YAMAHA

LIT-11616-10-60

YZF1 OOORJ/YZF1 OOOR-:lC SERVICE MANUAL"

©1996 by Yamaha Motor Corporation, U.S.A.

First edition, November 1996 All rights reserved.

Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

Printed in U.S.A.

PIN LlT-11616-10-60

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NOTICE

This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha motorcycles has a basic understanding of the mechanical ideas and the procedures of motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the motorcycle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that the motorcycle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Yamaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his motorcycle and to conform with federal environmental quality objectives.

Yamaha Motor Company, Ltd. is continually striving to improve all its 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.

NOTE: ___

• This Service Manual contains information regarding periodic maintenance to the emission control system. Please read this material carefully .

• Designs and specifications are subject to change without notice .

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

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

A WARNING

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

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

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

NOTE:

EB002000

HOW TO USE THIS MANUAL MANUAL ORGANIZATION

This manual is intended as a handy, easy-to-read reference book for the mechanic. It is divided into chapters, sections and sub-sections, Comprehensive explanations of all installation, removal, disassembly, assembly, repair and inspection procedures are laid out with the individual steps in sequential order.

PAGE FEATURES

The circled numbers below refer to the features indicated in the sample page.

CD : An abbreviation and symbol in the upper right corner of each page indicates the current chapter.

® : The current section title is shown at the top of each page.t

@ : Sub-section titles appear in smaller print than the section title.t

@ : Lines of asterisks (*) mark the beginning and end of a particularly important procedure. The steps of such procedures are marked with bullets (0).

® : Important information such as fluids, special tools and torques are framed and marked with a corresponding symbol,

® : A circled number refers to an illustrated part.

o : A circled lower case letter refers to an illustrated dimension or alignment mark. ® : An upper case letter in a box refers to other illustrated details.

® : An arrow mark after a given defect suggests the recommended course of action.

t : In Chapter 3, "Periodic Inspection and Adjustment", it is usually the current SUb-section title that appears at the top of each page, instead of the current section title.

EXPLODj:D DIAGRAMS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each disassembly section.

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ICOOLI ~ I ICARSI'ilI
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4 I EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols CD to ® are printed on the top right of each page and indicate the subject of each chapter.

CD General information

® SpecificationS

@ Periodic inspections and adjustments @Engine

® Cooling system ® Carburetion

(j) Chassis

® Electrical

® Troubleshooting

Illustrated symbols @) to @ are used to identify the specifications appearing in the text.

® Filling fluid ® Lubricant ® Special tool @lTorque

® Wear limit, clearance @ Engine speed

@)n, V, A

Illustreted symbols ® to @ in the exploded diagrams indicate the types of lubricants and lubrication points.

@ Apply engine oil

@> Apply gear oil

®> Apply molybdenum disulfide oil ® Apply wheel bearing grease

® Apply lightweight lithium-soap base grease @ Apply molybdenum disulfide grease Illustrated symbols @ to ~ in the exploded diagrams indicate where to apply a locking agent @ and when to install a new part @.

@ Apply the locking agent (LOCTITE®) @Replace

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CHAPTER TITLES

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTION AND ADJUSTMENT

ENGINE

COOLING

CARBURETION

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CONTENl"S CHAPTER f.

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION .................•............................................... 1~1

VEHICLE IDENTIFICATION NUMBER 1~1

ENGINESERIAL NUMBER 1~1

MODEL LABEL 1~1

IMPORTANT INFORMATION 1~2

PREPARATION. FOR REMOVAL PROCEDURES 1~2

REPLACEMENT PARTS 1~2

GASKETS, OIL SEALS AND O-RINGS : ~ 1-2

LOCK WASHERS/PLATES AND corrsn PINS 1-3

BEARINGS AND OIL SEALS 1-3

CIRCLIPS 1-3

SPECIAL TOOLS 1-4

FOR TUNE~UP 1-4

FOR ENGINE SERVICE 1~5

FOR CHASSIS SERVICE 1-7

FOR ELECTRICAL COMPONENTS 1-7

CHAPTER 2.

SPECIFICATIONS

GENERAL SPECIFICATIONS 2~1

'MAINTENANCE SPECIFICATIONS 2-4

ENGINE 2-4

CHASSIS 2-13

ELECTRICAL 2-17

HOW TO USE THE CONVERSION TABLE 2-19

GENERAL TORQUE SPECIFICATIONS ; 2-19

LUBRICATION POINTS AND LUBRICANT TYPES 2-20

ENGINE ............................................................................•................... 2-20

CHASSIS : ;' .........•............... 2-21

COOLING SYSTEM DIAGRAMS 2-22

LUBRICATION DIAGRAMS .... / .......•........................................................... 2-25

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CABLE ROUTING : 2-29

EMISSION HOSE ROUTING (california only) 2-36

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CHAPTER 3.

PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION 3-1 0--

ENGINE 3-11

VALVE CLEARANCE ADJUSTMENT 3-11

CARBURETOR SYNCHRONIZATION 3-19

IDLING. SPEED ADJUSTMENT 3-21

THROTTLE CABLE ADJUSTMENT 3-22

SPARK PLUG INSPECTION 3-24

IGNITION TIMING CHECK 3-25 CHAS

COMPRESSION PRESSURE MEASUREMENT 3-27

ENGINE OIL LEVEL INSPECTION 3-29

ENGINE OIL REPLACEMENT 3-30

ENGINE OIL PRESSURE INSPECTION 3-32

CLUTCH ADJUSTMENT 3-33 ELEC

CLUTCH FLUID LEVEL INSPECTION 3-34

AIR BLEEDING (HYDRAULIC CLUTCH SYSTEM) 3-35 ?

AIR FILTER CLEANING 3-36

CARBURETOR JOINT INSPECTION 3-37

FUEL LINE INSPECTION 3-38

CRANKCASE BREATHER HOSE INSPECTION 3-38

EXUP CABLE ADJUSTMENT 3-39

EXHAUST SYSTEM INSPECTION 3-41

COOLANT LEVEL INSPECTION 3-42

PERIODIC MAINTENANCE/EMISSION CONTROL SySTEM 3-1

GENERAL MAINTENANCE/LUBRICATION 3-2

COWLINGS ' 3-4

REMOVAL 3-6

INSTALLATION 3-7

SEATS 3-8

REMOVAL 3-8

INSTALLATION 3-8

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FUEL TANK 3-9

REMOVAL 3-9

INSTALLATION 3-10

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COOLANT REPLACEMENT 3-42

COOLING SYSTEM INSPECTION 3-46

CHASSIS ; 3-47

FRONT BRAKE ADJUSTMENT 3-47

REAR BRAKE ADJUSTMENT :., e : 3-47

BRAKE FLUID LEVEL INSPECTION ; 3-49

BRAKE PAD INSPECTION ; 3-50

BRAKE LIGHT SWITCH ADJUSTMENT 3-50

BRAKE HOSE INSPECTION 3-51

AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) 3-51

SHIFT PEDAL ADJUSTMENT 3-52

DRIVE CHAIN SLACK ADJUSTMENT 3-53

DRIVE CHAIN LUBRICATION 3-55

STEERING HEAD INSPECTION 3-55

FRONT FORK INSPECTION 3-58

FRONT FORK ADJUSTMENT 3-58

REAR SHOCK ABSORBER ADJUSTMENT 3-60

TIRE INSPECTION 3-62

WHEEL INSPECTION 3-65

CABLE INSPECTION AND LUBRICATION 3-65

LEVER AND PEDAL LUBRICATION 3-66

SIDESTAND LUBRICATION ; 3-66

REAR SUSPENSION LUBRICATION ; 3-66

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-ELECTRICAL 3-67

BATIERY INSPECTION ¥'. 3-67

FUSE INSPECTION 3-72

HEADLIGHT BEAM ADJUSTMENT 3-74

HEADLIGHT BULB REPLACEMENT .. ' 3-75

ENGINE REMOVAL ; ; 4-1

FUEL TANK AND COWUNGS 4-1

ENGINE OIL AND COOLANT 4-1

BATIERY LEADS 4-2

AIR FILTER CASE 4-2

CARBURETORS 4-2

RADIATOR 4-2

HOSES AND LEADS 4-3

DRIVE SPROCKET 4-3

WATER JACKET JOINTS AND WATER PUMP 4-4

AC GENERATOR AND STARTER MOTOR 4-5

MUFFLER ASSEMBLY ; 4-6

ENGINE REMOVAL - .. ; ; 4-7

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CHAPTER" 4.

