
Max. deflection 0.1 mm
(0.0039 in)
Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 14 mm (0.55 in)

Caliper cylinder inside diameter 30.2 mm (1.19 in) and 27 mm (1.06 in)
Rear brake
Brake type Single-disc brake
Operation Right-foot operation
Brake pedal position (from the top 4.3 9.3 mm (0.17 0.37 in)
of the brake pedal to the bottom of
the rider footrest bracket bolt center.)
Recommended fluid DOT 4
Brake discs
Diameter thickness 220 5 mm (8.66 0.20 in)
Min. thickness 4.5 mm
(0.18 in)
Max. deflection 0.1 mm
(0.0039 in)
Brake pad lining thickness 5 mm (0.2 in) 0.8 mm
(0.03 in)
Master cylinder inside diameter 12.7 mm (0.5 in)

Caliper cylinder inside diameter 27.0 mm (1.06 in) and 22.2 mm (0.87 in)
2-12
CHASSIS SPECIFICATION SPEC
Item Standard Limit

Front suspension
Suspension type Telescopic fork
Front fork type Coil spring/oil damper
Front fork travel 130 mm (5.12 in)
Spring
Free length 251.8 mm (9.91 in) 246 mm
(9.69 in)
Spacer length 125 mm (4.92 in)
Installed length 247.8 mm (9.76 in)
Spring rate (K1) 7.5 N/mm (0.75 kg/mm, 42.83 lb/in)
Spring stroke (K1) 0 130 mm (0.00 5.12 in)
Optional spring available No
Fork oil
Recommended oil Suspension oil “01” or equivalent
Quantity (each front fork leg) 476 cm3 (16.09356 US oz)
Level (from the top of the innertube, 107 mm (4.21 in)
with the inner tube fullycompressed,
and without thefork spring)
Damper adjusting rod locknut distance 25 mm (0.98 in)
Spring preload adjusting positions
Minimum 8
Standard 7.5
Maximum 1
Rebound damping adjusting positions
Minimum* 9
Standard* 6
Maximum* 1
Compression damping adjusting
positions
Minimum* 10
Standard* 6
Maximum* 1
*from the fully turned-in position
2-13
Item Standard Limit

Steering
Steering bearing type Angular ball bearings
Rear suspension
Suspension type Swingarm (link suspension)
Rear shock absorber assemblytype Coil spring/gas-oil damper
Rear shock absorber assemblytravel 60 mm (2.36 in)
Spring
Free length
Installed length 169.5 mm (6.67 in)
Spring rate (K1) 159 mm (6.26 in)
Spring stroke (K1) 95.1 N/mm (9.51 kg/mm, 543.02 lb/in)
Optional spring available 0 60 mm (0.00 2.36 in)
Standard spring preload gas/air No
pressure 1,200 kPa (12 kg/cm2, 174 psi)
Spring preload adjusting positions
Minimum 1
Standard 4
Maximum 9
Rebound damping adjusting positions
Minimum* 25
Standard* 9
Maximum* 1
Compression damping adjusting
positions
Minimum* 13
Standard* 7
Maximum* 1
*from the fully turned-in position
Swingarm
Free play (at the end of the swingarm)
Radial 1 mm
(0.04 in)
Axial 1 mm
(0.04 in)
Drive chain
Model (manufacturer) 532ZLV KAI (DID)
Link quantity 116
Drive chain slack 40 50 mm (1.57 1.97 in)
Maximum ten-link section 149 mm (5.87 in)
2-14
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V SSS
Ignition system
Ignition system type C.D.I. SSS
Ignition timing 10_ BTDC at 1300 r/min SSS
5_ BTDC at 1300 r/min (California) SSS
Advanced timing 55_ BTDC at 5250 r/min SSS
Advancer type Throttle position sensor and electrical SSS
Pickup coil resistance/color 248 372 Ω/Gy-B SSS
Transistorized coil ignition unit model F8T362 (MITSUBISHI) SSS
(manufacturer)
Ignition coils
Model (manufacturer) F6T549 (MITSUBISHI) SSS
Minimum ignition spark gap 6 mm (0.24 in) SSS
Primary coil resistance 0.204 0.276 Ω SSS
Secondary coil resistance 8.5 11.5 kΩ SSS
Throttle position sensor standard 4 6 kΩ SSS
resistance
Charging system
System type AC magneto SSS
Model (manufacturer) F4T366 (MITSUBISHI) SSS
Nominal output 14 V/320W at 5,000 r/min SSS
Stator coil resistance 0.27 0.33 Ω at 20_C (68_F) SSS
Voltage regulator
Regulator type Semiconductor, short circuit type SSS
Model (manufacturer) SH650A-12 (SHINDENGEN) SSS
No-load regulated voltage 14.1 14.9 V SSS
Rectifier
Model SH650A-12 SSS
Rectifier capacity 18 A SSS
Withstand voltage 200 V SSS
Battery
Battery type GT12B-4 SSS
Battery voltage/capacity 12 V/10 AH SSS
Headlight type Halogen bulb
Indicator light type quantity LED 6
Bulbs (voltage/wattage quantity)
Headlight 12 V 60 W/55 W 2 SSS
Tail/brake light 12 V 21 W/5 W 2 SSS
Turn signal/position light 12 V 27 W/8 W 2 (front) SSS
12 V 27 W 2 (rear) SSS
2-15
Item Standard Limit

Meter light 12 V 1.4 W 2
Electric starting system
System type Constant mesh
Starter motor
Model (manufacturer) SM-14 (MITSUBA)
Power output 0.6 kW
Brushes
Overall length 10 mm (0.39 in) 3.5 mm
(0.14 in)
Spring force 7.16 9.52 N (730 970 g,
25.77 34.27 oz)
Commutator resistance 0.012 0.022 Ω
Commutator diameter 28 mm (1.1 in) 27 mm
(1.06 in)
Mica undercut 0.7 mm (0.03 in)
Starter relay
Model (manufacturer) MS5F-631 (JIDECO)
Amperage 180 A
Coil resistance 4.18 4.62 Ω
Horn
Horn type Plain
Model (manufacturer) quantity YF-12 (NIKKO) 1
Max. amperage 3A
Flasher relay
Relay type Full-transistor
Model (manufacturer) FE246BH (DENSO)
Self-cancelling device built-in No
Turn signal blinking frequency 75 95 cycles/min.
Wattage 27 W 2 + 3.4 W
Oil level switch model (manufacturer) 5EB (DENSO)
Fuel sender
Model (manufacturer) 1UF (NIPPON SEIKI)
Resistance 0.7 1.1 kΩ GW-B
Sidestand relay
Model G8R-30Y-K
Coil resistance 162 198 Ω
Fuel pump maximum amperage 1A
Fuel pump relay model (manufacturer) G8R-30Y-K (OMRON)
Resistance 162 198 Ω
Radiator fan model (manufacturer) 4XV (TOYO RADIATOR)
Thermo switch model (manufacturer) 5EB (NIPPON THERMOSTAT)
Headlight relay (manufacturer) ACA12115 (MATSUSHITA)
Resistance 72 88 Ω
2-16
Item Standard Limit

Temperature sender
Model (manufacturer) 11H (NIPPON SEIKI) SSS
Resistance 50.6 64.2 Ω at 80_C (176_F) SSS
16.1 17.3 Ω at 120_C (248_F)
Fuses (amperage quantity)
Main fuse 30 A 1 SSS
Headlight fuse 20 A 1 SSS
Signaling system fuse 20 A 1 SSS
Ignition fuse 15 A 1 SSS
Radiator fan fuse 7.5 A 1 SSS
Backup fuse (odometer) 7.5 A 1 SSS
2-17
CONVERSION TABLE/TIGHTENING TORQUES SPEC
EB201000 EB202001
CONVERSION TABLE TIGHTENING TORQUES

All specification data in this manual are GENERAL TIGHTENING TORQUES
listed in SI and METRIC UNITS. This chart specifies tightening torques for standard
Use this table to convert METRIC unit data fasteners with a standard ISO thread pitch. Tighten-
to IMPERIAL unit data. ing torque specifications for special components or
Ex. assemblies are provided for each chapter of this
manual. To avoid warpage, tighten multi-fastener
METRIC MULTIPLIER IMPERIAL assemblies in a crisscross pattern and progressive
**mm 0.03937 = **in stages until the specified tightening torque is
reached. Unless otherwise specified, tightening
2 mm 0.03937 = 0.08 in torque specifications require clean, dry threads.
CONVERSION TABLE Components should be at room temperature.
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
mSkg 7.233 ftSlb
Tighten-
mSkg 86.794 inSlb
ing
cmSkg 0.0723 ftSlb
torque
cmSkg 0.8679 inSlb
kg 2.205 lb
Weight
g 0.03527 oz
Speed km / hr 0.6214 mph
km 0.6214 mi
m 3.281 ft A: Width across flats
Distance m 1.094 yd B: Thread diameter
cm 0.3937 in
mm 0.03937 in
General tightening
cc (cm3) 0.03527 oz (IMP liq.) A B torques
Volume / ( 3)
cc (cm 0.06102 cuSin (nut) (bolt)
Capacity lt (liter) 0.8799 qt (IMP liq.) Nm mSkg ftSlb
lt (liter) 0.2199 gal (IMP liq.)
10 mm 6 mm 6 0.6 4.3
kg / mm lb / in
55.997 12 mm 8 mm 15 1.5 11
kg / cm2 psi (lb / in2)
Misc. 14.2234
Centigrade Fahrenheit 14 mm 10 mm 30 3.0 22
9 / 5 + 32
(_C) (_F)
18 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-18
TIGHTENING TORQUES SPEC
ENGINE TIGHTENING TORQUES
Tightening
Thread torque
Item Fastener Q’ty
y Remarks
size
Nm mSkg ftSlb
Spark plugs – M10 4 13 1.3 9.4
Cylinder head Bolt M10 10 51 5.1 37
Cylinder head Bolt M6 2 10 1.0 7.2
Camshaft caps Bolt M6 20 10 1.0 7.2
Cylinder head cover Bolt M6 6 10 1.0 7.2
Oil passage check bolt Bolt M8 1 20 2.0 14
Cylinder head (exhaust pipe) Stud bolt M8 8 15 1.5 11
Connecting rod caps Nut M7 See NOTE
Generator rotor Bolt M12 1 65 6.5 47
Pickup rotor Bolt M8 1 35 3.5 25
Cap bolt (timing chain tensioner) Bolt M6 1 10 1.0 7.2
Timing chain tensioner bolt Bolt M6 2 12 1.2 8.7
Camshaft sprocket Bolt M7 4 24 2.4 17
Oil pump Bolt M6 3 12 1.2 8.7
Oil cooler Bolt M20 1 63 6.3 46
Engine oil drain bolt – M14 1 43 4.3 31
Oil pump assembly driven sprocket Bolt M6 2 10 1.0 7.2
cover
Oil pipe Bolt M6 2 15 1.5 11
Oil filter bolt Bolt M20 1 80 8.0 58
Oil filter cartridge – M20 1 17 1.7 12
Exhaust pipes Nut M8 8 20 2.0 14
Muffler clamp Bolt M8 1 20 2.0 14
Exhaust pipe emission check bolts Bolt M6 4 10 1.0 7.2
Exhaust pipe bracket Bolt M8 1 20 2.0 14
Crankcase Bolt M6 2 14 1.4 10
Crankcase Bolt M6 12 12 1.2 8.7
Crankcase Bolt M8 12 24 2.4 17
Generator rotor cover Bolt M6 9 12 1.2 8.7
Drive sprocket cover Bolt M6 5 10 1.0 7.2
NOTE:
After tightening to 15 Nm (1.5 mSkg, 11 ftSlb), tighten another 90_
2-19
Tightening
Thread torque
Item Fastener Q’ty
y Remarks
size
Nm mkg ftlb
Clutch cover Bolt M6 10 12 1.2 8.7
Pickup coil rotor cover Bolt M6 5 12 1.2 8.7
Shift shaft cover Bolt M6 6 12 1.2 8.7
Breather plate 2 – M6 3 12 1.2 8.7
Starter clutch Bolt M8 3 32 3.2 23
Clutch boss Nut M20 1 70 7.0 51 Use a lock
washer.
Clutch springs Bolt M6 6 8 0.8 5.8
Drive sprocket Nut M18 1 70 7.0 51 Use a lock
washer.
Main axle bearing housing Screw M6 3 12 1.2 8.7
Shift bar stopper Bolt M6 2 10 1.0 7.2
Shift shaft spring stopper Bolt M8 1 22 2.2 16
Shift rod locknut Nut M6 1 7 0.7 5.1
M8 1 10 1.0 7.2
Oil level switch Bolt M6 2 10 1.0 7.2
Shift arm Bolt M6 1 10 1.0 7.2
Stator coil Bolt M6 3 10 1.0 7.2
Ignitor unit Bolt M6 1 10 1.0 7.2
Neutral switch Screw M6 2 4.0 0.4 2.9
Pickup coil Bolt M5 2 10 1.0 7.2
Thermo unit – PT1/8 1 15 1.5 11
Thermo switch – M18 1.5 1 28 2.8 20
2-20
Crankcase tightening sequence:
2-21
CHASSIS TIGHTENING TORQUES
Tightening
Item Thread size torque Remarks
Nm mkg ftlb
Upper bracket pinch bolts M8 26 2.6 19
Steering stem nut M28 115 11.5 83
Handlebar pinch bolts M8 33 3.3 24
Lower ring nut M30 9 0.9 6.5 See NOTE.
Lower bracket pinch bolts M8 23 2.3 17
Brake fluid reservoir cap stopper M4 12 1.2 8.7
Front brake hose union bolts M10 30 3.0 22
Front brake master cylinder M6 13 1.3 9.4
Engine mounting
Front mounting bolts M12 55 5.5 40
M12 55 5.5 40
Rear mounting bolts M10 45 4.5 33
Pinch bolts M8 24 2.4 17
M6 13 1.3 9.4
Button head bolt M10 39 3.9 28
Exhaust pipe bracket M8 20 2.0 14
Pivot shaft nut M18 95 9.5 69
Connecting arms M10 40 4.0 29
Relay arm and connecting arms M10 40 4.0 29
Relay arm M10 40 4.0 29
Rear shock absorber and relay arm M10 55 5.5 40
Fuel cock M6 7 0.7 5.1
Fuel sender and fuel tank M6 7 0.7 5.1
Coolant reservoir and radiator M6 5 0.5 3.6
Rider footrest bracket M8 28 2.8 20
Passenger footrest bracket M8 28 2.8 20
Rear master cylinder M8 23 2.3 17
Rear brake hose union bolts M10 30 3.0 22
Sidestand M10 60 6.0 43
Front wheel axle M18 72 7.2 52
Rear wheel axle nut M24 150 15.0 108
Front brake caliper and front fork M10 40 4.0 29
Rear brake caliper and bracket M10 27 2.7 20
Brake disc and wheel M6 18 1.8 13
Rear wheel sprocket and rear wheel drive hub M10 69 6.9 50
Brake caliper and bleed screw M8 6 0.6 4.3
Pinch bolt (front wheel axle) M8 23 2.3 17
NOTE:
1. First, tighten the ring nut to approximately 17 Nm (1.7 mkg, 12 ftlb) with a torque wrench, then
loosen the ring nut completely.
2. Retighten the ring nut to specification.
2-22
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB202000
LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant

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)
Yamaha bond
Cylinder head cover mating surface
No.1215
Yamaha bond
Crankcase mating surface
No.1215
Yamaha bond
Clutch cover (crankcase mating surface)
No.1215
Yamaha bond
Generator rotor cover (crankcase mating surface)
No.1215
Yamaha bond
Cylinder head cover
No.1215
2-23
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB202010
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication Lubricant
Steering bearings and bearing races (upper and lower)
Front wheel oil seal (right and left)
Rear wheel oil seal
Rear wheel drive hub oil seal
Rear wheel drive hub mating surface
Rear brake pedal
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)
2-24
OIL FLOW DIAGRAMS SPEC
OIL FLOW DIAGRAMS

1 Intake camshaft
2 Exhaust camshaft
3 Crankshaft
4 Oil pipe
5 Oil strainer
6 Oil pump
2-25
1 Exhaust camshaft
2 Intake camshaft
3 Oil filter
4 Oil cooler
2-26
1 Cylinder head
2 Crankshaft
2-27
1 Main axle
2 Oil delivery pipe
3 driveaxle
2-28
COOLANT FLOW DIAGRAMS SPEC
COOLANT FLOW DIAGRAMS

1 Radiator
2 Radiator fan
3 Oil cooler
2-29
1 Thermostat housing
2 Thermostat
3 Radiator
4 Therm
2-30
1 Radiator cap
2 Radiator
3 Oil cooler
4 Water jacket joint
5 Water pump
2-31
1 Radiator
2 Radiator fan switch
3 Radiator fan
2-32
CABLE ROUTING SPEC
EB206000
CABLE ROUTING
1 Throttle cables A Install the headlight relays onto the headlight housing bridge.
2 Front brake hose B Route the headlight lead through the plastic guide.
3 Clutch cable C Route the right handlebar switch lead in front of the front fork inner
4 Starter cable tube.
5 Left handlebar switch lead D Route the wire harness through under the left handlebar switch lead
6 Main switch lead and starter cable.
E Fasten the left handlebar switch lead to the front fork with a plastic
locking tie and cut the end of locking tie.
F Fasten the throttle cables and starter cable with a band.
Locate the end of band to forward.
2-33
CABLE ROUTING SPEC
G 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.
H Route the throttle cables between the brake hose
and right handlebar switch lead.
2-34
CABLE ROUTING SPEC
1 Fuel pump lead E Fasten the clutch cable to the coolant hose protec-
2 Pickup coil lead tor with a plastic band.
3 Thermo switch F Fasten the rear brake switch lead to the footrest
4 Plastic clamp bracket with a plastic locking tie and cut the end of
5 Clutch cable locking tie.
6 Rear brake switch lead G Fasten the fuel pump lead and rear brake switch
lead with a plastic band on the fuel pump bracket.
A Route the ignition coil lead and thermo switch 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.
2-35
CABLE ROUTING SPEC
1 Oil lever switch lead D Pass the fuel tank drain hose and the fuel tank
2 Sidestand switch lead breather hose should between the reservoir thank
3 Reservoir tank breather hose breather hose and the coolant breather hose, and
4 AC magneto lead kept outside the leads.
5 Neutral switch lead E Route the wireharness through the slit of rear fender.
6 Fuel pump lead F Pass the fuel tank drain hose and the fuel tank
7 Speed sensor lead breather hose inside the curved under cowling.
A Route the throttle cable through inside of the radia- G Put the fuel tank drain hose and fuel tank breather
tor bracket and outside of the wireharness. hose into the reservoir tank by passing through the
B Fasten the wireharness, radiator hose and fan mo- tank holder.
tor lead with a plastic band. No fixed order required.
C Do not touch the wireharness with the throttle cable Do not twist the hoses.
pully. H Put the fuel tank drain hose and the fuel tank
Route the wireharness under the radiator hose. breather hose through the hook and the side
stand’s holder.
No fixed order required.
Do not twist the hoses.
2-36
CABLE ROUTING SPEC
I When the sidestand is down. O Route the rear turn signal light leads (left and right)
J The end of the drain hose must be located in through the hole of rear fender.
between.
K Fasten the sidestand switch lead and oil level sen-
sor lead with a band.
L 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.
M Route the starter cable between the main switch
lead and left handlebar switch lead.
N Route the seat lock cable outside of the wirehar-
ness.
2-37
CABLE ROUTING SPEC
1 Throttle cable 16 Starter motor lead
2 Handlebar switch lead (right) 17 Battery negative (–) cable
3 Coolant temperature sensor lead 18 Fuel sender connector
4 Coolant reservoir breather hose 19 Crankcase breather hose
5 Idle adjust screw 20 Coolant reservoir tank cap
6 Pickup coil connector 21 Heat protector
7 Neutral switch connector 22 Fan motor lead connector
8 Rear brake switch connector 23 Clutch cable
9 Handlebar switch (right) connec- 24 Handlebar switch lead (left)
tors 25 Starter cable
10 Throttle position sensor connector 26 Main switch lead
11 Main switch connectors
12 Handlebar switch (left) connec- A To headlight lead
tors B Route the clutch cable through the guide.
13 Neutral switch lead
14 Fuel pump connector
15 Rear brake switch lead
2-38
CABLE ROUTING SPEC
6
C Fasten the handlebar switch leads (left and right) I Insert the projection of the band to the hole of the
and main switch lead with a band. frame and fasten the wireharness, neutral switch
D Route the ignition coil lead and handlebar switch lead, handlebar switch leads (left and right), main
leads (left and right) over the heat protection plate. switch lead, throttle position sensor lead, rear
E Route the reservoir tank hose, carburetor heater brake switch lead and pickup coil lead with them.
hoses under the heat protector plate. J Route the starter motor lead under the wirehar-
F Route the coolant temperature lead upper the heat ness.
protection plate. K Fasten the starter motor to the rear fender with a
G Route the coolant breather hose upper the heat band.
protection plate. L Fasten the battery positive (+) cable and starter
H Fasten the neutral switch lead, right handlebar motor cable with a plastic band.
switch lead, main switch lead, TPS lead, left han- M Position the rear turn signal light connectors (left
dlebar switch lead, pickup coil lead and main har- and right) and taillight connector between the rear
ness with a band. fender and taillight bracket.
N Install the seat lock cable to the frame bracket with
protector side.
2-39
CABLE ROUTING SPEC
O Fasten the battery negative lead after passing un- V The fuel tank drain hose, coolant temperature lead
der the main harness and oil level sensor lead. and the coolant breather hose must be located
P Fasten the main harness, oil level sensor lead and over the groove.
ground lead with a band. W Fasten the leads (above 1 – 5) and starter motor
Q Fasten the starter relay lead and battery negative lead with a steel band on the engine.
(–) lead to the wireharness with a plastic band. X Route the coolant breather hose upper the main
harness.
R To fuel filter Y Route the fuel tank breather hose and fuel tank
S Fasten the battery negative (–) lead and wirehar- drain hose over the wireharness.
ness with a plastic band. Z To carburetor
T Insert the projection of the band (wireharness) into A’ The starter cable must not be out off the guide
the hole of the frame. groove of the cover.
U 1: Speed sensor connector B’ Route the starter cable upper the heat protec-
2: AC magneto connector tion plate.
3: Sidestand switch connector C’ Insert the starter cable to the guide.
4: Oil level switch connector D’ To fan motor
5: Meter ground lead E’ Route the starter cable and main harness through
the guide of the heat protection plate.
2-40
CHK
ADJ
CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE CHART FOR EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . . 3-2
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . 3-11
SYNCHRONIZING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . 3-16
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . 3-18
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . . 3-20
CHECKING THE SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . . . 3-24
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
MEASURING THE ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . . . 3-29
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . . . 3-30
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . . . 3-31
CHECKING THE CARBURETOR JOINTS . . . . . . . . . . . . . . . . . . . . . 3-32
CHECKING THE FUEL HOSES AND FUEL FILTER . . . . . . . . . . . . . 3-32
CHECKING THE CRANKCASE BREATHER HOSE . . . . . . . . . . . . . 3-33
CLEANING THE AIR INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 3-33
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . . . 3-41
CHECKING THE BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-42
CHK
ADJ
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . . . 3-42
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . . 3-43
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . . . 3-45
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-47
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . . 3-47
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 3-51
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 3-54
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . . . 3-60
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . . 3-60
LUBRICATING THE SIDESTAND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-60
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . 3-60
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61

CHECKING AND CHARGING THE BATTERY . . . . . . . . . . . . . . . . . . 3-61
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66
REPLACING THE HEADLIGHT BULBS . . . . . . . . . . . . . . . . . . . . . . . . 3-68
ADJUSTING THE HEADLIGHT BEAMS . . . . . . . . . . . . . . . . . . . . . . . 3-69
INTRODUCTION/PERIODIC MAINTENANCE CHART FOR CHK
EMISSION CONTROL SYSTEM ADJ
EB300000
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 CHART FOR EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS
600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi

No. ITEM ROUTINE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
Check and adjust valve clearance when

1 * Valve clearance Every 26,600 mi (42,000 km)
engine is cold.
Check condition.
Adjust gap and clean.
2 Spark plugs Replace at 8,000 mi (13,000 km) or √ Replace √ Replace √
12 months and thereafter every 8,000 mi
(12,000 km) or 12 months.
Crankcase ventilation Check ventilation hose for cracks or damage.

3 * √ √ √ √ √
system Replace if necessary.
Check fuel hose for cracks or damage.

4 * Fuel line √ √ √ √ √
Replace if necessary.
Replace initial 20,000 mi (31,000 km) and

5 * Fuel filter Replace
thereafter every 20,000 mi (31,000 km).
Check for leakage.

6 * Exhaust system Retighten if necessary. √ √ √ √ √
Replace gasket(s) if necessary.
Carburetor
7 * Adjust synchronization of carburetors. √ √ √ √ √ √
Synchronization
Check and adjust engine idle speed.

8 * Idle speed √ √ √ √ √
Adjust throttle cable free play.
Evaporative emission Check control system for damage.

9 * √ √
control system** Replace if necessary.
* Since these items require special tools, data and technical skills, they should be serviced by a Ya-
maha dealer.
** California only.
3-1
CHK
GENERAL MAINTENANCE AND LUBRICATION CHART ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL ODOMETER READINGS
600 mi 4,000 mi 8,000 mi 12,000 mi 16,000 mi 20,000 mi
No. ITEM ROUTINE (1,000 km) (7,000 km) (13,000 km) (19,000 km) (25,000 km) (31,000 km)
or or or or or or
1 month 6 months 12 months 18 months 24 months 30 months
1 Engine oil Replace. Warm engine before draining. √ √ √ √ √ √
Replace at 600 mi (1,000 km) or 1 month,
2 * Engine oil filter and thereafter every 8,000 mi (12,000 km) or √ √ √
12 months.
Clean.
3 * Air filter / Surge tank
Replace if necessary. √ √ √ √ √
Check hose for cracks or damage.
4 * Cooling system
Replace coolant every 24 months.
Ethylene glycol anti-freeze coolant. Replace
Check operation, pad wear, and fluid
5 * Brake system leakage. (See NOTE.) √ √ √ √ √ √
Correct if necessary.
Check operation.
6 * Clutch
Correct if necessary. √ √ √ √ √ √
Apply chain lube thoroughly.
Control
7 *
cable
Yamaha chain and cable lube or SAE 10 W 30 √ √ √ √ √ √
motor oil.
Check bearing assembly for looseness.
Swing arm pivot Moderately repack every 16,000 mi
8 *
bearing (24,000 km) or 24 months. √ Repack
Lithium soap base grease.
Rear suspension link Check operation.
9 *
pivots Correct if necessary. √ √
Check operation and oil leakage.
10 * Rear shock absorber
Ckeck operation and leakage.
11 * Front fork
Check bearing assembly for looseness.
Correct accordingly.
12 * Steering bearings Moderately repack every 16,000 mi √ √ √ Repack √
(24,000 km).
Lithum soap base grease.
Apply chain lube lightly.
Brake / clutch lever
13
pivot shaft
Yamaha chain and cable lube or SAE 10 W 30 √ √ √ √ √
motor oil.
Brake pedal and
14
shift pedal shafts
motor oil.
Check chain slack / alignment condition. Every 600 mi (1,000 km) and after washing the
15 * Drive chain Adjust and lubricate chain throughly.
motorcycle or riding in the rain
SAE 30 W-50 W motor oil.
16 * Wheel bearings Check bearing for smooth rotation. √ √ √ √ √
Check operation and lubricate.
17 * Sidestand pivot
motor oil.
18 * Sidestand switch Check and clean or replace if necessary. √ √ √ √ √ √
Check all chassis fittings and fasteners.
19 * Chassis fasteners
Correct if necessary. √ √ √ √ √
* Since these items require special tools, data and technical skills, they should be serviced by a Ya-
maha dealer.
NOTE:
For odometer readings or time periods higher than 20,000 mi (31,000 km) or 30 months, repeat the
same maintenance as listed in the chart from the 4,000 mi (7,000 km) or 6 months interval.
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
Hydraulic brake system
When disassembling the master cylinder or caliper cylinder, always replace the brake fluid. Check
the brake fluid level reqularly and fill as required.
Replace the oil seals on the inner parts of the master cylinder and caliper cylinder every two years.
Replace the brake hoses every four years or if cracked or damaged.
3-2
CHK
RIDER AND PASSENGER SEATS ADJ
EB302000
RIDER AND PASSENGER SEATS
7 Nm (0.7 mkg, 5.1 ftlb)
Order Job/Part Q’ty Remarks

Removing the rider and passenger Remove the parts in the order listed.
seats
1 Passenger seat 1
2 Rider seat 1
For installation, reverse the removal
procedure.
3-3
CHK
FUEL TANK ADJ
FUEL TANK
10 Nm (1.0 mkg, 7.2 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)

7 Nm (0.7 mkg, 5.1 ftlb)

Removing the fuel tank Remove the parts in the order listed
Rider seat Refer to “SEATS”.
1 Bolt 1
2 Bolts 2
3 Fuel sender coupler 1 Disconnect.
4 Fuel hose 1 NOTE:
Before disconnecting the fuel hose, set
the fuel cock “OFF”.
5 Fuel tank overflow hose 1

6 Fuel tank breather hose 1
7 Fuel tank 1
For installation reverse the removal
procedure.
3-4
CHK
COWLINGS ADJ
COWLINGS
5 Nm (0.5 mkg, 3.6 ftlb)
5 Nm (0.5 mkg, 3.6 ftlb)

Removing the cowlings Remove the parts in the order listed
Rider and passenger seats Refer to “SEATS”.
1 Rear cowling 1
2 Bottom cowling (left) 1
3 Bottom cowling (right) 1
4 Front cowling inner panel (left) 1
5 Front cowling inner panel (right) 1
6 Side cowling inner panel (left) 1
7 Side cowling inner panel (right) 1
3-5
CHK
COWLINGS ADJ
COWLINGS
5 Nm (0.5 mkg, 3.6 ftlb)
5 Nm (0.5 mkg, 3.6 ftlb)

8 Left side cowling 1
9 Right side cowling 1
10 Windshield 1
11 Rear view mirror 2
12 Front cowling 1
procedure.
3-6
CHK
COWLINGS ADJ
REMOVAL
1. Remove:
S rear cowling
S side cowlings
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 fastener’s head.
3-7
CHK
AIR FILTER CASE AND IGNITION COILS ADJ
AIR FILTER CASE AND IGNITION COILS

Removing the air filter case and Remove the parts in the order listed.
ignition coils
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK”.
Front cowling inner panel (left) Refer to “COWLINGS”.
Front cowling inner panel (right)
1 Crankcase breather hose 1
2 Air vent hose 1
3 Hoses 2
4 Drain cup 1
5 Air filter case balance hose 2
6 Clamp screw 4 Loosen.
7 Bolt 1
8 Surge tank joint (left) 1
9 Surge tank joint (right) 1
10 Air filter case 1
11 Clamp 2
12 Quick fastener 2
3-8
CHK
AIR FILTER CASE AND IGNITION COILS ADJ

13 Heat protector plate 1
14 Ignition coil coupler 4
15 Ignition coil 4
procedure.
3-9
CHK
AIR FILTER CASE AND IGNITION COIL PLATE ADJ
REMOVAL
1. Remove:
heat protector plate
NOTE:
To remove the quick fastener, push its center in
with a screwdriver, then pull the fastener out.
INSTALLATION
1. Install:
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 fastener’s head.
3-10
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EB303001
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature.
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:
rider seat
fuel tank
Refer to “SEATS” and “FUEL TANK”.
air filter case
Refer to “AIR FILTER CASE AND IGNITION
COILS”.
bottom cowling
side cowlings
Refer to “COWLINGS”.
carburetor assembly
Refer to “CARBURETORS” in chapter 6.
radiator assembly
Refer to “RADIATOR” in chapter 5.
2. Remove:
ignition coils
spark plugs
cylinder head cover 1
cylinder head cover gasket
3. Remove:
pickup coil rotor cover 1
3-11
CHK
4. Measure:
S valve clearance
Out of specification Adjust
Valve clearance (cold)

Intake valve
0.11 0.20 mm
(0.0043 0.0079 in)
Exhaust valve
0.21 0.30 mm
(0.0083 0.0118in)
a. Turn the crankshaft clockwise.

b. When piston #1 is at TDC on the compres-
sion 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 thick-

ness 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 spe-
cified in the following table.
B Degrees that the crankshaft is turned counter-
clockwise
C Cylinder
D Combustion cycle
Cylinder #2 180_
Cylinder #4 360_
Cylinder #3 540_
3-12
CHK
5. Remove:
timing chain tensioner
timing chain guide (exhaust side)
camshaft cap
timing chain
(from the camshaft sprockets)
intake camshaft
exhaust camshaft
NOTE:
Refer to “CAMSHAFTS” in chapter 4.
When removing the timing chain from cam-
shafts, fasten the timing chain with a wire to re-
trieve it if it falls into the crankcase.
6. Adjust:
valve clearance
a. Remove the valve lifter 1 and the valve pad

2.
NOTE:
Cover the timing chain opening with a rag to
prevent the valve pad from falling into the
crankcase.
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 follow-

ing table.
Valve pad thick- Available valve

ness range pads
Nos. 25 thicknesses in
1.20
120 0.05 mm incre-
2.40 mm
240 ments
NOTE:
The thickness a of each valve pad is marked
in hundredths of millimeters on the side that
touches the valve lifter.
Since valve pads of various sizes are originally
installed, the valve pad number must be
rounded in order to reach the closest equiva-
lent to the original.
3-13
CHK
c. Round off the original valve pad number ac-
cording to the following table.
Last digit Rounded value

0 or 2 0
5 5
8 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 approxi-
mation. 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 lift-

er 2 .
NOTE:
Lubricate the valve pad with molybdenum dis-
ulfide grease.
Lubricate the valve lifter with molybdenum dis-
ulfide oil.
The valve lifter must turn smoothly when ro-
tated by hand.
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 mkg, 7.2 ftlb)
NOTE:
Lubricate the camshaft lobes and camshaft
journals.
First, install the exhaust camshaft.
Align the camshaft marks with the camshaft
cap marks.
Turn the crankshaft counterclockwise several
full turns to seat the parts.
3-14
CHK
VALVE PAD SELECTION TABLE
INTAKE
B MEASURED A ORIGINAL VALVE PAD NUMBER
VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08 0.10 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11 0.20 C STANDARD CLEARANCE
0.21 0.22 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.23 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.28 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 0.77 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 0.82 185 190 195 200 205 210 215 220 225 230 235 240 Example:
0.83 0.87 190 195 200 205 210 215 220 225 230 235 240 Valve Clearance (cold)
0.88 0.92 195 200 205 210 215 220 225 230 235 240 0.11 0.20 mm
0.93 0.97 200 205 210 215 220 225 230 235 240 Rounded value 150
0.98 1.02 205 210 215 220 225 230 235 240
1.03 1.07 210 215 220 225 230 235 240
Measured valve clearance is 0.24 mm
1.08 1.12 215 220 225 230 235 240 Replace pad 150 with pad 160
1.13 1.17 220 225 230 235 240 Pad No. 150 = 1.50 mm
1.18 1.22 225 230 235 240 Pad No. 160 = 1.60 mm
1.23 1.27 230 235 240 Always install the valve pad with the
1.28 1.32 235 240
1.33 1.37 240
number facing down.
EXHAUST
B MEASURED A ORIGINAL VALVE PAD NUMBER
VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.08 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.18 0.20 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.21 0.30 C STANDARD CLEARANCE
0.31 0.32 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83 0.87 180 185 190 195 200 205 210 215 220 225 230 235 240
0.88 0.92 185 190 195 200 205 210 215 220 225 230 235 240 Example:
0.93 0.97 190 195 200 205 210 215 220 225 230 235 240 Valve Clearance (cold)
0.98 1.02 195 200 205 210 215 220 225 230 235 240 0.21 0.30 mm
1.03 1.07 200 205 210 215 220 225 230 235 240
Rounded value 175
1.08 1.12 205 210 215 220 225 230 235 240
1.13 1.17 210 215 220 225 230 235 240 Measured valve clearance is 0.35 mm
1.18 1.22 215 220 225 230 235 240 Replace pad 150 with pad 185
1.23 1.27 220 225 230 235 240 Pad No. 175 = 1.75 mm
1.28 1.32 225 230 235 240 Pad No. 185 = 1.85 mm
1.33 1.37 230 235 240
Always install the valve pad with the
1.38 1.42 235 240
1.43 1.47 240 number facing down.
3-15
ADJUSTING THE VALVE CLEARANCE/ CHK
SYNCHRONIZING THE CARBURETORS ADJ
g. Measure the valve clearance again.
h. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
7. Install:
all removed parts
NOTE:
For installation, reverse the removal procedure.
Note the following points.
8. Install:
pickup coil rotor cover
cylinder head cover
spark plugs
ignition coils
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:
rider seat
fuel tank
3-16
CHK
SYNCHRONIZING THE CARBURETORS ADJ
3. Remove:
hose 1
4. Install:
vacuum gauge attachments
(into the bolt holes)
vacuum gauge 1
(onto the vacuum gauge attachments)
engine tachometer 2
(onto the ignition coil of cylinder #1)
Vacuum gauge
90890-03094, YU-08030-A
Vacuum gauge attachment
90890-03060
Engine tachometer
90793-80009
5. Start the engine and let it warm up for several

minutes.
6. Measure:
engine idling speed
Out of specification Adjust.
Refer to “ADJUSTING THE ENGINE ID-
LING SPEED”.
Engine idling speed

1,250 1,350 r/min
7. Adjust:
carburetor synchronization
a. Synchronize carburetor #1 to carburetor #2

by turning the synchronizing screw 1 in ei-
ther direction until both gauges read the
same.
3-17
SYNCHRONIZING THE CARBURETORS/ CHK
ADJUSTING THE ENGINE IDLING SPEED 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

same.
c. Synchronize carburetor #2 to carburetor #3
same.
Vacuum pressure at engine

idling speed
24.0 kPa (0.24 kg/cm2, 3.41 psi)
NOTE:
The difference in vacuum pressure between
two carburetors should not exceed 1.33 kPa (10
mm Hg).
8. Measure:
engine idling speed
9. Stop the engine and remove the measuring
equipment.
10. Adjust:
throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play

(at the flange of the throttle grip)
6 8 mm (0.24 0.31 in)
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 com-
pression.
1. Start the engine and let it warm up for several

minutes.
3-18
CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
2. Remove:
air filter case
quick fasteners 1
band 2
COILS”.
3. Install:
engine tachometer
Engine tachometer
90793-80009
4. Install:
air filter case
COILS”.
5. Measure:
engine idling speed
Engine idling speed

1,250 1,350 r/min
6. Adjust:
engine idling speed
a. Turn the throttle stop screw 2 in direction a

or b until the specified engine idling speed is
obtained.
Engine idling speed is

Direction a
decreased.
Engine idling speed is
Direction b
increased.
3-19
ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
7. Adjust:
CABLE FREE PLAY”.

