Right handlebar switch lead 9. Front brake light switch lead Speedometer cable 2. Clutch cable 3. Decompression cable 4. Left handlebar switch lead 5.
Ignition coil 6. Wire harness 7. Spark plug lead 8. Throttle cable decelerator 9. Throttle cable accelerator Engine temperature sensor Fuel tank breather hose Fasten the breather hose and oil hose 2 with the 1. Breather hose clamp. Oil hose 2 P. Fasten the sidestand switch lead with the frame 3.
Intake air temperature sensor lead clamp. Rear brake light switch coupler Q. Clutch cable 2. Decompression cable 3. Brake hose 4. Throttle cable 5. Front brake light switch lead 6.
Right handlebar switch lead 7. Left handlebar switch lead 8. Clutch switch lead 9. Handlebar A. Fasten the right handlebar switch lead and front brake light switch lead with the plastic locking tie. Rear brake light switch lead 2. Fuse box 3. Rear left turn signal light lead 4. Rear right turn signal light lead 6. Joint coupler 7. Battery lead 8. Hook-and-loop fastener 1 9. Hook-and-loop fastener 2 A. Meter lead 2.
Clutch switch lead 3. Headlight coupler 4. Front left turn signal light lead 6. Main switch lead 7. Auxiliary light lead 8. Front right turn signal light lead 9. Right handlebar switch lead Tachometer cable 2. Speedometer cable 3. Clutch cable 4. Decompression cable 5. Wire harness 6. Brake hose 7. Throttle cable A. Route the speedometer cable to the front of the lower bracket. Fasten the brake hose with the clamp. Fuel hose fuel tank—fuel pump case 3. Fuel cock 4. Fuel sender 5.
Fuel tank breather hose 2 6. Clamp 7. Rollover valve 8. Fuel tank breather hose 1 9. Tank stopper Damper Pump case breather hose fuel pump case—fuel tank 3. Fuel hose fuel pump—fuel rail 5. Fuel hose fuel tank—fuel pump case 6.
Fuel cock 7. Fuel pump case box A. Insert the pump case breather hose fuel pump case—fuel tank to the base of the fuel tank pipe. Fuel pump case box 2.
Pressure regulator 4. Fuel pipe 5. Fuel hose pressure regulator—fuel pipe 6. Fuel hose fuel pipe—fuel tank A. Avoid contact of the end of the breather hose with the damper. Fuel hose pressure regulator—fuel tank 3. Air filter case 5. Battery box 6. Oil separator 7. Air filter case drain hose 8. Oil hose 2 9. Breather hose Clamp Stator coil assembly lead Air cut-off valve 2. Air induction system hose air filter case—air cut-off valve 3. Air induction system hose air cut-off valve—air induction system pipe 4.
Air induction system pipe A. Point the end of the clamp downward. Page Periodic Maintenance UK, a mileage-based maintenance, is performed instead. Measure the valve clearance with a thickness Valve clearance is decreased. Clutch lever free play 5. Specified brake fluid DOT 4 2.
Operate the brake. Locknut 2. Check: 7 Nm 0. Hold the vehicle upright and apply the front brake several times. Install the brake master cylinder reservoir di- Never attempt to make any repairs to the aphragm. After a tire or wheel has been changed or re- placed, always balance the wheel. Loosen the brake pedal free play adjusting nut and tension bar nut. O-rings between each side plate. Steam clean- ing, high-pressure washing, certain solvents, Set the torque wrench at a right angle to the and the use of a coarse brush can damage steering nut wrench.
Hold the vehicle upright and apply the front Spring preload adjusting positions brake. Minimum 4. Tighten the oil check bolt to specification. The following procedure applies to all of the in- Oil check bolt ner and outer cables. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. Install: 2. Battery connector Battery Battery box Remove: 1. Measure: 1. Stand the vehicle on a level surface.
Clean the outside of the front wheel hub. Check: between the screwdriver and the wheel surface. Turn the front wheel and make sure it stays at each position shown. Repeat steps c through e several times until all the marks come to rest at the same spot. Place the vehicle on a suitable stand so that the rear wheel is elevated.
Check: c. Tighten the bleed screw. Check: tem. Check: 2. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock. Remove: 2. Remove: 3. Install the brake camshaft so its punch mark is positioned as shown.
Check that the brake shoes are properly po- sitioned. The following procedure applies to both of the 1. Hold the front fork leg horizontally. Fork spring free length b. Securely clamp the brake caliper bracket in a Make sure the inner tube is flush with the top of the upper bracket. Install: 1. If the swingarm side play is out of specifica- tion, check the spacers and bearings. Swingarm end free play limit ra- dial 1.