ENGINE

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ENGINE DISASSEMBLY 4-9

OIL FILTER AND OIL COOLER 4-9

CYLINDER HEAD COVER, CYLINDER HEAD AND CAMSHAFTS 4-10

CYLINDERS AND PISTONS : ;; 4-14

CLUTCH ..............................................................•................................ 4-15

OIL PAN AND OIL STRAINER : 4-17

OIL PUMP AND SHIFT SHAFT 4-19

CRANKCASE DISASSEMBLY 4-20

SHIFT FORKS AND SHIFT CAM 4-21

TRANSMISSION 4-22

STARTER CLUTCH AND CRANKSHAFT , 4-22

VALVES AND CAMSHAFT CASE 4-23

CONNECTING RODS 4-25

OIL PUMP 4-25

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INSPECTION AND REPAIR 4-26

CYLINDER HEAD 4-26

VALVES AND VALVE GUIDES 4-27

VALVE SEATS 4-28

VALVE SPRINGS 4-30

CAMSHAFT CASE 4-31

VALVE LIFTERS ~ 4-31

CAMSHAFTS 4-31

TIMING CHAIN, HY-VO CHAIN, CAMSHAFT SPROCKETS

AND CHAIN GUIDES 4-33

TIMING CHAIN TENSIONER 4-33

CYLINDERS AND PISTONS 4-33

PISTON RINGS 4-35

PISTON PINS 4-36

CRANKSHAFT AND CONNECTING RODS 4-36

OIL PUMP .......................................................................................•..... 4-41

PRIMARY DRIVE · 4-42

STARTER DRIVES 4-42

AC GENERATOR SHAFT 4-43

CLUTCH , 4-43

TRANSMISSION AND SHIFTER 4-45

SHIFT SHAFT AND STOPPER LEVER 4-47

OIL-JET NOZZLE 4-47

RELIEF VALVE, OIL PIPE AND STRAINER 4-48

OIL COOLER 4-49

CRANKCASE 4-49

BEARINGS AND OIL SEALS 4-49

CIRCLIPS AND WASHERS 4-49

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ENGINE ASSEMBLY AND ADJUSTMENT 4-50

OIL PUMP 4-50

CONNECTING RODS 4-52

CAMSHAFT CASE AND VALVES 4-54

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CRANKSHAFT AND STARTER CLUTCH 4-57

TRANSMISSION 1.4-60

SHIFT CAM AND SHIFT FORKS 4-60

CRANKCASE ASSEMBLY 4-61

SHIFT SHAFT AND OIL PUMP 4-64

OIL PAN AND OIL STRAINER ; 4-65

CLUTCH 4-67

PISTONS AND CYLINDERS 4-72

CYLINDER HEAD AND CAMSHAFTS .......................•......................... 4-76

TIMING CHAIN TENSIONER 4-79

OIL COOLER AND OIL FILTER , .. 4-81

ENGINE REMOUNTING 4-82

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CHAPTER 5.

COOLING

RADIATOR/OIL COOLER 5-1

RADIATOR 5-2

REMOVAL 5-2

INSPECTION 5-4

INSTALLATION 5-5

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OIL COOLER 5-6

REMOVAL 5-6

I NSPECTION ~ 5-6

INSTALLATION 5-7

THERMOSTATIC VALVE/WATER PUMP 5-8

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THERMOSTATIC VALVE 5-9

REMOVAL 5-9

INSPECTION 5-10

INSTALLATION 5-11

WATER PUMP · 5-13

REMOVAL 5-13

INSPECTION 5-14

INSTALLATION , 5-17

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CHAPTER 6.

CARBURETION

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CARBURETORS 6-1

REMOVAL 6-3

DISASSEMBLY 6-5

INSPECTION 6-7

ASSEMBLY 6-9

INSTALLATION 6-11

FUEL LEVEL ADJUSTMENT 6-12

THROTTLE POSITION SENSOR (TPS) ADJUSTMENT

AND INSPECTION 6-13

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CHAPTER 7.

CHASSIS

FRONT WHEEL 7-1

REMOVAL 7-2

INSPECTION 7-3

INSTALLATION 7-4

FRONT WHEEL STATIC BALANCE ADJUSTMENT 7-5

REAR WHEEL ~ 7-7

REMOVAL 7-8

INSPECTION 7-9

INSTALLATION 7-9

REAR WHEEL STATIC BALANCE ADJUSTMENT 7-9

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FRONT AND REAR BRAKES 7 -10

FRONT BRAKE 7-10

REAR BRAKE 7-11

BRAKE PAD REPLACEMENT 7-12

BRAKE CALIPER DISASSEMBLY 7-16

MASTER CYLINDER DISASSEMBLY 7-18

INSPECTION AND REPAIR 7-20

BRAKE CALIPER ASSEMBLY 7-24

MASTER CYLINDER ASSEMBLY 7-28

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HYDRAULIC CLUTCH 7-33

DISASSEMBLY 7-34

INSPECTION AND REPAIR 7-36

ASSEMBLY 7-37

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FRONT FORK " " " ":., 7-41

REMOVAL :+.,.i' , 7-42

DISASSEMBLY ..................................•................................................. 7-43

INSPECTION 7-45

ASSEMBLY 7-46

INSTALLATION 7-51

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STEERING HEAD AND HANDLEBARS 7 -53

REMOVAL 7-54

INSPECTION " ; 7-57

INSTALLATION 7-58

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REAR SHOCK ABSORBER AND SWINGARM 7 -61

HANDLING NOTES " 7-62

NOTES ON DISPOSAL ' 7-62

REMOVAL 7-62

INSPECTION 7-67

INSTALLATION 7-68

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DRIVE CHAIN AND SPROCKETS 7 -71

REMOVAL 7-72

INSPECTION 7-73

INSTALLATION 7-75

CHAPTER 8. ELECTRICAL

ELECTRICAL COMPONENTS 8-1

CHECKING OF CONNECTIONS 8-3

IGNITION SYSTEM ~ : 8-4

CIRCUIT DIAGRAM : 8-4

TROUBLESHOOTING , 8-5

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ELECTRIC STARTING SYSTEM 8-11

CIRCUIT DIAGRAM 8-11

STARTING CIRCUIT OPERATION 8-12

TROUBLESHOOTING 8-13

STARTER MOTOR 8-20

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CHARGING SYSTEM 8-25

CIRCUIT DIAGRAM 8-25

TROUBLESHOOTING 8-26

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LIGHTING SYSTEM 8-30

CIRCUIT DIAGRAM 8-30

TROUBLESHOOTING 8-31

LIGHTING SYSTEM CHECK 8-33

SIGNAL SYSTEM .........................................................•... : 8-36

CIRCUIT DIAGRAM 8-36

TROUBLESHOOTING 8-38

SIGNAL SYSTEM CHECK 8-40

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COOLING. SYSTEM 8-49

CIRCUIT DIAGRAM , ""."."."",, .. , " 8-49

TROU BLESHOOTING ""." "" ""., " 8-50

FUEL PUMP SYSTEM , " 8-54

CIRCUIT DIAGRAM " " " 8-54

FUEL PUMP CIRCUIT OPERATION 8-55

TROUBLESHOOTING 8-56

FUEL PUMP TEST " " 8-61

EXUP SYSTEM"" "" " " "." "" " 8-62

CIRCUIT DIAGRAM " " "" " " ; " 8-62

TROUBLESHOOTING 8-63

SELF-DIAGNOSIS ", .. ,', 8-68

TROUBLESHOOTING 8-69

CHAPTER 9.

TROUBLESHOOTING

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STARTING FAILURE/HARD STARTING .. " " " " 9-1

FUEL SYSTEM "" " "" " " 9-1

ELECTRICAL SYSTEM " " 9-1

COMPRESSION SYSTEM .. " " .. " "." " .. " " 9-2

POOR IDLE SPEED PERFORMANCE" .. "" .. "" " " " 9-2

POOR IDLE SPEED PERFORMANCE" "" " " .. 9-2

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POOR MEDIUM-AND HIGH-SPEED PERFORMANCE .. " " 9-2

POOR MEDIUM-AND HIGH-SPEED PERFORMANCE " " " ".9-2

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FAULTY GEAR SHIFTING " " " " .. " " " " 9-3

HARD SHIFTING " .. " " " " 9-3

SHIFT PEDAL DOES NOT MOVE " .. " 9-3

JUMPS-OUT-OF GEAR 9-3

CHAS

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OVERHEATING 9-4

OVERHEATING 9-4

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CLUTCH SLIPPING/DRAGGING ., ,9-3

CLUTCH SLIPPING " 9-3

CLUTCH DRAGGING 9-3

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FAUL TV BRAKE 9-4

POOR BRAKING EFFECT ,.; 9-4

FRONT FORK OIL LEAKAGE: AND FRONT FORK MALFUNCTION 9-4

MALFUNCTION 9-4

OIL LEAKAGE " 9-4

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UNSTABLE HANDLING , 9-5

UNSTABLE HANDLING 9-5

FAUL TV LIGHTING AND SIGNALSVSTEMS 9-5

HEADLIGHT DOES NOT L1GHT 9-5

BULB BURNT OUT 9-5

FLASHER DOES NOT LIGHT 9-5

FLASHER BLINKS SLOWLY 9-5

FLASHER REMAINS LIT 9-5

FLASHER BLINKS QUICKLY 9-5

HORN DOES NOT SOLJND /~ 9-5

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VZF1000R WIRNING DIAGRAM

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EB100000

GENERAL INFORMATION

!MOTORCYCLE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle i(je[ltificatioli number CD is stamped into the right side of the steering head.

NOTE: __ _. ~

The vehicle identification number is used to identify the motorcycle and may be used to register the motorcycle with a licensing authority.

EB100030

ENGINE SERIAL NUMBER

The engine serial number CD is stamped into the crankcase .

NOTE: -- -- _

The first three digit$ of the engine serial number indicate the model type; the remaining digits are the unit production number.

MODEL LABEL

The model label CD is affixed to the frame. This information will be needed to order spare parts .

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IMPORTANTINfORMATION I ~~ I~I

300-008

300,009

E!l101000

'IMPORTANT INFORMATION

PREPARATION FOR REMOVAL PROCEDURES

[Link] removal and disassembly remove all dirt, mud, dust and foreign material.

[Link] proper tools and cleaning equipment.

Refer to "SPECIAL TOOLS".

[Link] disassembling the motorcycle, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been "mated" through normal wear. Mated parts must always be reused or replaced as an assembly.

_ 4.[:>uring motorcycle disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly and allow for the correct installation of all parts.

[Link] all parts away from any source of fire.

