g@ > é SNe P rr" Servi vice ManualYZF-RF SERVICE MANUAL, ©2015 by Yamaha Motor Corporation, U. First edition, January 2015 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. expressly prohibited.IMPORTANT This manual was produced by the Yamaha Motor Corporation, U.S.A. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in ‘one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use. ‘Yamaha Motor Corporation, U.S.A. is continually striving to improve all ofits models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable T1P Designs and specifications are subject to change without notice. IMPORTANT MANUAL INFORMATION Particularly important information is distinguished in this manual by the following notations, ‘This is the safety alert symbol. Itis used to alert you to potential personal inju- ad ry hazards. Obey all safety messages that follow this symbol to avold possible injury or death. . ‘A WARNING indicates a hazardous situation which, if not avoided, could result PMI fin death or serious injury. ‘ANOTIGE indicates special precautions that must be taken to avoid damage to WoneH the vehicle or other property. TIP ‘ATIP provides key information to make procedures easier or clearer.HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive ‘explanations of al installation, removal, disassembly, assembly, repair and check procedures are laid ‘out with the individual steps in sequential order. + The manual is divided into chapters and each chapter is divided into sections, The current section title “1” is shown at the top of each page. + Sub-section titles "2” appear in smaller print than the section title. + To help identify parts and clarity procedure steps, there are exploded diagrams “3” at the start of each removal and disassembly section, + Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas- sembly step. + Symbols “5” indicate parts to be lubricated or replaced. Refer to “SYMBOLS”. “A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation and assembly procedure, reverse the steps. * Jobs "7 requiing mere Infomation (éuch a8 special tole and tecrical dat) are described sequen- tially. 1 zSYMBOLS The following symbols are used in this manual for easier understanding. TP. The following symbols are not relevant to every vehicle, ‘SYMBOL, DEFINITION ‘SYMBOL, DEFINITION x Serviceable with engine mounted 1 _@ 1 mo) 1 Gear oil a Filing fluid Molybdenum disulfide oi Lubricant Brake fluid Special tool Whee! bearing grease Tightening torque ESI | Lihium-soap-based grease Wear limit, clearance SEH | Motyoconum disuitide grease Engine speed =ESP4 | Silicone grease Electrical data Apply locking agent (LOCTITE®) Engine oil Replace the part with anew one, o> (A[S|YLINIL Silicone fluidTABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING OoooGENERAL INFORMATION IDENTIFICATION 1... es VEHICLE IDENTIFICATION NUMBER... 14 MODEL LABEL.. ennntnnsesee 14 FEATURES... ‘OUTLINE OF THE Fi SYSTEM. FISYSTEM. MULTI-FUNCTION METER UNIT..... IMPORTANT INFORMATION 2.00. PREPARATION FOR REMOVAL AND DISASSEMBLY... REPLACEMENT PARTS, GASKETS, OIL SEALS AND O-RINGS...... LOCK WASHERS/PLATES AND COTTER PINS... BEARINGS AND OIL SEALS... CIRCLIPS. RUBBER PARTS... BASIC SERVICE INFORMATION. QUICK FASTENERS....ccsntnnsestnnseen i ELECTRICAL SYSTEM 112 SPECIAL TOOLS...IDENTIFICATION IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicte identification number“ is stamped into the frame under the passenger seat MODEL LABEL ‘The model label “1” is affixed to the frame under the passenger seat. This information will be needed to order spare parts. 1-1FEATURES FEATURES OUTLINE OF THE FI SYSTEM ‘The main function of a fuel supply system is to provide fuel to the combustion chamber at the optimum air-fuel ratio in accordance with the engine operating conditions and the atmospheric temperature. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet used in the respective carburetor. Despite the same volume of intake air, the fuel volume requirement varies by the engine operating con- sitions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that meter the {uel through the use of jets have been provided with various auxiliary devices, so that an optimum air- fuel ratio can be achieved to accommodate the constant changes in the operating conditions of the en- ine, A the requirements fr the engine to deliver more performance and cleaner exhaust gases increase, itbecomes necessary to control the air-fuel ratio in a more precise and finely tuned manner. To accom modate this need, this model has adopted an electronically controlled fuel injection (FI) system, in place ‘of the conventional carburetor system. This system can achieve an optimum air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel injection volume according to the engine operating conditions detected by various sensors. ‘The adoption of the Fl system has resulted in a highly precise fuel supply, improved engine response, better fuel economy, and reduced exhaust emissions. 16 151413 12. 1110 9 1. Engine trouble warning light 10.1SC (idle speed contro!) unit 2. Ignition coils 11. Throttle body sensor assembly 8. Air induction system solenoid 12.0 sensor 4, Coolant temperature sensor 13,Sidestand switch 5. Fuel pump 14.Crankshaft position sensor 6. Battery 18. Speed sensor 7. ECU (engine control unit) 16. Spark plugs 8. Lean angle sensor 9. Fuel injectors 1-2FEATURES FISYSTEM ‘The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains the {uel pressure that is applied to the fuelinjector at a certain level. Accordingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens, causing the fuel to be injected into the intake manifold only during the time the passage remains open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector is energized (injection duration), the lesser the volume of fuel that is supplied. ‘The injection duration and the injection timing are controlled by the ECU. Signals that are input from the throttle position sensor, coolant temperature sensor, lean angle sensor, crankshaft position sensor, in- take air pressure sensor, intake air temperature sensor, speed sensor and O, sensor enable the ECU to determine the injection duration. The injection timing is determined through the signals from the ‘crankshaft position sensor. Asa result, the volume of fuel that is required by the engine can be supplied at all times in accordance with the driving conditions. 1. Fue! pump 18. Intake air temperature sensor 2. Fuslinjector 14. Thvottle position sensor 3. Ignition coil 1. Inlake air pressure sensor ‘4. ECU (engine control unit) 16. Air filter case 6. Lean ange sre A Fuel sje ' B. Air system 7. 1SC (idle speed contol unit - 8. Opsonsor 9. Coolant temperature sensor 10.Crankshatt position sensor 11. Throttle body 12. Throttle body sensor assembly 1-3FEATURES MULTI-FUNCTION METER UNIT 2 678 1. “SEL’ button 2. *RES" button 3. Tachometer 4, Fuel meter 5. Shift timing indicator light 6. Clock 7. Transmission gear display 8. Speedometer 9. Multifunction display 10.Coolant temperature meter PI Be sure to stop the vehicle before making any setting changes to the multi-function meter unit. Changing settings while riding can distract the operator and increase the risk of an accident. ‘The multi-function meter unit is equipped with the following: +a speedometer +a tachometer *aclock + a fuel meter + a coolant temperature meter ‘a transmission gear display +a multi-function display +a shift timing indicator light +a self-diagnosis device 1p Be sure to turn the key to “0.” before using the “SEL” and “RES” buttons, except for setting the shift timing indicator light control mode. Speedometer ‘The speedometer shows the vehicle's traveling speed. 1-4 1. Tachometer 2. Tachometer red zone The tachometer allows the rider to monitor the engine speed and keep it within the ideal power range. When the key is tured to “0”, the tachometer will sweep across the rmin range and then re- tur to zero r/min in order to test the electrical cir- cuit. NOTICE Do not operate the engine in the tachometer red zon Red zone 12500 r/min and above Clock 1. Clock The clock displays when the key is turned to Oo [To set the clock] 4, Turn the key to “ 2. Push the “SEL” button and “RES” button to- gether for at least two seconds. When the hour digits start flashing, push the “RES” button to set the hours. Push the “SEL” button, and the minute digits will start flashing. 5, Push the "RES" button to set the minutes. 3. 4.FEATURES 6. Push the “SEL” button and then release it to start the clock. Fuel meter 1. Fuol meter ‘The fuel meter indicates the amount of fuel in the fuel tank. ‘When the key is turned to“, the display seg- ments of the fuel meter will sweep once across the fuel level range and then return to the current ‘amount in order to test the electrical circuit. The display segments of the fuel meter disap- pear towards “E" (Empty) as the fuel level de- creases. When the last segment starts flashing, refuel as soon as possible. T1P This fuel meter is equipped with a self-diagnosis system. If a problem is detected in the electrical circuit, the following cycle is repeated until the malfunction is corrected: fuel level segments flash eight times, then go off for approximately three seconds. If this occurs, check the electrical circuit. Referto “SIGNALING SYSTEM" on page 821 Coolant temperature meter MW a) f 1. Coolant temperature meter ce ‘The coolant temperature meter indicates the temperature of the coolant. When the key is tured to “0”, the display seg- ments of the digital coolant temperature gauge will sweep once across the temperature range and then retum to °C” in order to test the electri- cal circuit. Ifthe last segment on the right flashes, stop the vehicle, then stop the engine, and let the engine cool. NOTICE Do not continue to operate the engine if itis overheati TP The coolant temperature varies with changes in the weather and engine load. Transmission gear display 1. Neutral indicator ight “N” 2. Transmission gear display This display shows the selected gear. The neu- tral position is indicated by “=" and by the neu- tral indicator light. Multi-function display 1 \ 1. Multi-function display The muitifunction display is equipped with the following + an odometer + two tripmeters + a fuel reserve tripmeter + an instantaneous fuel consumption display + an average fuel consumption display + an oil change tripmeter 1-5FEATURES ‘+ an oll change indicator Push the “SEL” button to switch the display be- tween the odometer mode “ODO", tripmeter modes “TRIP 1” and “TRIP 2", instantaneous fuel consumption mode “km/L", “L/100" or “MPG, average fuel consumption mode "AVE _kmi/L”, “AVE__._L/100 km, of “AVE_ -_MPG" and oil change tripmeter mode “OIL RIP" in the following order: ODO > TRIP 1 > TRIP 2 — kmv/L, L100 km or MPG > AVE__._km/L, AVE__._L/100 km or AVE__._MPG— OIL TRIP > ODO I the left segment of the fuel meter starts flash- ing, the display automatically changes to the fuel reserve tripmeter mode “TRIP F” and starts counting the distance traveled from that point. In that case, push the “SEL" button to switch the display between the various tripmeter, odome- ter, instantaneous fuel consumption and aver- age fuel consumption modes in the following order: TRIP F > km/L, L100 km, or MPG —> AVE__ _km/L, AVE__._U/100 km or AVE__. MPG. OIL TRIP > ODO > TRIP 1 > TRIP 2—> TRIP F To reset a tripmeter, select it by pushing the “SEL” button, and then push the “RES” button {or at least one second, H you do not reset the fuel reserve tripmeter manually, it resets itself automatically and the display returns to the prior mode after refueling and traveling 5 km (3 mi) Instantaneous fuel consumption display A kt) (98 we 1. Instantaneous fuel consumption display ‘The instantaneous fuel consumption display can bbe set to either *km/L”, "L100 km” or *MPG", ‘+ °knv/L": The distance that can be traveled on 4.0 Lof fuel under the current riding conditions. is shown. *°L/100 km”: The amount of fuel necessary to travel 100 km under the current riding condi- tions is shown. IPG": The distance that can be traveled on 1.0 US Gallon of fuel under the current riding condition is shown To switch between the instantaneous fuel con- ‘sumption displays, push the “SEL” button for ‘one second. pe Iftraveling at speeds under 20 kmvh (12 mith), "_ _._" is displayed, Average fuel consumption display ‘Sa oe 7 1. Average fuel consumption di The average fuel consumption display can be set to either “AVE__._km/L”, “AVE___L/100 km” or “AVE__._M This display shows the average fuel consump- tion since it was last reset. + "AVE__._kmIL”: The average distance that 1n be traveled on 1.0 L of fuel is shown, \VE___ L/100 km”: The average amount of fuel necessary to travel 100 km is shown. + "AVE___MPG": The average distance that ‘can be traveled on 1.0 US Gallon of fuel is shown. To switch between the average fuel consump- tion displays, push the “SEL” button for one sec- ond. To reset the average fuel consumption display, push the "RES" button for at least one second. me ‘ter resetting the average fuel consumption dis play, is shown until the vehicle has trav- led 1 km (0.6 mi), 1-6FEATURES Oil change tripmeter 1. Oil change indicator “OIL” 2. Oil change triometer ‘The oil change tripmeter shows the distance traveled since itwas last reset (ie., since the last oil change). The oil change indicator “OIL” will flash at the ini tial 1000 km (600 mi), then at 5000 km (3000 mi) and every 5000 km (8000 mi) thereafter to indi- cate that the engine oil should be changed After changing the engine oil, reset the oil change tripmeter and the oil change indicator. To reset them both, select the oil change tripme- ter, and then push the "RES" button for one sec- ‘ond. Then, while “OIL” and the oil change {ripmeter are flashing, push the "RES" button for three seconds, The oil change indicator will be reset. It the engine oil is changed before the oil change indicator comes on (.¢., before the periodic oil change interval has been reached), the oil change tripmeter must be reset for the next peri- ‘odie oil change to be indicated at the correct time. ‘Shift timing indicator light 41. Shift timing indicator light 2. Brightness level display ‘The shift timing indicator light has four settings which can be adjusted. + Flashing pattem: this function allows you to choose whether or not the indicator light will come on and whether it should flash or stay on when activated 1-7 + Activation point: this function allows you to se- lect the engine speed at which the indicator light is activated. + Deactivation point: this function allows you to select the engine speed at which the indicator light is deactivated. + Brightness: this function allows you to adjust. the brightness of the indicator light. [To adjust the shift 1. Tum the key to “ 2, Push and hold the “SEL” button, 3. Tum the key to "0", and then release the “SEL” button after five seconds, The shift tim- ing indicator light can now be adjusted. ing indicator light] [To set the flashing pattern] 1, Push the “RES” button to select one of the fol lowing flashing pattern settings: + On: the indicator light stays on when activat- ed. (This setting is selected when the indica- tor light stays on.) ‘+ Flash: the indicator ight flashes when activat- ed. (This setting is selected when the indica- tor light flashes four times per second.) + Off: the indicator light is deactivated; in other words, it does not come on or flash. (This set- ting is selected when the indicator light flash- es once every two seconds.) Push the “SEL button to confirm the selected flashing patter. The shift timing indicator light changes to the activation point setting mode. The tachometer will show the current setting r/min for the activation point and deactivation point setting modes. [To set the shift activation point] a The shift timing indicator light activation point can be set between 7000 r/min and 13000 rimin. From 7000 rfmin to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 rimin to 13000 r/min, the indicator light can be set in increments of 200 r/min 1, Push the “RES" button to select the desired engine speed for activating the indicator light. 2, Push the "SEL" button to confirm the selected engine speed. The control mode changes to the deactivation point setting mode.FEATURES [To set the deactivation point] m1 + The shift timing indicator light deactivation point can be set between 7000 rimin and 18000 rmin. From 7000 rmin to 12000 r/min, the indicator light can be set in increments of 500 r/min. From 12000 r/min to 18000 r/min, the indicator light can be set in inerements of 200 rimin. + Be sure to set the deactivation point toa higher engine speed than for the activation point, oth- erwise the shift timing indicator light will not come on. 1. Push the “RES” button to select the desired engine speed for deactivating the indicator light. 2. Push the “SEL” button to confirm the selected ‘engine speed. The control mode changes to the brightness setting mode. [To adjust the brightness] 1, Push the “RES” button to select the desired shift indicator light brightness level. Push the “SEL” button to confirm the selected brightness level. The display exits the shift timing light control mode and returns to the standard multi-function display mode. 2 Self-diagnosis device 1. Engine trouble warning light "23" 2. Fault code display This model is equipped with a self-diagnosis de- vice for various electrical circuits Ha problem is detected in any of those circuits, the engine trouble waming light will come on and the display will indicate a fault code. Hthe display indicates any fault codes, note the ‘code number, and then check the fuel injection system, Refer to “FUEL INJECTION SYSTEM" on page 8-33, NOTICE It the display indicates a fault code, the vehi- cle should be checked as soon as possible in order to avoid engine damage. 1-8IMPORTANT INFORMATION IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2, Use only the proper tools and cleaning equip- ment. Refer to “SPECIAL TOOLS" on page 1-17. 8. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mat- ‘ed’ through normal wear. Mated parts must always be reused or replaced as an assem- bly. 4, During disassembly, clean all of the parts and place them in trays in the order of disassem- bly. This will speed up assembly and allow for the correct installation of all parts. 5. Keep all parts away from any source of fre. REPLACEMENT PARTS Use only genuine Yamaha parts for all replace- ments. Use oil and grease recommended by Yamaha forall lubrication jobs. Other brands may be similar in function and appearance, but inferior in quality GASKETS, OIL SEALS AND O-RINGS 1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfac- 8, oil seal lips and O-rings must be cleaned. 2. During reassembly, property ol all mating parts and bearings and lubricate the oil seal lips with grease. _ Ii a, 2 if \—3 1 {i 4 1. o# 2. Up 3. Spring 4. Grease LOCK WASHERSIPLATES AND COTTER PINS Ater removal, replace all lock washers/plates 1" and cotter pins. After the boltor nut has been tightened to specification, bend the lock tabs along a fat ofthe bolt or nutIMPORTANT INFORMATION BEARINGS AND OIL SEALS Install bearings “1” and oil seals “2” so that the manufacturer 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. NOTICE Do not spin the bearing with compressed air because this will damage the bearing surfac- es. CIRCLIPS Before reassembly, check all circlips carefully and replace damaged or distorted circlips, Al- ways replace piston pin clips after one use ‘When installing a circlip “", make sure the sharp-edged comer “2” is positioned opposite the thrust “3" that the circlip receives. 1-10 RUBBER PARTS ‘Check rubber parts for deterioration during in- spection. Some of the rubber parts are sensitive to gasoline, flammable oil, grease, etc. Do not al- low any items other than the specified one to contact the parts.BASIC SERVICE INFORMATION BASIC SERVICE INFORMATION ‘QUICK FASTENERS , — Rivet type 1. Remove: * Quick fastener . 1. To remove the quick fastener, pushits pin with a screwdriver, then pull the fastener out. ‘Screw type 1. Remove: * Quick fastener 1p To remove the quick fastener, loosen the screw ~ with a screwdriver, then pull the fastener out. 6 = 2. Install: a XO r= qe To install the quick fastener, push its pin so that it protrudes from the fastener head, then insert the fastenerintothe parttobe secured and push > Ingta the pin in with a screwdriver. Make sure that the + Quick fastener pin is flush with the fastener’s head i To install the quick fastener, insert the fastener into the part to be secured and tighten the screw. *¥3 - &)s _ 1-11BASIC SERVICE INFORMATION ELECTRICAL SYSTEM Electrical parts handling NOTICE Never disconnect a battery lead while the en- gine is running; otherwise, the electrical ‘components could be damaged. ;connecting the battery leads from , be sure to disconnect the nega- tive battery lead first, then the positive bat- tery lead. If the positive battery lead is disconnected first and a tool or similar item contacts the vehicle, a spark could be gener- ated, which is extremely dangerous. TP Ha battery lead is difficult to disconnect due to rust on the battery terminal, remove the rust us- ing hot water. NOTICE Be sure to connect the battery leads to the correct battery terminals. Reversing the bat- tery lead connections could damage the electrical components. NOTICE ‘When connecting the battery leads to tt battery, be sure to connect the positive bat- tery lead first, then the negative battery lead. If the negative battery lead is connected first and a tool or similar item contacts the vehi- cle while the positive battery lead is being connected, a spark could be generated, which is extremely dangerous. NOTICE. Turn the main switch to “OFF” before dis- connecting or connecting an electrical com- ponent. 