Мануал на tmax 500

• Page 1: Service Manual

  2009 SERVICE MANUAL XP500Y LIT-11616-22-08 4B5-28197-10…

• Page 2
  EAS20050 XP500Y SERVICE MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. First edition, March 2008 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11616-22-08…
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  If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform to federal environmental quality objectives.
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  EAS20090 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. •…
• Page 5
  EAS20100 1. Serviceable with engine mounted SYMBOLS 2. Filling fluid The following symbols are used in this manual 3. Lubricant for easier understanding. 4. Special tool 5. Tightening torque The following symbols are not relevant to every 6. Wear limit, clearance vehicle.

• Page 7: Table Of Contents

  EAS20110 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING…

• Page 9: General Information

  GENERAL INFORMATION IDENTIFICATION ……………….. 1-1 VEHICLE IDENTIFICATION NUMBER ………….1-1 MODEL LABEL………………1-1 FEATURES…………………. 1-2 OUTLINE OF FI SYSTEM …………….. 1-2 FI SYSTEM………………..1-3 MULTI-FUNCTION DISPLAY…………..1-4 IMPORTANT INFORMATION …………….. 1-7 PREPARATION FOR REMOVAL AND DISASSEMBLY……1-7 REPLACEMENT PARTS…………….1-7 GASKETS, OIL SEALS AND O-RINGS ………… 1-7 LOCK WASHERS/PLATES AND COTTER PINS ……..

• Page 10: Identification

  IDENTIFICATION EAS20130 IDENTIFICATION EAS20140 VEHICLE IDENTIFICATION NUMBER The vehicle identification number “1” is stamped into the right side of the frame. EAS20150 MODEL LABEL The model label “1” is affixed to the storage box. This information will be needed to order spare parts.

• Page 11: Features

  FEATURES EAS20170 FEATURES EAS4B51038 OUTLINE OF FI SYSTEM The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions. In a 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 chamber.

• Page 12: Fi System

  FEATURES EAS4B51039 FI SYSTEM The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator (in the fuel pump) maintains the fuel pressure that is applied to the fuel injector at 240–260 kPa (2.40–2.60 kg/cm², 34.1– 37.0 psi) higher than the intake manifold pressure.

• Page 13: Multi-Function Display

  FEATURES • an odometer (which shows the total distance EAS4B51037 MULTI-FUNCTION DISPLAY traveled) EWA4B54001 • two tripmeters (which show the distance trav- WARNING eled since they were last set to zero) Be sure to stop the vehicle before making • a fuel reserve tripmeter (which shows the dis- any setting changes to the multi-function tance traveled when the remaining fuel in the display.

• Page 14
  FEATURES Odometer and tripmeter modes 1. Fuel reserve tripmeter 1. Odometer/tripmeters To reset a tripmeter, select it by pushing the “SE- LECT” button until “F Trip”, “Trip-A” or “Trip-B” is displayed. While “F Trip”, “Trip-A” or “Trip-B” is displayed, push the “RESET” button for at least one second.
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  FEATURES “OIL” must be reset after the oil change for the Self-diagnosis device next periodic oil change to be indicated at the correct time. The electrical circuit of the indicator can be checked according to the following procedure. 1. Set the engine stop switch to “ ”…

• Page 16: Important Information

  5. Keep all parts away from any source of fire. EAS20200 REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in function and appearance, but…

• Page 17: Bearings And Oil Seals

  IMPORTANT INFORMATION EAS20230 BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease. Oil bearings liberally when installing, if appropriate.

• Page 18: Checking The Connections

  CHECKING THE CONNECTIONS EAS20250 CHECKING THE CONNECTIONS Pocket tester 90890-03112 Check the leads, couplers, and connectors for Analog pocket tester stains, rust, moisture, etc. YU-03112-C 1. Disconnect: • Lead • Coupler • If there is no continuity, clean the terminals. •…

• Page 19: Special Tools

  SPECIAL TOOLS EAS20260 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Compression gauge 3-10 90890-03081 Engine compression tester YU-33223 Oil filter wrench 3-12, 6-6 90890-01469 YM-01469 66.8 Oil pressure gauge set 3-13 90890-03120 Oil pressure adapter B 3-13 90890-03124 Pressure gauge 3-13, 7-4 90890-03153 YU-03153 Steering nut wrench…
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  Fork seal driver weight 4-54, 4-55 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 4-54 90890-01374 Replacement 43 mm YM-A5142-3 Yamaha bond No. 1215 5-14, 5-44, 90890-85505 5-52, 5-69, (Three Bond No.1215®) 6-12 Valve spring compressor 5-19, 5-24 90890-04019 YM-04019…
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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Valve guide installer (ø4) 5-21 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 5-21 90890-04113 Valve guide reamer (4.0 mm) YM-04113 Piston pin puller set 5-27 90890-01304 Piston pin puller YU-01304 YU-01304 Sheave holder…
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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Sheave spring compressor 5-41, 5-44 90890-04134 YM-04134 Sheave fixed block 5-41, 5-44 90890-04135 Sheave fixed bracket YM-04135 Oil seal guide (ø41) 5-43 90890-01396 Sheave holder 5-50, 5-51, 90890-01701 5-52 Primary clutch holder YS-01880-A Flywheel puller 5-50…
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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Clutch spring compressor 5-57, 5-60 90890-01482 Universal clutch holder 5-57, 5-60 90890-04086 YM-91042 Plane bearing installer 5-73, 5-76 90890-04139 Radiator cap tester 90890-01325 Radiator pressure tester YU-24460-01 YU-24460-01 Radiator cap tester adapter 90890-01352 Radiator pressure tester adapter YU-33984…
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  SPECIAL TOOLS Reference Tool name/Tool No. Illustration pages Mechanical seal installer 6-12 90890-04078 Water pump seal installer YM-33221-A Middle driven shaft bearing driver 6-12 90890-04058 Bearing driver 40 mm YM-04058 Fuel pressure adapter 90890-03181 Ignition checker 8-72 90890-06754 Opama pet-4000 spark checker YM-34487 1-16…
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  SPECIAL TOOLS 1-17…

• Page 27: Specifications

  SPECIFICATIONS GENERAL SPECIFICATIONS ……………. 2-1 ENGINE SPECIFICATIONS …………….2-2 CHASSIS SPECIFICATIONS …………….2-10 ELECTRICAL SPECIFICATIONS …………..2-13 TIGHTENING TORQUES …………….2-16 GENERAL TIGHTENING TORQUE SPECIFICATIONS……2-16 ENGINE TIGHTENING TORQUES…………2-17 CHASSIS TIGHTENING TORQUES…………2-21 LUBRICATION POINTS AND LUBRICANT TYPES ……..2-24 ENGINE………………..2-24 CHASSIS………………..2-26 LUBRICATION SYSTEM DIAGRAMS …………

• Page 28: General Specifications

  GENERAL SPECIFICATIONS EAS20280 GENERAL SPECIFICATIONS Model Model 4B54 (USA) Dimensions Overall length 2195 mm (86.4 in) Overall width 775 mm (30.5 in) Overall height 1445 mm (56.9 in) Seat height 800 mm (31.5 in) Wheelbase 1580 mm (62.2 in) Ground clearance 125 mm (4.92 in) Minimum turning radius 2800 mm (110.2 in)

• Page 29: Engine Specifications

  ENGINE SPECIFICATIONS EAS20290 ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 499.0 cm³ Cylinder arrangement Forward-inclined parallel 2-cylinder Bore × stroke 66.0 × 73.0 mm (2.60 × 2.87 in) Compression ratio 11.00 :1 Standard compression pressure (at sea level) 1400 kPa/360 r/min (199.1 psi/360 r/min) (14.0 kgf/cm²/360 r/min) Minimum–maximum…

• Page 30
  ENGINE SPECIFICATIONS Pressure check location MAIN GALLERY Cooling system Radiator capacity (including all routes) 1.48 L (1.56 US qt) (1.30 Imp.qt) Coolant reservoir capacity (up to the maximum level mark) 0.25 L (0.26 US qt) (0.22 Imp.qt) Radiator cap opening pressure 107.9–137.3 kPa (15.6–19.9 psi) (1.08–1.37 kgf/cm²) Thermostat…
• Page 31
  ENGINE SPECIFICATIONS Limit 24.856 mm (0.9786 in) Camshaft runout limit 0.030 mm (0.0012 in) Timing chain Model/number of links SCR-0409 SV/132 Tensioning system Automatic Valve, valve seat, valve guide Valve clearance (cold) Intake 0.15–0.20 mm (0.0059–0.0079 in) Exhaust 0.25–0.30 mm (0.0098–0.0118 in) Valve dimensions Valve head diameter A (intake) 24.90–25.10 mm (0.9803–0.9882 in)
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  ENGINE SPECIFICATIONS Valve margin thickness D (exhaust) 0.60–0.80 mm (0.0236–0.0315 in) Valve stem diameter (intake) 3.975–3.990 mm (0.1565–0.1571 in) Limit 3.945 mm (0.1553 in) Valve stem diameter (exhaust) 3.960–3.975 mm (0.1559–0.1565 in) Limit 3.930 mm (0.1547 in) Valve guide inside diameter (intake) 4.000–4.012 mm (0.1575–0.1580 in) Limit 4.050 mm (0.1594 in)
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  ENGINE SPECIFICATIONS Winding direction (exhaust) Clockwise Valve lifter Valve lifter outside diameter (intake) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Valve lifter outside diameter (exhaust) 24.476–24.500 mm (0.9636–0.9646 in) Limit 24.451 mm (0.9626 in) Cylinder Bore 66.000–66.010 mm (2.5984–2.5988 in) Wear limit 66.100 mm (2.6024 in) Taper limit…
• Page 34
  ENGINE SPECIFICATIONS Dimensions (B × T) 0.80 × 2.50 mm (0.03 × 0.10 in) End gap (installed) 0.40–0.50 mm (0.0157–0.0197 in) Limit 0.75 mm (0.0295 in) Ring side clearance 0.020–0.055 mm (0.0008–0.0022 in) Limit 0.100 mm (0.0039 in) Oil ring Dimensions (B ×…
• Page 35
  ENGINE SPECIFICATIONS Plate quantity 4 pcs Warpage limit 0.10 mm (0.0039 in) Clutch plate 2 thickness 1.80–2.00 mm (0.071–0.079 in) Plate quantity 2 pcs Warpage limit 0.20 mm (0.0079 in) Clutch spring free length 25.80 mm (1.02 in) Minimum length 20.40 mm (0.80 in) Spring quantity 6 pcs…
• Page 36
  ENGINE SPECIFICATIONS Intake air pressure sensor output voltage 3.15–4.15 V Intake air temperature sensor resistance 2.21–2.69 kΩ at 20 °C (68 °F) Coolant temperature sensor resistance 2.32–2.59 kΩ at 20 °C (68 °F) 310–326 Ω at 80 °C (176 °F) Idling condition Engine idling speed 1100–1300 r/min…

• Page 37: Chassis Specifications

  CHASSIS SPECIFICATIONS EAS20300 CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00° Trail 92.0 mm (3.62 in) Front wheel Wheel type Cast wheel 15M/C × MT3.50 Rim size Rim material Aluminum Wheel travel 120.0 mm (4.72 in) Radial wheel runout limit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in)

• Page 38
  Inner tube outer diameter 43.0 mm (1.69 in) Inner tube bending limit 0.2 mm (0.01 in) Optional spring available Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) Level 87.0 mm (3.43 in) Rear suspension…
• Page 39
  CHASSIS SPECIFICATIONS Installed length 180.0 mm (7.09 in) Spring rate K1 225.60 N/mm (1288.18 lb/in) (23.00 kgf/mm) Spring rate K2 294.00 N/mm (1678.74 lb/in) (29.98 kgf/mm) Spring stroke K1 0.0–28.8 mm (0.00–1.13 in) Spring stroke K2 28.8–43.0 mm (1.13–1.69 in) Optional spring available Enclosed gas/air pressure (STD) 4900 kPa (696.9 psi) (49.0 kgf/cm²)

• Page 40: Electrical Specifications

  ELECTRICAL SPECIFICATIONS EAS20310 ELECTRICAL SPECIFICATIONS Voltage System voltage 12 V Ignition system Ignition system Transistorized coil ignition (digital) Advancer type Digital Ignition timing (B.T.D.C.) 10.0°/1200 r/min Engine control unit Model/manufacturer TBDF81/DENSO Ignition coil Model/manufacturer JO313/DENSO Minimum ignition spark gap 6.0 mm (0.24 in) 1.87–2.53 Ω…

• Page 41
  ELECTRICAL SPECIFICATIONS Meter lighting Indicator light LED × 2 Turn signal indicator light High beam indicator light Engine trouble warning light Electric starting system System type Constant mesh Starter motor Model/manufacturer SM-18/MITSUBA Power output 0.70 kW 0.0100–0.0200 Ω at 20 °C (68 °F) Armature coil resistance Brush overall length 12.0 mm (0.47 in)
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  ELECTRICAL SPECIFICATIONS Fuel injection system relay Model/manufacturer 5JJ/MATSUSHITA Fuses Main fuse 30.0 A Headlight fuse 20.0 A Taillight fuse 10.0 A Signaling system fuse 15.0 A Ignition fuse 10.0 A Radiator fan fuse 15.0 A Fuel injection system fuse 10.0 A Backup fuse 10.0 A Spare fuse…

• Page 43: Tightening Torques

  TIGHTENING TORQUES EAS20320 TIGHTENING TORQUES EAS20330 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.

• Page 44: Engine Tightening Torques

  TIGHTENING TORQUES EAS20340 ENGINE TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Camshaft cap 10 Nm (1.0 m·kg, 7.2 ft·lb) Engine oil check bolt 20 Nm (2.0 m·kg, 14 ft·lb) Exhaust pipe stud bolt 15 Nm (1.5 m·kg, 11 ft·lb) Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) Cylinder head nut…

• Page 45
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Muffler nut 31 Nm (3.1 m·kg, 22 ft·lb) Muffler end protector bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Exhaust pipe protector bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler end protector cover bolt 8 Nm (0.8 m·kg, 5.8 ft·lb) Muffler protector (side) bolt 8 Nm (0.8 m·kg, 5.8 ft·lb)
• Page 46
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size BEL-RAY Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) assem- bly lube® Crankshaft right end bearing re- 11 Nm (1.1 m·kg, 8.0 ft·lb) tainer screw Secondary shaft bearing retainer 12 Nm (1.2 m·kg, 8.7 ft·lb) bolt Stator coil bolt 10 Nm (1.0 m·kg, 7.2 ft·lb)
• Page 47
  TIGHTENING TORQUES Cylinder head tightening sequence: 2-20…

• Page 48: Chassis Tightening Torques

  TIGHTENING TORQUES EAS20350 CHASSIS TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Engine mounting bolt (front upper 88 Nm (8.8 m·kg, 64 ft·lb) side) Engine mounting bolt (front right 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting bolt (front left 45 Nm (4.5 m·kg, 32 ft·lb) lower side) Engine mounting nut (rear side)

• Page 49
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Pivot shaft 7 Nm (0.7 m·kg, 5.1 ft·lb) Pivot shaft nut 100 Nm (10.0 m·kg, 72 ft·lb) Swingarm bolt 40 Nm (4.0 m·kg, 29 ft·lb) Swingarm damper nut 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear shock absorber assembly 53 Nm (5.3 m·kg, 38 ft·lb) rear nut…
• Page 50
  TIGHTENING TORQUES Thread Item Q’ty Tightening torque Remarks size Rear brake disc bolt 18 Nm (1.8 m·kg, 13 ft·lb) Rear wheel drive hub bolt 69 Nm (6.9 m·kg, 50 ft·lb) Front brake hose joint bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Front brake hose holder bolt 7 Nm (0.7 m·kg, 5.1 ft·lb) Rear brake hose holder bolt…

• Page 51: Lubrication Points And Lubricant Types

  LUBRICATION POINTS AND LUBRICANT TYPES EAS20360 LUBRICATION POINTS AND LUBRICANT TYPES EAS20370 ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Cylinder head nut seats and washers Camshaft cap bolt seats Big end bearings and crank pins Connecting rod big end contact surfaces (to crank) Balancer big end bearings and crank pin Balancer connecting rod big end contact surface (to crank) Pistons, ring grooves, and piston rings…

• Page 52
  BEL-RAY assembly Secondary sheave nut seats lube® Outer V-belt case crankshaft right end point Pivot shaft taper roller bearing Yamaha bond Cylinder head cover inner gaskets mating surface No.1215 (Three bond No.1215®) Yamaha bond Timing chain guide (upper side) mating surface No.1215 (Three bond…

• Page 53: Chassis

  LUBRICATION POINTS AND LUBRICANT TYPES EAS20380 CHASSIS Lubrication point Lubricant Steering bearings (upper and lower) Upper bearing cover seal lip and lower bearing dust seal lip Steering bearing races (inner and outer) Tube guide (throttle grip) inner surface and throttle cables Rear brake lock cable end (lever end) Brake lever pivoting point and metal-to-metal moving parts Drive axle spline…

• Page 54: Lubrication System Diagrams

  LUBRICATION SYSTEM DIAGRAMS EAS4B51021 LUBRICATION SYSTEM DIAGRAMS EAS20410 LUBRICATION DIAGRAMS 2-27…

• Page 55
  LUBRICATION SYSTEM DIAGRAMS 1. Oil delivery pipe 2. Oil pump 3. Oil cooler 4. Oil filter cartridge 5. Oil pipe 6. Oil strainer 2-28…
• Page 56
  LUBRICATION SYSTEM DIAGRAMS 2-29…
• Page 57
  LUBRICATION SYSTEM DIAGRAMS 1. Secondary shaft 2. Drive axle 3. Clutch 4. Crankshaft 2-30…

• Page 58: Cooling System Diagrams

  COOLING SYSTEM DIAGRAMS EAS20420 COOLING SYSTEM DIAGRAMS 2-31…

• Page 59
  COOLING SYSTEM DIAGRAMS 1. Radiator cap 2. Radiator filler hose 3. Radiator inlet hose 4. Coolant reservoir 5. Coolant pipe 6. Thermostat outlet hose 7. Oil cooler outlet hose 8. Thermostat 9. Oil cooler 10. Coolant hose 11. Water pump inlet pipe 12.
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  COOLING SYSTEM DIAGRAMS 2-33…
• Page 61
  COOLING SYSTEM DIAGRAMS 1. Thermostat outlet hose 2. Cooling system air bleed hose 3. Radiator cap 4. Radiator filler pipe 5. Radiator filler hose 6. Coolant reservoir hose 7. Radiator 8. Radiator inlet hose 9. Coolant reservoir 10. Coolant reservoir breather hose 11.

