Machine Translated by Google

DOCUMENT

REPAIR INSTRUCTIONS
SERVICE MANUAL

Yamaha YZF R15 2008

Machine Translated by Google

2008

SERVICE MANUAL

YZF-R15

20P-F8197-E0
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YZF-R15
SERVICE MANUAL All

rights reserved.
Any reproduction or unauthorized use
withoutthewrittenpermissionof YAMAHA
MOTOR INDIA SALES PVT. LTD. is expressly
prohibited.

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

NOTE:
Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION Particularly

important information is distinguished in this manual by the following.

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

Failure to follow WARNING instructions could result in severe injury or death to the vehicle operator,
a bystander or a person checking or repairing the vehicle.
WARNING

A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle.
CAUTION:

ANOTE provides key information to make procedures easier or clearer.

NOTE:

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HOW TO USE THIS MANUAL This

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

3 ClutchHubHolder
YSST-733 7
4

5
6
2

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SYMBOLS 1. Serviceable with engine mounted

The following symbols are used in this manual for 2. Filling fluid
easier understanding. 3. Lubricant
NOTE: 4. Special tool
5. Tightening torque
The following symbols are not relevant to every
vehicle 6. Wear limit, clearance
7. Engine speed
8. Electrical data
9. Engine oil
1 2 3 10. Gear oil
11. Molybdenum disulfide oil
12. Brake fluid
13. Wheel bearing grease
14. Lithium-soap-based grease
4 5 6 15 Molybdenum disulfide grease
16. Silicone grease
TR 17 Apply locking agent (LOCTITE®).
.
. 18 Replace the part with a new one.

7 8

9 10

E G

11 12

M BF

13 14
B LS

15 16
M S

17 18
LT New

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TABLE OF CONTENTS

GENERAL INFORMATION 1

SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3

CHASSIS 4

ENGINE 5

COOLING SYSTEM 6

FUEL SYSTEM 7

ELECTRICAL SYSTEM 8

TROUBLESHOOTING 9
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GENERAL INFORMATION

IDENTIFICATION ...................................................................................1-1 VEHICLE

IDENTIFICATION NUMBER...................................................................1-1 ENGINE SERIAL
NUMBER ...................................................................1-1

FEATURES ...................................................................................................1-2 OUTLINE OF THE

FI SYSTEM...................................................................1-2 FI
SYSTEM...................................................................................................1-3

IMPORTANT INFORMATION .........................................................................1-4 PREPARATION

FOR REMOVALAND DISASSEMBLY...................................1-5 REPLACEMENT
PARTS............................................................................1-5 GASKETS, OIL SEALS AND O-
RINGS....................................................................1-5 LOCK WASHERS/PLATESAND
COTTER PINS....................................1-5 BEARINGS AND OIL
SEALS...............................................................................1-6
CIRCLIPS...................................................................................................1-6

CHECKING THE CONNECTIONS ................................................................1-7

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

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IDENTIFICATION

IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER (FRAME NO.)

The vehicle identification number “1” is stamped into the

frame.

xxxxxxx

ENGINE SERIAL NUMBER The

engine serial number “1” is stamped into the crankcase.

NOTE:
Designs and specifications are subject to change without
notice.

1-1
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FEATURES

FEATURES

OUTLINE OF THE FI SYSTEM The

main function of a fuel supply system is to provide fuel to the combustion chamber at the optimal air-fuel ratio in
accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system,
the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and
the fuel that is metered by the jet used in the respective carburetor.

Despite the same volume of intake air, the fuel volume requirement varies by the engine operating conditions, such as
acceleration, deceleration, or operating under a heavy load. Carburetors that meter the fuel through the use of jets have
been provided with various auxiliary devices, so that an optimal airfuel ratio can be achieved to accommodate the constant
changes in the operating conditions of the engine.

As the requirements for the engine to deliver more performance and cleaner exhaust gases increase, it becomes necessary
to control the air-fuel ratio in a more precise and finely tuned manner. To accommodate this need, this model has adopted
an electronically controlled fuel injection (FI) system, in place of the conventional carburetor system. This system can
achieve an optimal air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors. The adoption of the FI system
has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust
emissions.

1 2 3 4 5.6 78

91011

1. Engine trouble warning light 2.

Spark plug 3.
Ignition coil 4.
Fuel pump 5.
FID (fast idle solenoid)
6. Throttle body sensor assembly (consisting of throttle
position sensor, intake air pressure sensor, intake air
temperature sensor)
7. ECU (engine control unit)
8. Lean angle sensor 9.
Crankshaft position sensor 10.Fuel
injector 11.Coolant
temperature sensor

1-2
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FEATURES

FI SYSTEM
The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the fuel pressure that is
applied to the fuel injector at only 250 kPa (2.50 kg/cm², 35.6 psi). formation, when the energizing signal from the ECU
energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the
time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration),
the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized
(injection duration), the lesser the volume of fuel that is supplied.

The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position
sensor, crankshaft position sensor, intake air pressure sensor, intake air temperature sensor, lean angle sensor and
coolant temperature sensor enable the ECU to determine the injection duration. The injection timing is determined through
the signals from the crankshaft position sensor. As a result, the volume of fuel that is required by the engine can be
supplied at all times in accordance with the driving conditions.

5 6
2

4
1 3
8

11 12
13
14
10

1. Fuel pump 2. 14. Intakeairpressuresensor A.

Fuel injector 3. Fuelsystem B.
Ignition coil 4. Airsystem C.
Coolant temperature sensor 5. ECU Controlsystem
(engine control unit)
6. Lean angle sensor 7.
Crankshaft position sensor 8. FID
(fast idle solenoid)
9. Air filter case 10.
Throttle body 11.
Throttle body sensor assembly 12.
Intake air temperature sensor 13.
Throttle position sensor

1-3
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FEATURES

MULTI-FUNCTION DISPLAY
Tripmeter will reset itself automatically and the display will
return to the prior mode after refueling and traveling 5 km
(3 mi).

Fuel meter

1.Multi-functiondisplay 2.
2
“RESET/SELECT” button

1. Fuel meter
The multi-function display is equipped with the
following: The fuel meter indicates the amount of fuel in the fuel tank.
• a speedometer (which shows the riding speed) • an
The display segments of the fuel meter disappear towards
odometer (which shows the total distance
“E” (Empty) as the fuel level diminishes. When the last fuel
traveled)
meter segment starts flashing, refuel as soon as possible.
• two tripmeters (which show the distance traveled since
they were last set to zero) • a fuel reserve
tripmeter (which shows the distance traveled since the fuel
level warning light came on)

• a fuel meter

Odometer and tripmeter modes (

A brief push less than one second on the )
“
/
RESET SELECT” button switches the display between the
“
odometer mode ODO” and the
“ “
tripmeter modes TRIP and TRIP1”in the following order
2” 1ÿ2
ÿ :
ODO TRIP ODO TRIP
ÿ

When approximately 9 L of1.

fuel remains in the fuel tank the
,
odometer display will automatically change to the fuel
“ -
reserve tripmeter mode F TRIP” and start counting the
distance traveled from that point and the last segment of
,
the fuel meter will start flashing In that case pushing the
. ,
“
/
RESET SELECT” button switches the display between the
various tripmeter and odometer modes in the following
order 2 ÿ ÿ - :
F -TRIP TRIP
ÿ 1 ÿ F TRIP
TRIP ODO

1-4
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IMPORTANT INFORMATION

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

GASKETS, OIL SEALSAND O-RINGS 1. When

overhauling the engine, replace all gaskets, seals and
O-rings. All gasket surfaces, oil seal lips and O-
rings must be cleaned.

2. During reassembly, properly oil all mating parts

2. Use only the proper tools and cleaning equipment. and bearings and lubricate the oil seallips with
grease.
Refer to“SPECIALTOOLS”on page 1-8.
3. When disassembling, always keep mated parts
together. This includes gears, cylinders, pistons and
other parts that have been “mated” through normal
wear. Mated parts must always be reused or replaced
as an assembly.

LOCK WASHERS/PLATESAND COTTER PINS After

removal, replace all lock washers/plates “1” and cotter

pins. After the bolt or nut has been tightened to
specification, bend the lock tabs along a flat of the bolt or
nut.
4. During disassembly, clean all of the parts and place
them in trays in the order of disassembly.
This will speed up assembly and allow for the correct
installation of all parts.
5. Keep all parts away from any source of fire.

REPLACEMENT PARTS Use

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

1-5
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IMPORTANT INFORMATION

BEARINGSAND OIL SEALS Install

bearings and oil seals so that the manufacturer's marks
or numbers are visible.
When installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease. Oil bearings
liberally when installing, if appropriate.

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

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

1-6
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CHECKINGTHECONNECTIONS

CHECKING THE CONNECTIONS NOTE:

,
Check the leads couplers ,
and connectors for stains rust • If there is no continuity, clean the terminals. • When
moisture
, etc , , . checking the wire harness, perform steps (1) to (3). • As a
quick remedy,
1. Disconnect : • Lead
use a contact revitalizer available at most part stores.
• Coupler •

Connector

2. Check : •

Lead •

Coupler •
Connector

ÿ
Moisture Dry with an air blower .
Ruststains
/ Connect
ÿ and disconnect several
times .

3. Check: •
All connections
ÿ
Loose connection Connect properly.
NOTE:
If the pin“1”on the terminal is flattened, bend it up.

4. Connect: •
Lead •
Coupler •
Connector
NOTE:
Make sure all connections are tight.
5. Check: •
Continuity
(with the multimeter)

1-7
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SPECIAL TOOLS

SPECIAL TOOLS The

following special tools are necessary for complete and accurate tune-up and assembly. Use only the
appropriate special tools like this will help prevent damage caused by the use of inappropriate tools
or improvised techniques.

Tool name/Tool No. Illustration

Tappet screw holder

YSST-706

Thistoolisusedtoloosenandtightentappetadjustingnut.

Tappet adjusting socket

YSST-706A

Thistoolisusedtoadjustthevalveclearancebytappet adjustingscrew

Feeler gauge
YSST-715

Thistoolisusedtoadjustthevalveclearance inanengine

Valve spring compressor

YSST-603

ThistoolisusedtoremoveandinstallValve&Spring Assemblies.

Magneto holder
YSST-701

Thistoolisusedtoholdthemagnetowhenremoving
orinstallingthemagnetsecuringNutandPrimary
DriveGearNut

Magneto puller
YSST-702

Thistoolisusedtoremovethemagnetowiththehelpof magnetoholder.

1-8
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SPECIAL TOOLS

Tool name/Tool No. Illustration

CrankShaftInstalling ToolwithSpacer
(a) (b)
(a) YSST-266
(b) YSST-267

ThesetoolsareusedforinstallationofCrankShaft.

Crankshaft removing tool

YSST-265

ThistoolisusedtoremovetheCrankShaftfrom theCrankCase.

Clutch hub holder

YSST-733

ThistoolisusedtoholdtheClutchHubwhile
removingorinstallingClutchMainShaftNut.

Timing

Thisinstrumentisusedtoresettheignitiontiming.

Compression gauge

Thisinstrumentisusedtomeasuretheengine compression.

FI diagnostic tool

Thisinstrumentisusedtodiagnosetheelectrical
faultsinfuelinjectionsystem

Scraper
YSST-612

Thistoolisusedforscrapingthesealentfrom
Crankcasejoiningsurface.

1-9
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SPECIAL TOOLS

Tool name/Tool No. Illustration

Radiator cap tester

Thisinstrumentisusedtotesttheradiatorcap functionality.

Radiator cap tester adapter

Thisadapterusedtoconnecttheradiatorcaptester
withradiatorcapforradiatorcaptesting.

Fuel Pressure Gauge

Thisinstrumentisusedtomeasurethefuelpressure.

Vacuum/pressure pump gauge set

Thisinstrumentisusedtoofferthevacuumtoair
inductionsystemforchecking.

Steering nut wrench

YSST-721

Thistoolisusedtoloosenandtightenthesteering nut.

T-handle
YSST-713

Thistoolisusedtoholdthe TFFplungerforloosening
andtighteningofHexSocketHeadBolt

TFF Oil Seal Installation Tool

YSST-775

ThistoolassiststoinstalltheTFFOilSeal.

1-10
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SPECIAL TOOLS

Reference
Tool name/Tool No. Illustration

Mechanical seal/bearing Installer

YSST-722

Thistoolisusedtoinstallthesealandbearinginwater pump assy.

Ignition checker

Thisinstrumentisusedtochecktheeffectivenessof
ignitionatsparkplug.

Multimeter

Thisinstrumentisusedtochecktheelectricalcircuits orcomponents.

Yamaha bond No. 1215

Thisadhesiveisusedonmatingsurfaceswhileassem-
blingCrankcase#1and#2.

LOCTITE
ThreeBond1322

Thisadhesiveisusedfortighteningof TorxScrew.