1-12BASIC SERVICE INFORMATION NOTICE Handle electrical components with special car and do not subject them to strong Checking the electrical system me Before checking the electrical system, make shocks. sure that the battery voltage is at least 12 V. NOTICE NOTICE Electrical components are very sensitive to and can be damaged by static electricity. Therefore, never touch the terminals and be sure to keep the contacts clean. Never insert the tester probes into the cou- pler terminal slots. Always insert the probes from the opposite end “a” of the coupler, tak- ing care not to loosen or damage the leads. 11 ‘When resetting the ECU by turing the main switch to “OFF”, be sure to wait approximately 5 seconds before turing the main switch back to pred For waterproof couplers, never insert the tester probes directly into the coupler. When performing any checks using a waterproof ‘coupler, use the specified test harness or a suitable commercially available test har- ness. 1-13BASIC SERVICE INFORMATION ‘Checking the connections ‘Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: Lead = Coupler = Connector Nore + When disconnecting a coupler, release the coupler lock, hold both sections of the cou- pler securely, and then disconnect the cou- pler. + There are many types of coupler locks; therefore, be sure to check the type of cou- pler lock before disconnecting the coupler. NOTICE ‘When disconnecting a connector, do not pull the leads. Hold both sections of the conneo- tor securely, and then disconnect the con- nector. 2. Check: ‘Lead Coupler Connector Moisture — Dry with an air blower. Rust/stains > Connect and disconnect sev- eral times. 8. Check: All connections Loose connection -> Connect propery. 1? + Ifthe pin “1” on the terminalis flattened, bend itup. + After disassembling and assembling a coupler, pull on the leads to make sure that they are in- stalled securely. 1-14BASIC SERVICE INFORMATION 4, Connect: Lead + Coupler = Connector TP + When connecting a coupler or connector, push both sections of the coupler or connector to- gether until they are connected securely. + Make sure all connections are tight + As a quick remedy, use a contact revitalizer available at most part stores. 6. Check: + Resistance Ua Pocket tester 90890-03112 Analog pocket tester YU-03112-C TIP °C (68 °F), ‘The resistance values shown were obtained at the standard measuring temperature of 20 °C (68 °F). I the measuring temperature is not 20 |, the specified measuring conditions will be shown. 5. Check: * Continuity (with the pocket tester) Z| Pocket tester 90890-03132 m1 + If there is no continuity, clean the terminals. + When checking the wire hamess, perform steps (1) to (4) ill Coolant temperature sensor re- sistance 210-221 0 at 100 °C (210-221 2 at 212 °F) 1-15BASIC SERVICE INFORMATION 1-16SPECIAL TOOLS 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, TIP + For U.S.A. and Canada, use part number starting with "YM-", “YU-', or “ACC~”, + For others, use part number starting with “90890-”. Tool name/To0! No. tustration Fefrence Pocket tester 1s 90890-08132 Pocket ster Tis, 805,584, 90890-08112 < 8.85, 885, 8-60, Analog pocket tester | 8-90, 8-91, 8-91, yUost 2c 8.02, 899, 8.0, 3 6-00, 895, 6-25, 8.06, 8978.07 8.98 Thickness gauge 35,36 555 20890-03180 Fooler gauge sot vu-2sd0o8 Valve apper or 36 90890-04101 — Vale lapping tot in Yu-aeaes cae soos soo Yamaha diagnostic tool US) 38,744, 774, 90800-05234 2.36 1-17SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Vacuum gauge 30890-03094 Vacuummate Yu-44456 0800-09004 yussssss, 38 Carburetor angle driver 2 90890-03173 ‘Steering nut wrench 90890-01403 Exhaust flange nut wrench ‘YU-A9472 319, 478 Oilfter wrench 90890-01426 Oilfiter wrench YU-38411 3:22, 675 Damper rod holder 90890-01460 470, 472 Thandie 90890-01326 ‘handle 3/8" drive 60 em long YM-01326 470, 472 Fork seal driver weight 90890-01367 Replacement hammer YM-A9409-7 YYM-A400-77YMAS 142-4 475, 478, 473 1-18SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Fork seal driver attachment (041) 90890-01381 Replacement 41 mm YM-AS142-2 473, 478 Extension 90890-04196 ot ‘Compression gauge 90890-03081 Engine compression tester Yu-33223, yusse23 ST Rotor holding too! 90890-01235, Universal magneto and rotor holder YU-01235 516, 618 Valve spring compressor 90890-04019 Valve spring compressor YM-04018 5-29, 5-34 Valve spring compressor attachment 90890-04108 Valve spring compressor adapter 22 mm YM-04108 5:20, 634 Valve guide remover (64.5) 90890-04116 Valve guide remover (4.5 mm) YM-04416 Valve guide installer (04.5) 90890-04117 Valve guide installer (4.5 mm) YM-04117 Sa BtSPECIAL TOOLS Tool namefToo! No. lustration Reference pages Valve guide reamer (e4.5) 90890-04118 Valve guide reamer (4.5 mm) M041 18 Sat Piston pin puller set 90890-01304 Piston pin puller YU-01304 Yorn 537 Rotor holding tool 90890-04166 YM-04166 5d, 5-44, 5-45, 5-46 Flywheel puller ‘90890-01404 Flywheel puller YM-01404 Baa Yamaha bond No. 1215 90890-85505 (Three bond No.1215@) 5-46, 5:76, 5-77 Digital circuit tester 90890-03174 Model 88 Multimeter with tachometer YU-A1927 5-40, 8-04 Universal clutch holder 90890-04086 Universal clutch holder YM-91042 ym.ar082 554, 657 1-20SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Radiator cap tester 90890-01925 Mityvac cooling system tester kit YU-24460-A 90880-01525 Yu-2s46-k 63 Radiator cap tester adapter 90890-01352 Pressure tester adapter YU-33984 63 Mechanical seal installer 90890-04145 610 Middle driven shaft bearing driver 90890-04058 Middle drive bearing installer 40 & 50 mm. ‘YM-04058 Pressure gauge 90890-03153 Pressure gauge YU-03153) TAB, TAS Fuel injector pressure adapter 90890-03210 Fuel injector pressure adapter YU-08210 TAR Fuel pressure adapter ‘90890-03176 Fuel pressure adapter YM-03176 1-21SPECIAL TOOLS Tool namefToo! No. lustration Reference pages Ignition checker 30890-06754 Oppama pet-4000 spark checker ‘YM-34487 B92 TTest hamess- lean angle sensor (6P) 90890-03209 Test hares lean angle sensor (6P) YU-03209 893 TTest hamess S- pressure sensor (9P) 90890-03207 ‘Test hamess S~ pressure sensor (3P) YU-03207 8-95 1-22SPECIAL TOOLS 1-23SPECIFICATIONS GENERAL SPECIFICATIONS .... ENGINE SPECIFICATIONS CHASSIS SPECIFICATIONS ELECTRICAL SPECIFICATIONS TIGHTENING TORQUES GENERAL TIGHTENING TORQUE SPECIFICATIONS. ENGINE TIGHTENING TORQUES. CHASSIS TIGHTENING TORQUES. LUBRICATION POINTS AND LUBRICANT TYPES, ENGINE. LUBRICATION SYSTEM CHART AND DIAGRAMS... ENGINE OIL LUBRICATION CHART LUBRICATION DIAGRAMS. COOLING SYSTEM DIAGRAMS CABLE ROUTING... 27 2-40 242 242 2.43 2418 2-22 2-22 2:25 2:25 2.27 244 2-43GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Model Dimensions ‘Overall length ‘Overall width Overall height Seat height Wheelbase Ground clearance Minimum turning radius 2Ms1 2090 mm (82.3 in) 720 mm (28.3 in) 1135 mm (44.7 in) 780 mm (30.7 in) 4380 mm (54.3 in) 160 mm (6.30 in) 2700 mm (106.3 in) Weight ‘Curb weight Maximum load 2-1 167 kg (368 Ib) 160 kg (353 Ib)ENGINE SPECIFICATIONS ENGINE SPECIFICATIONS Engine Engine type Liquid cooled 4-stroke, DOHC Displacement 321 om? Cylinder arrangement Inline 2-oylinder Bore x stroke 68.0 x 44,1 mm (2.68 x 1.74 in) ‘Compression ratio Standard compression pressure (at sea level) Minimum-maximum Starting system 12:4 1440 kP.a/390 rimin (14.4 kgl/em®/390 r/min, 204.8 psi‘390 r/min) 41250-1610 kPa/390 r/min (12.5-16.1 kgt/om#/390 rimin, 177.8-228.0 psi/390 r/min) Electric starter Fuel Recommended fuel Fuel tank capacity Fuel reserve amount Regular unleaded gasoline (Gasohol (E10) acceptable) 14.0 (3.70 US gal, 3.08 Imp.gal) 3.0 L (0.79 US gal, 0.66 Imp.gal) Engine oil Lubrication system Recommended brand Type Recommended engine oll grade Engine oil quantity Quantity (disassembled) Without oil fier cartridge replacement With oil iter cartridge replacement Oil pressure Wet sump YAMALUBE SAE 10W-30, 10W-40, 10W-50, 15W-40, 20W- 40 or 20W-50 API service SG type or higher, JASO standard MA 2.40 L (2.54 US qt, 2.11 Imp.qt) 1.80 L (1.90 US qt, 1.58 Imp.qt) 2.10 L (2.22 US qt. 1.85 Imp.qt) 206.0 kPa/5000 r/min at 130 °C (29.9 psi/5000 timin at 266 °F) Oil filter Oil fiter type Cartridge Oil pump il pump type Trochoid Inner-rotor-to-outer-rotor-tp clearance Limit uter-rotor-to-oll-pump-housing clearance Limit it pump-housing-to-inner-and-outer-rotor clearance Limit Bypass valve opening pressure Relief valve operating pressure (0.060-0.120 mm (0.0024-0.0047 in) 0.20 mm (0.0079 in) 0.09-0.17 mm (0,0035-0.0067 in) 0.24 mm (0.0094 in) 0.05~0.09 mm (0.0020-0.0037 in) 0.170 mm (0.0067 in) £80.0-120.0 kPa (0.80-1.20 kgllem, 11.6-17.4 psi) 650.0-770.0 kPa (6.50-7.70 kgt/om2, 94.3~ 111.7 psi) 2-2ENGINE SPECIFICATIONS Cooling system Radiator (including all routes) Coolant reservoir (up to the maximum level mark) Radiator cap opening pressure Thermostat ‘Valve opening temperature Valve full open temperature Valve lift (ull open) 0.96 L (1.01 US qt, 0.84 Imp.qt) 0.25 L (0.26 US qt, 0.22 Imp.at) 108.0-137.4 kPa (1.08-1.37 kaffem?, 15.7-19.9 psi) 80,5-89.5 °C (176.90-182.80 °F) 95.0 °C (203,00 °F) 3.0 mm (0.12 in) Radiator core Width 145.8 mm (6.74 in) Height 270.0 mm (10.63 in) Depth 24.0 mm (0.94 in) Water pump Water pump type Single suction centrifugal pump Reduction ratio 41/28 (1,783) Spark plug(s) Manufacturer/model NGKICR8E Spark plug gap 0.7-0.8 mm (0.028-0.031 in) Cylinder head ‘Combustion chamber volume 10.80-11.60 om? (0.66-0.71 cu.in) Warpage limit 0.05 mm (0.0020 in) ‘Camshaft Drive system Chain drive (right) ‘Camshaft cap inside diameter Camshaft joumal diameter ‘Camshaft-joural-to-camshaft-cap clearance Camshaft lobe dimensions Lobe height (Intake) Limit Base circle diameter (Intake) Limit Lobe height (Exhaust) Limit Base circle diameter (Exhaust) Limit Camshaft runout limit 22,500-22.521 mm (0.8858-0.8867 in) 22.459-22.472 mm (0.8842-0.8847 in) 0.028-0.062 mm (0.0011-0.0024 in) 32,650-32,750 mm (1.2854—1.2894 in) 32.550 mm (1.2815 in) 24.972-25.072 mm (0,9831-0.9871 in) 24.872 mm (0.9792 in) 30.750-30.850 mm (1.2106-1.2146 in) 30.650 mm (1.2067 in) 25.027-25.127 mm (0,9853-0.9893 in) 24.927 mm (0.9814 in) 0.030 mm (0.0012 in) Valve, valve seat, valve guide Valve clearance (cold) Intake Exhaust Valve dimensions Valve head diameter (intake) Valve head diameter (exhaust) Valve seat contact width (intake) Valve seat contact width (exhaust) Valve stem diameter (intake) Limit 2-3 0.11-0.18 mm (0.0043-0.0071 in) 0.21-0.90 mm (0.0083-0.0118 in) 25,90-26.10 mm (1.0197-1.0276 in) 22.40-22.60 mm (0.8819-0.8898 in) 0.90-1.20 mm (0,0354-0.0472 in) 0.90-1.20 mm (0,0354~0.0472 in) 4.475~4.490 mm (0.1762-0.1768 in) 4.445 mm (0.1750 in)ENGINE SPECIFICATIONS Valve stem diameter (exhaust) Limit Valve guide inside diameter (Intake) Limit Valve guide inside diameter (exhaust) Limit Valve-stem-to-valve-quide clearance (intake) Limit Valve-stem-to-valve-guide clearance (exhaust) Limit Valve stem runout Valve spring Free length (intake) Limit Free length (exhaust) Limit Installed length (intake) Installed length (exhaust) Spring rate Kt (intake) Spring rate K2 (intake) Spring rate K1 (exhaust) Spring rate K2 (exhaust) Installed compression spring force (intake) Installed compression spring force (exhaust) Spring tl (intake) ‘Spring tit (exhaust) Winding direction (intake) Winding direction (exhaust) 4.460-4.475 mm (0.1756-0.1762 in) 4.430 mm (0.1744 in) 4.500-4.512 mm (0.1772-0.1776 in) 4.550 mm (0.1791 in) 4.500-4.512 mm (0.1772-0.1776 in) 4.550 mm (0.1791 in) 0.010-0.037 mm (0.0004-0.0015 in) 0.080 mm (0.0032 in) 0.025-0.052 mm (0.0010-0.0020 in) 0.100 mm (0.0039 in) 0.010 mm (0.0004 in) 38.21 mm (1.50 in) 36.30 mmn (1.43 in) 38.21 mm (1.50 in) 36.30 mm (1.43 in) 32.00 mm (1.26 in) 32.00 mmn (1.26 in) 27.64 Nimm (2.82 kgf/mm, 157.82 Ibf/in) 98.73 Nimm (3.95 kgf/mm, 221.15 Ibn) 27.64 Nimm (2.82 kgf/mm, 157.82 Ibf/in) 98.73 Nimm (3.95 kgf/mm, 221.15 Ibn) 159.60-183.60 N (16.27-18.72 kgf, 35.88— 41.27 Ibf) 159,60-183,60 N (16.27-18.72 kgf, 35.88— 41.27 Ibf) 4.7 mm (0.07 in) 4.7 mm (0.07 in) Clockwise Clockwise Cylinder Bore Taper limit Out of round limit 68.000-68.010 mm (2.6772-2.6776 in) (0,050 mm (0.0020 in) 0.050 mm (0.0020 in) Piston Piston-to-oylinder clearance Diameter Measuring point (from piston skirt bottom) Offset Oftset direction Piston pin bore inside diameter Limit Piston pin outside diameter Limit Piston-pin-to-piston-pin-bore clearance 0,015-0.048 mm (0,0006-0.0019 in) 67.962-67.985 mm (2.6757-2.6766 in) 7.0 mm (0.28 in) 0.25 mm (0.0098 in) Intake side 15,002-15.013 mm (0.5906-0.5911 in) 1.043 mm (0.5922 in) 414.995-15.000 mm (0.5904~0.5906 in) 14.975 mm (0.5896 in) 0,002-0.018 mm (0.0001-0.0007 in) Piston ring Top ring Ring type End gap (installed) 2-4 Barrel 0.15-0.25 mm (0.0059-0.0098 in)ENGINE SPECIFICATIONS Limit Ring side clearance Limit 2nd ring Ring type End gap (installed) Limit 1g side clearance Limit Oilring End gap (installed) Connecting rod 0.50 mm (0.0197 in) 0,030-0.065 mm (0.0012-0.0026 in) 0.115 mm (0.0045 in) Taper 0.30-0.50 mm (0.0118-0.0197 in) 0.85 mm (0.0835 in) 0,020-0.055 mm (0.0008-0.0022 in) 0.11 mm (0.0045 in) 0,10-0.35 mm (0.0039-0.0138 in) Oil clearance 0.036-0.060 mm (0.0014-0.0024 in) Bearing color code 1, Blue 2. Black 3. Brown 4, Green Crankshaft Runout limit 0.030 mm (0.0012 in) Journal oil clearance 0.021-0.045 mm (0.0008-0.0018 in) Bearing color code 1.Blue 2.Black 3.Brown 4.Green 5.Yellow Balancer Balancer shaft journal to balancer shaft bearing clearance Bearing color code 0.021-0.045 mm (0.0008-0.0018 in) 1. Blue 2. Black 3. Brown 4, Green 5. Yellow Clutch Clutch type Clutch release method Clutch lever free play Friction plate thickness Wear limit Plate quantity Clutch plate thickness Plate quantity Warpage limit Clutch spring free length Limit Spring quantity Wet, muttiple-ise ‘Outer pull, rack and pinion pull 10.0-15.0 mm (0.39-0.59 in) 2.92-3.08 mm (0.115-0.121 in) 2.82 mm (0.111 in) 7 pes 1.50-1.70 mm (0.059-0.067 in) 6 pes 0.10 mm (0.004 in) 49.80 mm (1.96 in) 47.30 mm (1.86 in) 4 pes Transmission Transmission type Primary reduction ratio Final drive ‘Secondary reduction ratio Operation Gear ratio 1st 2nd 3rd ath sth eth 2-5 Constant mesh 6-speed 3.043 (70/23) Chain 3.071 (43/14) Left foot operation 2.500 (35/14) 1.824 (31/17) 1.348 (31/23) 1.087 (25/23) 0.920 (23/25) 0.800 (24/30)ENGINE SPECIFICATIONS Main axle runout limit Drive axle runout limit 0.06 mm (0.0024 in) 0,06 mm (0.0024 in) Shifting mechanism fork quide bar bending limit 0.050 mm (0.0020 in) Shift fork thickness 5.76-5.89 mm (0,2268-0.2319 in) Air filter Air fiter element Oi-coated paper element Fuel pump Pump type Electrical Maximum consumption amperage 1A Fuel injector ModeVquantity 297500-237072 Throttle body Type/quantity S2EHDW-2 1D mark 2MS1 00 Throttle position sensor Output voltage (at idle) 0.63-0.73 V Fuel injection sensor Crankshaft position sensor resistance 192-288 2 Intake air pressure sensor output voltage Intake air temperature sensor resistance Coolant temperature sensor resistance Coolant temperature sensor resistance 3.88-4.12 V at 101.3 kPa (8.88-4.12 V at 1.01 kgtfom®, 3.88-4.12 V at 147 psi) 5700-6300 © at 0 °C (5700-6300 © at 32°F) 2518-2777 Q at 20°C (2513-2777 Qat 68 °F) 210-221 © at 100 °C (210-221 Oat 212 °F) idling condition Fuel line pressure at idling Engine idling speed Intake vacuum Water temperature Throttle grip free play 220-300 kPa (2.2-3.0 kgt/cm?, 31.9-43.5 psi) 4300-1500 r/min 52.0-58.0 kPa (390-435 mmHg, 15.4-17.1 inHg) '95,0-105.0 °C (203,00-221.00 °F) 3.0-5.0 mm (0.12-0.20 in)CHASSIS SPECIFICATIONS CHASSIS SPECIFICATIONS Chassis Frame type Diamond Caster angle 25.00" Trail 95 mm (3.7 in) Front wheel Wheel type Cast wheel Rim size 47MIC x MT2.75 Rim material Aluminum Wheel travel 130 mm (5.1 in) Radial wheel runout limit 4.0. mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) Rear wheel Wheel type Cast wheel Rim size 47MIC x MT4.00 Rim material Aluminum Wheel travel 125 mm (4.9 in) Radial wheel runout limit Lateral wheel runout limit 4.0 mm (0.04 in) 0.5 mm (0.02 in) Front tire Type Size Manufacturer/model Wear limit (front) Rear tire Type Size Manufacturer/model Wear limit (rear) Tubeless, 110/70-17MIC (54H) MICHELIN/PILOT STREET 1.0 mm (0.04 in) Tubeless 140/70-17M/C (66H) MICHELIN/PILOT STREET 1.0 mm (0.04 in) Tire air pressure (measured on cold tires) Loading condition Front (1 person) Rear (1 person) Loading condition Front (2 persons) Rear (2 persons) Maximum load (0-90 kg (0-198 Ib) 200 kPa (2.00 kgt/om:, 29 psi) 250 kPa (2.50 katiem?, 36 psi) 90-160 kg (198-353 Ib) 200 kPa (2.00 kat/em?, 29 psi) 250 kPa (2.50 kat/om:, 36 psi) 160 kg (353 Ib) Front brake Type Operation Front disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc runout limit (as measured on wheel) Brake pad lining thickness (inner) 2-7 Single disc brake Right hand operation 298.0 x 4.5 mm (11.73 x 0.18 in) 4.0 mm (0.16 in) 0.15 mm (0.0059 in) 5.3 mm (0.21 in)CHASSIS SPECIFICATIONS Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Specified brake fluid Rear brake Type ‘Operation Rear disc brake Disc outside diameter x thickness Brake disc thickness limit Brake disc runout limit (as measured on wheel) Brake pad lining thickness (inner) Limit Brake pad lining thickness (outer) Limit Master cylinder inside diameter Caliper oylinder inside diameter 0.8 mm (0.03 in) 5.3 mm (0.21 in) 0.8 mm (0.03 in) 11.00 mm (0.43 in) 26.99 mm (1.06 in) 26.99 mm (1.06 in) DOT 4 Single disc brake Right foot operation 220.0 x 4.5 mm (8.66 x 0.18 in) 4.0 mm (0.16 in) 0.15 mm (0.0059 in) 7.7 mm (0.30 in) 0.8 mm (0.03 in) 7.7 mm (0.30 in) 0.8 mm (0.03 in) 12.7 mm (0.50 in) 33.34 mm (1.31 in) Specified brake fluid DoT 4 Steering Steering bearing type Angular bearing Center to lock angle (left) 34.0° Center o lock angle (right) 34.0° Front suspension Type Telescopic fork Spring/shock absorber type Coil spring/oil damper Front fork travel Fork spring free length Limit Collar length Spring rate K1 Spring stroke K1 Inner tube outer diameter Inner tube bending limit Recommended oil Quantity Level 130.0 mm (6.12 in) 297.8 mm (11.72 in) 294.4 mm (11.59 in) 229.0 mm (8.02 in) 6.45 Nimm (0.66 kg/mm, 36.83 Ibt/in) 0.0-130.0 mm (0,00-5.12 in) 41.0 mm (1.61 in) 0.2 mm (0.01 in) Fork oil 10W or equivalent 487.0 cm? (16.47 US 02, 17.18 Imp.0z) 421.0 mm (4.76 in) Rear suspension Type Spring/shock absorber type Rear shock absorber assembly travel Spring installed length Spring rate K1 Spring stroke K1 ‘Spring preload adjusting positions Minimum Standard 2-8 ‘Swingarm Coil spring/oil damper 45.0 mm (1.77 in) 157.0 mm (6.18 in) 161.60 N/mm (16.48 kgtimm, $22.74 Ibtfin) 0,045.0 mm (0,00-1.77 in) 1 3CHASSIS SPECIFICATIONS Maximum, 7 Drive chain Size/manufacturer S20VF/DAIDO Number of links. 