Install the clutch plate and friction plate as shown in the illustration. Then, install the clutch cover. S Apply oil onto the bearing. S Apply molybdenum disulfide grease onto the pull rod. Check: S oil pump operation Rough movement! Repeat steps 1 and 2 or replace the defective part s.
Replace the defective Lubricate: S inner rotor S outer rotor S oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2. Install: S oil strainer 1 S relief valve 2 NOTE: Make sure to check the arrow mark a located on the oil strainer housing for the front and rear direction of the engine and then install the oil strainer so that its arrow mark points to the front side of the engine.
Place the engine upside down. S Loosen the bolts in decreasing numerical or- der refer to the numbers in the illustration. Lubricate: S crankshaft journal bearings with the recommended lubricant Recommended lubricant Engine oil 2.
Apply: S sealant Yamaha bond No. Do not apply sealant to within 2 X 3 mm of the crankshaft journal bearings. Install: S dowel pin 4.
Remove: S connecting rod cap 1 S big end bearings NOTE: Identify the position of each big end bearing so that it can be reinstalled in its original place.
NOTE: Identify the position of each crankshaft journal upper bearing so that it can be reinstalled in its original place. Measure: S piston pin outside diameter a Out of specification!
Replace the piston pin. Piston pin outside diameter Measure: S piston pin bore inside diameter b Out of specification! Replace the piston. Measure: S crankshaft-pin-to-big-end-bearing clear- ance Out of specification! Replace the big end bearings. Crankshaft-pin-to-big-end-bearing clearance 0. Tighten the connecting rod nuts. Connecting rod nut 15 Nm 1. Replace the connecting rod bolts with new ones. Always install new bolts and nuts.
Tighten the connecting rod bolts. NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts Connecting rod bolt Connecting rod bolt 15 Nm 1.
Always install new bolts. Clean the connecting rod bolts. Remove the connecting rod and big end bearings. Measure the compressed Plastigauge width on the crankshaft pin. Offset: S piston ring end gaps a Top ring b Lower oil ring rail c Upper oil ring rail d 2nd ring e Oil ring expander 5.
Lubricate: S crankshaft pins S big end bearings S connecting rod big end inner surface with the recommended lubricant Recommended lubricant Clean the connecting rod bolts and nuts.
Put a mark 1 on the corner of the connecting rod nut 2 and the connecting rod cap 3. Tighten: NOTE: Install by carrying out the following procedures in order to assemble in the most suitable condi- tion. S connecting rod bolts.
Tighten: S connecting rod bolts 15 Nm 1. Crankcase Separate. Crankshaft Crankshaft journal lower bearing Crankshaft journal upper bearing For installation, reverse the removal procedure. Measure: S crankshaft runout Out of specification!
Replace the crank- shaft. Crankshaft runout Less than 0. Replace the crankshaft. Install the crankshaft journal upper bearings 1 and the crankshaft into the upper crank- case. NOTE: Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the up- per crankcase.
Put a piece of Plastigauge 2 on each crankshaft journal. Remove the lower crankcase and the crank- shaft journal lower bearings. Measure the compressed Plastigauge width c on each crankshaft journal.
If the crankshaft-journal-to-crankshaft-jour- nal-bearing clearance is out of specification, select replacement crankshaft journal bear- ings. Install: S crankshaft journal upper bearings 1 into the upper crankcase NOTE: S Align the projections a on the crankshaft jour- nal upper bearings with the notches b in the upper crankcase.
S Be sure to install each crankshaft journal up- per bearing in its original place. Insert two bolts 2 of the proper size, as shown in the illustration, into the main axle assembly bearing housing. Tighten the bolts until they contact the crank- case surface. Replace the shift drum assembly.
Replace the shift drum as- sembly. Check: S transmission gear engagement each pinion gear to its respective wheel gear Incorrect! Reassemble the transmission axle assemblies. Check: S transmission gear movement Rough movement! Check: S radiator fins Obstruction! Apply compressed air to the rear of the radia- tor.
Repair or replace. NOTE: Straighten any flattened fins with a thin, flat- head screwdriver. Install: S radiator S coolant hoses 2.
Check: S cooling system Leaks! Repair or replace any faulty part. Clean: S mating surfaces of the oil cooler and the crankcase with a cloth dampened with lacquer thinner 2.
Suspend the thermostat in a container filled with water. Slowly heat the water. Place a thermometer in the water. Install: S thermostat cover 12 Nm 1. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. S Before installing the water pump seal, apply Yamaha bond No. Install: S rubber damper S rubber damper holder NOTE: Before installing the rubber damper, apply tap water or coolant onto its outer surface.
If this function detects a malfunction in the system, it immediately operates the en- gine under substitute characteristics and illuminates the engine trouble warning light to alert the rider that a malfunction has occurred in the system.