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EB101010

REPLACEMENT PARTS

[Link] only genuine Yamaha parts for all replacements. Use. oil and grease recommended by Yamaha for all lubrication

jobs. Other brands may be similar in func- •

tion and appearance, but inferior in qual-

ity.

EB101020

GASKETS, OIL SEALS AND O-RINGS

[Link] overhauling the engine replace all

gaskets, seals and a-rings. All gasket surfaces, oil seal lips and a-rings must be cleaned.

[Link] reassembly properly oil all mating parts and bearings. Apply grease to the oil seal lips.

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IMPORTANT INFORMATION I::'~~J~I

300 000

300 003

300-002

300 001

EB10l030 , ' . __

LOCK WASHERS/PLATES AND COTTER

PINS,

[Link] removal replace' all lock washers! plates (j)and'cotter pins. After the bolt or nut has been tightened ·to specification bend the lock tab(s) along a flat side of the bolt or nut.

EB10l040

BEARINGS AND OIL SEALS

[Link] bearings and oil seals so that the manufacturer's marks or numbers are visible. When installing oil seals, apply a light coating of lightweight lithium base grease to the seal lips. When installing bearings oil them liberally, if appropriate.

CD Oil seal

Do not use compressed air to spin the bear· ings dry. This will damage the bearing surfaces.

CD Bearing

EB10l060

CIRCLIPS

[Link] reassembly, check atl circlips carefully. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip CD, make sure that the sharp-edged corner ® is positioned opposite the thrust ® it receives. See sectional view.

@Shaft

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EB102000

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools; this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools may differ in shape and part number from country to country. In such a case, two types are provided.

EB102010

FORTUN~-UP

Vacuum gCluge VU,08030

This gauge is needed for carburetor synchronization.

Carburetor angle driver 90890-03158

This tool is used to adjust the pilot screw.

Inductive timing light 908~0-03141

This tool is necessary for checking ignition timing.

SPECIAL TOOLS I~~~ I ~ I

When placing an order, refer to the following list to avoid any mistakes.

PIN, YM- 00000, YU-OOOOO YS- 00000, YK-OOOOO ACC-OOOOO

For CON

P/N.90890- 00000

Except for CON

Engine tachometer YU-8036-A 90890-03113

This tool is needed for detecting engine rpm.

, Vacuum gauge 90890-03094

This gauge is needed for carburetor synchronization.

Inductive timing light YM-33277-A

This tool is necessary for checking ignition timing.

Compression gauge r-

YU-33223 : ~, , , l~ "

This gauge is used to measure the engine compression.

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Compression gauge 90890-03081

This gauge is used to measure the engine compression.

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Fuel level gauge YM-01312-A 90890-01312

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This gauge is used to measure the fuel level in the float chamber.

EB102020

FOR ENGINE SERVICE

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Piston pin puller YU-01304 90890-01304

This tool is used to remove the piston pin.

Universal clutch holder

90890-04086 ~

This tool is used to hold the clutch when removing or installing the clutch boss locknut.

SPECIAL TOOLS I J~;I~I

This gauge is used to measure engine oil pressute .

Oil pressure gauge 90890-03153 Adapter 90890-03139

This tool is used When cutting the cam chain.

Universal clutch holder YM-91042

This tool is used to hold the clutch when removing or installing the clutch boss locknut.

Cam chain cutter YM-01112 90890-01112

Armature shock puller YU-1047-3 90890-01290

Weight YU-1047"4 90890-01291

These tools are used to remove the starter clutch shaft.

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,;c~~~il~~~~~:2a;'~~~;'~~~Jt.I;;';{:~<~et;,.","·~ .. ;.

Valve spring compressor YM-04019 :90890-040;9.

This tool is needed to remove and install the . ,valve assemblies.

Valve guide remover (4.5 mm) YM-4116

90890-04116

This tool is used to remove the valve guides.

Valve guide reamer (4.5 rnrn) YM-4118 90890-041 18

This tool is used to rebore the new valve guide.

Piston ring compressor YM-01066

90890-01066

This tool is used to compress piston rings when installing the cylinder.

Radiator cap tester YU-24460-01 90890-01325 Adaptor

YU-33984 90890-01352

This tester is needed for checking the cooling system.

SPECIAL TOOLS II~~~ I~I

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Attachment

(For exhaust valve) YM~4108

(For intake valve) YM-4114 .90890-04114

These tools are needed to remove and install the Valve assemblies.

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Valve guide installer (4.5 mm)

YM-4117 .

90890-04117

This tool is needed toinstal] the valve guides

properly. . .

,"_,_- '.~ -.:

Quick gasket@

ACC-11001-15-01

Y AMA'HABo'rid No.1 215' .. 90890-85505

This sealant (Bond) is used for crankcase mating surfaces, etc.

Piston base YM-Ol067 90890-01067

Use four pieces of these to hold the pistons during cylinder installation.

LE-J

Oil filter wrench

YU-38411 90890-01426

This tool is used to remove and install the oil filter.

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____________ S_P_EC_~_L_T_O_O_L_sl~l~1

EB102040

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Damper rod holder 90890-01447

FOR CHASSIS SERVICE

This tool is used to loosen and tighten the front fork damper rod holding bolt.

W

Ring nut wrench

YU-3397S 90890-01403

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Fork seal driver YM-01442 90890-01442

This tool is used to loosen and tighten the steering ring nut.

This tool is used when installing the fork seal.

EB102050

Dynamic spark tester YM-34487

FOR ELECTRICAL COMPONENTS

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This instrument is necessary for checking the ignition system components.

Ignition checker 90890-06754

Pocket tester YU-03112 90890-03112

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This instrument is necessary for checking the ignition system components.

This instrument is invaluable for checking the electrical system.

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GENERAL . SPECIFICATIONS

SPECIFICATIONS GENERAL SPECIFICATIONS

Model YZF1000RJfVZF1000RJC
Model code: 4YVV1 (YZF1000RJ)
4YVV2(YZF1000RJC)
Dimensions:
Overall length 2,085 mm (82.1 in)
Overall width 740 mm (29.1 in)
Overall height 1,175 mm (46.3 in)
Seat height 790 mm (31.1 in)
VVheelbase 1,430 mm (56.3 in)
Minimum ground clearance 140 mm (5.51 in)
Minimum turning radius 3,100 mm (122.0 in)
Basic weight:
VVith oil and full fuel tank 224 kg (494 Ib) (YZF1000RJ)
225 kg (496 Ib) (YZf1OOORJC)
Engine:
Engine type Liquid-cooled 4-stroke" DOHC
Cylinder arrangement Forward-inclined parallel 4-cylinder
Displacement 1,002 cm3
Bore x stroke 75.5 x 56.0 mm (2.97 x 2.20 in)
Compression ratio 11.5:1
Compression pressure (STD) 1,422 kPa (14.22 kg/cm2, 202 psi) at 400 r/min
Starting system Electric starter
Lubrication system: VVet sump
Oil type or grade:
Engine oil
30 40 50 60°F
1 14 1 .1-- Yamalube 4 or SAE10VV30 type SE motor oil,
- - or SAE20VV40 type SE motor oil

0 5 10 15'C
Oil capacity:
Engine oil
Periodic oil change 3 L (2.6 Imp qt, 3.2 US qt)
VVith oil filter replacement 3.2 L (2.8 Imp qt, 3.4 US qt)
Total amount 3.5 L (3.1 Imp qt, 3.7 .US qt)
Radiator capacity (including all routes): 2.7 L (2.38 Imp qt, 2.85 US qt) [Link] ISPEcl ~ I

Model f ~~ i YZF 1 OOORJ/yZF 1 OOORJ C
Air filter: [Link] element
Fuel: .<-'
Type UNLEADED FUEL
Fuel tank capacity 20 L (4.40 Imp gal, 5.28 US gal)
Fuel reserve amount 4.5 L (0.99 Imp gal, 1.19 US gal)
Carburetor:
Type / quantity BDSR38/4
Manufacturer MIKUNI
Spark plug:
Type DR8ENX24ESR-U
Manufacturer NGKINIPPONDENSO
Spark plug gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Clutch type: Wet, multiple-dlsc
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 68/41 (1.659)
Secondary reduction system Chain drive
Secondary reduction ratio 46/17 (2.706)
Transmission type , Constant mesh 5-speed
Operation Left foot operation
Gear ratio 1st 36/14 (2.571)
2nd 32/18 (1.778)
3rd 29/21 (1.381)
4th 27/23 (1,174)
5th 28/27 (1.037)
Chassis:
Frame type Diamond
Caster angle 24·
Trail 97 mm (3.82 in)
Tire:
Type Tubeless
Size front 120/70 ZR17
rear 180/55 ZR17
Manufacturer front BRI DGESTON E/DU N LOP
rear BRIDGESTONE/DUN LOP
Type front BT50F/D204FN
rear BT50R/D204M
Tire pressure (cold tire):
Maximum load-except motorcycle 196 kg (432 Ib) (YZF1000RJ)
195 kg (430 Ib) (YZF1000RJC) 2-2

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GEIllEAAl;SPECIFICATIONS ISPECI.,.,1

Model YZF 1 OOORJ/YZF 1 OOORJ C
0- 90 kg (0 - 198 Ib) load *
front 250 kPa (2.5 kg/cm2, 36 psi)
rear 250 kPa (2.5 kg/cm2, 36 psi)
90 kg (198Ib) - Maximum load *
front 290 kPa (2.9 kg/cm2, 41 psi)
rear 290 kPa (2.9 kg/cm2, 41 psi)
High-speed riding
front 290 kPa (2.9 kg/cm2, 41 psi)
rear 290 kPa (2.9 kg/cm2, 41 psi)
* Load is thetotaf weight of the cargo, rider,
passenger and accessories.
Brake:
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link suspension)
Shock absorber:
Front shock absorber Coil spring / Oil damper
Rear shock absorber Coil spring / Gas-oil damper
Wheel travel:
Front wheel travel 120 mm (4.7 in) '.
Rear wheel travel 120 mm (4.7 in)
Electrical:
Ignition system T.C.I. (Digital)
Generator system A.C. generator
Battery type YTX14-BS
Battery capacity 12 V 12 AH
Headlight type: Quartz bulb (Halogen)
Bulb wattage x quantity:
Headlight 12 V 35 W / 35 W x 2
Auxiliary light 12V5Wx 1
Tail/brake light 12V5W/21Wx2
Flasher light 12 V 27 Wx 2
Front flasher light 12 V 27 W / 8 W x 2
licence light 12V5Wx2
Meter light 12V1.7Wx4
Indicator light
Neutral indicator light 12 V 3.4 W x 1
Turn indicator light 12V3.4Wx1
Oil level indicator light 12V 3.4 Wx 1
High beam indicator light 12 V 3.4 W x 1
Fuel indicator light 12 V 3.4 W x 1 2 - 3.

MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS ENGINE

Model

YZF1000RJ/YZF1000RJC

Cylinder head:

Warp limit

*

0.10 mm (0.0039 in)

Cylinder:

Bore size Taper limit

Out of round limit

75.500 - 75.505 mm (2.9724 - 2.9726 in) 0.05 mm (0.002 in)

0.05 mm (0.0020 in)

Camshaft:

Drive method

Cam cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Cam cap inside diameter Shaft-to-cap clearance Cam dimensions

Chain drive (Center)

24.470 - 24.491 mm (0.9634 - 0.9642 in) 24.437 - 24.450 mm (0.9621 - 0.9626 in) 0.020 - 0.054 mm (0.0008 - 0.0021 in) 24.500 - 24.521 mm (0.9646 - 0.9654 in) 0.050 ... 0.084 mm (0.0020 - 0.0033 in)

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Intake IIA" 32.5 -32.6 mm (1.280 - 1.283 in) •
<limit> <32.4mm (1.276 in»
"B" 24.95 - 25.05 mm (0.982 - 0.986 in)
<limit> <24.85 mm (0.978 in»
"(:" 7.45 - 7.65 mm (0.293 - 0.301 in) •
Exhaust "A" 32.95 - 33.05 mm (1.297 - 1.301 in)
<limit> <32.85 mm (1.293 in»
"B" 24;95 - 25.05 mm (0.982 - 0.986 in)
<limit> <24.85 mm (0.978 in»
"(:" 7.75 - 7.95 mm (0.305 - 0.313 in) .~- 2-4

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MAINTENANCE SPECIFICATIONS ISPEcl 0-1

Model YZF1000RJ/VZF1000RJC
Camshaft runout limit 0.03 mm(0.0012 in)
~. ~ ~
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Cam chain:
Cam chain type / No. of links 219FTS/108
Cam chain adjustment method Automatic
Valve, valve seat, valve guide:
Valve clearance (cotd) IN 0.11 ..., 0.20 mm (0.004 ..., 0.008 in)
EX 0.21 ..., 0.30 mm (0.008 ..., 0.012 in)
Valve dimensions:
»; ~ ~ ~l.o.
I ~"B"
"-
F"A"===j I
Head Dia Face Width Seat Width Margin Thickness
"A" head diameter IN 23.4 ..., 23.6 mm (0.921 ..., 0.929 in)
EX 24.9 ..., 25.1 mm (0.980 ..., 0.988 in)
"8" face width IN 1.63 ..., 2.90 mm (0.064 ..., 0.114 in)
EX 1.63 ..., 2.90 mm (0.064 ..., 0.114 in)
"C" seat width IN 0.9 ..., 1.1 mm (0.035 ..., 0.043 in)
EX 0.9 ..., 1.1 mm (0.035 ..., 0.043 in)
"0" margin thickness IN 0.45..., 0.95 mm (0.018..., 0.037 in)
EX 0.75..., 1.25 mm (0.030 ..., 0.049 in)
Stem outside diameter IN 4.475..., 4.490 mm (0.1762 ..., 0.1768 in)
EX 4.460 ..., 4.475 mm (0.1756 ..., 0.1762 in)
<Limit> IN <4.445 mm (0.175 in»
EX <4.43 mm (0.174 in»
Guide inside diameter IN 4.500..., 4.512 mm (0.1772 ... 0.1776 in)
EX 4.500..., 4.512 mm (0.1772 ..., 0.1776 in)
<Limit> IN <4.55 mm (0.179 in»
EX <4.55 mm (0.179 in»
Stem-to-guide clearance IN 0.010..., 0.037 mm (0.0004..., 0.0015 in)
EX 0.025 ..., 0.052 mm (0.0010 ..., 0.0020 in)
<limit> IN <0.08 mm (0.003 in»
EX <0.1 mm (0.004 in» 2·5

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MAINTENANCE'SPl:OtFICATIONS jSPEcl ~ I

Model

•

YZF 1 OOORJIYZF 1 OOORJC

Stem runout limit

0.01 mm (0.0004 in)

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Valve seat width IN 0.9 - 1.1 mm (0.035 - 0.043 in)
EX 0.9 -1.1 mm (0.035 - 0.043 in) •
Valve spring:
Free length IN 40.73 mm (1.60 in)
EX 44.01 mm (1.73 in)
Set length (valve closed) IN 35 mm (1.4 in)
EX 35 mm (1.4 in)
Compressed pressure
(installed) IN 12.20 - 13.19 kg (26.90 - 29.09Ib)
EX 21 - 23 kg (46.30 - 50.71 Ib)
lilt limit IN 2.5°/1.7 mm (2.5"/0.067 in)
EX 2.5°/1.7 mm (2.5%.067 in) Direction of winding (top view)

IN

E:X Clockwise

Clockwise

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Piston:

Piston to cylinder clearance <Limit>

Piston size "0"

---- ---jJH

0--1 ,

0.06 - 0.08 mm (0.0024 - 0.0031 in) <0.1 mm (0.0039 in»

75.425 - 75.440 mm (2.969 - 2.970 in)

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3 mm (0.118 in)

Measuring point "H"

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_________ M_A_W_T_E_N_A_~_~_··_~_K_.·-F-.~-A-T-IO-N-S-~~c~~1

Model

YZF1000RJfYZF1000RJC

Piston off-set

Piston off-set direction

Piston pin bore inside diameter Piston pin outside diameter

0.5 mm (0.02 in) IN side

19.004 ... 19.015 mm (0.7482 - 0.7486 in) 18.991 - 19.000 mm (0.7477 - 0.7480 in)

Piston rings:

Top ring:

Type

Dimensions (B x T) End gap (installed)

Side clearance (installed) 2nd ring:

Type

Dimensions (B x T) End gap (installed) Side clearance

Oil ring:

Dimensions (B x T) End gap (installed)

I '\]B I. T .1

~]B

I. T .1

Barrel

0.8 x 2.8 mm (0.031 x 0.110 in) 0.3 ... 0.5 mm (0.012 ... 0.020 in) 0.03 ... 0.07 mm (0.001 - 0.003 in)

Taper

0.8 x 2.8 mm (0.031 x 0.110 in) 0.3 ... 0.5 mm (0.012 ... 0.020 in) 0.02 ... 0.06 mm (0.001 - 0.002 in)

1.5 x 2.5 mm (0.059 x 0.098 in) 0.2 -0.8 mm (0.008 ... 0.031 in)

Connecting rod:

Oil clearance

Color code (corresponding size)

0.032 - 0.056 mm (0.001 ... 0.002 in) CD Blue ® Black ® Brown @ Green

c c C

r- r- r- r-

Crankshaft:

Crank width II A" Assembly width "B" Runout limit "C"

Big end side clearance "0"

55.7 - 59.5 mm (2.193 ... 2.343 in) 339.8 - 340.2 mm (13.378 - 13.394 in) 0.03 mm (0.0012 in)

0.160 - 0.262 mm (0.006 ... 0.010 in)

MAINTEIllANCESPECIFICATIONS ISPECI ~ I

Model YZF1000RJ/yZF1000RJC
Journal oil clearance "E" 0.020 - 0.044 mm (0.0008 - 0~00171n)
Color code (corresponding size) G) Blue ® Black ® Brown@ Green ® Yellow
Clutch:
Friction plate thickness 2.9 - 3.1 mm (0.114 - 0.122 in)
Quantity 9
Friction plate wear limit 2.8 mm (0.11 in)
Clutch plate thickness 1.9 - 2.1 mm (0.075 - 0.083 in)
Quantity 8
Warp limit 0.1 mm (0.004 in)
Clutch spring free length 50 mm (1.97 in)
Quantity 6
Minimum length 48 mm (1.89 in)
Clutch release method Hydraulic inner push
Transmission:
Main axle deflection limit 0.08 mm (0.003 in)
Drive axle deflection limit 0.08 mm(0.003 in)
Shifter:
Shifter type Guide bar
Guide bar bending limit 0.1 mm (0.004 in)
Carburetor:
I. D. mark 4YW 00 (YZF1000RJ)
4YW 10 (YZF1000RJC)
Main jet (M.J) #1,4:#127.5:#2,3:#125
Main air jet (M.A.J) #1,4:#60:#2,3:#45
Jet needle ( .. I.N) 6DJP15~53
"
Needle jet (N.J) P~O
Pilot air jet W.A.J.1) #122.5
Pilot outlet (F~O) 1.0
Pilot jet WJ) #17.5
Bypass 1 (B.P.1) 0.8
Bypass 2 (B.P.2) 0.8
Bypass 3 (B.P.3) 0.8
Valve seat size (V.S) 1.5
Starter jet (G.S.1) #30
Starter jet (G.S.2) 0.8
Throttle valve size (Th.V) #105
Fuel level 4.1 - 5.1 mm (0.16 - 0.20 in)
IDLING CONDITION: .
Engine idle speed 1,850 - 1; 15Q r/min
Intake vacuum 20.3 - 30.7 (190 - 230 mm Hg, 7.48 - 9.055 in
Hg) 2-8

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MAINTENANCE SPECIFICATIONS I SPEC! u-!