• Page 62: Cable Routing

  CABLE ROUTING EAS20430 CABLE ROUTING A B C 2-35…

• Page 63
  CABLE ROUTING 1. Rear brake hose 2. Left handlebar switch lead 3. Right handlebar switch lead 4. Front brake hose 5. Throttle cable (decelerator cable) 6. Throttle cable (accelerator cable) 7. Rear brake lock cable 8. Front brake light switch connectors A.
• Page 64
  CABLE ROUTING 2-37…
• Page 65
  CABLE ROUTING 1. Front brake pipe 2. Wire harness (to horn) 3. Front brake hose (to left front brake caliper) 4. Front brake hose (to right front brake caliper) 5. Horn 6. Speed sensor lead 7. Speed sensor A. Fasten the wire harness (to horn) and front brake pipe with plastic locking ties, making sure to –…
• Page 66
  CABLE ROUTING 26 27 2-39…
• Page 67
  CABLE ROUTING 1. Left handlebar switch lead P. Route the starter motor lead and generator lead to the outside of the wire harness. 2. Right handlebar switch lead Q. To meter assembly 3. Rectifier/regulator R. Route the wire harness (to starter relay) behind 4.
• Page 68
  CABLE ROUTING 22 23 2-41…
• Page 69
  CABLE ROUTING 1. Positive battery lead L. Fasten the main switch lead with the holder, making sure that the plastic locking tie is 2. Fuse box positioned to the inside of the holder. Face the 3. Negative battery lead catch of the holder forward. 4.
• Page 70
  CABLE ROUTING 2-43…
• Page 71
  CABLE ROUTING 1. Intake air temperature sensor coupler P. Pass the wire harness (to storage box light switch) between the rear frame and the tail/brake light 2. Cylinder head breather hose assembly. 3. Fast idle plunger intake hose Q. Pass the plastic band through the holes in the 4.
• Page 72
  CABLE ROUTING 2-45…
• Page 73
  CABLE ROUTING 1. Rear brake hose 2. Rear brake pipe 3. Rear brake lock cable 4. Ribs (bottom of storage box) A. Install the rear brake hose holder to the front cowling stay, making sure to fit the projection on the holder into the hole in the stay.
• Page 74
  CABLE ROUTING H I J 2-47…
• Page 75
  CABLE ROUTING 1. Fast idle plunger intake hose 2. Cylinder head breather hose 3. Intake air pressure sensor hose 4. Fuel hose 5. Fast idle plunger inlet coolant hose 6. Fast idle plunger outlet coolant hose 7. Fuel injector #2 8.
• Page 76
  CABLE ROUTING 2-49…
• Page 77
  CABLE ROUTING 1. Rollover valve U. Route the canister purge hose (3-way joint to canister) over the frame cross member. 2. Fuel tank breather hose (fuel tank to rollover valve) 3. Fuel tank breather hose (rollover valve to canister) 4. Canister purge hose (throttle body #2 to 3-way joint) 5.
• Page 78
  CABLE ROUTING 2-51…

• Page 79: Periodic Checks And Adjustments

  PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE …………….3-1 INTRODUCTION ………………3-1 PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ………………..3-1 GENERAL MAINTENANCE AND LUBRICATION CHART …….3-1 ENGINE ………………….3-4 ADJUSTING THE VALVE CLEARANCE ……….3-4 SYNCHRONIZING THE THROTTLE BODY ……….3-7 ADJUSTING THE ENGINE IDLING SPEED ……….3-8 ADJUSTING THE THROTTLE CABLE FREE PLAY ……..3-9 CHECKING THE SPARK PLUGS ………….

• Page 80
  ELECTRICAL SYSTEM…………….. 3-30 CHECKING AND CHARGING THE BATTERY……..3-30 CHECKING THE FUSES …………….3-30 REPLACING THE HEADLIGHT BULBS ……….3-30 ADJUSTING THE HEADLIGHT BEAMS……….3-30…

• Page 82: Periodic Maintenance

  • Check control system for √ sion control sys- damage. • Replace if necessary. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. EAU32185 GENERAL MAINTENANCE AND LUBRICATION CHART INITIAL ODOMETER READINGS…

• Page 83
  • Adjust headlight beam. * Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service. From 24000 mi (37000 km) or 36 months, repeat the maintenance intervals starting from 8000 mi…
• Page 84
  PERIODIC MAINTENANCE EAU38260 • The air filter and V-belt filter need more frequent service if you are riding in unusually wet or dusty areas. • Hydraulic brake service • After disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and fill the reservoirs as required.

• Page 85: Engine

  ENGINE 6. Measure: EAS20471 ENGINE • Valve clearance Out of specification → Adjust. EAS20490 ADJUSTING THE VALVE CLEARANCE Valve clearance (cold) The following procedure applies to all of the Intake valves. 0.15–0.20 mm (0.0059–0.0079 in) Exhaust • Valve clearance adjustment should be made 0.25–0.30 mm (0.0098–0.0118 in) on a cold engine, at room temperature.

• Page 86
  ENGINE 0˚ 360˚ 720˚ A. Degrees that the crankshaft is turned c. Measure the valve clearance with a thickness clockwise gauge “1”. B. Cylinder C. Combustion cycle Cylinder #2 360° L LLL L LLL L LLL L LLL L LLL 7.
• Page 87
  ENGINE Last digit Rounded value 3, 4, 5, 6 7, 8, 9 Refer to the following table for the available valve pads. Valve pad range Nos. 120–240 1.20–2.40 mm b. Calculate the difference between the speci- Valve pad thickness (0.0472–0.0945 in) fied valve clearance and the measured valve clearance.

• Page 88: Synchronizing The Throttle Body

  ENGINE • Turn the crankshaft clockwise several full turns Vacuum gauge to seat the parts. 90890-03094 h. Measure the valve clearance again. Carburetor synchronizer i. If the valve clearance is still out of specifica- YU-44456 Digital tachometer tion, repeat all of the valve clearance adjust- 90890-06760 ment steps until the specified clearance is YU-39951-B…

• Page 89: Adjusting The Engine Idling Speed

  ENGINE 3. Install: ECA14900 NOTICE • Digital tachometer Do not use the throttle valve adjusting (onto the spark plug lead of cylinder #1) screws to adjust the throttle body syncroni- Digital tachometer zation. 90890-06760 YU-39951-B Carburetor angle driver 90890-03158 4. Check: •…

• Page 90: Adjusting The Throttle Cable Free Play

  ENGINE EAS20630 EAS20680 ADJUSTING THE THROTTLE CABLE FREE CHECKING THE SPARK PLUGS PLAY The following procedure applies to all of the spark plugs. 1. Remove: Prior to adjusting the throttle cable free play, the • Bottom cowling engine idling speed and throttle body synchroni- Refer to “GENERAL CHASSIS”…

• Page 91: Measuring The Compression Pressure

  ENGINE Spark plug 13 Nm (1.3 m·kg, 9.4 ft·lb) Before installing the spark plug, clean the spark plug and gasket surface. 9. Connect: • Spark plug 10.Remove: • Bottom cowling 7. Measure: Refer to “GENERAL CHASSIS” on page 4-1. • Compression pressure Out of specification →…

• Page 92: Checking The Engine Oil Level

  ENGINE Compression pressure (with oil applied into Type the cylinder) YAMALUBE 4 (10W-40) or SAE Reading Diagnosis 10W-40, YAMALUBE 4 (20W-50) or SAE 20W-50 Higher than without Piston ring(s) wear or Recommended engine oil grade damage → Repair. API service SG type or higher, Piston, valves, cylin- JASO standard MA der head gasket or…

• Page 93: Changing The Engine Oil

  ENGINE b. Lubricate the O-ring “3” of the new oil filter EAS20780 CHANGING THE ENGINE OIL cartridge with a thin coat of engine oil. 1. Start the engine, warm it up for several min- ECA13390 utes, and then turn it off. NOTICE 2.

• Page 94: Measuring The Engine Oil Pressure

  ENGINE 10.Start the engine, warm it up for several min- 2. Start the engine, warm it up for several min- utes, and then turn it off. utes, and then turn it off. 11.Check: ECA13410 NOTICE • Engine When the engine is cold, the engine oil will (for engine oil leaks) have a higher viscosity, causing the engine 12.Check:…

• Page 95: Replacing The Air Filter Element

  ENGINE Oil pressure (hot) 150.0 kPa/1200 r/min (21.8 psi/1200 r/min) (1.50 kgf/cm²/1200 r/min) Oil temperature 70.0 °C (158.00 °F) Out of specification → Adjust. Engine oil pressure Possible causes 4. Install: • Faulty oil pump • Clogged oil filter • Air filter case cover Below specification •…

• Page 96: Cleaning The V-Belt Case Air Filter Element

  ENGINE EAS20980 CLEANING THE V-BELT CASE AIR FILTER ELEMENT 1. Remove: • Footrest boards Refer to “GENERAL CHASSIS” on page 4-1. 2. Remove: • V-belt case air filter element (left) “1” 3. Remove: • V-belt case air filter case cover “1” •…

• Page 97: Checking The Fuel Line

  ENGINE 2. Check: 2. Check: • Throttle body joints “1” • Cylinder head breather hose “1” Cracks/damage → Replace the intake mani- Cracks/damage → Replace. Loose connection → Connect properly. folds. ECA14920 NOTICE Make sure the cylinder head breather hose is routed correctly.

• Page 98: Checking The Canister

  ENGINE Below the minimum level mark → Add the 4. Install: • Bottom cowling recommended coolant to the proper level. Refer to “GENERAL CHASSIS” on page 4-1. EAS21090 CHECKING THE CANISTER 1. Remove: • Storage box Refer to “GENERAL CHASSIS” on page 4-1. •…

• Page 99: Changing The Coolant

  ENGINE 3. Install: • Footrest boards • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. EAS21130 CHANGING THE COOLANT 1. Remove: • Bottom cowling Refer to “GENERAL CHASSIS” on page 4-1. 2. Disconnect: • Coolant reservoir hose “1” 3. Drain: •…

• Page 100
  ENGINE be blown out, which could cause serious in- Recommended antifreeze jury. When the engine has cooled, open the High-quality ethylene glycol an- radiator cap as follows: tifreeze containing corrosion in- Place a thick rag or a towel over the radiator hibitors for aluminum engines cap and slowly turn the radiator cap counter- Mixing ratio…
• Page 101
  ENGINE 12.Install: • Coolant reservoir cap 13.Start the engine, warm it up for several min- utes, and then stop it. 14.Check: • Coolant level Refer to “CHECKING THE COOLANT LEV- EL” on page 3-17. Before checking the coolant level, wait a few minutes until the coolant has settled.

• Page 102: Chassis

  CHASSIS EAS21140 M MMM M MMM M MMM M MMM M MMM CHASSIS a. While pushing the brake lever forward, turn the adjusting dial “1” until the brake lever is in EAS21160 the desired position. ADJUSTING THE FRONT DISC BRAKE 1.

• Page 103: Checking The Front Brake Pads

  CHASSIS 1. Operate the brake. 2. Check: • Front brake pad Wear indicator groove “a” has almost disap- peared → Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-18. EAS21260 CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads.

• Page 104: Checking The Rear Brake Hose

  CHASSIS 2. Check: Rear brake lock cable length • Brake hose holders 45–47 mm (1.77–1.85 in) Loose → Tighten the holder bolt. 3. Hold the vehicle upright and apply the brake 2. Adjust: several times. • Rear brake lock cable length “a” 4.

• Page 105: Checking The Chain Drive Oil Level

  CHASSIS caution could allow air to enter the hydraulic i. Repeat steps (e) to (h) until all of the air bub- brake system, considerably lengthening the bles have disappeared from the brake fluid in bleeding procedure. the plastic hose. • If bleeding is difficult, it may be necessary to let j.

• Page 106: Changing The Chain Drive Oil

  CHASSIS 3. Check: • Chain drive oil level Wipe the dipstick clean, insert it into the oil fill- er hole (without screw it in), and then remove it to check the oil level. The chain drive oil level should be between the minimum level mark “a”…

• Page 107
  CHASSIS 2. Check: EWA13140 WARNING • Steering head Do not overtighten the lower ring nut. Grasp the bottom of the front fork legs and gently rock the front fork. Binding/looseness → Adjust the steering Lower ring nut (final tightening torque) head.

• Page 108: Checking The Front Fork

  CHASSIS 2. Check: • Inner tube Damage/scratches → Replace. • Oil seal Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: • Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds d.

• Page 109
  No guarantee con- cerning handling characteristics can be giv- en if a tire combination other than one approved by Yamaha is used on this vehicle. 1. Tire tread depth Front tire 2. Side wall Size 3.

• Page 110: Checking The Wheels

  CHASSIS 1. Check: EWA13210 WARNING • Outer cable Damage → Replace. New tires have a relatively low grip on the road surface until they have been slightly 2. Check: worn. Therefore, approximately 100 km • Cable operation Rough movement → Lubricate. should be traveled at normal speed before any high-speed riding is done.