The engine trouble warning light does not come The engine trouble warning light comes on. Setting the diagnostic mode 1. Verify the operation of the sensor or actuator. S Sensor operation The data representing the operating condi- tions of the sensor appears on the trip LCD. No normal signals are received from S Defective crankshaft position sensor. S Malfunction in pickup rotor.
The program and data are not Faulty ECU memory. When this malfunction is detected, the code properly written on or read from the internal memory.
NOTE: S Check the intake air temperature and coolant temperature as close as possible to the intake air tem- perature sensor and the coolant temperature sensor respectively. Check and service the items or components that are the probable cause of the malfunction following the order. Symptom Intake air pressure sensor - open or short circuit detected.
Used diagnostic code No. Symptom Intake air pressure sensor - hose system malfunction clogged or detached hose. Symptom Stuck throttle position sensor detected. Reinstated by sensor. Symptom Open or short circuit detected from the intake air temperature sensor.
Symptom The motorcycle has overturned. Raise the motorcycle upright. Symptom Malfunction detected in the primary lead of the ignition coil 1, 4. Symptom 1 No normal signals are received from the speed sensor.
A1 X A4 No. Symptom The ECU is unable to monitor the battery voltage. Used diagnostic No. Er-4 Symptom Non-registered data has been received from the meter.
Throttle position sensor coupler Disconnect Intake air pressure sensor coupler Disconnect Cylinder 1-injector coupler Cylinder 2-injector coupler Cylinder 3-injector coupler Cylinder 4-injector coupler Sub wire harness Negative pressure hose Intake air pressure sensor Check: S injectors Damage! Replace the throttle bo- dies as a set. Remove the seat fuel tank. Connect the pressure gauge 1 and adapter 2 onto the fuel injection pipe. Check: S throttle position sensor a.
Disconnect the throttle position sensor cou- pler. While slowly opening the throttle, check that the throttle position sensor resistance is with- in the specified range. The resistance does not change or it changes abruptly! Replace the throttle position sensor. The slot is worn or broken! When there is negative pressure at the exhaust port, the reed valve opens, allowing secondary air to flow into the exhaust port. Check: S hoses Loose connection!
Connect properly. Replace the reed valve. Check S AI system solenoid a. Remove the AI system solenoid coupler from the wire harness. Tester positive probe! If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch.
Improperly connected! Properly connect. Incorrect continuity reading! Replace the switch. Repair or replace the bulb, bulb socket or both. Never pull the lead, other- wise it may be pulled out of the terminal in the coupler.
S 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 adverse Install a good bulb into the bulb socket.
Battery S Check the condition of the battery. Check: Minimum open-circuit voltage 1. Ignition spark gap The following procedure applies to all of the spark plugs. S Disconnect the spark plug cap from the spark plug. S Connect the ignition checker and spark plug cap as shown. S Measure the ignition spark gap Spark plug cap resistance S Crank the engine by pushing the starter Crankshaft position sensor resis- spark plug lead tance Positive tester probe!
Replace the crank- shaft position sen- sor. Sidestand switch sky blue S Check the sidestand switch for continuity. Negative tester probe! Positive tester probe!
Replace the ECU. The starter motor fails to turn. Starting circuit cut-off relay S Disconnect the starting circuit cut-off relay coupler from the wire harness. Sidestand switch Wiring S Check the sidestand switch for continuity.
S Is the sidestand switch OK? Replace the side Check: S commutator Dirt! Clean with grit sandpaper. Measure: S commutator diameter a Out of specification! Replace the starter motor. Commutator wear limit 27 mm 1. Measure: S brush length a. Replace the brushes as a set. Brush length wear limit 3.
Measure: S brush spring force Out of specification! Replace the brush springs as a set. S Is the battery OK? Check: 1. Stator coil lead 5. Stator coil resistance S Disconnect stator coil lead coupler. S Remove the generator cover. Just imagine how much you can save by doing simple repairs yourself. Many people buy this manual just to have it around for when the inevitable happens. Sooner or later, maintenance will need to be performed. Be prepared for it when it happens by simply purchasing this service manual for later use!
See below for a list of items that most of our manuals cover. Unscrew the bolts securing the front of the tank, noting the location of the washers see illustration. Raise the tank at the front to access the hoses and wiring connectors. Release the clamps securing the drain hose and, on all except California models, the breather hose to their unions on the underside of the tank and detach the hoses, noting which fits where see Illustration.
To remove the stand leg only, first unhook the spring with the stand in the raised position, then counterhold the nut on the pivot bolt and unscrew the bolt see illustration. Support the stand leg and withdraw the bolt. Note the location of the stand switch plunger.
0コメント