Model YZF1000RJ/YZF1000RJC
CO% 3.0 - 4.0%
Water temperature 80 - 85°C (176 - 185°F)
Oil temperature 65 - 70°C (149 - 158·F)
Fuel pump:
Type Electrical type
Model/manufacturer 4SV/MITSUBISHI
Consumption amperage <max> 1.2 A
Output pressure 20 kPa (0.2 kg/cm2, 2.8 psi)
Lubrication system:
Oil filter type Paper type
Oil pump type Trochoid type
lip clearance" A" or "B" 0.09 - 0.15 mm (0.004 - 0.006 in)
Side clearance 0.03 - 0.08 mm (0.001 - 0.003 in)
Bypass valve setting pressure 181 - 220 kPa (1.81 - 2.20 kg/cm2, 25.74 -
31.29 psi)
Relief valve operating pressure 370 - 460 kPa (3.70 - 4.60 kg/cm2, 52.63 -
65.43 psi)
Oil pressure (hot) 88 kPa (0.88 kg/cm2, 12.25 psi) at 1,100r/rnin
Cooling system:
Radiator core size
Width 318 mm (12.52 in)
Height 380 mm (14.96 in)
Thickness 24 mm (0.94 in)
Radiator cap opening pressure 95 - 125 kPa (0.95 - 1.25 kg/cm2, 13.51 -
17.78 psi)
Reservoir tank capacity 0.23 L (0.20 Imp qt, 0.24 US qt)
Water pump
Type Single suction centrifugal pump
Reduction ratio 68/41 x 41/43 (1.581) 2-9

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MAINTENANC6SPECIFICATIONS ISPECI ~ I

Model

YZF1000RJ/YZF1000RJC

Lubrication chart:

~ Pressure feed

• Splashed

Timing chain area

Drive axle

Crankcase tightening sequence:

Crankcase (Upper)

Crankcase (Lower)

* : 9 mm Bolt: 32 Nm (3.2 m • kg, 23 ft· Ib) x : 8 mm Bolt: 24 Nm (2.4 m • kg, 17 ft • Ib) 6.: 6 mm Bolt: 12 Nm (1.2 m· kg, 8.7 ft -{b)

2 - 10

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MAINTENANCE SPECIFICATIONS

• lightening torques

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Part to be tightened Part name Thread size Q'ty lightening torque Remarks
Nm m·kg ft·lb
Spark plug - M12 4 18 1.8 13
Cylinder head Nut M10 12 41 4.1 30 -G
---
Camshaft cap Bolt M6 40 10 1.0 7.2
Cylinder head cover Bolt M6 8 10 1.0 7.2
Cylinder head (exhaust pipe) Stud bolt M8 8 15 1.5 11 -G
Connecting rod Nut M8 36 36 3.6 25 .....
Timing chain tensioner end Cap bolt M11 1 20 2.0 14
Camshaft sprocket Bolt M7 4 24 2.4 17
Timing chain guide Bolt M6 2 10 1.0 7.2
Water pump inlet pipe Bolt M6 1 10 ,1.0 7.2
Radiator stay Bolt M6 2 10 1.0 7.2
Oil cooler Bolt M20 1 63 6.3 45 -G
Engine oil drain bolt - M14 1 43 4.3 31
Oil plug plate (spray nozzle) Bolt M6 1 10 1.0 7.2
Baffle plate (lower crankcase) Bolt M6 10 10 1.0 7.2
Baffle p-Iate (oil pan) Bolt M6 4 10 1.0 7.2
Oil filter <, - M20 1 17 1.7 12 -G
Exhaust pipe Nut M8 1 20 2.0 14
Exhaust pipe and muffler Bolt M8 3 20 2.0 14
Exup cover Bolt M6 3 10 1.0 7.2
Exup cable holder Bolt M6 3 10 1.0 7.2
Exhaust pipe and stay Bolt M8 1 20 2.0 14
Crankcase (cylinder head) Stud bolt M10 12 10 1.0 7.2 -G
Crankcase Bolt M9 11 32 3.2 23 -G
Crankcase Bolt M8 17 24 2.4 17 -G
Crankcase Bolt M6 7 12 1.2 8.7 ~
Crankshaft end cover Bolt M6 6 7 0.7 5.1 ~
Bearing retainer (main axle) Bolt M6 3 10 1.0 7.2
Breather cover (clutch cover) Bolt M6 4 7 0.7 5.1
Breather cover (clutch cover) Bolt M6 2- 7 0.7 5.1 ~
liming plug - M14 1 7 0.7 5.1
Main gallery plug - M20 2 12 1.2 8.7
HY-VO chain guide Bolt ~: I 2 10 1.0 7.2
Starter clutch Bolt 3 25 2.5 18
Clutch boss Nut M20 1 70 7.0 50 Use lock washer
Clutch spring Bolt M6 6 8 0.8 5.8 4
Drive sprocket Nut M18 1 80 8.0 58 Use lock-washer
Stopper plate· Bolt M6 2 10 1.0 7.2
Shift pedal adjuster Nut M6 2 10 1.0 7.2 1 of 2 has LH
thread
. ~ M5 4 0.4 2.9
Shift cam stopper bolt - 1
AC generator Bolt M8 3 25 2.5 18
Ignitor unit Bolt M6 1 10 1.0 7.2 2 - 11

MAINTENANCE SPECiFICATIONS ISPECI~ I

Part to be tightened Part name Thread size O'tv Tightening torque Remarks
Nm rn-kq ft-lb
GPS (gear position switch) Bolt M6 2 4 0.4 2.9
Thermo unit _. - 1 15 1.5 11
Thermo switch M16 1 23 2.3 17
Servo motor Bolt M6 2 10 1.0 7.2 2 - 12

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MAINTENANCE SPECIFICATIONS ISPEC,!.,..I

CHASSIS

Model YZF1000RJ/yZF1000RJC
Steering system:
Steering bearing type Ball bearing
Front suspension:
Front fork travel 120 mm (4.72 in)
Fork spring free length 297 mm (11.7 in)
Fitting length 270 mm (10.63 in)
Spring rate (K1 ) 80.0 N/mm (8 kg/mm 448.0 Ib/in)
Stroke (K1) 0 ... 120 mm (0.00 ... 4.72 in)
Optional spring No
Oil capacity 590 ern" (20.8Impoz, 19.9 US oz)
Oil level 123 mm (4.84 in)
Oil grade Suspension oil "01" or equivalent
Rear suspension:
Shock absorber travel 65 mm (2.56 in)
Spring free length 196 mm (7.72 in)
Fitting length 184 mm (7.24 in)
Spring rate (K1) 88.3 N/mm (8.83 kg/mrtl 494 Ib/in)
Stroke (K1 ) o ... 65 mm (0.00 ... 2.56 in)
Optional spring No
Enclosed gas / air pressure (STD) 1,200 kPa (12 kg/cm2, 170 psi)
Swingarm:
Free play limit end 1 mm (0.04 in)
side 1 mm (0.04 in)
Front wheel:
Type Cast wheel
Rim size 17 x MT3.50
Rim material Aluminum
Rim runout limit radial 1 mm (0.04 in)
lateral 0.5 mm (0.02 in)
Rear wheel:
Type Cast wheel
Rim size 17 x MT5.50 \
Rim material Aluminum
Rim runout limit radial 1 mm (0.04 in)
lateral 0.5 mm (0.02 in)
Drive chain:
Type / manufacturer 532ZLV KAI/DAIDO
No. of links 110
Chain free play 20 ... 35 mm (0.8 ... 1.4 in)
Front disc brake:
Type Dual
Disc outside diameter x thickness 298 x 5 mm (11.7 x 0.20 in) 2 - 13

.. ~

MAINTENANCE SPECIFICATIONS ISPECI 0-1

Model

Disc deflection limit Pad thickness <Limit>

Pad thickness <Limit>

inner

outer

*

Master cylinder inside diameter Caliper cylinder inside diameter Caliper cylinder inside diameter Brake fluid type

Rear disc brake:

Type--

Disc outside diameter x thickness Disc deflection limit

Pad thickness inner

<Limit>

Pad thickness

outer

<Limit>

*

Master cylinder inside diameter Caliper cylinder inside diameter Brake fluid type

Clutch:

Master cylinder inside diameter Release cylinder inside diameter Brake fluid type

Brake lever & brake pedal:

Brake pedal position

Clutch lever free play (at lever end) Throttle cable free play

YZF1000RJ/YZF1000RJC

0.1 mm (0.004 in) 5 mm (0.20 in) <0.5 mm (0.02 in» 5 rnrn (0.20 in) <0.5 mm (0.02 in»

