yamaha r6 99 - 2001

EB000000

YZF-R6SERVICE MANUAL

1998 by Yamaha Motor Co., Ltd.First edition, August 1998

All rights reserved. Any reproduction orunauthorized use without the writtenpermission of Yamaha Motor Co., Ltd.

is expressly prohibited.

NOTE:

WARNING

CAUTION:

EB001000

NOTICEThis manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealersand 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 vehiclesshould 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.

Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealersand will appear in future editions of this manual where applicable.

Designs and specifications are subject to change without notice.

EB002000

IMPORTANT MANUAL INFORMATIONParticularly important information is distinguished in this manual by the following.

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!

Failure to follow WARNING instructions could result in severe injury or death tothe motorcycle operator, a bystander or a person checking or repairing the mo-torcycle.

A CAUTION indicates special precautions that must be taken to avoid damageto the motorcycle.

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

126

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EB003000

HOW TO USE THIS MANUALThis manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensiveexplanations of all installation, removal, disassembly, assembly, repair and check procedures are laidout with the individual steps in sequential order.

1 The manual is divided into chapters. An abbreviation and symbol in the upper right corner of eachpage 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 eachremoval and disassembly section.

5 Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates adisassembly 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 ofparts, notes in jobs, etc.

8 Jobs requiring more information (such as special tools and technical data) are described sequen-tially.

22

1

3

5

7

9

2

4

8

6

24 25

2321

19 2018

16 1715

1413

11 12

10

GENINFO SPEC

ENG

CARB

ELECCHAS

COOL

CHKADJ

TRBLSHTG

EB004000

SYMBOLSThe following symbols are not relevant to everyvehicle.Symbols 1 to 9 indicate the subject of eachchapter.

1 General information2 Specifications3 Periodic checks and adjustments4 Engine5 Cooling system6 Carburetor(-s)7 Chassis8 Electrical system9 Troubleshooting

Symbols 10 to 17 indicate the following.

10 Serviceable with engine mounted11 Filling fluid12 Lubricant13 Special tool14 Tightening torque15 Wear limit, clearance16 Engine speed17 Electrical data

Symbols 18 to 23 in the exploded diagrams indi-cate the types of lubricants and lubricationpoints.

18 Engine oil19 Gear oil20 Molybdenum disulfide oil21 Wheel bearing grease22 Lithium soap base grease23 Molybdenum disulfide grease

Symbols 24 to 25 in the exploded diagrams indi-cate the following.

24 Apply locking agent (LOCTITE )25 Replace the part

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENT

ENGINE OVERHAUL

COOLING SYSTEM

CARBURETORS

CHASSIS

ELECTRICAL

TROUBLESHOOTING

GENINFO 1SPEC 2

3ENG 4

COOL 5CARB 6CHAS 7ELEC 8TRBLSHTG 9

CHKADJ

INDEX

GENINFO

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENINFO

1-1

MOTORCYCLE IDENTIFICATIONGENINFO

EB100000

GENERAL INFORMATIONMOTORCYCLE IDENTIFICATIONEB100010

VEHICLE IDENTIFICATION NUMBERThe vehicle identification number 1 is stampedinto the right side of the steering head pipe.

EB100020

MODEL CODEThe model code label 1 is affixed to the frame.This information will be needed to order spareparts.

1-2

IMPORTANT INFORMATIONGENINFO

EB102000

IMPORTANT INFORMATIONPREPARATION FOR REMOVAL AND DIS-ASSEMBLY1. Before removal and disassembly, remove all

dirt, mud, dust, and foreign material.

2. Use only the proper tools and cleaningequipment.Refer to “SPECIAL TOOLS”.

3. When disassembling, always keep matedparts together. This includes gears, cylin-ders, pistons and other parts that have been“mated” through normal wear. Mated partsmust always be reused or replaced as an as-sembly.

4. During disassembly, clean all of the partsand 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 PARTSUse only genuine Yamaha parts for all replace-ments. Use oil and grease recommended byYamaha for all lubrication jobs.Other brands may be similar in function and ap-pearance, but inferior in quality.

EB102020

GASKETS, OIL SEALS AND O-RINGS1. When overhauling the engine, replace all

gaskets, seals, and O-rings. All gasket sur-faces, oil seal lips, and O-rings must becleaned.

2. During reassembly, properly oil all matingparts and bearings and lubricate the oil seallips with grease.

1-3

IMPORTANT INFORMATIONGENINFO

CAUTION:

USING A DYNAMOMETERThe YZF-R6 has a carbon muffler that maychange color when exposed to high tempera-tures. Therefore, when using a dynamometeralways use a fan to cool the muffler.

EB102030

LOCK WASHERS/PLATES AND COTTERPINSAfter removal, replace all lock washers/plates1 and cotter pins. After the bolt or nut has beentightened to specification, bend the lock washertabs and the cotter pin ends along a flat of thebolt or nut.

EB102040

BEARINGS AND OIL SEALS1. Install bearings and oil seals so that the

manufacturer’s marks or numbers are vis-ible. When installing oil seals, lubricate theoil seal lips with a light coat of lithium soapbase grease. Oil bearings liberally wheninstalling, if appropriate.

1 Oil seal

Do not spin the bearing with compressed airbecause this will damage the bearing sur-faces.

1 Bearing

EB102050

CIRCLIPSBefore reassembly, check all circlips carefullyand replace damaged or distorted circlips. Al-ways replace piston pin clips after one use.When installing a circlip 1 , make sure that thesharp-edged corner 2 is positioned oppositethe thrust 3 that the circlip receives.

4 Shaft

1-4

CHECKING THE CONNECTIONSGENINFO

NOTE:

NOTE:

NOTE:

EB103000

CHECKING THE CONNECTIONSCheck the leads, couplers, and connectors forstains, rust, moisture, etc.1. Disconnect: leadcouplerconnector

2. Check: leadcouplerconnectorMoisture Dry with an air blower.Rust/stains Connect and disconnect sev-eral times.

3. Check:all connectionsLoose connection Connect properly.

If the pin 1 on the terminal is flattened, bend itup.

4. Connect: leadcouplerconnector

Make sure that all connections are tight.

5. Check:continuity(with the pocket tester)

Pocket tester90890-03112

If there is no continuity, clean the terminals.When checking the wire harness, performsteps (1) to (3).

As a quick remedy, use a contact revitalizeravailable at most part stores.

1-5

FEATURESGENINFO

Former thermostat

Tem

pera

ture

Time

New thermostat

Tem

pera

ture

Time

FEATURESAIR INTAKE SYSTEMSystem diagram

This system is designed to improve the power while riding a motorcycle at a high speed by increasingthe air intake efficiency by means of pressurizing the air filter case 2 where the air is taken in via the airduct 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 increasethe power.The air chamber 3 is also installed between the air filter case and carburetor for delivery of stabilizedair pressure to the carburetor.

THERMOSTATCoolant flow is controlled by the thermostat ofwhich flow control valve 1 is newly developedfor avoiding quick temperature change.(Refer to the graphs)2 Notch groove

1-6

FEATURESGENINFO

1) 2)

3) 4)

1 CDI unit2 Voltage converter3 Condenser4 Ignition coil

5 Spark plug6 Ignition timing controller7 Pickup coil8 T. P. S.

9 Speed sensor10 Battery11 Rectifier / regulator12 AC magneto

13 Stator coil

Flow control operation1) 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 notchdepending on its area at a section.

3) When the valve is set as middle-liftThe 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-liftIn the same way as the regular thermostatcontrol, the coolant flows through clearancec between the valve and flange.

IGNITION SYSTEM1. DC CDI1) 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

1-7

FEATURESGENINFO

2. Ignition coilCompact and right weight design is providedsince the plug top ignition coil is equipped inwhich the plug cap ignition coil are inte-grated.High tension cord was cut an end to use andignition energy loss has become lower.

3. Spark plugThe 2-pole spark plug is applied to improvethe ignition quality and combustion efficien-cy.

1-8

SPECIAL TOOLSGENINFO

EB104000

SPECIAL TOOLSThe 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 puller90890-01362Adapter90890-04089

Flywheel pullerAdapter

This tool is used to remove the generator ro-tor.

90890-01701

Sheave holder

This tool is used to hold the generator rotorwhen removing or installing the generator ro-tor bolt or pickup coil rotor bolt.

90890-01304

Piston pin puller

This tool is used to remove the piston pins.

90890-01312

Fuel level gauge

This tool is used to measure the fuel level inthe float chamber.

Radiator captester90890-01325Adapter90890-01352

Radiator cap testerAdapter

These tools are used to check the coolingsystem.

90890-01403

Steering nut wrench

This tool is used to loosen or tighten the steer-ing stem ring nuts.

90890-01425

Damper rod holder

This tool is used to hold the damper rod as-sembly when loosening or tightening thedamper rod assembly bolt.

90890-01471

Pivot shaft wrench

This tool is used to loosen or tighten the pivotadjust bolt and engine mount adjust bolt.

1-9



90890-01426

Oil filter wrench

This tool is needed to loosen or tighten the oilfilter cartridge.

90890-01434

Rod holder

This tool is used to support the damper ad-justing rod.

Rod puller90890-01437Rod puller attachment90890-01436

Rod pullerRod puller attachment

These tools are used to pull up the front forkdamper rod.

90890-01441

Fork spring compressor

This tool is used to disassemble or assemblethe front fork legs.

Fork seal driver90890-01376Fork seal driverattachment90890-01374

Fork seal driver weightFork seal driver attachment

This tool is used to install the front fork’s oilseal and dust seal.

90890-03008

Micrometer

This tool is used to measure the piston skirtdiameter.

90890-03017

Cylinder bore gauge (50~100mm)

This gauge is used to measure cylinder bore.

Vacuum gauge90890-03094Valve gaugeattachment90890-03060

Vacuum gaugeVacuum gauge attachment

This gauge is used to synchronize the carbu-retors.

Compressiongauge90890-03081Adapter90890-04136

Compression gaugeAdapter

These tools are used to measure enginecompression.

90890-03112

Pocket tester

This tool is used to check the electrical sys-tem.

1-10



90793-80009

Engine tachometer

This tool is used to check engine speed.

90890-03141

Timing light

This tool is used to check the ignition timing.

Oil pressure gauge90890-03153Adapter90890-03139

Oil pressure gaugeAdapter

These tools are used to measure engine oilpressure.

90890-04044

Piston ring compressor

This tool is used to compress piston ringswhen installing the cylinder.

90890-03158

Carburetor angle driver

This tool is used to turn the pilot screw whenadjusting the engine idling speed.

Valve spring compressor90890-04019Attachment90890-04108

Valve spring compressorAttachment

These tools are used to remove or install thevalve assemblies.

Middle driven shaftbearing driver90890-04058Mechanical seal in-staller90890-04078

Middle driven shaft bearing driverMechanical seal installer

These tools are used to install the water pumpseal.

90890-04086

Clutch holding tool

This tool is used to hold the clutch bosswhen removing or installing the clutch bossnut.

90890-04111

Valve guide remover

This tool is used to remove or install the valveguides.

1-11



90890-04112

Valve guide installer

This tool is used to install the valve guides.

90890-04113

Valve guide reamer

This tool is used to rebore the new valveguides.

90890-06754

Ignition checker

This tool is used to check the ignition systemcomponents.

90890-85505

Yamaha bond No. 1215

This bond is used to seal two mating surfaces(e.g., crankcase mating surfaces).

GENINFO

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1

GENERAL SPECIFICATIONS SPEC

SPECIFICATIONSGENERAL SPECIFICATIONS

Item Standard Limit

DimensionsOverall length

Overall widthOverall heightSeat heightWheelbaseMinimum ground clearanceMinimum turning radius

2025 mm (except for NOR, SWE, FIN, AUS NZL)2075 mm (for NOR, SWE, FIN, AUS, NZL)690 mm1105 mm820 mm1380 mm135 mm3400 mm

WeightWet (with oil and a full fuel tank)

Dry (without oil and fuel)

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

188 kg

169 kg

375 kg

2-2

ENGINE SPECIFICATIONS SPEC

Temp.