1-11
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SPECIFICATIONS

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

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

CHASSIS SPECIFICATIONS ..............................................................................2-9

ELECTRICAL SPECIFICATIONS ................................................................2-12

TIGHTENING TORQUES ..............................................................................2-15

GENERAL TIGHTENING TORQUE SPECIFICATIONS...................................2-15
ENGINE TIGHTENING TORQUES..............................................................2-16
CHASSIS TIGHTENING TORQUES............................................................2-20

LUBRICATION POINTS AND LUBRICANT TYPES ..............................................2-22

ENGINE...................................................................................................2-22
CHASSIS....................................................................................................2-24

LUBRICATION SYSTEM CHART AND DIAGRAMS ...................................2-25

ENGINE OIL LUBRICATION CHART ..............................................................2-25
LUBRICATION DIAGRAMS ...................................................................2-27

COOLING SYSTEM DIAGRAMS ...................................................................2-31

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

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GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS
Model
Model 20P1

Dimensions
Overall length 1995mm
Overall width 670mm
Overall height 1070mm
Seatheight 790mm
Wheelbase 1290mm
Ground clearance 160mm
Minimum turning radius 2500mm

Weight
Withoilandfuel 131kg
Maximum load 199kg

2-1
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ENGINE SPECIFICATIONS

ENGINE SPECIFICATIONS

Engine
Engine type 4- SOHC,
Liquid cooled stroke
Displacement 149.8 cm
Cylinder arrangement Forward-inclined single cylinder
Bore x stroke 57.0 x 58.7 mm
Compression ratio 10.40 :1
2
Compression pressure 5Psi 3.866
(/ kgfcm )
Starting system 5 Electric starter

Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 12.0 L

Engine oil
Lubrication system wet sump
Type SAE W20 40
Recommended engine oil grade YAMALUBE (Grade-SG)
Engine oil quantity
Total amount 1.15 L
Without oil filter element replacement 0.95 L
With oil filter element replacement 1.00 L

Oil filter
Oil filter type Paper

Oil pump
Oil pump type Gear pump
- -- - - Less than mm
0.15
Inner rotor to outer rotor tip clearance
Limit 0.23 mm
- --- - –
0.13 0.18 mm
Outer rotor to oil pump housing clearance
Limit 0.25 mm
- - -- - - -
Oil pump housing to inner and outer rotor
clearance –
0.06 0.11 mm
Limit 0.18 mm
Rotor thickness –
9.95 9.98 mm
2
–
39.2 78.4 kPa psi – –
Relief valve operating pressure (5.7
0.7811.4
/ ) (0.39 kgfcm )

Cooling system
(
Radiator capacity including all routes ) 0. 59L
Coolant reservoir capacity
( up to the maximum level
mark ) 0.25 L
Radiator cap opening pressure 107.9-137.3 kPa
Valve relief pressure 4.9 kPa
Thermostat
Manufacturer NIPPON THERMOSTAT

2-2
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ENGINE SPECIFICATIONS

Valve opening temperature 80.5–83.5 °C

Valve full open temperature 95.0 °C
Valve lift (full open) 3.0 mm
Radiator core
Width 198.0 mm
Height 128.0 mm
Depth 24.0mm
Water pump
Water pump type Single suction centrifugal pump
Reduction ratio ½ (0.500)

Spark plug(s)
Manufacturer/model NGK/CR8E
Manufacturer/model DENSO/U24ESR-N
Spark plug gap 0.7–0.8 mm

Cylinder head
Volume 9.90–10.50 cm³
Warpage limit 0.03 mm

Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
IntakeA 25.177 ± 0.05 mm
Limit 25.027 mm
Intake B 30.275 ± 0.05 mm
Limit 30.125mm
ExhaustA 25.115 ± 0.05 mm
Limit 24.965 mm
Exhaust B 30.282 ± 0.05 mm
Limit 30.132 mm

Camshaft runout limit 0.03 mm

2-3
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ENGINE SPECIFICATIONS

Timing chain
Model/number of links SILENT CHAIN/96
Tensioning system Automatic

Rocker arm/rocker arm shaft

Rocker arm inside diameter 9.985–10.000 mm
Limit 10,030 mm
Rocker arm shaft outside diameter 9.966–9.976 mm
Limit 9,950 mm
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm
Limit 0.08 mm

Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.10–0.14 mm
Exhaust 0.20–0.24 mm
Valve dimensions
Valve head diameterA (intake) 19.40–19.60 mm
Valve head diameterA (exhaust) 16.90–17.10 mm

A
Valve face width B (intake) 1.538–2.138 mm
Valve face width B (exhaust) 1.538–2.138 mm

Valve seat width C (intake) 0.90–1.10 mm

Valve seat width C (exhaust) 0.90–1.10 mm

Valve margin thickness D (intake) 0.50–0.90 mm

Valve margin thickness D (exhaust) 0.50–0.90 mm

Valve stem diameter (intake) 4.475–4.490 mm

Limit 4,450 mm
Valve stem diameter (exhaust) 4,460–4,475 mm
Limit 4.435 mm
Valve guide inside diameter (intake) 3,950–4,050 mm
Valve guide inside diameter (exhaust) 3,950–4,050 mm
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm

2-4
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ENGINE SPECIFICATIONS

Limit 0.080 mm
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm
Limit 0.100 mm
Valve stem runout 0.010 mm

Valve spring
Free length (intake) 41.71 mm
Limit 39.62 mm
Free length (exhaust) 41.71 mm
Limit 39.62 mm
Installed length (intake) 35.30mm
Installed length (exhaust) 35.30mm
Spring rate K1 (intake) 23.54 N/mm
Spring rate K2 (intake) 36.58 N/mm
Spring rate K1 (exhaust) 23.54 N/mm
Spring rate K2 (exhaust) 36.58 N/mm
Installed compression spring force (intake) 140–162 N
Installed compression spring force (exhaust) 140–162 N
Spring tilt (intake) 2.5°/1.8mm
Spring tilt (exhaust) 2.5°/1.8mm

Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise

Cylinder
Bore 56.985–57.010 mm
Taper limit 0.05 mm
Out of round limit 0.05 mm

Piston
Piston-to-cylinder clearance 0.020–0.045 mm
Limit 0.15 mm
Diameter D 56.965–56.990 mm

2-5
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ENGINE SPECIFICATIONS

Height H 5.0 mm

H
D
Offset 0.25 mm
Offset direction Intake side
–
14,002 14,013 mm
Piston pin bore inside diameter
Limit 14,043 mm
–
13,995 14,000 mm
Piston pin outside diameter
Limit 13,975 mm
Piston -pin to piston pin
- bore
- –
0.002 0.018 mm
--
clearance
Limit 0.068 mm

Piston ring
Top ring
Ring type Barrel
Dimensions( B x T) 0.80 x 2.10 mm

B
T

–
0.10 0.25 mm
(
End gap installed )
Limit 0.40 mm
–
0.030 0.065 mm
Ring side clearance
Limit 0.100 mm
2 nd ring
Ring type Taper
Dimensions B( x T) 0.80 x 2.00 mm

B
T

–
0.10 0.25 mm
(
End gap installed )
Limit 0.40 mm
–
0.020 0.055 mm
Ring side clearance
Limit 0.100 mm
Oil ring
Dimensions B( x T) 1.50 x 1.52 mm

B
T
–
0.20 0.70 mm
(
End gap installed )
0.040 –
0.160 mm
Ring side clearance

2-6
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ENGINE SPECIFICATIONS

Connecting rod
Small end inside diameter 14.015–14.028 mm
Connected Rod Length 99.90–100.10 mm

crankshaft
WidthA 47.95–48.00 mm
Runout limit C 0.030 mm
Big end side clearance D 0.110–0.410 mm
Big end radial clearance E 0.004–0.014 mm

Balancer
Balancer drive method Gear

Clutch
Clutch type Wet, multiple-disc
Clutch release method Inner push, cam push
Clutch lever free play 10.0–15.0 mm
Friction plate thickness 2.90–3.10 mm
Wear limit 2.80mm
Plate quantity 1 pc
Friction plate 2 thickness 2.90–3.10 mm
Wear limit 2.80mm
Plate quantity 4 pcs
Clutch plate thickness 1.45–1.75 mm
Plate quantity 4 pcs
Warpage limit 0.20 mm
Clutch spring free length 39.00 mm
Minimum length 36.80mm
Spring quantity 4 pcs
Push rod bending limit 0.500 mm

Transmission
Transmission type Constant mesh 6-speed
Primary reduction system spur gear
Primary reduction ratio 73/24 (3,042)
Secondary reduction system Chain drive
Secondary reduction ratio 42/14 (3,000)
Operation Left foot operation
Gear ratio
1st 12/34 (2,833)

2-7
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ENGINE SPECIFICATIONS

2nd 30/16 (1,875)

3rd 30/2 (1.
3642 )
4 th 24/21 (1,143)
5 th 22/23 (0.957)
6th 21/25 (0.840)

Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork L- thickness –
5.76 5.89 mm

Decompression device
Device type Auto Decompression

Air filter
Air filter element Dry element

Fuel injector
/ – 10/1
1100 87 H
Model quantity

Throttle body
/
Typequantity AC 28/1
Manufacturer MIKUNI
Throttle valve size #50

Fuel injection sensor

– ÿ 20 at C 0
Crankshaft position sensor resistance 248 372
–
0.789 4.000 20.00
V at
101.32 – kPa
Intake air pressure sensor output voltage
– ÿ k
5.7 6.3
Intake air temperature sensor resistance
– ÿ 80 at 0
Coolant temperature sensor resistance 310 326 C

Idling condition
–
1300 1500 / min
Engine idling speed
– 0 0
Water temperature 85.0 95.0 C (185.00-203.00 F)
– 0 – 0
Oil temperature 50.0 70.0 C (112.00- 158.00 F
–
3.0 5.0 mm
Throttle cable free play

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CHASSIS SPECIFICATIONS

CHASSIS SPECIFICATIONS
Chassis
Frame type Delta Box
Caster angle 26.00
Trail 100.0 mm

Front wheel
Wheel type Cast wheel
Rim size 17 x 1.60.
Rim material Aluminum
Wheel travel 115.0 mm
Radial wheel runout limit 1.0 mm
Lateral wheel runout limit 0.5 mm

Rear wheel
Wheel type Cast wheel
Rim size 17 M/C x MT 2.15
Rim material Aluminum
Wheel travel 105mm
.0
Radial wheel runout limit 1.0 mm
Lateral wheel runout limit 0.5 mm

Front tire
Type Tubeless
Size / 80/90-17M/C 44P
Manufacturer model MRF / ZAPPER

Rear tire
Type Tubeless
Size – 52P
1008/ 0MC
17 /
Manufacturermodel / MRF / ZAPPER

(
Tire air pressure measured on cold tires )
Front 200 kPa
Rear 2 25 kPa

Front brake
Type Single disc brake
Operation Right hand operation

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CHASSIS SPECIFICATIONS

Front disc brake

Disc outside diameter & thickness 267.0 x 4.0 mm
Brake disc thickness limit 3.5mm
Brake disc deflection limit 0.10 mm
Brake pad lining thickness (inner) 5.3 mm
Limit 0.8 mm
Brake pad lining thickness (outer) 5.3 mm
Limit 0.8 mm
Master cylinder inside diameter 11.00 mm
Caliper cylinder inside diameter 25.40mm x 2
Recommended fluid DOT 3 or DOT 4

Rear brake
Type Disk brake
Operation Right foot operation
Brake pedal position 44mm

Rear disc brake

Disc outside diameter & thickness 203.0 x 4.5 mm
Brake disc thickness limit 4.0 mm
Brake disc deflection limit 0.1 mm
Brake pad lining thickness (inner) 7.0 mm
Limit 1.5 mm
Brake pad lining thickness (outer) 7.0 mm
Limit 1.5 mm
Master cylinder inside diameter 12.7mm
Caliper cylinder inside diameter 32.0 mm
Recommended fluid DOT 3 or DOT 4

Steering
Steering bearing type Ball and angular bearing
Center to lock angle (left) 35.0°
Center to lock angle (right) 35.0°

Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 130.0 mm
Fork spring free length 384.8 mm
Limit 381.8 mm
Collar length 88.0 mm
Installed length 381.8 mm
Spring rate K1 5 N/mm
Spring rate K2 6.75 N/mm
Spring stroke K1 0–75.0 mm
Spring stroke K2 75.0–130 mm
Inner tube outer diameter 33.0 mm
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 240 cm³
Level 126.0 mm

Rear suspension
Type Swingarm (Link suspension)
Spring/shock absorber type Coil spring/oil damper
Rear shock absorber assembly travel 50.0 mm

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CHASSIS SPECIFICATIONS

Spring free length 166.8 mm

Installed length 156.5 mm
Spring rate K1 90.00 N/mm
Spring stroke K1 0.0–50.0 mm
Optional spring available No