6 8 mm (0.24 0.31 in)
EB303031
ADJUSTING THE THROTTLE CABLE FREE

PLAY
NOTE:
Prior to adjusting the throttle cable free play, the
engine idling speed and carburetor synchro-
nization should be adjusted properly.
1. Measure:
throttle cable free play a

6 8 mm (0.24 0.31 in)
2. Remove:
rider seat
fuel tank
air filter case
COILS”.
3-20
CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
3. Adjust:
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
in increased.
Direction b
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
is increased.
Direction d
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
CHK
CHECKING THE SPARK PLUGS ADJ
EB303040
CHECKING THE SPARK PLUGS

spark plugs.
1. Remove:
rider seat
fuel tank
air filter case
COILS”.
2. Disconnect:
Ignition coils
3. Remove:
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 fa-
ras 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:
spark plug type
Incorrect Change.
Spark plugs
type (manufacturer)
CR10EK (NGK)
CR9EK (NGK) (California)
3-22
CHECKING THE SPARK PLUGS/ CHK
CHECKING THE IGNITION TIMING ADJ
5. Check:
electrodes 1
Damage/wear Replace the spark plug.
insulator 2
Abnormal color Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
spark plug gap a
(with a wire gauge)
Out of specification Regap.
Spark plug gap

0.6 0.7 mm (0.02 0.03 in)
8. Install:
spark plug 13 Nm (1.3 mkg, 9.4 ftlb)
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:
bottom cowling
rider seat
fuel tank
air filter case
COILS”.
timing mark accessing screw 1
3-23
CHECKING THE IGNITION TIMING/ CHK
MEASURING THE COMPRESSION PRESSURE ADJ
2. Install:
timing light 1
engine tachometer
Timing light
90890-03141, YU-33277-A
Engine tachometer
90793-80009
3. Check:
ignition timing
a. Start the engine, warm it up for several min-

utes, and then let it run at the specified en-
gine idling speed.
Engine idling speed

1,250 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 PRES-

SURE
The following procedure applies to all of the cyl-
inders.
NOTE:
Insufficient compression pressure will result in a
loss of performance.
1. Measure:
valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”.
2. Start the engine, warm it up for several min-
utes, and then stop it.
3. Remove:
rider seat
fuel tank
air filter case
ignition coils
COILS”.
3-24
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
4. Remove:
spark plug
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
5. Install:
compression gauge 1
Compression gauge
90890-03081, YU-33223
Adapter
90890-04136
6. Measure:
compression pressure
Out of specification Refer to steps (c) and
(d).
Compression pressure (at sea

level)
Minimum
1300 kPa (13.0 kg/cm2,
184.90 psi)
Standard
1550 kPa (15.5 kg/cm2,
224.75 psi)
Maximum
1600 kPa (16.0 kg/cm2,
227.57 psi)
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 be-
tween cylinders should not exceed 100 kPa (1
kg/cm2, 14.22 psi).
3-25
MEASURING THE COMPRESSION PRESSURE/ CHK
CHECKING THE ENGINE OIL LEVEL 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 Diagnosis
Higher than Piston wear or
without oil damage Repair.
Piston ring(-s),
valve(-s), cylinder
Same as without head gasket or
oil piston possibly
defective
Repair.
7. Install:
spark plug 13 Nm (1.3 mkg, 9.4 ftlb)
EB303070
CHECKING THE ENGINE OIL LEVEL

NOTE:
Make sure that the motorcycle is upright.
2. Start the engine, let it idle for several min-

utes, and then stop it.
3. Check:
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/ CHK
CHANGING THE ENGINE OIL ADJ
Recommended oil:
At –10_C (10_F) or higher A :
Yamalube 4 (10W-30)
or SAE
10W-30 type SE motor oil
At 5_C (40_F) or higher B :
Yamalube 4 (20W-40)
or SAE
20W-40 type SE motor oil
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.
S Do not allow foreign materials to enter the
crankcase.
NOTE:
API Service “SE”, “SF” and “SG” type or equiva-
lent (e. g., “SF-SE”, “SF-SE-CC”, “SF-SE-SD”)

utes, 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
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
CHK
CHANGING THE ENGINE OIL 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, YU-38411
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 car-
tridge.
c. Tighten the new oil filter cartridge to specifi-

cation with an oil filter wrench.
Oil filter cartridge

17 Nm (1.7 mkg, 12 ftlb)
7. Check:
engine oil drain bolt washer
Damage Replace.
8. Install:
engine oil drain bolt
43 Nm (4.3 mkg, 31 ftlb)
9. Fill:
crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
3.5 L (3.7 US qt)
Without oil filter cartridge re-
placement
2.5 L (2.64 US qt)
With oil filter cartridge replace-
ment
2.7 L (2.85 US qt)
10. Install:
engine oil filler cap
12. Check:
engine
(for engine oil leaks)
3-28
CHANGING THE ENGINE OIL/ CHK
MEASURING THE ENGINE OIL PRESSURE ADJ
13. Check:
S engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
14. Install:
S bottom cowling
EB303090
MEASURING THE ENGINE OIL PRESSURE

1. Check:
S engine oil level
recommended engine oil to the proper level.
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 ex-
tremely 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, 34.1 psi)
Engine speed
Approx. 6000 r/min
Engine oil temperature
96_C (205°F)
3-29
CHK
MEASURING THE ENGINE OIL PRESSURE 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.

Engine oil pressure Possible cause
Faulty oil pump
Clogged oil filter
Below specification Leaking oil passapage
Broken or damaged
oil seal
Leaking oil passage
Above specification Faulty oil filter
Oil viscosity too high
6. Tighten the oil gallery bolt
20 Nm (2.0 mkg, 14 ftlb)
EB303100
ADJUSTING THE CLUTCH CABLE FREE

PLAY
1. Measure:
clutch cable free play a
Clutch cable free play (at the end
10 15 mm (0.39 0.59 in)
2. Adjust:
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 ob-
tained.
Direction a Clutch cable free play is in-
creased.
Direction b Clutch cable free play is de-
creased.
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
b. Turn the adjusting nut 3 in direction c or d
until the specified clutch cable free play is ob-
tained.
Direction c Clutch cable free play is in-
creased.
Direction d Clutch cable free play is de-
creased.
c. Tighten the locknut.
3-30
CHK
CLEANING THE AIR FILTER ELEMENT ADJ
EB303130
CLEANING THE AIR FILTER ELEMENT

1. Remove:
fuel tank
Refer to “FUEL TANK”.
air filter case cover 1
air filter element
2. Clean:
air filter element
Use solvent to clean the air filter element. Af-
ter 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:
air filter element
Damage Replace.
5. Install:
air filter element
air filter case cover
CAUTION:
Never operate the engine without the air fil-
ter 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 en-
gine performance and possible overheat-
ing.
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:
fuel tank
3-31
CHECKING THE CARBURETOR JOINTS/ CHK
CHECKING THE FUEL HOSES AND FUEL FILTER/ ADJ
EB303171
CHECKING THE CARBURETOR JOINTS

The following procedure applies to all of the car-
buretor joints and intake manifolds.
1. Remove:
carburetor assembly
2. Check:
carburetor joint 1
Cracks/damage Replace.
3. Install:
carburetor assembly
EB303181
CHECKING THE FUEL HOSES AND FUEL

FILTER
The following procedure applies to all of the fuel
hoses.
1. Remove:
fuel tank
2. Check:
fuel hose 1
fuel filter 2
Contaminants/damage Replace.
NOTE:
Drain and flush the fuel tank if abrasive dam-
age to any components of the fuel line is evi-
dent.
The arrow mark on the fuel filter must point to-
wards the fuel pump as shown.
3. Install:
fuel tank
3-32
CHECKING THE CRANKCASE BREATHER HOSE/ CHK
CLEANING THE AIR INTAKE SYSTEM ADJ
EB303190
CHECKING THE CRANKCASE BREATHER

HOSE
1. Remove:
fuel tank
2. Check:
crankcase breather hose 1
Cranks/damage Replace.
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
fuel tank
EAS00092
CLEANING THE AIR INTAKE SYSTEM

The following procedure applies to both air in-
take system.
1. Remove:
side cowling inner covers
side cowlings
front cowling inner covers
front cowling
fuel tank
2. Loosen:
clamps
(on the inside of the front cowling)
3. Remove:
air intake system air ducts 1
4. Clean:
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 up-
right 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:
air intake system air ducts
fuel tank
front cowling
front cowling inner covers
side cowlings
side cowlings inner covers
3-33
CLEANING THE AIR INTAKE SYSTEM/ CHK
CHECKING THE EXHAUST SYSTEM ADJ
2. Check:
crankcase breather hose 1
CAUTION:
Make sure that the crankcase breather hose
is routed correctly.
3. Install:
fuel tank
EB303200
CHECKING THE EXHAUST SYSTEM

The following procedure applies to all of the ex-
haust pipes and gaskets.
1. Remove:
radiator assembly
2. Check:
exhaust pipe 1
muffler 2
gasket 3
Exhaust gas leaks Replace.
3. Measure:
tightening torque
Exhaust pipe nut 4

20 Nm (2.0 mkg, 14 ftlb)
Muffler clamp bolt 5
20 Nm (2.0 mkg, 14 ftlb)
Exhaust pipe bolt 6
20 Nm (2.0 mkg, 14 ftlb)
Muffler bolt 7
38 Nm (3.8 mkg, 27 ftlb)
4. Install:
radiator assembly
3-34
CHECKING THE COOLANT LEVEL/ CHK
CHECKING THE COOLING SYSTEM ADJ
EB303220
CHECKING THE COOLANT LEVEL

NOTE:
2. Check:
coolant level
The coolant level should be between the
maximum level mark a and minimum level
marks b .
recommended coolant to the proper level.
CAUTION:
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.
Use only distilled water. Soft water may be
used if distilled water is not available.

4. Check:
coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
EB303230
CHECKING THE COOLING SYSTEM

1. Remove:
bottom cowling
side cowlings
2. Check:
radiator 1
radiator inlet hose 2
radiator outlet hose 3
oil cooler 4
oil cooler inlet hose 5
oil cooler outlet hose 6
water pump outlet hose 7
Refer to “COOLING SYSTEM” in chapter 5.
3. Install:
side cowlings
bottom cowling
Refer to “Cowlings”.
3-35
CHK
CHANGING THE COOLANT ADJ
EB303240
CHANGING THE COOLANT

1. Remove:
bottom cowling
left side cowling
reservoir hose clamps 1
2. Remove:
coolant reservoir bolts 2
coolant reservoir cap 3
NOTE:
When draining the coolant from the coolant res-
ervoir, be sure to tilt the reservoir so that coolant
cannot flow through the coolant reservoir
breather hose 4 .
3. Drain:
coolant
(from the coolant reservoir)
4. Install:
coolant reservoir bolts
reservoir cover
5. Remove:
radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the en-
gine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
ous 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 coun-
terclockwise toward the detent to allow any
residual pressure to escape. When the his-
sing sound has stopped, turn the radiator
cap counterclockwise while pressing down
on it and then remove it.
3-36
CHK
6. Remove:
coolant drain bolt 1
(along with the copper washer)
7. Drain:
coolant
8. Check:
coper washer 1
coolant drain bolt 2
Damage Replace
9. Install:
coolant drain bolt
7 Nm (0.7 mkg, 5.1 ftlb)
10. Fill:
cooling system
mended 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 (2.27 US qt)
Coolant reservoir capacity
0.44 L (0.47 US qt)
Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.
WARNING
If coolant splashes in your eyes, thorough-
ly wash them with water and consult a doc-
tor.
If coolant splashes on your clothes, quick-
ly wash it away with water and then with
soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.
3-37
CHK
CAUTION:
Adding water instead of coolant lowers the
antifreeze content of the coolant. If water is
used instead of coolant, check, and if nec-
essary, correct the antifreeze concentra-
tion of the coolant.
Use only distilled water. However, soft wa-
ter may be used if distilled water is not
available.
If coolant comes into contact with painted
surfaces, immediately wash them with wa-
ter.
Do not mix different types of antifreeze.
11. Install:
radiator cap
12. Fill:
coolant reservoir
(with the recommended coolant to the maxi-
mum level mark a )
13. Install:
coolant reservoir cap
15. Check:
coolant level
Refer to “CHECKING THE COOLANT LEV-
EL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
16. Install:
left side cowling
bottom cowling
3-38
ADJUSTING THE FRONT BRAKE/ CHK
ADJUSTING THE REAR BRAKE ADJ
EB304001
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
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 hold-
er.
Position #1 Distance a is the largest.

Position #5 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 ad-
justing dial.
EB304010
ADJUSTING THE REAR BRAKE

1. Measure:
brake pedal position
(distance a from the top of the brake pedal
to the bottom of the rider footrest bracket bolt
center)
Brake pedal position (from the

top of the brake pedal to the
bottom of the rider footrest
bracket bolt center)
4.3 9.3 mm (0.17 0.37 in)
b : 11mm (0.43 in)
3-39
CHK
ADJUSTING THE REAR BRAKE ADJ
2. Adjust:

b. Turn the adjusting bolt 2 in direction a or b
until the specified brake pedal position is ob-
tained.
Direction a Brake pedal is raised.

Direction b 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 mkg, 12 ftlb)
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 consid-
erably 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:
rear brake light switch
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH”.
3-40
CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
EB304020
CHECKING THE BRAKE FLUID LEVEL

NOTE:
A 2. Check:
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
Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
Refill with the same type of brake fluid that
is already in the system. Mixing brake
fluids may result in a harmful chemical
reaction, leading to poor brake perfor-
mance.
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/ CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EB304032
A
CHECKING THE BRAKE PADS
brake pads.
1. Operate the brake.
2. Check:
front brake pad
rear brake pad
Brake pad wear limit a
Wear limit reached Replace the brake
pads as a set.
B Refer to “FRONT AND REAR BRAKES” in
chapter 7.
Brake pad wear limit

a 0.5 mm (0.02 in)
b 0.8 mm (0.03 in)
A Front brake
B Rear brake
EB304050
ADJUSTING THE REAR BRAKE LIGHT

SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.
1. Check:
rear brake light operation timing
Incorrect Adjust.
2. Adjust:
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.
Brake light comes on

Direction a
sooner.
Brake light comes on
Direction b
later.
3-42
CHECKING THE BRAKE HOSES/ CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EB304062
CHECKING THE BRAKE HOSES

brake hoses and brake hose clamps.
1. Check:
brake hose 1
Cracks/damage/wear Replace.
2. Check:
brake hose clamp
Loose Tighten the clamp bolt.
3. Hold the motorcycle upright and apply the
brake several times.
4. Check:
brake hose
Brake fluid leakage Replace the damaged
hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE SYS-

TEM
WARNING
Bleed the hydraulic brake system whenev-
er:
the brake system was disassembled,
a brake hose was loosened, disconnected
or replaced,
the brake fluid level is very low,
brake operation is faulty.
NOTE:
Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
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 hydrau-
lic brake system, considerably lengthening the
bleeding procedure.
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
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
A 5. Bleed:
hydraulic brake system
a. Fill the brake fluid reservoir to the proper lev-

el 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 con-
B tainer.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully de-
press 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 ex-
tend.
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 mkg, 4.3 ftlb)
k. Fill the brake fluid reservoir to the proper lev-

el 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/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
EB304081
ADJUSTING THE SHIFT PEDAL

NOTE:
The shift pedal position is determined by the
shift rod length.
1. Measure:
incorrect Adjust.
The top of sift pedal should be

aligned with the lower part of the
bracket. (from the horizontal view)
2. Adjust:
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.
Installed shift rod length

Direction b
increases.
Installed shift rod length
Direction c
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 swin-
garm or cause an accident. Therefore, keep
the drive chain slack within the specified
limits.

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
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
2. Rotate the rear wheel several times and
check the drive chain to locate its tightest
point.
3. Measure:
drive chain slack a
Drive chain slack

40 50 mm (1.57 1.97 in)
4. Adjust:
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 ob-
tained.
Drive chain slack is

Direction a
reduced.
Drive chain slack is
Direction b
increased.
NOTE:
To maintain the proper wheel alignment, adjust
both sides evenly.
d. Tighten both locknuts to specification.
Locknut
16 Nm (1.6 mkg, 12 ftlb)
e. Tighten the wheel axle nut to specification.
Wheel axle nut

150 Nm (15.0 mkg, 108 ftlb)
3-46
LUBRICATING THE DRIVE CHAIN/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EB304100
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained prop-
erly, it will wear out rapidly. Therefore, the drive
chain should be serviced, especially when the
motorcycle is used in dusty areas. This motor-
cycle has a drive chain with small rubber O-
rings between each side plate. Steam cleaning,
high-pressure washing, certain solvents, and
the use of a coarse brush can damage these O-
rings. Therefore, use only kerosine to clean the
drive chain. Wipe the drive chain dry and thor-
oughly lubricate it with engine oil or chain lubri-
cant 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 STEER-

ING HEAD
WARNING
NOTE:
the front wheel is elevated.
2. Check:
steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Looseness/binding Adjust the steering
head.
3-47
CHK
3. Remove:
upper bracket bolts 1
front brake fluid reservoir bolt 2
4. Loosen:
upper bracket pinch bolts 1
handlebar pinch bolts 2
washer 3
5. Remove:
handlebars
(from the upper bracket)
6. Remove:
steering stem nut 1
washer 2
upper bracket 3
7. Adjust:
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, YU-33975
Lower ring nut (initial tightening

torque)
17 Nm (1.7 mkg, 12 ftlb)
3-48
CHK
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 mkg, 6.5 ftlb)
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 cor-
rectly in the ring nut slots b .
8. Install:
steering stem nut
115 Nm (11.5 mkg, 83 ftlb)
upper bracket bolt
13 Nm (1.3 mkg, 9.4 ftlb)
handlebar pinch bolt
13 Nm (1.3 mkg, 9.4 ftlb)
upper bracket pinch bolt
23 Nm (2.3 mkg, 17 ftlb)
9. Measure:
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 lock-
ing tie.
3-49
CHECKING AND ADJUSTING THE STEERING HEAD/ CHK
CHECKING THE FRONT FORK ADJ
d. Hold the spring gauge at a 90_ angle from
the handlebar, pull the spring gauge, and re-
cord the measurement when the handlebar
starts to turn.
Steering head tension

200 500 g (7.1 17.6 oz)
e. Repeat the above procedure on the opposite

handlebar.
f. If the steering head tension is out of specifi-
cation (both handlebars should be within
specification), remove the upper bracket and
loosen or tighten the upper ring nut.
g. Reinstall the upper bracket and measure the
steering head tension again as described
above.
h. Repeat the above procedure until the steer-
ing 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

WARNING
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
CHK
ADJUSTING THE FRONT FORK LEGS ADJ
EB304153
ADJUSTING THE FRONT FORK LEGS

The following procedure applies to both of the
front fork legs.
WARNING
Always adjust both front fork legs evenly.
Uneven adjustment can result in poor han-
dling and loss of stability.
Spring preload
CAUTION:
Grooves are provided to indicate the ad-
justment position.
Never go beyond the maximum or mini-
mum adjustment positions.
1. Adjust:
spring preload
a. Turn the adjusting bolt 1 in direction a or

b.
Spring preload is
Direction a increased (suspension is
harder).
Spring preload is
Direction b decreased (suspension is
softer).
Standard
Hard Soft
Adjusting
position 1 2 3 4 5 6 7 8
3-51
CHK
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
rebound damping
a. Turn the adjusting screw 1 in direction a or

b.
Rebound damping is
harder).
Rebound damping is
b
Direction decreased (suspension is
softer).
Adjusting positions
Minimum: 9 clicks out*
Standard: 6 clicks out*
Maximum: 1 clicks out*
* from the fully turned-in position
NOTE:
Although the number of clicks between the mini-
mum and maximum settings may vary with
each individual shock absorber and may not ex-
actly match these specifications, it is always the
full damping force range that extends over the
actual number of clicks.
Compression damping
CAUTION:
1. Adjust:
compression damping
b.
Compression damping is
harder).
softer).
3-52
CHK
Adjusting positions
Maximum: 1 clicks out*
NOTE:
Although the number of clicks between the mi-
numum and maximum settings may vary with
3-53
CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
EB304162
ADJUSTING THE REAR SHOCK ABSORB-

ER ASSEMBLY
WARNING
Spring preload
CAUTION:
1. Adjust:
spring preload
NOTE:
Adjust the spring preload with the special
wrench and extension bar included in the own-
er’s 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 .
Spring preload is
harder).
Spring preload is
softer).
Adjusting positions
Minimum: 1
Standard: 4
Maximum: 9
3-54
CHK
Rebound damping
CAUTION:
1. Adjust:
rebound damping

b.
Rebound damping is
harder).
Rebound damping is
softer).
Adjusting positions
Maximum: 1 click out*
NOTE:
Compression damping
CAUTION:
1. Adjust:
compression damping
b.
harder).
softer).
3-55
CHK
Adjusting positions
Maximum: 1 click out*
NOTE:
3-56
CHK
CHECKING THE TIRES ADJ
EB304170
CHECKING THE TIRES

tires.
1. Measure:
tire pressure
Out of specification Regulate.
WARNING
The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
The tire pressure and the suspension must
be adjusted according to the total weight
(including cargo, rider, passenger and ac-
cessories) and the anticipated riding
speed.
Operation of an overloaded motorcycle
could cause tire damage, an accident or an
injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil
188 kg
and a full
fuel tank)
Maximum
187 kg
load*
Cold tire
Front Rear
pressure
Up to 90 kg 250 kPa 250 kPa
(198 lb) (2.5 kg/cm2, (2.5 kg/cm2,
load* 36.3 psi) 36.3 psi)
90 kg (198 lb) 250 kPa 290 kPa
maximum (2.5 kg/cm2, (2.9 kg/cm2,
load* 36.3 psi) 42.1 psi)
250 kPa 250 kPa
High-speed
(2.5 kg/cm2, (2.5 kg/cm2,
riding
36.3 psi) 36.3 psi)
* total of cargo, rider, passenger and accesso-
ries
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-57
CHK
CHECKING THE TIRES ADJ
2. Check:
tire surfaces
Damage/wear Replace the tire.
Minimum tire tread depth

1.6 mm (0.06 in)
1 Tire tread depth
2 Side wall
3 Wear indicator
WARNING
A B Do not use a tubeless tire on a wheel de-
signed only for tube tires to avoid tire failure
and personal injury from sudden deflation.
When using a tube tire, be sure to install the
correct tube.
Always replace a new tube tire and a new
tube as a set.
To avoid pinching the tube, make sure that
the wheel rim band and tube are centered in
the wheel groove.
Patching a punctured tube is not recom-
mended. 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 Tube tire only
Tube or tubeless
Tubeless wheel
tire
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one ap-
proved by Yamaha is used on this
motorcycle.
Front tire
Manufacturer Size Model
120 / 60 ZR17
BRIDGESTONE BT56FE
(55W)
120 / 60 ZR17
DUNLOP D207FJ
(55W)
3-58
CHK
CHECKING THE TIRES/CHECKING THE WHEELS ADJ
Rear tire
Manufacturer Size Model
180/55 ZR17
BRIDGESTONE BT56RE
(73W)
180/55 ZR17
DUNLOP D207N
(73W)
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn. Therefore, approximately 100 km
sould be traveled at normal speed before
any highspeed riding is done.
NOTE:
For tires with a direction of rotation mark 1 :
Install the tire with the mark pointing in the
direction of wheel rotation.
Align the mark 2 with the valve installation
point.
EB304180
CHECKING THE WHEELS

wheels.
1. Check:
wheel
Damage/out-of-round Replace.
WARNING
Never attempt to make any repairs to the
wheel.
NOTE:
After a tire or wheel has been changed or re-
placed, always balance the wheel.
3-59
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS/ CHK
LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSION ADJ
EB304200
CHECKING AND LUBRICATING THE

CABLES
cable sheaths and cables.
WARNING
Damaged cable sheaths may cause the
cable to corrode and interfere with its move-
ment. Replace damaged cable sheaths and
cables as soon as possible.
1. Check:
cable sheath
Damage Replace.
2. Check:
cable operation
Rough movement Lubricate.
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 suit-
able lubing device.
EB304210
LUBRICATING THE LEVERS AND PEDALS

Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Lithium soap base grease
EB304220
LUBRICATING THE SIDESTAND

moving parts of the sidestand.
EB304240
LUBRICATING THE REAR SUSPENSION

moving parts of the rear suspension.
3-60
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EB305020
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
Wear protective eye gear when handling or
working near batteries.
Charge batteries in a well-ventilated area.
Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
DO NOT SMOKE when charging or han-
dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
Skin – Wash with water
Eyes – Flush with water for 15 minutes and
get immediate medical attention.
INTERNAL
Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg or
vegetable oil. Get immediate medical
attention.
CAUTION:
This is a sealed battery. Never remove the
sealing caps because the balance between
cells will not be maintained and battery
performance will deteriorate.
Charging time, charging amperage and
charging voltage for an MF battery are dif-
ferent from those of conventional batter-
ies. The MF battery should be charged as
explained in the charging method illustra-
tions. If the battery is overcharged, the
electrolyte level will drop considerably.
Therefore, take special care when charg-
ing the battery.
3-61
CHK
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
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 ter-

minals.
Tester positive probe battery positive
terminal
Tester negative probe battery nega-
tive terminal
13.0 Relationship between the open-circuit voltage NOTE:

Open-circuit voltage (V)
and the charging time at 20_C

S The charge state of an MF battery can be
12.5
checked by measuring its open-circuit voltage
12.0 (i.e., the voltage when the positive terminal is
11.5
disconnected).
S No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
5 6.5 10
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level. 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 30%
3-62
CHK
Charging 5. Charge:
Ambient temperature 20_C
S battery
(refer to the appropriate charging method il-

lustration)
WARNING
Do not quick charge a battery.
Time (minutes)
Check the open-circuit
voltage. CAUTION:
S Never remove the MF battery sealing caps.
Ambient S Do not use a high-rate battery charger
temperature since it forces a high-amperage current

20_C
into the battery quickly and can cause bat-
tery 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 re-
Charging condition of the battery (%) move 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 ter-
minal and that they are not shorted. A cor-
roded battery charger lead clip may gener-
ate 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, dis-
connect the battery charger and let the bat-
tery cool before reconnecting it. Hot batter-
ies can explode!
S As shown in the following illustration, the
open-circuit voltage of an MF battery stabi-
lizes about 30 minutes after charging has
been completed. Therefore, wait 30 min-
utes after charging is completed before
measuring the open-circuit voltage.
3-63
CHK
Charging method using a variable-voltage charger
Charger
Ammeter
Measure the open-circuit NOTE:
voltage prior to charging. Leave the battery unused for more than
30 minutes before measuring its open-
circuit voltage.
Connect a charger and am- NOTE:

meter to the battery and Set the charging voltage to 16 17 V.
start charging. (If the charging voltage is lower, charg-
ing will be insufficient, if it is higher, the
battery will be over-charged.)
Is the amperage higher

YES than the standard charging NO
amperage written on the
battery?
Adjust the charging voltage to

20 25 V.
Monitor the amperage for 3

Adjust the voltage to obtain the YES
5 minutes. Is the standard
standard charging amperage.
charging amperage exceed-
ed?
NO
Set the timer to the charging If the amperage does not

time determined by the open- exceed the standard charg-
circuit voltage. ing amperage after 5 min-
Refer to “CHECKING AND utes, replace the battery.
CHARGING 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 am-
perage, readjust the voltage to obtain the standard charging amper-
age.
Leave the battery unused for more than 30 minutes before measur-
ing its open-circuit voltage.
12.8 V Charging is complete.
12.0 12.7 V Recharging is required.
Under 12.0 V Replace the battery.
3-64
CHK
Charging method using a constant-voltage charger
Measure the open-circuit NOTE:

voltage prior to charging. Leave the battery unused for more than
30 minutes before measuring its open-
circuit voltage.
Connect a charger and am-

meter to the battery and
start charging.
Is the amperage higher

YES than the standard charging NO
amperage written on the
battery?
Charge the battery until the charging This type of battery charger cannot
voltage reaches 15 V. charge an MF battery. A variable-
voltage charger is recommended.
NOTE:
Set the charging time to a maximum of
20 hours.
Charger
Leave the battery unused for more

Ammeter
than 30 minutes before measuring its Voltmeter
open-circuit voltage.
12.8 V Charging is complete.
12.0 12.7 V Recharging is re-
quired.
Under 12.0 V Replace the battery.
CAUTION:
Constant amperage chargers are not
suitable for charging MF batteries.
3-65
CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSES ADJ
6. Install:
battery
7. Connect:
battery leads
(to the battery terminals)
CAUTION:
First, connect the positive lead 1 , then the
negative lead 2 .
8. Check:
battery terminals
Dirt Clean with a wire brush.
9. Lubricate:
battery terminals
Dielectric grease
10. Install:
rider seat
EB305040
CHECKING THE FUSES

fuses.
CAUTION:
To avoid a short circuit, always set the main
switch to “OFF” when checking or replacing
a fuse.
1. Remove:
rider seat
2. Check:
continuity
a. Connect the pocket tester to the fuse and

check the continuity.
NOTE:
Set the pocket tester selector to “Ω 1”.
Pocket tester
90890-03112, YU-03112
b. If the pocket tester indicates “∞”, replace the

fuse.
3-66
CHK
CHECKING THE FUSES ADJ
3. Replace:
blown fuse
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 Amperage Q’ty

Main fuse 30 A 1
Headlight
20 A 1
fuse
Signaling
20 A 1
system fuse
Ignition
15 A 1
fuse
Radiator
fan motor 7.5 A 1
fuse
Backup fuse
7.5 A 1
(odometer)
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 sys-
tems to malfunction and could possibly
cause a fire.
4. Install:
rider seat
3-67
CHK
REPLACING THE HEADLIGHT BULBS ADJ
EB305051
REPLACING THE HEADLIGHT BULBS

headlight bulbs.
1. Disconnect:
headlight coupler 1
headlight bulb holder cover 2
2. Detach:
headlight bulb holder 1
3. Remove:
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:
headlight bulb New
Secure the new headlight bulb with the head-
light bulb holder.
CAUTION:
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adversely
affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
5. Attach:
headlight bulb holder
6. Install:
headlight bulb holder cover
7. Connect:
headlight coupler
3-68
CHK
ADJUSTING THE HEADLIGHT BEAMS ADJ
EB305061
ADJUSTING THE HEADLIGHT BEAMS

headlights.
1. Adjust:
headlight beam (vertically)

b.
Direction a Headlight beams is raised.