ENGINE SPECIFICATIONS

Item Standard Limit

EngineEngine tipeDisplacementCylinder arrangementBore strokeCompression ratioEngine idling speedVacuum pressure at engine idlingspeedStandard compression pressure(at sea level)

Liquid-cooled, 4-stroke, DOHC600 cm3

Forward-inclined parallel 4-cylinder65.5 44.5 mm12.4 : 11,250 1,350 r/min24.0 kPa (0.24 kg/cm2)

1550 kPa (15.5 kgf/cm2) at 400 r/min

FuelRecommended fuelFuel tank capacityTotal (including reserve)Reserve only

Regular gasoline

17 L3.5 L

Engine oilLubrication systemRecommended oil

QuantityTotal amountWithout oil filter cartridgereplacementWith oil filter cartridge replacement

Oil pressure (hot)

Relief valve opening pressure

Wet sump

SAE20W40SE or SAE10W30SE

3.5 L2.5 L

2.7 L80 kPa at 1300 r/min(0.80 kgf/cm2 at 1300 r/min)450 550 kPa (4.5 5.5 kgf/cm2)

2-3


Item Standard Limit

Oil filterOil filter typeBypass valve opening pressure

Cartridge (paper)80 120 kPa (0.8 1.2 kgf/cm2)

Oil pumpOil pump typeInner-rotor-to-outer-rotor-tipclearanceOuter-rotor-to-oil-pump-housingclearance

Trochoidal0.03 0.09 mm

0.03 0.08 mm

0.15 mm

0.15 mm

Cooling systemRadiator capacityRadiator cap opening pressureRadiator coreWidthHeightDepth

Coolant reservoirCapacity

Water pumpWater pump typeReduction ratio

2.15 L110 140 kPa (1.10 1.40 kgf/cm2)

320 mm258 mm24 mm

0.44 L

Single-suction centrifugal pump86/44 31/31 (1.955)

Starting system type Electric starter

Spark plugsModel (manufacturer) quantitySpark plug gap

CR10EK/NGK 40.6 0.7 mm

Cylinder headMax. warpage 0.05 mm

2-4


Item Standard Limit

CamshaftsDrive systemCamshaft cap inside diameterCamshaft journal diameterCamshaft-journal-to-camshaftcap

clearanceIntake camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Exhaust camshaft lobe dimensions

Measurement AMeasurement BMeasurement C

Max. camshaft runout

Chain drive (right)23.000 23.021 mm22.967 22.980 mm0.020 0.054 mm

33.05 33.15 mm25.14 25.24 mm7.81 8.01 mm

32.55 32.65 mm25.07 25.17 mm7.38 7.58 mm

0.08 mm

33.0 mm25.09 mm

32.50 mm25.02 mm

0.06 mm

2-5


Head Diameter Face Width Seat Width Margin Thickness

Item Standard Limit

Timing chainModel/number of linksTensioning system

RH2015/120Automatic

Valves, valve seats, valve guidesValve clearance (cold)IntakeExhaust

Valve dimensions

0.11 0.20 mm0.21 0.30 mm

Valve head diameter AIntakeExhaust

Valve face width BIntakeExhaust

Valve seat width CIntakeExhaust

Valve margin thickness DIntakeExhaust

Valve stem diameterIntakeExhaust

Valve guide inside diameterIntakeExhaust

Valve-stem-to-valve-guide clearanceIntakeExhaust

Valve stem runout

Valve seat widthIntakeExhaust

24.9 25.1 mm21.9 22.1 mm

1.14 1.98 mm1.14 1.98 mm

0.9 1.1 mm0.9 1.1 mm

0.6 0.8 mm0.6 0.8 mm

3.975 3.990 mm3.960 3.975 mm

4.000 4.012 mm4.000 4.012 mm

0.010 0.037 mm0.025 0.052 mm

0.9 1.1 mm0.9 1.1 mm

1.6 mm1.6 mm

0.5 mm0.5 mm

3.950 mm3.935 mm

4.042 mm4.042 mm

0.08 mm0.1 mm0.04 mm

1.6 mm1.6 mm

2-6


Item Standard Limit

Valve springsFree lengthIntake (inner)

(outer)Exhaust

Installed length (valve closed)Intake (inner)

(outer)Exhaust

Compressed spring force(installed)Intake (inner)

(outer)Exhaust

Spring tilt

Intake (inner)(outer)

Exhaust

Winding direction (top view)IntakeExhaust

37.0 mm38.4 mm41.7 mm

30.0 mm32.5 mm36.1 mm

69 79 N (7.0 8.0 kgf)114 132 N (11.6 13.4 kgf)160 184 N (16.3 18.7 kgf)

ClockwiseClockwise

35 mm36.5 mm39.5 mm

2.5 /1.6 mm2.5 /1.7 mm2.5 /1.8 mm

CylindersCylinder arrangementBore strokeCompression ratioBoreMax. taperMax. out-of-round

Forward-inclined, parallel 4-cylinder65.5 45.5 mm12.4 : 165.50 65.51 mm

0.05 mm0.05 mm

2-7


Item Standard Limit

PistonsPiston-to-cylinder clearanceDiameter D

Height HPiston pin bore (in the piston)DiameterOffsetOffset direction

Piston pinsOutside diameter

Piston-pin-to-piston-pin-boreclearance

Piston ringsTop ring

Ring typeDimensions (B T)End gap (installed)Ring side clearance

2nd ring

Ring typeDimensions (B T)End gap (installed)Ring side clearance

Oil ring

Dimensions (B T)End gap (installed)

0.025 0.050 mm65.460 65.475 mm

4 mm

16.002 16.013 mm0.35 0.65 mmIntake side0.5 mm15.991 16.000 mm0.002 0.022 mm

Barrel0.80 2.45 mm0.15 0.25 mm0.030 0.065 mm

Taper0.8 2.5 mm0.40 0.50 mm0.020 0.055 mm

1.5 2.3 mm0.10 0.35 mm

0.07 mm

0.072 mm

0.50 mm0.115 mm

0.85 mm0.115 mm

2-8


Item Standard Limit

Connecting rodsCrankshaft-pin-to-big-end-bearingclearanceBearing color code

0.028 0.052 mm

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

Crankshaft

Width BMax. runout CBig end side clearance DCrankshaft-journal-to-crankshaft-journal-bearing clearanceBearing color code

268.8 270.0 mm

0.160 0.262 mm0.034 0.058 mm

0 = White 1 = Blue2 = Black 3 = Brown4 = Green

0.03 mm

ClutchClutch typeClutch release methodClutch release method operationOperationClutch cable free play (at the endof the clutch lever)Friction platesThicknessPlate quantity

Clutch platesThicknessPlate quantityMax. warpage

Clutch plateThicknessPlate quantityMax. warpage

Clutch springsFree lengthSpring quantity

Wet, multiple discRack and pinion (pull rod type)Cable operationLeft hand operation10 15 mm

2.9 3.1 mm8

1.9 2.1 mm7

2.2 2.4 mm1

55 mm6

2.8 mm

0.1 mm

0.1 mm

54 mm

2-9


Item Standard Limit

TransmissionTransmission typePrimary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioOperationGear ratios1st gear2nd gear3rd gear4th gear5th gear6th gear

Max. main axle runoutMax. drive axle runout

Constant mesh, 6-speedSpur gear86/44 (1.9545)Chain drive48/16 (3.000)Left-foot operation

37/13 (2.846)37/19 (1.947)28/18 (1.555)32/24 (1.333)25/21 (1.190)26/24 (1.083)

0.02 mm0.02 mm

Shifting mechanismShift mechanism typeMax. shift fork guide bar bendinginstalled shift rod length

Cam drum

242 mm

0.05 mm

Air filter type Dry element

Fuel pumpPump typeModel (manufacturer)Output pressure

Electrical5EB (MITSUBISHI)15 20 kPa (0.15 0.2 kgf/cm2)

CarburetorsModel (manufacturer) quantityThrottle cable free play (at theflange of the throttle grip)ID markMain jet

Main air jetJet needleNeedle jetPilot air jetPilot outletPilot jetBypass 1Bypass 2Bypass 3Pilot screw turns outValve seat size

CVRD37 (MIKUNI) 46 8 mm

5EB00, 5EB200 (G), 5EB300 (F)Carburetors 1 and 4: #152Carburetors 2 and 3: #148#110N7RA2.6#1100.9#380.80.80.821.2

2-10


Item Standard Limit

Starter jet 1Starter jet 2Butterfly valve sizeFuel level (below the line on thefloat chamber)

#500.6#11017.5 18.5 mm

2-11

CHASSIS SPECIFICATIONS SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

FrameFrame typeCaster angleTrail

Diamond2481 mm

Front wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 MT3.50Aluminum130 mm

1 mm0.5 mm

Rear wheelWheel typeRimSizeMaterial

Wheel travelWheel runoutMax. radial wheel runoutMax. lateral wheel runout

Cast wheel

17 MT5.50Aluminum120 mm

1 mm0.5 mm

Front tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg90 197 kgHigh-speed riding

Min. tire tread depth

Tubeless120/60ZR17 (55W)BRIDGESTON BT56F.EDUNLOP D207F.J

250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)250 kPa (2.5 kg/cm2, 2.5 bar)

1.6 mm

2-12


Item Standard Limit

Rear tireTire typeSizeModel (manufacturer)

Tire pressure (cold)0 90 kg90 197 kgHigh-speed riding

Min. tire tread depth

Tubeless180/55 ZR17 (73 W)BRIDGESTON BT56R.EDUNLOP D207.N

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

1.6 mm

Front brakesBrake typeOperationRecommended fluidBrake discsDiameter thicknessMin. thicknessMax. deflectionBrake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Dual-disc brakeRight-hand operationDOT 4

298 5 mm

5.5 mm

14 mm30.2 mm and 27 mm

4.5 mm0.1 mm0.5 mm

Rear brakeBrake typeOperationBrake pedal position (from the topof the brake pedal to the bottom ofthe rider footrest bracket bolt center.)Recommended fluidBrake discsDiameter thicknessMin. thicknessMax. deflectionBrake pad lining thickness

Master cylinder inside diameterCaliper cylinder inside diameter

Single-disc brakeRight-foot operation4.3 9.3 mm

DOT 4

220 5 mm

5 mm

12.7 mm27.0 mm and 22.2 mm

4.5 mm0.1 mm0.8 mm

2-13

CHASSIS SPECIFICATION SPEC

Item Standard Limit

Front suspensionSuspension typeFront fork typeFront fork travelSpringFree lengthSpacer lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableFork oilRecommended oilQuantity (each front fork leg)Level (from the top of the innertube, with the inner tube fullycompressed, and without thefork spring)

Damper adjusting rod locknut distanceSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjusting positions Minimum*

Standard*Maximum*

Compression damping adjustingpositions

Minimum*Standard*Maximum*

*from the fully turned-in position

Telescopic forkCoil spring/oil damper130 mm

251.8 mm125 mm247.8 mm7.5 N/mm (0.75 kgf/mm)0 130 mmNo

Suspension oil “01” or equivalent476 cm3

107 mm

25 mm

851

1161

1261

246 mm

2-14


Item Standard Limit

SteeringSteering bearing type Angular ball bearings

Rear suspensionSuspension typeRear shock absorber assemblytypeRear shock absorber assemblytravelSpringFree lengthInstalled lengthSpring rate (K1)Spring stroke (K1)

Optional spring availableStandard spring preload gas/airpressureSpring preload adjusting positionsMinimumStandardMaximum

Rebound damping adjusting positions Minimum*

Standard* Maximum*Compression damping adjustingpositions

Minimum*Standard*Maximum*

*from the fully turned-in position

Swingarm (link suspension)Coil spring/gas-oil damper60 mm

169.5 mm159 mm95.1 N/mm (9.51 kgf/mm)0 60 mmNo1,200 kPa (12 kgf/cm2)

149

2591

1371

SwingarmFree play (at the end of the swingarm)RadialAxial

1 mm1 mm

Drive chainModel (manufacturer)Link quantityDrive chain slackMaximum ten-link section

532ZLV KAI (DID)11640 50 mm149 mm

2-15

ELECTRICAL SPECIFICATIONS SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage 12 V

Ignition systemIgnition system typeIgnition timingAdvanced timingAdvancer typePickup coil resistance/colorTransistorized coil ignition unit model

(manufacturer)

C.D.I.10 BTDC at 1700 r/min55 BTDC at 5250 r/minThrottle position sensor and electrical248 372 Ω /Gy-BF8T354 (MITSUBISHI)

Ignition coilsModel (manufacturer)Minimum ignition spark gapPrimary coil resistanceSecondary coil resistance

F6T549 (MITSUBISHI)6 mm0.238 0.322 Ω8.16 11.04 kΩ

Throttle position sensor standardresistance

4 6 kΩ

Charging systemSystem typeModel (manufacturer)Nominal outputStator coil resistance

AC magnetoF4T366 (MITSUBISHI)14 V/320W at 5,000 r/min0.27 0.33 Ω at 20C

Voltage regulatorRegulator typeModel (manufacturer)No-load regulated voltage

Semiconductor, short circuit typeSH650A-12 (SHINDENGEN)14.1 14.9 V

RectifierModelRectifier capacityWithstand voltage

SH650A-1218 A200 V

BatteryBattery typeBattery voltage/capacity

GT12B-412 V/10 AH

Headlight type Halogen bulb

Indicator light type quantity LED 5

Bulbs (voltage/wattage quantity)HeadlightAuxiliary lightTail /brake lightTurn signal light