• Page 111
  ELECTRICAL SYSTEM 6. Install: EAS21750 ELECTRICAL SYSTEM • Headlight bulb Secure the new headlight bulb with the head- EAS21760 CHECKING AND CHARGING THE BATTERY light bulb holder. Refer to “ELECTRICAL COMPONENTS” on ECA13690 NOTICE page 8-57. Avoid touching the glass part of the head- EAS21770 light bulb to keep it free from oil, otherwise CHECKING THE FUSES…
• Page 112
  ELECTRICAL SYSTEM Direction “a” Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. Right headlight Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. L LLL L LLL L LLL L LLL L LLL…
• Page 113
  CHASSIS GENERAL CHASSIS………………4-1 REMOVING THE FUEL HOSE …………..4-7 INSTALLING THE FUEL HOSE …………..4-7 FRONT WHEEL………………..4-8 REMOVING THE FRONT WHEEL…………4-11 DISASSEMBLING THE FRONT WHEEL……….4-11 CHECKING THE FRONT WHEEL …………4-11 ASSEMBLING THE FRONT WHEEL…………4-12 ADJUSTING THE FRONT WHEEL STATIC BALANCE ……4-12 INSTALLING THE FRONT WHEEL (DISC) ……….4-13 REAR WHEEL ………………..4-15 REMOVING THE REAR WHEEL (DISC) ……….
• Page 114
  HANDLEBAR ………………..4-44 REMOVING THE HANDLEBAR…………..4-46 CHECKING THE HANDLEBAR …………..4-46 INSTALLING THE HANDLEBAR …………4-46 FRONT FORK………………..4-49 REMOVING THE FRONT FORK LEGS……….4-52 DISASSEMBLING THE FRONT FORK LEGS ……..4-52 CHECKING THE FRONT FORK LEGS ……….4-53 ASSEMBLING THE FRONT FORK LEGS ……….4-53 INSTALLING THE FRONT FORK LEGS ……….
• Page 116
  GENERAL CHASSIS EAS21830 GENERAL CHASSIS Removing the battery and windshield 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Rear view mirror…
• Page 117
  GENERAL CHASSIS Removing the bottom cowling 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Footrest board mat Footrest board cover Side panel Left side cowling Bottom panel Right side cowling Wire harness (to ignition coil) Unhook.
• Page 118
  GENERAL CHASSIS Removing the footrest boards 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Front lower outer panel Front lower inner panel Center panel Fuel tank overflow hose Unhook. Rear brake pipe Unhook. Left footrest board Fuel tank breather hose Unhook.
• Page 119
  GENERAL CHASSIS Removing the front cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Upper handlebar cover Windshield bracket lower cover Meter ring Meter assembly cover Meter assembly coupler Disconnect. Meter assembly Storage compartment Headlight sub-wire harness coupler Disconnect.
• Page 120
  GENERAL CHASSIS Removing the rear cowling assembly 7 Nm (0.7 m kg, 5.1 ft • • 16 Nm (1.6 m kg, 11 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

• Page 121: General Chassis

  GENERAL CHASSIS Removing the storage box 10 Nm (1.0 m kg, 7.2 ft 16 Nm (1.6 m kg, 11 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 10 Nm (1.0 m kg, 7.2 ft •…

• Page 122: Removing The Fuel Hose

  GENERAL CHASSIS EAS4B51010 ECA4B51021 REMOVING THE FUEL HOSE NOTICE 1. Remove: When installing the fuel hose, make sure that • Fuel hose connector cover “1” it is securely connected, and that the fuel 2. Disconnect: hose connector cover is in the correct posi- •…

• Page 123: Front Wheel

  FRONT WHEEL EAS21870 FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •…

• Page 124
  FRONT WHEEL Removing the front wheel and brake discs 7 Nm (0.7 m kg, 5.1 ft 40 Nm (4.0 m kg, 29 ft 7 Nm (0.7 m kg, 5.1 ft • • • • • • 72 Nm (7.2 m kg, 52 ft •…
• Page 125
  FRONT WHEEL Disassembling the front wheel Order Job/Parts to remove Q’ty Remarks Oil seal Wheel bearing Collar For assembly, reverse the disassembly pro- cedure. 4-10…

• Page 126: Removing The Front Wheel

  FRONT WHEEL EAS21900 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Front brake calipers Do not apply the brake lever when removing the L LLL L LLL L LLL…

• Page 127: Assembling The Front Wheel

  FRONT WHEEL 4. Check: L LLL L LLL L LLL L LLL L LLL • Wheel bearings EAS21970 Front wheel turns roughly or is loose → Re- ADJUSTING THE FRONT WHEEL STATIC place the wheel bearings. BALANCE • Oil seal Damage/wear →…

• Page 128: Installing The Front Wheel (Disc)

  FRONT WHEEL M MMM M MMM M MMM M MMM M MMM a. Turn the front wheel and make sure it stays at each position shown. f. Repeat steps (c) through (e) several times until all the marks come to rest at the same spot.

• Page 129
  FRONT WHEEL Be sure to fit the two projections on the speed sensor in between the projections on the wheel hub. 5. Install: • Front wheel Make sure the slot “a” in the speed sensor fits over the stopper “b” on the outer tube. 6.

• Page 130: Rear Wheel

  REAR WHEEL EAS22020 REAR WHEEL Removing the rear wheel and brake disc 40 Nm (4.0 m kg, 29 ft • • 17 Nm (1.7 m kg, 12 ft • • 105 Nm (10.5 m kg, 75 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

• Page 131
  REAR WHEEL Disassembling the rear wheel 69 Nm (6.9 m • kg, 50 ft • Ib) Order Job/Parts to remove Q’ty Remarks Rear wheel drive hub O-ring Oil seal Wheel bearing For assembly, reverse the disassembly pro- cedure. 4-16…

• Page 132: Removing The Rear Wheel (Disc)

  REAR WHEEL EAS22040 REMOVING THE REAR WHEEL (DISC) 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. Place the vehicle on the centerstand so that the rear wheel is elevated.

• Page 133: Front Brake

  FRONT BRAKE EAS22210 FRONT BRAKE Removing the front brake pads 7 Nm (0.7 m kg, 5.1 ft • • 5 Nm (0.5 m kg, 3.6 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of…

• Page 134
  FRONT BRAKE Removing the front brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
• Page 135
  FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-20…
• Page 136
  FRONT BRAKE Removing the front brake calipers 7 Nm (0.7 m kg, 5.1 ft • • 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers.
• Page 137
  FRONT BRAKE Disassembling the front brake calipers 5 Nm (0.5 m kg, 3.6 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front brake calipers. Brake pad clip Brake pad pin Brake pad spring Front brake pad Brake caliper piston Brake caliper piston dust seal…

• Page 138: Introduction

  FRONT BRAKE e. Measure the deflection 1.5 mm (0.06 in) be- EAS22220 INTRODUCTION low the edge of the brake disc. EWA4B51008 WARNING Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: • Never disassemble brake components un- less absolutely necessary.

• Page 139: Replacing The Front Brake Pads

  FRONT BRAKE d. Measure the brake disc deflection. 2. Install: e. If out of specification, repeat the adjustment • Front brake pads steps until the brake disc deflection is within • Brake pad spring specification. f. If the brake disc deflection cannot be brought Always install new brake pads and a new brake within specification, replace the brake disc.

• Page 140: Removing The Front Brake Calipers

  FRONT BRAKE Put the end of the brake hose into a container and pump out the brake fluid carefully. e. Install the brake pad pin and brake pad clips. L LLL L LLL L LLL L LLL L LLL 3. Install: •…

• Page 141: Checking The Front Brake Calipers

  FRONT BRAKE EWA4B51006 WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and piston seals. EAS22410 ASSEMBLING THE FRONT BRAKE CALIPERS EWA4B51007 WARNING • Before installation, all internal brake com- b. Remove the brake caliper piston dust seals ponents should be cleaned and lubricated and piston seals.

• Page 142: Removing The Front Brake Master Cylinder

  FRONT BRAKE • When refilling, be careful that water does ECA14170 NOTICE not enter the brake fluid reservoir. Water When installing the brake hose onto the will significantly lower the boiling point of brake caliper “1”, make sure the brake pipe the brake fluid and could cause vapor lock.

• Page 143: Checking The Front Brake Master Cylinder

  FRONT BRAKE • Install the brake master cylinder holder with the “UP” mark “a” facing up. • Align the end of the brake master cylinder hold- er with the punch mark “b” on the handlebar. • First, tighten the upper bolt, then the lower bolt. EAS22500 CHECKING THE FRONT BRAKE MASTER CYLINDER…

• Page 144
  FRONT BRAKE 3. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- mended brake fluid) Recommended fluid DOT 4 EWA13540 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance.

• Page 145: Rear Brake

  REAR BRAKE EAS22550 REAR BRAKE Removing the rear brake pads 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Rear brake caliper retaining bolt (rear) Rear brake caliper bolt Rear brake caliper Rear brake pad…

• Page 146
  REAR BRAKE Removing the rear brake master cylinder 10 Nm (1.0 m kg, 7.2 ft • • 6 Nm ( 0.6 m Ib ) kg, 4.3 ft • • 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…
• Page 147
  REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit Brake master cylinder body For assembly, reverse the disassembly pro- cedure. 4-32…
• Page 148
  REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •…
• Page 149
  REAR BRAKE Removing the rear brake caliper 30 Nm (3.0 m kg, 22 ft • • 40 Nm (4.0 m kg, 29 ft • • 31 Nm (3.1 m kg, 22 ft • • 22 Nm (2.2 m kg, 16 ft •…
• Page 150
  REAR BRAKE Disassembling the rear brake caliper 6 Nm (0.6 m kg, 4.3 ft • • Order Job/Parts to remove Q’ty Remarks Brake caliper piston Brake caliper piston dust seal Brake caliper piston seal Bleed screw Brake caliper body For assembly, reverse the disassembly pro- cedure.

• Page 151: Introduction

  REAR BRAKE EAS22560 INTRODUCTION Brake disc thickness limit EWA4B51008 4.5 mm (0.18 in) WARNING Disc brake components rarely require disas- 5. Adjust: sembly. Therefore, always follow these pre- • Brake disc deflection ventive measures: Refer to “CHECKING THE FRONT BRAKE •…

• Page 152
  REAR BRAKE 3. Measure: • Brake pad wear limit “a” Out of specification → Replace the brake pads as a set. Brake pad lining thickness (in- ner) 8.0 mm (0.31 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (out- M MMM M MMM M MMM…

• Page 153: Removing The Rear Brake Caliper

  REAR BRAKE 7. Install: • Rear brake caliper bolts Rear brake caliper bolt 40 Nm (4.0 m·kg, 29 ft·lb) 8. Check: • Brake fluid level Below the minimum level mark “a” → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL”…

• Page 154: Disassembling The Rear Brake Caliper

  REAR BRAKE Recommended brake component replace- ment schedule Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1. Check: • Brake caliper piston “1” Rust/scratches/wear → Replace the brake caliper piston. EAS22630 DISASSEMBLING THE REAR BRAKE •…

• Page 155: Assembling The Rear Brake Caliper

  REAR BRAKE • Rear brake caliper “1” EAS22660 ASSEMBLING THE REAR BRAKE CALIPER (temporarily) EWA4B51010 WARNING • Brake hose gaskets • Rear brake hose “2” • Before installation, all internal brake com- • Brake hose union bolt “3” ponents should be cleaned and lubricated with clean or new brake fluid.

• Page 156: Removing The Rear Brake Master Cylinder

  REAR BRAKE 4. Fill: Refer to “BLEEDING THE HYDRAULIC • Brake master cylinder reservoir BRAKE SYSTEM” on page 3-23. (with the specified amount of the recom- 8. Install: mended brake fluid) • Rear brake lock cable holder • Spring Recommended fluid •…

• Page 157: Assembling The Rear Brake Master Cylinder

  REAR BRAKE 2. Check: • Rear brake hose “2” • Brake master cylinder kit • Brake hose union bolt “3” Damage/scratches/wear → Replace. Brake hose union bolt 3. Check: 30 Nm (3.0 m·kg, 22 ft·lb) • Brake master cylinder reservoir •…

• Page 158
  REAR BRAKE • When refilling, be careful that water does not enter the brake master cylinder reser- voir. Water will significantly lower the boil- ing point of the brake fluid and could cause vapor lock. ECA13540 NOTICE Brake fluid may damage painted surfaces and plastic parts.

• Page 159: Handlebar

  HANDLEBAR EAS22840 HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft •…

• Page 160
  HANDLEBAR Removing the handlebar 26 Nm (2.6 m kg, 19 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 26 Nm (2.6 m kg, 19 ft • • 40 Nm (4.0 m kg, 29 ft •…

• Page 161: Removing The Handlebar

  HANDLEBAR EAS4B51014 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Handlebar grip “1” 3. Install: Blow compressed air between the left end of the •…

• Page 162
  HANDLEBAR 6. Connect: 9. Install: • Rear brake lock cable • Throttle grip “1” (to rear brake lock lever) • Throttle cables “2” Lubricate the inside of the rear brake lock cable Lubricate the inside of the throttle grip with a thin and rear brake lock lever with a thin coat of lithi- coat of lithium-soap-based grease and install it um-soap-based grease.
• Page 163
  HANDLEBAR Throttle cable free play 3.0–5.0 mm (0.12–0.20 in) 12.Adjust: • Rear brake lock cable length Refer to “ADJUSTING THE REAR BRAKE LOCK CABLE” on page 3-23. 4-48…

• Page 164: Front Fork

  FRONT FORK EAS22950 FRONT FORK Removing the front fork legs 23 Nm (2.3 m kg, 17 ft • • 30 Nm (3.0 m kg, 22 ft • • 26 Nm (2.6 m kg, 19 ft • • 7 Nm (0.7 m kg, 5.1 ft •…

• Page 165
  FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks The following procedure applies to both of the front fork legs. Cap bolt O-ring Spacer Fork spring seat Fork spring Dust seal Oil seal clip…
• Page 166
  FRONT FORK Disassembling the front fork legs 30 Nm (3.0 m kg, 22 ft • • Order Job/Parts to remove Q’ty Remarks Oil flow stopper Outer tube For assembly, reverse the disassembly pro- cedure. 4-51…

• Page 167: Removing The Front Fork Legs

  FRONT FORK EAS22960 EAS22980 REMOVING THE FRONT FORK LEGS DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the The following procedure applies to both of the front fork legs. front fork legs. 1. Stand the vehicle on a level surface. 1.

• Page 168: Checking The Front Fork Legs

  FRONT FORK • Outer tube Damper rod holder Bends/damage/scratches → Replace. 90890-01460 EWA13650 T-handle WARNING 90890-01326 Do not attempt to straighten a bent inner T-handle 3/8″ drive 60 cm long tube as this may dangerously weaken it. YM-01326 2. Measure: •…

• Page 169
  3. Lubricate: (with the fork seal driver weight “3” and fork • Inner tube’s outer surface “2” seal driver attachment “4”) Recommended oil Fork seal driver weight Yamaha fork oil 10WT 90890-01367 Replacement hammer YM-A9409-7 Fork seal driver attachment (ø43) 90890-01374…
• Page 170
  10.Fill: • Front fork leg (with the specified amount of the recom- mended fork oil) Recommended oil Yamaha fork oil 10WT Quantity 517.0 cm³ (17.48 US oz) (18.23 Imp.oz) ECA14230 NOTICE • Be sure to use the recommended fork oil.

• Page 171: Installing The Front Fork Legs

  FRONT FORK 11.After filling the front fork leg, slowly stroke the • Temporarily tighten the cap bolt. inner tube “1” up and down (at least ten times) to distribute the fork oil. EAS23050 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the Be sure to stroke the inner tube slowly because front fork legs.

• Page 172
  FRONT FORK 4-57…

• Page 173: Steering Head

  STEERING HEAD EAS23090 STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

• Page 174
  STEERING HEAD Removing the lower bracket 115 Nm (11.5 m kg, 85 ft • • 1st 52 Nm (5.2 m kg, 37 ft • • final 14 Nm (1.4 m kg, 10 ft • • Order Job/Parts to remove Q’ty Remarks Dust seal Lower bearing inner race…

• Page 175: Removing The Lower Bracket

  STEERING HEAD EAS23110 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Upper ring nut • Rubber washer •…

• Page 176: Installing The Steering Head

  STEERING HEAD 4. Check: • Upper bracket • Lower bracket (along with the steering stem) Bends/cracks/damage → Replace. EAS23140 INSTALLING THE STEERING HEAD 1. Lubricate: • Upper bearing • Lower bearing • Bearing races Recommended lubricant Lithium-soap-based grease 2. Install: •…

• Page 177: Rear Shock Absorber Assembly

  REAR SHOCK ABSORBER ASSEMBLY EAS23160 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 53 Nm (5.3 m kg, 38 ft • • 68 Nm (6.8 m kg, 49 ft • • Order Job/Parts to remove Q’ty Remarks Exhaust assembly Refer to “ENGINE REMOVAL”…

• Page 178: Handling The Rear Shock Absorber

  REAR SHOCK ABSORBER ASSEMBLY EAS23180 HANDLING THE REAR SHOCK ABSORBER Place the vehicle on the centerstand so that the EWA13740 WARNING rear wheel is elevated. This rear shock absorber contains highly 2. Remove: compressed nitrogen gas. Before handling • Rear shock absorber assembly bolts “1” the rear shock absorber, read and make sure you understand the following information.

