Stand the vehicle on a level surface. Lift the wheel up between the fork legs. Insert the wheel axle. Make sure that there is enough space between the brake pads before installing the brake cali- pers on to the brake discs.
Locknut left and right Loosen. Adjusting bolt left and right Loosen. Place the vehicle on a suitable stand so that the rear wheel is elevated. Check: crisscross pattern.
Brake hose holder Front brake caliper Brake pad clip Brake pad pin Brake pad spring Brake pad kit Bleed screw For installation, reverse the removal proce Stopper Brake fluid reservoir cap Brake fluid reservoir diaphragm holder Brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Brake lever Union bolt Washer Brake hose Brake caliper For installation, reverse the removal proce Install new brake pads and a new brake Brake lining thickness pad springs.
Before removing the brake caliper, drain the brake fluid from the entire brake system. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and 1. Check: b. Fill: system. Footrest plate Brake fluid reservoir cap Rear brake fluid reservoir diaphragm holder Rear brake fluid reservoir diaphragm Brake fluid reservoir tank Brake fluid reservoir hose Union bolt Measure: c. Tighten the bleed screw. Before disassembling the brake caliper, drain the brake fluid from the entire brake system.
Fill: 7. Mixing brake top of the brake pedal to the fluids may result in a harmful chemical center of the bolt mount on the reaction, leading to poor brake perfor- rider footrest bracket mance. Handlebar bolt Loosen. Upper bracket pinch bolt Loosen. Steering stem nut Main switch coupler Disconnect. Immobilizer unit coupler Disconnect. Do not attempt to straighten a bent handle- EWA bar as this may dangerously weaken it. Front fender Upper bracket pinch bolt Loosen. Each front fork leg is equipped with a spring preload adjusting bolt, the right fork leg is equipped with a rebound damping force adjusting screen and left front fork is equipped with a compression damping force adjusting screw.
Install: Fully compress the front fork leg. Remove the rod puller and rod puller o. Remove the rod holder and fork spring attachment. Lubricate: It replace with the assembly. Remove: compressed nitrogen gas. Dust cover 6. Collar 7. Swingarm 8. Pivot shaft A. Left side 5. Install: B. ECA Never install a new drive chain onto worn drive chain sprockets; Insufficient compression pressure will result in a loss of performance.
Measure: 1. Right muffler Right muffler gasket Rear brake light switch coupler Disconnect. Right footrest assembly Exhaust chamber cover Rear brake light switch sensor lead coupler Disconnect. Exhaust chamber pipe protector Exhaust chamber bracket Exhaust pipe Exhaust pipe gasket For installation, reverse the removal proce- dure.
Oil level switch lead coupler Disconnect. Gear position sensor coupler Disconnect. Engine ground lead Disconnect. Clutch cable Disconnect.
For installation, reverse the removal proce- dure. Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap Exhaust camshaft cap Intake camshaft Exhaust camshaft Intake camshaft sprocket Correct 3.
Hand press 1. Timing chain 4. Bearing 2. Camshaft sprocket or crankshaft sprocket b. Turn the crankshaft clockwise. Page When turning the crankshaft with a tool, der head cover gasket.
Check: bond No. Yamaha bond No. Coolant temperature sensor Cylinder head Cylinder head gasket Dowel pin Intake valve lifter Intake valve pad Intake valve cotter Intake valve spring retainer Intake valve spring Intake valve Intake valve stem seal Limit ECA14B 1. Apply a fine lapping compound to the valve face and repeat the above steps. Spring tilt limit Spring tilt intake 2. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft- face hammer.
ECA Hitting the valve tip with excessive force could damage the valve. Starter clutch gear Bearing Starter clutch assembly Starter idle gear For installation, reverse the removal proce- dure.
Sheave holder Primary clutch holder YSA Timing check bolt Pickup rotor cover 1 O-ring Sheave holder 2. Measure the armature assembly resis- 1. Check: tances with the digital circuit tester. Digital circuit tester 2. Brush spring force 5. Remove: 1. Install: 4. Pull lever cover Clutch cable Disconnect. Clutch cover Clutch cover gasket Dowel pin Oil filler cap For installation, reverse the removal proce- dure.
Thickness 4B 1. Thickness 5VY 2. Universal clutch holder YM 2. Three Bond No. Instead, replace the crankcase bolt with a new one and perform the procedure again. ECA14B Do not use a torque wrench to tighten the 6. Connecting rod cap Big end lower bearing Big end upper bearing Connecting rod Piston pin clip Piston pin Then, find the average of the mea- surements. Clean the big end bearings, crankshaft pins, and the inside of the connecting rods halves.