12 V 60 W/55 W 212 V 5 W 212 V 5 W/21 W 212 V 21 W 4

2-16


Item Standard Limit

License plate lightMeter light

12 V 5 W 212 V 1.4 W 2

Electric starting systemSystem typeStarter motorModel (manufacturer)Power outputBrushesOverall lengthSpring force

Commutator resistanceCommutator diameterMica undercut

Constant mesh

SM-14 (MITSUBA)0.6 kW

10 mm7.16 9.52 N (730 970 gf)0.012 0.022 Ω28 mm0.7 mm

3.5 mm

27 mm

Starter relayModel (manufacturer)AmperageCoil resistance

MS5F-631 (JIDECO)180 A4.18 4.62 Ω

HornHorn typeModel (manufacturer) quantityMax. amperage

PlainYF-12 (NIKKO) 13 A

Flasher relayRelay typeModel (manufacturer)Self-cancelling device built-inTurn signal blinking frequencyWattage

Full-transistorFE246BH (DENSO)No75 95 cycles/min.21 W 2 + 3.4 W

Oil level switch model (manufacturer) 4XV (DENSO)

Fuel senderModel (manufacturer)Resistance

1UF (NIPPON SEIKI)0.7 1.1 kΩ GW-B

Sidestand relayModelCoil resistance

G8R-30Y-K162 198 Ω

Fuel pump maximum amperage 1 A

Fuel pump relay model (manufacturer)Resistance

G8R-30Y-K (OMRON)162 198 Ω

Radiator fan model (manufacturer) 4XV (TOYO RADIATOR)

Thermo switch model (manufacturer) 5EB (NIPPON THERMOSTAT)

Headlight relay (manufacturer)Resistance

ACA12115 (MATSUSHITA)72 88 Ω

2-17


Item Standard Limit

Temperature senderModel (manufacturer)Resistance

11H (NIPPON SEIKI)50.6 64.2 Ω at 80C16.1 17.3 Ω at 120C

Fuses (amperage quantity)Main fuseHeadlight fuseSignaling system fuseIgnition fuseRadiator fan fuseBackup fuse (odometer)

30 A 120 A 120 A 115 A 17.5 A 17.5 A 1

2-18

CONVERSION TABLE/TIGHTENING TORQUES SPEC

EB202001

TIGHTENING TORQUESGENERAL TIGHTENING TORQUESThis chart specifies tightening torques for standardfasteners with a standard ISO thread pitch. Tighten-ing torque specifications for special components orassemblies are provided for each chapter of thismanual. To avoid warpage, tighten multi-fastenerassemblies in a crisscross pattern and progressivestages until the specified tightening torque isreached. Unless otherwise specified, tighteningtorque specifications require clean, dry threads.Components should be at room temperature.

A: Width across flats

B: Thread diameter

ftlb

61

4.3

11

22

40

94

A(nut)

B(bolt)

General tighteningtorques

10 mm

12 mm

14 mm

18 mm

19 mm

22 mm

6 mm

8 mm

10 mm

12 mm

14 mm

16 mm

Nm mkg6

15

30

55

85

130

0.6

1.5

3.0

5.5

8.5

13.0

EB201000

CONVERSION TABLEAll specification data in this manual arelisted in SI and METRIC UNITS.Use this table to convert METRIC unit datato IMPERIAL unit data.Ex.

METRIC MULTIPLIER IMPERIAL

**mm 0.03937 = **in

2 mm 0.03937 = 0.08 in

CONVERSION TABLE

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Tighten-ingtorque

mkgmkgcmkgcmkg

7.23386.7940.07230.8679

ftlbinlbftlbinlb

Weight kgg

2.2050.03527

lboz

Speed km/hr 0.6214 mph

Distance

kmmmcmmm

0.62143.2811.0940.39370.03937

miftydinin

Volume/cc (cm3)cc (cm3)

0.035270.06102

oz (IMP liq.)cuin

Capacity( )

lt (liter)lt (liter)

0.87990.2199

qt (IMP liq.)gal (IMP liq.)

Misc.

kg/mmkg/cm2

Centigrade(C)

55.99714.22349/5 + 32

lb/ inpsi (lb / in2)Fahrenheit(F)

2-19

TIGHTENING TORQUES SPEC

NOTE:

ENGINE TIGHTENING TORQUES

Item Fastener Thread size Q’tyTightening

torque RemarksyNm nkgf

Spark plugsCylinder headCylinder headCamshaft capsCylinder head coverOil passage check boltCylinder head (exhaust pipe)

–BoltBoltBoltBoltBolt

Stud bolt

M10M10M6M6M6M8M8

4102

20618

13511010102015

1.35.11.01.01.02.01.5

Connecting rod caps Nut M7 See NOTEGenerator rotorPickup rotorCap bolt (timing chain tensioner)Timing chain tensioner boltCamshaft sprocketOil pumpOil coolerEngine oil drain boltOil pump assembly driven sprocketcoverOil pipeOil filter boltOil filter cartridgeExhaust pipesMuffler clampExhaust pipe emission check boltsExhaust pipe bracketCrankcaseCrankcaseCrankcaseGenerator rotor coverDrive sprocket cover

BoltBoltBoltBoltBoltBoltBolt

–Bolt

BoltBolt

–NutBoltBoltBoltBoltBoltBoltBoltBolt

M12M8M6M6M7M6

M20M14M6

M6M20M20M8M8M6M8M6M6M8M6M6

111243112

21181412

121295

653510122412634310

158017202010201412241210

6.53.51.01.22.41.26.34.31,0

1.58.01.72.02.01.02.01.41.22.41.21.0

After tightening to 15 Nm (1.5mkg), tighten another 90

2-20


Item Fastener Threadsize

Q’tyTightening

torque Remarkssize

yNm mkgf

Clutch coverPickup coil rotor coverShift shaft coverBreather plate 2Starter clutchClutch boss

Clutch springsDrive sprocket

Main axle bearing housingShift bar stopperShift shaft spring stopperShift rod locknut

Oil level switchShift armStator coilIgnitor unitNeutral switchPickup coilThermo unitThermo switch

BoltBoltBolt

–BoltNut

BoltNut

ScrewBoltBoltNut

BoltBoltBoltBolt

ScrewBolt

––

M6M6M6M6M8

M20

M6M18

M6M6M8M6M8M6M6M6M6M6M5

PT1/8M18 1.5

1056331

61

3211121312211

121212123270

870

1210227

10101010104.0101528

1.21.21.21.23.27.0

0.87.0

1.21.02.20.71.01.01.01.01.00.41.01.52.8

Use a lockwasher.

Use a lockwasher.

2-21


Crankcase tightening sequence:

2-22


NOTE:

CHASSIS TIGHTENING TORQUES

Item Thread sizeTightening

torque RemarksNm mkgf

Upper bracket pinch boltsSteering stem nutHandlebar pinch boltsLower ring nutLower bracket pinch boltsBrake fluid reservoir cap stopperFront brake hose union boltsFront brake master cylinderEngine mountingFront mounting bolts

Rear mounting boltsPinch bolts

Button head boltExhaust pipe bracketPivot shaft nutConnecting armsRelay arm and connecting armsRelay armRear shock absorber and relay armFuel cockFuel sender and fuel tankCoolant reservoir and radiatorRider footrest bracketPassenger footrest bracketRear master cylinderRear brake hose union boltsSidestandFront wheel axleRear wheel axle nutFront brake caliper and front forkRear brake caliper and bracketBrake disc and wheelRear wheel sprocket and rear wheel drive hubBrake caliper and bleed screwPinch bolt (front wheel axle)

M8M28M8

M30M8M4

M10M6

M12M12M10M8M6

M10M8

M18M10M10M10M10M6M6M6M8M8M8

M10M10M18M24M10M10M6

M10M8M8

25115339

23123013

555545241339209540404040775

282823306072

150402718696

23

2.511.53.30.92.31.23.01.3

5.55.54.52.41.33.92.09.54.04.04.04.00.70.70.52.82.82.33.06.07.2

15.04.02.71.86.90.62.3

See NOTE.

1. First, tighten the ring nut to approximately 17 Nm (1.7 mkg) with a torque wrench, then loosen the ring nut completely.

2. Retighten the ring nut to specification.

2-23

LUBRICATION POINTS AND LUBRICANT TYPES SPEC

EB202000

LUBRICATION POINTS AND LUBRICANT TYPESENGINE 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)

Cylinder head cover mating surface Yamaha bondNo.1215

Crankcase mating surface Yamaha bondNo.1215

Clutch cover (crankcase mating surface) Yamaha bondNo.1215

Generator rotor cover (crankcase mating surface) Yamaha bondNo.1215

Cylinder head cover Yamaha bondNo.1215

2-24

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)

2-25

OIL FLOW DIAGRAMS SPEC

1 Intake camshaft2 Exhaust camshaft3 Crankshaft4 Oil pipe5 Oil strainer6 Oil pump

OIL FLOW DIAGRAMS

2-26


1 Exhaust camshaft2 Intake camshaft3 Oil filter4 Oil cooler

2-27


1 Cylinder head2 Crankshaft

2-28


1 Main axle2 Oil delivery pipe3 driveaxle

2-29

1 Radiator2 Radiator fan3 Oil cooler

COOLANT FLOW DIAGRAMS SPEC

COOLANT FLOW DIAGRAMS

2-30


1 Thermostat housing2 Thermostat3 Radiator4 Therm

2-31

1 Radiator cap2 Radiator3 Oil cooler4 Water jacket joint5 Water pump


2-32

1 Radiator2 Radiator fan switch3 Radiator fan


2-33

CABLE ROUTING SPEC

1 Throttle cables2 Front brake hose3 Clutch cable4 Starter cable5 Left handlebar switch lead6 Main switch lead7 Right handlebar switch lead

A Install the headlight relays onto the headlight housing bridge.B Route the headlight lead through the plastic guide.C Route the right handlebar switch lead in front of the front fork inner

tube.D Route the throttle cables between the brake hose and right handlebar

switch lead.E Route the wire harness through under the left handlebar switch lead

and starter cable.F Fasten the left handlebar switch lead to the front fork with a plastic

locking tie and cut the end of locking tie.

EB206000

CABLE ROUTING

2-34

CABLE ROUTING SPEC

G Fasten the throttle cables and starter cable with a band.Locate the end of band to forward.

H Route the horn lead outside the throttle cables and fasten it to the under bracket with a plastic locking tie. Cut the end of locking tie. And then, route the horn lead under the brake hose and clamp it to the under cover.

2-35

1 Fuel pump lead2 Pickup coil lead3 Clutch cable4 Rear brake switch lead

A Route the ignition coil lead over the heat protector plate.

B Position the face of steel clip up ward.C Route the clutch cable through the guide on the

frame.D Route the coolant hose under the heat protector

plate.

CABLE ROUTING SPEC

E Route the clutch cable through the guide on the ra-diator.

F Fasten the clutch cable to the coolant hose protec-tor with a plastic band.

G Fasten the rear brake switch lead to the footrest bracket with a plastic locking tie and cut the end of locking tie.

H Fasten the fuel pump lead and rear brake switch lead with a plastic band on the fuel pump bracket.

2-36

1 AC magneto lead2 Sidestand switch lead3 Oil lever switch lead4 Reservoir tank breather hose5 Fuel tank breather hose6 Fuel tank drain hose7 Speed sensor lead8 Neutral switch lead9 Fuel pump leadA Route the throttle cable through inside of the radia-

tor bracket and outside of the wireharness.B Fasten the wireharness, radiator hose and fan mo-

tor lead with a plastic band.

CABLE ROUTING SPEC

C Do not touch the wireharness with the throttle cablepully.Route the wireharness under the radiator hose.

D Route the wireharness through the slit of rear fender.E Route the rear turn signal light leads (left and right)

through the hole of rear fender.F Route the seat lock cable outside of the wirehar-

ness.G Fasten the sidestand switch lead and oil level sen-

sor lead with a band.H Route the fuel tank drain hose, fuel tank breather

hose, reservoir tank breather hose, oil level switch lead and sidestand switch lead through the guide on the frame.

I Route the starter cable between the main switch lead and left randlebar switch lead.

2-37

1 Throttle cable2 Handlebar switch lead (right)3 Coolant reservoir breather hose4 Carburetor idle adjusting cable5 Pickup coil connector6 Neutral switch connector7 Rear brake switch connector8 Handlebar switch (right) connec-

tors9 Main switch connectors10 Throttle position sensor connector11 Handlebar switch (left) connec-

tors12 Neutral switch lead13 Fuel pump connector14 Rear brake switch lead15 Starter motor lead

CABLE ROUTING SPEC

16 Battery negative (–) cable17 Fuel sender connector18 Coolant reservoir tank cap19 Crankcase breather hose20 Therm unit lead21 Fan motor lead connector22 Clutch cable23 Handlebar switch lead (left)24 Stater cable25 Main switch lead

A To headlight leadB Route the clutch cable through the guide.