• Page 179
  REAR SHOCK ABSORBER ASSEMBLY • Lubricate the rear shock absorber assembly front bolt seats with lithium-soap-based grease. 3. Tighten: • Rear shock absorber assembly rear nut Rear shock absorber assembly rear nut 53 Nm (5.3 m·kg, 38 ft·lb) 4. Tighten: •…

• Page 180: Swingarm And Transmission Chain Drive

  SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51015 SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft •…

• Page 181
  SWINGARM AND TRANSMISSION CHAIN DRIVE Removing the swingarm and transmission chain drive assembly 7 Nm (0.7 m kg, 5.1 ft • • 100 Nm (10.0 m kg, 72 ft • • 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft •…
• Page 182
  SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Outer chain drive case Secondary drive gear Secondary drive chain Secondary driven gear Chain drive case gasket Dowel pin Middle shaft…
• Page 183
  SWINGARM AND TRANSMISSION CHAIN DRIVE Disassembling the transmission chain drive assembly (18) 8 12 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Bearing retainer For assembly, reverse the disassembly pro- cedure. * Apply chain drive oil. 4-68…

• Page 184: Checking The Swingarm

  SWINGARM AND TRANSMISSION CHAIN DRIVE EAS4B51017 CHECKING THE SWINGARM 1. Check: • Swingarm “1” Damage/wear → Replace. EAS4B51018 ASSEMBLING THE TRANSMISSION CHAIN DRIVE ASSEMBLY 1. Install: • Outer chain drive case 2. Check: • Pivot shaft Chain drive case bolt •…

• Page 185
  SWINGARM AND TRANSMISSION CHAIN DRIVE 5. Fill: • Transmission chain drive case Refer to “CHANGING THE CHAIN DRIVE OIL” on page 3-25. 6. Check: • Chain drive oil level Refer to “CHECKING THE CHAIN DRIVE OIL LEVEL” on page 3-24. 2.
• Page 186
  SWINGARM AND TRANSMISSION CHAIN DRIVE 4-71…

• Page 187: Engine

  ENGINE ENGINE REMOVAL ………………5-1 INSTALLING THE ENGINE…………… 5-5 CAMSHAFTS………………..5-6 REMOVING THE CAMSHAFTS…………..5-9 CHECKING THE CAMSHAFTS …………..5-10 CHECKING THE CAMSHAFT SPROCKETS ………5-11 CHECKING THE TIMING CHAIN GUIDES……….5-11 CHECKING THE TIMING CHAIN TENSIONER……..5-12 INSTALLING THE CAMSHAFTS …………5-12 CYLINDER HEAD………………5-15 REMOVING THE CYLINDER HEAD…………5-16 CHECKING THE CYLINDER HEAD …………5-16 INSTALLING THE CYLINDER HEAD ………….5-16…

• Page 188
  V-BELT AUTOMATIC TRANSMISSION …………5-35 REMOVING THE PRIMARY SHEAVE AND SECONDARY SHEAVE..5-41 DISASSEMBLING THE SECONDARY SHEAVE……..5-41 CHECKING THE V-BELT…………….5-42 CHECKING THE PRIMARY SHEAVE …………5-42 CHECKING THE V-BELT CASE AIR DUCT ………..5-42 CHECKING THE PRIMARY SHEAVE WEIGHTS……..5-42 CHECKING THE SLIDERS …………..5-42 CHECKING THE SECONDARY SHEAVE ……….
• Page 189
  CRANKSHAFT ………………..5-71 REMOVING THE CONNECTING RODS ……….5-73 REMOVING THE CRANKSHAFT JOURNAL BEARINGS ……5-73 CHECKING THE CRANKSHAFT AND CONNECTING RODS….5-73 INSTALLING THE CRANKSHAFT JOURNAL BEARINGS…..5-76 INSTALLING THE CONNECTING RODS……….5-77 INSTALLING THE CRANKSHAFT ASSEMBLY……..5-78 TRANSMISSION……………….. 5-79 CHECKING THE TRANSMISSION …………5-80…

• Page 190: Engine Removal

  ENGINE REMOVAL EAS23710 ENGINE REMOVAL Removing the exhaust assembly 8 Nm (0.8 m kg, 5.8 ft • • 8 Nm (0.8 m kg, 5.8 ft • • 45 Nm (4.5 m kg, 32 ft • • 8 Nm (0.8 m kg, 5.8 ft •…

• Page 191
  ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Front cowling/Storage box 4-1. Drain. Engine oil Refer to “CHANGING THE ENGINE OIL”…
• Page 192
  ENGINE REMOVAL Disconnecting the leads 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “SWINGARM AND TRANSMIS- Transmission chain drive holder assembly SION CHAIN DRIVE” on page 4-65. Refer to “ELECTRIC STARTER”…
• Page 193
  ENGINE REMOVAL Removing the engine 83 Nm (8.3 m kg, 60 ft • • 105 Nm (10.5 m kg, 75 ft • • 45 Nm (4.5 m kg, 32 ft • • 88 Nm (8.8 m kg, 64 ft • •…

• Page 194: Installing The Engine

  ENGINE REMOVAL EAS23720 INSTALLING THE ENGINE 1. Install: • All removed parts • Apply locking agent (LOCTITE®) to engine mounting bolts (front right lower side) “1”, en- gine mounting bolts (front left lower side) “2”, and rear frame bolts “3”. •…

• Page 195: Camshafts

  CAMSHAFTS EAS23760 CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •…

• Page 196
  CAMSHAFTS Removing the cylinder head cover 7 Nm (0.7 m kg, 5.1 ft • • 13 Nm (1.3 m kg, 9.4 ft • • 10 Nm (1.0 m kg, 7.2 ft • • (10) 8 Nm (0.8 m kg, 5.8 ft •…
• Page 197
  CAMSHAFTS Removing the camshafts 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Timing chain tensioner rod accessing plug Timing chain tensioner Timing chain tensioner gasket Intake camshaft cap…

• Page 198: Removing The Camshafts

  CAMSHAFTS EAS23810 REMOVING THE CAMSHAFTS 1. Align: • “I” mark “a” on the generator rotor (with the stationary pointer “b” on the genera- tor cover) M MMM M MMM M MMM M MMM M MMM a. Turn the crankshaft clockwise. L LLL L LLL L LLL…

• Page 199: Checking The Camshafts

  CAMSHAFTS 3. Measure: • Camshaft runout EAS23850 Out of specification → Replace. CHECKING THE CAMSHAFTS 1. Check: Camshaft runout limit • Camshaft lobes 0.030 mm (0.0012 in) Blue discoloration/pitting/scratches → Re- place the camshaft. 2. Measure: • Camshaft lobe dimensions “a” and “b” Out of specification →…

• Page 200: Checking The Camshaft Sprockets

  CAMSHAFTS EAS4B51035 c. Install the dowel pins and camshaft caps. CHECKING THE CAMSHAFT SPROCKETS The following procedure applies to both of the • Tighten the camshaft cap bolts in stages and in camshaft sprockets. a crisscross pattern, working from the inner 1.

• Page 201: Checking The Timing Chain Tensioner

  CAMSHAFTS EAS23960 EAS24000 CHECKING THE TIMING CHAIN TENSIONER INSTALLING THE CAMSHAFTS 1. Check: 1. Install: • Timing chain tensioner • Exhaust camshaft “1” Cracks/damage → Replace. • Intake camshaft “2” M MMM M MMM M MMM M MMM M MMM a.

• Page 202
  CAMSHAFTS hole “d” on the exhaust camshaft sprocket ECA13730 NOTICE align with the cylinder head mating surface, as The camshaft cap bolts must be tightened shown in the illustration. evenly or damage to the cylinder head, cam- ECA4B51015 shaft caps, and camshafts will result. NOTICE 4.
• Page 203
  • Timing chain guide (upper side) • Gaskets (to the cylinder head cover) ECA4B51014 • Apply Yamaha bond No.1215 “1” onto the mat- NOTICE ing surface of the cylinder head cover and tim- Do not push up the timing chain. Push up “c”…

• Page 204: Cylinder Head

  CYLINDER HEAD EAS24100 CYLINDER HEAD Removing the cylinder head 10 Nm (1.0 m kg, 7.2 ft • • 46 Nm (4.6 m kg, 33 ft • • 35 Nm (3.5 m kg, 25 ft • • Order Job/Parts to remove Q’ty Remarks Camshafts…

• Page 205: Removing The Cylinder Head

  CYLINDER HEAD EAS24120 REMOVING THE CYLINDER HEAD Warpage limit 1. Remove: 0.03 mm (0.0012 in) • Cylinder head bolts • Cylinder head nuts • Loosen the bolts and nuts in the proper se- quence as shown. • Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them.

• Page 206
  CYLINDER HEAD Cylinder head nut 35 Nm (3.5 m·kg, 25 ft·lb) • Cylinder head nuts “2” Cylinder head nut 46 Nm (4.6 m·kg, 33 ft·lb) • Cylinder head bolts “3” Cylinder head bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) • Lubricate the cylinder head nuts and washers with engine oil.
• Page 207
  VALVES AND VALVE SPRINGS EAS24270 VALVES AND VALVE SPRINGS Removing the valves and valve springs Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Valve lifter Valve pad Valve cotter Valve retainer Valve spring Intake valve Exhaust valve Valve stem seal…

• Page 208: Valves And Valve Springs

  VALVES AND VALVE SPRINGS EAS24280 REMOVING THE VALVES Remove the valve cotters by compressing the The following procedure applies to all of the valve spring with the valve spring compressor valves and related components. “2” and the valve spring compressor attachment “3”.

• Page 209
  VALVES AND VALVE SPRINGS 1. Measure: • Valve-stem-to-valve-guide clearance Out of specification → Replace the valve guide. • Valve-stem-to-valve-guide clearance = Valve guide inside diameter “a” — Valve stem diameter “b” Valve-stem-to-valve-guide clear- ance (intake) b. Install the new valve guide with the valve 0.010–0.037 mm (0.0004–0.0015 guide installer “2”…

• Page 210: Checking The Valve Seats

  VALVES AND VALVE SPRINGS Valve guide remover (ø4) Valve stem runout 90890-04111 0.040 mm (0.0016 in) Valve guide remover (4.0 mm) YM-04111 Valve guide installer (ø4) 90890-04112 Valve guide installer (4.0 mm) YM-04112 Valve guide reamer (ø4) 90890-04113 Valve guide reamer (4.0 mm) YM-04113 L LLL L LLL…

• Page 211
  VALVES AND VALVE SPRINGS b. Install the valve into the cylinder head. c. Install the valve into the cylinder head. c. Press the valve through the valve guide and d. Turn the valve until the valve face and valve onto the valve seat to make a clear impres- seat are evenly polished, then clean off all of sion.

• Page 212: Checking The Valve Springs

  VALVES AND VALVE SPRINGS j. Measure the valve seat width again. If the valve seat width is out of specification, reface and lap the valve seat. L LLL L LLL L LLL L LLL L LLL EAS24310 CHECKING THE VALVE SPRINGS The following procedure applies to all of the valve springs.

• Page 213
  VALVES AND VALVE SPRINGS 1. Deburr: • Valve stem end (with an oil stone) 2. Lubricate: • Valve stem “1” • Valve stem seal “2” (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil b. Smaller pitch 4. Install: • Valve cotters “1” Install the valve cotters by compressing the valve spring with the valve spring compressor “2”…
• Page 214
  VALVES AND VALVE SPRINGS 5. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. ECA13800 NOTICE Hitting the valve tip with excessive force could damage the valve. 6. Lubricate: • Valve pad (with the recommended lubricant) Recommended lubricant Molybdenum disulfide oil…
• Page 215
  CYLINDER AND PISTONS EAS24370 CYLINDER AND PISTONS Removing the cylinder and pistons 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Cylinder head Refer to “CYLINDER HEAD” on page 5-15. Timing chain guide (exhaust side) Cylinder Cylinder gasket Dowel pin…

• Page 216: Cylinder And Pistons

  CYLINDER AND PISTONS • 2nd ring EAS24380 REMOVING THE PISTONS • Oil ring The following procedure applies to all of the pis- ton. When removing a piston ring, open the end gap 1. Remove: with your fingers and lift the other side of the ring •…

• Page 217: Checking The Piston Rings

  CYLINDER AND PISTONS EAS24430 CHECKING THE PISTON RINGS 1. Measure: • Piston ring side clearance Out of specification → Replace the piston and piston rings as a set. Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston rings.

• Page 218: Checking The Piston Pins

  CYLINDER AND PISTONS 3. Measure: • Piston ring end gap Out of specification → Replace the piston ring. The oil ring expander spacer end gap cannot be measured. If the oil ring rail gap is excessive, re- place all three piston rings. Piston ring 3.

• Page 219
  CYLINDER AND PISTONS 3. Install: • Dowel pins Be sure to install the top and 2nd rings so that the manufacturer marks or numbers face up. • Cylinder gasket 4. Lubricate: • Piston • Piston rings • Cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5.

• Page 220: Electric Starter

  ELECTRIC STARTER EAS24780 ELECTRIC STARTER Removing the starter motor 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Negative battery lead Starter motor lead Starter motor…

• Page 221
  ELECTRIC STARTER Disassembling the starter motor 11 Nm (1.1 m kg, 8.0 ft • • Order Job/Parts to remove Q’ty Remarks Starter motor front cover Bearing Oil seal Circlip Armature assembly Starter motor yoke O-ring Insulator Brush Brush spring Brush holder Starter motor rear cover For assembly, reverse the disassembly pro- cedure.

• Page 222: Checking The Starter Motor

  ELECTRIC STARTER EAS24790 CHECKING THE STARTER MOTOR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Mica undercut “a” Out of specification → Scrape the mica to the proper measurement with a hacksaw blade that has been grounded to fit the commutator. L LLL L LLL L LLL…

• Page 223: Installing The Starter Motor

  ELECTRIC STARTER 2. Install: • Starter motor yoke “1” • Starter motor front cover “2” • Starter motor rear cover “3” Align the match marks “a” on the starter motor yoke with the match marks “b” on the front and starter motor rear covers.

• Page 224
  V-BELT AUTOMATIC TRANSMISSION EAS24610 V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •…

• Page 225: V-Belt Automatic Transmission

  V-BELT AUTOMATIC TRANSMISSION Removing the V-belt case cover 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 10 Nm (1.0 m kg, 7.2 ft •…

• Page 226
  V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •…
• Page 227
  V-BELT AUTOMATIC TRANSMISSION Removing the V-belt and primary/secondary sheave 24 Nm (2.4 m kg, 17 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 24 Nm (2.4 m kg, 17 ft • • 90 Nm (9.0 m kg, 65 ft •…
• Page 228
  V-BELT AUTOMATIC TRANSMISSION Disassembling the primary sheave Order Job/Parts to remove Q’ty Remarks Slider Primary sheave weight Primary sliding sheave Collar Oil seal For assembly, reverse the disassembly pro- cedure. * Apply BEL-RAY assembly lube®. 5-39…
• Page 229
  V-BELT AUTOMATIC TRANSMISSION Disassembling the secondary sheave 90 Nm (9.0 m kg, 65 ft • • Order Job/Parts to remove Q’ty Remarks Secondary sheave spring seat nut Upper spring seat Secondary sheave compression spring Spring seat Guide pin Secondary sliding sheave O-ring Oil seal Secondary fixed sheave…

• Page 230: Removing The Primary Sheave And Secondary Sheave

  V-BELT AUTOMATIC TRANSMISSION EAS4B51022 EAS24640 REMOVING THE PRIMARY SHEAVE AND DISASSEMBLING THE SECONDARY SECONDARY SHEAVE SHEAVE 1. Remove: 1. Loosen: • Primary sheave nut “1” • Secondary sheave spring seat nut “1” • Secondary sheave nut “2” • While holding the secondary fixed sheave “2” While holding the primary and secondary with the sheave holder “3”, loosen the second- sheave with the sheave holder “3”, loosen the…

• Page 231: Checking The V-Belt

  V-BELT AUTOMATIC TRANSMISSION EAS24690 CHECKING THE PRIMARY SHEAVE WEIGHTS The following procedure applies to all of the pri- mary sheave weights. 1. Check: • Primary sheave weight Cracks/damage/wear → Replace. 2. Measure: • Primary sheave weight outside diameter Out of specification → Replace. EAS24670 CHECKING THE V-BELT Primary sheave weight outside…

• Page 232: Assembling The Primary Sheave

  V-BELT AUTOMATIC TRANSMISSION 2. Install: EAS24720 • Secondary sliding sheave “1” ASSEMBLING THE PRIMARY SHEAVE 1. Clean: Install the secondary sliding sheave onto the • Primary fixed sheave secondary fixed sheave “2” with the oil seal • Primary sliding sheave guide “3”.

• Page 233: Installing The Primary Sheave Assembly, Secondary Sheave Assembly And V-Belt

  INSTALLING THE PRIMARY SHEAVE ASSEMBLY, SECONDARY SHEAVE ASSEMBLY AND V-BELT 1. Apply: • Sealant (onto the inner V-belt case seal) Yamaha bond No. 1215 90890-85505 (Three Bond No.1215®) 2. Install: • V-belt case air duct joint clamp “1” 6. Tighten: •…

• Page 234
  V-BELT AUTOMATIC TRANSMISSION While holding the secondary sheave with the sheave holder “2”, tighten the secondary sheave nut. Secondary sheave nut 90 Nm (9.0 m·kg, 65 ft·lb) Sheave holder 90890-01481 3. Install: • Primary fixed sheave “1” • V-belt “2” •…

• Page 235: Installing The V-Belt Case

  V-BELT AUTOMATIC TRANSMISSION EAS4B51025 INSTALLING THE V-BELT CASE 1. Install: • Oil seal “1” (into outer V-belt case) Installed depth of oil seal “a” 4.0–4.3 mm (0.16–0.17 in) 2. Fill the space “b” shown in the illustration with 10 g or more of lithium-soap-based grease. 3.

• Page 236
  GENERATOR AND STARTER CLUTCH EAS24480 GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft •…

• Page 237: Generator And Starter Clutch

  GENERATOR AND STARTER CLUTCH Removing the generator rotor and starter clutch 30 Nm (3.0 m kg, 22 ft • • (19) 7 Nm (0.7 m kg, 5.1 ft • • 1st 65 Nm (6.5 m kg, 47 ft • • 30 Nm (3.0 m kg, 22 ft 10 Nm (1.0 m…

• Page 238
  GENERATOR AND STARTER CLUTCH Removing the stator coil and oil tank 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Oil tank…

• Page 239: Removing The Generator

  GENERATOR AND STARTER CLUTCH EAS24490 REMOVING THE GENERATOR 1. Remove: • Generator cover Loosen each bolt 1/4 of a turn at a time, in stag- es and in a crisscross pattern. After all of the bolts are fully loosened, remove them.