Drive chain slack Turn the AC magneto counterclockwise. Warpage limit 0. Three bond No. Install: 18 Nm 1. Rocker-arm-to-rocker-arm-shaft clearance 0. After replacing the valve guide, reface the valve seat. Install the valve into the cylinder head.
Press the valve through the valve guide and The following procedure applies to all of the onto the valve seat to make a clear impres- valves and valve seats. Larger pitch b. Smaller pitch 4. Valve spring compressor 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.
Limit Top ring b. Upper oil ring rail c. Oil ring expander d. Oil pump drive gear Circlip Plate washer Drain: 0. Outer-rotor-to-oil-pump-housing 2.
Page Disassembling The Crankcase 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. Crankshaft assembly Oil seal Bearing Big end side clearance 0. Turn the crankshaft installer nut until the crankshaft as- sembly bottoms against the bearing in the crank- case.
Check: d. Clamp 1 Rollover valve clamp Clamp 2 Plastic locking tie Gasoline is very flammable and dangerous. While handling gasoline, keep it away from an open flame as well as a spark or any other source of high heat. If the throttle position sensor is dropped, replace it. Air filter case 2. Air cut-off valve 4. Air induction system hose air cut-off valve—air induction system pipe 5. Air induction system pipe Air induction system hose air filter case—air Remove from the air filter case side cut-off valve Air cut-off valve Air induction system hose air cut-off valve—air The air induction system burns unburned ex- 3.
Crankshaft position sensor 2. Neutral switch 5. Battery 6. Main fuse 7. Main switch Ignition fuse Right handlebar switch Engine stop switch Sidestand switch Clutch switch Diode 1 ECU engine control unit Ignition coil Spark plug Lean angle sensor Joint coupler Frame ground This is because the electric current from the ECU does not flow to the ignition coil or in- jector when the neutral switch circuit or sidestand switch circuit is open.
Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU engine control unit 9. Neutral switch Negative battery lead Seat 2. Side cover left 3. Fuel tank 4. Crankcase cover left 5. Drive sprocket cover 1. Check the fuses. Main and ignition Replace the fuse s. Maximum fuel level Your Yamaha engine has been de- 2.
Fuel tank filler tube signed to use regular unleaded gaso- line with a research octane number of 3. Gas- ohol containing methanol recommended by Yamaha because it 1. Kickstarter 1. Decompression lever To start the engine, fold out the kick- When this lever is pulled, the exhaust starter lever, move it down lightly with valve is forced open so that the com- your foot until the gears engage, and pression pressure can be reduced.
Always adjust both shock absorber assemblies equally, otherwise poor handling and loss of stability may result. Page Sidestand Therefore, check this system regularly and have a Yamaha dealer repair it if it does not function properly. Page Ignition Circuit Cut-Off System Instrument and control functions EAU Ignition circuit cut-off system The ignition circuit cut-off system com- prising the sidestand switch, clutch switch and neutral switch has the fol- lowing functions.
Page 30 Does the engine start? The neutral switch may not be working correctly. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. Keep the clutch lever pulled.
If a problem cannot be corrected by the procedures provided in this manual, have the vehicle inspected by a Yamaha dealer. Before using this vehicle, check the following points Page Starting The Engine 3. Shift the transmission into the neu- tral position. The neutral indicator light should come on. If not, ask a Yamaha dealer to check the elec- trical circuit. Completely close the throttle and apply the decompression lever.
Page Starting Trouble Operation and important riding points EAU EAU Starting trouble Shifting If the engine fails to start after 4 to 5 kicks, clear out the combustion cham- ber with the following procedure. While applying the decompression lever, fully open the throttle grip and push the kickstarter lever down 4 to 5 times. Page 36 Operation and important riding points shock of forced shifting.
Pull the clutch lever to disengage The recommended shift points during the clutch. Page Parking Operation and important riding points EAU Parking When parking, stop the engine, and then remove the key from the main switch. Page Periodic Maintenance And Adjustment If you are not familiar with vehicle ser- vice, have a Yamaha dealer perform service.
Page Owner's Tool Kit If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. EAU Periodic maintenance chart for the emission control system Page Removing And Installing The Panel Periodic maintenance and adjustment EAU Removing and installing the panel The panel shown needs to be removed to perform some of the maintenance jobs described in this chapter.