14 mm (0.55 in) 30.2 mm (1.19 in) 27 mm (1.06 in) DOT 4

Single

245 x 5 mm (9.6 x 0.20 in) 0.15 mrn (0.01 in)

5.5 mm (0.22 in)

<0.5 mm (0.02 in»

5.5 mm (0.22 in)

<0.5 mm (0.02 in»

14 mm (0.55 in) 42.8 mm (1.69 in) DOT 4

15.87 rnm (0.62 in) 38.1 mm (1.50 in) DOT 4

50 mm (1.97 in)

10 - 15 mm (0.39 - 0.59 in) 3 -7mm (0.12 - 0.28 in)

2 - 14

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MAINTENANCE SPECIFICATIONS IS~ECI &:r-" I

• lightening torques

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Part to be tightened Thread size lightening torque Remarks
Nm m-kq ft-lb
Upper bracket and inner tube MB 26 2.6 19
Upper bracket and steering shaft M22 110 11.0 BO
Handlebar boss and inner tube MB 17 1.7 12
Ring nut (steering shaft) M25 16 1.6 11 See NOTE
Inner tube and. lower bracket MB 23 2.3 17
Union bolt (brake hose) M10 30 3.0 22
Master cylinder (front brake) M6 13 1.3 9.4
Union bolt (clutch hose) M10 30 3.0 22
Engine mounting:
Mounting bolt (front) M10 40 4.0 29
Mounting bolt (rear upper) M10 50 5.0 36
Mounting bolt (rear lower) M10 50 5.0 36
Pinch bolt (front) MB 22 2.2 16
Pinch bolt (rear upper) MB 15 1.5 11
Exhaust pipe bracket M10 36 3.6 25
Swingarm pivot shaft nut M1B 125 1Q.5 90
Relay arm and frame M10 4B 4.B 35
Relay arm and connecting rod M10 4B 4.B 35
Connecting rod and swingarm M10 4B 4.B 35
Rear shock absorber and relay arm M10 40 4.0 29
Rear shock absorber and frame M10 40 4.0 29
Fuel cock and fuel tank M6 7 0.7 5.1
Fuel sender and fuel tank M6 7 0.7 5.1
Fuel tank (front) M6 10 1.0 7.2
Fuel tank (rear) M6 10 1.0 7.2
Rider footrest bracket and frame MB 2B 2.B 20
Passenger footrest and frame MB 2B 2.B 20
Sidestand bracket and frame MB 43 4.3 31
Front wheel axle M18 70 7.0 50
Rear wheel axle M24 150 15.0 110
Front brake caliper and front fork M10 40 4.0 29
Rear brake caliper and bracket M10 40 4.0 29
Brake disc and wheel MB 23 2.3 17
Driven sprocket and clutch hub M10 60 6.0 43
Tension bar MB 30 3.0 22
Brake caliper and bleed screw MB 6 0.6 43
Pinch bolt (front wheel axle) MB 23 2.3 17 2 - 15

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_________________ M_A_I_N_T_EN_A_N_C_E_S_P_E_C_IF_IC_A_T_IO_N_S_ISPECI ~I

~: •

[Link], tighten the ring nut approximately 48 Nm(4.8'hl· kg, 35 ft· Ib) with a torque wrench,

then loosen the ring nut completely.

[Link] the ring nut to specification.

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MAINTENANCE SPECIFICATIONS ISPECI u-I

ELECTRICAL

Model YZF1000RJ/YZF1000RJC
Voltage: 12 V
Ignition system:
Ignition timing (B.T.D.C.) 5° at 1,100 r/min
T.C.I.:
Pickup coil resistance I color 135 - 165 o at 20°C (68°F) I Gray - Orange
T.C.I. unit model I manufacturer TNDF39/N I PPON DEN SO
Ignition coil:
Model I manufacturer J0313/NIPPONDENSO
Minimum spark gap 6 mm (0.24 in)
Primary winding resistance 1.9 - 2.5 n at 20°C (68°F)
Secondary winding resistance 12 - 18 kn at 20°C (68°F)
Spark plug cap:
Type Resin type
Resistance 10 kn
Charging system:
Type A.C. generator
Model I manufacturer B3G/NIPPONDENSO
Nominal output 12 V 28 A at 5,000 r/min
Field coil resistance 2.8 - 3.0 0 at 20°C (68°F)
Armature coil resistance 0.19 - 0.21 n at 20°C (68°F)
Brush overall length 13.7 mm (0.54 in)
<Wear limit> <4.7 mm (0.19 in»
Spring force 5.10 - 5.69 g (0.2 - 0.2 oz)
Voltage regulator:
Type Semi-conductor, field control type
No load regulated voltage 14.2 - 14.8 V
Electric starter system:
Type Constant mesh type
Starter motor:
Model I manufacturer SM-13/MITSUBA
Output 0.7 kW
Brush overall length 12.5 mm (0.49 in)
<Limit> <4 mm (0.16 in»
Spring force 6.67 - 9.02 g (0.2 - 0.3 oz)
Commutator diameter 28 mm (1.10 in)
<Wear limit> <27 mm (1.06 in»
Mica undercut 0.7 mm (0.03 in)
Starter relay:
Model I manufacturer MS5F/JIDECO
Amperage rating 100 A 2 - 17

MAINTENANCE SPECIFICATIONS ISPECI c;,-I

Model YZF1000RJ/YZF1000RJC
Horn:
Type Plane type
Quantity 1
Model/manufacturer YF~ 12/N I KKO
Maximum amperage 2.5A
Flasher relay:
Type Full transistor type
Model/manufacturer FE246BH/N I PPON DEN SO
Self cancelling device No
Flasher frequency 75 - 95 cycle/min
Wattage 21 Wx 2 + 3.4 W
Oil level switch:
Model/manufacturer 3GM/NIPPONDENSO
Fuel pump relay:
Model/manufacturer 3EN-00/OMRON
Thermostatic switch:
Model/manufacturer 2ElINIHON THERMOSTAT
Thermo unit:
Model/manufacturer 11H/NIPPON SEIKI
Circuit breaker:
Type Fuse
Amperage for individual circuit
MAIN 30 Ax 1
HEAD 20 Ax 1
SIGNAL 15 Ax 1
IGNITION 15 A x 1
FAN 7.5 Ax 2
. Reserve 30Ax 1
Reserve 20 Ax 1
Reserve 15 A x 1
Reserve 7.5 A x 1 2 - 18

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EB202001

GENERAL TORQUE

SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.0. pitch threads. Torque specifications for special components or assemblies are provided for each chapter of this manual. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until the specified torque is reached. Unless otherwise specified, torque specifications require clean, dry threads. Components should be at room temperature.

HOW TO USE THE CONVERSION TABLE/ I I I

GENERAL TORQUE SPECIFICATIONS :SPEC ~

EB201000

HOW TO USE THE CONVERSION

TABLE

All specification data in this manual are listed in SI and METRIC UNITS.

Use this table to convert METRIC unit data to IMPERIAL unit data.

Ex.

METRIC

** mm x 2mm x

MULTIPLIER 0.03937

=

** in

IMPERIAL

0.03937

0.08 in

A: Distance between flats B: Outside thread diameter

A B General torque
specifications
(nut) (bolt)
Nm rn-kq ft-lb
10mm 6mm 6 0.6 4.3
12mm 8mm 15 1.5 11
14mm 10mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19mm 14mm 85 8.5 61
22mm 16mm 130 13.0 94 2 - 19

CONVERSION TABLE

METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
rn-kq 7.233 ft-lb
Torque m·kg 86.794 in-lb
cm-kq 0.0723 ft-lb
cm-kq 0.8679 in-lb
Weight kg 2.205 Ib
g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance m 1.094 yd
cm 0.3937 in
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP liq.)
Volume/ cc (cm3) 0.06102 cu-in
Capacity It (liter) 0.8799 qt (IMP liq.)
It (liter) 0.2199 gal (IMP liq.)
kg/mm 55.997 lb/in
Misc. kg/cm2 14.2234 psi (lb/in2)
Centigrade
rc: 9/5+32 Fahrenheit rF) ___ L_U_B_R_IC_A_T_~_N_ro_IN_T_S_A_N_D_L_U_B_R_IC_A_N_T_n_p_E_s_ls~cl~1

EB203000

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrlcatlon Point Symbol
Oil seal lips ~
a-ring ~
Bearing ~
Piston surface ~
Piston pin ~
Connecting rod bearings ~
Crankshaft journal ~
Connecting rod bolt/nut ~
Camshaft cam lobe ~
Valve stem (IN, EX) ~
Valve stem end (IN, EX) ~
Water pump impeller shaft ~
Oil pump rotor (inner/outer), housing ~
Oil strainer assembly ~
Idle gear inner surface ~
Starter clutch outer assembly ~
Primary driven gear ~
Starter clutch ball ~
Transmission gear (wheel/pinion) ~
Axle (main/drive) ~
Shift cam ~
Shift fork/guide bar ~
Shift shaft assembly ~
Shift pedal ~ 2 - 20

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LUBRICATION POINTS AND LUBRICANT TYPES ISPECI 0-1

EB203010

CHASSIS

Lubrication Point Symbol
Steering bearing and bearing race (upper/lower) ......
Front wheel oil seal (right/left) ...
Rear wheel oil seal ...
Clutch hub oil seal ...
Clutch hub fitting area ......
Rear brake pedal shaft ......
Shift pedal ......
Sidestand sliding surface .....
Tube guide (throttle grip) inner surface ......
Brake lever pivot bolt, contact surface .....
Clutch lever pivot bolt, contact surface .....
Rear shock absorber (upper/lower) .....
Pivot shaft .....
Connecting rod bearing (on the swingarm) .....
Thrust cover (inner) .....
Relay arm bearing (inner) .....
Relay arm oil seal .....
Rear footrest pivot .....
Luggage strap holder pivot ...... 2 - 21

•. , . C~ . .- . .'