Install the big end upper bearing into the connecting rod and the big end lower bear- ing into the connecting rod cap. The following procedure applies to all of the b. Clean the connecting rod bolts and lubri- connecting rods and pistons. Top ring b. Instead, replace the connecting rod bolt with a new one and perform the procedure again. ECA Do not use a torque wrench to tighten the connecting rod bolt to the specified angle.
Balancer shaft Balancer shaft journal lower bearing Balancer shaft journal upper bearing Crankshaft Crankshaft journal lower bearing Remove the lower crankcase and the crankshaft journal lower bearings. If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specifica- tion, select replacement crankshaft journal bearings.
To obtain the correct balancer shaft-journal-to-balancer shaft-journal- bearing clearance and prevent engine dam- age, the balancer shaft journal bearings must be installed in their original positions. Clean the balancer shaft journal bearings, balancer shaft journals, and bearing por- tions of the crankcase.
Radiator cap Coolant reservoir hose Disconnect. Thermostat bypass hose 3 Radiator inlet pipe Radiator inlet hose For installation, reverse the removal proce- dure.
Apply compressed air to the rear of the radiator. Straighten any flattened fins with a thin, flat- head screwdriver. Apply the specified pressure for ten sec- onds and make sure there is no drop in pressure.
Apply Measure the indicated pressure with the gauge. Check: on page Check: replace it. YMA Middle driven shaft bearing Impeller shaft tilt limit driver 0. Fuel tank overflow hose Disconnect. Remove the screw on the fuel tank side cover. Crankcase breather hose Disconnect. Sub-wire harness coupler Disconnect. Fuel hose secondary injector fuel rail side Disconnect. Throttle position sensor coupler Disconnect. Heat protector Throttle body joint For installation, reverse the removal proce- dure.
Primary injector coupler 2 Disconnect. Primary injector coupler 3 Disconnect. Primary injector coupler 4 Disconnect. Sub-wire harness Intake air pressure sensor hose Intake air pressure sensor Fuel rail Primary injector joint Primary injector Push the lever in the direction shown in the illustration to hold the throttle valves in the open position.
Residual pres- Fuel injector pressure adapter sure in the fuel lines could cause fuel to spurt out when removing the hoses. If the throttle position sensor is dropped, replace it. Adjust the position of the accelerator posi- tion sensor angle so that 12—22 can appear in the meter.
Lower air filter case 2. Air induction system hose air filter case to air cut-off valve 3. Air cut-off valve 4. Air induction system hose air cut-off valve to reed valve cover Side air filter case duct Atmospheric pressure sensor coupler Disconnect. When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. Check: A. Main switch 4. Main fuse 8. Battery 9.
Fuel injection system fuse Relay unit Sidestand switch ECU engine control unit Ignition coil 1 Ignition coil 2 Ignition coil 3 Ignition coil 4 Spark plug Cylinder identification sensor Lean angle sensor Right handlebar switch Battery 2. Main fuse 3.
Ignition fuse 5. Engine stop switch 6. Ignition coil 7. Spark plug 8. ECU engine control unit 9. Relay unit diode Gear position sensor Battery negative lead Engine ground Rider seat 2. Passenger seat 3. Air filter case duct 4. Side cowlings 1. Check the fuses.
Check the main switch. Battery Starter relay Starter motor Starting circuit cut-off relay Right handlebar switch Engine stop switch Start switch Left handlebar switch Clutch switch Ignition fuse Engine ground Battery negative lead Heat protector 4. Check the engine stop switch.
AC magneto 3. Right side cowling 1. Check the fuse. Meter assembly High beam indicator light Meter light Pass switch Dimmer switch Headlight Auxiliary light Ground cord headlight License plate light Headlight relay Left side cowling 3. Air intake air duct covers 4. Fuel sender Coolant temperature sensor Fuel level warning light Oil level warning light Neutral indicator light Tachometer Shift timing indicator light Multi-function meter Check the front brake light switch.
The fuel level warning light fails to come on. The shift timing indicator light fails to come on. Radiator fan motor relay Right radiator fan motor fuse Left radiator fan motor fuse Right radiator fan motor Left radiator fan motor Fuel tank 3. Main fuse 7. Fuel pump relay Fuel pump O sensor If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
Check the operation of following sensors engine trouble warning light comes on. Disconnect the wire harness coupler from the fuel pump.