Refer to this section each time the panel needs to be removed and installed. Page Checking The Spark Plug Do not attempt to in accordance with the periodic mainte- diagnose such problems yourself. In- nance and lubrication chart. In addition, stead, have a Yamaha dealer check the condition of the spark plug can re- the vehicle. In addition, the oil 25 Nm 2. Page 48 Periodic maintenance and adjustment 1. Engine oil filler cap 1. Oil filter element cover bleed bolt 2.
Dipstick 2. Gasket 3. Maximum level mark 3. Oil filter element drain bolt 4. Minimum level mark 4. Remove the engine oil drain bolt 4. Page 49 Periodic maintenance and adjustment 1. Engine oil drain bolt oil tank 1. Oil filter element cover 2. Gasket 2. O-ring 3. Oil filter element 8. Install the oil filter element cover by Skip steps 6—8 if the oil filter element is installing the bolts, and then tight- not being replaced.
Page 50 See page Oil quantity: so it will not seize. If this occurs, Oil change: have a Yamaha dealer repair the 2. Install the air filter case cover by in- periodic maintenance and lubrication stalling the screws. Throttle grip free play Throttle grip free play: 3. Page Valve Clearance Therefore, it must be adjusted by a Yamaha dealer is essential to maintain the tires in good at the intervals specified in the periodic condition at all times and replace them maintenance and lubrication chart.
Page 54 This model is equipped with tube tires. Do not attempt even the Rear tire: smallest repair to the wheel. A de- Size Tighten the locknut and then slide the rubber cover to its original po- sition. If the specified free play cannot be ob- tained as described above or if the clutch does not operate correctly, have a Yamaha dealer check the internal If there is air in the hy- shown.
Brake pedal height The top of the brake pedal should be 1. Brake pedal height locknut positioned at the specified distance be- 2. Page Checking The Shift Pedal b. The operation of the shift pedal should be checked before each ride. If opera- tion is not smooth, have a Yamaha dealer check the vehicle. Brake pedal free play adjusting nut EWA Page Brake Light Switches If a brake direction b.
Observe set. Page Changing The Brake Fluid Water will signifi- EAU Changing the brake fluid cantly lower the boiling point of Have a Yamaha dealer change the the fluid and may result in vapor brake fluid at the intervals specified in lock.
Take the motorcycle off the center- Using the alignment marks on each stand, and then put the sidestand side of the swingarm, make sure that down. Page Cleaning And Lubricating The Drive Chain Periodic maintenance and adjustment EAU Cleaning and lubricating the drive chain The drive chain must be cleaned and lubricated at the intervals specified in the periodic maintenance and lubrica- tion chart, otherwise it will quickly wear out, especially when riding in dusty or wet areas.
If a cable is damaged fied in the periodic maintenance chart. Page Checking And Lubricating The Brake Pedal Periodic maintenance and adjustment EAU EAU Checking and lubricating the Checking and lubricating the brake and clutch levers brake pedal The operation of the brake and clutch The operation of the brake pedal levers should be checked before each should be checked before each ride, ride, and the lever pivots should be lu- and the pedal pivot should be lubricat- bricated if necessary.
Page Checking And Lubricating The Centerstand And Sidestand The operation of the centerstand and The swingarm pivots must be lubricat- sidestand should be checked before ed by a Yamaha dealer at the intervals each ride, and the pivots and metal-to- specified in the periodic maintenance metal contact surfaces should be lubri- and lubrication chart.
To charge the battery Have a Yamaha dealer charge the bat- tery as soon as possible if it seems to have discharged. Keep in mind that the battery tends to discharge more quickly if the vehicle is equipped with optional electrical accessories. Page Replacing The Fuses 8. Install the seat. If the fuse immediately blows again, have a Yamaha dealer check the electrical system. The fuse box, which contains the fuses for the individual circuits, is located un- der the seat.
Page 72 4. If a fuse immediately blows again, have a Yamaha dealer check the electrical system. Headlight fuse 2. Signaling system fuse 3.
If the headlight bulb burns out, replace it as follows. Install the headlight unit by install- 1. Screw ing the screws. Have a Yamaha dealer adjust the headlight beam if necessary.
Screw 2. Remove the socket together with the bulb by pushing it in and turn- ing it counterclockwise. Auxiliary light bulb socket 2. Auxiliary light bulb 1. Remove the turn signal light lens, turn signal light rim and gasket by removing the screws.
Turn signal light lens 2. Screw 1. Speedometer cable falling over. Remove the wheel axle nut and 1.
0コメント