2-38

C Fasten the handlebar switch leads (left and right) and main switch lead with a band.

D Route the ignition coil lead and handlebar switch leads (left and right) over the heat protection plate.

E Route the reservoir tank hose, carburetor heater hoses under the heat protector plate.

F Fasten the neutral switch lead, right handlebar switch lead, main switch lead, TPS lead, left han-dlebar switch lead, pickup coil lead and throttle stop screw cable with a band.

G Insert the projection of the band to the hole of the frame and fasten the wireharness, neutral switch lead, handlebar switch leads (left and right), main switch lead, throttle position sensor lead, rearbrake switch lead and pickup coil lead with them.

CABLE ROUTING SPEC

H Route the starter motor lead under the wirehar-ness.

I Fasten the starter motor to the rear fender with a band.

J Fasten the battery positive (+) cable and starter motor cable with a plastic band.

K Position the rear turn signal light connectors (left and right) and taillight connector between the rear fender and taillight bracket.

L Install the seat lock cable to the frame bracket with protector side.

M Fasten the wireharness, oil level sensor lead, ground lead and alarm leads (3 lines) with a band.

N Fasten the starter relay lead and battery negative (–) lead to the wireharness with a plastic band.

O Fasten the battery negative (–) lead and wirehar-ness with a plastic band.

2-39

P Insert the projection of the band (wireharness) into the hole of the frame.

Q 1: Speed sensor connector2: AC magneto connector3: Sidestand switch connector4: Oil level switch connector5: Meter ground lead

R Fasten the leads (above 1 – 5) and starter motor lead with a steel band on the engine.

S Route the fuel tank breather hose and fuel tank drain hose over the wireharness.

T Route the starter cable with slot of the heat protec-tion plate.

CABLE ROUTING SPEC

U Route the starter cable and wireharness through the guide of the heat protection plate.

V Route the fan motor lead under the throttle cable and then, fasten the fan motor lead and throttle cable with a band.

W To radiator fan motor

CHKADJ

CHAPTER 3.PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 3-1. . . . . .

RIDER AND PASSENGER SEATS 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FUEL TANK 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COWLINGS 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AIR FILTER CASE AND IGNITION COILS 3-8. . . . . . . . . . . . . . . . . . . . . . . . REMOVAL 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLATION 3-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE 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. . . . . . . . . . . . . CHECKING THE EXHAUST SYSTEM 3-33. . . . . . . . . . . . . . . . . . . . . . . . . CLEANING THE AIR INTAKE 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHKADJ

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 3-53. . . . . . CHECKING THE TIRES 3-55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE WHEELS 3-57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND LUBRICATING THE CABLES 3-58. . . . . . . . . . . . . . . . . LUBRICATING THE LEVERS AND PEDALS 3-58. . . . . . . . . . . . . . . . . . . LUBRICATING THE SIDESTAND 3-58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . LUBRICATING THE REAR SUSPENSION 3-58. . . . . . . . . . . . . . . . . . . . .

ELECTRICAL SYSTEM 3-59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING AND CHARGING THE BATTERY 3-59. . . . . . . . . . . . . . . . . . CHECKING THE FUSES 3-64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REPLACING THE HEADLIGHT BULBS 3-66. . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE HEADLIGHT BEAMS 3-67. . . . . . . . . . . . . . . . . . . . . . .

3-1

INTRODUCTION/PERIODIC MAINTENANCE ANDLUBRICATION INTERVALS

CHKADJ

EB300000

PERIODIC CHECKS AND ADJUSTMENTSINTRODUCTIONThis chapter includes all information necessary to perform recommended checks and adjustments. Iffollowed, these preventive maintenance procedures will ensure more reliable vehicle operation, alonger service life and reduce the need for costly overhaul work. This information applies to vehiclesalready in service as well as to new vehicles that are being prepared for sale. All service techniciansshould be familiar with this entire chapter.EB301000

PERIODIC MAINTENANCE AND LUBRICATION INTERVALSEVERY

No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL

(1,000 km)

6,000 km or6 months

(whichevercomes first)

12,000 kmor

12 months(whichevercomes first)

1 * Fuel line Check fuel hoses for cracks or damage. Replace if necessary.

√ √

2 * Fuel filter Check condition. Replace if necessary.

√

3 Spark plugs Check condition. Clean, regap or replace if necessary.

√ √ √

4 * Valves Check valve clearance. Adjust if necessary.

Every 42,000 km or 42 months (which-ever comes first)

5 Air filter element Clean or replace if necessary. √ √

6 Clutch Check operation. Adjust or replace cable.

√ √ √

7 * Front brake

Check operation, fluid level and vehicle for fluid leak-age. (See NOTE on page 3-2.)

Correct accordingly. Replace brake pads if necessary.

√ √ √

8 * Rear brake

Check operation, fluid level and vehicle for fluid leak-age. (See NOTE on page 3-2.)

Correct accordingly. Replace brake pads if necessary.

√ √ √

9 * Wheels Check balance, runout and for damage. Rebalance or replace if necessary.

√ √

10 * Tires

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

√ √

11 * Wheel bearings Check bearing for looseness or damage. Replace if necessary.

√ √

12 * Swingarm

Check swingarm pivoting point for play. Correct if necessary. Lubricate with lithium soap base grease every 24,000

km or 24 months (whichever comes first).

√ √

13 Drive chain

Check chain slack. Adjust if necessary. Make sure that the rear wheel is

properly aligned. Clean and lubricate.

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

14 * Steering bearings

Check bearing play and steering for roughness. Correct accordingly. Lubricate with lithium soap base grease every

24,000 km or 24 months (whichever comes first).

√ √

3-2

PERIODIC MAINTENANCE/LUBRICATION INTERVALSCHKADJ

NOTE:

EVERY

No. ITEM CHECKS AND MAINTENANCE JOBSINITIAL

(1,000 km)

6,000 km or6 months

(whichevercomes first)

12,000 kmor

12 months(whichevercomes first)

15 * Chassis fasteners Make sure that all nuts, bolts and screws are properly

tightened. Tighten if necessary.

√ √

16 Sidestand Check operation. Lubricate and repair if necessary.

√ √

17 * Sidestand switch Check operation. Replace if necessary.

√ √ √

18 * Front fork Check operation and for oil leakage. Correct accordingly.

√ √

19 *Rear shock absorberassembly

Check operation and shock absorber for oil leakage. Replace shock absorber assembly if necessary.

√ √

20 *Rear suspension relayarm and connectingarm pivoting points

Check operation. Lubricate with lithium soap base grease every 24,000

km or 24 months (whichever comes first).√ √

21 * Carburetors Check engine idling speed, synchronization and

starter operation. Adjust if necessary.

√ √ √

22 Engine oil Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.)

√ √ √

23Engine oil filter car-tridge

Replace. √ √

24 * Cooling system

Check coolant level and vehicle for coolant leakage. Correct if necessary. Change coolant every 24,000 km or 24 months (which-

ever comes first).

√ √

* Since these items require special tools, data and technical skills, they should be serviced by aYamaha dealer.

The air filter element needs more frequent service if you are riding in unusually wet or dusty areas.Hydraulic brake system.– Replace the brake fluid after disassembling the master cylinder or caliper cylinder.– Check the brake fluid level and add fluid as required.– Replace the master cylinder and caliper cylinder oil seals every two years.– Replace the brake hoses every four years, or if cracked or damaged.

3-3

Order Job/Part Q’ty Remarks

12

Removing the rider and passengerseatsPassenger seatRider seat

11

Remove the parts in the order listed.

For installation, reverse the removalprocedure.

7Nm (0.7 mkg)

RIDER AND PASSENGER SEATSCHKADJ

EB302000

RIDER AND PASSENGER SEATS

3-4


1234

567

Removing the fuel tankRider seatBoltBoltsFuel sender couplerFuel hose

Fuel tank overflow hoseFuel tank breather hoseFuel tank

1211

111

Remove the parts in the order listedRefer to “SEATS”.

Disconnect.

Before disconnecting the fuel hose, setthe fuel cock “OFF”.

For installation reverse the removalprocedure.

NOTE:

10 Nm (1.0 mkg)

10 Nm (1.0 mkg)

7 Nm (0.7 mkg)7 Nm (0.7 mkg)

FUEL TANKCHKADJ

FUEL TANK

3-5


1234567

Removing the cowlingsRider and passenger seatsRear cowlingBottom cowling (left)Bottom cowling (right)Front cowling inner panel (left)Front cowling inner panel (right)Side cowling inner panel (left)Side cowling inner panel (right)

1111111

Remove the parts in the order listedRefer to “SEATS”.

5 Nm (0.5 mkg)

5 Nm (0.5 mkg)

COWLINGSCHKADJ

COWLINGS

3-6


89

101112

Left side cowlingRight side cowlingWindshieldRear view mirrorFront cowling

11121


5 Nm (0.5 mkg)

5 Nm (0.5 mkg)

COWLINGSCHKADJ

COWLINGS

3-7

COWLINGSCHKADJ

NOTE:

NOTE:

REMOVAL1. Remove: rear cowlingside cowlings

To remove the quick fastener, turn its center to90 with a screwdriver, then pull the fastenerout.

INSTALLATION1. Install:side cowlings rear cowling

To install the quick fastener, push its pin so thatit protrudes from the fastener head, then insertthe fastener into the cowling and push the pin ain with a screwdriver. Make sure that the pin isflush with the fastener’s head.

3-8


123456789

101112

Removing the air filter case andignition coilsRider seat and fuel tankFront cowling inner panel (left)Front cowling inner panel (right)Crankcase breather hoseAir vent hoseHosesDrain cupAir filter case balance hoseClamp screwBoltSurge tank joint (left)Surge tank joint (right)Air filter caseClampQuick fastener

112124111122

Remove the parts in the order listed.

Refer to “SEATS” and “FUEL TANK”.Refer to “COWLINGS”.

Loosen.

AIR FILTER CASE AND IGNITION COILSCHKADJ

AIR FILTER CASE AND IGNITION COILS

3-9

AIR FILTER CASE AND IGNITION COILSCHKADJ


131415

Heat protector plateIgnition coil couplerIgnition coil

144


3-10

AIR FILTER CASE AND IGNITION COIL PLATECHKADJ

NOTE:

NOTE:

REMOVAL1. Remove:heat protector plate

To remove the quick fastener, push its center inwith a screwdriver, then pull the fastener out.

INSTALLATION1. Install:heat protector plate

To install the quick fastener, push its pin so thatit protrudes from the fastener head, then insertthe fastener into the rubber baffle and push thepin a in with a screwdriver. Make sure that thepin is flush with the fastener’s head.

3-11

ADJUSTING THE VALVE CLEARANCECHKADJ

NOTE:

EB303001

ENGINEADJUSTING THE VALVE CLEARANCEThe following procedure applies to all of thevalves.

Valve clearance adjustment should be madeon a cold engine, at room temperature.

When the valve clearance is to be measuredor adjusted, the piston must be at top deadcenter (TDC) on the compression stroke.

1. Remove: rider seat fuel tankRefer to “SEATS” and “FUEL TANK”.

air filter caseheat protector plateRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

bottom cowlingside cowlingsRefer to “COWLINGS”.

carburetor assemblyRefer to “CARBURETORS” in chapter 6.

radiator assemblyRefer to “RADIATOR” in chapter 5.

2. Remove: ignition coilsspark plugscylinder head cover 1cylinder head cover gasket

3. Remove:pickup coil rotor cover 1

3-12


NOTE:

NOTE:

4. Measure:valve clearanceOut of specification Adjust

Valve clearance (cold)Intake valve

0.11 0.20 mmExhaust valve

0.21 0.30 mm

a. Turn the crankshaft clockwise.b. When piston #1 is at TDC on the compres-

sion stroke, align the TDC mark a on thepickup coil rotor with the crankcase matingsurface b .

TDC on the compression stroke can be foundwhen the camshaft lobes are turned away fromeach other.

c. Measure the valve clearance with a thick-ness gauge 1 .

If the valve clearance is incorrect, record themeasured reading.

Measure the valve clearance in the followingsequence.

Valve clearance measuring sequenceCylinder #1 #2 #4 #3

A Frontd. 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 CylinderD Combustion cycle

Cylinder #2 180

Cylinder #4 360

Cylinder #3 540

3-13


NOTE:

NOTE:

NOTE:

5. Remove: timing chain tensioner timing chain guide (exhaust side)camshaft cap timing chain(from the camshaft sprockets)

intake camshaftexhaust camshaft

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 pad2 .

Cover the timing chain opening with a rag toprevent the valve pad from falling into thecrankcase.

Make a note of the position of each valve lifter1 and valve pad 2 so that they can beinstalled in the correct place.

b. Select the proper valve pad from the follow-ing table.