Swingarm
Swingarm end free play limit (axial) 2.4 mm

Drive chain
Type/manufacturer 428VI3/DAIDO
Link quantity 120
Drive chain slack 20–40 mm
15-link length limit 190.5 mm

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ELECTRICAL SPECIFICATIONS

ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V

Ignition system
Ignition system (
Transistorized coil ignition digital )
Advancer type ( . Digital
Ignition timing BTDC .). . 5.0 0/1400 rpm

Engine control unit

Model manufacturer
/ 3C MORIC
100/

Ignition coil
–
2.16 2.64 ÿ 20 at C 0
Primary coil resistance
–
8.64 12.96 ÿ k at 20 0 C
Secondary coil resistance

Spark plug cap

Material Resin
Resistance 5 Kohms

AC magneto
Model manufacturer
/ FC PT MORIC
3 1/
Standard output 14.0 160
VW@5000
rpm
Stator coil resistance –
0.448 0.672 ÿ at 20 0 C

/
Rectifierregulator
-
Semi conductor short circuit
Regulator type
–
14.1 14.9 V
Regulated voltage DC()
Rectifier capacity 14.0 A
Withstanding voltage 200.0 V

Battery
Model VRLA
,
Voltage capacity 12 V
3.5
Ah
,
Ten hour rate amperage 3.50 A

Headlight
Bulb type Halogen bulb

,
Bulb voltage wattage & qty.
Headlight / 12 35
V x2
,
Tailbrake light VWW
12 5.0 x1
, /21.0
Front turn signal light 12 VW
10.0
, x2
Rear turn signal light 12 VW
10.0
, x2
Meter lighting LED
Position light 12V, 5.0Wx2

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ELECTRICAL SPECIFICATIONS

Indicator light
Neutral indicator light LED
Turn signal indicator light LED
High beam indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED

Electric starting system

System type Constant mesh

Starter motor
Model/manufacturer 3C1/PT. MORIC
Power output 0.20 kW
Armature coil resistance 0.0315–0.0385 ÿ
Brush overall length 7.0 mm
Limit 3.50mm
Brush spring force 3.92–5.88 N
Commutator diameter 17.6mm
Limit 16.6mm
Mica undercut (depth) 1.35mm

Starter relay
Model/manufacturer 5TP/OMRON-LOCAL
Amperage 100A
Coil resistance 3.42–4.18 ÿ

Horn
Horn type Plane
Quantity 1 pc
Model/manufacturer Locally Made
Maximum amperage 1.5A
Coil resistance ÿ °C
4.30–4.80 at 20
Performance 108–115 dB/2 m

Turn signal relay

Relay type Full Transistor
Model/manufacturer Locally Made
Built-in, self-cancelling device No
Turn signal blinking frequency 70-100 cycles/min

Fuel sender
Model/manufacturer Locally Made
Sender unit resistance (full) 4.0–10.0 at ÿ20 °C
Sender unit resistance (empty) 90.0–100.0 at 20ÿ °C

Starting circuit cut-off relay

Model/manufacturer Locally Made
Coil resistance 90.0–110.0 ÿ

Fan motor relay

Model/manufacturer Locally Made

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ELECTRICAL SPECIFICATIONS

Coil resistance 54.0–66.0 ÿ

Fuse
Fuse 20.0A

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TIGHTENING TORQUES

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

A. Distance between flats

B. Outside thread diameter

General tightening
A (nut) B (bolt) torque
Nm m kg ft lb
10mm 6mm 6 0.6 4.3
12mm 8mm 15 1.5 11
14mm 10mm 30 3.0 22
17mm 12mm 55 5.5 40
19mm 14mm 85 8.5 61
22mm 16mm 130 13.0 94

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TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

Thread
Item Qty Tightening torque Remarks
size

Cylinder head bolt M8 4 22Nm(2.2m·kg, 16 ft·lb) E

Cylinder head bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) E

Spark plug M10 1 13 Nm (1.3 m·kg, 9.4 ft·lb)

Cylinder head cover bolt M6 5 10 Nm (1.0 m·kg, 7.2 ft·lb)
Air cut-off valve assembly bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil check bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Cylinder head stud bolt (exhaust M8 2 15 Nm (1.5 m·kg, 11 ft·lb)
pipe)
Coolant drain bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Balancer driven gear nut M10 1 50 Nm (5.0 m·kg, 36 ft·lb)
Valve adjusting screw locknut M5 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Camshaft sprocket bolt M8 1 30 Nm (3.0 m·kg, 22 ft·lb)
Camshaft retainer bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Timing chain guide bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Yamaha
Bond No.
1215
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
(Three
bond
1215®)
Water pump assembly bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Water pump housing cover bolt M6 4 10 Nm (1.0 m·kg, 7.2 ft·lb)
Impeller shaft retainer bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT

Thermostat cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump assembly screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb)
Engineoildrainplug M35 1 32Nm(3.2m·kg, 23 ft·lb)
Oil filter element cover bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Oil baffle plate bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT

Intake manifold bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Injector bolt M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) LT

Throttle body joint clamp screw M4 2 2 Nm (0.2 m·kg, 1.4 ft·lb)

Air filter case joint clamp screw M4 1 2 Nm (0.2 m·kg, 1.4 ft·lb)
Air filter case bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Resonator bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT

Locknut (throttle cable) M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb) LT

Muffler nut M8 2 15 Nm (1.5 m·kg, 11 ft·lb)

Muffler bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb)
Exhaust pipe protector screw M6 2 8 Nm (0.8 m·kg, 5.8 ft·lb) LT

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TIGHTENING TORQUES

Thread
Item Qty Tightening torque Remarks
size

Muffler protector screw M6 2 8 Nm (0.8 m·kg, 5.8 ft·lb) LT

Crankcase bolt M6 12 10 Nm (1.0 m·kg, 7.2 ft·lb)

Magneto cover bolt M6 8 10 Nm (1.0 m ·kg, 7.2 ft·lb)
Clutch cover bolt M6 10 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive sprocket cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Starter clutch bolt M6 3 14 Nm (1.4 m·kg, 10 ft·lb) Stake
Primary drive gear nut M12 1 60 Nm (6.0 m·kg, 43 ft·lb)
Clutch spring bolt M6 4 12 Nm (1.2 m·kg, 8.7 ft·lb)
Locknut short clutch push rod M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
Clutchbossnut M14 1 70Nm(7.0m·kg, 50 ft·lb)
Clutch cable locknut M8 1 9 Nm (0.9 m·kg, 6.5 ft·lb)
Clutch lever nut M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
clutch lever holder bolt M6 1 7 Nm(0.7m·kg, 5.1 ft·lb)
Drive sprocket retainer bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Bearingretainerscrew M6 2 7Nm(0.7 m·kg, 5.1 ft·lb) LT

Shift drum segment bolt M6 1 12Nm(1.2 m·kg, 8.7 ft·lb) LT

Stopper lever bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT

Stator coil bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT

Crankshaft position sensor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT

Magneto rotor nut M12 1 70 Nm (7.0 m·kg, 50 ft·lb)

Neutral switch M10 1 20 Nm (2.0 m·kg, 14 ft·lb)
Starter motor bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Coolant temperature sensor M12 1 18 Nm (1.8 m·kg, 13 ft·lb)

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TIGHTENING TORQUES

Cylinder head tightening sequence:

1 3
5

4 2

Magneto cover tightening sequence:

1.6
7

5 8

4
9

3.11
2.10

Clutch cover tightening sequence:

6
8
9
1.7

5 9

4 10
2.12
3.13 11

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TIGHTENING TORQUES

Crankcase tightening sequence:

A B

14
1.6 7
8 15

5 9
2.12
4
10
3.13 11

A. Left crankcase
B. Right crankcase

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TIGHTENING TORQUES

CHASSIS TIGHTENING TORQUES

Thread
Item Qty Tightening torque Remarks
size
Ignition coil bolt M6 2 9 Nm (0.9 m·kg, 6.5 ft·lb)
Engine mounting nut (front side) M10 1 49 Nm (4.9 m·kg, 35 ft·lb) LS

Engine mounting nut (rear lower M10 1 49 Nm (4.9 m·kg, 35 ft·lb) LS

side)
Engine mounting nut (rear upper M10 1
49 Nm (4.9 m·kg, 35 ft·lb) LS
side)
Rear fender bolt M6 6 9 Nm (0.9 m·kg, 6.5 ft·lb)
Seat lock bracket M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rectifier/regulator bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear shock absorber assembly M10 1 44 Nm (4.4 m·kg, 32 ft·lb)
upper nut
Rear wheel axle nut M14 1 110 Nm (11.0 m·kg, 80 ft·lb) LS

Relay arm nut M10 2 44 Nm (4.4 m·kg, 32 ft·lb) LS

Rear shock absorber assembly M10 1 44 Nm (4.4 m·kg, 32 ft·lb) LS

lower connecting arm nut
Rear shock absorber assembly M10 1
lower nut 44 Nm (4.4 m·kg, 32 ft·lb)

Swingarmpivotshaftnut M12 1 70Nm(7.0m·kg, 50 ft·lb) LS

Drive chain cover bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Brake hose union bolt M10 2 26Nm(2.6m·kg, 19 ft·lb)
Front brake caliper bolt M10 2 35Nm(3.5m·kg, 25 ft·lb)
Front wheel axle nut M12 1 60 Nm (6.0 m·kg, 43 ft·lb)
Front brake disc bolt M8 5 23 Nm (2.3 m·kg, 17 ft·lb) LT

Bleed screw (front brake caliper) M7 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

Brake hose holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front fender bolt M6 4 9 Nm (0.9 m·kg, 6.5 ft·lb)
Lower ring nut (initial tightening See
M25 1 48 Nm (4.8 m·kg, 35 ft·lb)
torque) NOTE.
Lower ring nut (final tightening See
M25 1 13 Nm (1.3 m·kg, 9.4 ft·lb)
torque) NOTE.
Steering stem bolt M10 1 35 Nm (3.5 m·kg, 25 ft·lb)
Meter assembly nut M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
Headlight housing and front turn M8 2 17 Nm (1.7 m·kg, 12 ft·lb)
signal light assembly nut
Main switch bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Upper bracket pinch bolt M8 2 23 Nm (2.3 m·kg, 17 ft·lb)
Lowerbracketpinchbolt M10 2 28Nm(2.8m·kg, 20 ft·lb)
Front fork capbolt M30 2 23Nm(2.3m ·kg, 17 ft·lb)
Headlightmountingbolt M12 2 33Nm(3.3m.kg,22ft.lb)

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TIGHTENING TORQUES

Thread
Item Qty Tightening torque Remarks
size

Damper rod bolt M10 2 28 Nm (2.8 m·kg, 20 ft·lb)

Front turn signal light assembly M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
and meter assembly bracket bolt
Horn bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank and frame bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel tank bracket and frame bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Fuel tank and fuel tank bracket
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
bolt
Fuel pump retainer bolt M5 6 4 Nm (0.4 m·kg, 2.9 ft·lb)
Rearside coverbolt M6 2 7 Nm(0.7m·kg, 5.1 ft·lb)
Rear side cover and rear panel M6 2
bolt 7 Nm (0.7 m·kg, 5.1 ft·lb)
Seat Handle M8 4 26 Nm (2.6 m·kg, 19 ft·lb)
Coolant reservoir bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Radiator bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
Radiator fan bolt M6 2 8 Nm (0.8 m·kg, 5.8 ft·lb)
Grip end screw M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front brake master cylinder hold-er M6 2
bolt 7 Nm (0.7 m·kg, 5.1 ft·lb)

Front brake lever bolt M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)

Front brake lever nut M6 1 6 Nm (0.6 m·kg, 4.3 ft·lb)
Front panel bolt M6 4 7Nm(0.7 m·kg, 5.1 ft·lb)
Side cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear wheel sprocket nut M8 6 43 Nm (4.3 m·kg, 31 ft·lb)
Brake pedal bolt M6 2 22 Nm (1.0 m·kg, 7.2 ft·lb)
Right footrest and right heel plate M10 2
bolt 30 Nm (4.5 m·kg, 32 ft·lb) LT

Shift arm bolt M6 2 10 Nm (1.0 m· kg, 7.2 ft·lb)

Heel plate bolt M8 kg, 22ft
30 Nm (3.0 m· ·lb)
Side stand bolt M10 1 44 Nm (4.4 m·kg, 32 ft·lb)

NOTE:
1. First, tighten the lower ring nut to approximately 48 Nm (4.8 m·kg, 35 ft·lb) with a torque wrench, then
loosen the lower ring nut completely.
2. Retightenthelowerringnutto13Nm(1.3m·kg, 9.4 ft·lb) with a torque wrench.