Headlight beams is low-
Direction b
ered.
2. Adjust:
headlight beam (horizontally)
a. Turn the adjusting knob 1 in direction a or

b.
Left headlight
Headlight beam moves

Direction a
to the right.
Headlight beams moves
Direction b
to the left.
Right headlight

Direction a
to the left.
Direction b
to the right.
3-69
CHK
ADJ
ENG
CHAPTER 4.
ENGINE OVERHAUL
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
EXHAUST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
LEAD AND HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
CAMCHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
REMOVING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
CHECKING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
CHECKING THE CAMSHAFT SPROCKETS
AND TIMING CHAIN GUIDES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
CHECKING THE TIMING CHAIN TENSIONER . . . . . . . . . . . . . . . . . 4-13
INSTALLING THE CAMSHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

REMOVING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
CHECKING THE VALVES AND VALVE GUIDES . . . . . . . . . . . . . . . . 4-23
CHECKING THE VALVE SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
CHECKING THE VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
CHECKING THE VALVE LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
INSTALLING THE VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
PICKUP COIL AND PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . . 4-31

REMOVING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-33
INSTALLING THE PICKUP COIL ROTOR . . . . . . . . . . . . . . . . . . . . . . 4-33
STARTER CLUTCH AND GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

REMOVING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
REMOVING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
CHECKING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
INSTALLING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-39
INSTALLING THE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
CHECKING THE STOPPER LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
ENG
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
CHECKING THE PRESSURE PLATE . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
CHECKING THE PULL LEVER SHAFT AND PULL ROD . . . . . . . . . 4-50
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51
OIL PAN AND OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53

REMOVING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
CHECKING THE RELIEF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
CHECKING THE OIL DELIVERY PIPE AND OIL PIPE . . . . . . . . . . . 4-57
CHECKING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
CHECKING THE OIL NOZZLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
ASSEMBLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
INSTALLING THE OIL STRAINER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
INSTALLING THE OIL PAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
OIL BAFFLE PLATES AND OIL FILTER BOLT . . . . . . . . . . . . . . . . . . 4-61
DISASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . 4-63
CHECKING THE SPROCKETS AND CHAINS . . . . . . . . . . . . . . . . . . 4-63
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
CONNECTING RODS AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66

REMOVING THE CONNECTING RODS AND PISTONS . . . . . . . . . 4-68
CHECKING THE CYLINDERS AND PISTONS . . . . . . . . . . . . . . . . . . 4-69
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
CHECKING THE PISTON PINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
CHECKING THE BIG END BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . 4-72
INSTALLING THE PISTONS AND CONNECTING RODS . . . . . . . . 4-74
CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-78
REMOVING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
CHECKING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
CHECKING THE CRANKSHAFT JOURNAL BEARINGS . . . . . . . . . 4-79
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . . . . 4-90
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-90
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91
ENGINE ENG
EAS00190
ENGINE OVERHAUL
ENGINE
DRIVE SPROCKET
10 Nm (1.0 mkg, 7.2 ftlb)
70 Nm (7.0 mkg, 51 ftlb)

Removing the drive sprocket Remove the parts in the order listed.
Reserve tank Refer to “CHANGING THE COOLANT”
1 Locknut 2
2 Shift rod 1
3 Shift arm 1
4 Drive sprocket cover 1
5 Nut 1
6 Lock washer 1
7 Drive sprocket 1
For installation reverse the remove
procedure.
4-1
ENGINE ENG
EXHAUST ASSEMBLY
38 Nm (3.8 mkg, 27 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
20 Nm (2.0 mkg, 14 ftlb)

20 Nm (2.0 mkg, 14 ftlb)

Removing the exhaust assembly Remove the parts in the order listed.
Bottom cowling and side cowlings Refer to “COWLINGS” in chapter 3
Coolant Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Radiator assembly Refer to “RADIATOR” in chapter 5.
1 Muffler 1
2 Exhaust pipe assembly 1
3 Exhaust pipe gasket 4
procedure.
4-2
ENGINE ENG
LEADS AND HOSES

Disconnecting the leads and hoses Disconnect the parts in the order listed.
Fuel tank Refer to “FUEL TANK” in chapter 3.
Air filter case Refer to “AIR FILTER CASE AND
IGNITION COILS” in chapter 3.
Carburetor assembly and joints Refer to “CARBURETORS” in chapter 6.
Engine oil and oil filter cartridge Drain.
Refer to “CHANGING THE ENGINE OIL”
in chapter 3.
Oil cooler Refer to “OIL COOLER” in chapter 5.
4-3
ENGINE ENG

1 Battery negative lead 1
2 Battery positive lead 1 CAUTION:
First, disconect the negative lead, then
the positive lead.
3 Startor coil assembly coupler 1
4 Pickup coil coupler 1
5 Engine earth 1
6 Clutch wire and holder 1
7 Crankcase breather hose 1
8 Separator 1
For connecting reverse the discomecting
procedure.
4-4
ENGINE ENG
ENGINE
24 Nm (2.4 mkg, 17 ftlb)
45 Nm (4.5 mkg, 33 ftlb)
55 Nm (5.5 mkg,
40 ftlb)
38 Nm (3.8 mkg,
27 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)

55 Nm (5.5 mkg,
40 ftlb)
24 Nm (2.4 mkg, 17 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)

Removing the engine Remove The Parts In The Order Listed.
NOTE:
Place a suitable stand under the frame and
engine.
1 Pinch bolts 4
2 Button head bolts 2
3 Collars 2
4 Front mounting bolts 2 Refer to “INSTALLING THE ENGINE”.
5 Collars 2
6 Rear mounting bolts 2
7 Engine mounting adjust bolts 2
NOTE:
Use the point shaft wrench to loosen the
engine mounting adjust bolt.
For Installation, Reverse The Removal

Procedure.
4-5
ENGINE ENG
EAS00192
INSTALLING THE ENGINE

1. Install:
engine mounting adjust bolts 1
rear mounting bolts 2
self-locking nuts 3
collars 4
front mounting bolts 5
collars 6
button head bolts 7
pinch bolts 8
NOTE:
Lubricate the rear mounting bolt threads with
lithium soap base grease.
Do not fully tighten the nuts and bolts.
2. Tighten:
self-locking nut 45 Nm (4.5 mkg, 33 ftlb)
front mounting bolts
55 Nm (5.5 mkg, 40 ftlb)
button head bolt
38 Nm (3.8 mkg, 27 ftlb)
pinch bolt M8 24 Nm (2.4 mkg, 17 ftlb)
M6 13 Nm (1.3 mkg, 9.4 ftlb)
engine adjusting bolts
NOTE:
Use the pivot shaft wrench 1 to tighten the en-
gine mounting adjust bolt to finger tightness.
Pivot shaft wrench

90890-01471
3. Install:
drive sprocket 70 Nm (7.0 mkg, 51 ftlb)
4. Install:
drive sprocket cover
10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
Refer to “CABLE ROUTING” in chapter 2.
5. Install:
shift arm 1 10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
Align the punch mark a in the shift shaft with
the slot in the shift arm.
4-6
CAMSHAFTS ENG
EAS00194
CAMSHAFTS
CYLINDER HEAD COVER
13 Nm (1.3 mkg, 9.4 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)

Removing the cylinder head cover Remove the parts in the order listed.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Radiator assembly Refer to “RADIATOR” in chapter 5.
1 Spark plugs 4
2 Cylinder head cover 1
3 Cylinder head cover gasket 1
4 Timing chain guide (top side) 1
procedure.
4-7
CAMSHAFTS ENG
EAS00196
CAMSHAFTS
10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)
12 Nm (1.2 mkg,
8.7 ftlb)
24 Nm (2.4 mkg, 17 ftlb)

Removing the camshafts Remove the parts in the order listed.
Pickup coil rotor cover Refer to “PICKUP COIL AND PICK UP
COIL COVER”.
1 Timing chain tensioner 1
2 Timing chain tensioner gasket 1 Refer to “REMOVING/INSTALLING
3 Camshaft cap 1 THE CAMSHAFTS”.
NOTE:
4 Camshaft cap gasket 4
5 Dowel pin 2 During removal, the dowel pins may still
be connected to the camshaft cap.
6 Intake camshaft 1
7 Exahust camshaft 1 Refer to “REMOVING/INSTALLING
8 Timing chain guide (exhaust side) 1 THE CAMSHAFT”.
4-8
CAMSHAFTS ENG
10 Nm (1.0 mkg, 7.2 ftlb)

10 Nm (1.0 mkg, 7.2 ftlb)
12 Nm (1.2 mkg,
8.7 ftlb)
24 Nm (2.4 mkg, 17 ftlb)

9 Intake camshaft sproket 1
10 Exhaust camshaft sproket 1 Refer to “INSTALLING THE
11 Pin 1 CAMSHAFTS”.
12 Timing chain guide (intake side) 1
procedure.
4-9
CAMSHAFTS ENG
EAS00198
REMOVING THE CAMSHAFTS

1. Align:
TDC mark on the pickup coil rotor (with the
crankcase mating surface)

sion stroke, align the 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.
2. Remove:
3. Remove:
camshaft cap
dowel pins
CAUTION:
To prevent damage to the cylinder head,
camshafts or camshaft cap, loosen the cam-
shaft cap bolts in stages and in a crisscross
pattern, working from the outside in.
4. Remove:
intake camshaft 1
exhaust camshaft 2
NOTE:
To prevent the timing chain from falling into the
crankcase, fasten it with a wire 3 .
5. Remove:
4-10
CAMSHAFTS ENG
EAS00204
CHECKING THE CAMSHAFTS

1. Check:
camshaft lobes
Blue discoloration/pitting/scratches Re-
place the camshaft.
2. Measure:
camshaft lobe dimensions a and b
Out of specification Replace the cam-
shaft.
Camshaft lobe dimensions limit

Intake camshaft
a 33.0 mm (1.3 in)
b 25.09 mm (0.99 in)
Exhaust camshaft
a 32.50 mm (1.28 in)
b 25.02 mm (0.99 in)
3. Measure:
camshaft runout
Out of specification Replace.
Max. camshaft runout

0.06 mm (0.0024 in)
4. Measure:
camshaft-journal-to-camshaft-cap clear-
ance
Out of specification Measure the cam-
shaft journal diameter.
Camshaft-journal-to-camshaftcap
clearance
0.020 0.054 mm
(0.0008 0.0021 in)
<Limit>: 0.08 mm (0.0031 in)
a. Install the camshaft into the cylinder head

(without the dowel pins and camshaft caps).
b. Position a strip of Plastigauge 1 onto the
camshaft journal as shown.
c. Install the dowel pins and camshaft caps.
4-11
CAMSHAFTS ENG
NOTE:
Tighten the camshaft cap bolts in stages and in
a crisscross pattern, working from the inner
caps out.
Do not turn the camshaft when measuring the
camshaft-journal-to-camshaft-cap clearance
with the Plastigauge.
Camshaft cap bolt

10 Nm (1.0 mkg, 7.2 ftlb)
d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge 1 .
5. Measure:
camshaft journal diameter a
Out of specification Replace the cam-
shaft.
Within specification Replace the cylinder
head and the camshaft caps as a set.
Camshaft journal diameter

22.967 22.980 mm
(0.9042 0.9047 in)
EAS00208
CHECKING THE CAMSHAFT SPROCKETS,

AND TIMING CHAIN GUIDES
camshaft sprockets and timing chain guides.
4-12
CAMSHAFTS ENG
1. Check:
camshaft sprocket
More than 1/4 tooth wear a Replace the
camshaft sprockets and the timing chain as a
set.
a 1 / 4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
2. Check:
timing chain guide (exhaust side) 1
timing chain guide (intake side) 2
timing chain guide (top side) 3
Damage/wear Replace the defective
part(-s).
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
Cracks/damage/rough movement Re-
place.
a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver 1 until
it stops.
b. Remove the screwdriver and slowly release

the timing chain tensioner rod.
c. Make sure that the timing chain tensioner rod
comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.
4-13
CAMSHAFTS ENG
INSTALLING THE CAMSHAFTS

1. Install:
timing chain guide (intake side)
2. Install:
intake camshaft sprocket
24 Nm (2.4 mkg, 17 ftlb)
exhaust camshaft sprocket
24 Nm (2.4 mkg, 17 ftlb)
NOTE:
Cam sprocket timing mark is outside and align
the cam sprocket hole to camshaft hole.
3. Install:
exhaust camshaft 3
intake camshaft 2
camshaft cap gasket
camshaft cap
NOTE:
The brim 1 of intake camshaft is not pro-
cessed.
The groove is processed around the brim 1 of
exhaust camshaft as illustration.

sion stroke, align the a mark on the pickup
coil rotor with the crankcase mating surface
b.
c. Install the timing chain onto both camshaft
sprockets and then install the camshaft
sprockets onto the camshafts.
CAUTION:
Do not turn the crankshaft when installing
the camshaft to avoid damage or improper
valve timing.
d. Install the exhaust and intake camshaft cap.
Camshaft cap bolt

10 Nm (1.0 mkg, 7.2 ftlb)
4-14
CAMSHAFTS ENG
NOTE:
Make sure that the camshaft sprocket timing
marks c are aligned with the cylinder head
edge d
Out of alignment Reinstall.
e. Remove the wire from the timing chain.
4. Install:
a. Lightly press the timing chain tensioner rod

into the timing chain tensioner housing by
hand.
b. While pressing the timing chain tensioner
rod, wind it clockwise with a thin screwdriver
1 until if stops.
C. With the screwdriver still inserted into the
timing chain tensioner, install the timing
chain tensioner 2 , gasket, and float cham-
ber air vent hose holder 3 onto the cylinder
block. Then, tighten the timing chain tension-
er bolts 4 to the specified torque.
WARNING
Always use a new gasket.
NOTE:
The “UP” mark on the timing chain tensioner
should face up.
Timing chain tensioner bolt

12 Nm (1.2 mkg, 8.7 ftlb)
d. Remove the screwdriver, make sure that the

timing chain tensioner rod releases, and
tighten the cap bolt to the specified torque.
Cap bolt
10 Nm (1.0 mkg, 7.2 ftlb)
5. Turn:
crankshaft (several turns counterclockwise)
4-15
CAMSHAFTS ENG
6. Check:
TDC mark a
Make sure that the TDC mark is aligned with
the crankcase mating surface b .
camshaft sprocket timing mark c
Make sure that the camshaft sprocket timing
mark is aligned with the cylinder head edge
d
Out of alignment Adjust.
Refer to the installation steps above.
7. Measure:
valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” in chapter 3.
8. Install:
cylinder head cover gasket
cylinder head cover
NOTE:
Apply bond TB1541 onto the mating surfaces
of the cylinder head cover and cylinder head
cover gasket.
Apply bond 1215B onto the mating surfaces of
the cylinder head cover gasket and cylinder
head.
Tighten the cylinder head cover bolts in stages
and in a crisscross pattern.
4-16
CYLINDER HEAD ENG
EAS00220
CYLINDER HEAD
51 Nm (5.1 mkg, 37 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)

Removing the cylinder head Remove the parts in the order listed.
Intake and exhaust camshafts Refer to “CAMSHAFTS”.
Water hose Disconnect
Temp senser lead Disconnect
Front mounting bolt Refer to “ENGINE”.
1 Cylinder head 1 Refer to “REMOVING/INSTALLING THE
CYLINDER HEAD”.
2 Cylinder head gasket 1
3 Dowel pin 2
procedure.
4-17
CYLINDER HEAD ENG
EAS00223
REMOVING THE CYLINDER HEAD

1. Remove:
cylinder head bolts
cylinder head
NOTE:
Loosen each bolt and nut 1/2 of a turn at a time,
in stages and in a crisscross pattern. After all of
the bolts and nuts are fully loosened, remove
them.
EAS00229
CHECKING THE CYLINDER HEAD

1. Eliminate:
combustion chamber carbon deposits (with
a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
spark plug bore threads
valve seats
2. Check:
cylinder head
cylinder head water jacket
Mineral deposits/rust Eliminate.
3. Measure:
cylinder head warpage
Out of specification Resurface the cylin-
der head.
Max. cylinder head warpage

0.05 mm (0.002 in)
a. Place a straightedge 1 and a thickness

gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limited in exceeded, resurface the cyl-
inder head as follows.
4-18
CYLINDER HEAD ENG
d. Place a 400 600 grit wet sandpaper on the

surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
EAS00223
INSTALLING THE CYLINDER HEAD

1. Install:
cylinder head gasket
cylinder head
cylinder headbolt
(M10) 51 Nm (5.1 mkg, 37 ftlb)
(M6) 10 Nm (1.0 mkg, 7.2 ftlb)
NOTE:
Lubricate the cylinder head nuts with engine
oil.
Tighten the cylinder head nuts and bolts in two
stages and in a crisscross pattern.
4-19
VALVES AND VALVE SPRINGS ENG
EAS00236
VALVES AND VALVE SPRINGS

Removing the valves and valve Remove the parts in the order listed.
springs
Cylinder head Refer to “CYLINDER HEAD”.
1 Intake valve lifter 8
2 Intake valve pad 8
3 Intake valve cotter 16
4 Intake valve upper spring seat 8
5 Intake valve spring outer 8 Refer to “REMOVING/INSTALLING
6 Intake valve spring inner 8 THE VALVES”.
7 Intake valve oil seal 8
8 Intake valve lower spring seat 8
9 Intake valve 8
10 Intake valve guide 8
4-20

11 Exhaust valve lifter 8
12 Exhaust valve pad 8
13 Exhaust valve cotter 16
Refer to “REMOVING/INSTALLING THE
14 Exhaust valve upper spring seat 8
VALVES”.
15 Exhaust valve spring 8
16 Exhaust valve oil seal 8
17 Exhaust valve lower spring seat 8
18 Exhaust valve 8
19 Exhaust valve guide 8
procedure.
4-21
EAS00237
REMOVING THE VALVES

valves and related components.
NOTE:
Before removing the internal parts of the cylin-
der head (e.g., valves, valve springs, valve
seats), make sure that the valves properly seal.
1. Remove:
valve lifter 1
valve pad 2
NOTE:
Make a note of the position of each valve lifter
and valve pad so that they can be reinstalled in
their original place.
2. Check:
valve
(for leakage)
Leakage at the valve seat Check the valve
face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
a. Pour a clean solvent a into the intake and

exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
1.
4-22
3. Remove:
valve cotters 1
NOTE:
Remove the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
Valve spring compressor

90890-04019, YM-04019
Attachment
90890-04114, YM-01253-1
4. Remove:
upper spring seat 1
valve spring outer 2
valve spring inner (intake only) 3
valve 4
oil seal 5
lower spring seat 6
NOTE:
Identify the position of each part very carefully
so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE

GUIDES
valves and valve guides.
1. Measure:
valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification Replace the valve

guide.
Valve-stem-to-valve-guide clea-
rance
Intake
0.010 0.037 mm
(0.0004 0.0015 in)
<Limit> : 0.08 mm (0.0031 in)
Exhaust
0.025 0.052 mm
(0.001 0.002 in)
<Limit>: 0.1 mm (0.0039 in)
4-23
2. Replace:
S valve guide
NOTE:
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100_C (212_F) in an oven.
a. Remove the valve guide with a valve guide

remover 1 .
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with a valve guide reamer 3 to
obtain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat .
Valve guide remover

(4.0 mm, 0.16 in)
90890-04111
Valve guide installer
(4.0 mm, 0.16 in)
90890-04112
Valve guide reamer
(4.0 mm, 0.16 in)
90890-04113
3. Eliminate:
S carbon deposits
(from the valve face and valve seat)
4. Check:
S valve face
Pitting/wear Grind the valve face.
S valve stem end
Mushroom shape or diameter larger than the
body of the valve stem Replace the valve.
4-24
5. Measure:
valve margin thickness a
Out of specification Replace the valve.
Valve margin thickness

0.6 mm 0.8 mm
(0.0236 0.0315 in)
<LIMIT>: 0.5 mm (0.02 in)
6. Measure:
valve stem runout
Out of specification Replace the valve.
NOTE:
When installing a new valve, always replace
the valve guide.
If the valve is removed or replaced, always re-
place the oil seal.
Valve stem runout

0.04 mm (0.0016 in)
EAS00240
CHECKING THE VALVE SEATS

valves and valve seats.
1. Eliminate:
carbon deposits
(from the valve face and valve seat)
2. Check:
valve seat
Pitting/wear Replace the cylinder head.
3. Measure:
valve seat width a
Out of specification Replace the cylinder
head.
Valve seat width

Intake: 0.9 1.1 mm
(0.0354 0.0433 in)
<Limit>: 1.6 mm (0.06 in)
4-25
a. Apply Mechanic’s blueing dye (Dykem) b

onto the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been re-
moved.
4. Lap:
valve face
valve seat
NOTE:
After replacing the cylinder head or replacing
the valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound a to the

valve face.
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
the lapping compound.
NOTE:
For the best lapping results, lightly tap the valve
seat while rotating the valve back and forth be-
tween your hand.
4-26
e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width c again. If the
valve seat width is out of specification, reface
and lap the valve seat.
EAS00241
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
valve spring free length a
spring.
Valve spring free length

Intake valve spring (inner)
37.0 mm (1.46 in)
<Limit>: 35mm (1.38 in)
Intake valve spring (outer)
38.4 mm (1.51 in)
<Limit>: 36.5mm (1.44 in)
Exhaust valve spring
41.7 mm (1.64 in)
<Limit>: 39.5mm (1.56 in)
4-27
2. Measure:
S compressed spring force a
spring.
b Installed length
Compressed spring force
(installed)
Intake valve spring inner
69 79 N (15.51 17.76 lb,
7.04 8.06 kg) at 30.0 mm
(1.18 in)
Intake valve spring outer
114 132 N (25.63 29.67 lb,
11.62 13.46 kg) at 32.5 mm
(1.28 in)
160 184 N (35.97 41.36 lb,
16.32 18.76 kg) at 36.1 mm
(1.42 in)
3. Measure:
S valve spring tilt a
spring.
Max. Spring tilt
Intake valve spring inner
2.5_/1.6 mm (0.06 in)
Intake valve spring outer
2.5_/1.7 mm (0.07 in)
2.5_/1.8 mm (0.07 in)
EAS00242
CHECKING THE VALVE LIFTERS

valve lifters.
1. Check:
S valve lifter
Damage/scratches Replace the valve lift-
ers and cylinder head.
EAS00247
INSTALLING THE VALVES

valves and related components.
1. Deburr:
S valve stem end
(with an oil stone)
2. Lubricate:
S valve stem 1
S oil seal 2
(with the recommended lubricant)
Molybdenum disulfide oil
4-28
3. Install:
lower spring seat 6
oil seal 5 New
valve 4
valve spring inner (intake only) 3
valve spring outer 2
upper spring seat 1
(into the cylinder head)
NOTE:
Make sure that each valve is installed in its
original place. Refer to the following em-
bossed marks.
Install the valve spring with the larger pitch a
facing up.
b Smaller pitch
4. Install:
valve cotters 1
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
2 and attachment 3 .
Valve spring compressor

90890-04019, YM-04019
Attachment
90890-04114, YM-01253-1
5. To secure the valve cotters 1 onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
4-29
6. Lubricate:
valve pad
Molybdenum disulfide oil
7. Install:
valve pad
valve lifter
NOTE:
The valve lifter must move smoothly when ro-
tated with a finger.
Each valve lifter and valve pad must be rein-
stalled in its original position.
4-30
PICKUP COIL AND PICKUP COIL ROTOR ENG
PICKUP COIL AND PICKUP COIL ROTOR
10 Nm (1.0 mkg, 7.2 ftlb)
15 Nm (1.5 mkg, 11 ftlb)
35 Nm (3.5 mkg, 25 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)

Removing the pickup coil and Remove the parts in the order listed.
pickup coil rotor
Riders seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Bottom cowling and right side Refer to “COWLINGS” in chapter 3.
cowling
Engine oil Drain.
in chapter 3.
Generator cover Refer to “STARTER CLUTCH AND
GENERATOR”.
4-31
PICKUP COIL AND PICKUP COIL ROTOR ENG
10 Nm (1.0 mkg, 7.2 ftlb)
15 Nm (1.5 mkg, 11 ftlb)
35 Nm (3.5 mkg, 25 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)

1 Clutch cable 1
2 Clutch cable holder 1
3 Pickup coil coupler 1 Disconnect
4 Pickup coil cover 1
5 Pickup coil cover gasket 1
6 Dowel pin 2 Refer to “REMOVING/INSTALLING
7 Pickup coil 1 THE PICKUP COIL ROTOR”.
8 Pickup rotor 1
procedure.
4-32
PICKUP COIL AND PICKUP ROTOR ENG
REMOVING THE PICKUP COIL ROTOR

1. Remove:
clutch cable holder 1
pickup coil cover 2
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
2. Remove:
pickup coil rotor bolt 1
plain washer 2
pickup coil rotor 3
NOTE:
While holding the generator rotor 4 with the ro-
tor holding tool 5 , loosen the pickup coil rotor
bolt.
Sheave holder
90890-01701, YS-01880
INSTALLING THE PICKUP COIL ROTOR

1. Install:
pickup coil rotor 1
plain washer
pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor, align the
pin 2 in the crankshaft sprocket with the
groove a in the pickup coil rotor.
4-33
PICKUP COIL AND PICKUP ROTOR ENG
2. Tighten:
pickup coil rotor bolt 1
35 Nm (3.5 mkg, 25 ftlb)
NOTE:
While holding the generator rotor 2 with the
sheave holder 3 , tighten the pickup coil rotor
bolt.
Sheave holder
90890-01701, YS-01880
3. Apply:
sealant
(onto the pickup coil lead grommet)
Yamaha bond No.1215

90890-85505, ACC-1100-15-01
4. Install:
pickup coil cover
clutch cable holder
NOTE:
When installing the pickup coil cover, align the
timing chain guide (intake side) pin 1 of the
with the hole 2 in the pickup coil cover.
Tighten the pickup coil cover bolts in stages
4-34
STARTER CLUTCH AND GENERATOR ENG
EAS00341
STARTER CLUTCH AND GENERATOR
65 Nm (6.5 mkg, 47 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)

Removing the starter clutch and gener- Remove the parts in the order listed.
ator
Riders seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Buttom and left side cowlings Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
in chapter 3.
Coolant treserver Drain.
chapter 3.
1 Stator coil assembly coupler 1 Disconnect.
2 Generator cover 1 Refer to “REMOVING/INSTALLING
THE GENERATOR”.
3 Generator rotor cover gasket 1
4 Dowel pin 2
5 Stator coil assembly lead holder 1
6 Stator coil assembly 1
4-35
65 Nm (6.5 mkg, 47 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb) 10 Nm (1.0 mkg, 7.2 ftlb)

7 Generator rotor bolt 1
8 Plain washer 1 Refer to “REMOVING/INSTALLING
9 Generator rotor 1 THE GENERATOR”.
10 Starter one-way assy 1
11 Idler gear shaft 1
12 Idler hear 1
13 Starter clutch gear 1
proceduer.
4-36
EAS00346
REMOVING THE GENERATOR

1. Remove:
generator rotor cover 1
NOTE:
2. Remove:
generator rotor bolt 1
Plain washer
NOTE:
sheave holder 3 , loosen the generator rotor
bolt.
Do not allow the sheave holder to touch the pro-
jection on the generator rotor.
Sheave holder
90890-01701, YS-01880
3. Remove:
generator rotor 1
(with the flywheel puller 2 and adapter 3 )
Flywheel puller
90890-01362, YU-33270
Flywheel puller attachment
90890-04089, YM-33282
4-37
EAS00345
REMOVING THE STARTER CLUTCH

1. Remove:
Generator
Starter one-way assy 1
Idler gear shaft 2
Idler gear 3
Starter clutch gear 4
EAS00351
CHECKING THE STARTER CLUTCH

1. Check:
Starter one-way assy
Damage/wear Replace.
2. Check:
Idler gear
Idler gear shaft
starter clutch gear
Pitting/Burrs/chips/roughness/wear Re-
place the defective parts.
3. Check:
Starter clutch operation
a. Install the starter clutch gear 1 onto the

starter clutch 2 and hold the starter clutch.
b. When turning the starter clutch drive gear
clockwise A , the starter clutch and the start-
er clutch gear should engage.
If the starter clutch gear and starter clutch do
not engage, the starter clutch is faulty and
must be replaced.
c. When turning the starter clutch drive gear
counterclockwise B , it should turn freely. If
the starter clutch drive gear does not turn
freely, the starter clutch is faulty and must be
replaced.
4-38
EAS00355
INSTALLING THE STARTER CLUTCH

1. Install:
starter clutch gear 1
idler gear 2
idler gear shaft 3
startor one-way assy 4
EAS00354
INSTALLING THE GENERATOR

1. Install:
generator rotor 1
washer 2
NOTE:
Clean the tapered portion of the crankshaft and
the generator rotor hub with lacquer tinner.
2. Tighten:
65 Nm (6.5 mkg, 47 ftlb)
NOTE:
sheave holder 3 , tighten the generator rotor
bolt.
Do not allow the sheave holder to touch the pro-
jection on the generator rotor.
Sheave holder
90890-01701, YS-01880
3. Apply:
sealant
(onto the stator coil assembly lead grommet)
Yamaha bond No.1215

90890-85505, ACC-1100-15-01
4. Install:
stator coil
5. Install:
generator rotor cover
NOTE:
Tighten the generator rotor cover bolts in stages
4-39
SHIFT SHAFT ENG
EAS00327
SHIFT SHAFT
22 Nm (2.2 mkg, 16 ftlb)

Removing the shift shaft Remove the parts in the order listed.
Coolant reserver Drain.
chapter 3.
Drive sprocket cover, sift rod and sift Refer to “ENGINE”.
arm.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3 Dowel pin 2
4 Oil seal 1
5 Sift shaft 1 Refer to “INSTALLING THE SHIFT
SHAFT”.
4-40
SHIFT SHAFT ENG
22 Nm (2.2 mkg, 16 ftlb)

6 Shift shaft spring 1
7 Collar 1
8 Stopper lever spring 1
9 Circrip 1
10 Washer 1
11 Stopper lever 1
12 Collar 1 Refer to “INSTALLING THE SHIFT
13 Washer 1 SHAFT”.
14 Shift shaft spring stopper 1
procedure.
4-41
SHIFT SHAFT ENG
EAS00329
CHECKING THE SHIFT SHAFT

1. Check:
shift shaft 1
Bends/damage/wear Replace.
shift shaft spring 2
EAS00330
CHECKING THE STOPPER LEVER

1. Check:
stopper lever 1
Bends/damage Replace.
Roller turns roughly Replace the stopper
lever.
EAS00334
INSTALLING THE SHIFT SHAFT

1. Install:
shift shaft spring stopper 1
22 Nm (2.2 mkg, 16 ftlb)
stopper lever spring 2
washer
stopper lever 3
NOTE:
Apply LOCTITE to the threads of the shift
shaft spring stopper.
Hook the ends of the stopper lever spring onto
the stopper lever and the crankcase boss.
Mesh the stopper lever with the shift drum seg-
ment assembly.
2. Install:
shift shaft 1
collor
NOTE:
Lubricate the oil seal lips with lithium soap
base grease.
Install the end of the shift shaft spring onto the
shift shaft spring stopper 2
4-42
CLUTCH ENG
EB405000
CLUTCH
CLUTCH COVER
12 Nm (1.2 mkg, 8.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)

Removing the clutch cover Remove the parts in the order listed.
Bottom cowing and right side cowling Refer to “COWLINGS” in chapter 3.
Engine oil Drain.
in chapter 3.
Coolant Drain.
chapter 3.
1 Therm bypass hose 1
2 Clutch cable 1
4-43
CLUTCH ENG
12 Nm (1.2 mkg, 8.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)

3 Clutch cover 1 Refer to “REMOVING/INSTALLING
THE CLUTCH”.
4 Clutch cover gasket 1
5 Dowel pin 2
procedure.
4-44
CLUTCH ENG

Disassembling the clutch cover Disassemble the parts in the order listed.
assembly
1 Circlip 2
2 Plain washer 2
3 Pull lever 1 Refer to “INSTALLING THE CLUTCH”.
4 Pull lever spring 1
5 Oil seal 1
6 Bearing 2
For assembly, reverse the disassembly
procedure.
4-45
CLUTCH ENG
CLUTCH
70 Nm (7.0 mkg, 51 ftlb)
8 Nm (0.8 mkg, 5.8 ftlb)

Removing the clutch Remove the parts in the order listed.
1 Compression spling 6
2 Pressure plate 1
3 Pull rod 1
Refer to “INSTALLING THE CLUTCH”.
4 Bearing 1
5 Friction plate 8
6 Clutch plate 7
7 Clutch plate 1 Refer to“REMOVING/INSTALLING
8 Clutch boss nut 1 THE CLUTCH”.
9 Look washer 1
10 Clutch boss 1
4-46
CLUTCH ENG
70 Nm (7.0 mkg, 51 ftlb)
8 Nm (0.8 mkg, 5.8 ftlb)