Valve pad thick-ness range

Available valvepads

Nos.120

240

1.20 2.40 mm

25 thicknesses in0.05 mm incre-

ments

The thickness a of each valve pad is markedin hundredths of millimeters on the side thattouches the valve lifter.

Since valve pads of various sizes are originallyinstalled, the valve pad number must berounded in order to reach the closest equiva-lent to the original.

3-14


NOTE:

NOTE:

NOTE:

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 = 150d. Locate the rounded number of the original

valve pad and the measured valve clearancein the valve pad selection table. The pointwhere the column and row intersect is thenew valve pad number.

The new valve pad number is only an approxi-mation. The valve clearance must be measuredagain and the above steps should be repeated ifthe measurement is still incorrect.

e. Install the new valve pad 1 and the valve lift-er 2 .

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 thecorrect place.

f. Install the exhaust and intake camshafts,timing chain and camshaft caps.

Camshaft cap bolt10 Nm (1.0 mkg)

Refer to “CAMSHAFTS” in chapter 4.Lubricate the camshaft lobes and camshaftjournals.

First, install the exhaust camshaft.Align the camshaft marks with the camshaftcap marks.

Turn the crankshaft counterclockwise severalfull turns to seat the parts.

3-15


Example:Valve Clearance (cold)

0.11 0.20 mmRounded value 150

Measured valve clearance is 0.24 mmReplace pad 150 with pad 160

Pad No. 150 = 1.50 mmPad No. 160 = 1.60 mm

Always install the valve pad with thenumber facing down.

MEASURED

VALVE CLEARANCEB ORIGINAL VALVE PAD NUMBERA

Example:Valve Clearance (cold)

0.21 0.30 mmRounded value 175

Measured valve clearance is 0.35 mmReplace pad 150 with pad 185

Pad No. 175 = 1.75 mmPad No. 185 = 1.85 mm

Always install the valve pad with thenumber facing down.

MEASURED

VALVE CLEARANCEB ORIGINAL VALVE PAD NUMBERA

STANDARD CLEARANCE

STANDARD CLEARANCEC

C

VALVE PAD SELECTION TABLEINTAKE

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 2250.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.08 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 2350.11 0.200.21 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 2400.23 0.27 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.28 0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.33 0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38 0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43 0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48 0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53 0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58 0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63 0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68 0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73 0.77 180 185 190 195 200 205 210 215 220 225 230 235 2400.78 0.82 185 190 195 200 205 210 215 220 225 230 235 2400.83 0.87 190 195 200 205 210 215 220 225 230 235 2400.88 0.92 195 200 205 210 215 220 225 230 235 2400.93 0.97 200 205 210 215 220 225 230 235 2400.98 1.02 205 210 215 220 225 230 235 2401.03 1.07 210 215 220 225 230 235 2401.08 1.12 215 220 225 230 235 2401.13 1.17 220 225 230 235 2401.18 1.22 225 230 235 2401.23 1.27 230 235 2401.28 1.32 235 2401.33 1.37 240

EXHAUST

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.00 0.02 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 2150.03 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 2200.08 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 2250.13 0.17 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 2300.18 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 2350.21 0.300.31 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 2400.33 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.38 0.42 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.43 0.47 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.48 0.52 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.53 0.57 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.58 0.62 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.63 0.67 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.68 0.72 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.73 0.77 170 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.78 0.82 175 180 185 190 195 200 205 210 215 220 225 230 235 2400.83 0.87 180 185 190 195 200 205 210 215 220 225 230 235 2400.88 0.92 185 190 195 200 205 210 215 220 225 230 235 2400.93 0.97 190 195 200 205 210 215 220 225 230 235 2400.98 1.02 195 200 205 210 215 220 225 230 235 2401.03 1.07 200 205 210 215 220 225 230 235 2401.08 1.12 205 210 215 220 225 230 235 2401.13 1.17 210 215 220 225 230 235 2401.18 1.22 215 220 225 230 235 2401.23 1.27 220 225 230 235 2401.28 1.32 225 230 235 2401.33 1.37 230 235 2401.38 1.42 235 2401.43 1.47 240

3-16

ADJUSTING THE VALVE CLEARANCE/SYNCHRONIZING THE CARBURETORS

CHKADJ

NOTE:

NOTE:

NOTE:

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 isobtained.

7. Install:all removed parts

For installation, reverse the removal procedure.Note the following points.

8. Install: timing chain guide (exhaust side) timing chain tensionerpickup coil rotor covercylinder head coverspark plugs ignition coilsRefer to “CAMSHAFTS” in chapter 4.

EB303010

SYNCHRONIZING THE CARBURETORS

Prior to synchronizing the carburetors, the valveclearance and the engine idling speed shouldbe properly adjusted and the ignition timingshould be checked.

1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.


3-17

SYNCHRONIZING THE CARBURETORSCHKADJ

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 gauge90890-03094

Vacuum gauge attachment90890-03060

Engine tachometer90793-80009

5. Start the engine and let it warm up for severalminutes.

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

Engine idling speed1,250 1,350 r/min

7. Adjust:carburetor synchronization

a. Synchronize carburetor #1 to carburetor #2by turning the synchronizing screw 1 in ei-ther direction until both gauges read thesame.

3-18

SYNCHRONIZING THE CARBURETORS/ADJUSTING THE ENGINE IDLING SPEED

CHKADJ

NOTE:

NOTE:

NOTE:

After each step, rev the engine two or threetimes, each time for less than a second, andcheck the synchronization again.

b. Synchronize carburetor #4 to carburetor #3by turning the synchronizing screw 2 in ei-ther direction until both gauges read thesame.

c. Synchronize carburetor #2 to carburetor #3by turning the synchronizing screw 3 in ei-ther direction until both gauges read thesame.

Vacuum pressure at engineidling speed

24.0 kPa (0.24 kg/cm 2)

The difference in vacuum pressure betweentwo carburetors should not exceed 1.33 kPa (10mm Hg).

8. Measure:engine idling speedOut of specification Adjust.

9. Stop the engine and remove the measuringequipment.

10. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.

Throttle cable free play(at the flange of the throttle grip)

6 8 mm

EB303020

ADJUSTING THE ENGINE IDLING SPEED

Prior to adjusting the engine idling speed, thecarburetor synchronization should be adjustedproperly, 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 severalminutes.

3-19

ADJUSTING THE ENGINE IDLING SPEEDCHKADJ

a

b

2. Remove:air filter casequick fasteners 1band 2Refer to “AIR FILTER CASE AND IGNITIONCOILS”.

3. Install:engine tachometer(onto the ignition coil of cylinder #1)


4. Install:air filter caseRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

5. Measure:engine idling speedOut of specification Adjust.


6. Adjust:engine idling speed

a. Turn the pilot screw 1 in until it is lightlyseated.

b. Turn the pilot screw out the specified numberof turns.

Carburetor angle driver90890-03158

Pilot screw setting2 turns out

c. Turn the throttle stop screw 2 in direction aor b until the specified engine idling speed isobtained.

Direction Engine idling speed isdecreased.

Direction Engine idling speed isincreased.

3-20

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

CHKADJ

NOTE:

7. Adjust: throttle cable free playRefer to “ADJUSTING THE THROTTLECABLE FREE PLAY”.


6 8 mm

EB303031

ADJUSTING THE THROTTLE CABLE FREEPLAY

Prior to adjusting the throttle cable free play, theengine idling speed and carburetor synchro-nization should be adjusted properly.

1. Measure: throttle cable free play aOut of specification Adjust.


6 8 mm



3-21

ADJUSTING THE THROTTLE CABLE FREE PLAYCHKADJ

NOTE:

a

b

NOTE:

c

d

WARNING

3. Adjust: throttle cable free play

When the throttle is opened, the acceleratorcable 1 is pulled.

Carburetor sidea. 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 isobtained.

Direction Throttle cable free playin increased.

Direction Throttle cable free playis decreased.

e. Tighten the locknuts.

If the specified throttle cable free play cannot beobtained on the carburetor side of the cable,use the adjusting nut on the handlebar side.

Handlebar sidea. Loosen the locknut 6 .b. Turn the adjusting nut 7 in direction c or d

until the specified throttle cable free play isobtained.

Direction Throttle cable free playis increased.

Direction Throttle cable free playis decreased.

d. Tighten the locknut.

After adjusting the throttle cable free play,start the engine and turn the handlebars tothe right and to the left to ensure that thisdoes not cause the engine idling speed tochange.

3-22

CHECKING THE SPARK PLUGSCHKADJ

NOTE:

CAUTION:

EB303040

CHECKING THE SPARK PLUGSThe following procedure applies to all of thespark plugs.1. Remove: rider seat fuel tankRefer to “SEATS” and “FUEL TANK”.


2. Disconnect: Ignition coils

3. Remove:spark plug

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 thelike.

Before removing the spark plugs, blowaway any dirt accumulated in the spark plugwells with compressed air to prevent it fromfalling into the cylinders.

4. Check:spark plug typeIncorrect Change.

Spark plugstype (manufacturer)

CR10EK (NGK)

3-23

CHECKING THE SPARK PLUGS/CHECKING THE IGNITION TIMING

CHKADJ

13 Nm (1.3 mkg)

NOTE:

NOTE:

5. Check:electrodes 1Damage/wear Replace the spark plug.

insulator 2Abnormal 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 gap0.6 0.7 mm

8. Install:spark plug

Before installing the spark plug, clean the sparkplug and gasket surface.

EB303050

CHECKING THE IGNITION TIMING

Prior to checking the ignition timing, check thewiring connections of the entire ignition system.Make sure that all connections are tight and freeof corrosion.

1. Remove:bottom cowlingRefer to “COWLINGS”.

rider seat fuel tankRefer to “SEATS” and “FUEL TANK”.

air filter caseRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

timing mark accessing screw 1

3-24

CHECKING THE IGNITION TIMING/MEASURING THE COMPRESSION PRESSURE

CHKADJ

NOTE:

NOTE:

2. Install: timing light 1engine tachometer(onto the ignition coil of cylinder #1)

Timing light90890-03141


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.


b. Check that the mark a is within the requiredfiring range b on the pickup coil rotor.Incorrect firing range Check the ignitionsystem.

The ignition timing is not adjustable.

EB303060

MEASURING THE COMPRESSION PRES-SUREThe following procedure applies to all of the cyl-inders.

Insufficient compression pressure will result in aloss of performance.

1. Measure:valve clearanceOut of specification Adjust.Refer to “ADJUSTING THE VALVE CLEAR-ANCE”.

2. Start the engine, warm it up for several min-utes, and then stop it.


air filter caseheat protector plate ignition coilsRefer to “AIR FILTER CASE AND IGNITIONCOILS”.

3-25

MEASURING THE COMPRESSION PRESSURECHKADJ

CAUTION:

WARNING

NOTE:

4. Remove:spark plug

Before removing the spark plugs, use com-pressed air to blow away any dirt accumu-lated in the spark plug wells to prevent itfrom falling into the cylinders.

5. Install:compression gauge 1

Compression gauge90890-03081

Adapter90890-04136

6. Measure:compression pressureOut of specification Refer to steps (c) and(d).

Compression pressure (at sealevel)

Minimum1300 kPa (13.0 kg/cm 2,13.0 bar)

Standard1550 kPa (15.5 kg/cm 2,15.5 bar)

Maximum1600 kPa (16.0 kg/cm 2,16.0 bar)

a. Set the main switch to “ON”.b. With the throttle wide open, crank the engine

until the reading on the compression gaugestabilizes.

To prevent sparking, ground all spark plugleads before cranking the engine.

The difference in compression pressure be-tween cylinders should not exceed 100 kPa (1kg/cm2, 1 bar).

3-26

MEASURING THE COMPRESSION PRESSURE/CHECKING THE ENGINE OIL LEVEL

CHKADJ

13 Nm (1.3 mkg)

NOTE:

c. If the compression pressure is above themaximum specification, check the cylinderhead, valve surfaces, and piston crown forcarbon deposits.Carbon deposits Eliminate.

d. If the compression pressure is below theminimum specification, squirt a few drops ofoil into the cylinder and measure again.

Refer to the following table.

Compression pressure(with oil applied into the cylinder)

Reading Diagnosis

Higher thanwithout oil

Piston wear ordamage Repair.

Same as withoutoil

Piston ring(-s),valve(-s), cylinderhead gasket orpiston possiblydefective Repair.

7. Install:spark plug

EB303070

CHECKING THE ENGINE OIL LEVEL1. Stand the motorcycle on a level surface.

Place the motorcycle on a suitable stand.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 levelThe engine oil level should be between theminimum level mark a and maximum levelmark b .Below the minimum level mark Add therecommended engine oil to the proper level.