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication point Lubricant

Oil seal lips LS

Bearings E

O-rings LS

Cylinder head bolts and washers E

Connectingrodbigend thrustsurface E

Piston, Piston rings, and cylinder inner surface E

Balancer driven gear inner surface E

Camshaft lobes M

Decompression orange E

Valve stem seal M

Valve stem (intake and exhaust) M

Valve stem ends (intake and exhaust) M

Rocker arm shaft E

Rocker arm inner surfaces M

Decompression lever pin M

Oil seal (clutch cover) E

Oil pump driven gear E

Oil pump rotors (inner and outer) E

Starterclutch idlegearthrustsurface E

Starter clutch idle gear shaft E

Starterclutch gearinnersurfaceandthrustsurface E

Starter clutch rollers E

clutchpush E

Primary driven gear inner surface E

Clutch push rod (short and long) and ball E

Clutch boss nut and lock washer contact surface E

Transmission gears (wheel and pinion) and collar M

Shift forks and shift fork guide bar E

Shift drum E

Shift shaft E

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

Lubrication point Lubricant

Yamaha bond No.
Crankshaft position sensor/stator assembly lead grommet 1215 (Three Bond
No.1215®)
Yamaha bond No.
Crankcase mating surface 1215 (Three Bond
No.1215®)
Yamaha bond No.
Timing chain tensioner bolts 1215 (Three Bond
No.1215®)

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

CHASSIS
Lubrication point Lubricant

Front wheel oil seal lip LS

Front wheel axle outer surface LS

Speed sensor unit LS

Rear wheel drive hub oil seal lip LS

Rear wheel drive hub mating surface LS

Rear wheel axle outer surface LS

Rearwheelaxleandnutthreads LS

Brakepedalpivotingpoint S

Brake caliper bracket boots inner surface S

Throttle grip tube guide inner surface and throttle cable end LS

Clutch cable ends at the clutch lever LS

Brake lever pivot bolt outer surface S

Steering head bearings and upper bearing cover lip LS

Steering head dust seal LS

Bolt and nut threads (relay arm and flame) LS

Bolt and nut threads (connecting rod and relay arm) LS

Bolt and nut threads (rear shock absorber and relay arm) LS

Bolt and nut threads (connecting rod and swingarm) LS

Bearing inner surface (relay arm and swingarm) LS

Oil seal lips (relay arm and swingarm) LS

Collars (relay arm and swingarm) LS

Pivot shaft and nut threads LS

Pivot shaft outer surface LS

Swingarm bushing outer surface LS

Swingarmdustcoverlips LS

Sidestand pivoting point and metal-to-metal moving point LS

Footrest pivoting point LS

Passenger footrest pivoting point LS

Shift pedal pivoting point LS

Engine mounting bolts and nuts E

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

LUBRICATION SYSTEM CHART AND DIAGRAMS

ENGINE OIL LUBRICATION CHART

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

1. Oil pump 2.
Oil filter element 3.
Crankshaft 4.
Camshaft 5.
Main axle 6.
Drive axle

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

LUBRICATION DIAGRAMS

2
A

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

1. Clutch push lever 2.

Main axle
3. Drive axle
4. Crankshaft
5. Oil filter
6. Oil pump assembly 7. Oil
strainer
A. To cylinder head

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

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LUBRICATIONPOINTS ANDLUBRICANTTYPES

1. Camshaft
2. Crankshaft
3. Main axle
4. Drive axle

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COOLINGSYSTEMDIAGRAMS

COOLINGSYSTEMDIAGRAMS

1 2 3

7 5 1

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COOLINGSYSTEMDIAGRAMS

1. Coolant reservoir 2.
Radiator inlet hose 3.
Coolant reservoir hose 4.
Radiator 5.
Water pump 6.
Radiator outlet hose 7. Water
pump breather hose

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CABLEROUTING

CABLE ROUTING
1

3 64
2
8

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CABLEROUTING

1. Head Light lead wire clamp.

2. Front flasher lead wire (left)
3. Head light lead wire 4.
Meter harness 5.

Auxiliary harness 6. Front

flasher lead wire (right)
7. Right Handle bar switch lead wire 8. Brake
switch lead wire

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CABLEROUTING

12

C
10

11

5 4
AA BB CC

11 12

10

B
B

A 6

789

12345 6 A C
C

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CABLEROUTING

1. Throttle body 2.
Coolant reservoir hose 3. Wire
harness 4. Radiator
inlet hose 5. Coolant
temperature sensor lead 6. Throttle cable 7.
Ignition coil 8. Spark

plug lead 9. Air

induction system
vacuum hose 10. Right handlebar switch lead
11. Front brake light switch lead 12.
Front brake hose A. Pass the wire
harness through the

guide.
B. Pass the front brake hose through the guide.
C. Fasten the grommet of front brake hose on position between
lower bracket and headlight bracket.

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CABLEROUTING

1 2

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CABLEROUTING

1. ECUwiringharnessclamp 2. Wire
harness 3. Starter
motor lead 4. Rear brake

light switch lead 5. Rear brake hose

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CABLEROUTING

4 3 6
14 3

16

14
15

AA BB CC DD

10

9
17 8 11 10

18 19

E FF GG
2 A
1
3

4
5 E
6

D 7
B A C
F
BD
13
A

D
12
E F
C

F
11

G
10
9
G
B 8

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CABLEROUTING

1. Front brake hose

2. Throttle cable
3. Left handlebar switch lead 4.
Clutch cable 5.

Wire harness (to horn)

6. Ignition coil 7.
Air filter case silencer hose 8.
Sidestand switch lead 9.
Coolant reservoir hose
10. Fuel tank breather hose
11. Coolant reservoir breather hose 12.

Front left turn signal light coupler 13. Speed

sensor lead 14. Wire
harness (to clutch switch)
15. Front left turn signal light lead 16.
Horn
17. Fuel hose
18. Fuel pump lead 19.
Fuel sender lead
A. Fasten the left handlebar switch lead, wire harness (to clutch
switch), and clutch cable with a plastic locking tie, making
sure to align the white tape on the leads and cable with the
tie.
B. Fasten the sidestand switch lead, coolant reservoir hose, and
fuel tank breather hose with the plastic clamp.

C. Fasten the sidestand switch lead, coolant reservoir hose, and

fuel tank breather hose to the left side cowling bracket
with the plastic clamp.
D. Fasten the wire harness (to clutch switch) and left handlebar
switch lead to the left radiator bracket with a plastic
locking tie, making sure to align the white tape on the
harness and lead with the tie, and then route the harness
and lead to the inside
of the clutch cable guide.
E. Fasten the grommet on the front brake hose with the holder.

F. Route the throttle cable to the inside of the radiator bracket

and pass the cable through the guide on the radiator cover.

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CABLEROUTING

1 2 A 3

8
B

A
10 9
A
D

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CABLEROUTING

1. Wire harness
2. Negative battery lead 3.
Battery 4.
Rectifier/regulator 5. Seat
lock cable
6. Tail/brake light lead 7.
Rear left turn signal light lead 8. Coolant
reservoir breather hose
9. Neutral switch lead
10. Crankshaft position sensor/stator coil lead A.
Fasten the negative battery lead to the frame with the plastic
locking tie. Do not cut off the excess end of the plastic
locking tie.
B. Fasten the crankshaft position sensor/stator coil
lead, neutral switch lead, and negative battery lead to the
frame with the plastic locking tie. Do not cut off the excess
end of the plastic locking tie.
C. Route the negative battery lead, along the front of
the battery
D. Pass the coolant reservoir breather hose and fuel
drain pipe through the slit of the mud guard.
E. Pass the coolant reservoir breather hose and fuel drain pipe
between the lower engine bracket.

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CABLEROUTING

ROUTING OFFUEL DRAINPIPE

Whileservicingofthevehicle,payattentiontoroutethefueldrainpipe.Itshouldnothaveanybendduringfitment,anybendmayresultthepoorperformanc

Pass the drain pipe “1” along with the recovery tank
breather hose “2” from the slit at the frame comp “3” and
adjust white paint “4” of fuel drain pipe “1” between
these slits.

1. Passthedrain ”1” pipeacrossthefuelhose “2”

asshowninillustration.

1
A

3. Pass the fuel drain pipe and recovery tank breather

hose from the slit of the mud guard

1 2

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CABLEROUTING

13

15

14
16 12

11 17
C A
AA

4 2
1 11
3
BB
A
10 B A

4
C C
9
4
D 5
D
B
CC B

6
10
E E

18 D

8
DD

4 7

EE

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CABLEROUTING

1. Coolant reservoir hose

2. Radiator inlet hose

3. Spark plug lead 4.

Wire harness

5. FID (fast idle solenoid) lead 6. Fuel

injector lead 7. Rear
brake light switch lead 8. Throttle
body sensor assembly 9. Ignition coil
leads 10. Air filter case
silencer hose

11. Wire harness (to horn)

12. Clutch cable
13. Throttle cable

14. Wire harness (to left handlebar switch)

15. Front brake light switch lead 16.
Right handlebar switch lead 17. Main
switch lead

18. Cylinder head breather hose A.

Fasten the wire harness with the plastic locking tie.
B. Fasten the fuel injector lead and FID (fast idle solenoid)
lead with a plastic locking tie.
C. Pass the clutch cable through the guide.
D. Secure the plastic locking tie by inserting the projection
on the tie into the hole in the frame.

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CABLEROUTING

A
19
18

17 1
D

16 2
C

15 3

20 2
B

5
21
14 B
E 6

A
7
13
5 F
8
12
C
4
A

9
BB

10

10
9 11

G
H

J 11
C

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CABLEROUTING

1. Positive battery lead 2.

Fuse box 3.

Lean angle sensor 4.

Condenser 5. Self-

diagnosis signal lead 6. ECU (engine

control unit)
7. Radiator fan motor relay 8.
Starting circuit cut-off relay 9. Rear
right turn signal light lead 10. Tail/brake
light lead 11. Rear left turn
signal light lead 12. Turn signal relay
13. Seat lock cable 14.
Rectifier/regulator 15.

Starter relay 16. Negative

battery lead 17.
Battery 18. Starter relay lead
19. Starter
motor lead 20. Fuse box
lead 21. Battery band A.
Cover the tail/brake

light lead and rear

turn signal leads with the connector cover.

B. Push the starter motor lead and starter relay lead down into
the space between the battery and the fender.

C. Install the fuse box, and then route the fuse box lead on top
of the starter motor lead and starter relay lead.

D. Connect the negative battery lead to the wire

harness, and then position the connector in the location
shown in the illustration.

E. Install the battery, and then fasten all of the leads and the
battery with the battery band.
F. Route the self-diagnosis signal lead under the condenser
and around the condenser bracket.

G. Pass the rear right turn signal light lead through the hole in
the connector cover.

H. Pass the tail/brake light lead through the hole in the

connector cover.

I. Pass the rear left turn signal light lead through the
hole in the connector cover.
J. Forward

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PERIODICCHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE ..............................................................................3-1

INTRODUCTION...................................................................................3-1
PERIODIC MAINTENANCEAND LUBRICATION INTERVALS ............3-1
ENGINE ...................................................................................................3-3
ADJUSTING THE VALVE CLEARANCE .............................................3-3
ADJUSTING THE ENGINE IDLING SPEED...................................................3-4
ADJUSTING THE EXHAUST GAS VOLUME .....................................3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY ..........................3-6
CHECKING THE SPARK PLUG .............................................................3-7
CHECKING THE IGNITION TIMING.....................................................3-7
MEASURING THE COMPRESSION PRESSURE................................3-8
CHECKING THE ENGINE OIL LEVEL................................................3-9
CHANGING THE ENGINE OIL............................................................3-10
ADJUSTING THE CLUTCH CABLE FREE PLAY.................................3-11
CLEANING THEAIR FILTER ELEMENT...................................................3-12
CHECKING THE THROTTLEBODY JOINT
ANDAIR FILTER CASE JOINT ...................................................3-12
CHECKING THE FUEL LINE ..............................................................3-13
CHECKING THE CYLINDER HEAD BREATHER
HOSE ...................................3-13 CHECKING THE EXHAUST
SYSTEM...................................................3-13 CHECKING THE COOLANT LEVEL..........................................
CHECKING THE COOLING SYSTEM................................................3-14
CHANGING THE COOLANT...................................................................3-14

CHASSIS ...................................................................................................3-17
ADJUSTING THE REAR DISK BRAKE...................................................3-17
CHECKING THE BRAKE FLUID LEVEL....................................................3-17
CHECKING THE FRONT BRAKE PADS...................................................3-18
CHECKING THE REAR BRAKE PADS................................................3-18
CHECKING THE FRONT BRAKE HOSE...................................................3-18
CHECKING THE REART BRAKE HOSE............................................3-19
BLEEDING THE HYDRAULIC BRAKE SYSTEM.................................3-19
ADJUSTING THE DRIVE CHAIN SLACK .............................................3-20
LUBRICATING THE DRIVE CHAIN....................................................3-21
CHECKINGANDADJUSTING THE STEERING HEAD .........................3-21
CHECKING THE FRONT FORK............................................................3-22
CHECKING THE TYRES...................................................................3-22
CHECKING THE WHEELS ..............................................................3-24
CHECKINGAND LUBRICATING THE CABLES ................................3-24
LUBRICATING THE CLUTCH LEVER................................................3-24
LUBRICATING THE BRAKE LEVER ................................................3-25
LUBRICATING THE PEDALS................................................................3-25
LUBRICATING THE SIDESTAND...................................................3-25
LUBRICATING THE REAR SUSPENSION...................................3-25