11 Thrust plate 1
procedure.
4-47
CLUTCH ENG
EAS00277
REMOVING THE CLUTCH

1. Remove:
clutch cover 1
NOTE:
After all of the bolts are fully loosened, remove
them.
Pressure plate
Fricttion and clutch plates
2. Straighten the lock washer tab.
3. Loosen:
clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the clutch
holding tool 3 , loosen the clutch boss nut.
Clutch holding tool

90890-04086, YM-91042
4. Remove:
clutch boss nut 1
lock washer 2
clutch boss 3
thrust plate 4
EAS00280
CHECKING THE FRICTION PLATES

The following procedure applies to all of the fric-
tion plates.
1. Check:
friction plate
Damage/wear Replace the friction plates
as a set.
2. Measure:
friction plate thickness
Out of specification Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness

2.9 3.1 mm (0.114 0.122 in)
<Limit>: 2.8 mm (0.11 in)
4-48
CLUTCH ENG
EAS00281
CHECKING THE CLUTCH PLATES

clutch plates.
1. Check:
clutch plate
Damage Replace the clutch plates as a
set.
2. Measure:
clutch plate warpage
(with a surface plate and thickness gauge
1)
Out of specification Replace the clutch
plates as a set.
Max. clutch plate warpage

0.1 mm (0.0039 in)
EAS00282
CHECKING THE CLUTCH SPRINGS

clutch springs.
1. Check:
clutch spring
Damage Replace the clutch springs as a
set.
2. Measure:
clutch spring free length a
Out of specification Replace the clutch
springs as a set.
Clutch spring free length
Clutch spring free length

55 mm (2.17 in)
<Limit>: 54 mm (2.13 in)
EAS00284
CHECKING THE CLUTCH HOUSING

1. Check:
clutch housing dogs
Damage/pitting/wear Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause er-
ratic clutch operation.
2. Check:
bearing
Damage/wear Replace the clutch hous-
ing.
4-49
CLUTCH ENG
EAS00285
CHECKING THE CLUTCH BOSS

1. Check:
clutch boss splines
Damage/pitting/wear Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS00286
CHECKING THE PRESSURE PLATE

1. Check:
pressure plate 1
bearing 2
EAS00287
CHECKING THE PULL LEVER SHAFT AND

PULL ROD
1. Check:
pull lever shaft pinion gear teeth a
pull rod teeth b
Damage/wear Replace the pull rod and
pull lever shaft as a set.
2. Check:
pull rod bearing
4-50
CLUTCH ENG
EAS00296
INSTALLING THE CLUTCH

1. Install:
thrust plate 1
clutch boss 2
2. Install:
lock washer 3 New
clutch boss nut 4
70 Nm (7.0 mkg, 51 ftlb)
NOTE:
While holding the clutch boss 2 with the clutch
holding tool 5 , tighten the clutch boss nut.
Clutch holding tool

90890-04086, YM-91042
3. Bend the lock washer tab along a flat side of

the nut.
4. Lubricate:
friction plates
clutch plates
Engine oil
5. Install:
friction plates
clutch plates
NOTE:
First, install a friction plate and then alternate
between a clutch plate and a friction plate.
6. Install:
washer
bearing 1
pull rod 2
NOTE:
Install the pull rod so that the teeth a face to-
wards the rear of the motorcycle. Then, install
the clutch cover.
Tighten the clutch cover bolts in stages and in a
crisscross pattern.
Apply oil onto the bearing.
Apply molybdenum disulfide grease onto the
pull rod.
4-51
CLUTCH ENG
7. Install:
pressure plate 1
clutch springs
clutch spring bolts
8 Nm (0.8 mkg, 5.8 ftlb)
NOTE:
Tighten the clutch spring bolts in stages and in a
criss cross pattern.
Align the punch mark b in the pressure plate
with the punch mark a in the clutch boss.
8. Install:
clutch cover 12 Nm (1.2 mkg, 8.7 ftlb)
NOTE:
When installing the clutch cover, push the pull
lever and check that the punch mark a on the
pull lever aligns with the mark b on the clutch
cover. Make sure that the pull rod teeth and
pull lever shaft pinion gear are engaged.
Tighten the clutch cover bolts in stages and in
a crisscross pattern.
4-52
OIL PAN AND OIL PUMP ENG
EAS00356
OIL PAN AND OIL PUMP
10 Nm (1.0 mkg, 7.2 ftlb)
43 Nm
12 Nm (1.2 mkg, (4.3 mkg,
8.7 ftlb) 31 ftlb)
10 Nm (1.0 mkg,
7.2 ftlb)

Removing the oil pan and oil pump Remove the parts in the order listed.
Engine oil Drain.
in chapter 3.
Coolant Drain.
chapter 3.
Radiator assembly and water pump Refer to “RADIATOR” and “WATER
assembly PUMP” in chapter 5.
Exhaust pipe assembly Refer to “ENGINE”.
1 Oil level switch couplar 1 Disconnect.
2 Oil level switch 1
4-53
10 Nm (1.0 mkg, 7.2 ftlb)
43 Nm
12 Nm (1.2 mkg, (4.3 mkg,
8.7 ftlb) 31 ftlb)
10 Nm (1.0 mkg,
7.2 ftlb)

3 Oil level switch lead holder 1
4 Oil pan 1 Refer to “REMOVEING/INSTALLING
5 Oil pan gasket 1 THE OIL PAN.
6 Dowel pin 2
7 Oil strainer 1 Refer to “INSTALLING THE OIL
STRAINER”.
8 Oil pipe 1
9 Oil delivery pipe 1
10 Gear cover 1
11 Dowel pin 2 Refer to “INSTALLING THE OIL PUMP”.
12 Oil pump assembly 1
13 Relief valve assembly 1
procedure.
4-54
EB411010
OIL PUMP
12 Nm (1.2 mkg, 8.7 ftlb)

Disassemblying the oil pump Disassemble the parts in the order listed.
assembly
1 Oil pump rotor housing 1
2 Dowel pin 2
3 Oil pump inner rotor 1
4 Oil pump outer rotor 1
5 Dowel pin 1
6 Washer 1
7 Oil pump cover 1
8 Driver gear 1
For assembly reverse the disassembly
procedure.
4-55
EAS00362
REMOVING THE OIL PAN

1. Remove:
oil level switch 1
oil pan 2
oil pan gasket
dowel pins
NOTE:
After all of the bolts are fully loosened, remove
them.
EAS00364
CHECKING THE OIL PUMP

1. Check:
oil/pump driven gear 1
rotor housing 2
Cracks/damage/wear Replace the defec-
tive part(-s).
2. Measure:
inner-rotor-to-outer-rotor-tip clearance a
outer-rotor-to-oil-pump-cover clearance b
Out of specification Replace the oil pump.
1 Inner rotor
2 Outer rotor
3 Oil pump cover
Inner-rotor-to-outer-rotor-tip
clearance
0.03 0.09 mm
(0.0012 0.0035 in)
<Limit>: 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-cover
clearance
0.03 0.08 mm
(0.0012 0.0031 in)
<Limit>: 0.15 mm (0.0059 in)
4-56
3. Check:
oil pump operation
Unsmooth Repair or replace the defective
part(-s).
EAS00365
CHECKING THE RELIEF VALVE

1. Check:
relief valve body 1
relief valve 2
spring 3
O-ring 4
part(-s).
EAS00367
CHECKING THE OIL DELIVERY PIPE AND

OIL PIPE
1. Check:
oil delivery pipe 1
oil pipe 2
Damage Replace.
Obstruction Wash and blow out with com-
pressed air.
EAS00368
CHECKING THE OIL STRAINER

1. Check:
oil strainer 1
Damage Replace.
Contaminants Clean with engine oil.
EAS00373
CHECKING THE OIL NOZZLES

The following procedure applies to all of the oil
nozzles.
1. Check:
oil nozzle 1
O-ring 2
Damage/wear Replace the oil nozzle.
oil nozzle passage
Obstruction Blow out with compressed air.
4-57
EAS00375
ASSEMBLING THE OIL PUMP

1. Lubricate:
inner rotor
outer rotor
impeller shaft
Engine oil
2. Check:
oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP

1. Install:
oil pump 1 12 Nm (1.2 mkg, 8.7 ftlb)
NOTE:
Install the oil pump assembly drive chain onto
the oil pump assembly driven sprocket.
EAS00378
INSTALLING THE OIL STRAINER

1. Install:
oil strainer 1
NOTE:
The arrow a on the oil strainer housing must
point towards the front of the engine.
EAS00380
INSTALLING THE OIL PAN

1. Install:
dowel pins
oil pan gasket New
oil pan 1 12 Nm (1.2 mkg, 8.7 ftlb)
oil level switch 2
10 Nm (1.0 mkg, 7.2 ftlb)
engine oil drain bolt 3
43 Nm (4.3 mkg, 31 ftlb)
NOTE:
Tighten the oil pan bolts in stages and in a
crisscross pattern.
Lubricate the oil level switch O-ring with lithium
soap base grease.
4-58
CRANKCASE ENG
CRANKCASE
12 Nm (1.2 mkg, 8.7 ftlb)

Separating the crankcase Remove the parts in the order listed.
Engine Refer to “ENGINE”.
Cylinder head Refer to “CYLINDER HEAD”.
Starter clutch and generator Refer to “STARTER CLUTCH AND
GENERATOR”.
Shift shaft Refer to “SHIFT SHAFT”.
Pickup coil and pickup rotor Refer to “PICKUP COIL AND PICKUP
ROTOR”.
Clutch assembly Refer to ‘‘CLUTCH’’.
Water pump assembly Refer to “WATER PUMP” in chapter 5.
Oil pan and oil pump Refer to “OIL PAN AND OIL PUMP”.
4-59
CRANKCASE ENG
12 Nm (1.2 mkg, 8.7 ftlb)

1 Timing chain 1
2 Oil pump drive chain guide 1
3 Oil pump drive chain 1
4 Lower crankcase 1 Refer to “DISASSEMBLY/ASSEMBLY
THE CRANKCASE”.
5 Dowel pin 3
procedure.
4-60
CRANKCASE ENG
OIL BAFFLE PLATES AND OIL FILTER BOLT
80 Nm (8.0 mkg, 58 ftlb)

12 Nm (1.2 mkg, 8.7 ftlb)
12 Nm (1.2 mkg, 8.7 ftlb)

Removing the oil baffle plates and Remove the parts in the order listed.
oil filter bolt
Transmission Refer to “TRANSMISSION”.
1 Oil baffle plate 1
2 Oil baffle plate 1
3 Oil delivery pipe 1
4 Bearing 1
5 Lower crankcase 1
6 Oil filter bolt 1
7 Upper crankcase 1
For instalation, reverse the removal
procedure.
4-61
CRANKCASE ENG
EAS00384
DISASSEMBLING THE CRANKCASE

1. Place the engine upside down.
NOTE:
Loosen the bolts in decreasing numerical or-
der (refer to the numbers in the illustration).
The numbers embossed on the crankcase in-
dicate the crankcase tightening sequence.
2. Remove:
crankcase bolts
3. Remove:
lower crankcase
CAUTION:
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure that the crankcase halves
separate evenly.
M8 85 mm bolts: 1 X 7 10
M8 115 mm bolts: 8 9
M8 65 mm bolt: 11 12
M6 65 mm bolts: 13 14 17 27
M6 55 mm bolts: 15 22 X 26
M6 45 mm bolt: 16 19 X 21
M6 75 mm bolt: 18
4. Remove:
dowel pins
4-62
CRANKCASE ENG
EAS00399
CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces.
3. Check:
upper crankcase
lower crankcase
oil delivery passages
EAS00401
CHECKING THE BEARINGS AND OIL

SEALS
1. Check:
bearings
Clean and lubricate the bearings, then rotate
the inner race with your finger.
Rough movement Replace.
2. Check:
oil seals
CHECKING THE SPROCKETS AND CHAINS
1. Check:
crankshaft sprocket 1
oil/water pump assembly drive sprocket 2
Cracks/damage/wear Replace the de-
fective part(-s).
2. Check:
timing chain 1
Damage/stiffness Replace the timing
chain and crankshaft sprocket as a set.
oil/water pump assembly drive chain 2
Damage/stiffness Replace the oil/water
pump assembly drive chain and oil/water
pump assembly drive sprocket as a set.
4-63
CRANKCASE ENG
EAS00415
ASSEMBLING THE CRANKCASE

1. Lubricate:
crankshaft journal bearings
Engine oil
2. Apply:
sealant
(onto the crankcase mating surfaces and the
groove a of the oil baffle plate)

90890-85505, ACC-1100-15-01
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings. Do not apply sealant to within 2 3 mm of
the crankshaft journal bearings.
3. Install:
dowel pin
4. Set the shift drum assembly and transmis-

sion gears in the neutral position.
5. Install:
lower crankcase 1
(onto the upper crankcase 2 )
CAUTION:
Before tightening the crankcase bolts, make
sure that the transmission gears shift cor-
rectly when the shift drum assembly is
turned by hand.
4-64
CRANKCASE ENG
6. Install:
crankcase bolts
NOTE:
Lubricate the bolt threads with engine oil.
Install a washer on bolts 1 X 10 .
Install a gasket on bolt 21 .
Not lubricate seal botts 18 12
Tighten the bolts in the tightening sequence
cast on the crankcase.
M8 85 mm bolts: 1 X 7 10
M8 115 mm bolts: 8 9
M8 65 mm bolt: 11 12
M6 65 mm bolts: 13 14 17 27
M6 55 mm bolts: 15 22 X 26
M6 45 mm bolts: 16 19 X 21
M6 75 mm bolts: 18
Bolt 15 X 27
12 Nm (1.2 mkg, 8.7 ftlb)
Bolt 13 X 14
14 Nm (1.4 mkg, 10 ftlb)
Bolt 1 X 12
24 Nm (2.4 mkg, 17 ftlb)
WARNING
Always use new copper washers.
4-65
CONNECTING RODS AND PISTONS ENG
EAS00252
CONNECTING RODS AND PISTONS

15 Nm (1.5 mkg, 11 ftlb)+90

Removing the connecting rods and Remove the parts in the order listed.
pistons
Lower crankcase Separate.
Refer to “CRANKCASE”.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Big end upper bearing 4 Refer to “REMOVING/INSTALLING THE
4 Piston pin clip 8 CONNECTING RODS AND PISTONS”.
5 Piston pin 4
6 Piston 4
7 Connecting rod 4
4-66
15 Nm (1.5 mkg, 11 ftlb)+90

8 Top ring 4
9 2nd ring 4 Refer to “REMOVING/INSTALLING THE
10 Oil ring 4 CONNECTING RODS AND PISTONS”.
procedure.
4-67
EAS00393
REMOVING THE CONNECTING RODS AND

PISTONS
connecting rods and pistons.
1. Remove:
connecting rod cap 1
big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
2. Remove:
piston pin clips 1
piston pin 2
piston 3
connecting rod
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
For reference during installation, put identifi-
cation marks on the piston crown.
Before removing the piston pin, deburr the pis-
ton pin clip groove and the piston pin bore area
in the piston. If both areas are deburred and
the piston pin is still difficult to remove, remove
it with the piston pin puller 4 .
Piston pin puller

90890-01304, YU-01304
3. Remove:
top ring
2nd ring
oil ring
NOTE:
To remove a piston ring, open the end gap with
your fingers and lift the other side of the ring
over the piston crown.
4-68
EAS00262
CHECKING THE CYLINDER AND PISTONS

The following procedure applies to all of the cyl-
inders and pistons.
1. Check:
piston wall
cylinder wall
Vertical scratches Replace the crank-
cases, and the piston and piston rings as a
set.
2. Measure:
piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder

bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-to-
side and front-to-back measurements of the
cylinder. Then, find the average of the measure-
ments.
Cylinder bore gauge

90890-03017, YU-03017
Cylinder bore “C” 65.50 65.51 mm

(25.787 25.791 in)
Max. taper “T” 0.05 mm (0.002 in)
Out of round “R” 0.05 mm (0.002 in)
b. If out of specification, replace the crank-
cases, and the piston and piston rings as a
set.
c. Measure piston skirt diameter “P” with the
micrometer.
Micrometer
90890-03008, YU-03008
a 4 mm from the bottom edge of the piston
Piston size “P”

Standard 65.460 65.475 mm
(2.5772 2.5778 in)
d. If out of specification, replace the piston and
piston rings as a set.
4-69
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.025 0.050 mm
(0.001 0.002 in)
<Limit>: 0.07 mm (0.0028 in)
f. If out of specification, replace the crank-

cases, and the pistons and piston rings as a
set.
EAS00263
CHECKING THE PISTON RINGS

1. Measure:
piston ring side clearance
Out of specification Replace the piston
and piston rings as a set.
NOTE:
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance

Top ring
0.030 0.065 mm
(0.0012 0.0026 in)
<Limit>: 0.115 mm (0.005 in)
2nd ring
0.020 0.055 mm
(0.0008 0.0022 in)
<Limit>: 0.115 mm (0.005 in)
2. Install:
piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the pis-
ton crown.
a 5 mm (0.20 in)
4-70
3. Measure:
piston ring end gap
Out of specification Replace the piston ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap

Top ring
0.15 0.25 mm
(0.006 0.009 in)
<Limit>: 0.50 mm (0.02 in)
2nd ring
0.40 0.50 mm
(0.016 0.02 in)
<Limit>: 0.85 mm (0.033 in)
Oil ring
0.10 0.35 mm
(0.004 0.014 in)
ABS00266
CHECKING THE PISTON PINS

The following procedure applies to all of the pis-
ton pins.
1. Check:
piston pin
Blue discoloration/grooves Replace the
piston pin and then check the lubrication sys-
tem.
2. Measure:
piston pin outside diameter a
pin.
Piston pin outside diameter

15.991 16.000 mm
(0.6296 0.6299 in)
3. Measure:
piston pin bore diameter (in the piston)
pin.
Piston pin bore diameter

(in the piston)
16.002 16.013 mm
(0.6300 0.6304 in)
4-71
4. Calculate:
piston-pin-to-piston-pin-bore clearance
pin.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter (in the piston)
–
Piston pin outside diameter
Piston-pin-to-piston-pin-bore
clearance
0.002 0.022 mm
(0.00008 0.0009 in)
<Limit>: 0.072 mm (0.0028 in)
CHECKING THE BIG END BEARINGS

1. Measure:
crankshaft-pin-to-big-end-bearing clearance
Out of specification Replace the big end
bearings.
Crankshaft-pin-to-big-end-
bearing clearance
0.028 0.052 mm
(0.0011 0.002 in)

connecting rods.
CAUTION:
Do not interchange the big end bearings and
connecting rods. To obtain the correct
crankshaft-pin-to-big-end-bearing clearance
and prevent engine damage, the big end
bearings must be installed in their original
positions.
a. Clean the big end bearings, crankshaft pins,

and bearing portions of the connecting rods.
b. Install the big end upper bearing into the con-
necting rod and the big end lower bearing
into the connecting rod cap.
NOTE:
Align the projections a on the big end bearings
with the notches b in the connecting rod and
connecting rod cap.
4-72
c. Put a piece of Plastigauge 1 on the crank-
shaft pin.
d. Assemble the connecting rod halves.
NOTE:
S Do not move the connecting rod or crankshaft
until the clearance measurement has been
completed.
S Lubricate the bolt threads and nut seats with
molybdenum disulfide grease.
S Make sure that the “Y” mark c on the connect-
ing rod faces towards the left side of the crank-
shaft.
S Make sure that the characters d on both the
connecting rod and connecting rod cap are
aligned.
e. Tighten the connecting rod nuts.

CAUTION:
S When tightening the connecting rod nuts,
be sure to use an F-type torque wrench.
S After tightening the connecting rod nut to
the specified torque, turn the connecting
rod nut another+90_.
Refer to “INSTALLING THE PISTONS AND

CONNECTING RODS”.
Connecting rod nut

15 Nm (1.5 mSkg, 11 ftSlb) + 90_
f. Remove the connecting rod and big end

bearings.
Refer to “REMOVING THE CONNECTING
RODS AND PISTONS”.
g. Measure the compressed Plastigauge
width e on the crankshaft pin.
If the crankshaft-pin-to-big-end-bearing
clearance is out of specification, select re-
placement big end bearings.
4-73
2. Select:
big end bearings (“P1” “P4”)
NOTE:
The numbers stamped into the crankshaft web
and the numbers on the connecting rods are
used to determine the replacement big end
bearing sizes.
“P1” “P4” refer to the bearings shown in the
crankshaft illustration.
For example, if the connecting rod “P1” and

the crankshaft web “P1” numbers are “5” and
“1” respectively, then the bearing size for
“P1” is:
“P1” (connecting rod) – “P1” (crank-

shaft) =
5–1=4
BIG END BEARING COLOR CODE

1 blue
2 black
3 brown
4 green
EAS00271
INSTALLING THE PISTONS AND CONNECT-

ING RODS
The following procedure applies to all of the pis-
tons and cylinders.
1. Install:
top ring
2nd ring
oil ring
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
4-74
2. Install:
piston 1
(onto the respective connecting rod 2 )
piston pin 3
piston pi clip 4 New
NOTE:
Apply engine oil onto the piston pin.
Make sure that the “Y” mark a on the connect-
ing rod faces left when the arrow mark b on
the piston is pointing up. Refer to the illustra-
tion.
Reinstall each piston into its original cylinder
(numbering order starting from the left: #1 to
#4).
3. Offset:
piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
A Intake side
4. Lubricate:
piston
piston rings
cylinder
Engine oil
5. Lubricate:
bolt threads
nut seats
Molybdenum disulfide grease
4-75
6. Lubricate:
S crankshaft pins
S big end bearings
S connecting rod big end inner surface
Engine oil
7. Install:
S big end bearings
S connecting rod assembly
(into the cylinder and onto the crankshaft
pin).
S connecting rod cap
(onto the connecting rod)
NOTE:
S Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
S Be sure to reinstall each big end bearing in its
original place.
S While compressing the piston rings with one
hand, install the connecting rod assembly into
the cylinder with the other hand.
S Make sure that the “Y” marks a on the con-
necting rods face towards the left side of the
crankshaft.
S Make sure that the characters b on both the
connecting rod and connecting rod cap are
aligned.
8. Align:
S bolt heads
(with the connecting rod caps)
9. Tighten:
S connecting rod nuts
15 Nm (1.5 mSkg, 11 ftSlb)+90_
a. Replace the connecting rod bolts and nuts

with new ones.
CAUTION:
Tighten the connecting rod bolts using the
plastic-region tightening angle method.
Always install new bolts and nuts.
4-76
b. Clean the connecting rod bolts and nuts.
c. Tighten the connecting rod nuts.
d. Put a mark 1 on the corner of the connecting
rod nut 2 and the connecting rod 3 .
e. Tighten the nut further to reach the specified

angle (90_).
WARNING
When the nut is tightened more than the
specified angle, do not loosen the nut and
then retighten it.
Replace the bolt with a new one and perform
the procedure again.
CAUTION:
S Do not use a torque wrench to tighten the
nut to the specified angle.
S Tighten the nut until it is at the specified
angles.
NOTE:
When using a hexagonal nut, note that the
angle from one corner to another is 60_.
4-77
CRANKSHAFT ENG
EAS00381
CRANKSHAFT

Removing the crankshaft Remove the parts in the order listed.
Crankcase lower Separate.
Connecting rods and pistons Refer to “CONNECTING RODS AND
PISTONS”.
1 Crankshaft 1
2 Crankshaft journal lower bearing 5 Refer to “REMOVING/INSTALLING
3 Crankshaft journal upper bearing 5 THE CRANKSHAFT”.
procedure.
4-78
CRANKSHAFT ENG
EAS00387
REMOVING THE CRANKSHAFT

1. Remove:
crankshaft 1
crankshaft journal upper bearings
(from the upper / lower crankcase)
NOTE:
Identify the position of each crankshaft journal
upper bearing so that it can be reinstalled in its
original place.
EAS00397
CHECKING THE CRANKSHAFT

1. Measure:
crankshaft runout
Out of specification Replace the crank-
shaft.
Max. crankshaft runout

0.03 mm (0.0012 in)
2. Check:
crankshaft journal surfaces
crankshaft pin surfaces
bearing surfaces
Scratches/wear Replace the crankshaft.
CHECKING THE CRANKSHAFT JOURNAL

BEARINGS
1. Measure:
crankshaft-journal-to-crankshaft-journal-
bearing clearance
Out of specification Replace the crank-
shaft journal bearings.
Crankshaft-journal-to-crankshaft-
journal-bearing clearance
0.034 0.058 mm
(0.0013 0.0023 in)
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft-
journal-to-crankshaft-journal-bearing
clearance and prevent engine damage, the
crankshaft journal bearings must be
installed in their original positions.
4-79
CRANKSHAFT ENG
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions of
the crankcase.
b. Place the upper crankcase upside down on a
bench.
c. Install the crankshaft journal upper bearings
1 and the crankshaft into the upper crank-
case.
NOTE:
Align the projections a on the crankshaft jour-
nal upper bearings with the notches b in the
upper crankcase.
d. Put a piece of Plastigauge 2 on each

crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil hole in
the crankshaft journal.
e. Install the crankshaft journal lower bearings

into the lower crankcase and assemble the
crankcase.
NOTE:
nal lower bearings with the notches b in the
lower crankcase.
Do not move the crankshaft until the clearance
measurement has been completed.
f. Tighten the bolts to specification in the tight-

ening sequence cast on the crankcase.
Bolt 15 27
12 Nm (1.2 mkg, 8.7 ftlb)
Bolt 13 14
14 Nm (1.4 mkg, 10 ftlb)
Bolt 1 12
24 Nm (2.4 mkg, 17 ftlb)
NOTE:
Lubricate the crankcase bolt threads with en-
gine oil.
4-80
CRANKSHAFT ENG
g. Remove the lower crankcase and the crank-
shaft journal lower bearings.
h. Measure the compressed Plastigauge
width c each crankshaft journal.
If the clearance is out of specification, select
replacement crankshaft journal bearings.
2. Select:
crankshaft journal bearings (J1 J5)
NOTE:
The numbers stamped into the crankshaft web
and the numbers stamped into the lower
crankcase are used to determine the replace-
ment crankshaft journal bearing sizes.
“J1” “J5” refer to the bearings shown in the
crankshaft illustration.
If “J1” “J5” are the same, use the same size
for all of the bearings.
For example, if the crankcase “J1” and crank-

shaft web “J1” numbers are “6” and “2” respec-
tively, then the bearing size for “J1” is:
Bearing size for J1:

“J1” (crankcase) – “J1” (crankshaft
web) – 1=
6–2–1=3
J1 J2 J3 J4 J5
CRANKSHAFT JOURNAL BEARING
COLOR CODE
0 White
1 Blue
2 Black
3 Brown
4 Green
NOTE:
If the size is the same for all “J1 to J5”, one digit
for that size is indicated. (crankcase side only)
4-81
CRANKSHAFT ENG
EAS00407
INSTALLING THE CRANKSHAFT

1. Install:
crankshaft journal upper bearings
(into the upper / lower crankcase)
NOTE:
nal upper bearings with the notches b in the
upper crankcase.
Be sure to install each crankshaft journal up-
per bearing in its original place.
4-82
TRANSMISSION ENG
EAS00419
TRANSMISSION
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)

Removing the transmission Remove the parts in the order listed.
Crankcase lower Separate.
Shift shaft and stopper lever Refer to “SHIFT SHAFT”.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Shift bar stopper 1
6 Shift fork guide bar 2
4-83
TRANSMISSION ENG
12 Nm (1.2 mkg, 8.7 ftlb)
10 Nm (1.0 mkg, 7.2 ftlb)

7 Spring 4
8 Shift fork “L” 1 Refer to “INSTALLING THE
9 Shift fork “R” 1 TRANSMISSION”.
10 Shift drum assembly 1 Refer to “REMOVING THE
11 Shift fork “C” 1 TRANSMISSION”.
12 Main axle assembly 1
procedure.
4-84
TRANSMISSION ENG

Disassembling the main axle Remove the parts in the order listed.
assembly
1 Bearing 1
2 2nd pinion gear 1
3 Toothed lock washer 1
4 Toothed lock washer retainer 1
5 6th pinion gear 1
6 Collar 1
7 Washer 1
8 Circlip 1
9 3rd pinion gear 1
10 Circlip 1
4-85
TRANSMISSION ENG

11 Washer 1
12 5th pinion gear 1
13 Collar 1
14 Main axle 1
15 Bearing housing 1
16 Bearing 1
procedure.
4-86
TRANSMISSION ENG

Disassembling the drive axle Remove the parts in the order listed.
assembly
1 Washer 1
2 1st wheel gear 1
3 Collar 1
4 5th wheel gear 1
5 Circlip 1
6 Washer 1
7 3rd wheel gear 1
8 Collar 1
9 Toothed lock washer 1
10 Toothed lock washer retainer 1
11 4th wheel gear 1
4-87
TRANSMISSION ENG

12 Collar 1
13 Washer 1
14 Circrip 1
15 6th wheel gear 1
16 Circrip 1
17 washer 1
18 2nd wheel gear 1
19 Collar 1
20 Collar 1
21 Oil seal 1
22 Bearing 1
23 Circrip 1
24 Drive axle 1
procedure.
4-88
TRANSMISSION ENG
EAS00420
REMOVING THE TRANSMISSION

1. Remove:
drive axle assembly
2. Remove:
main axle assembly 1
(with the Torx wrench T30)
a. Insert two bolts 2 of the proper size, as

shown in the illustration, into the main axle
assembly bearing housing.
b. Tighten the bolts until they contact the crank-
case surface.
c. Continue tightening the bolts until the main
axle assembly comes free from the upper
crankcase.
EAS00421
CHECKING THE SHIFT FORKS

The following procedure applies to all of the shift
forks.
1. Check:
shift fork cam follower 1
shift fork pawl 2
Bends/damage/scoring/wear
Replace the shift fork.
2. Check:
shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
4-89
TRANSMISSION ENG
3. Check:
shift fork movement
(along the shift fork guide bar)
Rough movement Replace the shift
fork(-s) and shift fork guide bar as a set.
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY

1. Check:
shift drum grooves
Damage/scratches/wear Replace the
shift drum assembly.
shift drum segment 1
Damage/wear Replace the shift drum as-
sembly.
shift drum bearing 2
Damage/pitting Replace the shift drum
assembly.
EAS00425
CHECKING THE TRANSMISSION

1. Measure:
main axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the main
axle.
Max. main axle runout

0.02 mm (0.0008 in)
2. Measure:
drive axle runout
(with a centering device and dial gauge 1 )
Out of specification Replace the drive
axle.
Max. drive axle runout

0.02 mm (0.0008 in)
3. Check:
transmission gears
Blue discoloration/pitting/wear
Replace the defective gear(-s).
transmission gear dogs
Cracks/damage/rounded edges
Replace the defective gear(-s).
4-90
TRANSMISSION ENG
4. Check:
transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
5. Check:
transmission gear movement
Rough movement Replace the defective
part(-s).
6. Check:
circlips
Bends/damage/looseness Replace.
INSTALLING THE TRANSMISSION

1. Install:
main axle assembly
shift fork “C”
shift drum assembly
shift fork “R”
shift fork “L”
springs
shift fork guide bars
drive axle assembly
NOTE:
Carefully position the shift forks so that they
are installed correctly into the transmission
gears.
Install shift fork “C” into the groove in the 3rd
and 4th pinion gear on the main axle.
Install shift fork “L” into the groove in the 6th
wheel gear and shift fork “R” into the groove in
the 5th wheel gear on the drive axle.
Make sure that the drive axle bearing circlip is
inserted into the grooves in the upper crank-
case.
2. Check:
transmission
Rough movement Repair.
NOTE:
Oil each gear, shaft, and bearing thoroughly.
4-91
ENG
COOL
CHAPTER 5.
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

CHECKING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
INSTALLING THE OIL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

DISASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . 5-15
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
ASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
COOL
RADIATOR COOL
COOLING SYSTEM
RADIATOR
9 Nm (0.9 mkg, 6.5 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)
28 Nm (2.8 mkg, 20 ftlb)

Removeing the radiator Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Air filter case and heat protector plate Refer to “AIRFILTER CASE AND IGNI-
TION COILS” in chapter 3.
Bottom cowling and side cowlings Refer to “COWLINGS” in chapter 3.
Coolant Drain.
1 Coolant reserver hose 1
2 Breather hose 2
3 Radiator outlet hose 1 Disconnect.
5-1
RADIATOR COOL
9 Nm (0.9 mkg, 6.5 ftlb)
7 Nm (0.7 mkg, 5.1 ftlb)
28 Nm (2.8 mkg, 20 ftlb)

4 Radiator inlet hose 1 Disconnect.
5 Oil cooler outlet hose 1
6 Thermo switch coupler 1 Disconnect.
7 Radiator fan motor coupler 1 Disconnect.
8 Radiator 1
9 Radiator fan 1
procedure.
5-2
RADIATOR COOL
EAS00455
CHECKING THE RADIATOR

1. Check:
radiator fins
Obstruction Clean.
Apply compressed air to the rear of the radia-
tor.
Damage Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:
radiator hoses
3. Measure:
radiator cap opening pressure
Below the specified pressure Replace the
radiator cap.
Radiator cap opening pressure

110 140 kPa
(1.1 1.4 kg/cm2,
16.0 20.3 psi)
a. Install the radiator cap tester 1 and adapter

2 onto the radiator cap 3 .
Radiator cap tester

90890-01325, YU-24460-01
Adapter
90890-01352, YU-33984
b. Apply the specified pressure for ten seconds

and make sure that there is no drop in pres-
sure.
4. Check:
radiator fan
Damage Replace.
Malfunction Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
5-3
RADIATOR COOL
EAS00456
INSTALLING THE RADIATOR

1. Fill:
cooling system
mended coolant)
chapter 3.
2. Check:
cooling system
Leaks Repair or replace any faulty part.
3. Measure:
radiator cap.
Refer to “CHECKING THE RADIATOR”.
5-4
OIL COOLER COOL
EAS00457
OIL COOLER
63 Nm (6.3 mkg, 46 ftlb)