• Page 240: Checking The Starter Clutch

  GENERATOR AND STARTER CLUTCH c. When turning the starter clutch gear clock- wise “B”, it should turn freely, otherwise the starter clutch is faulty and must be replaced. EAS24570 CHECKING THE STARTER CLUTCH 1. Check: • Starter clutch rollers “1” L LLL L LLL L LLL…

• Page 241: Installing The Generator

  • While holding the generator rotor “2” with the (onto the crankshaft position sensor lead sheave holder “3”, tighten the generator rotor grommet) nut. Yamaha bond No. 1215 • Do not allow the sheave holder to touch the 90890-85505 projection on the generator rotor. (Three Bond No.1215®)

• Page 242
  GENERATOR AND STARTER CLUTCH Generator cover bolt 10 Nm (1.0 m·kg, 7.2 ft·lb) Tighten the generator cover bolts in stages and in a crisscross pattern. 5-53…

• Page 243: Clutch

  CLUTCH EAS25061 CLUTCH Removing the clutch 65 Nm (6.5 m kg, 47 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Generator cover CLUTCH” on page 5-47. Clutch assembly nut Clutch assembly Washer For installation, reverse the removal proce- dure.

• Page 244
  CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Circlip Spring stopper plate Clutch spring plate Pressure plate Clutch plate 2 Clutch damper spring Friction plate Clutch plate 1 Clutch spring Clutch boss nut Primary drive gear…
• Page 245
  CLUTCH Disassembling the clutch 130 Nm (13.0 m kg, 94 ft • • (12) Order Job/Parts to remove Q’ty Remarks Clutch housing For assembly, reverse the disassembly pro- cedure. 5-56…

• Page 246: Removing The Clutch

  CLUTCH EAS25070 REMOVING THE CLUTCH 1. Remove: • Clutch assembly nut “1” • Clutch assembly “2” • Before removal, put alignment marks “a” and “b” as shown. • While holding the clutch assembly with the ro- tor holding tool “3”, loosen the clutch assembly nut.

• Page 247: Checking The Friction Plates

  CLUTCH EAS25100 CHECKING THE FRICTION PLATES The following procedure applies to all of the fric- tion plates. 1. Check: • Friction plate Damage/wear → Replace the friction plates as a set. 2. Measure: • Friction plate thickness Out of specification → Replace the friction EAS4B51027 plates as a set.

• Page 248: Checking The Clutch Springs

  CLUTCH EAS25140 EAS25160 CHECKING THE CLUTCH SPRINGS CHECKING THE CLUTCH BOSS The following procedure applies to all of the 1. Check: clutch springs. • Clutch boss splines 1. Check: Damage/pitting/wear → Replace the clutch • Clutch spring boss. Damage → Replace the clutch springs as a set.

• Page 249: Installing The Clutch

  CLUTCH • Friction plates “4” Recommended lubricant • Clutch plates 1 “5” Engine oil • Pressure plate “6” • Clutch spring plate “7” 2. Install: • Clutch boss • Primary drive gear • Clutch boss nut 3. Tighten: • Clutch boss nut “1” Clutch boss nut 130 Nm (13.0 m·kg, 94 ft·lb) While holding the clutch boss “2”…

• Page 250
  CLUTCH Clutch assembly nut 65 Nm (6.5 m·kg, 47 ft·lb) • Align the “a” and “b” during reassembly. • While holding the clutch assembly with the ro- tor holding tool “3”, tighten the clutch assembly nut. Rotor holding tool 90890-01235 Universal magneto &…

• Page 251: Oil Pump

  OIL PUMP EAS24901 OIL PUMP Removing the oil pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERATOR AND STARTER Starter clutch gear CLUTCH”…

• Page 252
  OIL PUMP Disassembling the oil pump Order Job/Parts to remove Q’ty Remarks Oil pump housing 1 Dowel pin Oil pump outer rotor 1 Oil pump inner rotor 1 Washer Oil pump housing center Oil pump outer rotor 2 Oil pump inner rotor 2 Oil pump driven gear Oil pump housing 2 For assembly, reverse the disassembly pro-…

• Page 253: Checking The Oil Pump

  OIL PUMP EAS24960 CHECKING THE OIL PUMP Inner-rotor-to-outer-rotor-tip 1. Check: clearance • Oil pump driven gear “1” 0.040–0.120 mm (0.0016–0.0047 • Oil pump housing 2 “2” Limit • Oil pump housing 1 “3” Cracks/damage/wear → Replace the defec- 0.20 mm (0.0079 in) Outer-rotor-to-oil-pump-housing tive part(s).

• Page 254: Assembling The Oil Pump

  OIL PUMP ECA13890 NOTICE After tightening the bolts, make sure the oil pump turns smoothly. EAS25000 ASSEMBLING THE OIL PUMP 1. Lubricate: • Inner rotor • Outer rotor • Oil pump shaft (with the recommended lubricant) Recommended lubricant Engine oil 2.

• Page 255: Crankcase

  CRANKCASE EAS25540 CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft •…

• Page 256
  CRANKCASE Separating the crankcase 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 43 Nm (4.3 m kg, 31 ft • • 24 Nm (2.4 m kg, 17 ft •…
• Page 257
  CRANKCASE Removing the oil seals and bearings 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Crankshaft assembly Refer to “CRANKSHAFT” on page 5-71. Transmission Refer to “TRANSMISSION” on page 5-79. Bearing retainer Oil seal Bearing For installation, reverse the removal proce- dure.

• Page 258: Disassembling The Crankcase

  (onto the crankcase mating surfaces) es and in a crisscross pattern. After all of the bolts are fully loosened, remove them. Yamaha bond No. 1215 • M8 × 110 mm bolts “1” 90890-85505 • M6 × 50 mm bolts “2”…

• Page 259
  CRANKCASE • M6 × 35 mm bolts “3” 5. Check: • Crankshaft and transmission operation Rough movement → Repair. 5-70…

• Page 260: Crankshaft

  CRANKSHAFT EAS25960 CRANKSHAFT Removing the crankshaft assembly 58 Nm (5.8 m kg, 42 ft • • Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Dowel pin Crankshaft assembly Balancer cylinder Oil seal Crankshaft journal bearing For installation, reverse the removal proce- dure.

• Page 261
  CRANKSHAFT Removing the connecting rods 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ 60 Nm (6.0 m kg, 43 ft • • 16 Nm (1.6 m kg, 11 ft • • final Specified angle 90˚ Order Job/Parts to remove Q’ty…

• Page 262: Removing The Connecting Rods

  CRANKSHAFT EAS26010 REMOVING THE CONNECTING RODS The following procedure applies to all of the con- necting rods. 1. Remove: • Connecting rod cap • Connecting rod “1” • Big end bearings Identify the position of each big end bearing so that it can be reinstalled in its original place.

• Page 263
  CRANKSHAFT 3. Measure: • Crankshaft-pin-to-big-end-bearing clearance • Do not move the connecting rod or crankshaft Out of specification → Replace the big end until the clearance measurement has been bearings. completed. • Lubricate the bolts threads and nut seats with Oil clearance (using plasti- molybdenum disulfide grease.
• Page 264
  CRANKSHAFT • P –P refer to the bearings shown in the crank- Journal oil clearance (using plas- shaft illustration. tigauge®) 0.040–0.082 mm (0.0016–0.0032 The following procedure applies to all of the crankshaft journal bearings. ECA13920 NOTICE Do not interchange the crankshaft journal bearings.

• Page 265: Installing The Crankshaft Journal Bearings

  CRANKSHAFT d. Measure the crankshaft journal bearing in- side diameter “b” of each crankshaft journal bearing at two places. e. If crankshaft journal bearing inside diameter is “45.03” and crankshaft journal diameter is “44.98”, then the journal oil clearance is: Journal oil clearance: Crankshaft journal bearing inside diameter — Crankshaft journal diameter…

• Page 266: Installing The Connecting Rods

  CRANKSHAFT • Make sure the characters “d” on both the con- necting rod and connecting rod cap are aligned. EAS26150 INSTALLING THE CONNECTING RODS 1. Lubricate: • Bolt threads • Nut seats 4. Tighten: (with the recommended lubricant) • Connecting rod nuts M MMM M MMM M MMM…

• Page 267: Installing The Crankshaft Assembly

  CRANKSHAFT c. Tighten the connecting rod nuts further to (6.0 m·kg, 43 ft·lb), loosen the nut to less reach the specified angle 90°. than 30 Nm (3.0 m·kg, 22 ft·lb) and start again. Connecting rod nut (final) Specified angle 90° EAS4B51033 INSTALLING THE CRANKSHAFT ASSEMBLY…

• Page 268: Transmission

  TRANSMISSION EAS26240 TRANSMISSION Removing the transmission Order Job/Parts to remove Q’ty Remarks Separate. Crankcase Refer to “CRANKCASE” on page 5-66. Secondary shaft Collar Primary driven gear Main axle 1st pinion gear Drive axle 1st wheel gear Circlip For installation, reverse the removal proce- dure.

• Page 269: Checking The Transmission

  TRANSMISSION EAS26300 CHECKING THE TRANSMISSION 1. Measure: • Main axle runout (with a centering device and dial gauge) Out of specification → Replace the main axle. Main axle runout limit 0.08 mm (0.0032 in) 4. Check: • Transmission gear movement Rough movement →…

• Page 270
  TRANSMISSION 5-81…

• Page 271: Cooling System

  COOLING SYSTEM RADIATOR …………………. 6-1 CHECKING THE RADIATOR…………..6-3 INSTALLING THE RADIATOR…………..6-3 OIL COOLER………………..6-4 CHECKING THE OIL COOLER …………..6-6 INSTALLING THE OIL COOLER ………….. 6-6 THERMOSTAT ………………..6-7 CHECKING THE THERMOSTAT………….. 6-8 INSTALLING THE THERMOSTAT ASSEMBLY ……..6-8 WATER PUMP………………..6-9 DISASSEMBLING THE WATER PUMP……….6-11 CHECKING THE WATER PUMP …………

• Page 272
  RADIATOR EAS26380 RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Footrest boards 4-1.
• Page 273
  RADIATOR Removing the radiator 30 Nm (3.0 m kg, 22 ft • • 7 Nm (0.7 m kg, 5.1 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Radiator fan Radiator bracket For installation, reverse the removal proce- dure.

• Page 274: Radiator

  RADIATOR EAS26390 CHECKING THE RADIATOR 1. Check: • Radiator fins Obstruction → Clean. Apply compressed air to the rear of the radia- tor. Damage → Repair or replace. Straighten any flattened fins with a thin, flat-head screwdriver. b. Apply the specified pressure for ten seconds and make sure there is no drop in pressure.

• Page 275: Oil Cooler

  OIL COOLER EAS26410 OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

• Page 276
  OIL COOLER Removing the oil cooler 10 Nm (1.0 m kg, 7.2 ft • • 17 Nm (1.7 m kg, 12 ft • • 63 Nm (6.3 m kg, 45 ft • • Order Job/Parts to remove Q’ty Remarks Oil cooler For installation, reverse the removal proce- dure.

• Page 277: Checking The Oil Cooler

  OIL COOLER 4. Fill: EAS26420 CHECKING THE OIL COOLER • Cooling system 1. Check: (with the specified amount of the recom- • Oil cooler mended coolant) Cracks/damage → Replace. Refer to “CHANGING THE COOLANT” on 2. Check: page 3-18. • Oil cooler inlet hose •…

• Page 278: Thermostat

  THERMOSTAT EAS26440 THERMOSTAT Removing the thermostat 10 Nm (1.0 m kg, 7.2 ft • • 18 Nm (1.8 m kg, 13 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK”…

• Page 279: Checking The Thermostat

  THERMOSTAT 2. Check: EAS26450 CHECKING THE THERMOSTAT • Thermostat cover 1. Check: Cracks/damage → Replace. • Thermostat Does not open at 71–85 °C (159.8–185.0 °F) EAS26480 INSTALLING THE THERMOSTAT → Replace. ASSEMBLY 1. Install: • Thermostat Install the thermostat with its breather hole “a” facing forward.

• Page 280: Water Pump

  WATER PUMP EAS26500 WATER PUMP Removing the water pump 10 Nm (1.0 m kg, 7.2 ft • • 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Left footrest board 4-1.

• Page 281
  WATER PUMP Disassembling the water pump 10 Nm (1.0 m kg, 7.2 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks It is not necessary to remove the impeller shaft, unless the coolant level is extremely low or coolant contains engine oil.

• Page 282: Disassembling The Water Pump

  WATER PUMP EAS26510 EAS26550 DISASSEMBLING THE WATER PUMP CHECKING THE WATER PUMP 1. Remove: 1. Check: • Rubber damper holder “1” • Water pump housing cover • Rubber damper “2” • Water pump housing (from the impeller, with a thin, flat-head •…

• Page 283: Installing The Water Pump

  WATER PUMP • Before installing the water pump seal, apply ECA14090 NOTICE Yamaha bond No.1215 “2” to the water pump Make sure the rubber damper and rubber housing “3”. damper holder are flush with the impeller. Mechanical seal installer Impeller shaft tilt limit 90890-04078 0.15 mm (0.0059 in)

• Page 284
  WATER PUMP 3. Check: • Cooling system Leaks → Repair or replace any faulty part. 4. Measure: • Radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Refer to “CHECKING THE RADIATOR” on page 6-3. 6-13…

• Page 285: Fuel System

  FUEL SYSTEM FUEL TANK………………… 7-1 REMOVING THE FUEL TANK …………..7-3 REMOVING THE FUEL PUMP …………..7-3 CHECKING THE FUEL PUMP BODY…………7-3 CHECKING THE ROLLOVER VALVE …………7-3 INSTALLING THE FUEL PUMP…………..7-3 CHECKING THE FUEL PRESSURE …………7-3 THROTTLE BODY………………. 7-5 CHECKING THE INJECTORS …………..7-8 CHECKING THE THROTTLE BODY …………7-8 ADJUSTING THE THROTTLE POSITION SENSOR……..7-8…

• Page 286
  FUEL TANK EAS26620 FUEL TANK Removing the fuel tank 4 Nm (0.4 m kg, 2.9 ft • • 10 Nm (1.0 m kg, 7.2 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1.
• Page 287
  FUEL TANK Removing the canister 7 Nm (0.7 m kg, 5.1 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Storage box 4-1. Fuel tank Refer to “FUEL TANK” on page 7-1. Fuel tank breather hose Canister purge hose (3-way joint to canister) Canister purge hose (throttle body to 3-way joint)

• Page 288: Fuel Tank

  FUEL TANK EAS26630 REMOVING THE FUEL TANK • Do not damage the installation surfaces of the 1. Extract the fuel in the fuel tank through the fuel tank when installing the fuel pump. fuel tank cap with a pump. • Always use a new fuel pump gasket. 2.

• Page 289
  FUEL TANK b. Connect the pressure gauge “1” and fuel pressure adapter “2” to the fuel pump and the fuel hose “3”. Pressure gauge 90890-03153 YU-03153 Fuel pressure adapter 90890-03181 c. Start the engine. d. Measure the fuel pressure. Faulty → Replace the fuel pump. Output pressure 246.0–254.0 kPa (35.7–36.8 psi) (2.46–2.54 kgf/cm²)

• Page 290: Throttle Body

  THROTTLE BODY EAS26970 THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft • • 12 Nm (1.2 m kg, 8.7 ft • • Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS”…

• Page 291
  THROTTLE BODY Removing the throttle body assembly 9 Nm (0.9 m kg, 6.5 ft • • 10 Nm (1.0 m kg, 7.2 ft 12 Nm (1.2 m kg, 8.7 ft • • • • Order Job/Parts to remove Q’ty Remarks Throttle body assembly Plastic band Coupler cover…
• Page 292
  THROTTLE BODY Disassembling the throttle body assembly Order Job/Parts to remove Q’ty Remarks Before disassembling the throttle body as- sembly, make sure to note the number of times the air screw is turned out from the seated position to its set position. Throttle position sensor Fast idle plunger Idling speed adjusting screw…
• Page 293
  THROTTLE BODY EAS26980 CHECKING THE INJECTORS 1. Check: • Injectors Damage → Replace. EAS26990 CHECKING THE THROTTLE BODY 1. Check: B/L Y • Throttle body Cracks/damage → Replace the throttle body. 2. Check: d. Measure the throttle position sensor output •…
• Page 294
  THROTTLE BODY…

• Page 295: Electrical System

  ELECTRICAL SYSTEM IGNITION SYSTEM ………………8-1 CIRCUIT DIAGRAM ……………… 8-1 TROUBLESHOOTING …………….8-3 ELECTRIC STARTING SYSTEM …………..8-5 CIRCUIT DIAGRAM ……………… 8-5 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ……8-7 TROUBLESHOOTING …………….8-9 CHARGING SYSTEM………………8-11 CIRCUIT DIAGRAM …………….8-11 TROUBLESHOOTING …………….8-13 LIGHTING SYSTEM ………………8-15 CIRCUIT DIAGRAM …………….