3-27

CHECKING THE ENGINE OIL LEVEL/CHANGING THE ENGINE OIL

CHKADJ

CAUTION:

NOTE:

Recommended oilRefer to the chart for the engine oilgrade which is best suited for cer-tain atmospheric temperatures.API standard

SE or higher grade(Non-Friction modified)ACEA standard G4 or G5

Engine oil also lubricates the clutch andthe wrong oil types or additives couldcause clutch slippage. Therefore, do notadd any chemical additives or use engineoils with a grade of CD c or higher and donot use oils labeled “ENERGY CONSERV-ING II” d or higher.

Do not allow foreign materials to enter thecrankcase.

4. Start the engine, warm it up for several min-utes, and then turn it off.

5. Check:engine oil level

Before checking the engine oil level, wait a fewminutes until the oil has settled.

EB303081

CHANGING THE ENGINE OIL1. Remove:bottom cowlingRefer to “COWLINGS”.


3. Place a container under the engine oil drainbolt.

4. Remove:engine oil filler cap 1engine oil drain bolt 2(along with the washer)

5. Drain:engine oil(completely from the crankcase)

3-28

CHANGING THE ENGINE OILCHKADJ

CAUTION:

43 Nm (4.3 mkg)

6. If the oil filter cartridge is also to be replaced,perform the following procedure.

a. Remove the oil filter cartridge 1 with an oilfilter wrench 2 .

Oil filter wrench90890-01426

b. Lubricate the O-ring 3 of the new oil filtercartridge with a thin coat of engine oil.

Make sure theat the O-ring 3 is positionedcorrectly 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 cartridge17 Nm (1.7 mkg)

7. Check:engine oil drain bolt washerDamage Replace.

8. Install:engine oil drain bolt

9. Fill:crankcase(with the specified amount of the recom-mended engine oil)

QuantityTotal amount

3.5 LWithout oil filter cartridge re-placement

2.5 LWith oil filter cartridge replace-ment

2.7 L

10. Install:engine oil filler cap


12. Check:engine(for engine oil leaks)

3-29

CHANGING THE ENGINE OIL/MEASURING THE ENGINE OIL PRESSURE

CHKADJ

CAUTION:

WARNING

13. Check:engine oil levelRefer to “CHECKING THE ENGINE OILLEVEL”.

14. Install:bottom cowlingRefer to “COWLINGS”.

EB303090

MEASURING THE ENGINE OIL PRESSURE1. Check:engine oil levelBelow the minimum level mark Add therecommended engine oil to the proper level.


When the engine is cold, the engine oil willhave a higher viscosity, causing the engineoil pressure to increase. Therefore, be sureto measure the engine oil pressure afterwarming up the engine.

3. Remove:oil gallery bolt 1

The engine, muffler and engine oil are ex-tremely hot.

4. Install:oil pressure gauge 1adapter 2

Oil pressure gauge90890-03153

Adapter90890-03139

5. Measure:engine oil pressure(at the following conditions)

Engine oil pressure240 kpa (2.4 kg/cm 2)

Engine speedApprox. 6000 r/min

Engine oil temperature96C

3-30

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

CHKADJ

NOTE:

20 Nm (2.0 mkg)

a

b

NOTE:

c

d

Regarding the oil pressure as its own data mayfluctuate depending on the oil temperature andviscosity, the oil pressure may fluctuate whenmeasuring. The following data should be usedonly as a reference when measuring the engineoil pressure.

Out of specification Adjust.

Engine oil pressure Possible cause

Below specification

Faulty oil pumpClogged oil filterLeaking oil passapageBroken or damagedoil seal

Above specificationLeaking oil passageFaulty oil filterOil viscosity too high

6. Tighten the oil gallery bolt

EB303100

ADJUSTING THE CLUTCH CABLE FREEPLAY1. Measure:clutch cable free play aOut of specification Adjust.

Clutch cable free play (at the endof the clutch lever)

10 15 mm

2. Adjust:clutch cable free play

Handlebar sidea. Turn the adjusting bolt 1 in direction a or b

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play is in-creased.

Direction Clutch cable free play is de-creased.

If the specified clutch cable free play cannot beobtained on the handlebar side of the cable, usethe adjusting nut on the engine side.

Engine sidea. Loosen the locknut 2 .b. Turn the adjusting nut 3 in direction c or d

until the specified clutch cable free play is ob-tained.

Direction Clutch cable free play is in-creased.

Direction Clutch cable free play is de-creased.

c. Tighten the locknut.

3-31

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

CHKADJ

CAUTION:

NOTE:

EB303130

CLEANING THE AIR FILTER ELEMENT1. Remove: fuel tankRefer to “FUEL TANK”.

air filter case cover 1air filter element

2. Clean:air filter elementUse solvent to clean the air filter element. Af-ter cleaning the air filter element, remove thesolvent from the air filter element.

3. Apply the engine oil to the entire surface ofthe filter and remove the excess oil. The airfilter should be wet but not dripping.

4. Check:air filter elementDamage Replace.

5. Install:air filter elementair filter case cover

Never operate the engine without the air fil-ter element installed. Unfiltered air willcause rapid wear of engine parts and maydamage the engine. Operating the enginewithout the air filter element will also affectthe carburetor tuning, leading to poor en-gine performance and possible overheat-ing.

When installing the air filter element into the airfilter case cover, make sure that their sealingsurfaces are aligned to prevent any air leaks.

6. Install: fuel tankRefer to “FUEL TANK”.

3-32

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

CHKADJ

NOTE:

EB303171

CHECKING THE CARBURETOR JOINTSThe following procedure applies to all of the car-buretor joints and intake manifolds.1. Remove:carburetor assemblyRefer to “CARBURETORS” in chapter 6.

2. Check:carburetor joint 1Cracks/damage Replace.Refer to “CARBURETORS” in chapter 6.

3. Install:carburetor assemblyRefer to “CARBURETORS” in chapter 6.

EB303181

CHECKING THE FUEL HOSES AND FUELFILTERThe following procedure applies to all of the fuelhoses.1. Remove: fuel tankRefer to “FUEL TANK”.

2. Check: fuel hose 1Cracks/damage Replace.

fuel filter 2Contaminants/damage Replace.

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.


3-33

CHECKING THE EXHAUST SYSTEM/CLEANING THE AIR INTAKE SYSTEM

CHKADJ

CAUTION:

EB303190

CHECKING THE CRANKCASE BREATHERHOSE1. Remove: fuel tankRefer to “FUEL TANK”.

2. Check:crankcase breather hose 1Cranks/damage Replace.Loose connection Connect properly.

Make sure that the crankcase breather hoseis routed correctly.


EAS00092

CLEANING THE AIR INTAKE SYSTEMThe following procedure applies to both air in-take system.1. Remove:side cowling inner coversside 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 airducts with clean water.

b. Hold the air intake system air ducts upsidedown to allow the water to drain out.

c. Repeat the flushing steps until the excesswater is clear and free of debris.

d. Place the air intake system air ducts in an up-right position to allow any remaining water todrain out of the lower drain tube.

e. Keep the air intake system air ducts uprightto allow it to dry sufficiently.

5. Install:air intake system air ducts fuel tank front cowling front cowling inner coversside cowlingsside cowlings inner covers

3-34

CHECKING THE CRANKCASE BREATHER HOSE/CHECKING THE EXHAUST SYSTEM

CHKADJ

CAUTION:

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

Make sure that the crankcase breather hoseis routed correctly.


EB303200

CHECKING THE EXHAUST SYSTEMThe following procedure applies to all of the ex-haust pipes and gaskets.1. Remove: radiator assemblyRefer to “RADIATOR” in chapter 5.

2. Check:exhaust pipe 1muffler 2Cracks/damage Replace.

gasket 3Exhaust gas leaks Replace.

3. Measure: tightening torque

Exhaust pipe nut 420 Nm (2.0 mkg)

Muffler clamp bolt 520 Nm (2.0 mkg)

Exhaust pipe bolt 620 Nm (2.0 mkg)

Muffler bolt 738 Nm (3.8 mkg)

4. Install: radiator assemblyRefer to “RADIATOR” in chapter 5.

3-35

CHECKING THE COOLANT LEVEL/CHECKING THE COOLING SYSTEM

CHKADJ

NOTE:

CAUTION:

NOTE:

EB303220

CHECKING THE COOLANT LEVEL1. Stand the motorcycle on a level surface.


2. Check:coolant levelThe coolant level should be between themaximum level mark a and minimum levelmarks b .Below the minimum level mark Add therecommended coolant to the proper level.

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused instead of coolant, check and correctthe antifreeze concentration of the coolant.

Use only distilled water. Soft water may beused if distilled water is not available.


4. Check:coolant level

Before checking the coolant level, wait a fewminutes until it settles.

EB303230

CHECKING THE COOLING SYSTEM1. Remove:bottom cowlingside cowlingsRefer to “COWLINGS”.

2. Check: radiator 1 radiator inlet hose 2 radiator outlet hose 3oil cooler 4oil cooler inlet hose 5oil cooler outlet hose 6water pump outlet hose 7Cracks/damage Replace.Refer to “COOLING SYSTEM” in chapter 5.

3. Install:side cowlingsbottom cowlingRefer to “Cowlings”.

3-36

CHANGING THE COOLANTCHKADJ

NOTE:

WARNING

EB303240

CHANGING THE COOLANT1. Remove:bottom cowling left side cowlingRefer to “COWLINGS”.

reservoir hose clamps 12. Remove:coolant reservoir bolts 2coolant reservoir cap 3

When draining the coolant from the coolant res-ervoir, be sure to tilt the reservoir so that coolantcannot flow through the coolant reservoirbreather hose 4 .

3. Drain:coolant(from the coolant reservoir)

4. Install:coolant reservoir bolts reservoir cover

5. Remove: radiator cap 1

A hot radiator is under pressure. Therefore,do not remove the radiator cap when the en-gine is hot. Scalding hot fluid and steammay 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 radiatorcap and slowly turn the radiator cap coun-terclockwise toward the detent to allow anyresidual pressure to escape. When the his-sing sound has stopped, turn the radiatorcap counterclockwise while pressing downon it and then remove it.

3-37


7 Nm (0.7 mkg)

WARNING

6. Remove:coolant drain bolt 1(along with the copper washer)

7. Drain:coolant

8. Check:coper washer 1coolant drain bolt 2Damage Replace

9. Install:coolant drain bolt

10. Fill:cooling system(with the specified amount of the recom-mended coolant)

Recommended antifreezeHigh-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines

Mixing ratio1:1 (antifreeze: water)

QuantityTotal amount

2.15 LCoolant reservoir capacity

0.44 L

Handling notes for coolantCoolant is potentially harmful and should behandled with special care.

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 withsoap and water.

If coolant is swallowed, induce vomitingand get immediate medical attention.

3-38


CAUTION:

NOTE:

Adding water instead of coolant lowers theantifreeze content of the coolant. If water isused 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 notavailable.

If coolant comes into contact with paintedsurfaces, 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 levelRefer to “CHECKING THE COOLANT LEV-EL”.

Before checking the coolant level, wait a fewminutes until the coolant has settled.

16. Install: left side cowlingbottom cowlingRefer to “COWLINGS”.

3-39

ADJUSTING THE FRONT BRAKE/ADJUSTING THE REAR BRAKE

CHKADJ

NOTE:

a

a

WARNING

EB304001

CHASSISADJUSTING THE FRONT BRAKE1. Adjust:brake lever position(distance a from the throttle grip to thebrake lever)

a. While pushing the brake lever forward, turnthe adjusting dial 1 until the brake lever is inthe desired position.

Be sure to align the setting on the adjusting dialwith the arrow mark 2 on the brake lever hold-er.

Position #1 Distance is the largest.

Position #5 Distance is the smallest.

After adjusting the brake lever position,make sure that the pin on the brake leverholder is firmly inserted in the hole in the ad-justing dial.

EB304010

ADJUSTING THE REAR BRAKE1. Measure:brake pedal position(distance a from the top of the brake pedalto the bottom of the rider footrest bracket boltcenter)Out of specification Adjust.

Brake pedal position (from the top of the brake pedal to the bottom of the rider footrest bracket bolt center)

4.3 9.3 mm

b : 11mm

3-40

ADJUSTING THE REAR BRAKECHKADJ

a

b

WARNING

WARNING

CAUTION:

2. Adjust:brake pedal position

a. Loosen the locknut 1 .b. Turn the adjusting bolt 2 in direction a or b

until the specified brake pedal position is ob-tained.

Direction Brake pedal is raised.

Direction Brake pedal is lowered.

After adjusting the brake pedal position,check that the end of the adjusting bolt c isvisible through the hole d .

c. Tighten the locknut 1 to specification.

Locknut16 Nm (1.6 mkg)

A soft or spongy feeling in the brake pedalcan indicate the presence of air in the brakesystem. Before the vehicle is operated, theair must be removed by bleeding the brakesystem. Air in the brake system will consid-erably reduce braking performance andcould result in loss of control and possiblyan accident.Therefore, check and, if necessary, bleedthe brake system.