Removing the oil cooler Remove the parts in the order listed.
Radiator assembly Refer to “RADIATOR”.
Exaust pipe assembly Refer to “ENGINE” in chapter 4.
Engine oil Drain.
in chapter 3.
1 Oil cooler outlet hose 1
2 Bolt 1
Refer to “INSTALLING THE OIL
3 Washer 1
COOLER”.
4 Oil cooler 1
5-5
OIL COOLER COOL
63 Nm (6.3 mkg, 46 ftlb)

5 Oil cooler inlet hose 1
6 Water jacket joint 1
7 Water jacket joint hose 1
8 Water pump outlet pipe 1
9 Water pump outlet hose 1
10 Water pump inlet hose 1
procedure.
5-6
OIL COOLER COOL
EAS00458
CHECKING THE OIL COOLER

1. Check:
oil cooler
2. Check:
oil cooler inlet hose
oil cooler outlet hose
3. Check:
water jacket joint
water jacket joint inlet hose
water pump outlet hose
EBS00459
INSTALLING THE OIL COOLER

1. Clean:
mating surfaces of the oil cooler and the
crankcase
(with a cloth dampened with lacquer thinner)
2. Install:
O-ring New
oil cooler 1
washer 2 New
bolt 3 63 Nm (6.3 mkg, 46 ftlb)
NOTE:
Before installing the oil cooler, lubricate the oil
cooler bolt and O-ring with a thin coat of engine
oil.
Make sure that the O-ring is positioned proper-
ly.
Align the projection a on the oil cooler with the
slot b in the crankcase.
3. Bend the lock washer tab along a flat side of

the bolt.
5-7
OIL COOLER COOL
4. Fill:
cooling system
mended coolant)
chapter 3.
crankcase
mended engine oil)
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
5. Check:
cooling system
6. Measure:
radiator cap.
5-8
THERMOSTAT COOL
THERMOSTAT

Removing the termostat Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEAT” and “FUEL TANK” in
chapter 3.
Coolant Drain.
chapter 3.
Air filter case Refer to “AIRFILTER CASE AND
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
5-9
THERMOSTAT COOL

1 Radiator inlet hose 1
2 Carburator outlet hose 1
3 Thermostat cover 1 Refer to “INSTALLING THE
4 Thermostat 1 THERMOSTAT
For installation, revers the removal
procedure.
5-10
THERMOSTAT COOL
EAS00462
CHECKING THE THERMOSTAT

1. Check:
S thermostat 1
Does not open at 71 84_C (160 183_F)
(without California) Replace.
Does not open at 82 95_C (178 203_F)
(California) Replace.
a. Suspend the thermostat in a container filled

with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the thermo-
stat and thermometer’s indicated tempera-
ture.
1 Thermostat
2 Thermometer
3 Water
4 Container
A Fully closed
B Fully opens
NOTE:
If the accuracy of the thermostat is in doubt, re-
place it. A faulty thermostat could cause serious
overheating or overcooling.
2. Check:
S thermostat housing cover
S thermostat housing
EB00467
INSTALLING THE THERMOSTAT

1. Install:
S thermostat
NOTE:
Install the thermostat with its breather hole a
facing up.
2. Install
S thermostat cover
10 Nm (1.0 mSkg, 7.2 ftSlb)
NOTE:
Befor installing the thermostat cover to the cyl-
inder head, lubricate the O-ring with a thin coat
of litium soap base grease.
5-11
THERMOSTAT COOL
3. Fill:
coolling system
mended coolant)
chapter 3.
4. Check:
cooling system
5. Measure:
radiator cap.
5-12
WATER PUMP COOL
WATER PUMP
12 Nm (1.2 mkg, 8.7 ftlb)

Removing the water pump assembly Remove the parts in the order listed.
Coolant Drain.
chapter 3.
1 Water pump inlet hose 1
2 Water pump outlet hose 1
3 Water pump hose 1
4 Clutch wire and holder 1
5 Water pump 1
procedure.
5-13
WATER PUMP COOL
10 Nm (1.0 mkg, 7.2 ftlb)
New

Disassembling the water pump Disassemble the parts in the order listed.
assembly
1 Water pump cover 1
2 O-ring 1
3 Impeller shaft (along with the impeller) 1
Refer to “DISASSEMBLING/
4 Water pump seal 1
ASSEMBLING THE WATER PUMP”.
5 Oil seal 1
6 Bearing 1
7 Circlip 1
procedure.
5-14
WATER PUMP COOL
EAS00470
DISASSEMBLING THE WATER PUMP

1. Remove:
water pump seal 1
NOTE:
Tap out the water pump seal from the inside of
the water pump housing.
2 Water pump housing
2. Remove:
oil seal 1
circlip
bearing 2
NOTE:
Tap out the bearing and oil seal from the outside
of the water pump housing.
3 Water pump housing
3. Remove:
rubber damper holder 1
rubber damper 2
(from the impeller, with a thin, flat-head
screwdriver)
NOTE:
Do not scratch the impeller shaft.
EAS00474
CHECKING THE WATER PUMP

1. Check:
water pump housing cover 1
water pump housing 2
impeller 3
rubber damper 4
rubber damper holder 5
2. Check:
water pump seal
oil seal
bearing
Rough movement Replace.
5-15
WATER PUMP COOL
EAS00475
ASSEMBLING THE WATER PUMP

1. Install:
bearing
oil seal 1 New
(into the water pump housing 2 )
NOTE:
Before installing the oil seal, apply tap water or
coolant onto its outer surface.
Install the oil seal with a socket that matches
its outside diameter.
2. Install:
water pump seal 1 New
CAUTION:
Never lubricate the water pump seal surface
with oil or grease.
NOTE:
Install the water pump seal with the special
tools.
Before installing the water pump seal, apply
Yamaha bond No.1215 2 to the water pump
housing 3 .
Mechanical seal installer

90890-04078, YM-33221 4
Middle driven shaft bearing
driver
90890-04058, YM-04058-1 5
90890-85505, ACC-1100-15-01
A Push down.
3. Install:
rubber damper 1 New
rubber damper holder 2 New
NOTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.
5-16
WATER PUMP COOL
4. Measure:
impeller shaft tilt
Out of specification Repeat steps (3) and
(4).
CAUTION:
Make sure that the rubber damper and rub-
ber damper holder are flush with the impel-
ler.
Max. impeller shaft tilt

0.15 mm (0.006 in)
1 Straightedge
2 Impeller
5-17
COOL
CARB
CHAPTER 6.
CARBURETORS
CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
ASSEMBLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
INSTALLING THE CARBURETORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 6-12
CHECKING AND ADJUSTING THE THROTTLE POSITION
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
CHECKING THE FUEL COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
CHECKING THE FUEL COCK OPERATION . . . . . . . . . . . . . . . . . . . 6-17
AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

AIR INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
AIR CUTOFF VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
AIR INDUCTION SYSTEM DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . 6-19
CHECKING THE AIR INDUCTION SYSTEM . . . . . . . . . . . . . . . . . . . 6-20
CARB
CARBURETORS CARB
EAS00481
CARBURETORS
CARBURETORS

Removing the carburetors Remove the parts in the order listed.
Rider seat and fuel tank Refer to “Seats” and “FUEL TANK” in
chapter 3.
Air filter case and heat protector plate Refer to “AIR FILTER CASE AND
1 Starter cable 1
2 Fuel hose 1
3 Throttle position sensor coupler 1 Disconnect
4 Throttle stop screw 1
6-1
CARBURETORS CARB

5 Therm bypass hose 2
6 Carburetor joint clamp screw 4
7 Throttle cable 2
8 Carburetor assembly 1
9 Carburetor joint 4
10 Side cover 2
procedure.
6-2
CARBURETORS CARB

Separating the carburetors Remove the parts in the order listed.
1 Starter plunger link 1
Refer to “ASSEMBLING THE
2 Connecting bolt 1
CARBURETORS”
3 Connecting bolt 1
4 Hose joint 2
5 Spring 2 Refer to “ASSEMBLING THE
CARBURETORS”
6 Fuel feed pipe 2
7 Fuel feed pipe 1
8 Pipe 2
10 Throttle position sensor 1
11 Water pipe 2
6-3
CARBURETORS CARB

12 Balance pipe 2
13 Balance pipe bracket 1
14 Throttle cable bracket 1
15 Carburetor 4
procedure
6-4
CARBURETORS CARB
: California only

Disassembling the carburetor Disassemble the parts in the order listed.
NOTE:
The following procedure applies to all of
the carburetors.
1 Starter plunger 1
2 Air funnel 1
3 Vacuum chamber cover 1
4 Piston valve spring 1
5 Jet needle holder 1
6 Jet needle kit 1
7 Piston valve 1 Refer to “ASSEMBLING THE
CARBURETORS.”
8 Fuel drain bolt 1
9 Float chamber 1
10 Float pivot pin 1
6-5
CARBURETORS CARB
: California only

11 Float 1
12 Needle valve 1
13 Main jet 1
14 Main jet holder 1
15 Pilot jet 1
procedure.
6-6
CARBURETORS CARB
EAS00486
CHECKING THE CARBURETORS

buretors.
1. Check:
carburetor body
float chamber
2. Check:
fuel passages
Obstruction Clean.
a. Wash the carburetor in a petroleum-based

solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
float chamber body
Dirt Clean.
4. Check:
float chamber rubber gasket 1
5. Check:
float
Damage Replace.
6. Check:
needle valve 1
Damage/obstruction/wear Replace the
needle valve, needle valve seat and O-ring
as a set.
6-7
CARBURETORS CARB
7. Check:
piston valve 1
Damage/scratches/wear Replace.
piston valve diaphragm 2
Cracks/tears Replace.
8. Check:
vacuum chamber cover 1
piston valve spring 2
jet needle holder 3
9. Check:
jet needle kit 1
main jet 2
main jet holder 3
pilot jet 4
starter plunger 5
Obstruction Clean.
Blow out the jets with compressed air.
10. Check:
piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
11. Check:
fuel feed pipes 1
pipes 2
hose joint 3
Obstruction Clean.
Blow out the pipes with compressed air.
6-8
CARBURETORS CARB
12. Check:
fuel hoses
Obstruction Clean.
Blow out the hoses with compressed air.
EAS00490
ASSEMBLING THE CARBURETORS

buretors.
CAUTION:
Before assembling the carburetors, wash
all of the parts in a petroleumbased sol-
vent.
Always use a new gasket.
1. Install:
piston valve 1
jet needle
jet needle holder
piston valve spring
vacuum chamber cover
NOTE:
Install the end of the piston valve spring onto
the spring guide on the vacuum chamber cov-
er.
Align the tab a on the piston valve diaphragm
with the recess b in the carburetor body.
6-9
CARBURETORS CARB
2. Install:
pipes
fuel feed pipes
vacuum chamber pipe
vacuum chamber air vent hose
springs
float chamber air vent hoses
hose joint
spacers
copper washer
connecting bolts
NOTE:
Do not tighten the connecting bolts yet.
Install the throttle valve lever 1 onto carbure-
tors #2, #3, and #4 between the spring 2 and
synchronizing screw 3 .
3. Install:
starter plunger link 1
NOTE:
Install the starter plunger link 1 onto each start-
er plunger.
4. Tighten:
connecting bolts
7 Nm (0.7 mkg, 5.1 ftlb)
NOTE:
Place the carburetor assembly on a surface
plate with the intake manifold side down.
Then, tighten the connecting bolts while push-
ing down the carburetor assembly with an
even force.
After tightening the connecting bolts, check
that the throttle valve lever and starter plunger
link operate smoothly.
5. Install:
starter cable 1
NOTE:
Install the starter cable holder 2 onto the start-
er cable.
6-10
CARBURETORS CARB
EAS00493
INSTALLING THE CARBURETORS

1. Adjust:
carburetor synchronization
Refer to “SYNCHRONIZING THE CARBU-
RETORS” in chapter 3.
2. Adjust:
engine idling speed
Engine idling speed

1250 1350 r/min
Refer to “ADJUSTING THE ENGINE ID-

LING SPEED” in chapter 3.
3. Adjust:
Throttle cable free play (at the

6 8 mm (0.24 0.31 in)

CABLE FREE PLAY” in chapter 3.
6-11
CARBURETORS CARB
EAS00497
MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Measure:
fuel level a
Fuel level (below the mark on

the body)
17.5 18.5 mm (0.69 0.73 in)
a. Stand the motorcycle on a level surface.

b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standing
straight up.
c. Install the fuel level gauge 1 onto the fuel
drain pipe 2 .
Fuel level gauge

90890-01312, YM-01312-A
d. Loosen the fuel drain bolt 3 .

e. Hold the fuel level gauge vertically next to the
line 4 on the float chamber.
f. Measure the fuel level a .
NOTE:
Fuel level readings should be equal on both
sides of the carburetor assembly.
2. Adjust:
fuel level
a. Remove the carburetor assembly.

b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by slight-
ly bending the float tang 1 .
e. Install the carburetor assembly.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
6-12
CARBURETORS CARB
EAS00502
CHECKING AND ADJUSTING THE THROTTLE

POSITION SENSOR
NOTE:
Before adjusting the throttle position sensor, the
engine idling speed should be properly ad-
justed.
1. Check:
S throttle position sensor
(installed on the carburetor)
a. Disconnect the throttle position sensor cou-

pler.
b. Connect the pocket tester (Ω 1k) to the
throttle position sensor.
Tester positive probe blue 1

Tester negative probe black/blue 2
c. Measure the throttle position sensor maxi-

mum resistance.
Out of specification Replace the throttle
position sensor.
Throttle position sensor maximum

resistance
4.0 X 6.0 kΩ at 20_C (68°F)
(blue – black/blue)
d. Connect the pocket tester (Ω 1k) to the

Tester positive probe yellow 3

e. While slowly opening the throttle, check that

the throttle position sensor resistance is
within the specified range.
NOTE:
Check mainly that the resistance changes grad-
ually when turning the throttle, since the read-
ings (from closed to wide-open throttle) may dif-
fer slightly from those specified.
Out of specification or the resistance changes

abruptly Go to step (2).
Throttle position sensor resistance

0 X 5 ± 1.0 kΩ at 20_C (68°F)
(yellow – black/blue)
6-13
CARBURETORS CARB
2. Check:
S throttle position sensor
(removed from the carburetor)
a. Disconnect the throttle position sensor cou-

pler.
b. Remove the throttle position sensor from the
carburetor.
c. Connect the pocket tester (Ω 1k) to the
Tester positive probe blue 1

d. Measure the throttle position sensor maxi-

mum resistance.
Out of specification Replace the throttle
position sensor.
Throttle position sensor maxi-

mum resistance
4.0 X 6.0 kΩ at 20_C (68°F)
(blue – black/blue)
e. Connect the pocket tester (Ω 1k) to the

throttle position sensor coupler.

f. While slowly opening the throttle, check that

the throttle position sensor resistance is
within the specified range.
The resistance does not change or it changes
abruptly Replace the throttle position sensor.
The slot is worn or broken Replace the
NOTE:
Check mainly that the resistance changes grad-
ually when turning the throttle, since the read-
ings (from closed to wide-open throttle) may dif-
fer slightly from those specified.
Throttle position sensor resistance

0 X 5 ± 1.0 kΩ at 20_C (68°F)
(yellow – black/blue)
6-14
CARBURETORS CARB
3. Adjust:
throttle position sensor angle
a. Set the main switch to “ON”.

b. Disconnect the throttle position sensor cou-
pler.
c. Reconnect the throttle position sensor cou-
pler.
NOTE:
After reconnecting the throttle position sensor
coupler, the tachometer switches to the throttle
position sensor adjustment mode.
d. Loosen the throttle position sensor screws

1.
e. Adjust the throttle position sensor angle ac-
cording to the following table.
NOTE:
The angle of the throttle position sensor is indi-
cated by the r/min which are displayed on the
tachometer.
Tachometer Throttle posi- Adjustment

Reading tion sensor direction
angle
5000 rpm 2 Correct –
0 rpm Incorrect a
10000 rpm Incorrect b
f. After adjusting the throttle position sensor
angle, tighten the throttle position sensor
screws.
NOTE:
To exit the throttle position sensor adjustment
mode, start the engine or set the main switch to
“OFF”.
6-15
CARBURETORS CARB
EAS00504
CHECKING THE FUEL PUMP

1. Check:
fuel pump 1
a. Remove the fuel tank.

Refer to “FUEL TANK” in chapter 3.
b. Disconnect the fuel-pump-to-carburetor fuel
hose 2 from the carburetor.
c. Connect the fuel-tank-to-fuel-pump fuel
hose to the fuel tank and then set the fuel
cock to “ON”.
d. Place a container under the end of the fuel
hose 2 .
e. Start the engine and check if fuel flows from
the fuel hose 2 .
Fuel flows. Fuel pump is OK.

Fuel does not Replace
p the fuel
flow. pump.
f. Stop the engine and check if the fuel stops
flowing from the fuel hose 2 .
Fuel stops flowing. Fuel pump is OK.

Replace
p the fuel
F el flows.
Fuel flows
pump.
6-16
CARBURETORS CARB
EAS00505
CHECKING THE FUEL COCK

1. Remove
fuel tank
fuel filter 1
fuel cock 2
2. Check:
fuel cock
3. Check:
fuel cock strainer 1
(with compressed air)
Dirt/obstruction Clean.
Damage Replace.
4. Install
fuel cock
fuel filter
fuel tank
EAS00506
CHECKING THE FUEL COCK OPERATION

NOTE:
After installing the fuel cock, check its opera-
tion.
1. Check that the fuel cock lever is turned to

“ON” or “OFF”.
2. Place a container under the end of the fuel
hose.
3. Check:
fuel cock operation
a. Suck on the end of the vacuum hose.
Fuel flows.
Fuel cock is OK.
Fuel does not flow.
Replace the fuel cock.
6-17
AIR INDUCTION SYSTEM CARB
EAS00507
AIR INDUCTION SYSTEM

AIR INJECTION
The air induction system burns unburned ex-
haust gases by injecting fresh air (secondary
air) into the exhaust port, reducing the emission
of hydrocarbons.
When there is negative pressure at the exhaust
port, the reed valve opens, allowing secondary
air to flow into the exhaust port. The required
temperature for burning the unburned exhaust
gases is approximately 600 to 700_C (1112 to
1292_F).
EAS00508
AIR CUTOFF VALVE

The air cutoff valve is operated by the intake gas
pressure through the piston valve diaphragm.
Normally, the air cutoff valve is open to allow
fresh air to flow into the exhaust port. During
sudden deceleration (the throttle valve sudden-
ly closes), negative pressure is generated and
the air cutoff valve is closed in order to prevent
after-burning.
Additionally, at high engine speeds and when
the pressure decreases, the air cutoff valve au-
tomatically closes to guard against a loss of per-
formance due to self-EGR.
(This “low-boost close” function is the same as
on the FZR600 (3HW).)
VIEW 1. (NO FLOW)

When decelerating (the throttle closes), the
valve will close.
VIEW 2. (FLOW)
During normal operation the valve is open.
A From the air filter
B To the reed valve
C To the carburetor joint
6-18
EAS00509
AIR INDUCTION SYSTEM DIAGRAMS
1 Reed valve A To the cylinders

2 Air cleaner B To the air cutoff valve
3 Air cutoff valve C To cylinder #1
4 Carburetor joint (cylinder #3) D To cylinder #2
E To cylinder #3
F To cylinder #4
6-19
EAS00510
CHECKING THE AIR INDUCTION SYSTEM

1. Check:
hoses
pipes
2. Check:
air cutoff valve
6-20
CHAS
CHAPTER 7.
CHASSIS
FRONT WHEEL AND BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CHECKING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
CHECKING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
INSTALLING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
ADJUSTING THE FRONT WHEEL STATIC BALANCE . . . . . . . . . . 7-6
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET . . . . 7-8

REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . . . . . . . . . 7-9
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
CHECKING THE REAR WHEEL DRIVE HUB . . . . . . . . . . . . . . . . . . 7-12
CHECKING AND REPLACING THE REAR WHEEL SPROCKET . 7-12
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
ADJUSTING THE REAR WHEEL STATIC BALANCE . . . . . . . . . . . . 7-13
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 7-16
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . 7-18
FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
REAR BRAKE MASTER CYLINDER AND BRAKE FLUID
RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
REMOVING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . 7-26
REMOVING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . . 7-26
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . 7-27
INSTALLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . . 7-29
FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
REMOVING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . . 7-35
REMOVING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . 7-36
CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . . 7-37
INSTALLING THE FRONT BRAKE CALIPERS . . . . . . . . . . . . . . . . . 7-38
INSTALLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . 7-40
CHAS
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . 7-45
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . 7-45
CHECKING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . 7-47
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . 7-48
INSTALLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . 7-53
HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54
REMOVING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
CHECKING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56
INSTALLING THE HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-61
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 7-62
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 7-64

HANDLING THE REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
DISPOSING OF A REAR SHOCK ABSORBER AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-65
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . . 7-66
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-66
CHECKING THE RELAY ARM AND CONNECTING ARM . . . . . . . . 7-67
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . 7-67
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-68

CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-70
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-71
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-73
INSTALLING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-75
FRONT WHEEL AND BRAKE DISCS CHAS
EAS00514
CHASSIS
FRONT WHEEL AND BRAKE DISCS
6 Nm (0.6 mkg, 4.3 ftlb)
72 Nm (7.2 mkg, 52 ftlb)
20 Nm (2.0 mkg, 14 ftlb)
40 Nm (4.0 mkg, 29 ftlb)
18 Nm (1.8 mkg, 13 ftlb)

Removing the front wheel and brake Remove the parts in the order listed.
discs
NOTE:
Place the motorcycle on a suitable stand
so that the front wheel is elevated.
1 Brake hose holders (left and right) 2

2 Front reflectors (left and right) 2 Refer to “REMOVING/INSTALLING THE
3 Brake calipers (left and right) 2 FRONT WHEEL”.
4 Wheel axle pinch bolt 1 Loosen
5 Front wheel axle 1 Refer to “REMOVING/INSTALLING THE
6 Front wheel 1 FRONT WHEEL”.
7 Collars (left and right) 2
8 Brake discs (left and right) 2
procedure.
7-1
EAS00518

Disassembling the front wheel Remove the parts in the order listed.
1 Oil seals (left and right) 2
2 Wheel bearings (left and right) 2
3 Spacer 1
procedure.
7-2
EAS00521
REMOVING THE FRONT WHEEL

WARNING
NOTE:
2. Remove:
Brake hose holders
front reflectors
left brake caliper
right brake caliper
wheel axle
NOTE:
Do not squeeze the brake lever when removing
the brake calipers.
3. Elevate:
front wheel
NOTE:
EAS00525
CHECKING THE FRONT WHEEL

1. Check:
wheel axle
Roll the wheel axle on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent wheel
axle.
2. Check:
tire
front wheel
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7-3
3. Measure:
radial wheel runout 1
lateral wheel runout 2
Over the specified limits Replace.
Front radial wheel runout

1.0 mm (0.04 in)
Front lateral wheel runout
0.5 mm (0.02 in)
4. Check:
wheel bearings
Front wheel turns roughly or is loose Re-
place the wheel bearings.
oil seals
5. Replace:
wheel bearings New
oil seals New
a. Clean the outside of the front wheel hub.

b. Remove the oil seals 1 with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag 2
between the screwdriver and the wheel surface.
c. Remove the wheel bearings 3 with a gener-

al bearing puller.
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing center
race 4 or balls 5 . Contact should be made
only with the outer race 6
NOTE:
Use a socket 7 that matches the diameter of
the wheel bearing outer race and oil seal.
7-4
EAS00533
CHECKING THE BRAKE DISCS

brake discs.
1. Check:
brake disc
Damage/galling Replace.
2. Measure:
brake disc deflection
Out of specification Correct the brake disc
deflection or replace the brake disc.
Max. brake disc deflection

Front: 0.1 mm (0.0039 in)
Rear: 0.1 mm (0.0039 in)
a. Place the motorcycle on a suitable stand so

that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the left or
right to ensure that the front wheel is station-
ary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in) be-
low the edge of the brake disc.
3. Measure:
brake disc thickness
Measure the brake disc thickness at a few
different locations.
Min. brake disc thickness

Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4. Adjust:
brake disc deflection
a. Remove the brake disc.

b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
7-5
Brake disc bolt

18 Nm (1.8 mkg, 13 ftlb)
LOCTITE
d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be brought
within specification, replace the brake disc.
EAS00545
INSTALLING THE FRONT WHEEL

1. Lubricate:
wheel axle
oil seal lips
2. Tighten:
wheel axle 1 72 Nm (7.2 mkg, 52 ftlb)
wheel axle pinch bolt 2
20 Nm (2.0 mkg, 14 ftlb)
CAUTION:
Before tightening the wheel axle nut, push
down hard on the handlebars several times
and check if the front fork rebounds
smoothly.
3. Install:
brake calipers 40 Nm (4.0 mkg, 29 ftlb)
front reflectors
brake hose holders
WARNING
Make sure that the brake hose is routed
properly.
EAS00549
ADJUSTING THE FRONT WHEEL STATIC

BALANCE
NOTE:
After replacing the tire, wheel or both, the front
wheel static balance should be adjusted.
Adjust the front wheel static balance with the
brake discs installed.
7-6
1. Remove:
S balancing weight(-s)
2. Find:
S front wheel’s heavy spot
a. Place the front wheel on a suitable balancing

stand.
b. Spin the front wheel.
c. When the front wheel stops, put an “X1” mark
at the bottom of the wheel.
d. Turn the front wheel 90_ so that the “X1” mark
is positioned as shown.
e. Release the front wheel.
f. When the front wheel stops, put an “X2” mark
at the bottom of the wheel.
g. Repeat steps (a) through (d) several times
until all the marks come to rest at the same
spot.
h. The spot where all the marks come to rest is
the front wheel’s heavy spot “X”.
3. Adjust:
S front wheel static balance
a. Install a balancing weight 1 onto the rim ex-

actly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90_ so that the heavy

spot is positioned as shown.
c. If the heavy spot does not stay in that posi-
tion, install a heavier weight.
d. Repeat steps (b) and (c) until the front wheel
is balanced.
4. Check:
S front wheel static balance
a. Turn the front wheel and make sure that it

stays at each position shown.
b. If the front wheel does not remain stationary
at all of the positions, rebalance it.
7-7
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET CHAS
EAS00550
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET

REAR WHEEL
27 Nm (2.7 mkg, 20 ftlb)
40 Nm (4.0 mkg, 29 ftlb)
150 Nm (15 mkg, 108 ftlb)

Removing the rear wheel Remove the parts in the order listed.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
1 Brake caliper 1
2 Locknuts (left and right) 2 Loosen.
3 Adjusting bolts (left and right) 2 Loosen.
4 Wheel axle nut 1
5 Washer 1
6 Rear wheel axle 1
7 Left adjusting block 1
8 Right adjusting block 1 NOTE:
9 Rear wheel 1 Make sure that the tapered side of the right
10 Brake caliper bracket bolt 1 adjusting block faces the wheel.
11 Brake caliper bracket 1
procedure.
7-8
SPROCKET CHAS
EAS00556
BRAKE DISC AND REAR WHEEL SPROCKET
18 Nm (1.8 mkg, 13 ftlb)
69 Nm (6.9 mkg, 50 ftlb)

Removing the brake disc and rear Remove the parts in the order listed.
wheel sprocket
1 Brake disc 1
2 Rear wheel sprocket 1
3 Spacers (left and right) 2
4 Oil seal 1
5 Bearing 1
6 Rear wheel drive hub 1
7 Rear wheel drive hub dampers 5
8 Rear wheel 1
procedure.
7-9
SPROCKET CHAS

Disassembling the rear wheel Disassemble the parts in the order listed.
1 Spacer 1
2 Bearing 1
3 Spacer 1
4 Oil seal 1
5 Circlip 1
6 Bearing 1
procedure.
7-10
SPROCKET CHAS
EAS00561
REMOVING THE REAR WHEEL

WARNING
NOTE:
2. Remove:
brake caliper
NOTE:
Do not depress the brake pedal when removing
the brake caliper.
3. Remove:
wheel axle nut
washer
wheel axle
adjusting blocks
brake caliper bracket.
rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
EAS00565
CHECKING THE REAR WHEEL

1. Check:
wheel axle
rear wheel
wheel bearings
oil seals
brake disc
Refer to “BRAKE DISC AND REAR WHEEL
SPROKET”.
2. Check:
tire
rear wheel
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7-11
SPROCKET CHAS
3. Measure:
radial wheel runout
lateral wheel runout
Refer to “FRONT WHEEL”.
Over the specified limits Replace.
Max. radial wheel runout

1.0 mm (0.04 in)
Max. lateral wheel runout
0.5 mm (0.02 in)
EAS00567
CHECKING THE REAR WHEEL DRIVE HUB

1. Check:
rear wheel drive hub 1
rear wheel drive hub dampers 2
EAS00568
CHECKING AND REPLACING THE REAR

WHEEL SPROCKET
1. Check:
rear wheel sprocket
More than 1/4 tooth a wear Replace the
rear wheel sprocket.
Bent teeth Replace the rear wheel sprock-
et.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
rear wheel sprocket
a. Remove the self-locking nuts and the rear

wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact the
sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking

nut
69 Nm (6.9 mkg, 50 ftlb)
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
7-12
SPROCKET CHAS
EAS00571
INSTALLING THE REAR WHEEL

1. Lubricate:
wheel axle
wheel bearings
oil seal lips
2. Install:
rear wheel
brake caliper bracket
adjusting blocks
wheel axle
washer
wheel axle nut
brake caliper
3. Adjust:
drive chain slack a
Drive chain slack

40 50 mm (1.57 1.97 in)
Refer to “ADJUSTING THE DRIVE CHAIN

SLACK” in chapter 3.
4. Tighten:
wheel axle nut 150 Nm (15.0 mkg, 108 ftlb)
brake caliper bolts
27 Nm (2.7 mkg, 20 ftlb)
brake caliper bracket bolt
40 Nm (4.0 mkg, 29 ftlb)
WARNING
Make sure that the brake hose is routed
properly.
EAS00575
ADJUSTING THE REAR WHEEL STATIC

BALANCE
NOTE:
After replacing the tire, wheel or both, the rear
wheel static balance should be adjusted.
Adjust the rear wheel static balance with the
brake disc and rear wheel drive hub installed.
1. Adjust:
rear wheel static balance
Refer to “FRONT WHEEL”.
7-13
FRONT AND REAR BRAKES CHAS
EAS00577
FRONT AND REAR BRAKES

FRONT BRAKE PADS
40 Nm (4.0 mkg, 29 ftlb) 6 Nm (0.6 mkg, 4.3 ftlb)

Removing the front brake pads Remove the parts in the order listed.
The following procedure applies to both
of the front brake calipers.
1 Brake pad clips 2
2 Brake pad pin 1
3 Brake pad spring 1 Refer to “REPLACING THE FRONT
4 Brake pads 2 BRAKE PADS”.
5 Brake pad shims 2
6 Bleed screw 1
procedure.
7-14
EAS00578
REAR BRAKE PADS
6 Nm (0.6 mkg, 4.3 ftlb)
27 Nm (2.7 mkg,
27 Nm (20 ftlb)
40 Nm (4.0 mkg, 29 ftlb)

Removing the rear brake pads Remove the parts in the order listed.
1 Brake caliper bolts 2
2 Brake pads 2 Refer to “REPLACING THE REAR
3 Brake pad shims 4 BRAKE PADS”.
4 Bleed screw 1
procedure.
7-15
EAS00579
CAUTION:
Disc brake components rarely require dis-
assembly.
Therefore, always follow these preventive
measures:
Never disassemble brake components un-
less absolutely necessary.
If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
Never use solvents on internal brake com-
ponents.
Use only clean or new brake fluid for clean-
ing brake components.
Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
First aid for brake fluid entering the eyes:
Flush with water for 15 minutes and get im-
mediate medical attention.
EAS00582
REPLACING THE FRONT BRAKE PADS

The following procedure applies to both brake
calipers.
NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
brake hose holder bolt 1
front refrector 2
brake caliper 3
7-16
2. Remove:
brake pad clips 1
brake pad pins 2
brake pad spring 3
brake pads
(along with the brake pad shims)
3. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.

0.5 mm (0.02 in)
4. Install:
brake pad shims
(onto the brake pads)
brake pads
brake pad spring
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to the

bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mkg, 4.3 ftlb)
d. Install a new brake pad shim onto each new

brake pads.
e. Install new brake pads and a new brake pad
spring.
NOTE:
The arrow a on the brake pad spring must
point in the direction of disc rotation.
7-17
5. Install:
brake pad pins
brake pad clips
brake caliper bolts
40 Nm (4.0 mkg, 29 ftlb)
brake hose holder bolt
6 Nm (0.6 mkg, 4.3 ftlb)
6. Check:
brake fluid level
LEVEL” in chapter 3.
7. Check:
brake lever operation
Soft or spongy feeling Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS

NOTE:
When replacing the brake pads, it is not neces-
sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Remove:
brake caliper 1
2. Remove:
brake pads
(along with the brake pad shims)
7-18
3. Measure:
brake pad wear limit a
Out of specification Replace the brake
pads as a set.