• Page 296
  ELECTRICAL COMPONENTS…………..8-57 CHECKING THE SWITCHES …………..8-61 CHECKING THE BULBS AND BULB SOCKETS ……..8-64 CHECKING THE FUSES …………….8-65 CHECKING AND CHARGING THE BATTERY……..8-66 CHECKING THE RELAYS …………..8-69 CHECKING THE TURN SIGNAL RELAY ……….8-70 CHECKING THE DIODE ……………..8-71 CHECKING THE SPARK PLUG CAPS………..8-71 CHECKING THE IGNITION COIL …………

• Page 298: Ignition System

  IGNITION SYSTEM EAS27090 IGNITION SYSTEM EAS27110 CIRCUIT DIAGRAM…

• Page 299
  IGNITION SYSTEM 1. Crankshaft position sensor 4. Main switch 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug 39.Lean angle sensor…

• Page 300: Troubleshooting

  IGNITION SYSTEM EAS27140 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). • Before troubleshooting, remove the following part(s): 1. Footrest boards 2. Front cowling assembly NG → 1. Check the fuses. (Main and ignition) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 301
  IGNITION SYSTEM NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch. SWITCHES” on page 8-61. OK ↓ NG → 10.Check the sidestand switch. Refer to “CHECKING THE Replace the sidestand switch.

• Page 302: Electric Starting System

  ELECTRIC STARTING SYSTEM EAS27160 ELECTRIC STARTING SYSTEM EAS27170 CIRCUIT DIAGRAM…

• Page 303
  ELECTRIC STARTING SYSTEM 4. Main switch 9. Signaling system fuse 11.Ignition fuse 14.Battery 15.Main fuse 16.Starter relay 17.Starter motor 18.Diode 1 20.Engine stop switch 21.Start switch 22.Front brake light switch 23.Diode 2 24.Starting circuit cut-off relay 28.Sidestand switch 57.Rear brake light switch…

• Page 304: Starting Circuit Cut-Off System Operation

  ELECTRIC STARTING SYSTEM EAS27180 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the starter motor can only operate if at least one of the following conditions is met: •…

• Page 305
  ELECTRIC STARTING SYSTEM 1. Battery 2. Main fuse 3. Main switch 4. Ignition fuse 5. Engine stop switch 6. Diode 2 7. Starting circuit cut-off relay 8. Sidestand switch 9. Signaling system fuse 10. Front brake light switch 11. Rear brake light switch 12.

• Page 306: Troubleshooting

  ELECTRIC STARTING SYSTEM EAS27190 TROUBLESHOOTING The starter motor fails to turn. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and signaling sys- tem) Replace the fuse(s).

• Page 307
  ELECTRIC STARTING SYSTEM NG → 8. Check the main switch. Refer to “CHECKING THE Replace the main switch. SWITCHES” on page 8-61. OK ↓ NG → 9. Check the engine stop switch. The engine stop switch is faulty. Replace Refer to “CHECKING THE the right handlebar switch.

• Page 308: Charging System

  CHARGING SYSTEM EAS27200 CHARGING SYSTEM EAS27210 CIRCUIT DIAGRAM 8-11…

• Page 309
  CHARGING SYSTEM 2. AC magneto 3. Rectifier/regulator 14.Battery 15.Main fuse 8-12…

• Page 310: Troubleshooting

  CHARGING SYSTEM EAS27220 TROUBLESHOOTING The battery is not being charged. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly NG → 1. Check the fuse. (Main) Replace the fuse. Refer to “CHECKING THE FUS- ES” on page 8-65. OK ↓…

• Page 311
  CHARGING SYSTEM 8-14…

• Page 312: Lighting System

  LIGHTING SYSTEM EAS27240 LIGHTING SYSTEM EAS27250 CIRCUIT DIAGRAM 8-15…

• Page 313
  LIGHTING SYSTEM 4. Main switch 5. Storage box light switch 6. Storage box light 8. Backup fuse (odometer and clock) 10.Headlight fuse 13.Taillight fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 47.License plate light 51.Tail/brake light 54.Dimmer switch 59.Front right turn signal/position light 60.Front left turn signal/position light 61.Headlight relay 62.Headlight (high beam)

• Page 314: Troubleshooting

  LIGHTING SYSTEM EAS27260 TROUBLESHOOTING Any of the following fail to light: headlight, high beam indicator light, taillight, license plate light, position lights, or meter light. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Mudguard NG → 1.

• Page 315
  LIGHTING SYSTEM NG → 8. Check the entire lighting system wiring. Properly connect or repair the lighting sys- Refer to “CIRCUIT DIAGRAM” on tem wiring. page 8-15. OK ↓ Replace the ECU (engine control unit) or meter assembly. 8-18…

• Page 316: Signaling System

  SIGNALING SYSTEM EAS27270 SIGNALING SYSTEM EAS27280 CIRCUIT DIAGRAM 8-19…

• Page 317
  SIGNALING SYSTEM 4. Main switch 8. Backup fuse (odometer and clock) 9. Signaling system fuse 11.Ignition fuse 13.Taillight fuse 14.Battery 15.Main fuse 22.Front brake light switch 27.Fuel sender 29.ECU (engine control unit) 40.Speed sensor 49.Rear left turn signal light 50.Rear right turn signal light 51.Tail/brake light 52.Turn signal relay 55.Horn switch…

• Page 318: Troubleshooting

  SIGNALING SYSTEM EAS27290 TROUBLESHOOTING • Any of the following fail to light: turn signal light, brake light or an indicator light. • The horn fails to sound. • The fuel meter fails to operate. • The speedometer fails to operate. •…

• Page 319
  SIGNALING SYSTEM NG → 3. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM” on system wiring. page 8-19. OK ↓ This circuit is OK. The tail/brake light fails to come on. NG → 1.
• Page 320
  SIGNALING SYSTEM NG → 3. Check the turn signal relay. Refer to “CHECKING THE TURN Replace the turn signal relay. SIGNAL RELAY” on page 8-70. OK ↓ NG → 4. Check the entire signaling system wiring. Properly connect or repair the signaling Refer to “CIRCUIT DIAGRAM”…
• Page 321
  SIGNALING SYSTEM 8-24…

• Page 322: Cooling System

  COOLING SYSTEM EAS27300 COOLING SYSTEM EAS27310 CIRCUIT DIAGRAM 8-25…

• Page 323
  COOLING SYSTEM 4. Main switch 11.Ignition fuse 12.Radiator fan fuse 14.Battery 15.Main fuse 29.ECU (engine control unit) 34.Coolant temperature sensor 45.Radiator fan motor relay 46.Radiator fan motor 65.Multi-function meter 66.Coolant temperature meter 8-26…

• Page 324: Troubleshooting

  COOLING SYSTEM EAS27320 TROUBLESHOOTING • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box 3. Fuel tank NG → 1. Check the fuses. (Main, ignition and radiator fan) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 325
  COOLING SYSTEM 8-28…

• Page 326: Fuel Injection System

  FUEL INJECTION SYSTEM EAS27330 FUEL INJECTION SYSTEM EAS27340 CIRCUIT DIAGRAM 8-29…

• Page 327
  FUEL INJECTION SYSTEM 1. Crankshaft position sensor 4. Main switch 7. Fuel injection system fuse 9. Signaling system fuse 10.Headlight fuse 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 23.Diode 2 24.Starting circuit cut-off relay 25.Fuel injection system relay 28.Sidestand switch 29.ECU (engine control unit) 30.Ignition coil 31.Spark plug…

• Page 328: Ecu Self-Diagnostic Function

  FUEL INJECTION SYSTEM EAS27350 ECU SELF-DIAGNOSTIC FUNCTION The ECU (engine control unit) is equipped with a self-diagnostic function in order to ensure that the fuel injection system is operating normally. If this function detects a malfunction in the system, it immediately operates the engine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.

• Page 329: Self-Diagnostic Function Table

  FUEL INJECTION SYSTEM a. Main switch “OFF” d. Engine trouble warning light on for 1.4 seconds b. Main switch “ON” c. Engine trouble warning light off EAS4B51034 SELF-DIAGNOSTIC FUNCTION TABLE If the ECU (engine control unit) detects an abnormal signal from a sensor while the vehicle is being driv- en, the ECU (engine control unit) illuminates the engine trouble warning light and provides the engine with alternate operating instructions that are appropriate for the type of malfunction.

• Page 330
  FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive Coolant temperature Coolant temperature sensor-open Able Able sensor or short circuit detected. Intake air tempera- Intake air temperature sensor- Able Able ture sensor open or short circuit detected.

• Page 331: Troubleshooting Method

  FUEL INJECTION SYSTEM Able / un- Fault Able / un- Item Symptom able to code No. able to start drive ECU (engine control unit) internal malfunc- Non-registered data has been re- Er-4 Unable Unable tion ceived from the meter. (input signal error) EAS27400 5.

• Page 332: Diagnostic Mode

  FUEL INJECTION SYSTEM EAS27431 DIAGNOSTIC MODE Setting the diagnostic mode 1. Turn the main switch to “OFF” and set the engine stop switch to “ ”. 2. Disconnect the wire harness coupler from the fuel pump. 3. Simultaneously press and hold the “SELECT” and “RESET” buttons, turn the main switch to “ON”, and continue to press the buttons for 8 seconds or more.

• Page 333
  FUEL INJECTION SYSTEM 8. Turn the main switch to “OFF” to cancel the diagnostic mode. Diagnostic code table Fault Diagnostic code Symptom Probable cause of malfunction code No. • Open or short circuit in wire harness. No normal signals are re- •…
• Page 334
  FUEL INJECTION SYSTEM Fault Diagnostic code Symptom Probable cause of malfunction code No. • Stuck fast idle plunger (in fully open posi- Engine speed is high when tion). the engine is idling. • Malfunction in ECU (engine control unit). • Open or short circuit in wire harness. Lean angle sensor: open or •…
• Page 335
  FUEL INJECTION SYSTEM Sensor operation table Diag- nostic Item Meter display Checking method code Throttle angle • Fully closed position (15–16) Check with throttle fully closed. • Fully opened position (97–102) Check with throttle fully open. Pressure difference Displays the intake air pres- Set the engine stop switch (atmospheric pressure and sure.
• Page 336
  FUEL INJECTION SYSTEM Diag- nostic Item Meter display Checking method code Malfunction history code — display • No history • History exists Fault codes 12–50 • (If more than one code number is detected, the dis- play alternates every two seconds to show all the de- tected code numbers.

• Page 337: Troubleshooting Details

  FUEL INJECTION SYSTEM Diag- nostic Item Actuation Checking method code Actuates the fuel injection system relay five times at one-second intervals. Illuminates the engine trou- Check the operating sound ble warning light. Fuel injection system relay of the fuel injection system (The engine trouble warning relay five times.

• Page 338
  FUEL INJECTION SYSTEM Fault code No. Symptom No normal signals are received from the crankshaft posi- tion sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of crankshaft posi- Check the installed area for Cranking the tion sensor.
• Page 339
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: open or short circuit detected. Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Cranking the •…
• Page 340
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air pressure sensor: hose system malfunction (clogged or detached hose). Diagnostic code No. Intake air pressure sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Intake air pressure sensor hose •…
• Page 341
  FUEL INJECTION SYSTEM Fault code No. Symptom Throttle position sensor: open or short circuit detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Turning the sensor.
• Page 342
  FUEL INJECTION SYSTEM Fault code No. Symptom Stuck throttle position sensor detected. Diagnostic code No. Throttle position sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of throttle position • Check for looseness or pinch- Reinstated by sensor.
• Page 343
  FUEL INJECTION SYSTEM Fault code No. Symptom Coolant temperature sensor: open or short circuit detect- Diagnostic code No. Coolant temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of coolant tempera- Check for looseness or pinching. Turning the ture sensor.
• Page 344
  FUEL INJECTION SYSTEM Fault code No. Symptom Intake air temperature sensor: open or short circuit de- tected. Diagnostic code No. Intake air temperature sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of intake air tem- Check for looseness or pinching.
• Page 345
  FUEL INJECTION SYSTEM Fault code No. Symptom No normal signal is received from the O sensor. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Installed condition of O sensor. Check for looseness or pinching. Starting and warming up the Connections •…
• Page 346
  FUEL INJECTION SYSTEM Fault code No. Symptom Malfunction detected in the primary wire of the ignition coil. Diagnostic code No. Ignition coil Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Starting the en- •…
• Page 347
  FUEL INJECTION SYSTEM Fault code No. Symptom Lean angle sensor: open or short circuit detected. Diagnostic code No. Lean angle sensor Order Item/components and probable Check or maintenance job Reinstatement cause method Connections • Check the coupler for any pins Reinstated im- •…
• Page 348
  FUEL INJECTION SYSTEM Fault code No. Symptom The ECU (engine control unit) is unable to monitor the battery voltage (an open or short circuit in the line to the ECU). Diagnostic code No. Fuel injection system relay Order Item/components and probable Check or maintenance job Reinstatement cause…
• Page 349
  FUEL INJECTION SYSTEM Fault code No. Symptom Power supply to the fuel injection system is not normal. Diagnostic code No. — — Order Item/components and probable Check or maintenance job Reinstatement cause method Connection. • Check the coupler for any pins Starting the en- •…

• Page 350: Fuel Pump System

  FUEL PUMP SYSTEM EAS27550 FUEL PUMP SYSTEM EAS27560 CIRCUIT DIAGRAM 8-53…

• Page 351
  FUEL PUMP SYSTEM 4. Main switch 7. Fuel injection system fuse 11.Ignition fuse 14.Battery 15.Main fuse 20.Engine stop switch 25.Fuel injection system relay 26.Fuel pump 29.ECU (engine control unit) 8-54…

• Page 352: Troubleshooting

  FUEL PUMP SYSTEM EAS27570 TROUBLESHOOTING If the fuel pump fails to operate. • Before troubleshooting, remove the following part(s): 1. Front cowling assembly 2. Storage box NG → 1. Check the fuses. (Main, ignition and fuel injection system) Replace the fuse(s). Refer to “CHECKING THE FUS- ES”…

• Page 353
  FUEL PUMP SYSTEM 8-56…

• Page 354: Electrical Components

  ELECTRICAL COMPONENTS EAS27971 ELECTRICAL COMPONENTS 8-57…

• Page 355
  ELECTRICAL COMPONENTS 1. Front brake light switch 2. Rear brake light switch 3. Battery 4. Main fuse 5. Starter relay 6. Diode 2 7. Diode 1 8. Rectifier/regulator 9. Ignition coil 10.Speed sensor 11.Turn signal relay 12.Horn 13.ECU (electronic control unit) 14.Lean angle sensor 15.Starting circuit cut-off relay 16.Headlight relay…
• Page 356
  ELECTRICAL COMPONENTS 8-59…
• Page 357
  ELECTRICAL COMPONENTS 1. Main switch 2. Intake air temperature sensor 3. Throttle position sensor 4. Intake air pressure sensor 5. Coolant temperature sensor 6. Fuel pump 7. O sensor 8. Crankshaft position sensor 9. Stator coil 10.Sidestand switch 11.Radiator fan 8-60…

• Page 358: Checking The Switches

  ELECTRICAL COMPONENTS EAS27980 CHECKING THE SWITCHES B/Y B/W Br/W Y Br/W Ch Dg Br B/Y L/B L/Y B (BLACK) B L/W R/W R/B R/W L/W R Br/L L/G L/B R L/G ( BLUE ) Br/L 8-61…

• Page 359
  ELECTRICAL COMPONENTS 1. Dimmer switch 2. Horn switch 3. Turn signal switch 4. Rear brake light switch 5. Engine stop switch 6. Start switch 7. Front brake light switch 8. Main switch 9. Sidestand switch 10. Storage box light switch 8-62…
• Page 360
  ELECTRICAL COMPONENTS Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14370 NOTICE Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from the opposite end of the coupler, taking care not to loosen or damage the leads.

• Page 361: Checking The Bulbs And Bulb Sockets

  ELECTRICAL COMPONENTS 1. Remove: EAS27990 CHECKING THE BULBS AND BULB • Bulb SOCKETS EWA4B51012 WARNING Do not check any of the lights that use LEDs. Since the headlight bulbs get extremely hot, keep flammable products and your hands Check each bulb and bulb socket for damage or away from them until they have cooled wear, proper connections, and also for continuity down.

• Page 362: Checking The Fuses

  ELECTRICAL COMPONENTS Set the pocket tester selector to “Ω × 1”. Pocket tester 90890-03112 Analog pocket tester YU-03112-C b. If the pocket tester indicates “∞”, replace the fuse. L LLL L LLL L LLL L LLL L LLL Checking the condition of the bulb sockets 3.