D Accelerator position sensor signal Illuminates the engine trou- ble warning light. ON 2 sec- relay five times. Check and ser- vice the items or components that are the probable cause of the malfunction following the order given.
After the check and service of the malfunctioning part has been completed, reset the meter display according to the reinstatement method. Normal signals are not received from the cylinder identification sen- Symptom sor. Normal signals are not received from the crankshaft position sen- Symptom sor.
Fault code No. Meter display Displays the intake air pressure. The intake air pressure sensor has failed due to clogging of hose or Symptom sensor disconnection. Engine startup: Possible Fail-safe action Riding: Possible Symptom Open or short circuit of throttle position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D ing code No.
When the main switch is ON, there is a big difference in voltage Symptom value of the intake air pressure sensor and atmospheric pressure sensor Engine startup: Possible Fail-safe action Riding: Possible Diagnostic monitor- D ing code No.
When engine is cold: Displays temperature closer to air temperature Meter display When engine is hot: Displays current coolant temperature Compare the actually measured coolant temperature with the meter Checking method Meter display Displays the atmospheric pressure. Compare the actually measured atmospheric pressure with the Checking method meter display value.
The O sensor does not operate. Symptom Ignition coil 1 primary lead malfunction Engine startup: Possible depending on the number of failed cylin- ders Fail-safe action Riding: Possible depending on the number of failed cylinders Diagnostic monitor- D ing code No.
Actuates the cylinder- 1 ignition coil five times at one-second inter- Meter display vals. Symptom Ignition coil 2 primary lead malfunction Engine startup: Possible depending on the number of failed cylin- ders Fail-safe action Riding: Possible depending on the number of failed cylinders Diagnostic monitor- D ing code No.
Actuates the cylinder- 2 ignition coil five times at one-second inter- Meter display vals. Symptom Ignition coil 3 primary lead malfunction Engine startup: Possible depending on the number of failed cylin- ders Fail-safe action Riding: Possible depending on the number of failed cylinders Diagnostic monitor- D ing code No.
Actuates the cylinder- 3 ignition coil five times at one-second inter- Meter display vals. Symptom Ignition coil 4 primary lead malfunction Engine startup: Possible depending on the number of failed cylin- ders Fail-safe action Riding: Possible depending on the number of failed cylinders Diagnostic monitor- D ing code No.
Actuates the cylinder- 4 ignition coil five times at one-second inter- Meter display vals. Symptom Open or short circuit of primary injector lead Engine startup: Possible depending on the number of failed cylin- ders Fail-safe action Riding: Possible depending on the number of failed cylinders D Diagnostic monitor- D ing code No.
Symptom Open or short circuit of secondary injector lead Engine startup: Possible depending on the number of failed cylin- ders Fail-safe action Riding: Possible depending on the number of failed cylinders D Diagnostic monitor- D ing code No. Symptom A. Normal signals are not received from the speed sensor.
Meter display Vehicle speed pulses: 0— Make sure that the indication value increases when the rota Meter display Approximately Symptom Incorrect voltage is supplied to the ECU. Symptom Open or short circuit of accelerator position sensor lead Engine startup: Possible under certain conditions Fail-safe action Riding: Possible under certain conditions Diagnostic monitor- D ing code No. Meter display The steering damper warning light lights up. Er-4 Symptom No registration data can be received from the meter unit.
Passenger seat 4. Left side cowling 1. Main fuse 5. Backup fuse 6. Immobilizer unit 8. Immobilizer system indicator light Multi-function meter Each standard key is registered during production, therefore re-registering at purchase is not neces- sary.
LED off a. Standby mode on b. Standby mode off c. LED on Standard key registration: Standard key registration is required when a standard key is lost and needs to be replaced, or when the code re-registering key is re-registered after the immobilizer unit or ECU are replaced. Registration mode a.
Registration of the second standard key is c. LED on complete. LED off B. Immobilizer system indicator light stops e. Less than 5. The pattern of blinking also shows the error code. Undefinition code is Noise interference or dis- 1. Check the wire received. Main switch 2. Immobilizer unit 3.
Front brake light switch 4. Clutch switch 5. Ignition coil 6. Battery 7. Fuse box 8. Main fuse 9. Rear brake light switch O sensor Intake air temperature sensor 2.