112 1¢link length limit Drive chain slack 2-9 239.3 mm (9.42 in) 35,0~45.0 mm (1.38-1.77 in)ELECTRICAL SPECIFICATIONS ELECTRICAL SPECIFICATIONS Voltage ‘System vottage 12v Ignition system Ignition system Tel Ignition timing (B.T.0.C.) Engine control unit Modelimanufacturer 5.0°/1400 rimin TBDFQS/DENSO Ignition coil Minimum ignition spark gap 6.0 mm (0.24 in) Primary coil resistance 2.16-2.64.0 Secondary coil resistance 8.64-12.96 ko Lean angle sensor output voltage Less than 45° O44 More than 45° 37-44 ‘AC magneto Standard output 14.0 V, 298 W at 5000 r/min Stator coil resistance 0.216-0.324 0 (W-W) Rectifier/regulator Regulator type Semi conductor-short circuit Regulated voltage (DC) 141-149 V Rectifier capacity 35.0A Battery Mode! GTzev Voltage, capacity 12V, 7.0Ah Specific gravity 1.350 Manufacturer Gs Ten hour rate charging current 0.70 Headlight Bulb type Halogen bulb Bulb voltage, wattage x quantity Headlight 12 V, 55.0Wx2 ‘Auxiliary light 12V,5.0Wx1 Taiiforake light LeD Front turn signal/position light 12V, 21.0 WI5.0W x2 Rear turn signal light 12V, 21.0Wx2 License plate light 12V,5.0Wx1 Meter lighting LED Indicator light Neutral indicator ight LED Tum signal indicator light LED 2-10ELECTRICAL SPECIFICATIONS Oil pressure warming light LED High beam indicator light LED Engine trouble warning light LED Starter motor Power output 0.40 kW Armature coil resistance Brush overall length Limit Brush spring force Mica undercut (depth) 0.0630-0.0770.9 7.0 mm (0.28 in) 8,00 mm (0.12 in) 6.08-9.12 N (620-930 gf, 21.89-32.83 oz) 1.50 mm (0.06 in) Starter relay ‘Amperage 150.0 Coil resistance 3.06-3.74.2 Horn Hom type Plane Quantity 1 Maximum amperage 35A Turn signal relay Built-in, self-canceling device No Fuel sender ut ‘Sender unit resistance (ful) 100-1400 ‘Sender unit resistance (empty) 267.0-2738.0.2 Fuses Main fuse 30.0 A Headlight fuse 150A Signaling system fuse 15.0 Ignition fuse 150A Radiator fan motor fuse 75A Backup fuse 75A Spare fuse 30.0 Spare fuse 15.0A Spare fuse 75A 2-11TIGHTENING TORQUES TIGHTENING TORQUES 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 multfastener assemblies in a crisscross pat- tem and progressive stages unti the specified tightening torque is reached. Unless otherwise specified, tightening torque specifications re- ‘quire clean, dry threads. Components should be at room temperature. A. Distance between flats B. Outside thread diameter General tightening torques, A (out) | B (bolt) Nm | mkgf | ftlbt 1omm | 6mm | 6 06 | 43 2mm | @mm | 18 | 18 | if 4mm | 10mm | 30 | 30 | 22 7mm | 2mm | 88 | 58 | 40 Tomm | témm| 88 | 85 | ot amm | temm | 130 | 180 | 94 2412TIGHTENING TORQUES ENGINE TIGHTENING TORQUES tem Thread | gy Tightening torque Remarks Air fiter case joint lamp serew us | 2 25 Nm (0.28 mkgf, 18 Wibt) Tirfiter case bot me [2 TN (0-7 mag, 5.1 FIBA, Air fiter case side cover screw (eh) | MB |S 2S Nm (0.35 m-kgf, 1.8 fbf) Airfiter case side cover sorew (ight)| MB | 8 | 1.9Nm/(0.13 mkgf, 0.94 Rb) Spark plug mio | 2 131Nm (1.3 mgt 84 PBA) Op sensor m2 | 4 25 Nm (2.5 maf, 18 ful) Muffler protector (outer) me ft Nm (0.8 mgt, 68 Rib) a Muffler protector (inner) we | 2 Nm (08 mkgl, 5.8 Tbh) =a Exhaust pipe protector bracket bot | MB | 2 TO Nm (1.0 mvkgf, 7.2 fbf) “a Exhaust pipe nut wef 4 45Nm (1.5 mkgh, 17 FbH) Exhaust pipe bolt Me [1 20 Nim (2.0 mk, 14 fbi) Muffler assembly bolt weft 20 Nim (2.0 m kof, 14 fb") Exhaust pipe joint bolt me [1 20 Nim (2.0 m kgf, 14 bi) Exhaust pipe protector bolt ue | 3 Nm (0.8 mgt, 68 Rib) a Engine ground lead bot uefa TONey (1.0 mekgh, 72 Rb) ‘Camshaft cap bolt me | 12 TO Nm (1.0 mgt, 7.2 Roh) —@ ‘Camshaft sprocket bolt wf 4 2O Nim (2.0 mk, 14 Wi) Timing chain tensioner bolt ue | 2 TO Nm (1.0 mkgh, 72 iby) Timing chain tensioner cap bolt ue [ 1 7 Nim (0.7 kg, 5.1 RBA) Timing mark accessing bolt weft TO Nev (1.0 mgt, 7.2 bt) Grankshaft end cover wae [ 1 2.0 Nm (0.20 mkgh, 14 Febf) Gylinder head cover bolt wef 4 TO Nm (1.0 mgt, 72 Roh) Coolant temperature sensor mio [1 17 Nm (1.7 mkof 12 fbf) Timing han bo (gH OTA | ys | akin (berks PN) Engine oil check bolt wef 4 78 Nm (1.8 mkgf, 17 fib Cylinder head bolt mio | 6 See TIP om Gylinderhead bat wef 2 See TIP Cylinder head biind plug m2 | 2 28 Nm (2.8 m kgf, 20 bi) “a ‘Starter olutch bolt M6 3 14.Nm (1.4 m-kgf, 10 ftlbf) -a Generator rotor bolt mio | 1 {60 Nm (6.0 m kgf, 43 fbi) <4 Generator cover bolt wef 9 TON (1.0 moh, 72 Roh) ‘Stator col bolt ue | 3 TO Nm (1.0 mkgh, 7.2 Rb) -a Crankshaft position sensor bot Me | 2 7 Nm (0.7 mg, 6.1 FDA) -a Siarier moior lead sorew ws ft 3.5 Nm (0:35 mkgh, 25 fbi) Siarter motor bolt me | 2 TONm (1.0 mvkof, 7.2 fbf) Starter motor front cover bolt maf 2 3.5 Nm (0:95 mkgf, 2.5 fbf) Brush holder sorew maf 2 7.5 Nm (0.18 mkgf, 1.4 Wit) 2413TIGHTENING TORQUES Item Thread | ay Tightening torque Remarks size ‘Clutch boss nut me | 1 400 Nm (10 m-kgf, 72 feb) =—@ Clutch spring bolt Me | 4 10 Nm (1.0 m-kgf, 7.2 Reh) ‘Clutch cover Bott Me [7 TONm (1.0 m-kgf, 7.2 RBA) Clutch cable holder bolt Me | 2 10 Nm (1.0 mkgf, 7.2 elbt) ~d ‘Shift shat spring stopper we | t 22. Nm (22 maf, 16 fib) -d Cilpump cover screw Ma | t 2.0 Nem (0.20 mvkaf, 1.4 tlb§) Oil pump bolt Me | 4 TO Nm (1.0 m-kgf, 7.2 febA) Oilpan bolt Me] 1 TO Ne (1.0 mikgf, 7.2 RIA) Engine oll dain Bot m2 | 7 BO Nm (2.0 mmkgf, 14 RBA) Grankcase bolt wa | 6 See TIP. =a Grankease bolt we | 2 See TIP, =e Grankease bolt Me | 14 See TIP. =a Banya chain guide bok (intake side | yg 7 10.Nm (1.0 mgt, 7.2 fot) “a Bayne chain guide bok (ewerside | yg | 2 1ONm (1.0 mgt, 7.2 feb) - Primary drive gear bot mo | 1 {60 Nm (6.0 mkgf, 43 fbf) <0 Oil pressure switch pri | 1 15Nm (1.5 mkgf, 11 Fibs) -d Cillpressure switch lead bot waft 18 Nm (0.18 mkgh, 13 feo ‘Gear position switch screw Ms | 2 3.5 Nm (0.35 m-kaf, 25 ftlbt) -d Oil iter cartridge mzo_| 1 T7 Nim (1.7 maf, 12 bh Giifiter cartridge union bolt 20 | 1 70 Nm (7.0 mg, 61 Felt) =—@ ‘Grankcase breather cover bolt Me | 8 TONm (1.0 mkgf, 7.2 RBA, ‘Speed sensor bolt Me | t TONm (1.0 m-kgf, 7.2 RBA) Connecting rod nut Me | 4 See TIP, —@ Balancer driven gear bolt we] t 35 Nm (3.5 maf, 25 fbf) —@ ‘Shift fork guide bar retainer bot Me | 2 TONm (7.0 m-Kgf, 7.2 fbf) -d ‘Shift drum segment sorew Me | ot 12 Nm (1.2 m-kgh, 8:7 FebA) - Radiator bolt Me | 2 TO Nin (1.0 mvkgf, 7.2 Pb) Radiator fan cover bolt Me | 8 ONm (0.8 mgt, 65 RIB Coolant reservoir cover Balt MS | 2 TE Nim (0.15 mkgf, 1.1 Ploy) Radiator outlot hose clamp screw | MS | 1 2.0 Nm (0.20 mvkgf, 1.4 Flbth Radiator inlet hose clamp screw Me [ot 2.0 Nm (0.20 m-kgf, 1.4 lof) Thermostat cover bolt Me | 2 TO Nm (1.0 m-kgf, 7.2 Reh) Water pump housing bolt Me | 8 TO Nm (1.0 m-kgf, 7.2 Reh) Coolant drain batt Me | t TONm (1.0 m-kgf, 7.2 RBA) Impeller shaft retaining plate bolt Me | 2 1 Nm (1.0 mkgf, 7.2 elt) ~d Throttle body joint bolt we [3 TO Nm (1.0 m-kgh, 7.2 Reb) TSC (le speed contro) unitate | yg | 4 Nm (0.5 mkgt, 2.6 ft) 2-14TIGHTENING TORQUES tem Thread | oty Tightening torque omarks Fala [EBS Rin OS IL EE TBH Thee body ni amp sew | MS | 2 | 28 Nm (025 mgt) Throttie cable bracket bolt M5 2 5.Nm (0.5 mkgf, 3.6 fbf) Reed valve cover bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) 1p Cylinder head bolt Tighten the oylinder head bolts “1"-"8" in the proper tightening sequence as follows: 1. Lubricate the cylinder head bolts “1"-"6” threads and mating surface with molybdenum disulfide ease. 2, Tighten the cylinder head bolts “t""6" to 10 Nm (1.0 maf, 72th) 3, Tighten the oylinder head bolts “1""6" to 30 Nm (3.0 m-kgf, 22 fbf). 4. Loosen and retighten each cylinder head bott “1"-"6" with the following steps (after loosening a bot, retighten it before loosening the next bolt) + Loosen the oylinder head bott. + Tighten the cylinder head bolt to 12 Nm (1.2 m-kgf, 8.7 ftibf). + Tighten the cylinder head bolt to reach the specified angle 115-125". 5, Tighten the cylinder head bolts “7” and “8” to 10 Nm (1.0 m-kgf, 7.2 ftibf) 1 Crankcase bolt Tighten the crankcase bolts “t’—"21" in the proper tightening sequence as follows: 1. Lubricate the crankcase bolts “1”="15" and "17'-"21” threads, mating surfaces with the engine oll 2. Lubricate the mating surface of the bolt "16" with engine oil and apply Yamaha bond No. 1215 to the bolt threads. 8. Tighten the crankcase bolts “1"-"6” to 20 Nm (2.0 m-kgf, 14 ft). 4, Loosen and retighten the crankcase bolts “1"-"6" to 24 Nm (2.4 m-kgf, 17 ftibf) in the proper tight- ening sequence (after loosening a bolt, retighten it before loosening the next bolt). 5, Tighten the crankcase bolts "7’-"8" to 20 Nm (2.0 m-kgf, 14 tb}. 2-15TIGHTENING TORQUES 6. Loosen and retighten the crankcase bolts “7"-"8" to 26 Nm (2.6 m-kgf, 19 ftbf) in the proper tight- ‘ening sequence (after loosening a bolt, retighten it before loosening the next bolt). 7. Tighten the crankcase bolts “9'-"21" to 10 Nm (1.0 m-kgf, 7.2 ftibf) in the proper tightening se- 7 x6 || «2 2-16TIGHTENING TORQUES A. Lower crankcase B. Upper crankcase T1P Connecting rod bolt 1. Lubricate the connecting rod bolts threads and connecting rod nuts mating surface with molybde- num disulfide oil 2, Tighten the connecting rodbolts to 15 Nm (1.5 m-kgf, 11 ftbf), and then tighten them further to reach the specified angle 145-155". 217TIGHTENING TORQUES CHASSIS TIGHTENING TORQUES tem Thread | oy Tightening torque Remarks Engine mounting ut ear upper | ig | 4 | G8 Nm (6@ msg, 49m) Seca eat WO |_| GN BS mg, a8 BH Engine mounting nut (rear lower Engr wo [1 | €8Nm(6.8mbgt, 49: Engine mounting bolt (right front Engr mio | + | Genm 6.8 mkat, 49 1) Engine mounting BOK (ei Wont side) | WHO | 1 | 68 Nim (68 mk 49 RTE Engine bracket Bo (ah WO | 2 | 68 Nm (68 mig, 40 Eb Engine bracket Bo (eh) WHO| | eB Nm 6S mgt AORN Engre mounting bar eRURP= T yig | 1 | G8 Nm 6.@maat 40.) Engine ‘mounting bolt (leit upper mo | 4 68 Nm (6.8 mig, 49 tb) Rider seat bolt MG 2 7. Nm (0.7 m-kgf, 5.1 ftlbf) Center cover screw MS | 2 7.8 Nm (0.18 m-kgf, 1.3 felbf) Passenger sat brackatiak wef 4 Rim (0.7 mh 6.16) Passenger sat band nut we 2 Fim (07 mag 8 TT Side panel bot WE [ TE Nn OE mgt TRH petal S| 2 | TB Nm O18 migh 13 RI Rear upper side cowling bolt M6 2 7. Nm (0.7 m-kgt, 5.1 ftlbf) ‘Seat lock nut M5 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf) Rear lower side cowling screw ‘M5. 5 1.8 Nm (0.18 m-kgf, 1.3 ft-lbf) ‘Seat lock key cylinder screw MS | 2 7.8 Nm (0.18 mkgf, 1.3 felbt) Lean angle sensor screw Ma | 2 7.0 Nm (0.10 maf, 0.72 fbi) Rectierreguator bot wef 2 TR (07 kgf 8.1 RTE Front panel bo WE [| TEN OEM Igh TTT Fuel ak cover Bol (ear Side) | WB | 4 | BN OS kg, 8 RBH Fool ank cover bof (Font side) | ~W6[ 7m (027 mk 8.4 Fuel tank cover screw M5. 6 1.8 Nm (0.18 m-kgf, 1.3 ftlbf) Bottom cowling screw M5, 4 1.8 Nm (0.18 m-kgf, 1.3 ftlbf) Front botom cowing Bok (UB x12 i ms | 4 1.8 Nm (0.18 m-kgf, 1.3 flbf) Frat Potom cowiing bol(MEx22 | yg) 2 7 Nm (0.7 mf, 6.1 fbf) Front Boom cowtng racket bot | WE | THR 07 GEE RTE Front ede cowfng sew WE_[ 2 [TSN OE migh TST Front side cowing imer panel screw | MS | 2 | _1.8Nm (0.18 mk, 1.9 7D) Front upper cowing ut (efsde) | WB | 1 Nm (0.7 mG 8.1 FH) Front upper cowling screw M5. 4 1.8 Nm (0.18 m-kgf, 1.3 ft-Ibf) Front upper cowing Bo we | 2 7 (07 mG 8.1 RIGA Front Tower cowing screw M5 [2 [FB Nm (OTB mk 13 RIB 2-18TIGHTENING TORQUES tem Thread | gy Tightening torque Remarks vise aan nina asa] Tn OT Frnt coving assembly Bat a} 2] aa in gt 2a Meter assembly bracket bolt M6 2 7. Nm (0.7 mkgf, 5.1 ftbf), Meter assembly screw M5 3 1.3 Nm (0.13 m-kgf, 0.94 ft-lbf) Windshield assembly screw M5 2 0.4 Nm (0.04 m-kgf, 0.29 ft-lbf) Front cowling screw M5 4 7.8 Nm (0.18 m-kgf, 1.3 ftlbf) Font cong mer panel serew | S| 6] 18 im (18 mal 1.3) Headlight assembly sew ws —|4 | TB Nin (18 magl 73H Fon aks Fase hoe a wie | | TNO gh Font rake calipr bot aie] aE Sg Font wheel ena wie [1 | SER 2 migh 38) | ea Fronts dse bot we [ 5 | Bain mig TRH “a Rear brake caliper bolt MB 1 23 Nm (2.3 m-kgf, 17 ftlbfy Drive chain puller locknut MB 2 16 Nm (1.6 m-kgf, 12 ft-lbf) Drive chain puller adjusting nut MB 2 1.5. Nm (0.15 m-kgf, 1.1 ft-lpf) Rear wheel axle nut mis | 1 57 Nm (5.7 m-kgf, 41 f-lbf) <1 Rear brake caliper bolt M12 1 31. Nm (3.1 m-kgf, 22 ft-lb) Rear wheel sprocket nut M10, 6 68 Nm (6.8 m-kgf, 49 ft-Ibf) Fear whoa spocktoudbat™ | wio| 6 | 27 Hm (27 maa 20m a Rear brake disc bolt we) 3 23 Nm (2.3 m-kgh, 17 felbi) “a Brake caliper bleed screw M7 2 6 Nm (0.6 m-kgf, 4.3 fbf) Fonbrakerastr nGereeeNT | yg |g | 15 nm OAS magl 11 RID Font ars Te BOTT Wea ST Font rake ave pot a et] oR Oo AT Front brake light switch screw wa | Tat Nem (0.11 rm gf, 0.80 felbt) “qd Frag foes union BOBBITT aq | | gon @8magl 21 HD) Fron rag hase union BENE yiq | | gon @9magl 21 HH Lor lores master cyliraler ticker: M6 2 10. Nm (1.0 m-kgf, 7.2 ftslbf) Rear brake fluid reservoir holder bolt | M6 1 7. Nm (0.7 m-kgf, 5.1 ftlbf) Rea Batefooe non Dok master I yiq | | gem @9magl 21 Rib Rearbrakeroso wen DORaIS yap | | gonm @amagl 21m) Tanaka gh baat bat | WE | ETN Ta gh TR Foote assonbiybot a —| a | ain Rear brake master cylinder bolt MB 2 23 Nm (2.3 m-kgf, 17 ft-lbf) Rear brake pedal bott mio | 1 ‘30 Nm (3.0 mAgh, 22 ftibi) -a Fear brake hose guia bal weft TO 2-19TIGHTENING TORQUES tem Thread | ty Tightening torque Remarks Fear brake pedal using o&nak [WB |B [ A Win oT GH TERT ip end bok We [2 [TN (07 mk 5.1 Handlebar switch screw (right) M5. 2 1.5 Nm (0.15 m-kgf, 1.1 ft-Ibf) TEyotigcablegude screw Mande: ys | | as nm (0.28migh 181) Handlebar pinch ba [ee Handlebar bolt M6 2 13 Nm (1.3 m-kgf, 9.4 ftlbf) Handlebar switch screw (lefty MS | 2 75 Nm (0.18 mkgf, 1.1 felbf) hich Tver pot a WE [ LT 0 gh TRI Chih cable Tock WB [ [TNO 5.1 Cc ever nls pinch bok We | [TN (0-7 mig 5.1 ‘Clutch switch sorew ms | 1 (0.6 Nm (0.06 m-kgf, 0.43 fbf) -a Front fender bolt (front) M6 2 7 Nm (0.7 mkof, 5.1 fbf) Front fender bolt (rear) Me | 7Nm (0.7 mkgf, 6.1 fbt) Tower bracket ch bo TWO | 2] 80 i OMG BRB Upper bracket ch Bot WE |B] BT im Et STB Front fork cap bolt M38 | 2 23 Nm (2.3 m-kgf, 17 ftlbf) Front fork damper rod bolt mo | 2 230 Nm (3.0 mf, 22 ftlbt) -a Hern We | | T6Nim (1.8 mk 2H Fai baka hose Ba WE [LR 7 8TH Horn bracket bo WE [2 [ TN 07 mh STR Cable guide Eo (oA ME] 1] TN (07 KGS Cable guide bolt (right) M6 1 7 Nm (0.7 m-kgf, 5.1 ft-lbf) Steering stem bolt M14 1 95 Nm (9.5 m-kof, 69 ftlbfy Lower tog ru OETERONG yay | | son eamiat a5 tie) Lowering mutraltonening yay | 4 | de Nm (.8magt 1989 dguarT BoE WEE a i OT GL TS TBH Rear shook absorber asemBvEOR Tyra | | ae nm .0magt, 42mB) Rear shook abeoborassombiyrat [ yyo | 4 | aa nm (.8migl, 42m) Drive chain guard bolt M6 2 10 Nm (1.0 m-kgf, 7.2 ftlbf) Pivot shaft nut mie | 1 15 Nm (17.5 m-kgl, 83 febA) Drive sprocket cover bolt Me | 2 10 Nm (1.0 mkgf, 7.2 felbf) Drive sprocket a WoO [ 1 | 78 Nim OS mh SHIEH a Shift arm pinch bolt M6 1 14. Nm (1.4 m-kgf, 10 ftlbf) ‘Shift rod locknut (shift arm side) M6 1 7 Nm (0.7 m-kgf, 5.1 ftlbf) Shitodocknut (eit pedal ido) | MB | 1 | 7Nm@7mag6.1 nb | Ueland Shilipdal bok Wao | 1 [80 Nin BOmmIGK ae 2-20TIGHTENING TORQUES tem Thread | oty Tightening torque omarks Foes ae Fo FiBL TON OGL TERT Fuel pump bok S| 6 | 0 Nim (040 magh 29 toy Rear fuel tank bracket bolt (fuel tank) | M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) Rear fuel tank bracket bolt (frame) MB 2 12.Nm (1.2 m-kgf, 8.7 ft-lbf) ean, fuel tank bracket bolt (uel M6 2 10 Nm (1.0 m-kgf, 7.2 ft-lbf) Front fuel tank bracket bolt (frame) M6 2 12.Nm (1.2 mkgf, 8.7 ftlbf) Too able guide bo vig [2] BN OS migh 68H) Sesion nat LL Passenger boTaSTaSSEmEW BaI | WE | | 28 im (BE igh 20TH Fea lender bot we [4 | BNO mg 6 by Taillight unit assembly bolt M6 2 3.3 Nm (0.33 m-kgf, 2.4 ftlbf) ‘Sidestand switch bolt M5 2 4.0 Nm (0.40 m-kof, 2.9 ftlbf) Canister bracket bolt (Engine) M6 2 7 Nm (0.7 m-kgf, 5.1 ft-lbf) ‘Canister bracket bolt (Frame) MB 1 16 Nm (1.6 m-kgf, 12 ftlbf) 2-21LUBRICATION POINTS AND LUBRICANT TYPES LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Bearings (O-rings: Oil seal lips Cylinder head bolt seats, cylinder head bolt threads and washers ‘Crankshaft big ends Connecting rod bolts| ‘Generator rotor bolt thread and washer ‘Crankshaft journals, Balancer gear and damper Balancer shaft journals, Cylinder inner surface, piston, ring grooves, and piston rings, Piston pins ‘Camshaft lobes ‘Camshaft journals Valve stems (intake and exhaust) Valve stem ends (intake and exhaust) Valve lifter surfaces Valve stem seals, Timing chain tensioner outer surface il pump rotors (inner and outer) (ll pump shaft Gil fiter cartridge union bolt Oil strainer seal SAseee Sebebsessssaraataat tte Oil pump idle gear shaft (il pump idle gear inner and thrust surfaces ‘Starter clutch ile gear thrust surfaces ‘Starter clutch rollers and starter elutch gear boss ‘Starter clutch idle gear shaft Primary drive gear bolt threads and washer Primary driven gear inner surface ‘Grankease cover and clutch pull rod <4 Oil pump drive gear inner surface and washer =e ‘Clutch boss nut and conical washer ol ‘Clutch housing thrust washer —@ 2-22LUBRICATION POINTS AND LUBRICANT TYPES Lubrication point Lubricant ‘Transmission gears (wheel and pinion) and collar ‘Transmission gears inner surface (shift fork contact parts) Shift fork and transmission gear contact surface ‘Shift drum assembly Shift forks and shift fork guide bars ‘Shift shaft moving surface Shift shaft washer addaadla 2-23LUBRICATION POINTS AND LUBRICANT TYPES 2-24LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION SYSTEM CHART AND DIAGRAMS ENGINE OIL LUBRICATION CHART (JOO 00] 4 16 2-25LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Olt strainer 2. Ollpump 3. Relief valve 4. Olititer cartdge 5. Sub gallery 6. Oil pressure switch 7. Main gallery 8. Crankshaft 9. Oilnozzie 40. Balancer shaft assembly 11, Timing chain tensioner 12. Intake camshatt 19. Exhaust camshatt 14. Main axle 16, Transmission shower 16. Drive axle 2-26LUBRICATION SYSTEM CHART AND DIAGRAMS LUBRICATION DIAGRAMS rankcase, cylinder, and cylinder head (right side view) 2-27LUBRICATION SYSTEM CHART AND DIAGRAMS “Trming chaln tensioner Intake camshatt Exhaust camshaft Crankshaft Balancer shaft assem il fiter cartridge i strainer i! pump ‘Transmission shower Ny 2-28LUBRICATION SYSTEM CHART AND DIAGRAMS Crankcase and cylinder (left side view) 2-29LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft Balancer shaft assembly ‘Connecting rod i rain bot il fiter cartridge il pressure switch 2-30LUBRICATION SYSTEM CHART AND DIAGRAMS ll pump (right side view) 2-31LUBRICATION SYSTEM CHART AND DIAGRAMS 1. Ol pump 2. Relief valve 2-32LUBRICATION SYSTEM CHART AND DIAGRAMS il strainer (bottom view) 2-33LUBRICATION SYSTEM CHART AND DIAGRAMS Main gallery il fiter cartidge Sub gallery 1 strainer 2-34LUBRICATION SYSTEM CHART AND DIAGRAMS J OF — 0's Camshaft (top view) rLUBRICATION SYSTEM CHART AND DIAGRAMS 1. Intake camshatt 2. Exhaust camshaft 38. Cylinder head 2-36LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft (rear view) aa) SI =) | aor | Yy eS fo £ (LUBRICATION SYSTEM CHART AND DIAGRAMS Grankshatt il nozzle Piston Main gallery ‘Sub gallery 2-38LUBRICATION SYSTEM CHART AND DIAGRAMS Crankshaft and transmission (top view)LUBRICATION SYSTEM CHART AND DIAGRAMS Grankshatt Balancer shaft assembly Main axle Drive axle 2-40COOLING SYSTEM DIAGRAMS COOLING SYSTEM DIAGRAMS 2-41COOLING SYSTEM DIAGRAMS Radator Radiator outlet hose Water pump ‘Thermostat Radiator init hose 2-42CABLE ROUTING CABLE ROUTING Handlebar (ront view) 2-43CABLE ROUTING ‘Throttle cable (accelerator cable) ‘Throtle cable (decelerator cable) Front brake light switch lead Handlebar suitcn lead (right handlebar switch) Clutch cable ‘Clutch switch fead Handlebar suit lead (left handlebar switch) Hom ‘Main switch lead Hom lead Front brake hose Upper bracket ‘Main switen Guide FRoute the thottie cables through the guide Route the horn lead through the guid. Route the clutch cable to the trot ofthe trata cables and letthandlebar switch lead. Route the left handlebar switch lead so that the horn lead that branches off om the lett handlebar sitch lead is routed forward, Fasten the hom lead at the white tape tothe front brake hose with the plastic band. Pesition the horn lead to the ront ofthe front orake hose. ‘The main switch lead, left handlobar switch lea, ‘and right handlebar sultch lead may be routed in any otder. Route the horn lead to the outside of the tront brake hose. Foute the main switch, left handlebar switch, and right handlebar switch ieads according to instructions “',"K', ", and “M"in the order listed, Formard Route the main switch lead between the cable {guide and the main switch Route the main switch lead through the cable {guide as shown in the ilustration, making sure to ft {the lead In between the bends in the guide Flute the main switch lead back through the cable ‘guide so that it is looped around the guide as shown inthe ilstration. Route the left handlebar switch lead and right handlebar switc lead through the guide as shown in the tlustation, 2-44CABLE ROUTING Engine (right side view) 2-45CABLE ROUTING Negative battery sub-wire hamess coupler Engine bracket (right) Fuel tank overtiow hose Ignition col lead Headlight lead (ight) Front turn signal ight lead (right turn signal ight) Coolant reservoir nose Air cutoff valve Speed sensor coupler (0p sensor ‘Coolant temperature sensor coupler ‘Starier motor lead Nogative battory sub-wire harness (0, sensor lead ‘Speed sensor lead Stator coll lead ‘Spark plug aad Electrical components tray Radiator fan motor relay Haadlight relay Dust seal Lower crankcase Fasten the fuel tank overflow hose between the hose clamps, Route the tue tank evertiow hose tothe front and under the engine braoket (igh), ‘Connect the ignition col lead with the white tape to the right ignition col ‘The main switch lead, eft handlebar switch lead, ‘and right handlebar suit lead may be routed in any order. Fasten the O, sensor lead withthe holders. Fasten the stator coll ead, coolant temperature ‘sensor lead, oll pressure switch lead, gear position ‘switch lead, Op Sensor lead, negative battery sub- wire harness, and starter motor lead with the holder. The leads may be fastened in any order, Fasten the speed sensor lead, O, sensorlead, and negative battery sub-wire hamess with the holder. ‘The leads may be fastened in any order. Install re raciator fan motor relay and headlight relay completely onto the tabs on the electrical ‘components tray. ‘Adjust the main switch lead, left handlebar switch lead, and right handlebar switch lead so thatthe upper edge ofthe white tape on each lead is positioned below the upper edge of the dust seal ‘Att adjusting the leads in instruction “G’, fasten the main switch lead, let handlebar switch lead, land right handlebar switch lead with the