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TROUBLESHOOTING

ELECTRICAL SYSTEM...................................................................................3-26
CHECKING AND CHARGING THE BATTERY...................................3-26
CHECKING THE FUSE.....................................................................3-26
REPLACING THE HEADLIGHT BULB...................................................3-26
ADJUSTING THE HEADLIGHT BEAM.................................................3-27

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PERIODIC MAINTENANCE

PERIODIC MAINTENANCE

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

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

ODOMETERREADING(x1000km)
NO. ITEM CHECKORMAINTENANCEJOB
1 3 6 9 12 15

1 * Fuelline • Check fuel hoses for cracks or damage. ÿ ÿ ÿ ÿ ÿ

• Check condition. ÿ ÿ
2 Sparkplug • Clean and reset the gap

• Replace. Every12000km

3 * Valves • Check valve clearance. ÿ ÿ

• Adjust.
• Clean. ÿ ÿ ÿ ÿ ÿ
4 * Air filter
element ÿ Every12000km ÿ
• Replace.
5 * Battery • Check Battery output voltage ÿ ÿ ÿ ÿ ÿ

• Check operation.
ÿ ÿ ÿ ÿ ÿ ÿ
6 Clutches • Adjust.
• Lubricating Lever

• Check operation, fluid level and vehicle ÿ ÿ ÿ ÿ ÿ ÿ

7 * Front brake for fluid leakage.
• Replace brake pads. Wheneverworntothelimit

• Check operation, fluid level and vehicle ÿ ÿ ÿ ÿ ÿ ÿ

8 Rear brake for fluid leakage.

• Replace brake pads. Wheneverworntothelimit

9 * Brakelines • Check for cracks or damage. ÿ ÿ ÿ ÿ ÿ

• Replace. Every4years

10 * Wheels • Check runout and for damage. ÿ ÿ ÿ ÿ ÿ

• Check tread depth and for damage.

• Replace if necessary. ÿ ÿ ÿ ÿ ÿ
11 * Tires • Check air pressure.
• Correct if necessary.

12 * Wheel bearings ÿ ÿ ÿ ÿ ÿ
• Check bearing for looseness or damage.

• Check operation and for excessive play. ÿ ÿ ÿ ÿ ÿ ÿ

13 * Swingarm
• Lubricate with lithium-soap-based
Every12000km
grease

14 Drivechain • Check chain slack, alignment and

condition
Every500kmandafterwashingthemotorcycleorridingintherain
• Adjust and thoroughly lubricate chain.

3-1
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PERIODIC MAINTENANCE

ODOMETERREADING(x1000km)
NO. ITEM CHECKORMAINTENANCEJOB
1 3 6 9 12 15

• Check bearing play and steering for ÿ ÿ ÿ ÿ ÿ ÿ

roughness
15 * Steering
• Lubricate with lithium-soap-based
bearings Every12000km
grease

16 * Chassis • Make sure all nuts, bolts and screws are included
ÿ ÿ ÿ ÿ ÿ
fasteners are properly tightened.
17 Sidestand • Check operation.
• Lubricate. ÿ ÿ ÿ ÿ ÿ

18 * Front fork • Check operation and for oil leakage ÿ ÿ ÿ ÿ ÿ

19 * Shock absorber • Check operation and shock absorber for

ÿ ÿ ÿ ÿ ÿ
assembly oil leakage

20 * Injector • Check operation. ÿ ÿ ÿ ÿ ÿ ÿ

• Adjust engine idling speed.

• Change.
21 * Engine oil ÿ ÿ ÿ ÿ ÿ ÿ
• Check oil level and vehicle for oil leakage.

22 Engine oil filter • Replace. ÿ Every10000km(onodometer)

element
• Check coolant level and vehicle for
23 Cooling system ÿ ÿ ÿ ÿ ÿ ÿ
coolant leakage
• Change coolant Every2 Years

24. Front and rear • Check operation

ÿ ÿ ÿ ÿ ÿ ÿ
brake switches

Movingpartsand ÿ ÿ ÿ ÿ ÿ
25 * cables • Lubricate.

• Check operation and free play.

• Adjust the throttle cable free play if
Throttlegrip necessary. ÿ ÿ ÿ ÿ ÿ
26 * andcable • Lubricate the throttle grip housing and
cable

• Check the air cut-off valve, reed valve,

Air induction and hose for damage. ÿ ÿ ÿ ÿ ÿ
27 * system • Replace any damaged parts if
necessary.
• Check operation.
Lights, signals and
28 * switches • Adjust headlight beam (if necessary). ÿ ÿ ÿ ÿ ÿ ÿ

NOTE:
l The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
l Hydraulic brake service
l Regularly check and, if necessary, correct the brake fluid level.
l Every two years replace the internal components of the brake master cylinder and caliper, and change the
brake fluid
l Replace the brake hoses every four years and if cracked or damaged.

3-2
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ENGINE

ENGINE Valve clearance (cold)

Intake
0.10–0.14 mm
ADJUSTING THE VALVE CLEARANCE The
Exhaust
following procedure applies to all of the valves. 0.20–0.24 mm

NOTE:
a. Turn the crankshaft counterclockwise. b. Align
Valve clearance adjustment should be made on a
the TDC mark “a” on the magnero rotor with the
cold engine, at room temperature.
When the valve clearance is to be measured or stationary pointer “b” on the magneto
cover
adjusted, the piston must be at top dead center (TDC)
on the compression stroke.

1. Remove:
b
Front panels
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Disconnect: a
Spark plug cap
Air induction system vacuum hose Air c. Check that the cam lobes are positioned as
induction system hose (3-way joint to air cut-off shown in the illustration.
valve)
Refer to “AIR INDUCTION SYSTEM” on page 7-9.

3. Remove:
Air cut-off valve
Reed valve
Reed valve plate
Refer to “AIR INDUCTION SYSTEM” on page 7-9.

Cylinder head cover

Cylinder head cover gasket Refer d. Measure the valve clearance with a thickness
to “CYLINDER HEAD” on page 5-6.
gauge “1”.
4. Remove:
Out of specification ÿ Adjust.
Timing mark accessing screw “1”
Crankshaft end accessing screw “2”

1
1

5. Measure: 6. Adjust:
Valve clearance
Valve clearance
Out of specification ÿ Adjust. a. Loosen the locknut “1”. b.
Insert a thickness gauge “2” between the end of the
adjusting screw and the valve tip.

3-3
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ENGINE

8. Install:
1 New
Cylinder head cover gasket
Cylinder head cover
Refer to “CYLINDER HEAD” on page 5-6.
2 Reed valve plate
Reed valve
Air cut-off valve
Refer to “AIR INDUCTION SYSTEM” on page 7-9.

9. Connect:
c. Turn the adjusting screw “3” in direction “a” or “b” Air induction system hose (3-way joint to air cut-off
until the specified valve clearance is ob-tained. valve)
Air induction system vacuum hose Refer
to “AIR INDUCTION SYSTEM” on page 7-9.
a
Spark plug cap
b 3 10.Install:
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Seat
Front panels
Refer to “GENERAL CHASSIS” on page 4-1.

ADJUSTING THE ENGINE IDLING SPEED

Direction “a”
Valve clearance is increased. NOTE:
Direction “b” Prior to adjusting the engine idling speed, the air filter
Valve clearance is decreased. element should be clean, and the engine should have
adequate compression.

Tappet screw holder 1. Start the engine and let it warm up for several minutes.
YSST-706
Tappet adjusting socket 2. Remove:
YSST-706A Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Hold the adjusting screw to prevent it from moving 3. Lift the front of the fuel tank. (Do not discon-nect the
and tighten the locknut to specifica-tion. fuel hose.)
4. Install:
Digital tachometer
Locknut 7
TR (onto the spark plug lead)
.
. Nm (0.7 m·kg, 5.1 ft·lb) 5. Check:
Engine idling speed Out
d. Measure the valve clearance again. e. If the
of specification ÿ Adjust.
valve clearance is still out of specifica-tion, repeat all of
the valve clearance adjust-ment steps until the
Engine idling speed 1300–
specified clearance is obtained. 1500 r/min

6. Remove:
7. Install: Right side panel
Crankshaft end accessing screw (along Refer to “GENERAL CHASSIS” on page 4-1.
New ) 7. Adjust:
with the O-ring
Engine idling speed
Timing mark accessing screw (along

with the O-ring New )

3-4
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ENGINE

a. Turn the pilot screw “1” in direction “a” or “b” until FI diagnostic tool
the specified engine idling speed is ob-tained.

1
2
a b

5. While pressing the “MODE” button “1”, turn the main

Direction “a” switch to “ON”.
Engine idling speed is increased.
Direction “b”
NOTE:
Engine idling speed is decreased. “DIAG” appears on the LCD “2” of the FI diag-nostic
tool.
“POWER” LED (Green) “3” comes on.

8. Remove:
Digital tachometer 9.
Install: 3
Fuel tank FI Diagnostic Tool
2
Refer to “FUEL TANK” on page 7-1.
DIAG
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
10.Install: 1
Right side panel
Refer to “GENERAL CHASSIS” on page 4-1.
11.Adjust:
6. Press the “UP” button to select the CO adjust-ment
Throttle cable free play
mode “CO” or the diagnostic mode “DI-AG”.
Refer to “ADJUSTING THE THROTTLE CA-BLE FREE
PLAY” on page 3-6.
7. After selecting “CO”, press the “MODE” but-
tone
Throttle cable free play 3.0–
5.0 mm 8. Check that “C1” appears on the LCD of the FI
diagnostic tool, and then press the “MODE” button.

ADJUSTING THE EXHAUST GAS VOLUME 9. Start the engine.

NOTE:
CAUTION:
Be sure to set the CO density level to standard, and then
Perform the adjustment after the battery has been
adjust the exhaust gas volume.
sufficiently charged.
1. Remove:
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
2. Turn the main switch to “OFF”.
3. Disconnect:
Self-diagnosis signal connector “1”
4. Connect: FI
diagnostic tool “2”

3-5
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ENGINE

Throttle cable free play

3.0–5.0 mm
FI Diagnostic Tool
1400rpm 2. Adjust:
C1 :-10 Throttle cable free play

Throttle body side a.

Loosen the locknut “1” on the accelerator ca-
ble

10.Change the CO adjustment volume by press-ing the b. Turn the adjusting button “2” in direction “a” or “b”
“UP” and “DOWN” buttons. until the specified throttle cable free play is
obtained.
NOTE:
The CO adjustment volume and engine idling speed Direction “a”
appear on the LCD of the FI diagnostic tool. Throttle cable free play is increased.
Direction “b”
To decrease the CO adjustment volume, press the Throttle cable free play is decreased.
“DOWN” button.
To increase the CO adjustment volume, press the c. Tighten the locknut.
“UP” button.

11.Release the “DOWN” and “UP” buttons to ex- 1

ecute the selection. a
12.Set the main switch to “OFF” to cancel the
mode b
13.Disconnect:
FI diagnostic tool
14.Connect:
Self-diagnosis signal connector 2
15.Install:
Seat NOTE:
Refer to “GENERAL CHASSIS” on page 4-1. If the specified throttle cable free play cannot be obtained
on the throttle body side of the cable,
ADJUSTING THE THROTTLE CABLE FREE usetheadjustingnutonthehandlebarside.
PLAY
NOTE:
Prior to adjusting the throttle cable free play, the engine Handlebar side
idling speed should be adjusted. a. Slide back the rubber cover “1” b.
1. Check: Loosen the locknut “2”. c.

Throttle cable free play “a” Turn the adjusting button “3” in direction “a” or “b” until
Out of specification ÿ Adjust. the specified throttle cable free play is obtained.

Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.

3-6
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ENGINE

7. Measure:
Spark plug gap “a”
(with a wire thickness gauge)
Out of specification ÿ Regap.

Spark plug gap 0.7–

0.8 mm
b3

1
a 2
d. Tighten the locknut e.
Slide the rubber cover to its original position.

WARNING
After adjusting the throttle cable free play, start the
engine and turn the handlebar to the rightor
lefttoensurethatthisdoesnot cause the engine
idling speed to change.
8. Install:
Spark plug

CHECKING THE SPARK PLUG 1. Spark plug 13

TR
Remove: .
. Nm (1.3 m·kg, 9.4 ft·lb)
Right front panel
Refer to “GENERAL CHASSIS” on page 4-1. NOTE:
2. Disconnect: Before installing the spark plug, clean the spark plug
Spark plug cap 3. and gasket surface.
Remove:
9. Connect:
Spark plug
Spark plug cap
10.Install:
CAUTION:
Right front panel
Before removing the spark plug, blow away any dirt
Refer to “GENERAL CHASSIS” on page 4-1.
accumulated in the spark plug well with compressed
air to prevent it from falling into the cylinder.
CHECKING THE IGNITION TIMING

4. Check:
NOTE:
Spark plug type Prior to checking the ignition timing, check the wiring

Incorrect ÿ Change. connections of the entire ignition system.