• Page 363: Checking And Charging The Battery

  ELECTRICAL COMPONENTS 4. Install: • Battery cover Since VRLA (Valve Regulated Lead Acid) bat- Refer to “GENERAL CHASSIS” on page 4-1. teries are sealed, it is not possible to check the charge state of the battery by measuring the EAS28030 CHECKING AND CHARGING THE BATTERY specific gravity of the electrolyte.

• Page 364
  ELECTRICAL COMPONENTS • When charging a battery, be sure to remove Example it from the vehicle. (If charging has to be Open-circuit voltage = 12.0 V done with the battery mounted on the vehi- Charging time = 6.5 hours Charge of the battery = 20–30% cle, disconnect the negative battery lead from the battery terminal.) •…
• Page 365
  ELECTRICAL COMPONENTS c. Make sure that the current is higher than the standard charging current written on the bat- Voltage should be measured 30 minutes after tery. the engine is turned off. b. Connect a charger and ammeter to the bat- If the current is lower than the standard charging tery and start charging.

• Page 366: Checking The Relays

  ELECTRICAL COMPONENTS • Battery cover 4. Negative tester probe Refer to “GENERAL CHASSIS” on page 4-1. Result EAS28040 Continuity CHECKING THE RELAYS (between “3” and “4”) Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, re- place the relay.

• Page 367: Checking The Turn Signal Relay

  ELECTRICAL COMPONENTS Fuel injection system relay M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (DC 20 V) to the turn signal relay terminal as shown. Pocket tester 90890-03112 Analog pocket tester YU-03112-C L/ R •…

• Page 368: Checking The Diode

  ELECTRICAL COMPONENTS c. Check the diode 1 for continuity. d. Check the diode 1 for no continuity. L LLL L LLL L LLL L LLL L LLL EAS28070 CHECKING THE SPARK PLUG CAPS The following procedure applies to all of the spark plug caps.

• Page 369: Checking The Ignition Spark Gap

  ELECTRICAL COMPONENTS c. Measure the secondary coil resistance. Pocket tester L LLL L LLL L LLL L LLL L LLL 90890-03112 EAS28930 Analog pocket tester CHECKING THE IGNITION SPARK GAP YU-03112-C 1. Check: • Ignition spark gap • Positive tester probe→ Out of specification →…

• Page 370: Checking The Lean Angle Sensor

  ELECTRICAL COMPONENTS 2. Check: Pocket tester • Crankshaft position sensor resistance 90890-03112 Out of specification → Replace the crank- Analog pocket tester shaft position sensor/stator assembly. YU-03112-C Crankshaft position sensor resis- • Positive tester probe → tance 189–231 Ω at 20 °C (68 °F) yellow/green “1”…

• Page 371: Checking The Stator Coil

  ELECTRICAL COMPONENTS b. Check the starter motor operation. b. Measure the stator coil resistance. L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL L LLL EAS28150 EAS28170 CHECKING THE STATOR COIL CHECKING THE RECTIFIER/REGULATOR 1.

• Page 372: Checking The Horn

  ELECTRICAL COMPONENTS EAS28180 EAS28230 CHECKING THE HORN CHECKING THE FUEL SENDER 1. Check: 1. Disconnect: • Horn resistance • Fuel pump coupler Out of specification → Replace. • Fuel hose (from the fuel pump) Coil resistance Refer to “GENERAL CHASSIS” on page 4-1. 1.06–1.11 Ω…

• Page 373: Checking The Speed Sensor

  ELECTRICAL COMPONENTS c. Elevate the front wheel and slowly rotate it. d. Measure the voltage of white and black/blue. With each full rotation of the front wheel, the voltage reading should cycle from 0 V to 5.0 V to 0 V to 5.0 V. L LLL L LLL L LLL…

• Page 374: Checking The Throttle Position Sensor

  ELECTRICAL COMPONENTS M MMM M MMM M MMM M MMM M MMM a. Connect the pocket tester (Ω × 100) to the Pocket tester 90890-03112 coolant temperature sensor terminals as Analog pocket tester shown. YU-03112-C Pocket tester • Tester positive lead → 90890-03112 Analog pocket tester blue “1”…

• Page 375: Checking The Intake Air Temperature Sensor

  ELECTRICAL COMPONENTS • Positive tester probe → blue “1” • Negative tester probe → pink/white “2” B/L P/W L b. Measure the intake air temperature sensor resistance. L LLL L LLL L LLL L LLL L LLL b. Turn the main switch to “ON”. c.

• Page 376
  ELECTRICAL COMPONENTS 8-79…

• Page 377: Troubleshooting

  TROUBLESHOOTING TROUBLESHOOTING………………9-1 GENERAL INFORMATION …………… 9-1 STARTING FAILURE/HARD STARTING……….9-1 INCORRECT ENGINE IDLING SPEED ………… 9-1 POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ……9-2 FAULTY CLUTCH ………………9-2 OVERHEATING ………………9-2 OVERCOOLING………………9-3 POOR BRAKING PERFORMANCE…………9-3 FAULTY FRONT FORK LEGS…………..9-3 UNSTABLE HANDLING …………….9-3 FAULTY LIGHTING OR SIGNALING SYSTEM ……..9-4…

• Page 378: Troubleshooting

  TROUBLESHOOTING • Sucked-in air EAS28450 TROUBLESHOOTING Electrical system EAS28460 1. Battery GENERAL INFORMATION • Discharged battery • Faulty battery The following guide for troubleshooting does not 2. Fuse(s) cover all the possible causes of trouble. It should • Blown, damaged or incorrect fuse be helpful, however, as a guide to basic trouble- •…

• Page 379: Poor Medium-And-High-Speed Performance

  TROUBLESHOOTING • Improper throttle cable free play 2. Engine oil • Flooded throttle body • Incorrect oil level • Incorrect oil viscosity (low) Electrical system • Deteriorated oil 1. Battery 3. Primary sliding sheave • Discharged battery • Seized primary sliding sheave •…

• Page 380: Overcooling

  TROUBLESHOOTING • Thermostat • Damaged oil seal lip • Thermostat stays closed • Incorrect oil level (high) • Oil cooler • Loose damper rod bolt • Clogged or damaged oil cooler • Damaged damper rod bolt copper washer • Hose(s) and pipe(s) •…

• Page 381: Faulty Lighting Or Signaling System

  TROUBLESHOOTING Turn signal flashes quickly EAS28710 FAULTY LIGHTING OR SIGNALING SYSTEM • Incorrect turn signal bulb • Faulty turn signal relay Headlight does not come on • Burnt-out turn signal bulb • Wrong headlight bulb • Too many electrical accessories Horn does not sound •…

• Page 382: Wiring Diagram

  EAS28740 57. Rear brake light switch EAS28750 WIRING DIAGRAM COLOR CODE 58. Horn Black 59. Front right turn signal/position XP500Y 2009 Brown light 1. Crankshaft position sensor Chocolate 60. Front left turn signal/position 2. AC magneto Dark green light 3. Rectifier/regulator Green 61.

• Page 384
  YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN…
• Page 385
  XP500Y 2009 WIRING DIAGRAM HEADLIGHT HEADLIGHT GRIP WARMER STORAGE BOX WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS LIGHT SUB-WIRE HARNESS HARNESS HARNESS HARNESS W/Y Y/R L/Y B/L P/W Br/W G/R R/B R/W B/W B/Y W Gy/G Y/G Y/L (BLACK) W W W W W W…
• Page 386
  XP500Y 2009 WIRING DIAGRAM HEADLIGHT HEADLIGHT GRIP WARMER STORAGE BOX WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS SUB-WIRE WIRE HARNESS LIGHT SUB-WIRE HARNESS HARNESS HARNESS HARNESS (BLACK) (BLACK) (GREEN) (BLACK) (GREEN) ( GREEN ) ( GREEN ) (DARK BLUE) ( BLACK ) ( BLUE ) ( BLACK )

• Page 1
  OWNER’S MANUAL XP500 XP500A 15B-28199-E0…
• Page 2
  EAU26943 DECLARATION of CONFORMITY Company: MORIC CO., LTD. Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan Hereby declare that the product: Kind of equipment: IMMOBILIZER Type-designation: 5SL-00 is in compliance with following norm(s) or documents: R&TTE Directive(1999/5/EC) EN300 330-2 v1.1.1(2001-6), EN60950-1(2001) Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC) Place of issue: Shizuoka, Japan Date of issue: 1 Aug.
• Page 3
  Yamaha a reputation for dependability. Please take the time to read this manual thoroughly, so as to enjoy all advantages of your XP500/XP500A. The owner’s man- ual does not only instruct you in how to operate, inspect and maintain your scooter, but also in how to safeguard yourself and others from trouble and injury.
• Page 4
  This manual should be considered a permanent part of this scooter and should remain with it even if the scooter is sub- sequently sold. Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your scooter and this manual.
• Page 5
  IMPORTANT MANUAL INFORMATION EAU10200 XP500/XP500A OWNER’S MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st edition, September 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

• Page 6: Table Of Contents

  TABLE OF CONTENTS SAFETY INFORMATION ….1-1 Ignition circuit cut-off system ..3-18 Checking the throttle cable free Further safe-riding points ….1-4 play ……….6-19 PRE-OPERATION CHECKS ….4-1 Valve clearance ……6-19 DESCRIPTION ……..2-1 Pre-operation check list ….4-2 Tires ……….6-19 Left view ………..2-1 Cast wheels ……..

• Page 7
  TABLE OF CONTENTS Replacing an auxiliary light bulb ..6-35 Troubleshooting ……6-35 Troubleshooting charts ….6-36 SCOOTER CARE AND STORAGE ………..7-1 Matte color caution ……7-1 Care ……….7-1 Storage ……….7-3 SPECIFICATIONS ……8-1 CONSUMER INFORMATION….9-1 Identification numbers …..9-1…

• Page 8: Safety Information

  SAFETY INFORMATION EAU10261 TIONS. Many accidents involve inexperi- enced operators. In fact, many op- SCOOTERS ARE SINGLE TRACK Safe riding erators who have been involved in VEHICLES. THEIR SAFE USE AND Always make pre-operation accidents do not even have a cur- OPERATION DEPENDENT checks.

• Page 9
  SAFETY INFORMATION Always signal before turning or ries. The use of a safety helmet is the approved by Yamaha, or the removal of changing lanes. Make sure that single most critical factor in the preven- original equipment, may render the other motorists can see you.
• Page 10
  Gasoline and exhaust gas this scooter. Since Yamaha cannot test should be kept to a minimum. GASOLINE IS HIGHLY FLAMMA- all other accessories that may be avail-…

• Page 11: Further Safe-Riding Points

  SAFETY INFORMATION Take care not to spill any gaso- sene heater, or near an open EAU10371 Further safe-riding points line on the engine or exhaust flame), otherwise it could catch Be sure to signal clearly when system when refueling. fire. making turns.

• Page 12
  SAFETY INFORMATION and ankle so they do not flap), and a bright colored jacket. Do not carry too much luggage on the scooter. An overloaded scoot- er is unstable.
• Page 13
  SAFETY INFORMATION…

• Page 14: Description

  DESCRIPTION EAU10410 Left view 9 8 7 6 1. Fuel tank cap (page 3-12) 9. Engine oil level check window (page 6-11) 2. Rear storage compartment (page 3-16) 10. Oil filter cartridge (page 6-11) 3. Helmet holder (page 3-15) 4. Grab bar (page 5-2) 5.

• Page 15: Right View

  DESCRIPTION EAU10420 Right view 1. Battery (page 6-29) 9. Passenger footrest 2. Fuses (page 6-30) 3. Owner’s tool kit (page 6-1) 4. Front storage compartment (page 3-16) 5. Air filter element (page 6-17) 6. Coolant level check window (page 6-15) 7.

• Page 16: Controls And Instruments

  DESCRIPTION EAU10430 Controls and instruments 1. Rear brake lever (page 3-10) 9. Throttle grip (page 6-19) 2. Left handlebar switches (page 3-9) 10. Main switch/steering lock (page 3-2) 3. Rear brake lock lever (page 3-11) 4. Speedometer (page 3-4) 5. Multi-function display (page 3-5) 6.

• Page 17: Instrument And Control Functions

  Do not expose any key to exces- the vehicle along with all three keys to sively high temperatures. a Yamaha dealer to have them re-reg- Do not place any key close to istered. Do not use the key with the red magnets (this includes, but not bow for driving.

• Page 18: Main Switch/Steering Lock

  INSTRUMENT AND CONTROL FUNCTIONS EAU10471 come on, and the engine can be start- To unlock the steering Main switch/steering lock ed. The key cannot be removed. Push the key in, and then turn it to “OFF” while still pushing it. NOTE: EWA10060 The headlights come on automatically…

• Page 19: Indicator And Warning Lights

  ” and “ ” on for a few seconds, then go off, have 2. High beam indicator light “ ” a Yamaha dealer check the electrical 3. Immobilizer system indicator light circuit. 4. Engine trouble warning light “ ” NOTE: 5.

• Page 20: Speedometer

  If the indicator light does not come on ABS. for a few seconds, then go off, have a The electrical circuit of the warning light Yamaha dealer check the electrical cir- can be checked by setting the engine cuit. stop switch to “…

• Page 21: Tachometer

  INSTRUMENT AND CONTROL FUNCTIONS EAU11872 EAU33519 Tachometer Multi-function display EWA12311 WARNING Be sure to stop the vehicle before making any setting changes to the multi-function display. 1. V-belt replacement indicator “V-BELT” 2. Fuel level warning indicator “ ” 1. Tachometer 3.

• Page 22
  INSTRUMENT AND CONTROL FUNCTIONS cator started flashing) automatically change to the fuel re- will reset itself automatically and the a self-diagnosis device serve tripmeter mode “TRIP F” and display will return to the prior mode af- a clock start counting the distance traveled ter refueling and traveling 5 km (3 mi).
• Page 23
  If the multi-function display indicates NOTE: such an error code, note the code num- The oil change indicator may flash ber, and then have a Yamaha dealer Oil change indicator “OIL” when the engine is revved with the check the vehicle.

• Page 24: Anti-Theft Alarm (Optional)

  Contact a Yamaha dealer for two-digit error code when the key is any error codes, note the code number, more information. turned to “ON”. and then have a Yamaha dealer check the vehicle. NOTE: If the multi-function display indicates er- Clock mode…

• Page 25: Handlebar Switches

  INSTRUMENT AND CONTROL FUNCTIONS EAU12347 Right leased, the switch returns to the center Handlebar switches position. To cancel the turn signal lights, push the switch in after it has re- Left turned to the center position. EAU12500 Horn switch “ ”…

• Page 26: Front Brake Lever

  INSTRUMENT AND CONTROL FUNCTIONS EAU41700 EAU12900 EAU12950 Front brake lever Rear brake lever The engine trouble warning light will come on when the key is turned to “ON” and the start switch is pushed, but this does not indicate a malfunction. EAU12733 Hazard switch “…

• Page 27: Rear Brake Lock Lever

  EAU12991 Rear brake lock lever ABS (for ABS models) To provide secure locking of the The Yamaha ABS (Anti-lock Brake rear wheel, apply the rear brake le- System) features a dual electronic con- ver first before moving the rear trol system, which acts on the front and brake lock lever to the left.

• Page 28: Fuel Tank Cap

  ABS is operating. However, 1. Fuel tank cap special tools are required, so To install the fuel tank cap please consult your Yamaha deal- 1. Align the match marks, insert the er when performing this test. fuel tank cap into the tank opening, and then push down on the cap.

• Page 29: Fuel

  EWA10880 WARNING Your Yamaha engine has been de- Do not overfill the fuel tank, oth- signed to use regular unleaded gaso- erwise it may overflow when the line with a research octane number of fuel warms up and expands.

• Page 30: Catalytic Converter

  INSTRUMENT AND CONTROL FUNCTIONS EAU13431 EAU13932 Catalytic converter Seat This model is equipped with a catalytic converter in the exhaust system. To open the seat 1. Place the scooter on the center- EWA10860 WARNING stand. The exhaust system is hot after op- 2.

• Page 31: Adjusting The Rider Backrest

  INSTRUMENT AND CONTROL FUNCTIONS EAU14270 EAU14340 Adjusting the rider backrest Helmet holder The rider backrest can be adjusted to the three different positions shown. 1. Rider backrest 2. Bolt 1. Helmet holder 3. Slide the backrest forward or back- The helmet holder is located under the ward to the desired position.

• Page 32: Storage Compartments

  INSTRUMENT AND CONTROL FUNCTIONS EAU14503 Rear storage compartment EWA10160 Storage compartments WARNING A helmet can be stored in the rear stor- age compartment under the seat. (See Never ride with a helmet attached to Front storage compartment page 3-14.) To store a helmet in the the helmet holder, since the helmet To open the front storage compart- rear storage compartment, place the…

• Page 33: Shock Absorber

  Do not exceed the maximum er handling, read and understand side it. load of XP500 188 kg (414 lb) the following information before To avoid humidity from spread- XP500A 183 kg (403 lb) for the handling the shock absorber.