plastic band. Align the plastic band with the white tape on the right handlebar switch lead. Insert the projection on the holder into the hole in the engine bracket (ight), 2-46CABLE ROUTING Rear fender (right side view) 2-47B>geernemrene Fuse box Rear fender Fuse box lead Raat brake light switch coupler Rear brake light switch lead Fuel tank overtiow hose Down tube Stay Engine stay Frame Install the fuse box onto the tab on the rear fender. Pass a plastic locking tie through the ricer seat bracket and through the nole Inthe stay. Face the Ducks ofthe plastic locking tle outward wth the ‘end pointing downward, Cutoff the excess end of the plastic locking tie to 3 mm (0,12 in) or less, Position the plastic locking te atthe location ‘shown in the ilustration, Route the rear brake light switch lead tothe front of the frame cross mame. Route the fuel tank overtiow hose between the stay land the engine stay Fasten the rear brake ight switch lead atthe white tape to the down tube with a plastc locking tie. Face the buckle ofthe plastic locking tle outward vith the end pointing upward. Cut off the excess. ‘end ofthe plastic locking tle to 3 mm (0.12 in) or less, 2-48 CABLE ROUTINGCABLE ROUTING Engine (left side view) 2-49CABLE ROUTING 18, ‘Auxiliary light lead Fuel tank breather hose Guide Coolant reservoir hose (Oz sensor lead (©, sensor coupler Sidestand switch connector ‘Stator col lead Gear position switch lead Fuel tank overtiow hose ‘Sidestand switch il pressure switch lead ‘Coolant temperature sensor coupler Front turn signal light load (left turn signal light) Front coming assembly bracket ‘Meter assembly lead Bracket Wire harness Frame Drive sprocket cover Coolant reservoir cover Coolant reservoir Cylinder head ‘Sidestand switch lead wire ‘Chain case cover Route the auxiliary light lead as shown in the ilustation Fasten the fuel tank breather hose, oll pressure ‘switch load, gear position Staten lead and sidastand sich lead atthe location shown in the illustration wath a plastic locking te. The leads may be routed in any order. Cutoff the excess end of the plastic locking tle to 3 mm (0.12 in) or less. Fasten the oll pressure switch lead and gear positon switch lead at the location shown in the itustration vath a plastic locking ie. The leads may be routed In any ardor. Route the fuel tank breather hose through the ‘guide on the sidestand bracket, Point the end ofthe plastic locking tle downwara, Position the white paint mark on the fuel tank broather hose at the location shown in the ilustation Insert the projection on the wire hamess holder into the hole inthe front couling assembly Bracket. Fasten the meter assembly lead to the bracket with a plastic locking i. Face the buckle of the plastic locking te outward with the end pointing ‘downward. Cut olf the excess end of the plastic locking te to 3 mm (0.12 in) ar less, Fasten the main switch ead, let handlebar switch lead, and right handlebar switch lead atthe white tape on each lead witha plastic locking te Fasten the main switch lead, left handlebar switch lead, and night handlebar switch lead with a plastic locking te as shown in the illustration. Fit ie end ‘of the plastic locking tie into the electrical ‘components tray. ‘The main switch lead, left handlebar switch lead, ‘and right handlebar switch lead may be routed in any otder 2-50 The gear position switch lead, negative battery sub-wire harness, and starter motor aad may be routed in any order. Insert the projection on the wire harness holder Into the note in the frame. L. Face the paint mark on the fuel tank breather hose forwars, Fooute the fuel tank breather hose under the stator col load, Roule the ol pressure switch lead, gear position ‘itch lead, and fuel tank breather hose to the Dulside ofthe nib on the drive sprocket cover. ‘when instaling the drive chain cover, be sure not topinch the leads Route the oll pressure switch lead, uel tank breather hose, gear positon switch lead ang sidestand switch lead may be routed in any order Fooute the fuel tank breather hose to tha outside of the coolant resorvor. Route the fuel tank breather hose through the guide. Hold lead wires thoroughiy with clamp. ACM, water temperature sensor, pressure sensor, neutral Sith, Op sensor, minus lead wir, starter lead Wite, and sidestand switch in any order. Pass breather hose and sidestand switch lead wire to guide of chain case cover. Pass sidestand switch load wir to clamp.CABLE ROUTING Rear fender (left side view) 2-51CABLE ROUTING 24. Coolant reservoir breather hose Gear positon switch coupler Starting circuit cutoff relay ‘Starter motor lead terminal ‘Starter relay coupler ‘Yamaha diagnostic tool coupler ‘Tallbrake light lead Lean angle sensor lead Rctiferregulator coupler License plate light connector ‘Talibrake light coupler ‘Stator col lead Negative battery lead Wire harness Frame Starter relay Rear tender ‘Mudguard Rear turn signal light lead (left turn signal ight) License plate light lead Far turn signal light lead (right turn signal light) ECU (engine control unit) Battery Nogativ battory sub-wire harness Positive battery lead Fasten the starter motor lead, negative battery sub-nire harness, stator coil lead, and gear position switch ead to the wire harness with a Dlasic locking te. Do not install the plastic locking tie on the section ofthe stator col lead that isnot ‘covered by the protective sleeve Insert the end of the coolant reservoir breather hose into the frame pipe. Make sure thal the end of the hose protector onthe coolant reservoir breather hose contacts the edge ofthe le inthe Install the stating circuit cut-off relay onto the tab ‘on the rear fender. Instal tho startor motor lead and positive battory lead terminals so that the crimped section ofthe terminal that secures the lead is facing upward, Fasten the starter motor lead and negative battery ‘sulbvre harnass tothe wire harass wth a plastic lacking te at the lacation shown in the ilustration, ‘Make sure that there is no slack in the starter motor lead and negative ballery sub-wire harness. between the plastic locking ties. ‘The stator coll lead and gear position switch lead may be routed in any order. Fasten the starer motor lead, negative battery ‘subwire harness, stator col lead, and gear position switch lead to the wire harness with a Dlasic locking tie as shown in the illustration, Face {he buckle of te plastic locking te outward withthe ‘end pointing upward. Cutoff the excess end of the plastic locking te to 3 mm (0,12 in) or les. ‘The negative battery sub-wire hamess and starter motor lead may be routed in any order. ‘The wire hamess and tallbrake light lead may be routed in any order. 2-52 Fasten the wire hamess and talbrake light lad to the frame witha plastic locking teas shown in the llustton, Point the end af the plastic eking te ‘utara, Cutoff the excess end ofthe plastic locking be to 3 mm (0.12 in) oF lass. LInstall the starter relay completly onto the tabs on the rear fender. Route the rear left turn signal light lead, rea right tur signal ight lead, and license plate light lead under the starter relay, The leads may be routed in any order. NN. Route the rear lft turn signal light lead, rear right tur signal light lead, and license plate light lead through the guides on the mudguard. Insert the projection on the wite harness holder Ito the hole inthe rear fonder. P. Fasten the starter motor lead and negative battery Sub-wire harness tothe wire hamess with aplastic locking te as snown in tha ilustration. Face the buckle of the plastic locking te outward with the fend pointing upward. Cut otf the excess end of the plastic locking ie to 3 mm (0.12 in) or lass,CABLE ROUTING Engine (top view) 2-53CABLE ROUTING eo @ CCluteh cable Handlebar suitch lead (elt handlebar switch) Front turn signal light lead (left tur signal light) Headlight lead (et) ‘Auxiliary light lead ‘Meter assembly ‘Meter assembly lead ‘Throtle cable (accelerator cable) Throttle cable (decelerator cable) Hom lead Headlight lead (right) Front turn signal ight lead (right turn signal ight) Front brake hose Handlebar suitch coupler (right handlebar switch) Coolant reservoir hose Fuel tank overtiow hose Frame Fuel tank breather hose Electrical components tray Handlebar switch coupler (left handlebar switch) ‘Main switch coupler Front side cowiing inner panel (lft) Front side cowiing inner panel (right) Fuel injector lead Fuel rail ‘Spark plug lead Place the let handlebar switch coupler, right handlebar switch coupler, and main switch coupler in the electrical components tray go thatthe leads to the switches are routed upward. Insert the projection on the wire harness holder into the hole inthe frame. TT fuel pump Route the headlight lead through the guides on the front side cowting inner panel. Insert the projection on the plastic locking te nto the Note in the electrical components tray. ‘The main switch lead, eft handlebar switch lead, ‘and right handlebar switch lead may be routed in any otder. Fasten the main switch lead, left hanslebar switch lead, and right handlebar switch lead atthe white tape on each lead withthe plastic locking te. Point ‘tho end ofthe plastic locking te outward. Cut off the excess end ofthe plastic locking tie to 3 mm (0.12 in) or less. Fasten the fue injector lead atthe white tape to the ‘uel al with aplastic locking te. Face the buckle of the plastic lacking te rearward with he ang pointing downward. Cutoff the excoss and of the plastic locking te to 3 mm (0.12 In) or lass. Gross the throttle cables above the plastic locking tie Wite tape Faston the throtle cable (accelerator cable) and throtle cable (decelerator cable) with the plastic locking te. Be sure to route the throttle cable (accelerator cable) above the throtle cable (decelerator cable). Cut off the excess end of the plastic locking te to 3 mm (0.12 In) or less. Route the spark plug ead tothe front ofthe projection on the electical components tray 2-54CABLE ROUTING Rear fender (top view) 2-55CABLE ROUTING @ Fuel tank overtiow hose (©z sensor lead Negative battery sub-wire hamess. Frame Raat brake light switch lead Fuse box lead “Tur signal relay Fuse box ECU (engine control unit) Rocifierregulator ‘Yamaha diagnostic tool coupler ‘Yamaha diagnostic tool coupler lead Rear turn signal light lead (right turn signal light) License plate light lead Roar turn signal light lead (Jett urn signal ight) Lean angle sensor ‘Tallbrake light lead Froar fender Starter relay Reciierreguiator lead ‘Starting rout cut-off rotay ECU (engine control unit) lead Wire harness Nagative battery sub-wire hamess coupler Battery Gear position switch coupler Crankshaft position sensor coupler ‘Stator coi coupler Negative battery sub-wire harness. Positive battery lead Insert the projection on the holder at the waite tape ‘on the wire harnass into the frame hole shown the illustration Insert the projection on the wire harness holder into the hole inthe frame. Fit the turn signal relay into the Hole in the ECU. bana, Route the negative battery sub-wire harness undor the ECU (engne contsol uni). Route the rear turn signa light leads, license plate light lead, and Yamaha diagnostic tool coupler lead tough the guide on the rear fender. Fasten the wire harness to the trame with a plastic locking te. Position the plastic locking te to the front of where the leads branch off from the wire hamess. Route the rear turn signal light leads between the {um signal relay lead and the negative battery sub- wire harness, Fit the negative battary sub-wire hamess coupler into the hole inthe ECU band, ‘The rear tur signal light leads may be routed in any order. Fasten the wire harness to the trame with a plastic locking tie as shown in ine lustraion. Face the buckle ofthe plastic locking ie outward with the ‘end pointing downward, Cutoff the excess end of the plastic locking tie to 3 mm (0,12 in) or less, 2-56 K. The starter motor lead, negative battery sub-wire harness, taorake light lead, and wire harness ‘may be routed in any orcer.CABLE ROUTING Front brake (right side view)CABLE ROUTING Brene Front brake hose Front brake caliper Guide Flute the front brake hose aver the guide. ‘When installing the brake hose onto the brake ‘caliper, make sure that the brake pipe touches the projection on the brake caliper. 2-58CABLE ROUTING Rear brake (right side view) 2-59CABLE ROUTING pas Rear brake callper Brake hose (rear brake master cylinder to rear brake caliper) Brake fuid reservoir hose Roar brake master cylindar ‘When installing the brake hose (rear brake master cylinder to rear brake caliper) on the rear brake master cylinder, make sure that the brake pipe touches the projection on the master cylinder. ‘Connect the end ofthe brake hose (rear brake master eylinder to rear brake calipet) that is Identiied by the white paint mark tothe rear brake master eylinde. ‘When instling the brake hose onto the brake ccaliper, make sure that the brake pipe touches the projection on the brake caliper 2-60CABLE ROUTING Fuel tank (left side view) 2-61CABLE ROUTING OD >exepeenn Fuel tank Fuel hase (uel tank to fuel rai) Fuel pump Fuel tank breather hose (fuel tank to hose joint) Fuel tank breather hose Hose joint Fuel tank evertiow hose Fuel tank overtiow hose (vel tank to hose joint) ‘Connect the orange connector ofthe fuel Nose (fuel tank to tue al) to the fuel pump. Fommard Face the white paint mark on the fuel tank overflow hose (ue! tank to hose joint) forwara, Face the white paint mark on the fuel tank breather hose (ue! tank to hose joint) forward. Install the fuel tank breather hose (Iuel tank to hose joint) so thatit contacts the tapered portion of the Nose ting on the fuel tank and it contacts the ‘stopper on the hose joint ‘Align the yellow paint mark on the fuel tank breather hose with the yellow paint mark on the fuel tank breather hose (tue tank to hose joint). ‘Align the yellow paint mark on the fuel tank ‘overiow hose withthe yellow paint mark on the ‘uel tank overflow hose (fuel tank to hose joint) Install the fuel tank overfiow hose (fuel tank to hose joint) so that it contacts the tapered portion of the hose tting on the fuel tank and iteantacts the stopper on the hose joint. 2-62CABLE ROUTING ‘Throttle bodies (left and right view) 2-63CABLE ROUTING zee xp MDM @ >ZePNeRAeNe ze ‘Throtia bodies: Fuel hase (uel tank to fuel rail) Crankcase breather hose Air fter case assembly Clip CCrankcase breather cover Pipe balance (canister purge hose) ISC (idle speed contro) unit inlet hose Way (joint pipe) Clamp Direction of yellow paint shall be let side of vehieie Part should install yellow paint being part side and let ot vehicle. Prt should insert incicate rear end of pipe. Patt should not get on pipe spool Front Direction of clip shall be back side of vehicle, and ‘one side ear is parallel to a vehicle crecton, and the other ear is parallel to a vehicle direction, and the other ear tuming tothe body inside. ‘Artach black side ta throttle body assy. Part should install yellow paint being part side and right of vehicie. Direction of clip shal be lower sie of vehicle Direction of clip shall be back side of vehicte. Direction of clip shall be right slant lower direction of vehicle. Direction of white paint shall be right side of vehicte Direction of clip shal be right side of vehicle, Direction of clip shal be front side of vehicle, 2-64CABLE ROUTING Air induction system (top view) 2-65CABLE ROUTING Raed valve cover Air induction system hose (air cut-off valve to reed valve cover) Air cutoff valve ‘Air induction system hase (air iter case to ar cut- off valve) Air fiter case assembly Point tne ends of the hase clamp upward. Face the yellow paint mark on the air induction system hose (air fiter case to air cutof valve) upward, Face the white paint mark on the alr induction system hose (ar fiter case to alr cut-off valve) upward, Point ta ends of the hose clamp downwar Install te hose completely onto the hose fting Point tha ands of the hase clamp to the forward, angled downward. 2-66CABLE ROUTING Radiator (top view) HH a SnCABLE ROUTING Bresogsene Radator Radiator outlet hose Coolant reservoir nose Coolant reservoir cap Coolant reservoir breather hase Coolant reservoir Radator init hose Coolant hose ce Face the white paint mark on the coolant reservotr hose upward 40° 31mm (0.12 in) or more. Make sure not to install the hose clamp on the ralsed portion of the hose ‘ting. Downware Install te coolant reservoir hose untl the end ot the hose contacts the raised portion of the hose fiting.. 401mm (0.99 in) or more 5mm (0.20 in) Install the pipe up tothe groove in the coolant reservoir cap. Install te coolant reservoir breather hose ‘completely onto the hose fting of te coolant reservoir Lott side Install the coolant hose so that the end ofthe hose Is positioned as shown inthe lustration 2-68CABLE ROUTING Radiator (left side view) 2-69CABLE ROUTING peenogeenn oc - za omm Coolant reservoir hose Electrical components tray Coolant reservoir cap Coolant reservoir areather hose Frame Coolant reservoir ‘Thermostat cover Radiator init hose Radator Insert the end of the coolant reservoir breathor hose into the frame pipe. Make sure thatthe end of the hose protector on the coolant reservoir breather hose contacts the edge ofthe hole in the trame. Face the white paint mark on the coolant reservoir breather hose outward, Install the radiator inlet hose completely onto the hose fiting of the thermostat cover. Connect the end of he radiator inlet hose that is identifies by the white paint mar tothe raciatr. White paint mark Install the racator inlet hose up to the projection ‘on the hose fting 3. Outwaret Insert the projection on the holder into the hole in the electrical components tray ‘The fastener of the screw clamp should be facing downward with the screw head facing outward, Downward 2-70CABLE ROUTING Radiator (right side view) 271CABLE ROUTING moO @ paeNe Coolant reservoir hose Radator Radiator outlet hose Water pump housing Connect the end of the radiator out hose that is. Identified by the white paint mark tothe radiator. Install he radiator outiet hose completely onto the hose fiting ofthe water pump housing. ‘Outwarc ite paint mark Install te raciator outlet hose up to the projection ‘on the hose fing. “The fastener ofthe screw clamp should be facing forward with the screw head facing outwars. 2-72CABLE ROUTING Canister >e ie 2-73CABLE ROUTING 1. Fuel tank compartment 2. Fuelhose 3, Throttle wire assy 4. Canister assy 5. Canister purge hose 6. Rollover valve assy 7. Radator hose 8. Frame 9. Fuel tank breather hose 40. Staner lead wire 11, Way (jint pipe) 12. Clamp ‘A. Tum clip to front side of vehicle B. Fox clamp on canister purge hose at closest clip. ‘Should not be clamp way (joint pipe). C. Clamp canister purge nose and starter lead wire Fix smaller ole of clamo to starter lead wire. Open side of clamp should be on back side of vehicle, 2-74CABLE ROUTING 2-75PERIODIC CHECKS AND ADJUSTMENTS PERIODIC MAINTENANCE... INTRODUCTION. PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL, SYSTEM.. GENERAL MAINTENANCE AND LUBRICATION CHART CHECKING THE FUEL LINE....... CHECKING THE SPARK PLUGS. ADJUSTING THE VALVE CLEARANCE .... CHECKING THE ENGINE IDLING SPEED SYNCHRONIZING THE THROTTLE BODIES. CHECKING THE THROTTLE BODY JOINT. 3-10 CHECKING THE CANISTER .. neces 340 CHECKING THE EXHAUST SYSTEM....... 3-10 CHECKING THE GRANKCASE BREATHER HOSE «00... Sot CHECKING THE AIR INDUCTION SYSTEM. att REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE att ADJUSTING THE CLUTCH LEVER FREE PLAY... B12 CHECKING THE BRAKE OPERATION.... 343 CHECKING THE FRONT BRAKE PADS. 313 CHECKING THE REAR BRAKE PADS 3-13 CHECKING THE FRONT BRAKE HOSES... CHECKING THE REAR BRAKE HOSE... BLEEDING THE HYDRAULIC BRAKE SYSTEM... i CHECKING THE BRAKE FLUID LEVEL. 315 CHECKING THE WHEELS. 3-15 CHECKING THE TIRES ..rnorn 3-15 CHECKING THE WHEEL BEARINGS... 3417 CHECKING THE SWINGARM OPERATION... : 3-17 LUBRICATING THE SWINGARM PIVOT 3-47 ADJUSTING THE DRIVE CHAIN SLACK. 3417 LUBRICATING THE DRIVE CHAIN 348 CHECKING AND ADJUSTING THE STEERING HEAD ......0necennnn 348 LUBRICATING THE STEERING HEAD... oe 319 CHECKING THE CHASSIS FASTENERS... enenennneesene AQ LUBRICATING THE BRAKE LEVER, 349 LUBRICATING THE PEDAL ...s:rrsnnnnniesnnnnnnnnennsnnniennnns S20 LUBRICATING THE CLUTCH LEVER... 3:20 CHECKING THE SIDESTAND.... 3-20 LUBRICATING THE SIDESTAND.. CHECKING THE SIDESTAND SWITCH... CHECKING THE FRONT FORK... . . CHECKING THE REAR SHOCK ABSORBER ASSEMBLY..... ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY... CHECKING THE ENGINE OIL LEVEL. 3.21 CHANGING THE ENGINE OIL 3.22 CHECKING THE COOLANT LEVEL..... 3-23, CHECKING THE COOLING SYSTEM 3-23 CHANGING THE COOLANT. sono: sonnei 22M CHECKING THE BRAKE LIGHT SWITCHES. 3.25 3-20 3-20ADJUSTING THE REAR BRAKE LIGHT SWITCH CHECKING AND LUBRICATING THE CABLES... CHECKING THE THROTTLE GRIP OPERATION CHECKING THE SWITCHES, LIGHTS AND SIGNALS........ REPLACING THE HEADLIGHT BULBS ADJUSTING THE HEADLIGHT BEAM..... 3:26 3-26 3:26 27 3.07 3-28PERIODIC MAINTENANCE PERIODIC MAINTENANCE INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures wil ensure more reliable vehicle operation, a long- ‘er service lite and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM 1p + From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months. + Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service. TNITIAL ‘ODOMETER READINGS 77900 mi | 10000 mi | 13000 mi | 16000 mi (ooo | "sooo" | "fet000" | "teso00 vam) | “my? | Samy | Sey ‘12 months| 16 months|24 months 30 months 600m | 4000 mt (1000 Km) | (6000 en) ‘month | 6 months No.) TEM ROUTINE * Check uel hoses freaks or 1) | Fuel tine mage \ y y y ¥ + Replace # necessary. * Check conten, 5 Adjust gap and clean, + piace at 7000 ms ($1000 y Xen) or 12 marine an ore fry 6000 ri (10000, "2inonth, 7 Check and adjust ave clear ‘sce when engine cle * Ghosk breather hove for 2) | spark plugs replace. | ¥ | Replace. | ¥ ‘|| Valve clearance ‘Every 20600 mi (42000 kn) | Crankease breather system |. Roa i nootsary . : . : : '5] [Fuel inection |» Adust synchronization y v 7 qv 7 7 Shack akage : 1 Tighten if nooossary. 7 6) *| exh 5 apisce gaskets i neces: y ‘ ‘ t sy. Evaporative emis- |» Check contol system fr 7|;| siomeontrol sys |" damaoo y 4 tem + Ropace It necessary. * Check he air eu-of valve, 2) | Aiinduetonays- |" reed vane, and hose ord \ y me + Rope ary damaged parts GENERAL MAINTENANCE AND LUBRICATION CHART TIP + From 19000 mi (31000 km) or 36 months, repeat the maintenance intervals starting from 7000 mi (11000 km) or 12 months, + Items marked with an asterisk require special tools, data and technical skills, have a Yamaha dealer perform the service. 3-1PERIODIC MAINTENANCE TNA ‘ODOMETER READINGS o00 mi | 10000 ni | 19000 ni | 16000 mi eM ROUTINE (500 mi | 4000 mi | “(14000 | (16000 | (21000 | (26000 «09k eona em) | im? | Sm | Sms | St ‘Tmonth | 6 months |12 months) 18 months |24 months|30 months| Tier sement | Repco 7 Torche 1, en, q q 7 Y ri Y 7 Check opanon qi q , : 7 Clute ‘+ Adjust or replace cable. . hack poratin idoval oe : Frombate |, aertulenage, “| 1 4 y ‘ 1 oy 7 Chack apartin, oval See ears : « Fpl bate pace noe: | 8 y x y ‘ ‘ Sy ‘heck Tor acs od ‘Check for eorect routings y y y y ¥ Brake hose siaroig. Replace Boy yea Brake uid | Replace Biya © Shoo rnou and ora Wheels oe 1 y Y ri \ «Fobice it nacetary ~ Qhotread ep andor rss Tees Farle inwcsusany, 1 4 1 ‘ ‘ heck a preure Comes! feeesenry, “Gheck bearings for smooth Wheel bearings |” sneraton y y Y y ¥ Fopace i necossary ‘Check bearing assemblos for ‘Swingarm pivot | looseness. 4 beantgs Moderately repack with thie Urssoaps aed tease. FRopack ‘Check chain slack, alignment FER cate chain | Every $00 mi (800 kr) ard ator washing the motorcyeo sing nthe ‘nha special Oning chan la rain or ing in wat areas rican! oroughiy Drive chain ‘Check bearing assembles for ‘eosenese Meseratsy repack wn tni- | ’ y vo | Repack | Uinecoap-based grease. ‘Steering bearings ‘Check al chaseie iting and Chassis fastonors |" faconers. y y y y Comes necessary, Brake Fever HOE] Appi icone ooase ty. y y q 1 Y ‘rake pedal vat |» Appy lium soap based 7 7 7 7 7 shat ‘owe tony. ‘loth Tavera |= Apply Wtumraoap based i Shan *erPNet | eign ‘ : 4 3 4 Shit peda pot |» Api wun-soap-based shan ‘tease igh , . . . * Check operation sidestand pivot | ply wu soap-besed 4 4 4 4 \ SR Siestand switch |* Ghe%epaaton ardrepace | y y q 1 Y 7 Check operation andor Front for veaage 4 4 4 4 \ + Roplace necessary.PERIODIC MAINTENANCE TWITIAL ‘ODOMETER READINGS vo] em noone om | aa | ae | ORs as | ee cine) in| Sea | tg? | ‘Tmonth | months |+2 months| 16 months 24 months| 30 months “Shock absorber |* Check operation andr of fea Keakage y y Y y ¥ assembly + Ropiace # necessary. Ghange. v When ie ll change nator Tashes 3) | engine oi * Check ol vel and vais for 7 q v v leakage ‘ ‘ boa) [Engine sitter | opine y y v eatndge * Gheok hoses foreracks oF avage v fe fae fou ds f|-|cootnasystem |» HeS snacossan. = Ghange cova q bs - + Cheat operation yt. yep. ps Toa aaa sabe cant for -|contoteaoue |" fettersuapenneun | < | x | v | vy |v |v Seat 7 Ghosk open + Shes Prose goo ax f|-|rmrowe one |” Shaul aes v fv fue fu fy ~ | Hai, signals [> heck ons j P| seewicRoe® [> Sat heaatmam epee pepe pe ys 1? + Air filter + This mode's air fter is equipped with a disposable oil-coated paper element, which must not be cleaned with compressed air to avoid damaging it. + The air filter element needs to be replaced more frequently when 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 fil the reservoirs as required. + Every two years replace the internal components of the brake master oylinders and calipers, and change the brake fluid ‘+ Replace the brake hoses every four years and if cracked or damaged. 3-3PERIODIC MAINTENANCE CHECKING THE FUEL LINE 1. Remove: * Rider seat Refer to “GENERAL CHASSIS (1)" on page 41 + Side panels Rofer to “GENERAL CHASSIS (2)" on page 43 + Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. 2. Remove: * Front fuel tank bracket bolt rame) “1” + Rear uel tank bracket bolts (frame) "2" woric! ‘When lifting up the fuel tank, be careful not to pull the fuel tank overflow hose and fuel tank breather hose. 8. Check: + Fuel hose “1” ‘+ Fuel tank breather hose “2” ‘Fuel tank overflow hose “3” Cracks/damage -> Replace. Loose connection > Connect properly. NOTICE Make sure the fuel tank breather/overflow hose is routed correctly. 4, Install: ‘+ Front fuel tank bracket bolt (frame) + Rear fuel tank bracket bolt (frame) Rear fuel tank bracket bolt (frame) 12. Nm (1.2 m-kgf, 8.7 ttlbf) Front fuel tank bracket bolt (frame) 12. Nm (1.2 m-kgf, 8.7 ftlbf) 5. Install + Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. + Side panels Refer to “GENERAL CHASSIS (2)" on page 43. + Rider seat Refer to “GENERAL CHASSIS (1)" on page 4a CHECKING THE SPARK PLUGS The following procedure applies to all of the spark plugs. 1. Remove: “Rider seat Refer to “GENERAL CHASSIS (1)" on page a + Side panels Refer to “GENERAL CHASSIS (2)" on page 43. ‘+ Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. + Fuel tank Refer to “FUEL TANK” on page 7-1. 2. Disconnect: + Spark plug caps 8. Remove: + Spark plugs NOTICE Before removing the spark plugs, blow away any dirt accumulated in the spark plug wells with compressed air to preventit from falling 0 the cylinders. 4. Check: + Spark plug type Incorrect ~> Change. Manufacturer/model NGK/CR8E 5. Check: + Electrode “1” Damage/wear > Replace the spark plug.PERIODIC MAINTENANCE + Insulator "2" ‘Abnormal color —+ Replace the spark plug Normal color is medium-to-light tan. 6. Clean: * Spark plug (with a spark plug cleaner or wire brush) 7. Measure: Spark plug gap “a” (with a wire thickness gauge) Out of specification > Regan. ‘Spark plug gap 0.7-0.8 mm (0.028-0.031 in) 8. Install: + Spark plugs Spark plug 13 Nm (1.3 m-kgf, 9.4 ftlbf) Ar plug and gasket surface. 9. Connect: + Spark plug caps 10.install + Fuel tank Refer to “FUEL TANK" on page 7-1 + Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. + Side panels Refer to “GENERAL CHASSIS (2)" on page 43 + Rider seat Refer to “GENERAL CHASSIS (1)" on page a4 ADJUSTING THE VALVE CLEARANCE The following procedure applies to all of the valves. Before installing the spark plug, clean the spark 3-5 a Valve clearance adjustment should be made on a cold engine, at room temperature. 1. Remove’ “Rider seat Refer to “GENERAL CHASSIS (1)" on page 41. + Side panels Refer to “GENERAL CHASSIS (2)" on page 43. + Fuel tank cover assembly + Front side cowling assembly (right) Refer to “GENERAL CHASSIS (3)" on page 45. + Fuel tank Refer to “FUEL TANK” on page 7-1. * Air cut-off valve/Reed valve Refer to “AIR INDUCTION SYSTEM" on page 7-15. 2, Disconnect: * Spark plug cap Refer to “CAMSHAFTS" on page 5-13. 8. Remove + Spark plugs + Cylinder head cover + Cylinder head cover gasket Refer to “CAMSHAFTS’ on page 5-13. 4, Remove + Crankshaft end cover “1” + Timing mark accessing bolt "2" 5. Measure: * Valve clearance Out of specification + Adjust. a Valve clearance (cold) Intake 0.11-0.18 mm (0.0043-0.0071 in)} Exhaust (0.21-0.30 mm (0.0083-0.0118 in)} 1? + Ifthe vaive clearance is incorrect, record the measured readingPERIODIC MAINTENANCE + Measure the valve clearance in the following sequence. . Measure the valve clearance #2 with a thick- ness gauge. Valve clearance measuring sequence Cylinder #1 —> #2 A. Front YWYVYY YY YY YY YY YY YY YY YY YYYYYYYTY a. Turn the crankshaft counterclockwise. b. When piston #1 is at TDC on th sion stroke, align the TDC mart ‘generator rotor with the slots "b” ator rotor cover. c, Measure the valve clearance #1 with a thick- ness gauge “1” SF Thickness gauge 90890-03180 Feeler gauge set YU-26900-9 4. Turn the crankshaft counterclockwise 180 degrees. Thickness gauge ‘90890-03180 Feeler gauge set YU-26800-9 x SUVUUUVUVUVUUUVUVUVUUUVUUUVUUUYTY 6. Remove * Camshaft me + Refer to "CAMSHAFTS" on page 5-13. + When removing the timing chain and cam- shafts, fasten the timing chain with a wire to re~ trieve iti it falls into the crankcase. 7. Adjust: + Valve clearance YY VY VY VY YYVYYYYYVYYYYYYYYYyTTyy a. Remove the valve lifer “1” and the valve pad “2” with a valve lapper "3". se me * Cover the timing chain opening with a rag to prevent the valve pad from falling into the crankcase. + Make a note of the position of each valve lifter "1" and valve pad *2" so that they can be in- stalled in the correct place Valve lapper 90890-04101 Valve lapping tool YM-A8998.PERIODIC MAINTENANCE b. Calculate the difference between the speci- fied valve clearance and the measured valve clearance, Example: Specified valve clearance = 0.11-0.18 mm (0.0043-0.0071 in) Measured valve clearance = 0.25 mm (0.0098 in) 0.25 mm (0.0098 in)-0.18 mm (0.0071 in) 0.07 mm (0.0028 in) c. Check the thickness of the current valve pad. 1p ‘The thickness “a” of each valve pad is marked in hundredths of millimeters on the side that touch- es the valve lifter. Example: Ifthe valve pad is marked "158", the pad thickness is 1.58 mm (0.0622 in) ¢. Calculate the sum of the values obtained in ‘steps (b) and (c) to determine the required valve pad thickness and the valve pad num- ber. Example: 1.58 mm (0.0622 in) + 0.07 mm (0.0028 in) = 1.65 mm (0.0649 in) ‘The valve pad number is 165. e, Round off the valve pad number according to the following table, and then select the suit- able valve pad. Last digit Rounded value 01,2 0 Last digit Rounded value 34,5,6 5 7.8.9 70 T1P Refer to the following table for the available valve pads. Valve pad range No, 150-240 1,502.40 mm (0.0580-0.0944 in) 19 thicknesses in 0.050 sm (0.0020 in) inore- ments Valve pad thickness Available valve pads Example: Valve pad number = 165 Rounded value = 165 New valve pad number = 165 1. Install the new valve pad “1” and the valve lift- er'2". 1p + Lubricate the valve lifter with engine oil + Install the valve lifter and the valve pad in the correct place. + The valve lifter must tun smoothly when rotat- ed by hand, g. Install the exhaust and intake camshafts, tim- ing chain and camshaft caps. Camshaft cap bolt 10Nm (1 yf, 7.2 ftlbf) 1p + Refer to "CAMSHAFTS" on page 5-13. + Lubricate the camshaft lobes and camshaft journals with molybdenum disulfide oil. + First, install the exhaust camshaft. * Align the camshafts sprocket marks with the cylinder head edge.PERIODIC MAINTENANCE ‘Tum the crankshaft counterclockwise several full tums to seat the parts, h. Measure the valve clearance again. i. Ifthe valve clearance is stil out of specificar tion, repeat all of the valve clearance adjust- ment steps until the specified clearance is obtained. AAAAAAAAAAAAAAAAAAAAAAA ALARA 8. Install: * All removed parts me For installation, reverse the removal procedure. CHECKING THE ENGINE IDLING SPEED me Prior to checking the engine idling speed, the throttle body synchronization should be adjusted properly, the air filter element should be clean, and the engine should have adequate compres sion 1. Start the engine and let it warm up for several minutes. 2, Check: + Engine idling speed Out of specification -> Go to next step. 8. Check: + ISC (idle speed control) learning value “00° or “01” Check the intake system, “02 + Clean the ISC (idle speed control) unit Refer to “CHECKING THE THROTTLE BODIES AND ISC (IDLE SPEED CON- TROL) UNIT” on page 7-9. 2." Connecl the Yamaha dagnostc to) Use the diagnostic code number “67”. Refer to “SELF-DIAGNOSTIC FUNCTION AND DIAGNOSTIC CODE TABLE” on page 95. 7 b. Check the ISC (idle speed control) leaning value. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAA Engine idling speed 1300-1500 r/min Yamaha diagnostic tool (US) 90890-03234 SYNCHRONIZING THE THROTTLE BODIES TP Before synchronizing the throttle bodies, check the following items: + Valve clearance * Spark plugs + Air fiter element + Throttle body joint + Fuel hose + Exhaust system * Crankease breather hose Checking the throttle body synchronization 1, Stand the vehicle on a level surface 1p Place the vehicle on a suitable stand. 2. Remove: * Rider seat Refer to “GENERAL CHASSIS (1)" on page 44. + Side panels Refer to “GENERAL CHASSIS (2)" on page 43. + Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. + Fuel tank Refer to “FUEL TANK” on page 7-1. 3, Remove: Caps “1” 4, Install + Vacuum gauge hose #1 + Vacuum gauge hose #2 + Vacuum gauge “3” Vacuum gauge ‘90890-03094 Vacuummate YU-44456PERIODIC MAINTENANCE 5, Install: + Fuel tank Refer to “FUEL TANK” on page 7-1 6. Check: + Throttle body synchronization VV VYYYYVYVYVYYYYYYY NYY YY YY YY YY a. Start the engine, warm it up for several min- tutes, and then let it run at the specified en- gine idling speed. Gy Engine idling speed 1300-1500 r/min + If a bypass air screw was removed, tum the screw in fully and be sure to synchronize the throttle bodies. + Ifthe throttle body synchronization can not be adjusted using the bypass air screw, clean or replace the throttle bodies. + The difference in vacuum pressure between the throttle bodies should not exceed 2 kPa (16 mmHg). b. Check the vacuum pressure, The difference in vacuum pres- ‘sure between the throttle bodies should not exceed 2 kPa (16 mmHg). IF out of specification —> Adjust the throttle body synchronization, AAAAAAAADdA added ddd ed deb de dd Adjusting the throttle body synchronization 1. Adjust * Throttle body synchronization 27 Slarthe engin, warmup fr Several Fun utes, and then let it run at the specified en- idling speed. Engine idling speed 1300-1500 r/mi b. With throttle body #2 as standard, adjust throttle body #1 using the air screw "1" me + Tum the bypass air screw using the carburetor angle driver. + After each step, rev the engine two or three times, each time for less than a second, and check the synchronization again. 3-9 A. Throttle body #1 B. Throttle body #2 AAAAAAAAAAAAAAAAAA AAA AAA AAAAL 2, Stop the engine and remove the measuring equipment, 3. Install + Caps 4, Install + Fuel tank Refer to “FUEL TANK” on page 7-1. + Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. + Side panels Refer to “GENERAL CHASSIS (2)" on page 43. + Rider seat Refer to “GENERAL CHASSIS (1)" on page 4a.PERIODIC MAINTENANCE 5. Adjust: * Throttle grip free play Referto"CHECKING THE THROTTLE GRIP OPERATION” on page 3-26, Throttle grip free play 3.0-5.0 mm (0.12-0. in) CHECKING THE THROTTLE BODY JOINT 1. Remove: * Rider seat Refer to “GENERAL CHASSIS (1)" on page 44 + Side panels Refer to “GENERAL CHASSIS (2)" on page 43 + Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. + Fuel tank Refer to “FUEL TANK" on page 7-1 2. Remove: + Throttle bodies Refer to “THROTTLE BODIES" on page 7-6. 38. Check: * Throttle body joint “1” Cracks/damage — Replace. 4, Install: ‘Throttle bodies Refer to “THROTTLE BODIES’ on page 7-6. 5. Install: Fuel tank Refer to “FUEL TANK" on page 7-1 + Fuel tank cover assembly Refer to “GENERAL CHASSIS (3)" on page 45. * Side panels Refer to “GENERAL CHASSIS (2)" on page 43 + Rider seat Rofer to “GENERAL CHASSIS (1)" on page a ‘CHECKING THE CANISTER 1. Remove: + Fuel tank Refer to “FUEL TANK” on page 7-1 2. Check: Canister + Canister purge hoses + Fuel tank breather hoses + Canister breather hose Cracks/damage— Replace. 3. Install + Fuel tank Refer to “FUEL TANK” on page 7-1. CHECKING THE EXHAUST SYSTEM 1, Remove: * Side panels Refer to “GENERAL CHASSIS (2)" on page 43. + Front side cowling assembly (left) Refer to “GENERAL CHASSIS (3)" on page 45. + Coolant reservoir Refer to “RADIATOR” on page 6-1. + Footrest assembly (right) Refer to “REAR BRAKE" on page 4-48 2. Check: + Exhaust pipe “1” ‘+ Muffler assembly "2" Cracks/damage —> Replace. + Gasket ‘3’, “4” Exhaust gas leaks > Replace. 8. Check: Tightening torque + Exhaust pipe nuts “5” + Exhaust pipe bolt 6” ‘Muffler assembly bolt “7” + Exhaust pipe joint bolt 8” Exhaust pipe nut 15 Nm (1.5 m-kgf, 11 ftbf) Exhaust pipe bolt 20 Nm (2.0 m-kgf, 14 ftbf) Muffler assembly bolt 20 Nm (2.0 mkgf, 14 ftbf) Exhaust pipe joint bolt 20 Nm (2.0 m-kaf, 14 fbf) 3-10PERIODIC MAINTENANCE 5 CHECKING THE CRANKCASE BREATHER HOSE 1. Remove: + Side panel (loft) Refer to “GENERAL CHASSIS (2)" on page 43 + Front bottom cowling (left) Refer to “GENERAL CHASSIS (3)" on page 45. + Coolant reservoir Refer to “RADIATOR” on page 6-1 2. Check: + Crankcase breather hose “1” Cracks/damage — Replace. Loose connection —+ Connect property. NOTICE Make sure the crankcase breather hose is routed correctly. 3. Install: * Coolant reservoir Refer to “RADIATOR” on page 6-1. ‘Front bottom cowling (lett) Refer to “GENERAL CHASSIS (3)" on page 45. + Side panel (left) Refer to “GENERAL CHASSIS (2)" on page 43. ‘CHECKING THE AIR INDUCTION SYSTEM Refer to “CHECKING THE AIR INDUCTION SYSTEM" on page 7-19. REPLACING THE AIR FILTER ELEMENT AND CLEANING THE CHECK HOSE me ‘There is an airfiter check hose “1” atthe bottom ofthe air filter case. If dust andlor water collects in this hose, clean the air fitar check hose and replace the air fiter element, 1, Remove: * Side panel (left) Refer to “GENERAL CHASSIS (2)" on page 43. 2, Remove: * Air filter case side cover (left) “1” Refer to “GENERAL CHASSIS (6)" on page 418. 3. Remove: * Air filter element “1”PERIODIC MAINTENANCE 4, Check: * Air filter element Damage —+ Replace. me ‘The air filter needs more frequent service if you are riding in unusually wet or dusty areas. 5. Install: * Air fiter element + Air filter case side cover (left) » | Air filter case side cover screw (left) 2.5 Nm (0.25 m-kof, 1.8 fbf) NOTICE 2, Remove: * Side panel (right) Refer to “GENERAL CHASSIS (2)" on page 43. + Front bottom cowling (right) Refer to “GENERAL CHASSIS (3)" on page 45. 3. Adjust: * Clutch lever free play Handlebar side ” a. Loosen the locknut b. Turn the adjusting bolt "2" in direction “a” or “b” until the specified clutch lever free play is obtained. Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect throttle body synchronization, leading to poor engine per- formance and possible overheating, 6. Install * Side panel (left) Refer to “GENERAL CHASSIS (2)" on page 43 ‘ADJUSTING THE CLUTCH LEVER FREE PLAY 4. Check: * Clutch lever free play “a” Out of specification —> Adjust. Clutch lever free play 10. Direction “a” Clutch lever free play is increased. Direction “b” Clutch lever free play is decreased. 1 Ifthe specified olutch lever free play cannot be obtained on the handlebar side of the cable, use the adjusting nut on the engine side. FOVUNUVUUUUUUVYUUYUUYUTUNYUUTYTY VYYUV YY Y YY YYYTY YY YY YY TYYEYY YY, Engine side ‘a. Loosen the locknut “1”. 3412PERIODIC MAINTENANCE b. Tumthe adjusting nut“2" in direction “a” or“b Until the specified clutch lever free play is ob- tained. Direction “a” Clutch lever free play is increased. Direction “b” Clutch lever free play is decreased. cc. Tighten the locknut “1”, Clutch cable locknut AAAAAAAAAAAAAAAAAAAAAAAAAAA AAA 4, Install: ‘Front bottom cowling (right) Refer to “GENERAL CHASSIS (3)" on page 45. + Side panel (right) Refer to “GENERAL CHASSIS (2)" on page 43 ‘CHECKING THE BRAKE OPERATION 1. Cheek + Brake operation Brake not working properly > Check the brake system. Refer to "FRONT BRAKE” on page 4-35 and “REAR BRAKE" on page 4-48. que Drive on the dry road, operate the front and rear brakes separately and check to see if the brakes ate operating properly. ‘CHECKING THE FRONT BRAKE PADS ‘The folowing procedure apples to al of the brake pads 4. Operate the brake, 2, Check: ‘Front brake pad Wear indicator grooves “a’ almost disap- peared — Replace the brake pads as a set. Refer to “FRONT BRAKE” on page 4-35. ‘CHECKING THE REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Operate the brake. 2. Check: * Rear brake pad Wear incicator grooves ‘a’ almost disap- peared —> Replace the brake pads as a set Reler to “REAR BRAKE" on page 4-48 ‘CHECKING THE FRONT BRAKE HOSES 1. Check * Brake hose Cracks/damage — Replace, “QF 2. Check: ‘Brake hose holder Loose —> Tighten the holder bolt. 3413PERIODIC MAINTENANCE + Brake hose guide Loose > Tighten the guide bot. 8. Hold the vehicle upright and apply the brake several times. 4. Check: + Brake hose Brake fluid leakage —> Replace the damaged hose. Refer to “FRONT BRAKE" on page 4-35. CHECKING THE REAR BRAKE HOSE 4. Check: + Brake hose “1” Cracksidamage —> Replace. 