':~:bTn1rfwt~_bi;-:+~i~~~*:?~-~tt4r'~jf~~~S,£c~lf~;-:~f+:J;;;£k'~--~-~~~;'~~~r~:""

COOLING SYSTEM DIAGRAMS ISPECI u-I

EB204000

COOLING SYSTEM DIAGRAMS

CD Radiator ®Fan

@ Thermostatic valve housing @ Coolant reservoir

®Water pump

® Drain bolt (water pump)

8-8

4

2 - 22

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COOLING SYSTEM DIAGRAMS ISPECI ~ I

CD Radiator cap ® Radiator ®Fan

@ Thermostatic valve housing

4

2 - 23

<D Thermostatic valve housing ® Thermostatic valve

@ Radiator cap

COOLING SYSTEM DIAGRAMS ISPECI ~ I

2 - 24

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LUBRICATION DIAGRAMS ISPECI 0-1

EB206000

LUBRICATION DIAGRAMS

<D Oil delivery pipe

® Intake camshaft

@ Exhaust camshaft

@Oilfilter

® Relief valve ® Oil strainer (j) Oil pump

2 - 25

LUBRICATION DIAGRAMS ISPECI ~ I

<D Timing chain guide (upper) ® Timing chain

® Timing chain guide (intake side) @ Timing chain tensioner

® Main axle

® Oil delivery pipe #1

<V Timing chain guide (exhaust side)

2 - 26

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LUBRICATION DIAGRAMS ISPECI ~ I

CD Timing plug

® Crankshaft end cover (left) ® Crankshaft

@ Crankshaft end cover (right) ® Main axle

® Oil delivery pipe #5 (J) Drive axle

2 - 27

LUBRICATION DIAGRAMS ISPECI ~ I

<D Oil delivery pipe

® Oil delivery pipe #3 @ Oil jet nozzle

[Link] journal bearing (upper crankcase) ® Oil delivery pipe #2

® Oil delivery pipe #1

(J) Starter clutch shaft

® Oil spray nozzle

4

2 - 28

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CABLE ROUTING ISPECI ~ I

EB206000

CABLE ROUTING

<D Throttle cable

® Clutch switch lead

® Handlebar switch lead (left) @ Clutch hose

®Horn

® Front brake hose

(J) Handlebar switch lead (right) ® Fan motor lead

[lg Pass the throttle cables through the wire guide.

lID Use a plastic band to fasten the handlebar switch lead (left) to the left front fork inner tube.

© Use a plastic band to fasten the handlebar switch lead (right) to the right front fork inner tube.

[QJ Connect the right handlebar switch lead coupler to the wire harness and pull the rubber cover over the connectors.

lliJ Pass the throttle cables between the frame and the ignitiM coil plate.

@70-90mm

E

8

0000

2 - 29

<D Coolant reservoir

® Coolant reservoir breather hose @ Fuel tank overflow hose

@ Air filter case breather hose ® Handlebar switch lead (right) ® Thermo switch

(j) Thermo unit

® Ground lead

®EXUP motor

@) Ground lead (battery) @ Coolant reservoir hose

CABLE ROUTING ISPECI 0-1

@ Rollover hose (for 0)

A

2 - 30

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@ Use a plastic guide to fasten the coolant reservoir hose and coolant reservoir breather hose on the brake reservoir.

lID Pass the coolant reservoir hose, coolant reservoir breather hose and battery ground lead through the plastic clamp.

@ Use a metal guide to fasten the right handlebar switch lead.

(QJ Be sure there is no slack in the fan motor lead in front of the radiator.

CABLE ROUTING ISPECI 0-1

II} Use a plastic band to fasten the radiator sub lead and wire harness, then insert the projection on the plastic band into the hole in the ignition coil plate. Be sure the end of the plastic band faces outward.

!£] Coolant reservoir breather hose: 40 ._ 60 mm [QJ Other hose(s): max. 30 mm

A

2 - 31

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[HJ~





~ 9

A B C • CD Main fuse ® Starter relay

@ Sidestand switch

@ GPS (gear position switch) lead ® Pickup coil lead

® Oil level switch relay (j) Ignitor unit

® Flasher relay

® Relay assembly

@) Air filter case breather hose @ Fuel tank overflow hose

CABLE ROUTING ISPECI 0-1

@ Coolant reservoir breather hose @ Rollover hose (for 0) @EXUPcable

2 - 32

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~ Fasten the clutch hose, starter cable, left handlebar switch lead and main switch lead with the metal guides; the items should be installed in the order listed with the first item on top.

lID Place the couplers on top of the ignition coil plate.

19 Install the wire harness, starter cable and clutch cable in the order listed with the first item on top.

CABLE ROUTING ISPECI ~ I

[Q) Use a plastic clamp to fasten the wire harness at the position marked with white tape.

III Pass the seat lock cable under the wire harness. [§] Use a plastic band to fasten the meter lead, headlight sub lead, fan motor lead, main switch lead and left handlebar switch lead, then insert the hook on the plastic band into the hole in the ignition coil plate.

IBl Front

------ ..

~ .. ~ \.

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7

6

9

A

B

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2 - 33

<D Rear brake switch lead ® Battery e lead

@ Battery ® lead

@ Sidestand switch lead

CABLE ROUTING ISPECI ~ I

119 Use a plastic band to fasten the starter motor lead, AC generator lead, GPS (gear position switch) lead, sidestand switch lead and pickup coil lead. Fold the AC generator lead so that there is no slack in it.

@] Be sure the wire harness does not contact the EXUP servo motor. @ Pass the EXUP cables over the ground lead and then pass the other leads and hose over the ~XUP cables.

[Q] Pull the rubber covers over the EXUP servo motor coupler, rear brake switch coupler, GPS (gear position switch) coupler and pickup coil coupler, then insert them between the EXUP cables and the starter motor.

2 - 34

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CABLE ROUTING ISPEcl 0-1

II! Use a plastic band to fasten the ground lead, coolant reservoir hose and rear brake switch lead.

[£] Use a plastic locking tie to fasten the wire harness to the frame, then cut off the excess locking tie.

[Q] Pass the air filter case breather hose and fuel tank overflow hose over the fuel pump, then pass the wire harness under the fuel pump.

2 - 35

EMISSION HOSE ROUTING ISPECI ~ I EMISSION HOSE ROUTING (California only)

CD Canister ass'y ® Fuel tank

® Roll over valve assembly

@ Hose (canister-roll over valve) ®Clip

® Hose (Roll over valve-fuel tank)

(j) Hose (Canister-joint) ®Joint

® Hose (joint-carburetor)

@) Hose (Canister-atmosphere)

A

2 - 36

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EMISSION HOSE ROUTING ISPECI 0-1

~ The ends of the metal clip should face down. @) The ends of the metal clip should face in.

[g Pass the hose (canister-atmosphere) under oil delivery pipe #2

[QJ Attach the hose (Canister-roll over valve) to the lower pipe on the canister. The white paint mark on the hose should face up.

A

2 - 37

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INTRODUCTION/PERIODIC MAINTENANCE/ IINSP I to) I EMISSION CONTROL SYSTEM ADJ ~

a...:....:.::;..;:;-... =."

PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION

EB300000

This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a longer service life. The need for costly overhaul work will be greatly reduced. 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.

EB30'OOO

PERIODIC MAINTENANCE/EMISSION CONTROL SYSTEM

INITIAL ODOMETER READINGS
1,000 km 7,000km 13,000 km 19,000 km 25,000km 31,000km
NO. ITEM REMARKS (600 mil (4,400 mil (8,200 mil (12,000 mil (15,800 mil (19,600 mil
or or or or or or
1 month 7 months 13 months 19 months 25 months 31 months
1 * Valve clearance • Check and adjust valve clearance Every 42,000 km (26,600 mil
when engine is cold.
• Check condition.
• Adjust gap and clean.
2 Spark plugs • Replace at 13,000 km (or 13 0 Replace 0 Replace 0
months) and thereafter every
12,000 km (or 12 months).
Crankcase venti- • Check ventilation hose for cracks
3 * lation system or damage. 0 0 0 0 0
• Replace if necessary.
• Check fuel hose for cracks or
4 • Fuel line damage. 0 0 0 0 0
• Replace if necessary.
• Replace initial 31,000 km (19,600
5 * Fuel filter mil and thereafter every 30,000 Replace
km (19,000 mil.
• Check for leakage.
6 * Exhaust system • Retighten if necessary. 0 0 0 0 0
• Replace gasket(s) if necessary.
7 * Carburetor Syn- • Adjust svnchronlzation of carbu- 0 0 0 0 0 0
chronization retors.
• Check and adjust engine idle
8 * Idle speed speed. 0 0 0 0 0
• Adjust cable free play.
Evaporative • Check control system for dam-
emission control
9 * system (For Cali- age. 0 0
fornia only) • Replace if necessary. Items marked with an asterisk (*) require special tools, data and technical skills for servicing.

NOTE:

For odometer readings or time periods higher than 31,000 km (19,600 mi) or 31 months repeat the same maintenance as listed in the table from the 7,000 km (4,400 mi) or 7 months every 6,000 km (3,800 mi) or 6 month interval.