• Page 34: Sidestand

  Yamaha’s ignition circuit cut-off system has been designed to assist the operator in fulfilling the respon- sibility of raising the sidestand be- fore starting off. Therefore, check this system regularly as described below and have a Yamaha dealer re- 3-18…

• Page 35
  Does the engine start? The sidestand switch may be defective. The scooter should not be ridden until checked by a Yamaha dealer. With the engine still off: 6. Move the sidestand up. 7. Keep the front or rear brake applied.

• Page 36: Pre-Operation Checks

  PRE-OPERATION CHECKS EAU15592 The condition of a vehicle is the owner’s responsibility. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused (for example, as a result of exposure to the elements). Any damage, fluid leakage or loss of tire air pressure could have serious consequences.

• Page 37: Pre-Operation Check List

  If necessary, add recommended brake fluid to specified level. Check hydraulic system for leakage. Make sure that operation is smooth. Check cable free play. Throttle grip 6-19, 6-25 If necessary, have Yamaha dealer adjust cable free play and lubricate cable and grip housing.

• Page 38
  Make sure that all nuts, bolts and screws are properly tightened. Chassis fasteners — Tighten if necessary. Instruments, lights, signals Check operation. — and switches Correct if necessary. Check operation of ignition circuit cut-off system. Sidestand switch 3-18 If system is defective, have Yamaha dealer check vehicle.

• Page 39: Operation And Important Riding Points

  If a warning light, indicator light or Consult a Yamaha dealer re- In order for the ignition circuit cut-off indicator does not go off, see page garding any control or function…

• Page 40: Starting Off

  OPERATION AND IMPORTANT RIDING POINTS cold! EAU16760 EAU16780 Starting off Acceleration and deceleration NOTE: Before starting off, allow the engine to warm up. 1. While pulling the rear brake lever with your left hand and holding the grab bar with your right hand, push the scooter off the centerstand.

• Page 41: Braking

  OPERATION AND IMPORTANT RIDING POINTS EAU16792 Rear cult. Braking 1. Close the throttle completely. 2. Apply both front and rear brakes simultaneously while gradually in- creasing the pressure. Front EWA10300 WARNING Avoid braking hard or suddenly (especially when leaning over to one side), otherwise the scooter may skid or overturn.

• Page 42: Tips For Reducing Fuel Consumption

  Yamaha dealer check the vehi- avoided. cle. EAU36530 0–1000 km (0–600 mi) Avoid prolonged operation above 4000 r/min.

• Page 43: Parking

  OPERATION AND IMPORTANT RIDING POINTS EAU17212 Parking When parking, stop the engine, and then remove the key from the main switch. EWA10310 WARNING Since the engine and exhaust system can become very hot, park in a place where pedestri- ans or children are not likely to touch them.

• Page 44: Periodic Maintenance And Minor Repair

  Con- safest and most efficient condition pos- sult a Yamaha dealer for proper sible. The most important points of in- maintenance intervals. spection, adjustment, and lubrication are explained on the following pages.

• Page 45
  PERIODIC MAINTENANCE AND MINOR REPAIR a Yamaha dealer perform it for you. EWA10350 WARNING Modifications approved Yamaha may cause loss of perfor- mance and render the vehicle un- safe for use. Consult a Yamaha dealer before attempting any chang-…

• Page 46: Periodic Maintenance And Lubrication Chart

  The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead. From 50000 km, repeat the maintenance intervals starting from 10000 km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. ODOMETER READING (× 1000 km)

• Page 47
  PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK √ √ √ √ √ Check for cracks or damage. 9 * Brake hoses Replace. Every 4 years √ √ √ √ 10 * Wheels Check runout and for damage.
• Page 48
  PERIODIC MAINTENANCE AND MINOR REPAIR ODOMETER READING (× 1000 km) ANNUAL ITEM CHECK OR MAINTENANCE JOB CHECK Front and rear brake √ √ √ √ √ √ 25 * Check operation. switches √ √ √ √ √ Moving parts and cables Lubricate.

• Page 49: Removing And Installing Cowlings And Panels

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU18712 Removing and installing cowlings and panels The cowlings and panels shown need to be removed to perform some of the maintenance jobs described in this chapter. Refer to this section each time a cowling or panel needs to be re- moved and installed.

• Page 50
  PERIODIC MAINTENANCE AND MINOR REPAIR 2. Remove the cowling bolts, and then pull the cowling off. To install the cowling 1. Place the cowling in the original position, and then install the bolts. 2. Install the battery cover by install- ing the screws.
• Page 51
  PERIODIC MAINTENANCE AND MINOR REPAIR 3. Pull outward on the front of the panel. To install the panel Place the panel in the original position, and then install the screws. 1. Screw 1. Screw To install the panel To install the panel Place the panel in the original position, Place the panel in the original position, and then install the screws.

• Page 52: Checking The Spark Plugs

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU19593 3. Remove the spark plug cap. Checking the spark plugs The spark plugs are important engine components, which are easy to check. Since heat and deposits will cause any spark plug to slowly erode, the spark plugs should be removed and checked in accordance with the periodic mainte- nance and lubrication chart.

• Page 53
  5. Place the spark plug cover in the diagnose such problems yourself. In- Spark plug gap: original position as shown, and stead, have a Yamaha dealer check 0.7–0.8 mm (0.028–0.031 in) then install the cowling. the vehicle. 2. Clean the surface of the spark plug 3.

• Page 54: Engine Oil And Oil Filter Cartridge

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU19854 tles, and then check the oil level To change the engine oil (with or Engine oil and oil filter through the check window located without oil filter cartridge replace- cartridge at the bottom-left side of the crank- ment) The engine oil level should be checked case.

• Page 55
  17 Nm (1.7 m·kgf, 12.3 ft·lbf) An oil filter wrench is available at a not being replaced. Yamaha dealer. 7. Install the engine oil drain bolt, and 4. Remove the oil filter cartridge with then tighten it to the specified 5.
• Page 56
  PERIODIC MAINTENANCE AND MINOR REPAIR check the oil level and correct it if reset after the oil change for the next Recommended engine oil: necessary. periodic oil change to be indicated at See page 8-1. 11. Reset the oil change indicator ac- the correct time.

• Page 57: Chain Drive Oil

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU19994 Chain drive oil Tightening torque: Chain drive oil drain bolt: The chain drive oil should be changed 20 Nm (2.0 m·kgf, 14.5 ft·lbf) as follows at the intervals specified in the periodic maintenance and lubrica- 5.

• Page 58: Coolant

  PERIODIC MAINTENANCE AND MINOR REPAIR 10. Install the panel. EAU20070 Coolant The coolant level should be checked before each ride. In addition, the cool- ant must be changed at the intervals specified in the periodic maintenance and lubrication chart. EAU42831 To check the coolant level 1.

• Page 59
  PERIODIC MAINTENANCE AND MINOR REPAIR er by removing the screw. coolant, have a Yamaha dealer check the antifreeze content of the coolant as soon as possible, otherwise the effectiveness of the coolant will be reduced. EWA10380 WARNING Never attempt to remove the radiator cap when the engine is hot.

• Page 60: Cleaning The Air Filter Element

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU21121 Cleaning the air filter element The air filter element should be cleaned at the intervals specified in the periodic maintenance and lubrication chart. Clean the air filter element more fre- quently if you are riding in unusually wet or dusty areas.

• Page 61: Adjusting The Engine Idling Speed

  Yamaha dealer make the adjustment. ing screw. To increase the engine idling speed, turn the screw in di- 3. Install the panel.

• Page 62: Checking The Throttle Cable Free Play

  To prevent this note the following points regarding the from occurring, the valve clearance specified tires. must be adjusted by a Yamaha dealer at the intervals specified in the periodic Tire air pressure maintenance and lubrication chart.

• Page 63
  Do not carry along loosely Rear: packed items, which can shift 250 kPa (36 psi) (2.50 kgf/cm during a ride. XP500 90–188 kg (198–414 lb) Securely pack the heaviest XP500A 90–183 kg (198–403 lb): items close to the center of the Front: 225 kPa (33 psi) (2.25 kgf/cm…

• Page 64: Cast Wheels

  DUNLOP/D252F fore each ride. If any damage is BRIDGESTONE/TH01F Rear tire: found, have a Yamaha dealer re- Size: place the wheel. Do not attempt 160/60R15 M/C 67H even the smallest repair to the Manufacturer/model: wheel.

• Page 65: Front And Rear Brake Lever Free Play

  Front in the hydraulic system. If there is air in the hydraulic system, have a Yamaha dealer bleed the system be- fore operating the vehicle. Air in the hydraulic system will diminish the braking performance, which may re- sult in loss of control and an acci- dent.

• Page 66: Checking The Front And Rear Brake Pads

  EAU22390 indicator grooves have almost disap- Checking the front and rear cable length, turn the adjusting nut in peared, have a Yamaha dealer replace brake pads direction (b). the brake pads as a set. The front and rear brake pads must be…

• Page 67: Checking The Brake Fluid Level

  PERIODIC MAINTENANCE AND MINOR REPAIR stalling the bolts, then tightening EAU22710 enter the brake system, possibly caus- Checking the brake fluid level them to the specified torque. ing it to become ineffective. Before riding, check that the brake fluid Tightening torque: Front brake is above the minimum level mark and Brake caliper bolt:…

• Page 68: Changing The Brake Fluid

  EAU23111 Changing the brake fluid Checking and lubricating the cantly lower the boiling point of the Have a Yamaha dealer change the throttle grip and cable fluid and may result in vapor lock, brake fluid at the intervals specified in…

• Page 69: Lubricating The Front And Rear Brake Levers

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU23171 tenance and lubrication chart. EAU23211 Lubricating the front and rear Checking and lubricating the Recommended lubricant: brake levers centerstand and sidestand Lithium-soap-based grease (all-pur- pose grease) Front brake lever Rear brake lever The operation of the centerstand and sidestand should be checked before each ride, and the pivots and met- The pivoting points of the front and rear…

• Page 70: Checking The Front Fork

  If the centerstand or sidestand does fork must be checked as follows at the not move up and down smoothly, intervals specified in the periodic main- have a Yamaha dealer check or re- tenance and lubrication chart. pair it. To check the condition…

• Page 71: Checking The Steering

  2. Hold the lower ends of the front fork legs and try to move them for- ward and backward. If any free play can be felt, have a Yamaha dealer check or repair the steering. 6-28…

• Page 72: Battery

  To charge the battery away from the battery and pro- Have a Yamaha dealer charge the bat- vide sufficient ventilation when tery as soon as possible if it seems to charging it in an enclosed have discharged.

• Page 73: Replacing The Fuses

  If you do not have access to a The fuse box, which contains the fuses sealed-type (MF) battery charg- for the individual circuits, is located un- er, have a Yamaha dealer der the battery cover and can be ac- charge your battery. cessed as follows.

• Page 74
  PERIODIC MAINTENANCE AND MINOR REPAIR amperage. For non-ABS models For ABS models NOTE: To access the main fuse, remove the main fuse box cover as shown. 1. Signaling system fuse 1. Signaling system fuse 2. Headlight fuse 2. Headlight fuse 3.

• Page 75: Replacing The Headlight Bulb

  This model is equipped with a quartz 4. If the fuse immediately blows 30.0 A bulb headlight. If the headlight bulb Headlight fuse: again, have a Yamaha dealer 15.0 A burns out, replace it as follows. check the electrical system. Signaling system fuse: 1.

• Page 76: Tail/Brake Light

  Thoroughly clean off any dirt If the tail/brake light does not come on, and fingerprints on the headlight have a Yamaha dealer check its electri- bulb using a cloth moistened with al- cal circuit or replace the bulb. cohol or thinner.

• Page 77: Replacing A Front Turn Signal Light Bulb

  PERIODIC MAINTENANCE AND MINOR REPAIR EAU43050 EAU24270 bulb) by turning it clockwise. Replacing a front turn signal Replacing a rear turn signal 7. Install the cowling. light bulb light bulb 1. Place the scooter on the center- 1. Place the scooter on the center- stand.

• Page 78: License Plate Light

  However, should your scooter re- quire any repair, take it to a Yamaha dealer, whose skilled technicians have the necessary tools, experience, and know-how to service the scooter prop- erly.

• Page 79: Troubleshooting Charts

  Remove the spark plugs and check the electrodes. The engine does not start. Have a Yamaha dealer check the vehicle. Check the battery. 4. Battery The engine turns over The battery is good.

• Page 80
  Start the engine. If the engine overheats again, have a The coolant level Yamaha dealer check and repair the cooling system. is OK. NOTE: If coolant is not available, tap water can be temporarily used instead, provided that it is changed to the recommended coolant as soon as possible.

• Page 81: Scooter Care And Storage

  Be Rust and corrosion can develop even if ECA10780 CAUTION: sure to consult a Yamaha dealer for high-quality components are used. A advice on what products to use be- rusty exhaust pipe may go unnoticed Avoid using strong acidic wheel fore cleaning the vehicle.

• Page 82
  SCOOTER CARE AND STORAGE thinner, fuel (gasoline), rust re- After normal use salt. movers or inhibitors, brake flu- Remove dirt with warm water, a mild 2. Apply a corrosion protection spray id, antifreeze or electrolyte. detergent, and a soft, clean sponge, on all metal, including chrome- and Do not use high-pressure wash- and then rinse thoroughly with clean…

• Page 83: Storage

  “Care” section of this chapter. away the paint. 2. Fill up the fuel tank and add fuel stabilizer (if available) to prevent NOTE: the fuel tank from rusting and the Consult a Yamaha dealer for advice on…

• Page 84
  SCOOTER CARE AND STORAGE fuel from deteriorating. pivoting points of all levers and 3. Perform the following steps to pro- pedals as well as of the sidestand/ tect the cylinders, piston rings, etc. centerstand. from corrosion. 5. Check and, if necessary, correct a.

• Page 85: Specifications

  SAE80 API GL-4 Hypoid gear oil Spur gear/helical gear With oil and fuel: Quantity: Primary reduction ratio: XP500 227.0 kg (500 lb) 0.70 L (0.74 US qt) (0.62 Imp.qt) 52/32 × 36/22 (2.659) XP500A 232.0 kg (511 lb) Cooling system:…

• Page 86
  Rear: Front suspension: 95.0 mm (3.74 in) 250 kPa (36 psi) (2.50 kgf/cm Type: Front tire: Loading condition: Telescopic fork XP500 90–188 kg (198–414 lb) Type: Spring/shock absorber type: XP500A 90–183 kg (198–403 lb) Tubeless Coil spring/oil damper Front: Size: Wheel travel: 225 kPa (33 psi) (2.25 kgf/cm…
• Page 87
  ABS warning light: XP500A 14 V, 1.4 W × 1 Immobilizer system indicator light: Fuses: Main fuse: 30.0 A Headlight fuse: 15.0 A Signaling system fuse: XP500 20.0 A XP500A 15.0 A Ignition fuse: 10.0 A Parking lighting fuse: 10.0 A…

• Page 88: Consumer Information

  Record the key identification number, vehicle identification number and mod- el label information in the spaces pro- vided below for assistance when ordering spare parts from a Yamaha dealer or for reference in case the vehi- cle is stolen. KEY IDENTIFICATION NUMBER: 1.

• Page 89
  The model label is affixed to the inside of the rear storage compartment. (See page 3-16.) Record the information on this label in the space provided. This in- formation will be needed when ordering spare parts from a Yamaha dealer.
• Page 90
  INDEX Front and rear brake pads, checking ..6-23 Pre-operation check list……4-2 Front fork, checking ………6-27 ABS (for ABS models) ……3-11 Fuel…………3-13 ABS warning light (for ABS models) ..3-3 Rear brake lock lever ……3-11 Fuel consumption, tips for reducing…5-4 Acceleration and deceleration….
• Page 91
  INDEX Valve clearance ……..6-19 Vehicle identification number…..9-1 Wheel bearings, checking …….6-28 Wheels………….6-21…
• Page 94
  YAMAHA MOTOR CO., LTD. YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED ON RECYCLED PAPER PRINTED IN JAPAN PRINTED IN JAPAN 2006.10–0.2×1 ! 2006.10–0.2×1 !

21:00

Yamaha XP500 Tmax (2001) Обзор и тест-драйв | Полуспортивный табурет

00:59

Used Engine Yamaha XP500 T-Max 2001 259784

00:58

Yamaka T-Max accelaration 0-Top speed

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Yamaha T-max 500 (2002)

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Yamaha Tmax 500 2001 acceleration

21:53

Yamaha T-Max 500. Пол-литра годного скутера.

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Обзор- тестдрайв Yamaha Tmax 500, по улицам Улан-Удэ.

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Yamaha T-MAX 500 Обзор макси скутера.