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

3. Adjust: rear brake light switchRefer to “ADJUSTING THE REAR BRAKELIGHT SWITCH”.

3-41

CHECKING THE BRAKE FLUID LEVELCHKADJ

A

NOTE:

WARNING

CAUTION:

NOTE:

EB304020

CHECKING THE BRAKE FLUID LEVEL1. Stand the motorcycle on a level surface.


2. Check:brake fluid levelBelow the minimum level mark a Add therecommended brake fluid to the proper level.

Recommended brake fluidDOT 4

A Front brake

B Rear brake

Use only the designated brake fluid.Other brake fluids may cause the rubberseals to deteriorate, causing leakage andpoor brake performance.

Refill with the same type of brake fluid thatis already in the system. Mixing brakefluids may result in a harmful chemicalreaction, leading to poor brake perfor-mance.

When refilling, be careful that water doesnot enter the brake fluid reservoir. Waterwill significantly lower the boiling point ofthe brake fluid and could cause vapor lock.

Brake fluid may damage painted surfacesand plastic parts. Therefore, always cleanup any spilt brake fluid immediately.

In order to ensure a correct reading of the brakefluid level, make sure that the top of the brakefluid reservoir is horizontal.

3-42

CHECKING THE BRAKE PADS/ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHKADJ

A

B

NOTE:

a

b

EB304032

CHECKING THE BRAKE PADSThe following procedure applies to all of thebrake pads.1. Operate the brake.2. Check: front brake pad rear brake padBrake pad wear limit aWear limit reached Replace the brakepads as a set.Refer to “FRONT AND REAR BRAKES” inchapter 7.

Brake pad wear limita 0.5 mm b 0.8 mm

A Front brake

B Rear brake

EB304050

ADJUSTING THE REAR BRAKE LIGHTSWITCH

The rear brake light switch is operated bymovement of the brake pedal.

The rear brake light switch is properly adjustedwhen the brake light comes on just before thebraking effect starts.

1. Check: rear brake light operation timingIncorrect Adjust.

2. Adjust: rear brake light operation timing

a. Hold the main body 1 of the rear brake lightswitch so that it does not rotate and turn theadjusting nut 2 in direction a or b until therear brake light comes on at the proper time.

Direction Brake light comes onsooner.

Direction Brake light comes onlater.

3-43

CHECKING THE BRAKE HOSES/BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHKADJ

WARNING

NOTE:

EB304062

CHECKING THE BRAKE HOSESThe following procedure applies to all of thebrake hoses and brake hose clamps.1. Check:brake hose 1Cracks/damage/wear Replace.

2. Check:brake hose clampLoose Tighten the clamp bolt.

3. Hold the motorcycle upright and apply thebrake several times.

4. Check:brake hoseBrake fluid leakage Replace the damagedhose.Refer to “FRONT AND REAR BRAKES” inchapter 7.

EB304072

BLEEDING THE HYDRAULIC BRAKE SYS-TEM

Bleed the hydraulic brake system whenev-er: the brake system was disassembled,a brake hose was loosened, disconnectedor replaced,

the brake fluid level is very low,brake operation is faulty.

Be careful not to spill any brake fluid or allowthe brake fluid reservoir to overflow.

When bleeding the hydraulic brake system,make sure that there is always enough brakefluid before applying the brake. Ignoring thisprecaution could allow air to enter the hydrau-lic brake system, considerably lengthening thebleeding procedure.

If bleeding is difficult, it may be necessary to letthe brake fluid settle for a few hours. Repeatthe bleeding procedure when the tiny bubblesin the hose have disappeared.

3-44

BLEEDING THE HYDRAULIC BRAKE SYSTEMCHKADJ

A

B

NOTE:

WARNING

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 braked. Place the other end of the hose into a con-

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.

Loosening the bleed screw will release thepressure and cause the brake lever to contactthe throttle grip or the brake pedal to fully ex-tend.

h. Tighten the bleed screw and then release thebrake lever or brake pedal.

i. Repeat steps (e) to (h) until all of the airbubbles have disappeared from the brakefluid in the plastic hose.

j. Tighten the bleed screw to specification.

Bleed screw6 Nm (0.6 mkg)

k. Fill the brake fluid reservoir to the proper lev-el with the recommended brake fluid.Refer to “CHECKING THE BRAKE FLUIDLEVEL”.

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

3-45

ADJUSTING THE SHIFT PEDAL/ADJUSTING THE DRIVE CHAIN SLACK

CHKADJ

NOTE:

b

c

NOTE:

CAUTION:

WARNING

NOTE:

EB304081

ADJUSTING THE SHIFT PEDAL

The shift pedal position is determined by theinstalled.

1. Measure: incorrect Adjust.

The top of sift pedal should bealigned with the lower part of thebracket. (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.

Direction Installed shift rod lengthincreases.

Direction Installed shift rod lengthdecreases.

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

within specification.

EB304092

ADJUSTING THE DRIVE CHAIN SLACK

The drive chain slack must be checked at thetightest point on the chain.

A drive chain that is too tight will overloadthe engine and other vital parts, and one thatis too loose can skip and damage the swin-garm or cause an accident. Therefore, keepthe drive chain slack within the specifiedlimits.

1. Stand the motorcycle on a level surface.

Securely support the motorcycle so thatthere is no danger of it falling over.

Place the motorcycle on a suitable stand so thatthe rear wheel is elevated.

3-46

ADJUSTING THE DRIVE CHAIN SLACKCHKADJ

a

b

NOTE:

2. Rotate the rear wheel several times andcheck the drive chain to locate its tightestpoint.

3. Measure:drive chain slack aOut of specification Adjust.

Drive chain slack40 50 mm

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.

Direction Drive chain slack isreduced.

Direction Drive chain slack isincreased.

To maintain the proper wheel alignment, adjustboth sides evenly.

d. Tighten both locknuts to specification.

Locknut16 Nm (1.6 mkg)

e. Tighten the wheel axle nut to specification.

Wheel axle nut150 Nm (15.0 mkg)

3-47

LUBRICATING THE DRIVE CHAIN/CHECKING AND ADJUSTING THE STEERING HEAD

CHKADJ

WARNING

NOTE:

EB304100

LUBRICATING THE DRIVE CHAINThe drive chain consists of many interactingparts. If the drive chain is not maintained prop-erly, it will wear out rapidly. Therefore, the drivechain should be serviced, especially when themotorcycle 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, andthe use of a coarse brush can damage these O-rings. Therefore, use only kerosine to clean thedrive 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 notuse any other lubricants on the drive chain sincethey may contain solvents that could damagethe O-rings.

Recommended lubricantEngine oil or chain lubricant suitable for O-ring chains

EB304130

CHECKING AND ADJUSTING THE STEER-ING HEAD1. Stand the motorcycle on a level surface.


Place the motorcycle on a suitable stand so thatthe front wheel is elevated.

2. Check:steering headGrasp the bottom of the front fork legs andgently rock the front fork.Looseness/binding Adjust the steeringhead.

3-48

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

NOTE:

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

4. Loosen:upper bracket pinch bolts 1handlebar pinch bolts 2washer 3

5. Remove:handlebars(from the upper bracket)

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

7. Adjust:steering head

a. Remove the lock washer 1 , the upper ringnut 2 , and the washer 3 .

b. Loosen the lower ring nut 4 and then tightenit to specification with a ring nut wrench 5 .

Set the torque wrench at a right angle to thesteering nut wrench.

Steering nut wrench90890-01403

Lower ring nut (initial tightening torque)

17 Nm (1.7 mkg)

3-49

CHECKING AND ADJUSTING THE STEERING HEADCHKADJ

WARNING

NOTE:

115 Nm (11.5 mkg)

13 Nm (1.3 mkg)

13 Nm (1.3 mkg)

23 Nm (2.3 mkg)

NOTE:

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

Do not overtighten the lower ring nut.

Lower ring nut (final tightening torque)

9 Nm (0.9 mkg)

d. Check the steering head for looseness orbinding by turning the front fork all the way inboth directions. If any binding is felt, removethe lower bracket and check the upper andlower 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 andtighten the upper ring nut until their slots arealigned.

h. Install the lock washer 1 .

Make sure that the lock washer tabs a sit cor-rectly in the ring nut slots b .

8. Install:steering stem nut

upper bracket bolthandlebar pinch boltupper bracket pinch bolt

9. Measure:steering head tension(with the motorcycle still on the stand)

Make sure that all of the cables and wires areproperly 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.

3-50

CHECKING AND ADJUSTING THE STEERING HEAD/CHECKING THE FRONT FORK

CHKADJ

WARNING

d. Hold the spring gauge at a 90 angle fromthe handlebar, pull the spring gauge, and re-cord the measurement when the handlebarstarts to turn.

Steering head tension200 500 g

e. Repeat the above procedure on the oppositehandlebar.

f. If the steering head tension is out of specifi-cation (both handlebars should be withinspecification), remove the upper bracket andloosen or tighten the upper ring nut.

g. Reinstall the upper bracket and measure thesteering head tension again as describedabove.

h. Repeat the above procedure until the steer-ing head tension is within specification.

i. Grasp the bottom of the front fork legs andgently rock the front fork.Looseness or binding Adjust the steeringhead.

EB304141

CHECKING THE FRONT FORK1. Stand the motorcycle on a level surface.


2. Check: inner tube 1Damage/scratches Replace.

oil seal 2Oil leakage Replace.

3. Hold the motorcycle upright and apply thefront brake.

4. Check: front fork operationPush down hard on the handlebars severaltimes and check if the front fork reboundssmoothly.Rough movement Repair.Refer to “FRONT FORK” in chapter 7.

3-51

ADJUSTING THE FRONT FORK LEGSCHKADJ

WARNING

CAUTION:

a

b

EB304153

ADJUSTING THE FRONT FORK LEGSThe following procedure applies to both of thefront fork legs.

Always adjust both front fork legs evenly.Uneven adjustment can result in poor han-dling and loss of stability.


Spring preload

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 orb .

Direction Spring preload isincreased (suspension isharder).

Direction Spring preload isdecreased (suspension issofter).

HARD STD SOFT

1 2 3 4 5 6 7 8

3-52

ADJUSTING THE FRONT FORK LEGSCHKADJ

CAUTION:

a

b

CAUTION:

a

b

Rebound damping

Never go beyond the maximum or minimumadjustment positions.

1. Adjust: rebound damping

a. Turn the adjusting screw 1 in direction a orb .

DirectionRebound damping isincreased (suspension isharder).

DirectionRebound damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 12 clicks out*Standard: 6 clicks out*Maximum: 1 clicks out*

* from the fully turned-in position

Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 11 clicks out*Standard: 6 clicks out*Maximum: 1 clicks out*


3-53

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

WARNING

CAUTION:

NOTE:

a

b

EB304162

ADJUSTING THE REAR SHOCK ABSORB-ER ASSEMBLY


Spring preload


1. Adjust:spring preload

Adjust the spring preload with the specialwrench and extension bar included in the own-er’s tool kit.

a. Turn the adjusting ring 1 in direction a orb .

b. Align the desired position on the adjustingring with the position indicator 2 .

Direction Spring preload isincreased (suspension isharder).

Direction Spring preload isdecreased (suspension issofter).

Adjusting positionsMinimum: 1Standard: 4Maximum: 9

3-54

ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLYCHKADJ

CAUTION:

a

b

CAUTION:

a

b

Rebound damping


1. Adjust: rebound damping


DirectionRebound damping isincreased (suspension isharder).

DirectionRebound damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 25 clicks out *

Standard: 9 clicks out *

Maximum: 1 click out *


Compression damping


1. Adjust:compression damping


DirectionCompression damping isincreased (suspension isharder).

DirectionCompression damping isdecreased (suspension issofter).

Adjusting positionsMinimum: 13 clicks out *

Standard: 7 clicks out *

Maximum: 1 click out *


3-55

CHECKING THE TIRESCHKADJ

WARNING

WARNING

EB304170

CHECKING THE TIRESThe following procedure applies to both of thetires.1. Measure: tire pressureOut of specification Regulate.

The tire pressure should only be checkedand regulated when the tire temperatureequals the ambient air temperature.

The tire pressure and the suspension mustbe adjusted according to the total weight(including cargo, rider, passenger and ac-cessories) and the anticipated ridingspeed.

Operation of an overloaded motorcyclecould cause tire damage, an accident or aninjury.

NEVER OVERLOAD THE MOTORCYCLE.