2, Check: + Brake hose guide Loose > Tighten the bolt. 8. Hold the vehicle upright and apply the rear brake several times. 4, Check: + Brake hose Brake fluid leakage — Replace the damaged hose, Refer to “REAR BRAKE” on page 4-48. BLEEDING THE HYDRAULIC BRAKE Bleed the hydraulic brake system whenever: + the system is disassembled. + a brake hose is loosened, disconnected or very low. brake operation is faulty. 1p + Be careful not to spill any brake fluid or allow the brake master cylinder reservoir or brake fluid reservoir to overflow. + When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake. Ignoring this pre~ caution could allow air to enter the hydraulic brake system, considerably lengthening the bleeding procedure. + Ifbleeding is diffcuit, it may be necessary to let the brake fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles inthe hose have disappeared. 1. Bleed: ‘* Hydraulic brake system WvyvyvyyyvyyyyyyyyYyyvyYyrYyy a, Fillthe brake fluid reservoir to the proper level with the specified brake fluid b. Install the diaphragm (brake master cylinder reservoir or brake fluid reservoir). . Connect a clear plastic hose “1” tightly to the bleed screw “2” 4d. Place the other end of the hose into a con- tainer. e. Slowly apply the brake several times. 4. Fully pull the brake lever or fully press down the brake pedal and hold it in position g. Loosen the bleed screw. Se Loosening the bleed screw will release the pres- ‘sure and cause the brake lever to contact the throttle grip or the brake pedal to fully extend. 3-14PERIODIC MAINTENANCE h. Tighten the bleed screw, and then release the brake lever or brake pedal. i. Repeat steps (e) to (h) until all of the air bub- bles have disappeared from the brake fluid in the plastic hose j._ Tighten the bleed screw to specification, Brake caliper bleed screw 6.Nm (0.6 m-kgf, 4.3 fbf) k. Fill the brake master cylinder or brake fluid reservoirto the proper level with the specified brake fluid Refer to “CHECKING THE BRAKE FLUID LEVEL" on page 3-15. AAAAAAAAAAAAAAAAAAAAAAAAAA AAA CHECKING THE BRAKE FLUID LEVEL 4. Stand the vehicle on a level surface m1 + Place the vehisle on a suitable stand + Make sure the vehicle is upright. 2. Check: * Brake fluid level Below the minimum level mark “a” > Add the specified brake fluid to the proper level. A. Front brake B. Rear brake |—___ + Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. + Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result ina harmful chemical reaction, leading to poor brake performance. + When refilling, be careful that water does, not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. NOTICE Brake fluid may damage painted surfaces and plastic parts, Therefore, always clean up any spilt brake fluid immediately. 1p In order to ensure a correct reading of the brake fluid level, make sure the top of the brake fluid reservoir is horizontal. CHECKING THE WHEELS The following procedure applies to both of the wheels. 4. Check: + Wheel Damage/out-of-round —> Replace. PONS Never attempt to make any repairs to the wheel. 1 Alter a te or wheel has been changed or re- placed, always balance the wheel. 2, Measure: ‘ Radial wheel runout + Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-23 and “CHECKING THE REAR WHEEL" on page 4-31. CHECKING THE TIRES ‘The following procedure applies to both of the tires. 4. Check: + Tire pressure Out of specification +> Regulate. 3-415PERIODIC MAINTENANCE * The tire pressure should only be checked and regulated when the tire temperature ‘equals the ambient air temperature. + The tire pressure and the suspension must be adjusted according to the total weight (including cargo, rider, passenger and ac- cessories) and the anticipated riding speed. + Operation of an overloaded vehicle could cause tire damage, an accident or an injury. NEVER OVERLOAD THE VEHICLE. Tire air pressure (measured on cold tires) Loading condition 0-90 kg (0-198 Ib) Front (1 person) 200 kPa (2.00 kgt/cm®, 29 psi) Rear (1 person) 250 kPa (2.50 kgf/cm? 36 psi) Loading condition 90-160 kg (198-353 Ib) Front (2 persons) 200 kPa (2.00 kgt/cm®, 29 p: Rear (2 persons) 250 kPa (2.50 kgt/cm?, 36 psi) Maximum load 1. Tire tread depth 2. Side wall 3. Wear indicator A _—_————— After extensive tests, the tires listed below have been approved by Yamaha Motor Co., Ltd. for this model. The front and rear tires should always be by the same manufacturer and of the same design. 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. Front tire Size 110/70-17M/C (54H) Manufacturer/model MICHELIN/PILOT STREET Wear limit (front) 1.0 mm (0.04 in) Wear limit (rear) 1.0 mm (0.04 in) 160 kg (353 Ib) "140/70-17M/C (66H) + Total weight of rider, passenger, cargo Manufacturer/model and accessories. MICHELIN/PILOT STREET 2. Check: ‘ Tire surfaces Damage/wear —> Replace the tire is dangerous to ride with a worn-out tire. ‘When the tire tread reaches the wear limit, re- place the tire immediately. New tires have a relatively low grip on the road surface until they have been slightly worn. Therefore, approximately 100 km should be traveled at normal speed before any high-speed riding is done. TP For tires with a direction of rotation mark “1”: + Install the tire with the mark pointing in the di- rection of wheel rotation. 3-16PERIODIC MAINTENANCE with the valve installation * Align the mark “ point. CHECKING THE WHEEL BEARINGS The following procedure applies to all of the wheel bearings. 4. Check: * Wheel bearings Refer to “CHECKING THE FRONT WHEEL" on page 4-23 and “CHECKING THE REAR WHEEL” on page 4-31 CHECKING THE SWINGARM OPERATION 1. Check: ‘+ Swingarm operation Swingarm not working property > Check the swingarm, Refer to “SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY” on page 4-80. Check: + Swingarm excessive play Refer to “SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY” on page 4-80. LUBRICATING THE SWINGARM PIVOT 1. Lubricate: Bearings + Spacer + Dust covers Recommended lubricant Lithium-soap-based grease Referto INSTALLING THE SWINGARM" on page 4-83, 2. ‘ADJUSTING THE DRIVE CHAIN SLACK the engine and other vital parts, and one that is too loose can skip and damage the swing- arm or cause an accident. Therefore, keep the drive chain slack within the specified lim- its. 1. Stand the vehicle on a level surface Securely support the vehicle so that th no danger of it falling over. ~~ Pace he vehicle on sulle sland so hat the rear afeal i leet 2. Move the rear wheel several times and find the tightest position of the drive chain. 8. Check: * Drive chain slack ut of specification + Adjust. me Measure the drive chain slack ‘a’ as shown in the illustration 4, Remove the drive chain puller cap “1”, and. then loosen the axle nut “2”. 5. Adjust: * Drive chain slack Yyvvvyvyvyyvyyyyyyvryyy ry ry ryyy a. Loosen both of the drive chain puller locknuts v 3417PERIODIC MAINTENANCE b. Tum both of the drive chain puller adjusting nuts “2” in direction “a” or *b” until the speci- fied drive chain slack is obtained. Drive chain puller adjusting nut 1.5 Nm (0.15 m-kgf, 1.1 ft-bf) Direction “a” Drive chain is tightened. Direction “b” Drive chain is loosened. TIP + Using the alignment marks “c” on each side of the swingarm, make sure that both drive chain pullers “3” are in the same position for proper wheel alignment. + There should be no clearance between the swingarm end plate and the adjusting nuts. . Tighten the wheel axle nut to specification. Rear wheel axle nut is 57 Nm (5.7 m-kgf, 41 ftibf) Drive chain puller locknut 16 Nm (1.6 m-kgf, 12 fbf) AAbAAAAdAAdAddAdddds dd bbb dbs db LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. Ifthe drive chain is not maintained proper- ly, twill wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. This vehicle has a drive chain with small rubber O-rings between each side plate. Steam clean- ing, high-pressure washing, certain solvents, and the use of a coarse brush can damage these O-rings. Therefore, use only kerosene to lean the drive chain. Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is suitable for O-ring chains. Do not use any other lubricants on the drive chain since they may contain solvents that could damage the O-rings. Recommended lubricant Chain lubricant suitable for O- ring chains a CHECKING AND ADJUSTING THE ‘STEERING HEAD 1. Stand the vehicle on a level surface. ‘Securely support the vehicle so that there is no danger of it falling over. 1 PYace th voice one sulable sand soa the front wheel is elevated. TP Apply lithium-soap-based grease to the contact surface and threads of the rear wheel axle nut. 4. Tighten the drive chain puller adjusting nuts and the drive chain puller locknuts to specif cation 2, Check: * Steering head Grasp the bottom ofthe front fork legs and gently rock the front fork. Blinding/looseness —> Adjust the steering head. 3, Remove: + Upper bracket Refer to “STEERING HEAD" on page 4-76. 4. Adjust: * Steering head 3-18PERIODIC MAINTENANCE VVVYWYYY YY YY VY WY YYYYYYYYYYYTY YY a. Remove the lock washer "1", the upper ring) nut "2", and the washer "3". b. Loosen the lower ring nut"4” and then tighten. itto specification with a steering nut wrench “s Steering nut wrench 90890-01403 Exhaust flange nut wrench ‘YU-A9472 Lower ring nut (initial torque) 48 Nm (4.8 m-kgf, 35 ftbf) ightening mp Set the torque wrench at a right angle to the steering nut wrench. . Loosen the lower ring nut completely and then tighten it to specification with a steering nut wrench, A WaRNIN Do not overtighten the lower ring nut. Lower ring nut (final tightening torque) 18 Nm (1.8 mkgf, 13 ftbf) d. Check the steering head for looseness or binding by turning the front fork all the way in both directions. If any binding is felt, remove the lower bracket and check the upper and lower bearings. Refer to “STEERING HEAD" on page 4-76. «. Install the washer “3’. 4. Install the upper ring nut “2”. 9. Finger tighten the upper ring nut, then align the slots of both ring nuts, If necessary, hold the lower ring nut and tighten the upper ring ‘nut until their slots are aligned. h. Install the lock washer “1 mp Make sure the lock washer tabs “a” sit correctly in the ring nut slots * ee tai, Mee ™ MADAAAAAAAdddAdddsddb ee deesbad 5. Install * Upper bracket Rofer to “STEERING HEAD’ on page 4-76. LUBRICATING THE STEERING HEAD 1. Lubricate: + Upper bearing + Lower bearing + Bearing cover + Lower bearing dust seal CHECKING THE CHASSIS FASTENERS Make sure that all nuts, bolts, and screws are property tightened, Refer to “CHASSIS TIGHTENING TORQUES" on page 2-18. LUBRICATING THE BRAKE LEVER Lubricate the pivoting point and metal-to-metal moving parts of the lever. 3419PERIODIC MAINTENANCE Recommended lubricant 1) ‘silicone grease LUBRICATING THE PEDAL Lubricate the pivoting point and metal-to-metal moving parts of the pedal Recommended lubricant ‘m4 Lithium-soap-based grease LUBRICATING THE CLUTCH LEVER Lubricate the pivoting point and metal-to-metal moving parts of the lever. Recommended lubricant — ium-soap-based grease ‘CHECKING THE SIDESTAND 1. Check * Sidestand operation Check that the sidestand moves smoothly. Rough movement —> Repair or replace. LUBRICATING THE SIDESTAND Lubricate the pivoting point, metal-to-metal mov- ing parts and spring contact point of the side- stand, Recommended lubricant jum-soap-based grease ‘CHECKING THE SIDESTAND SWITCH eter to“ELECTRICAL COMPONENTS" on page 8-77 CHECKING THE FRONT FORK 1. Stand the vehicle on a level surace. PMU ‘Securely support the vehicle so that there is no danger of it falling over. 2. Check: * Inner tube Damagelscratches —> Replace. + Front fork leg Oil leaks between inner tube and outer tube — Replace the oil seal. 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 smoothly. Rough movement + Repair. Refer to “FRONT FORK” on page 4-67. ‘CHECKING THE REAR SHOCK ABSORBER ASSEMBLY Refer to “CHECKING THE REAR SHOCK AB- SORBER ASSEMBLY" on page 4-62. ‘ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY POG ‘Securely support the vehicle so that there is no danger of it falling over. Spring preload ‘NOTICE Never go beyond the maximum or minimum, adjustment pos: 1. Adjust: + Spring preload VV VV YY YY YTV YY YTV YY YY yyy Ty TTT yTy, a. Adjust the spring preload with the special wrench “1” and extension bar '2” included in the owner's tool kit b. Tur the adjusting ring "3" in direction * + «. Align the desired position on the adjusting ring with the stopper “4”. or 3-20PERIODIC MAINTENANCE Direction “a” Spring preload is increased (suspen- Direction “b” ‘Spring preload is decreased (suspen- softer). Spring preload adjusting po: Minimum 1 Standard 3 Maximum AARAAAAAAADAAdAAddddedhd db bbb CHECKING THE ENGINE OIL LEVEL 1. Stand the vehicle on a level surface m1 + Place the vehisle on a suitable stand + Make sure the vehicle is upright. 2, Start the engine, warm it up for several min- utes, and then tum it off. 3. Check: + Engine oil level The engine oil level should be between the minimum level mark “a” and maximum level mark *b’ Below the minimum level mark > Add the recommended engine cil to the proper level. m1 Before checking the engine oil level, wait a few minutes until the oil has settled. 3-21 Recommended brand YAMALUBE ‘Type SAE 10W-30, 10W-40, 10W-50, +15W-40, 20W-40 or 20W-50 Recommended engine oil grade API service SG type or higher JASO standard MA 918 99 9 79 w NOK Se oN Sse aI SEO aE NOTICE + Engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils witha grade of “CD” or higher and do not use oils labeled “ENERGY CONSERVING II”. * Do not allow foreign materials to enter the crankcase. 4, Start the engine, warm it up for several min- tutes, and then tum it off 5. Check the engine oil level again. a Before checking the engine oil level, wait a few minutes until the oil has settiedPERIODIC MAINTENANCE ‘CHANGING THE ENGINE OIL. 1. Start the engine, warm it up for several min- utes, and then tum it off 2. Place a container under the engine oil drain bolt 3. Remove: + Engine oil filer cap “1 + Engine oil drain bolt “2 (along with the gasket “3 BW wey 4. Drain + Engine oil (completely from the oil pan) 5. Ifthe oll iter cartridge is also to be replaced, perform the following procedure. VVYYYYY YY YY YYW YY YYYYYYYYYY YY Ty a. Remove the oil fiter cartridge “1” with an oil, filter wrench *2”. il filter wrench 90890-01426 Oil filter wrench 3-22 b. Lubricate the O-ring “3” of the new oil filter cartridge with a thin coat of engine oi NOTICE Make sure the O-ring “3” is positioned cor- rectly in the groove of the ¢. Tighten the new oil fiter cartridge to spectt- cation with an oil fiter wrench Oil filter cartridge 17 Nm (1.7 m-kgf, 12 fbf) PUVUVUVUVUVUVUUCUUYUUYUYUVYYTUYTY 6. Install ‘+ Engine oil drain bolt 1” (along with the gasket “2” IIE) me Install the new gasket as shown in the illustra- 7. Fil: 4A IF C7 (with the specified amount of the recom- mended engine oil) Engine oil drain bolt 20 Nm (2.0 m-kgf, 14 fbf)PERIODIC MAINTENANCE Engine oil quantity ‘Quantity (disassembled) 2.40 L (2.54 US gt, 2.11 Imp.qt) Without oil filter cartridge re- placement 1.80 L (1.90 US gt, 1.58 Imp.qt) With oil filter cartridge replace- ment 2.10 L (2.22 US qt, 1.85 Imp.qt) 8. Install: ‘Engine oil filer cap {along with the O-ring INEM) 1. Lubricate the O-ring with lithium-soap-based grease. 9. Start the engine, warm it up for several min- Utes, and then tum it off. 10.Check: + Engine (for engine oil leaks) 11.Cheok: + Engine oil level Refer to “CHECKING THE ENGINE OIL. LEVEL” on page 3-21 12.Cheok: ‘+ Engine oil pressure Wuvyvyvyvvvyvvvyvyvyvyyyy9ryyyy a, Slightly loosen the engine oll check bolt 1” . Start the engine and keep itidling until engine oil starts to seep from the oil check bolts. f no ‘engine oil comes out after one minute, turn the engine off so that it will not seize, ©. Check the engine oil passages, the oil fiter cartridge and the oil pump for damage or leakage. Refer to “OIL PUMP" on page 5-64. 4. Start the engine atter solving the problem(s) and check the engine oil pressure again, €. Tighten the oil check botts to specification. » | Engine oll check bolt 15Nm (1.5 1 bf) PUVUVUVUVUVUUUUCUUYUYYUYUVYYTUYTY CHECKING THE COOLANT LEVEL, 1. Stand the vehicle on a level surface. me + Place the vehicle on a suitable stand, ‘+ Make sure the vehicle is upright. 2. Check: * Coolant level The coolant level should be between the min- imum level mark“a” and maximum level mark. v Below the minimum level mark > Add the recommended coolant to the proper level. NOTICE + Adding water instead of coolant lowers the antifreeze content of the coolant. If water is used instead of coolant check, and if nec essary, correct the antifreeze concentra- ion of the coolant. + Use only distilled water. However, if dis- tilled water ble, soft water may be used, 8. Start the engine, warm it up for several min- tutes, and then tum it off 4. Check: * Coolant level m1 Before checking the coolant level, wait a few minutes unt it settles. CHECKING THE COOLING SYSTEM 1. Check: Radiator “1” ‘+ Radiator inlet hose + Radiator outlet hose “3” 3-23PERIODIC MAINTENANCE ‘+ Thermostat cover “a” + Thermostat 5" Cracks/damage — Replace. Refer to “RADIATOR” on page 6-1, “THER- MOSTAT? on page 6-4 and "WATER PUMP" ‘on page 6-7. ‘\'se CHANGING THE COOLANT 1. Remove: * Side panels Refer to “GENERAL CHASSIS (2)" on page 43 + Front side cowling assembly (left) Refer to “GENERAL CHASSIS (3)" on page 45. 2. Disconneet: ‘Front turn signal light connector (left) Refer to “GENERAL CHASSIS (3)" on page 45. 3. Remove: + Radiator cap “t Anhot radiator is under pressure. Therefore, do not remove the radiator cap when the en- gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- jury. When the engine has cooled, open the radiator cap as follows: Place thick rag or a towel over the radiator cap and slowly turn the radiator cap counter- clockwise toward the detent to allow any re~ sidual pressure to escape. When the hissing ‘sound has stopped, press down on the ra ator cap and turn it counterclockwise to re~ move. * Coolant reservoir cover * * Coolant reservoir cap * Coolant reservoir Refer to “RADIATOR” on page 6-1 5. Drain: * Coolant (from the coolant reservoir) 6. Remove: + Coolant drain bolt “1” {along with the copper washer) 3-24PERIODIC MAINTENANCE 7. Drain * Coolant (from the engine and radiator) 8. Install: * Coolant drain bolt (along with the copper washer [XENM) \Qy | Coolant drain bott Se] 10 Nm (1.0 mg, 7.2 Af) 9. Install: + Coolant reservoir Refer to “RADIATOR” on page 6-1 10 * Cooling system (with the specified amount of the recom- mended coolant) Recommended antifreeze h-quality ethylene glycol anti- freeze containing corrosion in- itors for aluminum engines Mixing ratio 1:1 (antifreeze: water) Radiator (including all routes) 0.96 L (1.01 US qt, 0.84 Imp.qt) Coolant reservoir (up to the maxi} mum level mark) 0.25 L (0.26 US qt, 0.22 Imp.qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care, * If coolant splashes in your eyes, thorough- ly wash them with water and consult a doc- tor. * If coolant splashes on your clothes, quickly wash it away with water and then with soap and water. * If coolant is swallowed, induce vomiting and get immediate medical attention. * Adding water instead of coolant lowers the antifreeze content of the coolant. If water is, used instead of coolant, check, and if nec- essary, correct the antifreeze concentra- tion of the coolant. + Use only distilled water. However, if dis- tilled water is not available, soft water may be used. + If coolant comes into contact with painted surfaces, immediately wash them with wa- ter. + Do not mix different types of antifreeze. unstal: + Radiator cap 12 Fil: * Coolant reservoir (with the recommended coolant to the maxi- mum level mark “a") 13.Install: * Coolant reservoir cap + Coolant reservoir cover Refer to “RADIATOR” on page 6-1. 14.Connect + Front turn signal light connector (let) Refer to “GENERAL CHASSIS (3)" on page 45. 15.Install “+ Front side cowling assembly (left) Refer to “GENERAL CHASSIS (3)" on page 45. + Side panels Refer to “GENERAL CHASSIS (2)" on page 43, 46 Start the engine, warm it up for several min- tutes, and then tum it off 17.Check: * Coolant level Refer to “CHECKING THE COOLANT LEV- EL’ on page 3-23. 1p Before checking the coolant level, wait a few minutes until the coolant has settled. CHECKING THE BRAKE LIGHT SWITCHES 4. Check ‘Front brake light switch operation ‘+ Rear brake light switch operation When operating the brake lever and brake pedal, confirm that the brake light turns on. 3-25PERIODIC MAINTENANCE Faulty -> Refer to “CHECKING THE SWITCHES’ on page 8-81 ADJUSTING THE REAR BRAKE LIGHT ‘SWITCH 1. ‘The rear brake light switch is operated by move- ment of the brake pedal. The rear brake light switch is properly adjusted when the brake light ‘comes on just before the braking effect starts. 1. Check: ‘ Rear brake light operation timing Incorrect + Adjust. 