Make sure all connections are tight and free of corrosion.
5. Check:
Electrode “1”
1. Remove:
Damage/wear ÿ Replace the spark plug.
Timing mark accessing screw “1”
Insulator “2”
Abnormal color ÿ Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
Spark plug 1
(with a spark plug cleaner or wire brush)

3-7
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ENGINE

2. Remove: 6. Remove:
Seat Digital tachometer
Refer to “GENERAL CHASSIS” on page 4-1. Timing light
3. Lift the front of the fuel tank. (Do not discon-nect the 7. Install:
fuel hose.) Fuel tank
4. Connect: Refer to “FUEL TANK” on page 7-1.
Timing light “1” Seat
Digital tachometer Refer to “GENERAL CHASSIS” on page 4-1.
8. Install:
Timing light Timing mark accessing screw (along

with the O-ring New )

MEASURING THE COMPRESSION

PRESSURE

NOTE:
Insufficient compression pressure will result in a loss of
performance.

1. Measure:
1 Valve clearance
Out of specification ÿ Adjust.
Refer to “ADJUSTING THE VALVE CLEAR-ANCE” on
page 3-3.
5. Check: 2. Start the engine, warm it up for several min-
Ignition timing utes, and then turn it off.
3. Remove:
a. Start the engine, warm it up for several min-utes, and Right front panel
then let it run at the specified en-gine idling speed. Refer to “GENERAL CHASSIS” on page 4-1.
4. Disconnect:
Spark plug cap 5.
Engine idling speed 1300– Remove:
1500 r/min
Spark plug

b. Check that stationary pointer “a” in the magn-eto CAUTION:

cover is within the firing range “b” on the magneto
Before removing the spark plug, use com-pressed air
rotor.
to blow away any dirt accumulat-ed in the spark plug
Incorrect firing range ÿ Check the ignition system.
wells to prevent it from falling into the cylinder.

6. Remove:
Seat
a
Refer to “GENERAL CHASSIS” on page 4-1.
7. Lift the front of the fuel tank. (Do not discon-nect the
b fuel hose.)
8. Install:
Compression gauge “1”

Compression gauge

NOTE:
The ignition timing is not adjustable.

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ENGINE

Seat
Refer to “GENERAL CHASSIS” on page 4-1.
12.Install:
Spark plug
1
Spark plug 13
TR
.
. Nm (1.3 m·kg, 9.4 ft·lb)

13.Connect:
Spark plug cap
14.Install:
9. Measure:
Right front panel
Compression pressure Out
Refer to “GENERAL CHASSIS” on page 4-1.
of specification ÿ Refer to steps (c) and (d).

CHECKING THE ENGINE OIL LEVEL 1. Stand

the vehicle on a level surface.
Standard compression pressure 55 Psi
NOTE:
(3,866 kg/cm )²
Place the vehicle on the centerstand.
Make sure the vehicle is upright.

a. Set the main switch to ON”. b. With 2. Start the engine, warm it up for several min-
the throttle wide open, crank the engine until the reading utes, and then turn it off.
3. Check:
on the compression gauge stabilizes.
Engine oil level
c. If the compression pressure is above the The engine oil level should be between the minimum
level mark “a” and maximum level mark “b”.
maximum specification, check the cylinder head,
valve surfaces and piston crown for carbon
Below the minimum level mark ÿ Add the
deposits.
Carbon deposits ÿ Eliminate. d. If recommended engine oil to the proper level.
the compression pressure is below the min-imum NOTE:
specification, pour a teaspoonful of en-gine oil into Before checking the engine oil level, wait a few minutes
the spark plug bore and measure again. until the oil has settled.
Do not screw the dipstick “1” while checking the oil
Refer to the following table. level.

Compression pressure (with oil applied into the

cylinder)
1
Reading Diagnosis

Higherthanwithout oil Piston ring(s) wear or

damage ÿ Repair.
1
Piston, valves, cylinder
Same as without oil head gasket or piston
possibly defec-tive ÿ b
Repair.
a

10.Remove:
Type
Compression gauge SAE20W40 (YAMALUBE-4 stroke motor oil)
11.Install:
Fuel tank
Refer to “FUEL TANK” on page 7-1.

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ENGINE

CAUTION:
Do not allow foreign materials to enter the crankcase.

4. Start the engine, warm it up for several min-

utes, and then turn it off.
5. Check the engine oil level again.
NOTE:
Before checking the engine oil level, wait a few minutes 2 New 3 1
until the oil has settled.
c. Install the new oil filter element and the oil filter element
cover.
CHANGING THE ENGINE OIL 1. Start
Oil filter element cover bolt 10 Nm
the engine, warm it up for several min- TR
.
. (1.0 m·kg, 7.2 ft·lb)
utes, and then turn it off.
2. Place a container under the engine oil drain
bolt.
6. Check:
3. Remove:
Engine oil strainer Dirt
Engine oil filler cap “1”
ÿ Clean 7.
Engine oil drain plug “2”
Install:
O-ring “3”
Engine oil strainer
Spring “4”
Spring
Engine oil strainer “5”
O-ring New
Engine oil drain plug

Engine oil drain plug 32 Nm

TR
.
. (3.2 m·kg, 23 ft·lb)

1
8. Fill:
Crankcase
(with the specified amount of the recom-mended
engine oil)

Engine oil quantity Total

amount 1.15 L

Without oil filter element replace-ment 0.95

L With
oil filter
5
4 element replace-ment 1.00 L

3
2
2

4. Drain: 9. Install:
Engine oil filler cap
Engine oil
10.Start the engine, warm it up for several min-
(completely from the crankcase)
utes, and then turn it off.
5. If the oil filter element is also to be replaced, perform
11.Check:
the following procedure.
Engine
a. Remove the oil filter element cover “1” and oil filter (for engine oil leaks)
element “2”.
b. Install new O-ring “3”.

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ENGINE

12.Check: 2. Adjust:
Engine oil level Clutch cable free play
Refer to “CHECKING THE ENGINE OIL LEVEL”
on page 3-9.
13.Check: Handlebar side
a. Pull back the rubber cover “1” b.
Engine oil pressure
Loosen the locknut “2”. c. Turn
a. Slightly loosen the oil check bolt “1”. the adjusting bolt “3” in direction “a” or “b” until the
specified clutch cable free play is obtained.

Direction “a”
1 Clutch cable free play is increased.
Direction “b”
Clutch cable free play is decreased.

1 23

b. Start the engine and keep it idling until engine oil a

starts to seep from the oil check bolt. If no engine oil
comes out after one minute, turn the engine off so
that it will not seize. c. Check the engine oil
b
passages, the oil filter element and the oil pump for
damage or leak-age. Refer to “OIL PUMP” on page
5-49. d. Start the engine after solving the
problem(s) and check the engine oil pressure again. e.
d. Tighten the locknut. e.
Tighten the oil check bolt to specification.
Place the rubber cover in its original position.
NOTE:
Oil check bolt 7 If the specified clutch cable free play cannot be obtained
TR
.
. Nm (0.7 m·kg, 5.1 ft·lb) on the handlebar side of the cable, use the adjusting nut
on the engine side.

ADJUSTING THE CLUTCH CABLE FREE PLAY 1.

Check: Engine side a.
Clutch Loosen the locknut “1”. b. Turn
cable free play “a” the adjusting button “2” in direction “a” or “b” until the
Out of specification ÿ Adjust. specified clutch cable free play is ob-tained.

Clutch lever free play 10.0–

15.0 mm Direction “a”
Clutch cable free play is increased.
Direction “b”
Clutch cable free play is decreased.

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ENGINE

3. Clean:
Air filter element “1”
a Apply compressed air to the outer surface of the air
filter element.

b 1
2 1

c. Tightenthelocknut.

Locknut 7
TR
.
. Nm (0.7 m·kg, 5.1 ft·lb)
4. Check:
Air filter element
Damage ÿ Replace.
CLEANING THE AIR FILTER ELEMENT
5. Install:
NOTE: Air filter element
There is a check hose “1” at the bottom of the air filter Air filter case cover
case. If dust and/or water collects in this hose, clean (along with a gaskets)
the air filter element and air filter
case CAUTION:
Never operate the engine without the air filter element
installed. Unfiltered air will cause rapid wear of engine
parts and may damage the engine. Operating the engine
without the air filter element will also affect throttle body
turning, leading to poor engine performance and
possible overheating.
1
NOTE:
Make sure the air filter element is properly in-stalled
in the air filter case.
1. Remove:
6. Install:
Seat
Fuel tank
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Seat
Refer to “FUEL TANK” on page 7-1.
2. Remove: Refer to “GENERAL CHASSIS” on page 4-1.

Air filter case cover “1”

Air filter element CHECKING THE THROTTLE BODY JOINT AND AIR
FILTER CASE JOINT 1. Remove: Seat
Refer to

1
“GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
2. Check:
Throttle body joint “1”
Air filter case joint “2”
Cracks/damage ÿ Replace.

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ENGINE

Loose connection ÿ Connect properly.

CAUTION:
Make sure the cylinder head breather hose is routed
correctly.

2
1

3. Install:
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1. 1
3. Install:
CHECKING THE FUEL LINE 1. Fuel tank
Remove: Seat Refer to “FUEL TANK” on page 7-1.
Refer Seat
to “GENERAL CHASSIS” on page 4-1. Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1. CHECKING THE EXHAUST SYSTEM 1. Check:
2. Check:
Fuel hose “1” Muffler “1”
Cracks/damage ÿ Replace. Cracks/damage ÿ Replace.
Loose connection ÿ Connect properly. Exhaust pipe gasket “2”
Exhaust gas leaks ÿ Replace.
2. Check:
Tightening torque
1 Muffler nuts “3”
Muffler bolt “4”

Muffler nut
TR
.
. 15 Nm (1.5m.kg,11ft.lb)
Muffler bolt
20 Nm (2.0m.kg,15ft.lb)
3. Install:
Fuel tank
Refer to “FUEL TANK” on page 7-1.
Seat
Refer to “GENERAL CHASSIS” on page 4-1.
314
CHECKING THE CYLINDER HEAD
BREATHER HOSE 1.
Remove: Seat
Refer
2
to “GENERAL CHASSIS” on page 4-1.
Fuel tank CHECKING THE COOLANT LEVEL 1. Stand
Refer to “FUEL TANK” on page 7-1. the vehicle on a level surface.
2. Check:
NOTE:
Cylinder head breather hose “1”
Place the vehicle on the centerstand.
Cracks/damage ÿ Replace.

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ENGINE

Make sure the vehicle is upright.

CHECKING THE COOLING SYSTEM 1.
2. Check: Remove:
Coolant level Front panels
The coolant level should be between the Seat
maximum level mark “a” and minimum level mark Refer to “GENERAL CHASSIS” on page 4-1.
“b”. Fuel tank
Below the minimum level mark ÿ Add the Refer to “FUEL TANK” on page 7-1.
recommended coolant to the proper level. 2. Check:
NOTE: Radiator “1”
Radiator inlet hose “2”
To access the coolant reservoir cap “1”, remove the left
side cover. Refer to “GENERAL CHAS-SIS” on page Radiator outlet hose “3”
Coolant reservoir hose “4”
4-1.
Water pump breather hose “5”
Cracks/damage ÿ Replace.
Refer to “RADIATOR” on page 6-1.
a 4
b 2

3
1
3. Install:
Fuel tank
1
Refer to “FUEL TANK” on page 7-1.
Seat
Front panels
Refer to “GENERAL CHASSIS” on page 4-1.

CHANGINGTHECOOLANT 1.
Remove:
CAUTION:
Right front panel
Adding water instead of coolant lowers the antifreeze Refer to “GENERAL CHASSIS” on page 4-1.
content of the coolant. If water is used instead of
Side panels
coolant check, and if nec-essary, correct the
Refer to “GENERAL CHASSIS” on page 4-1.
antifreeze concentra-tion of the coolant. Seat
Refer to “GENERAL CHASSIS” on page 4-1.
Use only distilled water. However, if dis-tilled Fuel tank
water is not available, soft water may be used. Refer to “FUEL TANK” on page 7-1.
Air filter case
3. Start the engine, warm it up for several min- Refer to “GENERAL CHASSIS” on page 4-1.
utes, and then turn it off. 2. Remove:
4. Check: Radiator cap “1”
Coolant level
NOTE:
Before checking the coolant level, wait a few minutes
until it settles.