Headlight relay 3. Atmospheric pressure sensor 5. Intake air pressure sensor 6. Intake funnel servo motor 7. Fuel pump 8. Relay unit 9. Disconnect: S lead. Dry with an air blower. Connect and disconnect several times. If the pin 1 on the terminal is flattened, bend it up. S If there is no continuity, clean the terminals. S When checking the wire harness, perform steps 1 to 3. S As a quick remedy, use a contact revitalizer available at most part stores.
The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.
S For U. This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross pattern and progressive stages until the specified tightening torque is reached.
Unless otherwise specified, tightening torque specifications require clean, dry threads. Components should be at room temperature. First, tighten the bolts to approximately 19 Nm 1.
Retighten the bolts 67 Nm 6. First, tighten the bolts to approximately 20 Nm 2. Loosen the all bolts one by one following the tightening order and then tighten them to 20 Nm 2. Welcome to ManualMachine. We have sent a verification link to to complete your registration. Log In Sign Up. Forgot password? Enter your email address and check your inbox. Please check your email for further instructions. Enter a new password. First edition, December All rights reserved. Printed in U.
To set the clock 1. TRIP B! TRIP A! Stopwatch mode Standard measurement 1. Split-time measurement 1. Coolant temperature display The coolant temperature display indicates the temperature of the coolant. Air intake temperature display The air intake temperature display indicates the temperature of the air drawn into the air filter case. NOTE: S Even if the air intake temperature is set to be displayed, the coolant temperature warning light comes on when the engine overheats.
Display brightness and shift timing indicator light control mode This mode cycles through five control functions, allowing you to make the following settings in the order listed below. S Display brightness: This function allows you to adjust the brightness of the displays and tachometer to suit the outside lighting conditions.
S Shift timing indicator light activity: This function allows you to choose whether or not the indicator light should be activated and whether it should flash or stay on when activated.
S Shift timing indicator light activation: This function allows you to select the engine speed at which the indicator light will be activated. S Shift timing indicator light deactivation: This function allows you to select the engine speed at which the indicator light will be deactivated. S Shift timing indicator light brightness: This function allows you to adjust the brightness of the indicator light to suit your preference.
To adjust the brightness of the multifunction meter displays and tachometer 1. To set the shift timing indicator light activity function 1. To adjust the shift timing indicator light brightness 1. During reassembly, properly oil all mating grease parts and bearings and lubricate the oil seal lips with grease.
Tool No. Radiator cap tester Radiator cap tester Radiator cap tester adapter YU Adapter These tools are used to check the cooling system. YU Steering nut wrench YU This tool is used to loosen or tighten the steering stem ring nuts. Damper rod holder This tool is used to hold the damper rod as- YM sembly when loosening or tightening the damper rod assembly bolt. Oil filter wrench YU This tool is needed to loosen or tighten the oil filter cartridge.
Rod holder YM This tool is used to support the damper ad- justing rod. Rod puller Rod puller Rod puller attachment YM Rod puller attachment These tools are used to pull up the front fork damper rod. YM Vacuum gauge YU This guide is used to synchronize the car- buretors.
Compression Compression gauge gauge Compression gauge adapter YU These tools are used to measure engine Adapter compression. YM Middle driven shaft Middle driven shaft bearing driver bearing driver Mechanical seal installer YM Mechanical seal These tools are used to install the water installer pump seal.
YM Clutch holding tool This tool is used to hold the clutch boss YM when removing or installing the clutch boss nut. Valve guide remover YM This tool is used to remove or install the valve guides. Valve guide installer YM This tool is used to install the valve guides. Ignition checker YM This tool is used to check the ignition sys- tem components.
Yamaha bond No. Digital circuit tester This tool is used to check the electrical sys- tem. Pivot shaft wrench Pivot shaft wrench Pivot shaft wrench adapter YM Pivot shaft wrench This tool is need to loosen or tighten the adapter spacer bolt. Pocket tester YU This instrument is needed for checking the engine oil temperature.
Oil pressure Oil pressure gauge gauge Adapter YU These tools are used to measure engine oil Adapter pressure. Engine tachometer This tool is needed for observing engine rpm.
Fuel pressure adapter YM This tool is needed to measure fuel pres- sure. Pressure gauge YU This tool is used to measure fuel pressure.
Camshaft wrench YM This tool is used to hold and rotate the cam- shaft sprocket. You can only view or download manuals with.
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Buy as many as you need. View and download manuals available only for. Register and get 5 for free. Upload manuals that we do not have and get 1 for each file. Get 1 for every download of your manual. Buy as much as you need. S a speedometer which shows the riding. S a tachometer witch shows engine speed. This tool is used to hold the damper rod as-.
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