2, Adjust: ‘* Rear brake light operation timing 2.” Holdtha main body tof the ear brake nant ‘switch so that it does not rotate and tum the adjusting nut "2" in direction “a’ orb" until the rear brake light comes on at the proper time. Direction “a” Brake light comes on sooner. Direction “b” Brake light comes on later. ‘CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. —— Damaged outer cable may cause the cable to. corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible. 1. Check: * Outer cable Damage -> Replace 2. Check: * Cable operation Rough movement -» Lubricate. =m |_ Recommended lubricant Engine oil or a suitable cable Iu- bricant TP Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suit- able lubricating device. CHECKING THE THROTTLE GRIP OPERATION 1. Check: * Throttle cables Damage/deterioration > Replace. + Throttle cable installation Incorrect —> Reinstall the throttle cables. Refer to “HANDLEBARS” on page 4-61. 2. Check: * Throttle grip movement Rough movement > Lubricate or replace the detective part(s) Recommended lubricant Suitable cable lubricant 1p With the engine stopped, turn the throttle grip slowly and release it. Make sure that the throttle ‘tip turns smoothly and returns properly when released Repeat this check with the handlebar turned all the way to the left and right. 3. Check: + Throttle grip free play “a” Out of specification —> Adjust. Throttle grip free play 3.0-5.0 mm (0.12-0.2 3-26PERIODIC MAINTENANCE 4, Adjust: += Throttle grip free play me Prior to adjusting the throttle grip free play, throt- tle body synchronization should be adjusted properly. YYVYVUVYVYVYVYVYVYVYYYVYYYYYTYY a, Slide back the rubber cover * b, Loosen the locknut “2”, . Tumthe adjusting nut "3" in direction “a” or *b” Until the specified throttle grip free play is ob- tained. Direction “a” Throttle grip free play Direction “b” Throttle grip free play is decreased. 4. Tighten the locknut. €. Slide the rubber cover to its original position. me Make sure that the adjusting nutis covered com- pletely by the rubber cover. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAL ‘CHECKING THE SWITCHES, LIGHTS AND SIGNALS. 1. Check that all switches operate and that all lights come on, Refer to “INSTRUMENT AND CONTROL FUNCTIONS" in Owner’s manual. Faulty —> Refer to “CHECKING THE SWITCHES’ on page 8-81 and "CHECKING ‘THE BULBS AND BULB SOCKETS’ on page 8-84. REPLACING THE HEADLIGHT BULBS The following procedure applies to both of the headlight bulbs. 1. Remove: + Headlight bulb cover “1” 3-27 2. Disconnect ‘* Headlight coupler * Headlight bulb holder “3” 4, Remove’ ‘+ Headlight bulb “4” Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb until it has cooled down. 5. Install: + Headlight bulb [EM ‘Secure the new headlight bulb with the head- light bulb holder. NOTICE Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adverselyPERIODIC MAINTENANCE affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. 6 Hook + Headlight bulb holder 7. Connect Headlight coupler 8. Install: + Headlight bulb cover 1 Be sure to align the mark “a’ on the headlight bulb cover with the mark ” on the headlight. ADJUSTING THE HEADLIGHT BEAM 1. Adjust: ‘+ Headlight beam (vertically) VwyvyyyVyyyYyVyVyVyYy¥yYYYyYY yyy a. Tum the adjusting bolts “1” in direction “a” or Ee Direction “a” Headlight beam is raised. Direction “b” Headlight beam is lowered. AAAAAAAAAAAAAAAAAAAAAAAAAAA AAA 2. Adjust: ‘+ Headlight beam (horizontally) YWYVYVYVYVWVYVYVYYYYYVYVYYYYY TTY a. Tum the adjusting bolts “1” in direction “a” or aos Left headlight 3-28 Direction “a” Headlight beam moves to the left. Direction “b” Headlight beam moves to the right. Right headlight Direction “a Headlight beam moves to the right. Direction “b” Headlight beam moves to the left. AAdAAAAdAAAAAAAdAAdddddbbes ede,PERIODIC MAINTENANCE 3-29CHASSIS GENERAL CHASSIS (1). REMOVING THE CENTER COVER INSTALLING THE BATTERY... INSTALLING THE RIDER SEAT INSTALLING THE CENTER COVER INSTALLING THE PASSENGER SEAT. GENERAL CHASSIS (2)... REMOVING THE SIDE PANELS .. INSTALLING THE SIDE PANELS. REMOVING THE UPPER TAIL PANEL INSTALLING THE UPPER TAIL PANEL. GENERAL CHASSIS (3).. REMOVING THE FRONT PAI INSTALLING THE FRONT PANELS. DISASSEMBLING THE FUEL TANK COVER ASSEMBLY. ASSEMBLING THE FUEL TANK COVER ASSEMBLY INSTALLING THE FUEL TANK COVER ASSEMBLY REMOVING THE BOTTOM COWLING INSTALLING THE BOTTOM COWLING. REMOVING THE FRONT BOTTOM COWLINGS INSTALLING THE FRONT BOTTOM COWLINGS cesar 410 REMOVING THE FRONT SIDE COWLING ASSEMBLY «0.0.0.0 4-10 INSTALLING THE FRONT SIDE COWLING ASSEMBLY. ant REMOVING THE FRONT UPPER COWLING att INSTALLING THE FRONT UPPER COWLING at GENERAL CHASSIS (4)... onsen lS INSTALLING THE FRONT COWLING ASSEMBLY «...00..00 14 GENERAL CHASSIS (5) REMOVING THE WINDSHIELD ASSEMBLY... INSTALLING THE WINDSHIELD ASSEMBLY one REMOVING THE FRONT COWLING CENTER COVER....... INSTALLING THE FRONT COWLING CENTER COVER GENERAL CHASSIS (6)........ . INSTALLING THE AIR FILTER CASE FRONT WHEEL... REMOVING THE FRONT WHEEL....... DISASSEMBLING THE FRONT WHEEL CHECKING THE FRONT WHEEL ASSEMBLING THE FRONT WHEEL. ADJUSTING THE FRONT WHEEL STATIC BALANCE INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS)REAR WHEEL 4.27 REMOVING THE REAR WHEEL......nsonnnnnnnnnsnnnnennnnnnneen BA DISASSEMBLING THE REAR WHEEL 431 CHECKING THE REAR WHEEL... = CHECKING THE REAR WHEEL DRIVE HUB... CHECKING AND REPLACING THE REAR WHEEL SPROCKET .. ASSEMBLING THE REAR WHEEL ADJUSTING THE REAR WHEEL STATIC BALANCE. INSTALLING THE REAR WHEEL (REAR BRAKE DISC) FRONT BRAKE......... INTRODUCTION. CHECKING THE FRONT BRAKE DISC... REPLACING THE FRONT BRAKE PADS REMOVING THE FRONT BRAKE CALIPER... DISASSEMBLING THE FRONT BRAKE CALIPEI CHECKING THE FRONT BRAKE CALIPER wc. ASSEMBLING THE FRONT BRAKE CALIPER INSTALLING THE FRONT BRAKE CALIPER REMOVING THE FRONT BRAKE MASTER CYLINDER CHECKING THE FRONT BRAKE MASTER CYLINDER......... ASSEMBLING THE FRONT BRAKE MASTER CYLINDER .. INSTALLING THE FRONT BRAKE MASTER CYLINDER, REAR BRAKE INTRODUCTION... CHECKING THE REAR BRAKE DISC... a REPLACING THE REAR BRAKE PADS.....cc.csnncnnennnennnnnenner ASA, REMOVING THE REAR BRAKE CALIPER 4-56 DISASSEMBLING THE REAR BRAKE CALIPER 456 CHECKING THE REAR BRAKE CALIPER, 4-56 ASSEMBLING THE REAR BRAKE CALIPER. INSTALLING THE REAR BRAKE CALIPER, REMOVING THE REAR BRAKE MASTER CYLINDER CHECKING THE REAR BRAKE MASTER CYLINDER. ASSEMBLING THE REAR BRAKE MASTER CYLINDER. INSTALLING THE REAR BRAKE MASTER CYLINDER... HANDLEBARS... oo REMOVING THE HANDLEBARS .. CHECKING THE HANDLEBARS.. INSTALLING THE HANDLEBARS FRONT FORK.... REMOVING THE FRONT FORK LEGS... . : DISASSEMBLING THE FRONT FORK LEGS. 4-70 CHECKING THE FRONT FORK LEGS .....sennniennnnnnneien ASSEMBLING THE FRONT FORK LEGS 471 INSTALLING THE FRONT FORK LEGSSTEERING HEAD. 4-76 REMOVING THE LOWER BRACKET.....0scs:nsnnnnnenniennnnnnnnns 478 CHECKING THE STEERING HEAD 478 INSTALLING THE STEERING HEAD .....se.0 4-78 SWINGARM AND REAR SHOCK ABSORBER ASSEMBLY 4-80 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY ....0..0..- 4-82 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4-82 REMOVING THE SWINGARM.....cosssssennsninnetnisnnnitnnnes 482 CHECKING THE SWINGARM 4-82 INSTALLING THE SWINGARM... . 4-83 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4-83 CHAIN DRIVE... stninnnniieninnnnnsinnasennene 485 REMOVING THE DRIVE CHAIN. 4-86 CHECKING THE DRIVE CHAIN... 4-86 CHECKING THE DRIVE SPROCKET. 4.87 CHECKING THE REAR WHEEL SPROCKET. 4-87 CHECKING THE REAR WHEEL DRIVE HUB 487 INSTALLING THE DRIVE SPROCKET. 4-87 INSTALLING THE DRIVE CHAIN wos. 4-88GENERAL CHASSIS (1) GENERAL CHASSIS (1) [Removing the seats and battery Ta Nm (0.18 magi 13 MBH) ‘Order ‘Job/Parts to remove ay Remarks Passenger seat ‘Owners toolkit Genter cover Rider seat Nogative batory load Discomect. Postive battery lead Disconnect. Battery band Batiory Battery seat 41GENERAL CHASSIS (1) REMOVING THE CENTER COVER 1. Remove: + Center cover ™ TIP from the rear upper side cowlings INSTALLING THE BATTERY 1. Install: = Battery “1” + Battery band “ 1 is facing upward. INSTALLING THE RIDER SEAT 1. Instal: + Rider seat “t" Rider seat bolt 7 Nm (0.7 m-kgf, 5.1 ftlbf) me Insert the projection “a” on the front of the rider ‘seat into the hole *b" as showr Unhook the projections “a” on the center cover Make sure that the portion ‘a’ of the battery band 4-2 INSTALLING THE CENTER COVER 1. Insta: * Center cover “1” Center cover screw 1.8.Nm (0.18 m-kgf, 1.3, TIP Fit the projections “a” on the center cover into the rear upper side cowlings. INSTALLING THE PASSENGER SEAT 1. Install: + Passenger seat “1” 1p Insert the projections “a’ on the front of the pas- ‘senger seat into the grooves “b” as shown, and then push the rear of the seat down to lock it in. place.GENERAL CHASSIS (2) GENERAL CHASSIS (2) Ramaving the rear akie cowllnge (imeprmgsinm] [temo AY “G]7 Nin (0.7 rg 8.1 THON) ee! 18 Nm (0.16 kg, 1.3 MBN) ‘Order ‘Job/Parts to remove ay Remarks [ierto "GENERAL CHASSIS (17 on page Rider seat ‘Side panel (tt) ‘Side panel (ght) Upper tail panel ‘Seat lack Rear side cowiing assembly (et) Rear lower side cowiing (ett Seat lock key cylinder Rear upperside cowiing (eft) Fear side cowling assembly (right) Rear loner side cowiing (ight) Rear upperside cowing (right) 4-3GENERAL CHASSIS (2) REMOVING THE SIDE PANELS ‘The following procedure applies to both of the side panels. 4. Remove: * Side panel VVVYVYY YY YYW YY Y NYY YY YYYYYYY TY a. Remove the side panel bots. b. Remove the projections “a’ on the side panel from the grommets, and then remove the pro- jection *b” on the panel from the front upper cowling, b— AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AA INSTALLING THE SIDE PANELS The following procedure applies to both of the side panels. 1. Install: + Side panel “1” Vvvyyvyy yyy vy yyy yyy yyy YY yyy yyy a. Insertthe projection “a’ on the side panel into the hole in the front upper cowling, fit the pro jections “b" on the panel into the grommets, and then tighten the side panel bolts, le panel bolt Nm (0.18 m-kof, 1.3, AN pyeyveveyyyvyyuveveyeyyyyyyUYVUS REMOVING THE UPPER TAIL PANEL 1. Remove: * Upper tal panel YWYVY YY YY YY YY YY yy TY v YY yy TTT Ty, a” Remove the upper tall panel screws. 4-4 b. Slide the upper tail panel rearward and re- move it. AAAAAAAAAAAAAAAAAAA AAA AAA AAAAL INSTALLING THE UPPER TAIL PANEL 4. Install + Upper tail panel “1” 3 Fithe projections “aon the upper fal panel into the holes "b” in the rear lower side cowl ings, and then slide the panel forward while fiting the projection “c" on the tailbrake light assembly into the slots “d” in the panel ribs, and then slide the panel forward. Tighten the upper tail panel screws. Upper tail panel screw 1.8 Nm (0.18 m-kgf, 1 PVVUVUVUVUVUUUUUUUYYUVUVUUYUCUYYYGENERAL CHASSIS (3) GENERAL CHASSIS (3) [Removing the fuel tank covers: Nm (0.7 mwkgf, 6.1 felbf) Nm (0.5 mig 36 fb)] ‘Job/Parts to remove Remarks Rider seat [ierto "GENERAL CHASSIS (17 on page Side panels: ‘iger "GENERAL CHASSIS (27 on page Front panel (lefty Front panel (ight) Fuel tank cover assembly Fuel tank cover (eft) Fuel tank cover (right) Fuel tank cover (enter) 4-5GENERAL CHASSIS (3) [Removing the cowlings [7 Nim (0.7 reg, 5.1 RBI) 78 Nm (0.18 mekgt, 13 RBI) 1.8 Nm (0.18 mgt, 1.3 RBI) [8 Nim (0-18 mg 1.3 MBN) =]7 Nm (0.7 m-kgf, 5.1 Rbh) ELAS Nm (0.78 migh, 13 MAb ‘Job/Parts to remove Remarks Bottom cowing Front bottom cowling (eft) Front side coming assembly (lft) Front tum signal light connector (ft) Disconnect Front side coming inner panel (eft) Front upper cowiing (eft) Front lower cowing (6M) Front side coming (lef) Front Bottom cowiing (ight) Front sce eowing assamBly (ght) Front tur signal light eannactor (ight) Disconnect. Front side eowiing inner panal (ght) Front upper cowling (right) 4-6GENERAL CHASSIS (3) [Removing the cowlings [7 Nim (0.7 reg, 5.1 RBI) «(LS Nm (0:18 miko 1.3 RH) = ITS Nm 0.16 mkgh 13 fb] [8 Nim (0-18 mg 1.3 MBN) TZN (0.7 mgt 5.1 Rib) ©) Ea Nm (078 mig 13 RBH ‘Order ‘Job/Parts to remove ay Remarks 74 __| Front lowar cowing right) 7 7 __| Front side coating (ight) 1GENERAL CHASSIS (3) REMOVING THE FRONT PANELS. ‘The following procedure applies to both of the front panels. 4. Remove: + Front panel 1” WvvvvyvyyyyvyyyyWyYYYyYYYTYYY yy a. Remove the front panel bolts "2" and quick fasteners “3”. , Slide the front panel rearward to remove the projections ‘a’ on the panel from the holes “b’ in the front side cowiing, and then lit up the panel to remove it AAdAAAAADAAAAdAAAA deed hdd d ddd, INSTALLING THE FRONT PANELS The following procedure applies to both of the front panels, 1. Install: ‘Front panel "1" YWevyvvyvyvyvyvyvyyyvyvyyyryyyy a, Fit the projections “a” on the front panel into the holes “b” in the front side cowling, and then slide the panel forward. 4-8 b. Install the front panel bolts and quick fasten- ers, and then tighten the bolts to specifica: tion. AAdAAAAdAAdAAdAdddd edd bbdes dba, DISASSEMBLING THE FUEL TANK COVER ASSEMBLY ‘The following procedure applies to both of the {uel tank side covers. 1. Remove the projections “a” on the fuel tank side cover “1” from the holes °b” in the fuel tank center cover "2" ASSEMBLING THE FUEL TANK COVER ASSEMBLY ‘The following procedure applies to both of the fuel tank side covers. 1. Fit the projections “a” on the fuel tank side cover "1” into the holes “b” in the fuel tank center cover2", and fit the portions “c” of the center cover into the slots “d” in the side cov- 2. Install the fuel tank cover screws, and then tighten the screws to specification. Fuel tank cover screw 1.8. Nm (0.18 m-kgf, 1.3 ftlbf)GENERAL CHASSIS (3) INSTALLING THE FUEL TANK COVER ASSEMBLY 1. Install: ‘+ Fuel tank cover assembly “1” Ry Fuel tank cover bolt (front side) 7Nm (0.7 m-kgf, 5.1 ftlbf) Fuel tank cover bolt (rear side) 5.Nm (0.5 m-kgf, 3.6 fbf) me Tighten the fuel tank cover bolts in the proper tightening sequence as shown. ns a 2 REMOVING THE BOTTOM COWLING 1. Remove: * Bottom cowling “1” YVVY YY VY VY YY yy TYvY YY TTY YYYYYTyy a, Remove the bottom cowling screws, b. Remove the projections “a” on the bottom ‘cowling from the portions °b” of the front side cowling inner panels, and then remove the bottom cowling b. Install the bottom cowling screws, and then tighten the screws to specification. Bottom cowling scr 8Nm (0.18 MADAAAAAdAdAdddddddb ee dsesbad REMOVING THE FRONT BOTTOM COWLINGS The following procedure applies to both of the front bottom cowlings. 1, Remove: ‘+ Front bottom cowling “1” YVYVYWYY YYW YY YYYYYYYYyYYyYYTYY a. Remove the front Bottom cowling bots. b. Remove the projection “a” on the front bottom owing from the hole “b” in the front side cowiing, AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AA INSTALLING THE BOTTOM COWLING 1. Install: * Bottom cowling “1” YWUVYVYVYVYVYVYVYVYVYVYVYYTYY TTY 2, Fit the projections “2” on the bottom cowling into the portions “b” of the front side cowling inner panels, and then install the bottom coming, ¢. Slide the front bottom cowling downward to remove the projections “c” on the front bottom cowing from the holes “a in the front side cowling and to remove the projection “e” on the front upper cowling from the hole “in the front bottom cowling, and then remove the front bottom cowiing. 4-9GENERAL CHASSIS (3) AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAL INSTALLING THE FRONT BOTTOM ‘COWLINGS The following procedure applies to both of the front bottom cowlings. 1. Install: ‘= Front bottom cowling “1” UV VYVYVYVYVYVYVYYYVYVYYYYYTTY a, Fit the projections “a” on the front bottom, Cowling into the holes “b” in the front side ccowling and fit the projection “o” on the front Upper cowling into the hole “a” in the front bo! tom cowling, and then slide the front bottom cowling upward. b. Fitthe projection “e" on the front bottom cowl- ing into the hole ‘tin the front side cowling. ©. Install the front bottom cowling bolt (M6 x 22 mm) ‘2” and front bottom cowiing bolts (M5 x 12 mm) °3”, and then tighten the bolts to specification. Front bottom cowling bolt (M6 x 22 mm) 7 Nm (0.7 m-kgf, 5.1 ftbf) Front bottom cowling bolt (M5 x 12mm) 1.8 Nm (0.18 mkgf, 1.3 ft-bf) AAMAMAMAAAMAAAAAAAAAAAAAAAAAAAAA REMOVING THE FRONT SIDE COWLING ASSEMBLY The following procedure applies to both of the front side cowling assembly 1, Remove: ‘+ Front side cowling assembly “1” 2” Romove the quick fasteners scrow J bolt “4”, and nut “5°, (Lett front side cowling assembly) Remove the quick fastener “2", screw “3”, and bolts “4”. (Right front side cowling as- sembly) 4-10GENERAL CHASSIS (3) A. Left side B. Right side 'b, Remove the projection “a” on the front side ccowling assembly from the grommet, ¢. Remove the portion *b” ofthe front cowling in- ner panel from the slot “c” in the front side ‘cowling assembly, and then slide the front side cowling assembly forward to remove the projections “a” on the front side cowling as- ‘sembly from the holes “e”in the front cowling inner panel. PUY YY UVUVYYYUVUUUYUUUYYYYUYYUS INSTALLING THE FRONT SIDE COWLING ASSEMBLY ‘The following procedure applies to both of the front side cowling assembly. 1. Install: ‘Front side cowling assembly "1" VVYYWYYYYYYYYYYYYYYYYYYYYYYY YY a. Fit the projections “a” on the front side cow- ing assembly into the holes “b” in the front cowling inner panel, slide the front side cowl- ing assembly rearward, and then fit the por- tion ‘c” of the front cowling inner panel into the slot “dl” in the front side cowling assembly. b. Fitthe projection “e” on the front side cowling assembly into the grommet. ¢. Install the quick fasteners, screw, bolt, and ‘ut, and then tighten the screw, bolt, and nut to specification. (Left front side cowiing as- sembly) Install the quick fastener, screw, and bolts, and then tighten the screw and bolts to spec ification. (Right front side cowling assembly) Pe Front upper cowling bolt 7 Nm (0.7 m-kgf, 5.1 ftbf) Front side cowling screw 1.8 Nm (0.18 m-kgf, 1.3 ft-bf) Front upper cowling nut (left side) 7 Nm (0.7 m-kgf, 5.1 ftlbf) AAAAAAAAAAAAAAAAA AAA AA AMA M ddd, REMOVING THE FRONT UPPER COWLING The following procedure applies to both of the front upper cowling 1, Remove: ‘Front upper cowling “1” mp Slide the front upper coving in the direction of the arrow shown in the illustration to remove the projections “a” on the front side cowling “2" from the holes *b” in the front upper cowlin INSTALLING THE FRONT UPPER COWLING ‘The following procedure applies to both of the front upper cowiing 4aGENERAL CHASSIS (3) 1. Install: * Front upper cowiing * Front upper cowling screw 1.8 Nm (0.18 m-kgi Ibf) TIP Fit the projections "a’ on the front side cowling “2” into the holes *b” in the front upper cowiing, and then slide the front upper cowling in the di- rection of the arrow shown in the illustration. 412GENERAL CHASSIS (4) GENERAL CHASSIS (4) [Removing the front cowling assembly UZ Nm (07 mkgt 62 eb) 7 Nim (0.7 mekgf. 5.4 RBH) \ Oma, / 2 ‘Order ‘Job/Parts to remove Remarks ‘Side panels Figerto "GENERAL CHASSIS ey on page Front side comling assemblies ‘iger "GENERAL CHASSIS (37 on page 7 __[ Rearview miror 2 2__| Meter assembly coupler 1__ [Disconnect 3 __| Headlight coupler (ef) 1 _| Disconnect, 4 __ | Headlight coupler (right) 1 | Disconnect, 5 __| Aunilary ight coupler 1__ [Disconnect e 1 Front cowiing assembly 4-13GENERAL CHASSIS (4) INSTALLING THE FRONT COWLING ASSEMBLY 1. Install: ‘+ Front cowling assembly Front cowling assembly bolt 33 Nm (3.3 m-kgf, 24 ftbf) me Fit the projection “a” on the front cowling assem- bly bracket into the hole "b” in the frame. 414GENERAL CHASSIS (5) GENERAL CHASSIS (5) [Disassembling the front cowling assembly JOA Nim (0.04 mekgf, 03 ABD, Z]1a Nm (0:73 mkgt, 0.94 Fb) ‘order ‘Job/Parts to remove Meter assembly bracket Meter assembly Windshield assembly Front cowing Front cowiing center cover Front eowiing ier panel 7 2 3 a 3 | windsnieta 6 7 @ | Headlight bub cover a Headlight coupler Disconnect. 