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ENGINE

1 3

7. Drain:
WARNING Coolant
A hot radiator is under pressure. Therefore, (from the coolant reservoir)
Do not remove the radiator cap when the 8. Install:
engine is hot. Scalding hot fluid and steam sewing Coolant reservoir
be blown out, which could cause serious in-
jury. When the engine has cooled, open the Coolant reservoir bolt
TR
radiator cap as follows: .
. 7 Nm (0.7 m·Kg, 5.1 ft·lb)
Place a thick rag or a towel over the radiator
9. Connect:
cap and slowly turn the radiator cap counter-
Coolant reservoir hose
clockwise toward the detent to allow any re-
10.Install:
sidual pressure to escape. When the hissing
Coolant drain bolt
sound has stopped, press down on the radio-
ator cap and turn it counterclockwise to re- (along with the copper washer New )
move
Coolant drain bolt
3. Remove: TR
.
. 7 Nm (0.7 m·Kg, 5.1 ft·lb)
Coolant drain bolt “1”
(along with the copper washer) 11.Fill:
Cooling system
(with the specified amount of the
recom-mended coolant)
1
Recommended antifreeze
High-quality ethylene glycol an-
tifreeze containing corrosion in-
hibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
4. Drain: Radiator capacity (including all
routes)
Coolant 0.59 L
(from the engine and radiator) Coolant reservoir capacity (up
5. Disconnect: to the maximum level mark)
Coolant reservoir hose “1” 0.25 L
6. Remove:
Coolant reservoir “2”
Coolant reservoir cap “3” Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.

WARNING
If coolant splashes in your eyes, thoroughly wash
them with water and consult a doctor.

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ENGINE

If coolant splashes on your clothes, quickly wash it 18.Install:

away with water and then with soap and water. Seat
Refer to “GENERAL CHASSIS” on page 4-1.
If coolant is swallowed, induce vomiting and get Side panels
immediate medical attention. Refer to “GENERAL CHASSIS” on page 4-1.
Right front panel
CAUTION: Refer to “GENERAL CHASSIS” on page 4-1.

Adding water instead of coolant lowers the antifreeze

content of the coolant. If water is used instead of
coolant check, and if nec-essary, correct the
antifreeze concentra-tion of the coolant.

Use only distilled water. However, if dis-tilled water

is not available, soft water may be used.

If coolant comes into contact with painted surfaces,

immediately wash them with water.

Do not mix different types of antifreeze.

12.Install:
Radiator cap
13.Fill:
Coolant reservoir
(with the recommended coolant to the maxi-mum
level mark “a”)

14.Install:
Coolant reservoir cap
15.Install:
Air filter case
Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank
Refer to “FUEL TANK” on page 7-1.
16.Start the engine, warm it up for several min-utes,
and then stop it.
17.Check:
Coolant level
Refer to “CHECKING THE COOLANT LEV-EL” on
page 3-13.
NOTE:
Before checking the coolant level, wait a few minutes
until the coolant has settled.

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CHASSIS

CHASSIS WARNING
A soft or spongy feeling in the brake pedal can indicate
ADJUSTING THE REAR DISC BRAKE 1. Check: the presence of air in the brake system. Before the
Brake pedal vehicle is operated, the air must be removed by
position (distance “a” bleeding the brake system. Air in the brake system will
from the center of the rider foot-rest to the center of consid-erably reduce braking performance.

the brake pedal)

Out of specification ÿ Adjust.
CAUTION:
Brake pedal position 44.0 After adjusting the brake pedal position, make sure
mm
there is no brake drag.

e. Install the battery, washer, and cotter battery.

WARNING
Always use a new cotter pin.

a CHECKING THE BRAKE FLUID LEVEL 1. Stand

the vehicle on a level surface.

NOTE:
Place the vehicle on a suitable stand.
2. Adjust:
Make sure the vehicle is upright.
Brake pedal position
2. Check:
a. Loosen the locknut “1”. b. Brake fluid level
Remove the cotter pin “2”, washer “3”, and pin “4”. Below the minimum level mark “a” ÿ Add the
recommended brake fluid to the proper level.
c. Turn the adjusting button “5” in direction “a” or “b”
Recommended fluid
until the specified brake pedal position is ob-tained.
DOT 3 or DOT 4

Direction “a”
Brake pedal is raised.
Direction “b” A
Brake pedal is lowered. LOWER
a

1 a
5
2 b

34

d. Tighten the locknut “1” to specification.

Locknut
TR
.
. 17 Nm (1.7 m·kg, 12 ft·lb)

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CHASSIS

1. Operate the brake.

2. Check:
B
Front brake pad
Wear indicator grooves “a” havealmostdis-appeared
ÿ Replace the brake pads as a set.
a
Refer to “FRONT BRAKE” on page 4-15.

A. Front brake
B. Rear brake

WARNING
Use only the designated brake fluid. Other brake fluids
may cause the rubber seals to deteriorate, causing
CHECKING THE REAR BRAKE PADS The
leakage and poor brake performance.
following procedure applies to all of the brake pads.

Refill with the same type of brake fluid that is already in

1. Operate the brake.
the system. Mixing brake fluids may result in a harmful
2. Check:
chemical reaction, leading to poor brake performance.
Rear brake pad
Wear indicator groove “a” has almost disap-peared
When refilling, be careful that water does not enter
ÿ Replace the brake pads as a set.
the brake fluid reservoir. Water will significantly lower
Refer to “REAR BRAKE” on page 4-25.
the boiling point of the brake fluid and could cause
vapor lock.

CAUTION:
Brake fluid may damage painted surfaces and plastic
parts. Therefore, always clean up any spill brake fluid
immediately.

NOTE:
In order to ensure a correct reading of the brake fluid
level, make sure the top of the brake fluid reservoir is
horizontal.
CHECKING THE FRONT BRAKE HOSE 1. Check:
Brake hose
“1”
CHECKING THE FRONT BRAKE PADS The
Cracks/damage/wear ÿ Replace.
following procedure applies to all of the brake pads.
2. Check:
Brake hose holder “2”
Loose connection ÿ Tighten the holder bolt.

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CHASSIS

the brake fluid level is very low. brake

operation is faulty.

NOTE:
Be careful not to spill any brake fluid or allow the
brake master cylinder reservoir or brake fluid
reservoir to overflow.
1
When bleeding the hydraulic brake system, make
sure there is always enough brake fluid before
2 applying the brake. Ignoring this pre-caution could
allow air to enter the hydraulic brake system,
3. Hold the vehicle upright and apply the front brake considerably lengthening the bleeding procedure.
several times.
4. Check:
If bleeding is difficult, it may be necessary to let the
Brake hose
brake fluid settle for a few hours. Repeat the bleeding
Brake fluid leakage ÿ Replace the damaged hose. procedure when the tiny bubbles in the hose have
disappeared.
Refer to “FRONT BRAKE” on page 4-15.
1. Bleed:
Hydraulic brake system
CHECKING THE REAR BRAKE HOSE 1. Check:
Brake
a. Fill the brake fluid reservoir to the proper level with
hoses “1” the recommended brake fluid. b. Install
Cracks/damage/wear ÿ Replace. the diaphragm (brake master cylinder reservoirorbrakefluid
2. Check:
reservoir). c. Connect a clear plastic
Brake hose holder “2”
hose “1” tightly to the bleed screw “2”.
Loose connection ÿ Tighten the holder bolt.
Loose or open holder ÿ Fasten properly.

2
1 2

B
3. Hold the vehicle upright and apply the rear brake 1
several times.
4. Check:
Brake hoses 2
Brake fluid leakage ÿ Replace the damaged hose.

Refer to “REAR BRAKE” on page 4-25.

BLEEDING THE HYDRAULIC BRAKE

SYSTEM A. Front
B. Rear
WARNING
d. Place the other end of the hose into a con-
Bleed the hydraulic brake system whenever: the system
shipper
is disassembled. a brake hose is
loosened, disconnected or replaced. e. Slowly apply the brake several times.

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CHASSIS

f. Fully pull the brake lever or fully press down the brake 2. Spin the rear wheel several times and find the tightest
pedal and hold it in position. g. Loosen the position of drive chain.
bleed screw. 3. Check:
NOTE: Drive chain slack “a”

Loosening the bleed screw will release the pres-sure Out of specification ÿ Adjust.
and cause the brake lever to contact the throttle grip
or the brake pedal to fully extend.

h. Tighten the bleed screw and then release the brake

lever or brake pedal. i. Repeat
steps (e) to (h) until all of the air bubbles have
disappeared from the brake fluid in the plastic hose.
j. Tighten the bleed
screw to specification.

Front brake caliper bleed screw 6 Nm

TR
.
. (0.6 m·kg, 4.5 ft ·lb) Drive chain slack 20–
Rearbrakecaliperbleedscrew 6 Nm (0.6 40 mm
m·kg, 4.5 ft·lb)
NOTE:
k. Fill the brake fluid reservoir to the proper level with
the recommended brake fluid. Measure the drive chain slack halfway between the
Refer to “CHECKING THE BRAKE FLUID LEVEL” drive axle and the rear wheel axle.

on page 3-17. 4. Adjust:

Drive chain slack
WARNING
After bleeding the hydraulic brake system, check the
a. Loosen the wheel axle nut “4” b.
brake operation.
Turn the drive chain adjusting plate “5” in di-rection
“a” or “b” until the specified drive chain slack is
obtained.

ADJUSTING THE DRIVE CHAIN SLACK

Direction “a”
NOTE:
Drive chain is tightened.
The drive chain slack must be checked at the tightest Direction “b”
point on the chain. Drive chain is loosened.

CAUTION:
A drive chain that is too tight will overload the engine
a
and other vital parts, and one that is too loose can skip b
and damage the swing-arm or cause an accident.
Therefore, keep the drive chain slack within the 2
specified lim-its. 1

1. Stand the vehicle on a level surface.

WARNING
NOTE:
Securely support the vehicle so that there is nodanger
ofitfallingover. To maintain the proper wheel alignment, adjust both
sides evenly. f.
NOTE:
Place the vehicle on the centerstand so that the rear Tighten the wheel axle nut.
wheel is elevated.

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CHASSIS

NOTE:
Wheel axle nut 110 Place the vehicle on a suitable stand so that the front
TR
.
. Nm (11.0 m·kg, 80 ft·lb) wheel is elevated.

2. Check:

LUBRICATING THE DRIVE CHAIN The Steering head

Grasp the bottom of the front fork legs and gently
drive chain consists of many interacting parts. If the
rock the front fork.
drive chain is not maintained properly, it will wear out
Blinding/looseness ÿ Adjust the steering head.
quickly. Therefore, the drive chain should be serviced,
especially when the vehicle is used in dusty areas.
CHECKING AND ADJUSTING THE STEERING
Use recomended chain cleaner and lubricant lubricant HEAD 1. Stand the
that is suitable for non-O-ring chains. vehicle on a level surface.

Recommended lubricant WARNING

Chain lubricant suitable for
Securely support the vehicle so that there is no danger
O-ring chains of it falling over.

NOTE:
1. Remove all deposits of dust, soil, mud , oil Place the vehicle on a suitable stand so that the front
etc during washing and drying it with air blow.. wheel is elevated.

2. Spray the chain cleaning solvent to remove 2. Check:

grease deposition for 5 minutes. Steering head
3. Wipe the chain with clean cloth Grasp the bottom of the front fork legs and gently
rock the front fork.
Binding/looseness ÿ Adjust the steering head.

3. Remove:
Upper bracket
Refer to “STEERING HEAD” on page 4-49.

4. Adjust:
Steering head

a. Remove the lock washer “1”, the upper ring nut “2”,
and the rubber washer “3”.

4 Spray the Lubricant inside the chain between

inner/ outer plates, roller and bushes.
5 After spraying wait for 15 minutes.
6 Excess lubricant should be wiped with a
clean cloth before riding.

CHECKING AND ADJUSTING THE STEERING

HEAD 1. Stand the
b. Tighten the lower ring nut “4” with a steering wheel
vehicle on a level surface.
nut wrench “5”.
WARNING
Securely support the vehicle so that there is nodanger
ofitfallingover.

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CHASSIS

NOTE:
Set the torque wrench at a right angle to the steering
nut wrench.

5. Install:

4 Upper bracket
Refer to “STEERING HEAD” on page 4-49.

CHECKING THE FRONT FORK 1. Stand

Steering nut socket
the vehicle on a level surface.
YSST-721

WARNING
Securely support the vehicle so that there is no danger
Lowerringnut(initial tightening torque)
TR
. of it falling over.
.
48 Nm (4.8 m·kg, 35 ft·lb) 2. Check:
Inner tube
c. Loosen the lower ring nut “4” completely, and then
Damage/scratches ÿ Replace.
tighten it to specification with a steering nut wrench. Oil seal
Oil leakage ÿ Replace.
WARNING 3. Hold the vehicle upright and apply the front
brake.
Do not overtighten the lower ring nut.
4. Check:
Front fork operation
Lowerringnut(finaltightening torque) Push down hard on the handlebar several times
TR
.
. and check if the front fork rebounds smoothly.
13 Nm (1.3 m·kg, 9.4 ft·lb)

Rough movement ÿ Repair.

d. Check the steering head for looseness or looseness Refer to “FRONT FORK” on page 4-41.
binding by turning the front fork all the way in both
directions. If any binding is felt, remove the lower
bracket and check the upper and lower bearings.