0.8 mm (0.03 in)
4. Install:
brake pad shims
(onto the brake pads)
brake pads
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
a. Connect a clear plastic hose 1 tightly to the

bleed screw 2 . Put the other end of the hose
into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 mkg, 4.3 ftlb)
d. Install a new brake pa shim onto each new

brake pad.
7-19
5. Install:
brake caliper bolts
27 Nm (2.7 mkg, 20 ftlb)
6. Check:
brake fluid level
7. Check:
brake pedal operation
system.
7-20
EAS00584
FRONT BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR
30 Nm (3.0 mkg, 22 ftlb) 6 8

2 7
12
3 13
14
13
4 14 9
13
1 5 New
16
15 10
11
17
13 Nm (1.3 mg, 9.4 ftlb)

Removing the front brake master Remove the parts in the order listed.
cylinder and brake fluid reservoir
Brake fluid Drain.
1 Brake fluid reservoir cap stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Circlip 1
8 Dust cover 1
9 Hose joint 1
10 Brake lever 1
11 Front brake switch connector 2 Disconnect.
12 Union bolt 1 Refer to “INSTALLING THE FRONT
13 Copper washer 3 BRAKE MASTER CYLINDER”.
7-21
30 Nm (3.0 mkg, 22 ftlb) 6 8

2 7
12
3 13
14
13
4 14 9
13
1 5 New
16
15 10
11
17
13 Nm (1.3 mg, 9.4 ftlb)

14 Brake hose 2
15 Brake master cylinder holder 1 Refer to “INSTALLING THE FRONT
16 Brake master cylinder 1 BRAKE MASTER SYLINDER”.
17 Front brake switch 1
procedure.
7-22
EAS00585

Disassembling the front brake Remove the parts in the order listed.
master cylinder
1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
4 Brake master cylinder 1
procedure.
7-23
EAS00586
REAR BRAKE MASTER CYLINDER AND BRAKE FLUID RESERVOIR
5 Nm (0.5 mkg, 3.6 ftlb)
30 Nm (3.0 mkg, 22 ftlb)
23 Nm (2.3 mkg, 17 ftlb)

Removing the rear brake master Remove the parts in the order listed.
cylinder and brake fluid reservoir
Brake fluid Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
3 Brake fluid reservoir diaphragm 1
4 Brake fluid reservoir 1
5 Brake fluid reservoir hose 1
6 Hose joint 1
7 Union bolt 1
8 Copper washer 2 Refer to “INSTALLING THE REAR
9 Brake hose 1 BRAKE MASTER SYLINDER”.
procedure.
7-24
EAS00587
16 Nm (1.6 mkg, 12 ftlb)

Disassembling the rear brake Remove the parts in the order listed.
master cylinder
1 Brake master cylinder kit 1
procedure.
7-25
EAS00588
REMOVING THE FRONT BRAKE MASTER

CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
union bolt 1
copper washers 2
brake hoses 3
master cylinder holder 4
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
of the brake hose.
EAS00589
REMOVING THE REAR BRAKE MASTER

CYLINDER
1. Remove:
union bolt 1
copper washers 2
brake hose 3
button head bolts 4
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the end
A of the brake hose.
EAS00593
CHECKING THE FRONT AND REAR BRAKE

MASTER CYLINDERS
brake master cylinders.
1. Check:
brake master cylinder
B brake fluid delivery passages
(brake master cylinder body)
A Front
B Rear
7-26
A 2. Check:
brake master cylinder kit
A Front
B Rear
A B 3. Check:
brake fluid reservoir 1
brake fluid reservoir diaphragm 2
4. Check:
brake hoses
EAS00607
INSTALLING THE FRONT BRAKE MASTER

CYLINDER
WARNING
Before installation, all internal brake com-
ponents should be cleaned and lubricated
with clean or new brake fluid.
ponents.

DOT 4
7-27
1. Install:
brake master cylinder 1
13 Nm (1.3 mkg, 9.4 ftlb)
brake master cylinder holder
NOTE:
Install the brake master cylinder holder with
the “UP” mark facing up.
Align the end of the brake master cylinder
holder with the punch mark a in the right han-
dlebar.
First, tighten the upper bolt, then the lower
bolt.
2. Install:
copper washers New
brake hose
union bolt 30 Nm (3.0 mkg, 22 ftlb)
WARNING
Proper brake hose routing is essential to in-
sure safe motorcycle operation. Refer to
“CABLE ROUTING”.
NOTE:
While holding the brake hose, tighten the
union bolt as shown.
Turn the handlebars to the left and to the right
to make sure that the brake hose does not
touch other parts (e.g., wire harness, cables,
leads). Correct if necessary.
3. Fill:
brake fluid reservoir
mended brake fluid)
DOT 4
WARNING
Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
mance.
7-28
CAUTION:
4. Bleed:
brake system
5. Check:
brake fluid level
6. Check:
system.
EAS00608
INSTALLING THE REAR BRAKE MASTER

CYLINDER
1. Install:
copper washers New
brake hoses
union bolt 30 Nm (3.0 mkg, 22 ftlb)
button head bolts
WARNING
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure that the
brake pipe touches the projection a as
shown.
7-29
2. Fill:

DOT 4
WARNING
brake performance.
mance.
not enter the reservoir. Water will signifi-
cantly lower the boiling point of the brake
fluid and could cause vapor lock.
CAUTION:
3. Bleed:
brake system
4. Check:
brake fluid level
5. Adjust:
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake pedal position (from the

top of the brake pedal to the bot-
tom of the rider footrest bracket
bolt center)
4.3 9.3 mm (0.17 0.37 in)
6. Adjust:
Refer to “ADJUSTING THE REAR BRAKE
LIGHT SWITCH” in chapter 3.
7-30
EAS00613
FRONT BRAKE CALIPERS
6 Nm (0.6 mkg, 4.3 ftlb)
40 Nm (4.0 mkg, 29 ftlb)
30 Nm (3.0 mkg, 22 ftlb)

Removing the front brake calipers Remove the parts in the order listed.
Brake fluid Drain.
1 Front refrector 1
2 Union bolt 1
3 Copper washer 2 Refer to “INSTALLING THE FRONT
4 Brake hose 1 BRAKE CALIPERS”.
5 Brake caliper 1
procedure.
7-31
EAS00615
6 Nm (0.6 mkg, 4.3 ftlb)

Disassembling the front brake Disassemble the parts in the order listed.
calipers
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake caliper piston 4 Refer to “REMOVING THE FRONT
6 Brake caliper piston seal 8 BRAKE CALIPERS”.
7 Bleed screw 1
procedure.
7-32
EAS00616
REAR BRAKE CALIPER
30 Nm (3.0 mkg, 22 ftlb)
27 Nm (2.7 mkg,
27 Nm (20 ftlb)

Removing the rear brake caliper Remove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2 Refer to “INSTALLING THE REAR
3 Brake hose 1 BRAKE CALIPERS”.
4 Brake caliper 1
procedure.
7-33
EAS00617
6 Nm (0.6 mkg, 4.3 ftlb)

Disassembling the rear brake caliper Disassemble the parts in the order listed.
1 Brake pad 2
2 Brake caliper piston 2 Refer to “REMOVING THE REAR
3 Brake caliper piston seal 4 BRAKE CALIPERS”.
4 Bleed screw 1
procedure.
7-34
EAS00625
REMOVING THE FRONT BRAKE CALIPERS

brake calipers.
NOTE:
Before removing either brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
front refrector 1
union bolt 2
copper washers 3
brake hose 4
brake caliper 5
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper pistons 1
brake caliper piston seals 2
a. Secure the right side brake caliper pistons

with a piece of wood a .
b. Blow compressed air into the brake hose
joint opening b to force out the pistons from
the brake caliper.
WARNING
Never try to pry out the brake caliper pis-
tons.
Do not loosen the bolts 3 .
c. Remove the brake caliper piston seals.

d. Repeat the previous steps to force out the
right side pistons from the brake caliper.
7-35
EAS00628
REMOVING THE REAR BRAKE CALIPER

NOTE:
Before removing the brake caliper, drain the
brake fluid from the entire brake system.
1. Remove:
union bolt 1
copper washers 2
brake hose 3
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
brake caliper piston seals 2
a. Blow compressed air into the brake hose

joint opening a to force out the pistons from
the brake caliper.
Be careful not to get injured when the pistons
are expelled from the brake caliper..
WARNING
Cover the brake caliper piston with a rag.
Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper piston seals.
7-36
EAS00633
CHECKING THE FRONT AND REAR BRAKE

CALIPERS
Recommended brake component

replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Every two years and
A Brake fluid whenever the brake
is disassembled
1. Check:
Rust/scratches/wear Replace the brake
caliper.
brake caliper cylinders 2
Scratches/wear Replace the brake cali-
per.
brake calipers 3
B brake fluid delivery passages
(brake caliper body)
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
A Front
B Rear
2. Check:
rear brake caliper bracket 1
7-37
EAS00640
INSTALLING THE FRONT BRAKE CALIPERS

brake calipers.
WARNING
ponents as they will cause the piston seals
to swell and distort.

DOT 4
1. Install:
brake caliper 1
(temporarily)
copper washers New
brake hose 2
union bolt 3 30 Nm (3.0 mkg, 22 ftlb)
WARNING
CAUTION:
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
2. Remove:
brake caliper
3. Install:
brake pads
brake pad spring
brake caliper 40 Nm (4.0 mkg, 29 ftlb)
front refrector
brake hose holder
6 Nm (0.6 mkg, 4.3 ftlb)
Refer to “REPLACING THE FRONT BRAKE
PADS”.
7-38
4. Fill:
mended brake fluid)

DOT 4
WARNING
brake performance.
mance.
CAUTION:
5. Bleed:
brake system
6. Check:
brake fluid level
7. Check;
system.
7-39
EAS00642
INSTALLING THE REAR BRAKE CALIPER

WARNING
ponents as they will cause the piston seals
to swell and distort.

DOT 4
1. Install:
brake pads
brake caliper 1
copper washers New
brake hose 2
union bolt 3 30 Nm (3.0 mkg, 22 ftlb)
WARNING
CAUTION:
brake caliper 1 , make sure that the brake
pipe a touches the projection b on the
brake caliper.
7-40
2. Fill:
mended brake fluid)

DOT 4
WARNING
Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
mance.
CAUTION:
3. Bleed:
brake system
4. Check:
brake fluid level
5. Check:
brake pedal operation
system.
7-41
FRONT FORK CHAS
FRONT FORK
EAS00647
13 Nm (1.3 mkg, 9.4 ftlb)
33 Nm (3.3 mkg, 24 ftlb)
26 Nm (2.6 mkg, 19 ftlb)

23 Nm (2.3 mkg, 17 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
6 Nm (0.6 mkg,
6 Nm (4.3 ftlb)
6 Nm (0.6 mkg, 4.3 ftlb)

Removing the front fork legs Remove the parts in the order listed.
Front brake calipers The following procedure applies to both
of the front fork legs.
Front wheel Refer to ”FRONT WHEEL AND BRAKE
DISCS”.
Front cowling inner panel Refer to ”COWLINGS” in chapter 3.
1 Front fender 1
2 Handlebar pinch bolt 2 Loosen
3 Upper bracket bolt 2
4 Handlebar (left) 1
5 Handlebar (right) 1
6 Cap bolts 2 Loosen
7 Upper bracket pinch bolts 2 Loosen
8 Lower bracket pinch bolts 4 Loosen
9 Front fork legs 2
procedure.
7-42
FRONT FORK CHAS
EB703002
23 Nm (2.3 mkg, 17 ftlb)
15 Nm (1.5 mkg, 11 ftlb)
40 Nm (4.0 mkg, 29 ftlb)

Disassembling the front fork legs Remove the parts in the order listed.
The following procedure applies to both of
the front fork legs.
1 Cap bolt 1
2 O-ring 1
3 Nut 1
4 Washer 1
5 Spacer 1 Refer to “DISASSEMBLING/
6 Washer 1 ASSEMBLING THE FRONT FORK
7 Fork spring 1 LEGS”.
8 Copper washer 1
9 Damper rod assembly bolt 1
10 Damper rod assembly 1
7-43
FRONT FORK CHAS
23 Nm (2.3 mkg, 17 ftlb)
15 Nm (1.5 mkg, 11 ftlb)
40 Nm (4.0 mkg, 29 ftlb)

11 Dust seal 1
12 Oil seal clip 1
13 Oil seal 1 Refer to “DISASSEMBLING/
14 Washer 1 ASSEMBLING THE FRONT FORK
15 Outer tube bushing 1 LEGS”.
16 Inner tube 1
17 Oil lock piece 1
procedure.
7-44
FRONT FORK CHAS
EAS00649
REMOVING THE FRONT FORK LEGS

front fork legs.
WARNING
NOTE:
2. Loosen:
upper bracket pinch bolt 3
cap bolt 2
handlebar pinch bolt 1
lower bracket pinch bolt
upper bracket bolt 4
handlebar 5
WARNING
Before loosening the upper and lower
bracket pinch bolts and handlebar pinch
bolt, support the front fork leg.
3. Remove:
front fork leg
EAS00655
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Remove:
cap bolt 1
(from the damper adjusting rod)
spacer 2
nut 3
a. Press down on the spacer with the fork

spring compressor 4 .
b. Install the rod holder 5 between the nut 3
and the spacer 2 .

90890-01441
Rod holder
90890-01434
7-45
FRONT FORK CHAS
NOTE:
Use the side of the rod holder that is marked “B”.
c. Loosen the nut.

d. Remove the cap bolt.
e. Remove the rod holder and fork spring com-
pressor.
WARNING
The fork spring is compressed.
f. Remove the spacer and nut.

g. Remove the fork spring.
2. Drain:
fork oil
NOTE:
Stroke the damper rod 1 several times while
draining the fork oil.
3. Remove:
dust seal
oil seal clip 1
oil seal
washer
(with a flat-head screwdriver)
Slide metal
4. Remove:
damper rod assembly bolt
copper washer
NOTE:
While holding the damper rod with the damper
rod holder 1 , loosen the damper rod assembly
bolt.
Damper rod holder

90890-01425, YM-01425
7-46
FRONT FORK CHAS
EAS00657
CHECKING THE FRONT FORK LEGS

front fork legs.
1. Check:
inner tube 1
outer tube 2
Bends/damage/scratches Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
spring free length a
Spring free length limit

251.8 mm (9.91 in)
<Limit>: 246 mm (9.69 in)
3. Check:
damper rod 1
Obstruction Blow out all of the oil pas-
sages with compressed air.
CAUTION:
The front fork leg has a built-in damper ad-
justing rod and a very sophisticated inter-
nal construction, which are particularly
sensitive to foreign material.
When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
7-47
FRONT FORK CHAS
4. Check:
cap bolt O-ring
EAS00661
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
WARNING
Make sure that the oil levels in both front
fork legs are equal.
Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
Before assembling the front fork leg, make
sure that all of the components are clean.
1. Install:
oil lock piece
inner tube 2
damper rod assembly 1
WARNING
Always use new copper washers.
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube 2 until it pro-
trudes from the bottom of the inner tube. Be
careful not to damage the inner tube.
2. Lubricate:
inner tube’s outer surface
Yamaha fork and suspension oil
01 or equivalent
7-48
FRONT FORK CHAS
3. Tighten:
damper rod assembly bolt 1
40 Nm (4.0 mkg, 29 ftlb)
NOTE:
While holding the damper rod with the damper
rod holder 2 , tighten the damper rod assembly
bolt.
Damper rod holder

90890-01425, YM-01425
4. Install:
outer tube bushing 1
washer 2
oil seal 3
oil seal clip 4
dust seal 5
CAUTION:
Make sure that the numbered side of the oil
seal faces up.
NOTE:
Before installing the oil seal, lubricate its lips
with lithium soap base grease.
Lubricate the outer surface of the inner tube
with fork oil.
Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 6 to protect
the oil seal during installation.
5. Install:
washer
oil seal 1
(with the fork seal driver 2 )
Fork seal driver weight

90890-01367, YM-33963
Fork seal driver attachment
90890-01374, YM-8020
6. Install:
oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube’s groove.
7-49
FRONT FORK CHAS
7. Install:
dust seal 1
(with the fork seal driver 2 )
8. Install:
rod puller 1
adapter 2
(onto the damper rod 3 )
Rod puller
90890-01437, YM-01437
Adapter
90890-01436
9. Fully compress the front fork leg.

10. Fill:
front fork leg
mended fork oil)
Quantity (each front fork leg)

476 cm3 (16.09356 US oz)
Recommended oil
Yamaha fork and suspension
oil 01
or equivalent
CAUTION:
Be sure to use the recommended fork oil.
Other oils may have an adverse effect on
front fork performance.
When disassembling and assembling the
front fork leg, do not allow any foreign ma-
terial to enter the front fork.
11. After filling the front fork leg, slowly stroke

the damper rod 1 up and down (at least ten
times) to distribute the fork oil.
NOTE:
Be sure to stroke the damper rod slowly be-
cause the fork oil may spurt out.
7-50
FRONT FORK CHAS
12. Slowly stroke the inner tube 1 up and down

to distribute the fork oil once more (1 stroke
= about 100 mm (3.94 in)).
NOTE:
Be careful not to stroke the inner tube over 100
mm (3.94 in) as this will cause air to enter. If the
inner tube is stroked more than 100 mm (3.94
in), repeat steps (12) and (13).
13. Before measuring the fork oil level, wait ten

minutes until the oil has settled and the air
bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any residual
air.
14. Measure:
front fork leg oil level a
Out of specification Correct.
Front fork leg oil level (from the

top of the inner tube, with the
inner tube fully compressed,
and without the spring)
107 mm (4.21 in)
15. Install:
nut 1
fork spring 2
washer 3
spacer 4
washer 5
damper adjusting rod 6
cap bolt 7
a. Remove the rod puller and adapter.

b. Install the nut.
7-51
FRONT FORK CHAS
c. Install the rod puller and adapter onto the

damper rod.
Rod puller
90890-01437, YM-01437
Adapter
90890-01436
d. Install the fork spring, washers and spacer.

e. Press down on the spacer with the fork
spring compressor 8 .
f. Pull up the rod puller and install the rod hold-
er 9 between the nut 1 and the spacer 4 .
NOTE:
Use the side of the rod holder that is marked “B”.

90890-01441
Rod holder
90890-01434
g. Remove the rod puller and adapter.

h. Install the nut 1 and position it as specified
b.
Distance b
11 mm (0.43 in)
i. Install the damper adjusting rod and cap bolt,

and then finger tighten the cap bolt.
j. Hold the cap bolt and tighten the nut to speci-
fication.
Nut:
15 Nm (1.5 mkg, 11 ftlb)
k. Remove the rod holder and fork spring com-

pressor.
WARNING
The fork spring is compressed.
Always use a new cap bolt O-ring.
7-52
FRONT FORK CHAS
16. Install:
cap bolt
(onto the inner tube)
NOTE:
Temporarily tighten the cap bolt.
EAS00662
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure that the inner fork tube is flush with
the top of the handlebar.
2. Tighten:
23 Nm (2.3 mkg, 17 ftlb)
handlebar pinch bolt 1
33 Nm (3.0 mkg, 24 ftlb)
cap bolt 2 23 Nm (2.3 mkg, 17 ftlb)
upper bracket pinch bolt 3
26 Nm (2.6 mkg, 19 ftlb)
WARNING
Make sure that the brake hoses are routed
properly.
3. Adjust:
spring preload
rebound damping
compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
7-53
HANDLEBARS CHAS
EAS00665
HANDLEBARS
150 Nm (11.5 mkg, 83 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
18
33 Nm (3.3 mkg, 24 ftlb)
26 Nm (2.6 mkg, 19 ftlb)

Removing the handlebars Remove the parts in the order listed.
1 Left grip end 1 Refer to “REMOVING/INSTALLING THE
2 Handlebar grip 1 HANDLEBARS”.
3 Clutch switch connector 2 Disconnect.
4 Left handlebar switch 1 Refer to “INSTALLING THE
HANDLEBARS”.
5 Starter cable 1 Disconnect.
6 Starter lever 1
7 Clutch cable 1 Disconnect.
8 Clutch lever holder 1
9 Right grip end 1 Refer to “INSTALLING THE
10 Throttle cable 2 HANDLEBARS”.
11 Throttle grip 1
7-54
HANDLEBARS CHAS
115 Nm (11.5 mkg, 83 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
13 Nm (1.3 mkg, 9.4 ftlb)
18
33 Nm (3.3 mkg, 24 ftlb)
26 Nm (2.6 mkg, 19 ftlb)

12 Front brake switch connector 2 Disconnect.
13 Right handlebar switch 1
Refer tp “INSTALLING THE
14 Brake master cylinder holder 1
HANDLEBARS”.
16 Handlebar pinch bolt 2
18 Upper bracket pinch bolt 2
19 Steering stem nut 1
20 Left handlebar 1
21 Right handlebar 1
22 Upper bracket 1
procedure.
7-55
HANDLEBARS CHAS
EAS00667
REMOVING THE HANDLEBARS

WARNING
2. Remove:
grip end
handlebar grip
left handlebar switch
clutch lever holder
NOTE:
Blow compressed air between the left handle-
bar and the handlebar grip, and gradually push
the grip off the handlebar.
3. Remove:
grip end
right handle switch 1
throttle grip 2
right handlebar switch
brake master cylinder holder
EAS00669
CHECKING THE HANDLEBARS

1. Check:
left handlebar
right handlebar
Bends/cracks/damage Replace.
WARNING
Do not attempt to straighten bent handle-
bars as this may dangerously weaken them.
7-56
HANDLEBARS CHAS
EAS00674
INSTALLING THE HANDLEBARS

1. Install:
brake master cylinder holder 1
CAUTION:
Install the brake master cylinder holder
with the “UP” mark facing up.
First, tighten the upper bolt, then the lower
bolt.
NOTE:
Align the mating surfaces of the brake master
cylinder holder with the punch mark a in the
right handlebar.
There should be 2 mm of clearance between
the right handlebar switch and the brake mas-
ter cylinder holder.
2. Install:
right handlebar switch 1
throttle cables
grip end
NOTE:
Align the projection a on the throttle cable
housing with the hole b in the right handlebar.
3. Install:
clutch lever holder 1
NOTE:
Align the slit in the clutch lever holder with the
punch mark a in the left handlebar.
7-57
HANDLEBARS CHAS
4. Install:
left handlebar switch 1
NOTE:
Align the projection a on the left handlebar
switch with the hole b in the left handlebar.
5. Install:
handlebar grip
grip end
a. Apply a thin coat of rubber adhesive onto the

end of the left handlebar.
b. Slide the handlebar grip over the end of the
left handlebar.
c. Wipe off any excess rubber adhesive with a
clean rag.
WARNING
Do not touch the handlebar grip until the
rubber adhesive has fully dried.
6. Adjust:
clutch cable free play
Refer to “ADJUSTING THE CLUTCH
Clutch cable free play (at the end

10 15 mm (0.39 0.59 in)
7. Adjust:
Throttle cable free play (at the

6 8 mm (0.24 0.31 in)
7-58
STEERING HEAD CHAS
EAS00676
STEERING HEAD
LOWER BRACKET
13 Nm (1.3 mkg, 9.4 ftlb) 115 Nm (11.5 mkg, 83 ftlb)
33 Nm (3.3 mkg,
27 Nm (24 ftlb)
23 Nm (2.3 mkg,
23 Nm (17 ftlb)
26 Nm (2.6 mkg, 19 ftlb)
1st. 17 Nm (1.7 mkg, 12 ftlb)

2nd. 9 Nm (0.9 mkg, 6.5 ftlb)

Removing the lower bracket Remove the parts in the order listed.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Front fork legs Refer to “FRONT FORK”.
1 Main switch coupler 2 Disconnect.
3 Left handlebar assembly 1
4 Right handlebar assembly 1
5 Steering stem nut 1
6 Washer 1
7 Upper bracket 1
8 Lower bracket panel 1
9 Brake hose holder bolt 2
10 Lock washer 1
11 Upper ring nut 1 Refer to ”CHECK AND ADJUSTING THE
12 Rubber washer 1 STEERING HEAD” in chapter 3.
7-59
STEERING HEAD CHAS
13 Nm (1.3 mkg, 9.4 ftlb) 115 Nm (11.5 mkg, 83 ftlb)
33 Nm (3.3 mkg,
27 Nm (24 ftlb)
23 Nm (2.3 mkg,
23 Nm (17 ftlb)
26 Nm (2.6 mkg, 19 ftlb)
1st. 17 Nm (1.7 mkg, 12 ftlb)

2nd. 9 Nm (0.9 mkg, 6.5 ftlb)

13 Lower ring nut 1 Refer to “CHECK AND ADJUSTING THE
STEERING HEAD” in chapter 3.
14 Lower bracket 1
15 Bearing cover 1
16 Bearing inner race 2
17 Upper bearing 1
18 Lower bearing 1
19 Dust seal 1
20 Bearing outer race 2
procedure.
7-60
STEERING HEAD CHAS
EAS00677
REMOVING THE LOWER BRACKET

WARNING
2. Remove:
front fork legs
steering stem nut
upper bracket
ring nuts 1
(with the special tool 2 )
Ring nut wrench

90890-01403, YU-33975
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00682
CHECKING THE STEERING HEAD

1. Wash:
bearing balls
bearing races
Recommended cleaning solvent

Kerosine
2. Check:
bearing balls 1
bearing races 2
Damage/pitting Replace.
3. Replace:
bearing balls
bearing races
a. Remove the bearing races from the steering

head pipe with a long rod 1 and hammer.
7-61
STEERING HEAD CHAS
b. Remove the bearing race from the lower

bracket with a floor chisel 2 and hammer.
c. Install a new dust seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
Always replace the bearing balls and bearing
races as a set.
Whenever the steering head is disassembled,
replace the dust seal.
4. Check:
upper bracket
lower bracket
(along with the steering stem)
EAS00683
INSTALLING THE STEERING HEAD

1. Lubricate:
upper bearing
lower bearing
bearing races
2. Install:
bearing
bearing cover
lower ring nut 1
rubber washer 2
upper ring nut 3
lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
7-62
STEERING HEAD CHAS
3. Install:
upper bracket
steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts, and handlebar pinch bolts.
5. Tighten:
steering stem nut
115 Nm (11.5 mkg, 83 ftlb)
23 Nm (2.3 mkg, 17 ftlb)
upper bracket pinch bolt
26 Nm (2.6 mkg, 19 ftlb)
upper bracket bolt
13 Nm (1.3 mkg, 9.4 ftlb)
handlebar pinch bolt
33 Nm (3.3 mkg, 24 ftlb)
7-63
REAR SHOCK ABSORBER ASSEMBLY CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
55 Nm (5.5 mkg, 40 ftlb)
40 Nm (4.0 mkg, 29 ftlb)
40 Nm (4.0 mkg, 29 ftlb)

Removing the rear shock absorber Remove the parts in the order listed.
assembly
Rear wheel Refer to “REMOVING THE REAR WHEEL”.
1 Self-locking nut/bolt 1/1
2 Self-locking nut/bolt 1/1
3 Self-locking nut/bolt/coller 1/1/1 Refer to “REMOVING THE REAR
4 Self-locking nut/bolt 1/1 SHOCK ABSORBER ASSEMBLY”.
5 Pin/clip/washer 1/1/1
6 Rear shock absorber assembly 1
7 Coller/oil seal/bearing 1/2/1
8 Relay arm 2
10 Connecting arm 1
procedure.
7-64
EAS00687
HANDLING THE REAR SHOCK ABSORBER

AND GAS CYLINDER
WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you under-
stand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause
an explosion due to excessive gas pres-
sure.
Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK ABSORB-

ER AND GAS CYLINDER
Gas pressure must be released before dispos-
ing of a rear shock absorber and gas cylinder.
To release the gas pressure, press on the gas
valve needle with a suitable tool as shown, until
all of the gas is released (the hissing has
stopped).
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
7-65
EAS00694
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
WARNING
NOTE:
2. Remove:
rear wheel
rear shock absorber assembly lower bolt 1
relay-arm-to-swingarm bolt 2
NOTE:
While removing the rear shock absorber as-
sembly lower bolt, hold the swingarm so that it
does not drop down.
3. Remove:
rear shock absorber assembly upper bin 1
rear shock absorber assembly
NOTE:
Raise the swingarm and then remove the rear
shock absorber assembly from between the
swingarm.
EAS00696
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY AND GAS CYLINDER
1. Check:
rear shock absorber rod
Bends/damage Replace the rear shock
absorber assembly.
rear shock absorber
Gas leaks/oil leaks Replace the rear
shock absorber assembly.
spring
Damage/wear Replace the rear shock
absorber assembly.
gas cylinder
Damage/gas leaks Replace.
bushings
dust seals
bolts
7-66
CHECKING THE RELAY ARM AND CON-

NECTING ARM
1. Check:
relay arm 1
connecting arm 2
bearings
oil seals
spacers
EAS00698
INSTALLING THE REAR SHOCK ABSORB-

ER ASSEMBLY
1. Lubricate:
bearings
oil seals
spacers
2. Install:
connecting arm
relay arm
NOTE:
When installing the rear shock absorber assem-
bly, lift up the swingarm.
3. Tighten:
connecting-arm-to-frame nut
40 Nm (4.0 mkg, 29 ftlb)
relay-arm-to-connecting-arm nut
40 Nm (4.0 mkg, 29 ftlb)
relay-arm-to-swingarm nut
40 Nm (4.0 mkg, 29 ftlb)
rear shock absorber assembly lower nut
55 Nm (5.5 mkg, 40 ftlb)
7-67
SWINGARM AND DRIVE CHAIN CHAS
EAS00700
SWINGARM AND DRIVE CHAIN
95 Nm (9.5 mkg, 69 ftlb)
6 Nm (0.6 mkg, 4.3 ftlb)
6 Nm (0.6 mkg,
6 Nm (4.3 ftlb)

Removing the swingarm and drive Remove the parts in the order listed.
chain
Drive sprocket Refer to “ENGINE” in chapter 4.
Rear wheel Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
1 Adjusting bolt/locknut 2/2
2 Drive chain guard 1
3 Rear fender 1
4 Flap 1
5 Pivot shaft nut/washer 1/1
6 Pivot shaft 1
7 Swingarm 1
7-68
95 Nm (9.5 mkg, 69 ftlb)
6 Nm (0.6 mkg, 4.3 ftlb)
6 Nm (0.6 mkg,
6 Nm (4.3 ftlb)

8 Pivot shaft adjust bolt 2 Refer to “REMOVING/INSTALLING THE
SWINGARM”.
9 Drive chain 1
10 Dust cover 1
11 Oil seal 1
12 Bush 1
13 Shim 1
14 Drive chain guide 1
15 Bush 1
16 Left bearing 1
17 Right bearing 1
procedure.
7-69
NOTE:
Before removing the drive sprocket, drive chain,
and rear wheel, measure the drive chain slack
and the length of a tenlink section of the drive
chain.
EC573000
REMOVING THE SWINGARM

1. Remove:
Bolt (connecting rod) 1
Connecting rod 2
NOTE:
Remove the bolt while holding the swingarm.
2. Loosen:
Pivot shaft adjust bolt 1
NOTE:
Loosen the pivot shaft adjust bolt using a pivot
shaft wrench 2
Pivot shaft wrench:

90890-01471, YM-01471
3. Remove:
Pivot shaft 1
Swingarm
EAS00704
REMOVING THE DRIVE CHAIN

1. Remove:
drive chain
NOTE:
When replacing the swingarm, the drive chain is
cut.
7-70
EAS00703
CHECKING THE SWINGARM

WARNING
NOTE:
2. Measure:
swingarm side play
swingarm vertical movement
a. Measure the tightening torque of the pivot

shaft nut.
Pivot shaft nut

95 Nm (9.5 mkg, 69 ftlb)
b. Measure the swingarm side play A by mov-

ing the swingarm from side to side.
c. If the swingarm side play is out of specifica-
tion, check the spacers, bearings, washers,
and dust covers.
Swingarm side play (at the end

of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement B

by moving the swingarm up and down.
If swingarm vertical movement is not smooth or
if there is binding, check the spacers, bearings,
washers, and bust covers.
3. Check:
swingarm
NOTE:
If the swingarm must be replaced, the drive
chain must be cut with a drive chain cutter.
7-71
4. Check:
pivot shaft
Roll the pivot shaft on a flat surface.
Bends Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
5. Wash:
pivot shaft
pivot shaft adjust bolt
dust covers
spacer
bearings
Recommended cleaning solvent

Kerosine
6. Check:
dust covers
spacer
oil seals
bearings
7-72
EAS00709
CHECKING THE DRIVE CHAIN

1. Measure:
ten-link section a of the drive chain
Out of specification Replace the drive
chain.
Max. ten-link drive chain section

149 mm (5.87 in)
NOTE:
While measuring the ten-link section, push
down on the drive chain to increase its tension.
Measure the length between drive chain roller
1 and 11 as shown.
Perform this measurement at two or three dif-
ferent places.
2. Check:
drive chain
Stiffness Clean and lubricate or replace.
3. Clean:
drive chain
a. Wipe the drive chain with a clean cloth.

b. Put the drive chain in kerosine and remove
any remaining dirt.
7-73
c. Remove the drive chain from the kerosine

and completely dry it.
CAUTION:
This motorcycle has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean
the drive chain.
High-pressure methods could force dirt or
water into the drive chain’s internals, and
solvents will deteriorate the O-rings. A
coarse brush can also damage the O-rings.
Therefore, use only kerosine to clean the
drive chain.
Don’t soak drive drain in kerosine more
them ten minutes. O-ring is damage by kero-
sine.
4. Check:
O-rings 1
Damage Replace the drive chain.
drive chain rollers 2
Damage/wear Replace the drive chain.
drive chain side plates 3
Cracks/damage/wear Replace the drive
chain.
5. Lubricate:
drive chain
Engine oil or chain lubricant
suitable for O-ring chains
6 Check:
drive sprocket
rear wheel sprocket
More than 1/4 tooth a wear Replace the
drive chain sprockets as a set.
Bent teeth Replace the drive chain
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
7-74
EAS00711
INSTALLING THE SWINGARM

1. Lubricate:
bearings
spacers
dust covers
pivot shaft
2. Install:
swingarm
pivot shaft
washer
pivot shaft adjust bolt 1
pivot shaft nut 95 Nm (9.5 mkg, 69 ftlb)
NOTE:
Use the pivot shaft wrench 2 to tighten the piv-
ot adjust bolt to finger tightness.
Pivot shaft wrench:

90890-01471, YM-01471
3. Install:
rear wheel
Refer to “REAR SHOCK ABSORBER AS-
SEMBLY” and “REAR WHEEL”.
4. Adjust:
drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack

40 50 mm (1.5 1.97 in)
EAS00713
INSTALLING THE DRIVE CHAIN

1. Lubricate:
drive chain
2. Install:
drive chain
(with the drive chain riveter)
7-75
CHAS
ELEC
CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
INSTRUMENT FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

INDICATOR LIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT . . . . . . 8-2
COMBINATION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . . 8-8

TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . 8-8
CHECKING THE CONDITION OF THE BULB SOCKETS . . . . . . . . 8-10
CHECKING THE LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
ELECTRIC STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-16
STARTING CIRCUIT CUTOFF SYSTEM OPERATION . . . . . . . . . . . 8-17
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-22

CHECKING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
ASSEMBLING THE STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . 8-25
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-26
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
ELEC
SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
CHECKING THE SIGNALING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 8-38
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
FUEL PUMP SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-50
FUEL PUMP CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8-51
CHECKING THE FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-54
SELF-DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-55
ELECTRICAL COMPONENTS ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Wire harness 10 Starter relay 20 Oil level switch
2 Main switch 11 Main fuse 21 Pickup coil
3 Front brake light switch 12 Oil level relay 22 Radiator fan
4 Plug top ignition coils 13 Battery 23 Horn
5 Clutch switch 14 Rectifier/ regulator 24 Thermo unit
6 Starting circuit cutoff relay 15 Rear brake light switch 25 Thermo switch
7 Fuse box 16 Neutral switch 26 Headlight relay (HI, LO)
8 Flasher relay 17 Speed sensor
9 CDI unit 18 Sidestand switch
19 Stator coil assembly
8-1
INSTRUMENT FUNCTIONS ELEC
INSTRUMENT FUNCTIONS
INDICATOR LIGHTS
Turn indicator light “ ”
This indicator flashes when the turn switch is
moved to the left or right.
Neutral indicator light “ ”
This indicator comes on when the transmis-
sion is in neutral.
High beam indicator light “ ”
This indicator comes on when the headlight
high beam is used.
Fuel indicator light “ ”
When the fuel level drops below approxi-
1 Neutral indicator light “”
mately 3.7 L, this light will come on.
2 High beam indicator light “ ”
When this light comes on, fill the fuel tank at
3 Turn indicator light “ ” the first opportunity.
4 Fuel indicator light “ ”
OIL LEVEL/COOLANT TEMPERATURE WARNING LIGHT

This warning light has two functions.
The light will come on and symbol “ ” will
flash if the engine oil level is low. If this sym-
bol flashes, stop the engine immediately
and fill it with oil to the specified level.
The light will come on and symbol “ ” will
flash if the coolant temperature is too high.
The following chart shows the conditions of
the indicator light, symbol and temperature
display in accordance with the coolant tem-
perature.
1 Oil level / coolant temperature warning light “ ”
2 Oil level symbol “ ” CAUTION:
3 Coolant temperature symbol “ ”
Do not run the motorcycle until you know it
has sufficient engine oil.
Do not run the motorcycle if the engine is
overheated.
NOTE:
Even if the oil is filled to the specified level, the
warning light may flicker when riding on a slope
or during sudden acceleration or deceleration,
but this is normal.
8-2
Coolant
Display Conditions What to do
temperature
0_C 40_C Symbol is on and

Go ahead with riding.
(0°F 104°F) “LO” is displayed.
Symbol is on and
41_C 117_C
temperature is dis- Go ahead with riding.
(106°F 243°F)
played.
Stop the motorcycle and

allow it to idle until the
Symbol and tem- coolant temperature goes
118_C 140_C perature flashes down.
(244°F 284°F) and indicator light If the temperature does
comes on. not go down, stop the en-
gine. Refer to “OVER-
HEATING” in chapter 9.
Symbol flashes,
Stop the engine and allow
“HI” is displayed
141 _C it to cool.
and flashes, and
(286°F) Refer to “OVERHEATING”
the indicator light
in chapter 9.
comes on.
COMBINATION METER
This combination meter is equipped with the fol-
lowing.
S A speedometer
S An odometer
S Two trip odometers
S A fuel reserve tripmeter
S A clock
To change the speedometer display from kilo-
meters to miles, press the “SELECT” button for
at least two seconds.
1 Speedometer
2 Clock, odometer
Odometer and trip meters
Use the trip meters to estimate how far you can
3 “SELECT” button
ride on a tank of fuel.
4 “RESET” button
Use the fuel reserve trip meter to see the dis-
tance traveled from when the fuel level dropped
to the reserve level.
Push the “SELECT” button to change between

the odometer mode “ODO” and the trip odome-
ter modes “TRIP 1”and “TRIP 2” in the following
order:
“ODO” “TRIP 1” “TRIP 2” “ODO”
8-3
When the fuel level indicator light comes on the
odometer display will automatically change to
the fuel reserve trip meter mode “TRIP F” and
start counting the distance traveled from that
point. Push the “SELECT” button to change be-
tween the fuel odometer, trip odometer and
odometer modes in the following order:
“TRIP F” “TRIP 1” “TRIP 2” “ODO”
“TRIP F”
To reset a trip odometer to 0.0, select it by push-

ing the “SELECT” button and push the “RESET”
button for at least one second. To reset the fuel
reserve trip meter, select it by pushing the “SE-
LECT” button and push the “RESET” button for
at least one second.
The display will return to “TRIP 1”. If you do not
reset the fuel reserve trip meter manually, it will
automatically reset and return to “TRIP 1” after
refueling and the motorcycle has traveled both
5 km and for approximately 3 minutes.
Clock
To change the display to the clock mode, push
both the “SELECT” and “RESET” buttons.
To set the clock:
1. Push both the “SELECT” and “RESET” but-
tons for at least two seconds.
2. When the hour digits start flashing, push the
“RESET” button to set the hours.
3. Push the “SELECT” button to change the
minutes.
4. When the minute digits start flashing, push
the “RESET” button to set the minutes.
5. Push the “SELECT” button to start the clock.
NOTE:
After setting the clock, be sure to push the “SE-
LECT” button before turning the main switch to
“OFF”, otherwise the clock will not be set.
8-4
SWITCHES ELEC
EB801000
SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect,
check the wiring connections and if necessary,
replace the switch.
CAUTION:
Never insert the tester probes into the cou-
pler terminal slots 1 . Always insert the
probes from the opposite end of the coupler,
taking care not to loosen or damage the
leads.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
When checking for continuity, switch back and
forth between the switch positions a few times.
The terminal connections for switches (e.g.,

main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
The switch positions are shown in the far left
column and the switch lead colors are shown in
the top row in the switch illustration.
NOTE:
“ ” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows

that:
There is continuity between blue/red and red
when the switch is set to “ ”.
There is continuity between blue/red and blue,
between brown/blue and red, and between
blue/yellow and blue/black when the switch is
set to “ON”.
8-5
CHECKING THE SWITCHES ELEC
EB801010
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the termi-
nals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear Repair or replace the switch.
Improperly connected Properly connect.
Incorrect continuity reading Replace the switch.
8-6
CHECKING THE SWITCHES ELEC
1 Main switch 7 Start switch
2 Dimmer switch 8 Front brake light switch
3 Turn signal switch 9 Rear brake light switch
4 Horn switch 10 Neutral switch
5 Clutch switch 11 Fuse
6 Engine stop switch 12 Sidestand switch
13 Oil level switch
8-7
CHECKING THE BULBS AND BULB SOCKETS ELEC
EB801020
CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for damage or
wear, proper connections, and also for continu-
ity between the terminals.
Damage/wear Repair or replace the bulb,
bulb socket or both.
Improperly connected Properly connect.
Incorrect continuity reading Repair or re-
place the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown in
the illustration on the left.
Bulbs A and B are used for headlights and
usually use a bulb holder which must be de-
tached before removing the bulb. The majority
of these bulbs can be removed from their re-
spective socket by turning them counterclock-
wise.
Bulb C is used for turn signal and tail/brake
lights and can be removed from the socket by
pushing and turning the bulb counterclock-
wise.
Bulbs D and E are used for meter and indica-
tor lights and can be removed from their re-
spective socket by carefully pulling them out.
CHECKING THE CONDITION OF THE BULBS

bulbs.
1. Remove:
bulb
8-8
WARNING
Since the headlight bulb gets extremely hot,
keep flammable products and your hands
away from the bulb until it has cooled down.
CAUTION:
Be sure to hold the socket firmly when re-
moving the bulb. Never pull the lead, other-
wise it may be pulled out of the terminal in
the coupler.
Avoid touching the glass part of the head-
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be adverse-
ly affected. If the headlight bulb gets soiled,
thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.
2. Check:
bulb (for continuity)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the pocket
tester to “0” and to the “Ω 1” range.
a. Connect the tester positive probe to terminal

1 and the tester negative probe to terminal
3 , and check the continuity.
b. Connect the tester positive probe to terminal
2 and the tester negative probe to terminal
3 , and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
8-9
CHECKING THE CONDITION OF THE BULB
SOCKETS
bulb sockets.
1. Check:
bulb socket (for continuity)
No continuity Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb section;
however, note the following.
a. Install a good bulb into the bulb socket.

b. Connect the pocket tester probes to the re-
spective leads of the bulb socket.
c. Check the bulb socket for continuity.
If any of the readings indicate no continuity,
replace the bulb socket.
CHECKING THE LEDs

LEDs.
1. Check:
LED (for proper operation)
a. Disconnect the meter assembly coupler

(meter assembly side).
b. Connect two jumper leads 1 from the bat-
tery terminals to the respective coupler ter-
minals as shown.
WARNING
A wire that is used as a jumper lead must
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may
burn.
This check is likely to produce sparks,
therefore make sure that no flammable gas
or fluid is in the vicinity.
c. When the jumper leads are connected to the

terminals the respective LED should illumi-
nate.
Does not light Replace the meter assem-
bly.
8-10
IGNITION SYSTEM ELEC
EB802001
IGNITION SYSTEM
CIRCUIT DIAGRAM
1 Main switch
5 Battery
6 Main fuse
9 Starting circuit cutoff relay
11 Sidestand switch
14 CDI unit
15 Ignition coil #1
16 Ignition coil #4
17 Ignition coil #2
18 Ignition coil #3
19 Spark plugs
20 Pickup coil
21 Neutral switch
53 Ignition fuse
59 Engine stop switch
62 Diode 2
8-11
EB802011 EB802401
TROUBLESHOOTING 2. Battery
The ignition system fails to operate (no S Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING THE
BATTERY” in chapter 3.
Check:
Min. open-circuit voltage
1. main and ignition fuses
12.8 V or more at 20_C (68_F)
2. battery
3. spark plugs S Is the battery OK?
4. ignition spark gap
5. spark plug cap resistance YES NO
6. ignition coil resistance
7. pickup coil resistance
S Clean the battery
8. main switch
terminals.
9. engine stop switch
S Recharge or re-
10. neutral switch
place the battery.
11. sidestand switch
12. starting circuit cutoff relay
13. wiring
(of the entire ignition system)
NOTE: EB802403
S Before troubleshooting, remove the following 3. Spark plugs

part(-s):
1) rider seat
spark plugs.
2) fuel tank
S Check the condition of the spark plug.
3) air filter case
S Check the spark plug type.
4) heat protector plate
S Measure the spark plug gap.
5) front cowling inner panel (right)
Refer to “CHECKING THE SPARK PLUGS”
6) side cowling inner panel (right)
in chapter 3.
7) side cowling (right)
S Troubleshoot with the following special tool Standard spark plug
(-s). CR10EK (NGK)
CR9EK (NGK) (California)
Spark plug gap
Ignition checker 0.6 0.7 mm (0.02 0.03 in)
90890-06754
Pocket tester S Is the spark plug in good condition, is it of the
90890-03112 correct type, and its gap within specification?
EB802400 YES NO
1. Main and ignition fuses
S Check the main and ignition fuses for conti- Re-gap or replace the
nuity. spark plug.
Refer to “CHECKING THE FUSES” in chap-
ter 3.
S Are the main and ignition fuses OK?
YES NO
Replace the fuse(-s).
8-12
EB802405 EB802409
4. Ignition spark gap 6. Ignition coil resistance

The following procedure applies to all of the The following procedure applies to all of the
spark plugs. ignition coils.
S Disconnect the spark plug cap from the spark S Disconnect the ignition coil connectors from
plug. the ignition coil terminals.
S Connect the ignition checker 1 as shown. S Connect the pocket tester (Ω 1) to the igni-
S 2 Spark plug cap tion coil as shown.
S Set the main switch to “ON”.
Tester positive probe
S Measure the ignition spark gap a .
ignition coil terminal
S Crank the engine by pushing the start switch Tester negative probe
and gradually increase the spark gap until a ignition coil terminal
misfire occurs.
S Measure the primary coil resistance.

Min. ignition spark gap Primary coil resistance
6 mm (0.24 in) 0.238 X 0.322 Ω at 20_C (68°F)
S Is there a spark and is the spark gap within S Connect the pocket tester (Ω 1k) to the
specification? ignition coil as shown.
S Measure the secondary coil resistance.
NO YES
ignition coil terminal 1
The ignition system is Tester positive probe
OK. spark plug terminal 2
Secondary coil resistance

8.16 X 11.04 kΩ at 20_C (68°F)
S Is the ignition coil OK?
YES NO
Replace the ignition

coil.
8-13
EB802410 EB802411
7. Pickup coil resistance 8. Main switch

S Disconnect the pickup coil coupler from the S Check the main switch for continuity.
wire harness. Refer to “CHECKING THE SWITCHES”.
S Connect the pocket tester (Ω 100) to the S Is the main switch OK?
pickup coil terminal.
YES NO
Tester positive probe gray 1
Tester negative probe black 2
Replace the main
switch.
EB802412
9. Engine stop switch

S Check the engine stop switch for continuity.
Refer to “CHECKING THE SWITCHES”.
S Is the engine stop switch OK?
S Measure the pickup coil resistance.
YES NO
Pickup coil resistance
248 X 372 Ω at 20_C (68°F)
Replace the right
(between gray and black) handlebar switch.
S Is the pickup coil OK?
YES NO EB802413
10. Neutral switch

Replace the pickup S Check the neutral switch for continuity.
coil. Refer to “CHECKING THE SWITCHES”.
S Is the neutral switch OK?
YES NO
Replace the neutral

switch.
EB802414
11. Sidestand switch

S Check the sidestand switch for continuity.
S Is the sidestand switch OK?
YES NO
Replace the side-

stand switch.
8-14
EB802415 EB802416
12. Starting circuit cutoff relay 13. Wiring

Remove the relay unit from the wire harness. Check the entire ignition system’s wiring.
Connect the pocket tester (Ω 1) to the relay Refer to “CIRCUIT DIAGRAM”.
terminals as shown. Is the ignition system’s wiring properly con-
Check the starting circuit cutoff relay for connected and without defects?
tinuity.
NO YES
sky blue 1 No
Tester negative probe continuity Properly connect or Replace the ignitor
blue/yellow 2 repair the ignition unit.
system’s wiring.
blue/yellow 2 Continuity
Tester negative probe
sky blue 1
NOTE:
When you switch the “–” and “)” leads of the
digital pocket tester, the readings in the above
chart will be reversed.
Are the tester readings correct?
YES NO
Replace the starting

circuit cutoff relay.
8-15
ELECTRIC STARTING SYSTEM ELEC
EB803000
ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM
1 Main switch
5 Battery
6 Main fuse
7 Starter relay
8 Starter motor
11 Sidestand switch
21 Neutral switch
37 Clutch switch
53 Ignition fuse
60 Start switch
61 Diode 1
62 Diode 2
8-16
EB803010
STARTING CIRCUIT CUTOFF SYSTEM OP-

ERATION
If the engine stop switch is set to “ ” and the
main switch is set to “ON” (both switches are
closed), the starter motor can only operate if at
least one of the following conditions is met:
The transmission is in neutral (the neutral
switch is closed).
The clutch lever is pulled to the handlebar (the
clutch switch is closed) and the sidestand is up
(the sidestand switch is closed).
The starting circuit cutoff relay prevents the
starter motor from operating when neither of
these conditions has been met. In this instance,
the starting circuit cutoff relay is open so current
cannot reach the starter motor. When at least
one of the above conditions has been met the
starting circuit cutoff relay is closed and the en-
gine can be started by pressing the start switch.
WHEN THE TRANSMISSION IS IN
NEUTRAL
WHEN THE SIDESTAND IS UP AND
THE CLUTCH LEVER IS PULLED TO
THE HANDLEBAR
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
7 Diode
8 Clutch switch
9 Sidestand switch
10 Neutral switch
11 Start switch
12 Starter relay
13 Starter motor
8-17
EB803020 EB802401
The starter motor fails to turn. S Check the condition of the battery.
Refer to “CHECKING AND CHARGING THE
Check: BATTERY” in chapter 3.
2. battery Open-circuit voltage
3. starter motor 12.8 V or more at 20_C (68°F)
4. starting circuit cutoff relay S Is the battery OK?
5. Diode
6. starter relay YES NO
7. main switch
8. engine stop switch
9. neutral switch S Clean the battery
10. sidestand switch terminals.
11. clutch switch S Recharge or
12. start switch replace the battery.
13. wiring
(of the entire starting system)
NOTE:
S Before, troubleshooting, remove the following
EB803400
part(-s):
1) rider seat 3. Starter motor
2) fuel tank S Connect the battery positive terminal 1 and
3) air filter case starter motor lead 2 with a jumper lead 3 .
4) front cowling inner panels
5) Side cowling inner panels
6) Side cowlings
S Troubleshoot with the following special tool
(-s).
Pocket tester
90890-03112
EB802400

WARNING
S Check the main and ignition fuses for conti-
S A wire that is used as a jumper lead must
nuity.
have at least the same capacity of the
battery lead, otherwise the jumper lead
ter 3.
may burn.
S Are the main and ignition fuses OK?
S This check is likely to produce sparks,
NO therefore make sure that no flammable
YES
gas or fluid is in the vicinity.
Replace the fuse(-s). S Does the starter motor turn?
YES NO
Repair or replace the

starter motor.
8-18
EB803402 EB803403
4. Starting circuit cutoff relay 5. DIODE

Disconnect the relay from the coupler. Disconnect the relay from the coupler.
Connect the pocket tester (Ω 1) and bat- Connect the pocket tester (Ω 1) to the relay
tery (12 V) to the relay terminals as shown. terminals as shown.
Measure the starting circuit cutoff relay for
Battery positive terminal red/black 1
continuity as follows.
Battery negative terminal
black/yellow 2 Tester positive probe
sky blue 1
Tester positive probe blue/white 3
Tester negative probe blue 4
black/yellow 2
No
Tester positive probe continuity
sky blue 1
blue/yellow 3
black/yellow 2
sky blue 1
Continuity
Does the starting circuit cutoff relay have Tester positive probe
continuity between black and blue/white? blue/yellow 3
YES NO sky blue 1

circuit cutoff relay
NOTE:
When you switch the “–” and “)” leads of the
digital pocket tester, the readings in the above
chart will be reversed.
Are the tester readings correct?
YES NO

circuit cutoff relay
8-19
EB803404 EB802412
6. Starter relay 8. Engine stop switch

Disconnect the starter relay from the coupler. Check the engine stop switch for continuity.
Connect the pocket tester (Ω 1) and bat- Refer to “CHECKING THE SWITCHES”.
tery (12 V) to the starter relay coupler as Is the engine stop switch OK?
shown.
YES NO
Battery positive terminal red/white 1
Battery negative terminal
blue/white 2 Replace the right
handlebar switch.
Tester positive probe red 3
EB802413
9. Neutral switch
Check the neutral switch for continuity.
Is the neutral switch OK?
YES NO
Replace the neutral

Does the starter relay have continuity be- switch.
tween red and black?
YES NO
10. Diode
Replace the starter
Check the diode for continuty.
relay.
Disconnect the diode from the coupler.
Connect the pocket tester (Ω 1) to the diode
terminals as a shown.
EB802411
Measur the diode for continuity as follows.
7. Main switch
Check the main switch for continuity. blue/yellow 1 No
Refer to “CHECKING THE SWITCHES”. Tester negative probe continuity
Is the main switch OK? blue/black 2
YES NO Tester positive probe

blue/black 2
Tester negative probe Continuity
Replace the main blue/yellow 1
switch.
Is the diode ok?
YES NO
Replace the diode.

8-20
EB8022414
11. Sidestand switch

Check the sidestand switch for continuity.
Is the sidestand switch OK?
YES NO
Replace the
sidestand switch.
EB803405
12. Clutch switch

Check the clutch switch for continuity.
Is the clutch switch OK?
YES NO
Replace the clutch

switch.
EB803406
13. Start switch

Check the start switch for continuity.
Is the start switch OK?
YES NO
Replace the right

handlebar switch.
EB803408
14. Wiring
Check the entire starting system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
Is the starting system’s wiring properly con-
nected and without defects?
NO YES
Properly connect or The starting system

repair the starting circuit is OK.
system’s wiring.
8-21
STARTER MOTOR ELEC
EAS00767
STARTER MOTOR
5 Nm (0.5mkg, 3.6 ftlb)

Removing the starter motor Remove the parts in the order listed.
Rider seat Refer to “SEATS” in chapter 3.
Fuel tank Refer to “FUEL TANK” in chapter 3.
Carburetors Refer to “CARBURETORS” in chapter 6.
Coolant Drain
Refer to “CHANGING THE COOLANT”
in chapter 3.
Thermostat Refer to “THERMOSTAT” in chapter 5.
1 Starter motor lead 1
2 Starter motor assembly 1
procedure.
8-22
STARTER MOTOR ELEC
5 Nm (0.5mkg, 3.6 ftlb)
10 Nm (1.0mkg, 0.4 ftlb)

Disassembling the starter motor Remove the parts in the order listed.
1 O-ring 1
2 Starter motor front cover 1
3 Lock washer 1
4 Oil seal 1
5 Bearing 1
6 Washer set 1
7 Starter motor rear cover 1
8 Washer set 1
9 O-ring 2
10 Brush holder set 1
11 O-ring 1
12 Armature assembly 1
13 Starter motor yoke 1
procedure.
8-23
STARTER MOTOR ELEC
EB803511
CHECKING THE STARTER MOTOR

1. Check:
S commutator
Dirt Clean with 600 grit sandpaper.
2. Measure:
S commutator diameter a
Out of specification Replace the starter
motor.
Min. commutator diameter

27 mm (1.06 in)
3. Measure:
S mica undercut a
Out of specification Scrape the mica to the
proper measurement with a hacksaw blade
which has been grounded to fit the commuta-
tor.
Mica undercut
0.7 mm (0.03 in)
NOTE:
The mica must be undercut to ensure proper
operation of the commutator.
4. Measure:
S armature assembly resistances (commuta-
tor and insulation)
Out of specification Replace the starter
motor.
a. Measure the armature assembly resis-

tances with the pocket tester.
Pocket tester
90890-03112
Armature assembly
Commutator resistance 1
0.012 0.022 Ω at 20_C (68°F)
Insulation resistance 2
Above 1 MΩ at 20_C (68°F)
b. If any resistance is out of specification, re-

place the starter motor.
8-24
STARTER MOTOR ELEC
5. Measure:
brush length a
Out of specification Replace the brushes
as a set.
Min. brush length

3.5 mm (0.14 in)
6. Measure:
brush spring force
Out of specification Replace the brush
springs as a set.
Brush spring force

7.16 9.52 N (7.16 9.52 g,
25.77 34.27 oz)
7. Check:
gear teeth
Damage/wear Replace the gear.
8. Check:
bearing
oil seal
part(-s).
EB803701
ASSEMBLING THE STARTER MOTOR

1. Install:
brush seat 1
NOTE:
Align the tab a on the starter motor rear cover
with the slot b in the yoke.
2. Install:
starter motor yoke 1
O-rings 2 New
starter motor front cover 3
starter motor rear cover 4
bolts 5 Nm (0.5 mkg, 3.6 ftlb)
NOTE:
Align the match marks a on the starter motor
yoke with the match marks b on the front and
rear covers.
8-25
CHARGING SYSTEM ELEC
EB804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
3 Rectifier/ regulator
4 AC magneto
5 Battery
6 Main fuse
8-26
EB804010 EB802401
The battery is not being charged. S Check the condition of the battery.
1. main fuse
Open-circuit voltage
2. battery
12.8 V or more at 20_C (68°F)
3. charging voltage
4. stator coil assembly resistance S Is the battery OK?
5. wiring
(of the entire charging system) YES NO
NOTE:
S Before troubleshooting, remove the following S Clean the battery
part(-s): terminals.
1) rider seat S Recharge or
2) fuel tank replace the battery.
S Troubleshoot with the following special
tool(-s).
EB804400
Engine tachometer 3. Charging voltage

90793-80009 S Connect the engine tachometer to the spark
Pocket tester plug lead of cylinder #1.
90890-03112 S Connect the pocket tester (DC 20 V) to the
battery as shown.
battery positive terminal
battery negative terminal
EB802400
1. Main fuse
S Check the main fuse for continuity.
ter 3.
S Is the main fuse OK?
YES NO S Start the engine and let it run at approximate-

ly 5,000 r/min.
S Measure the charging voltage.
Replace the fuse.
Charging voltage
14 V at 5,000 r/min
8-27
EB804404
5. Wiring
NOTE:
Make sure that the battery is fully charged. S Check the wiring connections of the entire
charging system.
S Is the charging voltage within specification? Refer to “CIRCUIT DIAGRAM”.
S Is the charging system’s wiring properly con-
NO YES nected and without defects?
NO YES
The charging circuit
is OK.
Properly connect or Replace the rectifier/
EB804401
repair the charging regulator.
4. Stator coil assembly resistances system’s wiring.
S Remove the generator cover.
S Connect the pocket tester (Ω 1) to the sta-
tor coil assembly coupler as shown.
Tester positive probe white 1
Tester negative probe white 2
Tester positive probe white 1
Tester negative probe white 3
S Measure the stator coil assembly resis-

tances.
Stator coil resistance
0.27X 0.33 Ω at 20_C (68°F)
S Is the stator coil assembly OK?
YES NO
Replace the stator

coil assembly.
8-28
LIGHTING SYSTEM ELEC
EB805000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1 Main switch 45 Headlight relay (Hi)
5 Battery 46 Headlight relay (Lo)
6 Main fuse 47 Tail/ brake light
30 High beam indicator light 51 Headlight fuse
32 Illumination light 52 Signaling system fuse
34 Dimmer switch
40 Front turn signal / position light (L)
41 Front turn signal / position light (R)
44 Headlight
8-29
EB805010 EB802401
Any of the following fail to light: head- S Check the condition of the battery.
light, high beam indicator light, taillight, Refer to “CHECKING AND CHARGING THE
auxiliary light or meter light. BATTERY” in chapter 3.
Check: Open-circuit voltage

1. main, signaling system, and headlight fuses 12.8 V or more at 20_C (68°F)
2. battery S Is the battery OK?
3. main switch
4. dimmer switch YES NO
5. wiring
(of the entire charging system)
S Clean the battery
NOTE: terminals.
S Before troubleshooting, remove the following S Recharge or
part(-s): replace the battery.
1) seats
2) fuel tank
3) air filter case EB802411

3. Main switch
5) front cowling
6) rear cowling S Check the main switch for continuity.
S Troubleshoot with the following special Refer to “CHECKING THE SWITCHES”.
tool(-s). S Is the main switch OK?
YES NO
Pocket tester
90890-03112
Replace the main
switch.
EB802400
1. Main, signaling system, and headlight

fuses
S Check the main, signaling system, and
headlight fuses for continuity.
ter 3.
S Are the main, signaling system, and head-
light fuses OK?
YES NO
8-30
EB805401 EB805410
4. Dimmer switch CHECKING THE LIGHTING SYSTEM

1. The headlight and the high beam indicator
Check the dimmer switch for continuity. light fail to come on.
Is the dimmer switch OK? 1. Headlight bulb and socket
Check the headlight bulb and socket for con-
YES NO
tinuity.
Refer to “CHECKING THE BULBS AND
The dimmer switch is BULB SOCKETS”.
faulty. Replace the Are the headlight bulb and socket OK?
left handlebar switch.
YES NO
EB805404
Replace the head-
5. Wiring light bulb, socket or
both.
Check the entire lighting system’s wiring.
Is the lighting system’s wiring properly con-
2. High beam indicator light LED
YES NO
Check the LED of the high beam indicator
light.
Check the condition Properly connect or Refer to “CHECKING THE LEDs”.
of each of the lighting repair the lighting Is the high beam indicator light LED OK?
system’s circuits. system’s wiring.
Refer to “CHECKING YES NO
THE LIGHTING
SYSTEM”.
Replace the meter
assembly.
3. Voltage
Connect the pocket tester (DC 20 V) to the
headlight and high beam indicator light cou-
plers as shown.
A When the dimmer switch is set to “ ”
B When the dimmer switch is set to “ ”
Headlight
yellow 1 or green 2
High beam indicator light
8-31
Headlight coupler (wire harness side)
Meter assembly couply (wire harness side) Does the headlight relay have continuity be-
tween yellow (green) and red/yellow?
YES NO
This circuit is OK. Replace the head-

light relay.
EB805411
2. Illumination fails to come on.
Set the main switch to “ON”.
Set the dimmer switch to “ ” or “ ”. 1. Meter light bulb and socket.
Measure the voltage (12 V) of yellow (green) Check the meter light bulb and socket for
2 on the headlight coupler (headlight side). continuity.
Is the voltage within specification? Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
YES NO Are the meter light bulb and socket OK?
The wiring circuit YES NO

from the main switch
to the headlight cou- Replace the meter
pler is faulty and must light bulb, socket or
be repaired. both.
4. Headlight relay (Hi or Lo) 2. Voltage
Disconnect the headlight relay from the cou- Connect the pocket tester (20 V) to the meter
pler. assembly coupler (wire harness side) as
Connect the pocket tester (Ω 1) and bat- shown.
tery (12 V) to the headlight relay terminals as
shown. Tester positive probe blue 1
Battery positive terminal white/yellow
(white/green) 1
Battery negative terminal black 2
yellow (green) 4
Tester negative probe red/yellow 3
8-32
Set the main switch to “ON”. Set the main switch to “ON”.
Measure the voltage (12 V) of blue 1 on the Measure the voltage (12 V) of blue/red 1 on
meter assembly coupler (wire harness side). the tail/brake light coupler (wire harness
Is the voltage within specification? side).
Is the voltage within specification?
YES NO YES NO
This circuit is OK. The wiring circuit This circuit is OK. The wiring circuit
from the main switch from the main switch
to the meter assem- to the tail/brake light
bly coupler is faulty coupler is faulty and
and must be re- must be repaired.
paired.
EB805413
EB805412
4. The turn signal/position light fails to come
3. A tail/brake light fails to come on. on.
1. Tail/brake light bulb and socket 1. Turn signal/position light bulb and socket
Check the tail/brake light bulb and socket for Check the turn signal/position light bulb and
continuity. socket for continuity.
Refer to “CHECKING THE BULBS AND Refer to “CHECKING THE BULBS AND
BULB SOCKETS”. BULB SOCKETS”.
Are the tail/brake light bulb and socket OK? Are the turn signal/position light bulb and
socket OK?
YES NO
YES NO
Replace the tail/
brake light bulb, sock- Replace the turn sig-
et or both. nal/position light bulb,
socket or both.
2. Voltage
2. Voltage
tail/brake light coupler (wire harness side) as Connect the pocket tester (DC 20 V) to the
shown. turn signal/position light couplers (wire har-
ness side) as shown.
Tester positive probe blue/red 1
Tester negative probe black 2 Tester positive probe blue 1
8-33

Measure the voltage (12 V) of blue 1 on the
turn signal/position light couplers (wire har-
ness side).
YES NO
This circuit is OK. The wiring circuit

to the turn signal/posi-
tion light connectors
is faulty and must be
repaired.
8-34
SIGNALING SYSTEM ELEC
EB806000
SIGNALING SYSTEM
CIRCUIT DIAGRAM
8-35
1 Main switch
5 Battery
6 Main fuse
12 Fuel sender
21 Neutral switch
22 Speed sensor
25 Fuel level indicator light
26 Oil level / coolant temperature
warning light
27 Neutral indicator light
28 Tachometer
29 Combination meter
31 Turn signal indicator light
35 Horn switch
36 Horn
38 Turn signal switch
39 Flasher relay
40 Front turn signal/position light (L)
41 Front turn signal/position light (R)
42 Rear turn signal light (L)
43 Rear turn signal light (R)
47 Tail/ brake light
52 Signaling system fuse
54 Oil level relay
55 Oil level switch
56 Rear brake light switch
58 Front brake light switch
8-36
EB806010 EB802401
S Any of the following fail to light: turn sig- S Check the condition of the battery.
nal light, brake light or an indicator light. Refer to “CHECKING THE BATTERY” in
S The horn fails to sound. chapter 3.
Check: Open-circuit voltage

1. main and signaling system fuses 12.8 V or more at 20_C (68°F)
2. battery S Is the battery OK?
3. main switch
4. wiring YES NO
(of the entire signaling system)
NOTE: S Clean the battery
S Before troubleshooting, remove the following terminals.
part(-s): S Recharge or re-
1) seats place the battery.
2) fuel tank
3) air filter case
EB802411
5) bottom cowling 3. Main switch
6) side cowling inner panels S Check the main switch for continuity.
7) side cowlings Refer to “CHECKING THE SWITCHES”.
8) windshield S Is the main switch OK?
9) rear cowling
S Troubleshoot with the following special tool YES NO
(-s).
Replace the main
Pocket tester switch.
90890-03112
EB802400 EB806400
1. Main and signaling system fuses 4. Wiring
S Check the main and signaling system fuses S Check the entire signaling system’s wiring.
for continuity. Refer to “CIRCUIT DIAGRAM”.
Refer to “CHECKING AND CHARGING S Is the signaling system’s wiring properly con-
THE FUSES” in chapter 3. nected and without defects?
S Are the main and signaling system fuses
OK? YES NO
YES NO Check the condition Properly connect or

of each of the signal- repair the signaling
Replace the fuse(-s). ing system’s circuits. system’s wiring.
Refer to “CHECKING
THE SIGNALING
SYSTEM”.
8-37
EB806410
CHECKING THE SIGNALING SYSTEM 3. Horn