Basic weight(with oiland a fullfuel tank)

188 kg

Maximumload* 187 kg

Cold tirepressure Front Rear

Up to 90 kgload*

250 kPa(2.5 kgf/cm 2,

2.5 bar)

250 kPa(2.5 kgf/cm 2,

2.5 bar)

90 kg max-imum load*

250 kPa(2.5 kgf/cm 2,

2.5 bar)

290 kPa(2.9 kgf/cm 2,

2.9 bar)

High-speedriding

250 kPa(2.5 kgf/cm 2,

2.5 bar)

250 kPa(2.5 kgf/cm 2,

2.5 bar)

* total of cargo, rider, passenger and accesso-ries

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

3-56

CHECKING THE TIRESCHKADJ

BA

WARNING

2. Check: tire surfaces

Damage/wear Replace the tire.

Minimum tire tread depth1.6 mm

1 Tire tread depth2 Side wall3 Wear indicator

Do not use a tubeless tire on a wheel de-signed only for tube tires to avoid tire failureand personal injury from sudden deflation.

When using a tube tire, be sure to install thecorrect tube.

Always replace a new tube tire and a newtube as a set.

To avoid pinching the tube, make sure thatthe wheel rim band and tube are centered inthe 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 soonas possible with a good quality replacement.

A Tire B Wheel

Tube wheel Tube tire only

Tubeless wheel Tube or tubelesstire

After extensive tests, the tires listed belowhave been approved by Yamaha Motor Co.,Ltd. for this model. The front and rear tiresshould always be by the same manufacturerand 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 thismotorcycle.

Front tire

Manufacturer Size Model

BRIDGESTONE 120/60 ZR17(55W) BT56FE

DUNLOP 120/60 ZR17(55W) D207FJ

3-57

CHECKING THE TIRES/CHECKING THE WHEELSCHKADJ

WARNING

NOTE:

WARNING

NOTE:

Rear tire

Manufacturer Size Model

BRIDGESTONE 180/55 ZR17(73W) BT56RE

DUNLOP 180/55 ZR17(73W) D207N

After mounting a new tire, ride conserva-tively for a while to become accustomed tothe “feel” of the new tire and to allow the tireto seat itself properly in the rim. Failure to doso could lead to an accident with possibleinjury to the rider or damage to the motor-cycle.

For tires with a direction of rotation mark 1 : Install the tire with the mark pointing in thedirection of wheel rotation.

Align the mark 2 with the valve installationpoint.

EB304180

CHECKING THE WHEELSThe following procedure applies to both of thewheels.1. Check:wheelDamage/out-of-round Replace.

Never attempt to make any repairs to thewheel.

After a tire or wheel has been changed or re-placed, always balance the wheel.

3-58

CHECKING AND LUBRICATING THE CABLES/LUBRICATING THE LEVERS AND PEDALS/

LUBRICATING THE SIDESTAND/LUBRICATING THE REAR SUSPENSIONCHKADJ

WARNING

NOTE:

EB304200

CHECKING AND LUBRICATING THECABLESThe following procedure applies to all of thecable sheaths and cables.

Damaged cable sheaths may cause thecable to corrode and interfere with its move-ment. Replace damaged cable sheaths andcables as soon as possible.

1. Check:cable sheathDamage Replace.

2. Check:cable operationRough movement Lubricate.

Recommended lubricantEngine oil or a suitable cable lubricant

Hold the cable end upright and pour a few dropsof lubricant into the cable sheath or use a suit-able lubing device.

EB304210

LUBRICATING THE LEVERS AND PEDALSLubricate the pivoting point and metal-to-metalmoving parts of the levers and pedals.

Recommended lubricantLithium soap base grease

EB304220

LUBRICATING THE SIDESTANDLubricate the pivoting point and metal-to-metalmoving parts of the sidestand.


EB304240

LUBRICATING THE REAR SUSPENSIONLubricate the pivoting point and metal-to-metalmoving parts of the rear suspension.


3-59

CHECKING AND CHARGING THE BATTERYCHKADJ

WARNING

CAUTION:

EB305020

ELECTRICAL SYSTEMCHECKING AND CHARGING THE BATTERY

Batteries generate explosive hydrogen gasand contain electrolyte which is made ofpoisonous and highly caustic sulfuric acid.Therefore, always follow these preventivemeasures:Wear protective eye gear when handling orworking near batteries.

Charge batteries in a well-ventilated area.Keep batteries away from fire, sparks oropen flames (e.g., welding equipment,lighted cigarettes).

DO NOT SMOKE when charging or han-dling batteries.

KEEP BATTERIES AND ELECTROLYTEOUT OF REACH OF CHILDREN.

Avoid bodily contact with electrolyte as itcan cause severe burns or permanent eyeinjury.

FIRST AID IN CASE OF BODILY CONTACT:EXTERNALSkin – Wash with waterEyes – Flush with water for 15 minutes andget immediate medical attention.

INTERNALDrink large quantities of water or milk fol-lowed with milk of magnesia, beaten egg orvegetable oil. Get immediate medicalattention.

This is a sealed battery. Never remove thesealing caps because the balance betweencells will not be maintained and batteryperformance will deteriorate.

Charging time, charging amperage andcharging voltage for an MF battery are dif-ferent from those of conventional batter-ies. The MF battery should be charged asexplained in the charging method illustra-tions. If the battery is overcharged, theelectrolyte level will drop considerably.Therefore, take special care when charg-ing the battery.

3-60

Relationship between the open-circuit voltageand the charging time at 20C

Ope

n-ci

rcui

t vol

tage

(V

)

These values vary with the temperature, the condition ofthe battery plates, and the electrolyte level.

13.0

12.5

12.0

11.5

5 6.5 10Charging time (hours)


NOTE:

CAUTION:

NOTE:

Since MF batteries are sealed, it is not possibleto check the charge state of the battery by mea-suring the specific gravity of the electrolyte.Therefore, the charge of the battery has to bechecked by measuring the voltage at the batteryterminals.

1. Remove: rider seatRefer to “SEATS”.

2. Disconnect:battery leads(from the battery terminals)

First, disconnect the negative lead 2 , thenthe positive lead 1 .

3. Remove:battery

4. Measure:battery charge

a. Connect a digital voltmeter to the battery ter-minals.

Tester positive probe battery positiveterminalTester negative probe battery nega-tive terminal

The charge state of an MF battery can bechecked by measuring its open-circuit voltage(i.e., the voltage when the positive terminal isdisconnected).

No charging is necessary when the open-cir-cuit voltage equals or exceeds 12.8 V.

b. Check the charge of the battery, as shown inthe charts and the following example.

ExampleOpen-circuit voltage = 12.0 VCharging time = 6.5 hoursCharge of the battery = 20 30%

3-61


ChargingAmbient temperature 20C

Ope

n-ci

rcui

t vol

tage

(V

)

Check the open-circuitvoltage.

Time (minutes)

Ambienttemperature20C

Ope

n-ci

rcui

t vol

tage

(V

)

Charging condition of the battery (%)

WARNING

CAUTION:

5. Charge:battery(refer to the appropriate charging method il-lustration)

Do not quick charge a battery.

Never remove the MF battery sealing caps.Do not use a high-rate battery chargersince it forces a high-amperage currentinto the battery quickly and can cause bat-tery overheating and battery plate damage.

If it is impossible to regulate the chargingcurrent on the battery charger, be carefulnot to overcharge the battery.

When charging a battery, be sure to re-move it from the motorcycle. (If charginghas to be done with the battery mounted onthe motorcycle, disconnect the negativelead from the battery terminal.)

To reduce the chance of sparks, do notplug in the battery charger until the batterycharger leads are connected to the battery.

Before removing the battery charger leadclips from the battery terminals, be sure toturn off the battery charger.

Make sure that the battery charger leadclips 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 clipspring may cause sparks.

If the battery becomes hot to the touch atany time during the charging process, dis-connect the battery charger and let the bat-tery cool before reconnecting it. Hot batter-ies can explode!

As shown in the following illustration, theopen-circuit voltage of an MF battery stabi-lizes about 30 minutes after charging hasbeen completed. Therefore, wait 30 min-utes after charging is completed beforemeasuring the open-circuit voltage.

3-62


Measure the open-circuitvoltage prior to charging.

Connect a charger and am-meter to the battery andstart charging.

Is the amperage higherthan the standard chargingamperage written on thebattery?

Adjust the charging voltage to20 25 V.

Adjust the voltage to obtain thestandard charging amperage.

Monitor the amperage for 3 5 minutes. Is the standardcharging amperage exceed-ed?

Set the timer to the chargingtime determined by the open-circuit voltage.Refer to “CHECKING ANDCHARGING THE BATTERY”.

If the amperage does notexceed the standard charg-ing amperage after 5 min-utes, replace the battery.

If the required charging time exceeds 5 hours, it is advisable to checkthe 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.

YES NO

YES

NO

NOTE:Leave the battery unused for more than30 minutes before measuring its open-circuit voltage.

NOTE:Set the charging voltage to 16 17 V.(If the charging voltage is lower, charg-ing will be insufficient, if it is higher, thebattery will be over-charged.)

ChargerAmmeter

Charging method using a variable-voltage charger

3-63


CAUTION:

Measure the open-circuitvoltage prior to charging.

Connect a charger and am-meter to the battery andstart charging.

NOTE:Leave the battery unused for more than30 minutes before measuring its open-circuit voltage.

Is the amperage higherthan the standard chargingamperage written on thebattery?

Charge the battery until the chargingvoltage reaches 15 V.

This type of battery charger cannotcharge an MF battery. A variable-voltage charger is recommended.

Leave the battery unused for morethan 30 minutes before measuring itsopen-circuit voltage.12.8 V Charging is complete.12.0 12.7 V Recharging is re-quired.Under 12.0 V Replace the battery.

NOTE:Set the charging time to a maximum of20 hours.

YES NO

Constant amperage chargers are notsuitable for charging MF batteries.

Voltmeter

Charger

Ammeter

Charging method using a constant-voltage charger

3-64

CHECKING AND CHARGING THE BATTERY/CHECKING THE FUSES

CHKADJ

CAUTION:

CAUTION:

NOTE:

6. Install:battery

7. Connect:battery leads(to the battery terminals)

First, connect the positive lead 1 , then thenegative lead 2 .

8. Check:battery terminalsDirt Clean with a wire brush.Loose connection Connect properly.

9. Lubricate:battery terminals

Recommended lubricantDielectric grease

10. Install: rider seatRefer to “SEATS”.

EB305040

CHECKING THE FUSESThe following procedure applies to all of thefuses.

To avoid a short circuit, always set the mainswitch to “OFF” when checking or replacinga fuse.

1. Remove: rider seatRefer to “SEATS”.

2. Check:continuity

a. Connect the pocket tester to the fuse andcheck the continuity.

Set the pocket tester selector to “Ω 1”.

Pocket tester90890-03112

b. If the pocket tester indicates “∞”, replace thefuse.

3-65

CHECKING THE FUSESCHKADJ

WARNING

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

Headlightfuse

20 A 1

Signalingsystem fuse

20 A 1

Ignitionfuse

15 A 1

Radiatorfan motor

fuse7.5 A 1

Backup fuse(odometer)

7.5 A 1

Never use a fuse with an amperage otherthan that specified. Improvising or using afuse with the wrong amperage rating maycause extensive damage to the electricalsystem, cause the lighting and ignition sys-tems to malfunction and could possiblycause a fire.

4. Install: rider seatRefer to “SEATS”.

3-66

REPLACING THE HEADLIGHT BULBSCHKADJ

WARNING

CAUTION:

EB305051

REPLACING THE HEADLIGHT BULBSThe following procedure applies to both of theheadlight bulbs.1. Disconnect:headlight coupler 1headlight bulb holder cover 2

2. Detach:headlight bulb holder 1

3. Remove:headlight bulb 2

Since the headlight bulb gets extremely hot,keep flammable products and your handsaway from the bulb until it has cooled down.

4. Install:headlight bulb NewSecure the new headlight bulb with the head-light bulb holder.

Avoid touching the glass part of the head-light bulb to keep it free from oil, otherwisethe transparency of the glass, the life of thebulb and the luminous flux will be adverselyaffected. If the headlight bulb gets soiled,thoroughly clean it with a cloth moistenedwith alcohol or lacquer thinner.

5. Attach:headlight bulb holder

6. Install:headlight bulb holder cover

7. Connect:headlight coupler

3-67

ADJUSTING THE HEADLIGHT BEAMSCHKADJ

a

b

a

b

a

b

EB305061

ADJUSTING THE HEADLIGHT BEAMSThe following procedure applies to both of theheadlights.1. Adjust:headlight beam (vertically)


Direction Headlight beams is raised.

Direction Headlight beams is low-ered.

2. Adjust:headlight beam (horizontally)

a. Turn the adjusting knob 1 in direction a orb .

Left headlight

Direction Headlight beam movesto the right.

Direction Headlight beams movesto the left.

Right headlight

Direction Headlight beam movesto the left.

Direction Headlight beam movesto the right.

CHKADJ

yamaha r6 99 - 2001

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