Refer to “STEERING HEAD” on page 4-49. e. Install

the rubber washer “3”. f. Install the
upper ring nut “2”. g. Finger tighten
the upper ring nut“2”, and then align the slots of both
ring nuts. If necessary, hold the lower ring nut and
tighten the upper ring nut until their slots are aligned.

NOTE:
CHECKING THE TYRES The
Make sure the lock washer tabs “a” sit correctly in the
following procedure applies to both of the tires.
ring nut slots “b”.

1. Check: •
Tire pressure Out
of specification ÿ Regulate.

3-22
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CHASSIS

1. Tire tread depth 2.

Side wall 3.
Wear indicator

WARNING

Do not use a tube tire on a wheel de-signed

only for tubeless tires to avoid tire failure and personal
injury from sudden deflation.

After extensive tests, the tires listed below have been

WARNING
approved by YAMAHA for this model. The front
The tire pressure should only be checked and rear tires should always be by the same
and regulated when the tire temperature manufacturer and of the same design. No handling
equals the ambient air temperature. guarantee characteristics can be given if a tire
The tire pressure must be adjusted accord- combination other than one approved by YAMAHA
ing to the total weight (including cargo, is used on this vehicle.
rider, passenger and accessories) and
the anticipated riding speed.
Operation of an overloaded vehicle could
cause tire damage, an accident or an injury.
NEVER OVERLOAD THE VEHICLE.
Front tire
Size
Tire air pressure (measured on cold tires) 80/90 –17 M/C 44P
Manufacturer/model
MRF/ZAPPER
Front
200 kPa (28 psi) (2.00 kgf/cm²)
Rear
225 kPa (33 psi) (2.25 kgf/cm²)

WARNING

It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit, re-place the
tire immediately.
2. Check:
Tire surfaces
Damage/wear ÿ Replace the tire.

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CHASSIS

CHECKING AND LUBRICATING THE CABLES

Rear tire The
Size
following procedure applies to all of the inner and
100/80–17 M/C 52P
outer cables.
Manufacturer/model
MRF/ZAPPER
WARNING
Damaged outer cable may cause the cable to corrode
and interfere with its movement. Re-replace damaged
WARNING
outer cable and inner cables as soon as possible.
New tires have a relatively low grip on the road surface
until they have been slightly worn. Therefore, 1. Check:
approximately 100 km should be traveled at normal Outer cable
speed before anyhigh-speedridingisdone.
Damage ÿ Replace.
2. Check:
NOTE: Cable operation
For tires with a direction of rotation mark“1”: Install Rough movement ÿ Lubricate.
the tire with the mark pointing in the di-rection of
Recommended lubricant
wheel rotation.
Engine oil or a suitable cable lu-bricant
Align the mark “2” with the valve installation point.

NOTE:
Hold the cable end upright and pour a few drops of
lubricant into the cable sheath or use a suit-
ablelubricating device.

LUBRICATING THE CLUTCH LEVER Lubricate

the pivoting point and metal-to-metal moving parts of
the lever.

Recommended lubricant
Lithium-soap-based grease

CHECKING THE WHEELS The

following procedure applies to both of the wheels.

1. Check:
Wheel
Damage/out-of-round ÿ Replace.

WARNING
Never attempt to make any repairs to the wheel.

NOTE:
After a tire or wheel has been changed or re-placed,
alwaysbalance the wheel.

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CHASSIS

LUBRICATING THE BRAKE LEVER Lubricate

the pivoting point and metal-to-metal moving parts of
the lever.

Recommended lubricant
Silicone grease

LUBRICATING THE PEDALS

Lubricate the pivoting point and metal-to-metal moving
parts of the pedals.

Recommended lubricant
Lithium-soap-based grease

LUBRICATING THE SIDESTAND

Lubricate the pivoting point and metal-to-metal moving
parts of the sidestand.

Recommended lubricant
Lithium-soap-based grease

LUBRICATING THE REAR SUSPENSION Lubricate

the pivoting point and metal-to-metal moving parts of
the rear suspension.

Recommendedlubricant
Lithium-soap-based grease

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ELECTRICAL SYSTEM

ELECTRICAL SYSTEM WARNING

Since the headlight bulb gets extremely hot, keep
CHECKING ANDCHARGINGTHEBATTERY
flammable products and your hands away from the
Referto “ELECTRICAL COMPONENTS” on page8-61
bulb until it has cooled down.

CHECKINGTHEFUSES
4. Install:
Referto “ELECTRICAL COMPONENTS” on page8-61
• Headlight bulb New
Secure the new headlight bulb with the head-light
REPLACING THE HEADLIGHT BULBS The bulb holder.

following procedure applies to the low beam headlight CAUTION:

bulb.
1. Remove: Avoid touching the glass part of the head-light bulb
to keep it free from oil, otherwise the transparency of
• Headlight bulb cover “1”
the glass, the life of the bulb and the luminous flux will
be dangerously affected. If the headlight bulb gets
soiled, thoroughly clean it with a cloth moistened
with alcohol or lacquer thinner.

5. Install: •
Headlight bulb holder 6.
Install: •
Headlight bulb cover
The following procedure applies to the high beam
headlight bulb.
1. Remove:
• Headlight bulb cover “1”
1
2. Remove:
• Headlight bulb holder “1”

1
1
2. Disconnect: •
Headlight coupler “1”

3. Remove: •
Headlight bulb “1”

3. Remove: •
1
Headlight bulb holder “1”

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ELECTRICAL SYSTEM

a. Turn the adjusting screw “1” in direction “a” or

“b”.

Direction “a”
Headlight beam is lowered.
Direction “b”
1
Headlight beam is raised.

A
4. Remove: •
Headlight bulb “1”

b
a +

1 B

a
WARNING
+
Since the headlight bulb gets extremely hot, keep b
flammable products and your hands away from the
bulb until it has cooled down. 1
5. Install:
A. Left headlight
• Headlight bulb New
B. Right headlight
Secure the new headlight bulb with the head-light
bulb holder.

CAUTION:
Avoid touching the glass part of the head-light bulb
to keep it free from oil, otherwise the transparency of
the glass, the life of the bulb and the luminous flux will
be dangerously affected. If the headlight bulb gets
soiled, thoroughly clean it with a cloth moistened
with alcohol lacquerthinner.

6. Install: •
Headlight bulb holder
7. Connect: •
Headlight coupler 8.
Install: •
Headlight bulb cover

ADJUSTING THE HEADLIGHT BEAMS The

following procedure applies to both of the headlights.

1. Adjust: •
Headlight beam (vertically)

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CHASSIS

GENERAL CHASSIS...................................................................................4-1 INSTALLING THEAIR

FILTER CASE .........................................................4-3

FRONT WHEEL...................................................................................................4-4 REMOVING THE

FRONT WHEEL...................................................4-6 DISASSEMBLING THE FRONT
WHEEL...................................................4-6 CHECKING THE FRONT
WHEEL............................................................4-6 ASSEMBLING THE FRONT
WHEEL....................................................4-7 ADJUSTING THE FRONT WHEEL STATIC
BALANCE...................................4-7 INSTALLING THE FRONT WHEEL
(DISC) ..............................................4-8

REAR WHEEL...................................................................................................4-10 REMOVING THE

REAR WHEEL (DISC)....................................4-13 DISASSEMBLING THE REAR
WHEEL...................................................4-13 CHECKING THE REAR BRAKE CALIPER
BRACKET ..........................4-13 CHECKING AND REPLACING THE REAR WHEEL
SPROCKET ......4-13 ASSEMBLING THE REAR WHEEL ..........................................4-14
ADJUSTING THE REAR WHEEL STATIC BALANCE ..........................4-14 INSTALLING
THE WHEEL (DISC) .........................................4-14

FRONT BRAKE............................................................................................4-15
INTRODUCTION...................................................................................4-18 CHECKING THE
FRONT BRAKE DISC .............................................4-18 REPLACING THE FRONT BRAKE
PADS ..............................................4-19 REMOVING THE FRONT BRAKE
CALIPER....................................................4-20 DISASSEMBLING THE FRONT BRAKE
CALIPER...................................4-20 CHECKING THE FRONT BRAKE
CALIPER ...................................4-20 ASSEMBLING THE FRONT BRAKE
CALIPER...................................4-21 INSTALLING THE FRONT BRAKE
CALIPER ...................................4-21 REMOVING THE FRONT BRAKE MASTER
CYLINDER...................4-22 CHECKING THE FRONT BRAKE MASTER
CYLINDER....................4-22 ASSEMBLING THE FRONT BRAKE MASTER
CYLINDER .............4-22 INSTALLING THE FRONT BRAKE MASTER
CYLINDER...................4-22

REAR BRAKE............................................................................................4-25 CHECKING THE REAR

BRAKE DISC...................................................4-30 REPLACING THE REAR BRAKES
PADS .............................................4-30 REMOVING THE REAR BRAKE
CALIPER .........................................4-31 DISASSEMBLING THE REAR BRAKE
CALIPER .............................4-32 CHECKING THE REAR BRAKE
CALIPER .........................................4-32 ASSEMBLING THE REAR BRAKE
CALIPER ...................................4-33 INSTALLING THE REAR BRAKE
CALIPER ..........................4-33 REMOVING THE REAR BRAKE MASTER
CYLINDER ...................4-34 ASSEMBLING THE REAR BRAKE MASTER
CYLINDER ...................4-34 INSTALLING THE REAR BRAKE MASTER
CYLINDER ...................4-35

HANDLEBAR ...................................................................................4-36 REMOVING THE

HANDLEBAR ...................................................4-38 CHECKING THE
HANDLEBAR ...................................................4-38 INSTALLING THE
HANDLEBAR ...................................................4-38

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CHASSIS

FRONT FORK............................................................................................4-41
REMOVING THE FRONT FORK LEGS...................................................4-44
DISASSEMBLING THE FRONT FORK LEGS....................................4-44
CHECKING THE FRONT FORK LEGS....................................................4-45
ASSEMBLING THE FRONT FORK LEGS............................................4-45
INSTALLING THE FRONT FORK LEGS....................................................4-48

STEERING HEAD...................................................................................4-49
REMOVING THE LOWER BRACKET...................................................4-51
CHECKING THE STEERING HEAD...................................................4-51
INSTALLING THE STEERING HEAD....................................................4-51

REAR SHOCK ABSORBER ASSEMBLY ...................................................4-53

REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................4-54
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ..............4-54
CHECKING THE CONNECTINGARMAND RELAYARM.................4-54
INSTALLING THE RELAY ARM............................................................4-54
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ..............4-54

SWINGARM............................................................................................4-56
REMOVING THE SWINGARM...................................................4-58
CHECKING THE SWINGARM .............................................................4-58
INSTALLING THE SWINGARM .........................................................4-58

CHAIN DRIVE............................................................................................4-60
CHECKING THE DRIVE CHAIN .............................................................4-61
INSTALLING THE DRIVE CHAIN .........................................................4-62

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GENERAL CHASSIS

GENERAL CHASSIS
Moving the seats and covers
TR
. 7Nm(0.7m kg,5.1ft Ib)
TR
.
.
7Nm(0.7m kg,5.1ft Ib)
.

4
6

10 TR
.
.
26Nm(2.6m kg,19ft Ib)

5
8

TR
.
.
7 Nm (0.7 m kg, 5.1 ft Ib)

TR
7Nm(0.7m kg,5.1ft Ib)
9
.
.

7 Nm (0.7 m

11 1

Order Job/Parts to remove Qty Remarks

1 Left front panel 1

2 Right front panel 1

3 Lowercowling1
4 Seat 1
5 Handle Seat 1
6 Rear panel 1
7 Left rear side cover 1
8 Right rear side cover 1
9 Left side cover 1
10 Right side cover 1
11 Head Light 1

For installation, reverse the removal procedure.

4-1
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GENERAL CHASSIS

Removing the air filter case

7
4

3
TR
.
.
2Nm(0.2m kg,1.4ft Ib)

TR
.
.
10Nm(1.0mkg,7.2ftIb)
6

TR
10Nm(1.0mkg,7.2ftIb)
5
.
.

Order Job/Parts to remove Qty Remarks

Refer to “GENERAL CHASSIS” on page

Seat/Left and Right side covers 4-1.
”
Fuel tank Refer to “FUEL TANK on page 7-1.
1 Air filter case cover 1
2 Air filter element 1
3 Air filter case joint clamp screw 1 Loosen.
4 Air filter case 1
5 Cylinder head breather hose 1 Disconnect.

6 Air induction system hose (air filter case to 3- 1 Disconnect.

way joint)
7 Air filter case silencer 1

For installation, reverse the removal procedure.

4-2
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