70_| Headlight bub T1__| Front eowiing assembly bracket 72 __| Headlight assembly 4-15GENERAL CHASSIS (5) REMOVING THE WINDSHIELD ASSEMBLY 1. Remove: + Windshield assembly “ YYYYYYYYYYY YY YYW YYY YY YY YY YY Ty a. Remove the windshield assembly screws. ». Slide the windshield assembly in the direction of the arrow shown in the illustration. c, Remove the projections: assembly from the holes ing inner panel AAAAMAAAAAAAAAAAAAAMAAAAAAAAAAAA INSTALLING THE WINDSHIELD ASSEMBLY 1. Insta * Windshield assembly “1” WerrrvevyveryyTrryyrrerrrrTrry Ty 2.” Hi the projections “aon the windshield ase sembly into the holes °b in the front cowling inner panel. . Slide the windshield assembly in the direction of the arrow shown in the illustration. ¢. Install the windshield assembly screws, and then tighten the screws to specification AAAAAAAAAAAAAAAAAAAAAAA AAA ALAA REMOVING THE FRONT COWLING CENTER COVER 1. Remove: ‘+ Front cowling center cover “1” me Slide the front cowling center cover in the direc- tion of the arrow shown in the illustration to re~ move the projections “a” on the windshield “2” {rom the holes *b” in the front cowling center cov- er. INSTALLING THE FRONT COWLING CENTER COVER 4. Install + Front cowling center cover “1” 1p Fit the projections “a’ on the windshield “2” into the holes “b” in the front cowling center cover, and then slide the front cowling center cover in the direction of the arrow shown in the illustra- tion. 4-16GENERAL CHASSIS (5) 417GENERAL CHASSIS (6) GENERAL CHASSIS (6) [Removing the air filter case 3 Nm (0-13 meh, 0.94 TE] 2.5 Nm (0.25 mgt, 1.6 fb) \ 7] 25 Nm (0.25 mekgf, 1.8 Mb) QU dip Replace it Radial wheel runout lit 1.0 mm (0.04 in) Lateral wheel runout limit 0.5 mm (0.02 in) 4-23FRONT WHEEL 4, Check: + Wheel bearings Front wheel tums roughly oF is loose —> Re- place the wheel bearings. + Oil seals Damage/wear > Replace. A / & ‘ASSEMBLING THE FRONT WHEEL 1. Install + Wheel bearings IN + Oil seals INE Yvvyvyvyv vv yyy viv yy yy yy yyy ry yyy a, Install the new wheel bearing (right side). wore Do not contact the wheel bearing inner race “1” of balls “2”. Contact should be made only with the outer race “3”. me Use a socket “4" that matches the diameter of the wheel bearing outer race. b. Install the spacer. «. Install the new wheel bearing (left side). me Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “a” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer "5" [Gee AAAAAAAAAAAAAAAAAAA AAA AAA AAAAL ADJUSTING THE FRONT WHEEL STATIC BALANCE mp + After replacing the tire, wheel or both, the front wheel static balance should be adjusted + Adjust the front wheel static balance with the brake disc installed 1. Remove’ * Balancing weight(s) 2. Find: “+ Front wheel's heavy spot a Place the front wheel on a suitable balancing stand, VY VY NYY VY VY YYY YY TY YY TYYVTTYY, a. Spin the front wheel, b. When the front wheel stops, putan"X,” mark at the bottom of the wheel. 4 (om o A Oo . Turn the front wheel 90° so that the *X," mark is positioned as shown. 424FRONT WHEEL 4. Release the front wheel, e. When the wheel stops, put an "Xp" mark at the bottom of the wheel. Repeat steps (c) through (e) several times Until all the marks come to rest at the same spot. ‘The spot where all the marks come to rest is the front wheel's heavy spot "X”. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAA AA 3. Adjust: + Front wheel static balance me Install up to four balancing weights on the rim. VVVY YY y vv YY Vv VvVVYYWvYYYYYYYYY a, Install a balancing weight “1” onto the rim ex actly opposite the heavy spot “X’. 1p Start with the lightest weight b. Tum the front wheel 90° so that the heavy spot is positioned as shown, ~ . Ifthe heavy spot does not stay in that posi- tion, install a heavier weight. 4. Repeat steps (b) and (c) until the front wheel is balanced AAMAMAAAAAMAAAAAAAAAAAAAAAMA MAMA 4, Check: + Front wheel static balance 37 Fumio rontwhealand make sure n sayeat each position shown, x ~ b. Ifthe front wheel does not remain stationary at all of the positions, rebalance it FUOVUUVUUUVUUVUYUUUVUVUUUUYTUYUTY INSTALLING THE FRONT WHEEL (FRONT BRAKE DISCS) 1. Install ‘+ Front brake disc * Front brake disc bolt 23 Nm (2.3 m-kgf, 17 ftbf) Sa, LOCTITE® pe + Install the front brake dise with its chamfered side “a” facing inward. + Tighten the brake disc bolts in stages and in a crisscross pattern. 4-25FRONT WHEEL 2. Check: ‘+ Front brake discs Refer to “CHECKING THE FRONT BRAKE DISC’ on page 4-41. 38. Lubricate: * Oil seal lips Recommended lubricant Lithium-soap-based greas 4. Install: = Collars + Front wheel ‘Front wheel axle ‘+ Front wheel axle nut me + Install the front wheel with the mark “a” on the front tire pointing in the direction of wheel rota- tion + Apply ithium-soap-based grease to the con- tact surface and threads of the front wheel axle nut. J 5. Tighten: '* Front wheel axle nut Front wheel axle nut 52 Nm 38 ftibf) NOTICE Before tightening the wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smooth- 6. Install ‘+ Front brake caliper ‘+ Front brake hose holder “1” + Front reflector |\\p | Front brake caliper bott | 35 Nm (3.5 m-kgf, 25 ftibf) Front brake hose holder bolt 7 Nm (0.7 m-kgf, 5.1 ftibf) po Make sure the brake hose is routed property. mp ‘While holding the tront brake hose holder so that the portion “a” of the holder contacts the portion “b’ of the front fork, tighten the front brake hose holder bolt. 4-26REAR WHEEL REAR WHEEL amaving the rear wh 7 Nm (6.7 ekgf, 41 RB) 31 Nm (Gt mekgf, 22 fb 7123 im (2.3 mgt 17 RBH) 1.5 Nin (0.18 mkt 1.1 fb) 16 Nn (16 meegf 12 feb) ‘Order ‘Job/Parts to remove ay Remarks 7_| Rear brake caliper 2_| Brive chain puller cap) ‘3_| Drive chain puller ooknut 4 __| Drive chain adjusting nut 3 | Washer € 7 e @ ‘Swingarm end plate ear wheel axie nut Washer ear wheel axle 70 | Rear whee! Tt__| Brake caliper bracket 12 __| Brake caliper retaining bolt 4-27REAR WHEEL <[31 Nin G.1 kgf, 22 feb 25 Nm (2.3 rekgf, 17 BD ‘Order ‘Job/Parts to remove ay Remarks 72 __| Chain puller 2 14 | Collar (eh) 7 15 _| Collar (ighty 1 4-28REAR WHEEL [Removing the rear brake disc and rear wheel sprocket, iy 1 aatin ea migh hw] [27 Nm 2.7 mkof, 20 febH) [23 Nim (2.3 mgt, 17 fA] ‘Job/Parts to remove ay Remarks Rear wheel drive hub assombly Prato Bracket 1 Bracket 2 Fear wheel sprocket ear wheel arive hub ‘Oisear Bearing Collar ‘Rear wheel drive hub damper ear brake aise ear wheel 4-29REAR WHEEL ssembling the rear wheel 11 ‘Order ‘Job/Parts to remove ay Remarks 1 [Osea 1 2 | Whee! bearing (right) 1 3 __| Whee! bearing (eft) 1 4 | Spacer 1REAR WHEEL REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. ‘Securely support the vehicle so that there is no danger of it falling over. 11 rear wheel Is elevated, 2. Remove: ‘+ Rear brake caliper TP the brake caliper. 8. Loosen: + Drive chain puller locknuts “ + Drive chain adjusting nuts 4, Remove: ‘+ Rear wheel axle nut “1” + Washers. + Rear wheel axle "2" + Rear wheel TP Push the rear wheel forward and remove the Grive chain from the rear wheel sprocket. DISASSEMBLING THE REAR WHEEL 1. Remove: + Ol seal Place the vehicle on a suitable stand so that the Do not depress the brake pedal when removing + Wheel bearings, Refer to “DISASSEMBLING THE FRONT WHEEL” on page 4-23. CHECKING THE REAR WHEEL 1. Check: + Rear wheel axle + Wheel bearings + Oil seal Refer to “CHECKING THE FRONT WHEEL” on page 4-23. 2, Check: ‘Tire + Rear wheel Damage/wear ~> Replace. Refer to “CHECKING THE TIRES" on page 3-15 and “CHECKING THE WHEELS" on page 3-15, 3, Measure: ‘+ Radial wheel runout + Lateral wheel runout Refer to “CHECKING THE FRONT WHEEL” on page 4-23. CHECKING THE REAR WHEEL DRIVE HUB 1. Check: + Rear wheel drive hub “1” Cracks/damage —> Replace. + Rear wheel drive hub dampers “2" Damage/wear -> Replace. CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1. Check: ‘+ Rear wheel sprocket More than 1/4 tooth “a” wear — Replace the drive chain sprockets as a set. Bent teeth — Replace the drive chain sprock- ets as a set.REAR WHEEL b. Correct 1. Drive chain roller 2. Rear wheel sprocket 2, Replace: ‘+ Rear wheel sprocket “1” VVVYYYY YY VY VY VYYY YY YYYYYYYYT a. Remove the rear wheel sprocket nuts, plates, rear wheel sprocket brackets, and the rear wheel sprocket, b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install a new rear wheel sprocket. 68 Nm (6.8 m-kgf, 49 ftIbf) mp + Install the rear wheel sprocket with its stamped mark “a” facing outward, + Tighten the rear wheel sprocket nuts in stages and in a crisscross pattem PUVUVUVUVUVUUVUCUUYUUVUYUVYYTUYTY ‘ASSEMBLING THE REAR WHEEL 1. Install: + Whee! bearings + Oilseal INEM Wwvvyvyvyvyyyyyvyvyyyyyyyyyyy yyy a, Install the new wheel bearing (right side), NOTICE Do not contact the wheel bearing inner race “4” or balls “2”. Contact should be made only with the outer rac pp Use a socket "a" that matches the diameter of the wheel bearing outer race. [5 b. Install the spacer. c. Install the new wheel bearing (left side). qe Place a suitable washer “1” between the socket “2” and the bearing so that both the inner race “3” and outer race “a” are pressed at the same time, and then press the bearing until the inner race makes contact with the spacer "S"REAR WHEEL 3. Check: + Rear brake disc Refer to “CHECKING THE REAR BRAKE DISC” on page 4-54. 4. Lubricate: * Oil seal lips [ AAAAAAAAAAAAA DA dsdd edd ‘ADJUSTING THE REAR WHEEL STATIC BALANCE, me + After replacing the tire, whee! or both, the rear wheel static balance should be adjusted. + Adjust the rear wheel static balance with the brake disc and rear wheel drive hub installed. 1. Adjust: + Rear wheel static balanoe Refer to “ADJUSTING THE FRONT WHEEL STATIC BALANCE" on page 4-24. INSTALLING THE REAR WHEEL (REAR BRAKE DISC) 1. Install: ‘* Rear brake disc "1" Rear brake disc bolt 23 Nm (2.3 m-kgf, 17 ftibf) LOCTITE® me Install the rear brake disc with its chamfered side “a” facing inward. 2. Install: ‘+ Rear wheel sprocket Refer to "CHECKING AND REPLACING THE REAR WHEEL SPROCKET’ on page 431 Recommended lubricant 1) ‘Lithium-soap-based grease 5. Install * Collar (right) + Collar (left) * Chain pullers “+ Brake caliper bracket “1” + Rear wheel + Rear wheel axle + Washers + Rear wheel axle nut + Swingarm end plates a + Install the rear wheel with the mark “a’ on the rear tire pointing in the direction of wheel rota~ tion + Align the projection *b”in the swingarm with the slot “o’ of the brake caliper bracket. + Apply ithium-soap-based grease to the con- tact surface and threads of the rear wheel axle 6. Lubricate: ‘+ Rear brake caliper boltREAR WHEEL Recommended lubricant 1) ‘silicone grease 7. Install ‘+ Rear brake caliper + Rear brake caliper bolt 8. Adjust: * Drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK" on page 8-17. Drive chain slack '35.0-45.0 mm (1.98-1.77 in) 9. Tighten: ‘+ Rear wheel axle nut + Rear brake caliper bolt \yy | Rear wheel axle nut e 57 Nm (5.7 m-kgf, 41 ftibf) Rear brake caliper bolt 23 Nm (2.3 m-kgf, 17 ftbf) Make sure the brake hose is routed properly. 4-34FRONT BRAKE FRONT BRAKE [Removing the front brake pads [35 Nm G5 mgt 25 fbf) ‘Order ‘Job/Parts to remove ay Remarks Front brake caliper bot 2 Front brake caliper 7 Brake pad ci z Brake pad pin 1 1 1 1 7 Brake pad (inner) Brake pad (outer) Brake pad spring ‘Brake caliper bleed serowFRONT BRAKE [Removing the front brake master cylinder TO Nm (1.0 mkgh 7.2 Mbt) @ TS Nm (0.15 mgt, 11 MBO [E Nm (0.5 mgt, 4:3 RBA) 29 Nm (2.9 avkgf, 21 bh) EN (0.6 mkgt 4.3 abt) Ti Nm (0-17 mekgf, 0.80 fb) ‘Job/Parts to remove ay Remarks Brake fd Drain Fofer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-14, Front brake master oylinder reservoir cap ‘Brake master cylinder reservoir diaphragm hold ‘Brake master oyinder reservoir diaphragm Brake lever Front brake light switch connector Front brake light switch 7 7 2__ [Disconnect 1 Front brake hose union bok (master cylinder side) Brake hose gasketFRONT BRAKE [Removing the front brake master cylinder @ TS Nm (0.15 mgt, 11 MBO TE Nm (0.5 mgt, 4.3 fbf) SLO Ni (1.0 mekgf, 7.2 PBA) [28 Nm @.9 nko, 21 EN (0.6 mkgt 4.3 abt) SLi (07 meegf, 0.80 feabA) ‘Order ‘Job/Parts to remove ay Remarks @ | Brake hase 7 70 | Front brake mastar cylinder holder 1 T1__| Front brake master cyinder assembly 1FRONT BRAKE [Disassembling the front brake master cylinder ‘Order ‘Job/Parts to remove ay Remarks 1 __| Brake master oylinder kit 7 2__| Brake master oyinder body 1FRONT BRAKE [Removing the front brake caliper [35 Nim G5 meg, 25 RA ‘Order ‘Job/Parts to remove ay Remarks Drain Brake fd Fofer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3-14, 1__| Front brake hose union bolt (rake caliper side) | 1 2 __| Brake hose gasket 2 a [Brake hese i 4 | Front brake caliper bolt 2 S| Front brake caliper 7FRONT BRAKE (Disassembling the front brake caliper [Ei (08 ekg. 43 RABI) ‘Job/Parts to remove ay Remarks Brake pad clip Brake pad pin Brake pad (inner) Brake pad (outer) Front brake caliper bracket ‘Brake caliper piston Brake caliper piston dust seal 7 2 3 4 5 ___| Brake pad spring @ 7 8 9 Brake caliper piston seal 70 __| Brake caliper bieed screwFRONT BRAKE INTRODUCTION ——_______ Disc brake components rarely require disas- sembly. Therefore, always follow these pre- ventive measures: + Never disassemble brake components un- less absolutely necessary. + If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reas- sembly. + Never use solvents on internal brake com- ponents. + Use only clean or new brake fluid for clean- ing brake components. * Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. * Avoid brake fluid coming into contact with the eyes as it can cause serious injury. FIRST AID FOR BRAKE FLUID ENTERING THE EYES: + Flush with water for 15 minutes and get im- mediate medical attention. CHECKING THE FRONT BRAKE DISC 1. Remove: + Front wheel Refer to “FRONT WHEEL! on page 4-21 2. Check: ‘+ Front brake disc Damage/galling +> Replace. 8. Measure: Brake disc deflection ‘Out of specification —> Correct the brake disc deflection or replace the brake disc. A YWUVY VV YVYVYVYVYYYVYVYYYVTYY TTY a. Place the vehicle on a suitable stand so that the front wheel is elevated. b. Before measuring the brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary. ¢. Remove the brake caliper. . Hold the dial gauge at a right angle against the brake disc surface, Brake disc runout limit (as mea- sured on wheel) 0.15 mm (0.0059 in) . Measure the deflection 1.5 mm (0.06 in) be- low the edge of the brake disc. “1 m ) } et Top SSS ur AAMAAAAAMAAAAAAAAAAAAAAAAA AA LALA 4, Measure: ‘Brake disc thickness Measure the brake disc thickness at a few dif ferent locations. Out of specification > Replace. Brake disc thickness limit 5. Adjust: ‘Brake disc deflection YVUV YY TY YY YTV YY YY YY TY TTY YY, a. Remove the brake disc. b. Rotate the brake disc by one bolt hole. . Install the brake disc. Ivy | Front brake dise bolt OR] 23Nm (23 mikgf, 17 telbf) LOcTITE® NOTICE Replace the brake disc bolts with new ones. me + Install the front brake disc “1” with its cham- fered side “a” facing inward, + Tighten the brake disc bolts in stages and in a crisscross pattern. 44FRONT BRAKE d. Measure the brake disc deflection. €. If out of specification, repeat the adjustment ‘steps until the brake disc deflection is within specification. Ifthe brake disc deflection cannot be brought within specification, replace the brake disc. AAAAAAAAAAAAAAAAAAAAAAAAAAAAAAAL 6. Install: + Front wheel Refer to “FRONT WHEEL" on page 4-21. REPLACING THE FRONT BRAKE PADS mp ‘When replacing the brake pads, itis not neces- sary to disconnect the brake hose or disassem- ble the brake caliper, 1. Measure: ‘Brake pad wear limit “a” ‘Out of specification > Replace the brake pads as a set. XS Brake pad lining thickness (in- ner) 5.3 mm (0.21 in) Limit 0.8 mm (0.03 in) Brake pad lining thickness (out- er) 5.3 mm (0.21 in) Limit (0.8 mm (0.03 in) A. Inner B. Outer 2, Install: ‘+ Brake pad spring + Brake pads que Always install new brake pads and new brake pad spring as a set. YwyvyvyvyvyvyvyyyyyyYyYvryyyyyyy a, Connect a clear plastic hose “1” tightly to the bleed screw “2”. Putthe other end of the hose into an open container. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger.FRONT BRAKE 4d. Install a new brake pad spring and new brake pads. AAAAAAAAAAAAAAAAAAAAAAAAAA ALAA AA 3. Install + Brake pad pin + Brake pad clips + Front brake caliper 35 Nm (3.5 m-kgf, 25 ftbf) 4, Check: + Brake fluid level Below the minimum level mark “a” > Add the specified brake fluid to the proper level Refer to “CHECKING THE BRAKE FLUID LEVEL? on page 3-15. 5. Check: + Brake lever operation Soft or spongy feeling + Bleed the brake sys- tem, Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-14 REMOVING THE FRONT BRAKE CALIPER me Before removing the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: * Brake hose union bolt “1” + Brake hose gaskets + Brake hose °3” me Put the end of the brake hose into a container ‘and pump out the brake fluid carefully. DISASSEMBLING THE FRONT BRAKE CALIPER 1. Remove: ‘+ Brake caliper pistons “1” “Brake caliper piston dust seals + Brake caliper piston seals "3" yyvyvevyvyvyvyvyvyvrvyvrvyrTyyy a. Blow compressed air into the brake hose joint ‘opening “a” to force out the pistons from the brake caliper. * Cover the brake cal ion with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. + Never try to pry out the brake caliper pis- ton. b. Remove the brake caliper piston dust seals. and brake caliper piston seals. AAMAAAAAAAAAAAAAAAAAAAAAAAAAAAAAFRONT BRAKE CHECKING THE FRONT BRAKE CALIPER Recommended brake component replacement schedule + Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals and brake caliper piston seals. Brake hose Every four years Every two years and Brake fluid whenever the brake is disassembled 1. Check: = Brake caliper pistons “1” Rustscratches/wear —> Replace the brake caliper pistons. + Brake caliper cylinders “2” Scratches/wear —> Replace the brake caliper assembly. + Brake caliper body “3” ‘Cracks/damage —> Replace the brake caliper assembly. + Brake fluid delivery passages (brake caliper body) Obstruction + Blow out with compressed air. TENN Whenever a brake caliper is disassembled, replace the brake caliper piston dust seals ASSEMBLING THE FRONT BRAKE CALIPER — * Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. + Never use solvents on internal brake com- ponents as they will cause the brake caliper piston dust seals and brake caliper piston seals to swell and distort. Brake pads Ifnecessary Ny Specified brake fluid Piston seals Every wo years DoT 4 Piston dust seals Every two years INSTALLING THE FRONT BRAKE CALIPER 1. Install ‘+ Front brake caliper (temporarily) + Brake hose gaskets + Brake hose 3” + Brake hose union bolt “4” |\wp | Front brake hose union bolt (brake caliper side) 29 Nm (2.9 m-kgf, 21 ftibf) ___. Proper brake hose routing is essential to in- sure safe vehicle operation. NOTICE When installing the brake hose onto the brake caliper, make sure the brake pipe “a” touches the projection “b” on the brake call- per. 2. Remove: ‘+ Front brake caliper 3. Instal: + Brake pad spring + Brake pads + Brake pad pin + Brake pad clips Front brake caliper bolt 35 Nm (3.5 m-kgf, 25, bf) Refer to “REPLACING THE FRONT BRAKE PADS" on page 4-42, 444FRONT BRAKE 4, Fill: + Brake master cylinder reservoir (with the specified amount of the specified brake fluid) Specified brake fluid DOT REMOVING THE FRONT BRAKE MASTER CYLINDER 1p Before removing the front brake master cylinder, drain the brake fluid from the entire brake sys- tem, OO + Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. * Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance. + When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 5. Bleed + Brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-14 6. Check: + Brake fluid level Below the minimum level mark “a> Add the specified brake tluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL? on page 3-15. 7. Check: * Brake lever operation Soft or spongy feeling + Bleed the brake sys- tem, Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM" on page 3-14 1. Disconnect: ‘Front brake light switch connectors (from the front brake light switch) 2. Remove’ ‘+ Front brake light switch 3. Remove’ ‘+ Brake hose union bolt “1” + Brake hose gaskets “2" + Brake hose 11P To collect any remaining brake fluid, place @ container under the master cylinder and the end of the brake hose, ‘CHECKING THE FRONT BRAKE MASTER CYLINDER 1, Check: + Brake master cylinder Damage/scratches/wear -» Replace. + Brake fluid delivery passages (brake master oylinder body) Obstruction — Blow out with compressed air. 2. Check: + Brake master cylinder kit Damage/scratches/wear —> Replace. 8. Check: + Brake master cylinder reservoir “1” + Brake master cylinder reservoir diaphragm holder *2" Cracks/damage —> Replace. + Brake master cylinder reservoir diaphragm 3 Damagelwear > Replace. 4-45FRONT BRAKE 4. Check: * Brake hose Cracks/damage/wear —> Replace. ‘(ASSEMBLING THE FRONT BRAKE MASTER CYLINDER a * Before installation, all internal brake com- ponents should be cleaned and lubricated with clean or new brake fluid. + Never use solvents on internal brake com- ponents. Specified brake fluid DoT 4 xy INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: ‘+ Front brake master cylinder assembly + Front brake master cylinder holder 2. Install + Brake hose + Brake hose gaskets IM + Brake hose union bolt |\\o | Front brake hose u | (master cylinder side) 29 Nm (2.9 m-kgf, 21 fbf) Proper brake hose routing is essential to in- ‘sure safe vehicle operation. er bolt % Front brake master cylinder hold-| 10 Nm (1.0 m-kgf, 7.2 ft-bf) me + Install the front brake master cylinder holder with the “UP mark “a” facing up. + Align the mating surfaces of the front brake master cylinder holder with the punch mark on the handlebar (right), or install the front brake master cylinder so that the distance “c* between the bottom of the handlebar (right) and the bottom of the front brake master cylin- der is 11 mm (0.43 in) as shown in the illustra~ tion «First, tighten the upper bolt, then the lower bott. tp * Attach the brake hose so that ts angle is 75° to 85° against the straight line in parallel with the ceiling plane of the master oylinder. + While holding the brake hose, tighten the union bolt as shown. + Turn the handlebar tothe left and right to make sure the brake hose does not touch other parts. (€.g., wire hamess, cables, leads). Correct if necessary. 4-46