1. The horn fails to sound. Disconnect the black connector at the horn
terminal.
1. Horn switch
Connect a jumper lead 1 to the horn terminal
Check the horn switch for continuity. and ground the jumper lead.
Refer to “CHECKING THE SWITCHES”. Set the main switch to “ON”.
Is the horn switch OK? Push the horn switch.
Does the horn sound?
YES NO
Replace the left han-

dlebar switch.
2. Voltage
horn connector at the horn terminal as
shown.
NO YES
Tester positive probe pink 1
Tester negative probe ground
The horn is OK.
4. Voltage
horn connector at the black terminal as
shown.
Tester positive probe black 1
Push the horn switch.
Measure the voltage (12 V) of pink 1 at the
horn terminal.
YES NO
The wiring circuit

to the horn connector Set the main switch to “ON”.
is faulty and must be Measure the voltage (12 V) of brown 1 at the
repaired. horn terminal.
YES NO
Repair or adjust the Replace the horn.

horn.
8-38
EB806411
2. A tail/brake light fails to come on. Set the main switch to “ON”.
Pull in the brake lever or push down on the
1. Tail/brake light bulb and socket brake pedal.
Measure the voltage (12 V) of yellow at the
Check the tail/brake light bulb and socket for
tail/brake light coupler (wire harness side).
continuity.
BULB SOCKETS”. YES NO
Are the tail/brake light bulb and socket OK?
YES NO This circuit is OK. The wiring circuit

to the tail/brake light
Replace the tail/
coupler is faulty and
brake light bulb, sock-
must be repaired.
et or both.
2. Brake light switches

Check the brake light switches for continuity.
EB806413
Is the brake light switch OK? 3. A turn signal light, turn signal indicator light
or both fail to blink.
YES NO
1. Turn signal light bulb and socket
Replace the brake Check the turn signal light bulb and socket for
light switch. continuity.
BULB SOCKETS”.
3. Voltage Are the turn signal light bulb and socket OK?
Connect the pocket tester (DC 20 V) to the YES NO

tail/brake light coupler (wire harness side) as
shown.
Replace the turn sig-
Tester positive probe yellow 1 nal light bulb, socket
Tester negative probe black 2 or both.
2. Turn signal indicator light LED

Check the LED of the turn signal indicator
light.
Refer to “CHECKING THE LEDs”.
Is the turn signal indicator light LED OK?
YES NO
Replace the meter

assembly.
8-39
3. Turn signal switch Tester positive probe brown/white 1

Check the turn signal switch for continuity.
Is the turn signal switch OK?
YES NO
Replace the left han-

dlebar switch.
4. Voltage
Connect the pocket tester (DC 20 V) to the Set the main switch to “ON”.
relay coupler (wire harness side) as shown. Set the turn signal switch to “ ” or “ ”.
Measure the voltage (12 V) or brown/white at
Tester positive probe brown 1
the turn signal relay coupler (wire harness
side).
YES NO
The turn signal relay

is faulty and must be
replaced.
6. Voltage
Set the main switch to “ON”. Connect the pocket tester (DC 20 V) to the
Measure the voltage (12 V) of brown 1 at the turn signal light connectors or the meter as-
turn signal relay coupler (wire harness side). sembly coupler (wire harness side) as
Is the voltage within specification? shown.
A Turn signal light
YES NO
B Turn signal indicator light
Left turn signal light
The wiring circuit
Tester positive probe chocolate 1
to the turn signal relay
Right turn signal light
coupler (turn signal
Tester positive probe dark green 2
relay side) is faulty
and must be repaired.
A B
5. Voltage
turn signal relay coupler (wire harness side)
as shown.
8-40
Set the main switch to “ON”. 3. Voltage

Set the turn signal switch to “ ” or “ ”.
Measure the voltage (12 V) of chocolate 1 or
meter assembly coupler (wire harness side)
dark green 2 at the turn signal light connec-
as shown.
tor (wire harness side).
Is the voltage within specification? Tester positive probe brown 1
Tester negative probe sky blue 2
YES NO

from the turn signal
switch to the turn sig-
nal light connector is
faulty and must be re-
paired.
EB806414
4. The neutral indicator light fails to come on. Set the main switch to “ON”.
1. Neutral indicator light LED Measure the voltage (12 V) of brown 1 and
sky blue 2 at the meter assembly coupler.
Check the LED of the neutral indicator light. Is the voltage within specification?
Is the neutral indicator light LED OK? YES NO
YES NO
Replace the meter to the meter light bulb
assembly. coupler is faulty and
must be repaired.
EB806416
2. Neutral switch 5. The oil level warning light fails to come on.
Check the neutral switch for continuity. 1. Oil level warning light LED
Refer to “CHECKING THE SWITCHES”. Check the LED of the oil level warning light.
Is the neutral switch OK? Refer to “CHECKING THE LEDs”.
Is the oil level warning light LED OK?
YES NO
YES NO
Replace the neutral
switch. Replace the meter
assembly.
8-41
2. Oil level switch 4. Voltage

Drain the engine oil and remove the oil level Connect the pocket tester (DC 20 V) to the
switch from the oil pan. meter assembly coupler (wire harness side)
Check the oil level switch for continuity. as shown.
Is the oil level switch OK? Tester positive probe brown 1
Tester negative probe red/blue 2
YES NO
Replace the oil level

switch.
3. Oil level relay

Disconnect the oil level relay from the cou-
pler.
Connect the pocket tester (Ω 1) and bat- Set the main switch to “ON”.
tery (12 V) to the oil level relay terminals as Measure the voltage (12 V) of brown 1 and
shown. red/blue at the meter assembly coupler.
Battery positive terminal brown 1 Is the voltage within specification?
Battery negative terminal white 2
YES NO
Tester positive probe red/blue 3
to the meter assem-
bly coupler is faulty
and must be re-
paired.
EB806417
6. The fuel level indicator light fails to come
on.
1. Fuel level indicator light LED

Does the oil level relay have continuity be-
Check the LED of the fuel level indicator light.
tween red/blue and black?
YES NO Is the fuel level indicator light LED OK?
YES NO
Replace the oil level
relay.
Replace the meter
assembly.
8-42
2. Fuel sender Set the main switch to “ON”.

Measure the voltage (12 V).
Disconnect the fuel sender coupler from the
wire harness.
Drain the fuel from the fuel tank and remove YES NO
the fuel sender from the fuel tank.
Check the fuel sender for continuity.
This circuit OK. The wiring circuit from
Tester positive probe green 1 the main switch to the
Tester negative probe black 2 meter assembly cou-
pler is faulty and must
be repaired.
EAS00805
7.The clock fails to come on.
1. Voltage
Connect the pocket tester (20 V DC) to the
clock coupler (clock side) as shown.
Tester positive probe brown 1
Is the fuel sender OK? Tester negative probe ground
YES NO
Replace the fuel

sender.
3. Voltage
Connect the pocket tester (DC 20 V) to the me-
ter assembly coupler (wire harness side) as Set the main switch to “ON”.
shown. Measure the voltage (12 V).
Tester positive probe green/white 1
Tester negative probe black/blue 2 YES NO
The wiring circuit from the main

switch to the clock coupler
(clock side) is faulty and must be
repaired.
2. Clock
Check that the clock is operating properly.
When setting the clock after its power source
has been disconnected (e.g., when the battery
is removed), first set the clock to 1:00 AM and
then to the correct time.
Is the clock operating properly?
YES NO
This circuit is OK. Replace the clock.

8-43
EAS00806
8. The speedometer fails to come on. 3. Voltage

1. Speedometer bulb socket Connect the pocket tester (20 V DC) to the
speedometer bulb socket coupler (wire har-
Check the speedometer bulb socket for con- ness side) as shown.
tinuity.
Is the speedometer bulb socket OK? Tester positive probe blue 1
YES NO
Replace the speedometer bulb

socket.
2. Voltage
speedometer coupler (wire harness side) as
shown.
Battery positive lead green/yellow 1
Battery negative lead black/blue 2 Set the main switch to “ON”.
Battery positive lead red 3 Measure the voltage (12 V) of blue 1 on the
speedometer bulb socket coupler (wire har-
ness side).
YES NO
The wiring circuit from the main

switch to the speedometer bulb
socket coupler (wire harness
side) is faulty, repair it.
NOTE:
First, connect the battery to the brown 1 and
black/blue 2 coupler terminals, then connect
the battery positive lead to the red 3 termi-
nal.
When connecting the battery, check whether
the startup display 4 appears first and then
after approximately three seconds the normal
display appears 5 .
Does the startup display appear first and then

after approximately three seconds the normal
display appears?
YES NO
Replace the speedometer.

8-44
4. Speedometer sensor
speedometer coupler (wire harness side) as
shown.
Tester positive probe blue/yellow 1

Elevate the rear wheel and slowly rotate it.
Measure the voltage (5 V) of blue/yellow and
black/blue. With each full rotation of the rear
wheel, the voltage reading should cycle from
0 V to 5 V to 0 V to 5 V.
Does the voltage reading cycle correctly?
YES NO
This circuit is OK. Replace the speedom-

eter sensor.
8-45
COOLING SYSTEM ELEC
EB807000
COOLING SYSTEM
CIRCUIT DIAGRAM
1 Main switch
5 Battery
6 Main fuse
23 Thermo unit
warning light
48 Radiator fan motor
49 Thermo switch
50 Radiator fan motor fuse
52 Signaling system fuse
8-46
COOLING SYSTEM ELEC
EB807010
TROUBLESHOOTING Open-circuit voltage

12.8 V or more at 20_C (68°F)
S The radiator fan motor fails to turn.
S Is the battery OK?
S The coolant temperature display and/or
warning light fails to indicate when the YES NO
engine is warm.
Check: S Clean the battery

1. main, signal system, and radiator fan motor terminals.
fuses S Recharge or re-
2. battery place the battery.
3. main switch
4. radiator fan motor EB802411
5. thermo switch 3. Main switch

6. thermo unit
S Check the main switch for continuity.
7. wiring
(the entire cooling system)
S Is the main switch OK?
NOTE:
S Before troubleshooting, remove the following YES NO
part(-s):
1) rider seat
Replace the main
2) bottom cowling
switch.
4) side cowling inner panels
EB807400
5) side cowlings
6) windshield 4. Radiator fan motor (test 1)
S Troubleshoot with the following special tool S Disconnect the radiator fan motor coupler
(-s). from the wire harness.
S Connect the battery (12 V) as shown.
Pocket tester Battery positive lead blue 1
90890-03112 Battery negative lead black 2
EB802400
1. Main, signal system and radiator fan

motor fuses
S Check the main, signal system, and radiator
fan motor fuses for continuity.
ter 3.
S Are the main, signal system, and radiator fan
motor fuses OK?
S Does the radiator fan motor turn?
YES NO
YES NO
EB802401 The radiator fan mo-
tor is faulty and must
2. Battery
be replaced.
S Check the condition of the battery.
Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
8-47
COOLING SYSTEM ELEC
EB807400
Test Coolant temperature

5. Radiator fan motor (test 2) Continuity
step Thermo switch
S Disconnect the thermo switch coupler. 0 X 105 ± 3_C
S Set the main switch to “ON”. *1* NO
S Connect the brown 1 and blue 2 terminals (0 X 221 ± 5.4°F)
*
with a jumper lead 3 as shown. More than 105 ± 3_C
*2* YES
(221 ± 5.4°F)
105 ± 3_C to 100 ± 3_C
*3* (221 ± 5.4°F to 212 ± YES
5.4°F)
Less than 100 ± 3_C
*4* (212 ± 5.4°F)
NO
Test steps 1 & 2: Heating phase

Test steps 3* & 4*: Cooling phase
S Does the radiator fan motor turn?
YES NO
The wiring circuit

to the radiator fan mo-
tor coupler is faulty
and must be repaired.
6. Thermo switch
S Remove the thermo switch from the radiator.
S Connect the pocket tester (Ω 1) to the ther-
mo switch 1 as shown.
S Immerse the thermo switch in a container
filled with coolant 2 .
NOTE:
Make sure that the thermo switch terminals
do not get wet.
WARNING
S Place a thermometer 3 in the coolant. S Handle the thermo switch with special
S Slowly heat the coolant, then let it cool to the care.
specified temperature as indicated in the S Never subject the thermo switch to
table. strong shocks. If the thermo switch is
S Check the thermo switch for continuity at the dropped, replace it.
temperatures indicated in the table.
Thermo switch
28 Nm (2.8 mSkg, 20 ftSlb)
Three bond sealock 10
A The thermo switch circuit is open and the ra-
diator fan is off.
B The thermo switch circuit is closed and the
radiator fan is on.
8-48
COOLING SYSTEM ELEC
100 ± 3 _C 105 ± 3 _C
(212 ± 5.4°F) (221 ± 5.4°F)
S Does the thermo switch operate properly as
described above?
YES NO
Replace the thermo

switch.
7. Thermo unit
S Remove the temperature sender from the
cylinder head. WARNING
S Connect the pocket tester (Ω 10) to the Handle the temperature sender with spe-
thermo unit 1 as shown. cial care.
S Immerse the thermo unit in a container filled Never subject the temperature sender to
with coolant 2 . strong shocks. If the temperature sender
S Place a thermometer 3 in the coolant. is dropped, replace it.
S Slowly heat the water, then let it cool down to
the specified temperature. Temperature sender
S Check the thermo unit for continuity at the 15 Nm (1.5 mSkg, 11 ftSlb)
temperatures indicated below. Three bond sealock 10
Thermo unit resistance
50.6 X 64.2 Ω at 80_C (176°F) YES NO
17.3 X 16.1 Ω at 120_C (248°F)
Replace the tempera-
ture sender.
EB807403
8. Wiring
S Check the entire cooling system’s wiring.
S Is the cooling system’s wiring properly con-
YES NO
Replace the com- Properly connect or

bination meter. repair the cooling
system’s wiring.
8-49
FUEL PUMP SYSTEM ELEC
EB808000
FUEL PUMP SYSTEM

CIRCUIT DIAGRAM
1 Main switch
5 Battery
6 Main fuse
10 Fuel pump
14 CDI unit
53 Ignition fuse
8-50
EB808010
FUEL PUMP CIRCUIT OPERATION

The CDI unit includes the control unit for the fuel pump.
1 Battery
2 Main fuse
3 Main switch
4 Ignition fuse
6 CDI unit
8 Fuel pump
8-51
EB808020 EB802401
The fuel pump fails to operate. S Check the condition of the battery.
2. battery Open-circuit voltage
3. main switch 12.8 V or more at 20_C (68°F)
4. engine stop switch S Is the battery OK?
5. starting circuit cutoff relay
6. fuel pump YES NO
7. wiring
(the entire fuel pump system)
S Clean the battery
NOTE: terminals.
S Before troubleshooting, remove the following S Recharge or re-
part(-s): place the battery.
1) rider seat
2) fuel tank
EB802411
3) air filter case
4) front cowling inner panel (left) 3. Main switch
S Troubleshoot with the following special S Check the main switch for continuity.
tool(-s). Refer to “CHECKING THE SWITCHES”.
S Is the main switch OK?
Pocket tester YES NO
90890-03112
EB802400 Replace the main

switch.
S Check the main and ignition fuses for conti-
nuity. EB802412
Refer to “CHECKING THE FUSES” in chap- 4. Engine stop switch

ter 3.
S Are the main and ignition fuses OK? S Check the engine stop switch for continuity.
YES NO S Is the engine stop switch OK?
YES NO
Replace the right
handlebar switch.
8-52
5. Starting circuit cutoff relay S Measure the fuel pump resistance.

S Disconnect the relay from the coupler. Fuel pump resistance
S Connect the pocket tester (Ω 1) and bat- 4 X 30 Ω at 20_C (68°F)
tery (12 V) to the relay terminals as shown.
S Is the fuel pump OK?
Battery positive terminal red /black 1
Battery negative terminal blue/red 2 YES NO
Tester positive probe red/black 1
Tester negative probe blue/black 3 Replace the fuel
pump.
EB808401
7. Wiring
S Check the entire fuel pump system’s wiring.
S Is the fuel pump system’s wiring properly
connected and without defects?
YES NO
S Does the fuel pump relay have continuity be-
tween red/black and blue/black?
Replace the CDI unit. Properly connect or
YES NO repair the fuel pump
system’s wiring.

circuit cutoff relay.
EB808400
6. Fuel pump resistance

S Disconnect the fuel pump coupler from the
wire harness.
S Connect the pocket tester (Ω 1) to the fuel
pump coupler (fuel pump side) as shown.
Tester positive probe blue/black 1
8-53
EB808410
CHECKING THE FUEL PUMP

WARNING
Gasoline is extremely flammable and under
certain circumstances there can be a dan-
ger of an explosion or fire. Be extremely
careful and note the following points:
Stop the engine before refuelling.
Do not smoke and keep away from open
flames, sparks or any other source of fire.
If you do accidentally spill gasoline, wipe it
up immediately with dry rags.
If gasoline touches the engine when it is
hot, a fire may occur. Therefore, make sure
that the engine is completely cool before
performing the following test.
1. Check:
fuel pump operation
a. Fill the fuel tank.

b. Put the end of the fuel hose into an open con-
tainer.
c. Connect the battery (12 V) to the fuel pump
coupler as shown.
Battery positive lead blue/black 1

Battery negative lead black 2
d. If fuel flows out of the fuel hose, the fuel

pump is OK. If fuel does not flow, replace the
fuel pump.
8-54
SELF-DIAGNOSIS ELEC
EB812000
SELF-DIAGNOSIS
The YZF-R6 L/YZF-R6CL features a self-diagnosing system for the following circuit(-s):
throttle position sensor
fuel level indicator light
If any of these circuits are defective, their respective condition codes will be displayed on the tachome-
ter when the main switch is set to “ON” (irrespective of whether the engine is running or not)
Circuit Defect(-s) System response Condition code

Throttle posi- Disconnected The ignitor unit stays set to the 3,000 r/min
tion sensor Short-circuit wide-open throttle ignition timing.
Locked The motorcycle can be ridden.
The tachometer displays the
condition code.
Fuel level indi- Improper connec- The tachometer displays the 8,000 r/min
cator light tion condition code.
Tachometer display sequence
Revolution 1 0 r / min ... 3 seconds

( 103 r / min) 2 Condition code ... 2.5 seconds Tachometer display
3 Engine speed ... 3 seconds
Engine speed
Time (seconds)
When more than one item is being monitored, the tachometer needle displays the condition codes in
ascending order, cycling through the sequence repeatedly.
If the engine is stopped, the engine speed 3 is 0 r/min.
8-55
SELF-DIAGNOSIS ELEC
EB812010
TROUBLESHOOTING 1. Wire harness

Check the wire harness for continuity.
The tachometer starts to display the self-
diagnosis sequence.
Is the wire harness OK?
Check:
YES NO
1. throttle position sensor
2. fuel level indicator light
NOTE: Repair or replace the
Before troubleshooting, remove the following wire harness.
part(-s):
EB812401
1) rider seat
2) fuel tank 2. Throttle position sensor
3) air filter case Check the throttle position sensor for conti-
4) right side cowling inner panel nuity.
5) right side cowling Refer to “CHECKING AND ADJUSTING
Troubleshoot with the following special THE THROTTLE POSITION SENSOR” in
tool(-s). chapter 6.
Is the throttle position sensor OK?
Pocket tester YES NO
90890-03112
EB812020 Replace the CDI unit. Replace the throttle

1. Throttle position sensor position sensor.
CIRCUIT DIAGRAM
13 Throttle position sensor

14 CDI unit
8-56
SELF-DIAGNOSIS ELEC
EB812040 EB812403
2. Fuel level indicator light 1. Fuel level indicator light LED

CIRCUIT DIAGRAM
Check the LED of the fuel level indicator light.
Is the fuel level indicator light LED OK?
YES NO
Repair the fuel level

indicator light LED.
EB812404
2. Fuel sender
Disconnect the fuel sender coupler from the
wire harness.
Connect the pocket tester (W 1) to the fuel
sender coupler as shown.
Tester positive probe green 1
Check the fuel sender for continuity.

Is the fuel sender OK?
YES NO
Replace the fuel

sender.
12 Fuel sender
14 CDI unit
8-57
SELF-DIAGNOSIS ELEC
EB812405
3. Wire harness
Check the wire harness for continuity.
Is the wire harness OK?
YES NO
Replace the CDI unit. Replace or replace

the wire harness.
8-58
TRBL
SHTG
CHAPTER 9.
TROUBLESHOOTING
STARTING PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 9-2

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CLUTCH DRAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
OVERCOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

LEAKING OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
TRBL
SHTG
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
FAULTY LIGHTING AND SIGNALING SYSTEMS . . . . . . . . . . . . . . . . . . 9-5

HEADLIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
HEADLIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TAIL/BRAKE LIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . 9-5
TAIL/BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . 9-5
TURN SIGNAL DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TURN SIGNAL BLINKS SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TURN SIGNAL REMAINS LIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TURN SIGNAL BLINKS QUICKLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
HORN DOES NOT SOUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
TRBL
STARTING PROBLEMS SHTG
EB900000
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure is this manual for
checks, adjustments, and replacement of parts.
STARTING PROBLEMS
ENGINE FUEL SYSTEM
Cylinders and cylinder head(-s) Fuel tank
Loose spark plug Empty fuel tank
Loose cylinder head Clogged fuel filter
Damaged cylinder head gasket Clogged fuel tank breather hose
Worn or damaged cylinder Deteriorated or contaminated fuel
Incorrect valve clearance Fuel pump
Incorrectly sealed valve Faulty fuel pump
Incorrect valve-to-valve-seat contact Faulty fuel pump relay
Incorrect valve timing Fuel cock
Faulty valve spring Clogged or damaged fuel hose
Seized valve Carburetors
Pistons and piston rings Deteriorated or contaminated fuel
Incorrectly installed piston ring Clogged pilot jet
Damaged, worn or fatigued piston ring Clogged pilot air passage
Seized piston ring Sucked-in air
Seized or damaged piston Damaged float
Air filter Worn needle valve
Incorrectly installed air filter Incorrectly installed needle valve seat
Clogged air filter element Incorrect fuel level
Crankcase and crankshaft Incorrectly installed pilot jet
Incorrectly assembled crankcase Clogged starter jet
Seized crankshaft Faulty starter plunger
Incorrectly adjusted starter cable
ELECTRICAL SYSTEMS
Battery Ignition system
Faulty battery Faulty CDI unit
Discharged battery Faulty pickup coil
Fuses Switches and wiring
Blown, damaged or incorrect fuse Faulty main switch
Incorrectly installed fuse Faulty engine stop switch
Spark plugs Broken or shorted wiring
Incorrect spark plug gap Faulty neutral switch
Incorrect spark plug heat range Faulty start switch
Fouled spark plug Faulty sidestand switch
Worn or damaged electrode Faulty clutch switch
Worn or damaged insulator Incorrectly grounded circuit
Faulty spark plug cap Loose connections
Ignition coils Starting system
Damaged ignition coil Faulty starter motor
Broken or shorted primary or secondary coils Faulty starter relay
Faulty starting circuit cutoff relay
Faulty starter clutch
9-1
INCORRECT ENGINE IDLING SPEED/POOR MEDIUM-AND- TRBL
HIGH-SPEED PERFORMANCE/FAULTY GEAR SHIFTING SHTG
EB901000
INCORRECT ENGINE IDLING SPEED

ENGINE ELECTRICAL SYSTEMS
Cylinders and cylinder head Battery
Incorrect valve clearance Faulty battery
Damaged valve train components Discharged battery
Air filter Spark plugs
Clogged air filter element Incorrect spark plug gap
Incorrect spark plug heat range
FUEL SYSTEM Fouled spark plug
Carburetors Worn or damaged electrode
Faulty starter plunger Worn or damaged insulator
Loose or clogged pilot jet Faulty spark plug cap
Loose or clogged pilot air jet Ignition coils
Damaged or loose carburetor joint Broken or shorted primary or secondary coils
Incorrectly synchronized carburetors Faulty spark plug lead
Incorrectly adjusted engine idling speed Damaged ignition coil
(throttle stop screw) Ignition system
Incorrect throttle cable free play Faulty ignition unit
Flooded carburetor Faulty pickup coil
EB902000
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE

Refer to “STARTING PROBLEMS”.
ENGINE FUEL SYSTEM
Air filter Carburetors
Clogged air filter element Faulty diaphragm
Air intake system Incorrect fuel level
Clogged air ducts Loose or clogged main jet
Fuel pump
Faulty fuel pump
EB903000
FAULTY GEAR SHIFTING

SHIFTING IS DIFFICULT JUMPS OUT OF GEAR
Refer to “CLUTCH DRAGS”. Shift shaft
SHIFT PEDAL DOES NOT MOVE Incorrect shift pedal position
Shift shaft Incorrectly returned stopper lever
Incorrectly adjusted shift rod Shift forks
Bent shift shaft Worn shift fork
Shift drum and shift forks Shift drum
Foreign object in a shift drum groove Incorrect axial play
Seized shift fork Worn shift drum groove
Bent shift fork guide bar Transmission
Transmission Worn gear dog
Seized transmission gear
Foreign object between transmission gears
Incorrectly assembled transmission
9-2
TRBL
FAULTY CLUTCH/OVERHEATING/OVERCOOLING SHTG
EB904000
FAULTY CLUTCH
CLUTCH SLIPS CLUTCH DRAGS
Clutch Clutch
Incorrectly assembled clutch Unevenly tensioned clutch spring plate
Incorrectly adjusted clutch cable Warped pressure plate
Loose or fatigued clutch spring Bent clutch plate
Worn friction plate Swollen friction plate
Worn clutch plate Bent clutch pull rod
Engine oil Damaged clutch boss
Incorrect oil level Burnt primary driven gear bushing
Incorrect oil viscosity (low) Match marks not aligned
Deteriorated oil Engine oil
Incorrect oil level
Incorrect oil viscosity (high)
Deteriorated oil
EB905001
OVERHEATING
ENGINE FUEL SYSTEM
Clogged coolant passages Carburetors
Cylinder head(-s) and piston(-s) Incorrect main jet setting
Heavy carbon buildup Incorrect fuel level
Engine oil Damaged or loose carburetor joint
Incorrect oil level Air filter
Incorrect oil viscosity Clogged air filter element
Inferior oil quality
CHASSIS
COOLING SYSTEM Brakes
Coolant Dragging brake
Low coolant level
Radiator ELECTRICAL SYSTEMS
Damaged or leaking radiator Spark plugs
Faulty radiator cap Incorrect spark plug gap
Bent or damaged radiator fin Incorrect spark plug heat range
Water pump Ignition system
Damaged or faulty water pump Faulty CDI unit
Thermostat
Thermostat stays closed
Oil cooler
Clogged or damaged oil cooler
Hoses and pipes
Damaged hose
Incorrectly connected hose
Damaged pipe
Incorrectly connected pipe
EB906000
OVERCOOLING
COOLING SYSTEM
Thermostat
Thermostat stays open
9-3
POOR BRAKING PERFORMANCE/FAULTY FRONT FORK TRBL
LEGS/UNSTABLE HANDLING SHTG
EB907000
POOR BRAKING PERFORMANCE

Worn brake pad Loose union bolt
Worn brake disc Damaged brake hose
Air in hydraulic brake system Oil or grease on the brake disc
Leaking brake fluid Oil or grease on the brake pad
Faulty brake caliper piston seal Incorrect brake fluid level
EB908001
FAULTY FRONT FORK LEGS

LEAKING OIL MALFUNCTION
Bent, damaged or rusty inner tube Bent or damaged inner tube
Damaged outer tube Bent or damaged outer tube
Incorrectly installed oil seal Damaged fork spring
Damaged oil seal lip Worn or damaged outer tube busing
Incorrect oil level (high) Bent or damaged damper rod
Loose damper rod assembly bolt Incorrect oil viscosity
Damaged damper rod assembly bolt copper Incorrect oil level
washer
Damaged cap bolt O-ring
EB909001
UNSTABLE HANDLING
Handlebars Swingarm
Bent or incorrectly installed right handlebar Worn bearing or bushing
Bent or incorrectly installed left handlebar Bent or damaged swingarm
Steering head components Rear shock absorber assembly
Incorrectly installed upper bracket Faulty rear shock absorber spring
Incorrectly installed lower bracket Leaking oil or gas
(incorrectly tightened ring nut) Tires
Bent steering stem Uneven tire pressures (front and rear)
Damaged ball bearing or bearing race Incorrect tire pressure
Front fork legs Uneven tire wear
Unevenoil levels (both front fork legs) Wheels
Unevenly tensioned fork spring (both front fork Incorrect wheel balance
legs) Deformed cast wheel
Damaged fork spring Damaged wheel bearing
Bent or damaged inner tube Bent or loose wheel axle
Bent or damaged outer tube Excessive wheel runout
Frame
Bent frame
Damaged steering head pipe
Incorrectly installed bearing race
9-4
TRBL
FAULTY LIGHTING AND SIGNALING SYSTEMS SHTG
EB910000
FAULTY LIGHTING AND SIGNALING SYSTEMS

HEADLIGHT DOES NOT LIGHT TURN SIGNAL DOES NOT LIGHT
Wrong headlight bulb Faulty turn signal switch
Too many electrical accessories Faulty turn signal relay
Hard charging Burnt-out turn signal bulb
Incorrect connection Incorrect connection
Incorrectly grounded circuit Damaged or faulty wire harness
Poor contacts (main or light switch) Incorrectly grounded circuit
Burnt-out headlight bulb Faulty battery
Blown, damaged or incorrect fuse
HEADLIGHT BULB BURNT OUT
Wrong headlight bulb TURN SIGNAL BLINKS SLOWLY
Faulty battery Faulty flasher relay
Faulty rectifier/regulator Faulty main switch
Incorrectly grounded circuit Faulty turn signal switch
Faulty main switch Wrong turn signal bulb
Faulty light switch
Headlight bulb life expired TURN SIGNAL REMAINS LIT
Faulty flasher relay
TAIL/BRAKE LIGHT DOES NOT LIGHT Burnt-out-turn signal bulb
Wrong tail/brake light bulb
Too may electrical accessories TURN SIGNAL BLINKS QUICKLY
Incorrect connection Incorrect turn signal bulb
Burnt-out tail/brake light bulb Faulty flasher relay
Burnt-out turn signal bulb
TAIL/BRAKE LIGHT BULB BURNT OUT
Wrong tail/brake light bulb HORN DOES NOT SOUND
Faulty battery Incorrectly adjusted horn
Incorrectly adjusted rear brake light switch Damaged or faulty horn
Tail/brake light bulb life expired Faulty main switch
Faulty horn switch
Faulty battery
Blown, damaged or incorrect fuse
Faulty wire harness
9-5
TRBL
SHTG
Main switch
YZF-R6 L/YZF-R6CL WIRING DIAGRAM 1
2 Fuse (backup)
3 Rectifier / regulator
4 AC magneto
5 Battery
6 Fuse (main)
7 Starter relay
8 Starter motor
10 Fuel pump
11 Sidestand switch
12 Fuel sender
13 Throttle position sensor
14 CDI unit
15 lgnition coil #1
16 lgnition coil #4
17 lgnition coil #2
18 lgnition coil #3
19 Spark plug
20 Pickup coil
21 Neutral switch
22 Speed sensor
23 Thermo unit
24 Meter assembly
warning light
27 Neutral indicator light
28 Tachometer
30 High beam indicator light
31 Turn signal indicator light
32 lllumination light
33 Handlebar switch (left)
34 Dimmer switch
35 Horn switch
36 Horn
37 Clutch switch
38 Turn signal switch
49 Flasher relay
40 Front turn signal / position light (L)
41 Front turn signal / position light (R)
42 Rear turn signal light (L)
43 Rear turn signal light (R)
44 Headlight
45 Headlight relay (Hi)
46 Headlight relay (Lo)
47 Tail / brake light
48 Radiator fan motor
49 Thermo switch
50 Fuse (radiator fan motor)
51 Fuse (headlight)
52 Fuse (signaling system)
53 Fuse (ignition)
54 Oil level relay
55 Oil level switch
56 Rear brake light switch
57 Handlebar switch (right)
58 Front brake light switch
60 Start switch
61 Diode 1
62 Diode 2
COLOR CODE
B ...... Black Y ...... Yellow L/B . . . . Blue / Black Y / B . . . . Yellow / Black
Br . . . . . Brown B/L . . . . Black / Blue L/R . . . . Blue / Red
Ch . . . . Chocolate B / R. . . . Black / Red L/W . . . Blue / White
Dg . . . . Dark green B/Y. . . . Black / Yellow L/Y . . . . Blue / Yellow
G ..... Green B/W . . . Black / White O / B. . . . Orange / Black
Gy . . . . Gray Br / B . . . Brown / Black R / B. . . . Red / Black
L ...... Blue Br / L . . . Brown / Blue R/L . . . . Red / Blue
O ..... Orange Br / W . . . Brown / White R/W . . . Red / White
P ...... Pink G/R . . . Green / Red R / Y. . . . Red / Yellow
R...... Red G /W . . . Green / White W/G . . . White / Green
Sb . . . . . Sky blue G / Y. . . . Green / Yellow W/R . . . White / Red
W ..... White Gy / B . . . Gray / Black W/Y . . . White / Yellow

Yzf-R6 1999

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What information is provided in the troubleshooting section?

EAS00001

IMPORTANT MANUAL INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

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

VEHICLE IDENTIFICATION NUMBER

2. Use only the proper tools and cleaning

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS

Former thermostat New thermostat

1 CDI unit 5 Spark plug 9 Speed sensor 13 Stator coil

This tool is used to check engine speed.

GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-23

OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

COOLANT FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

A : Yamalube 4 (10 W 30) or SAE 10 W

Item Standard Limit

Item Standard Limit

Measurement A 33.05 33.15 mm (1.3012 1.3051 in) 33.0 mm

Measurement A 32.55 32.65 mm (1.2815 1.2854 in) 32.50 mm

Item Standard Limit

Head Diameter Face Width Seat Width Margin Thickness

Valve seat width

Item Standard Limit

Intake (inner) SSS 2.5_/1.6 mm

Winding direction (top view)

Item Standard Limit

Height H 4 mm (0.16 in)

Ring type

Ring type

Item Standard Limit

Item Standard Limit

Item Standard Limit

Tire pressure (cold)

Item Standard Limit

Master cylinder inside diameter 14 mm (0.55 in)

Master cylinder inside diameter 12.7 mm (0.5 in)

Item Standard Limit

Item Standard Limit

Item Standard Limit

Item Standard Limit

CONVERSION TABLE TIGHTENING TORQUES