3 - 1

GENERAL MAINTENANCE/LUBRICATION

GENERAL MAINTENANCE/LUBRICATION

INITIAL ODOMETER READINGS
1,000 km 7,000 km 13,000 km 19,000 km 25,000 km 31,000km
NO. ITEM REMARKS (600mi) (4,400 mil (8,200 mil (12,000 mil (15,800 mil (19,600 mil
or or or or or or
1 month 7 months 13 months 19 months 25 months 31 month.
1 Engine oil • Replace (Warm engine before 0 0 0 0 0 0
draining). (See NOTE)
• Replace at 1,000 km (600 mil or 1
2 Engine oil filter month, and thereafter every 0 0 0
* 12,000 km (7,600 mil or 12
months.
3 * Air filter • Clean with compressed air. 0 0 0 0 0
• Replace if necessary.
• Check hose for cracks or dam-
age. 0 0 0 0 0
4 * ~ooling system • Replace if necessary.
• Replace coolant every 24 Replace
months.
• Check operation, pad wear, and
5 * Brake system fluid leakage. (See NOTE) 0 0 0 0 0 0
• Correct if necessary.
• Check operation and fluid leak-
6 * Clutch age (See NOTE) 0 0 0 0 0 0
• Correct if necessary.
7 * Control and • Apply chain lube thoroughly. 0 0 0 0 0 0
meter cable
• Check bearing assembly for
8 • Swing arm pivot looseness. 0 0
bearing o Moderately repack every 24,000 Repack
km (15,200 mil or 24 months.
Rear suspension • Check operation.
9 * • Apply grease lightly every 24,000 0 0
link pivots km (15,200 mil or 24 months.
10 * Rear shock • Check operation and oil leakage. 0 0 0 0 0
absorber • Replace if necessary.
11 * Front fork • Check operation and leakage. 0 0 0 0 0
• Replace if necessary.
• Check bearing assembly for
12 * Steering bear- looseness. 0 0 0 0 0
ings • Moderately repack every 24,000 Repack
km (15,200 mil.
13 Brake/Clutch o Apply chain lube lightly. 0 0 0 0 0
lever pivot shaft
14 Brake pedal and o Apply chain lube lightly. 0 0 0 0 0
shift pedal shafts
o Check chain slack/alignment con
15 * Drive chain dition. Every 1,000 km 1600 mil
o Adjust and lubricate chain thor-
oughly.
16 • Wheel bearings • Check bearing for smooth rota- 0 0 0 0 0
tion.
17* Sidestand pivot • Check operation and lubricate. 0 0 0 0 0
• Apply chain lube lightly.
18 * Sidestand switch o Check and clean or replace if 0 0 0 0 0 0
necessary.
• Check all chassis fittin!~s and fas-
19 * Chassis fasteners teners. 0 0 0 0 0
• Correct it necessary. Items marked with an asterisk (*) require special tools, data and technical skills for servicing. 3-2

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GENERAL MAINTENANCE/LUBRICA nON II~gs I_I

NOTE: -----

• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

• For odometer readings or time periods higher than 31,000 km (19,600 mi) or 31 months repeat the same maintenance as listed in the table from the 7,000 km (4,400 mi) or 7 months

every 6,000 km (3,800 mi) or 6 month interval. '

• Brake fluid replacement:

[Link] disassembling the master cylinder or caliper cylinder, replace the brake fluid.

Normally check the brake fluid level and add the fluid as required.

2.0n the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.

[Link] the brake hoses every four years, or if cracked or damaged. • Engine oil type:

YAMALUBE 4 (20W40) or SAE 20W40 type "SE" motor oil for temperatures 5°C (40°F) OJ above.

YAMALUBE 4 (10W30) or SAE 10W30 type "SE" motor oil for temperatures 15°C (600~) or below.

3·3

COWLINGS II:gs I_I

EB30ZQ03

COWLINGS

CD Windshield

® Rear view mirror @ t,Jpper cowling

~ g~:::ng stay (upper) ng stay (lower)

~ S~de panel (right) \U SIde panel (left)

2

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IINSPI_I

COWLINGS AD~

----~I-·-g-(r~ig:ht~)----------------------;:~------

<D Side cow In ft)

~ Side cowling. (Ie \6J cowling

® Bottom ling (front)

@Bottomcow

COWLINGS I':gs I_I

;:========================~-:R:EM:=O~VA~L~------- [Link]:

• Bottom cowling (front) CD

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[Link]:

• Bottom cowling CD

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[Link]:

• Speedometer cable CD

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[Link]

• Side cowlings (left and right) CD [Link]

• Front flasher light leads (left and right)

NOTE: ----

Remove the speedometer cable from the •

guide on the inside of the left cowling.

[Link]: •

• Rear view mirrors (left and right) CD

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COWLINGS I':g! 1.1

~====~====~~~~---

[Link]:

• Screws (left and right) CD

(on the instrument panel cover)

8. Disconnect:

• Meter assembly coupler CD

• Headlight/front flasher lights coupler ®

NOTE: ___

The arrow on the rubber dampers face towards the front of the motorcycle.

[Link]:

• Nuts (front cowltng stay) CD

[Link]:

• Front cowling assembly <D

INSTALLATION

Reverse the "REMOVAL" procedure.

3-7

EB302001

SEATS

REMOVAL [Link]:

• RIder seat CD

NOTE: _

Insert the key into the helmet lock and turn •

the key to the left.

__________________________ SE_A_T_S l~g!I~1

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[Link]:

• Passenger seat CD

•

NOTE: _

Lift up the passenger seat and pull it forward.

INSTALLATION

Reverse the "REMOvAL" procedure. Note the following points.

[Link]]:

• Passenger seat

NOTE: __

When installing the passenger seat, insert the projection CD on the back of the seat into the receptacle @ on the frame. Then slide the projections ® on the front of the seat into the receptacles @ on the frame and push down the front of the seat.

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[Link]:

• Rider seat

•

NOTE: __

When installing the rider seat, insert the projection on the front of the seat into the receptacle on the frame and then push down the seat end.

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________________________ FU_E_L_TA_N_K_I':gS~~1

EB302002

FUEL TANK

REMOVAL [Link]:

• Rider seat

• Passenger seat Refer to "SEATS".

[Link]:

• Side panels (left and right) <D

[Link]:

• Bolt <D

• Bolt®

[Link] the fuel cock to "OFF".

[Link]:

• Fuel sender coupler <D

• Drain hose (fuel tank) ®

• Fuel hose ®

NOTE: ~------ _

Place a rag under the fuel line to absorb any fuel that might spill.

A WARNING

Gasoline is highly flammable.

Avoid spilling fuel onto a hot engine.

[Link]: • Fuel tank

3-9

__________ ........... __ F __ , U __ EL_T ..... ,A_N_K p:gr I_I

INSTALLATION

Reverse the "REMOVAL" procedure. Note the following points.

1.1nstall:

• Fuel tank

Nut CD:

10 Nm (1.0 m • kg, 7.2 ft ·Ib) ._____, Bolt ®:

10 Nm (1.0 m • kg, 7.2 ft ·Ib)

3 - 10

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IIANDSJP I·oa I

VALVE CLEARANCE ADJUSTMENT ~

-----------------------------------------------------

4

e8303001

ENGINE

VALVE CLEARANCE ADJUSTMENT

NOTE: ___

• Valve clearance adjustment should be made with the engine cool, at room temperature.

• When the valve clearance is to be measured or adjusted, the piston must be at Top Dead Center (T.D.C.) on the compression stroke.

[Link]:

• Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

• Bottom cowling (front)

• Bottom cowling

• Side cowlings (left and right)

Refer to "SEATS", "FUEl TANK" and "COWlINGS" .

[Link]:

• Breather-hose (crankcase) CD

• Drain hose (air filter case) ® [Link]:

• Clamp screws (carburetor joints) @ [Link]:

• Air filter case @ [Link]:

• Radiator assembly

Refer to "RADIATOR" in CHAPTER 5. [Link]:

• Carburetor assembly

Refer to "CARBURETORS" in CHAPTER 6.

7 .Disconnect:

• Spark plug caps CD

3 - 11

IIANOSJP l·oa·1

VALVE CLEARANCE ADJUSTMENT ~

-----------------------------------------------------

[Link]:

• Leads (ignition coils)<D

• Couplers (right handlebar switch) ®

[Link]:

• Ignition coil plate <D (with the ignition coils)

[Link]:

• Spark plugs [Link]:

• Cylinder head cover <D

• Gasket (cylinder head cover)

[Link]:

• Crankshaft end cover (left) <D (with the O-ring)

• Timing plug ® (with the O-ring)

[Link]:

• Valve clearance

Out of specification ~ Adjust.

Valve clearance (cold):

Intake valve:

0.11 ... 0.20 mm (0.004 ... 0.008 in) Exhaust valve:

0.21 ... 0.30 mm (0.008 ... 0.012 in)

3 - 12

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VALVE CLEARANCE ADJUSTMENT 11,:a:S I_I

EX

IN

**********************************

Measuring steps:

Procedure 1 .

• Install a suitable collar CD and a bolt ®

and then tighten the bolt.

® 15 mm (0.6 in) @ 12 mm (0.5 in)

~ 75 mm (3.0 in) ® 60 mm (2.4 in)

© 8 mm (0.3 in)

.Turn the crankshaft counterclockwise.

Procedure 2 .

• Insert the pin ®, use. it to position the pick-up rotor CD, then install the bolt @.

Part no. ® 4U8-81673-10 or 33M-81673-10 ~ 91317·08030

© 93604-08071

• Turn the crankshaft counterclockwise.

~ For #1 and #4 cylinders .

• Align the TDC mark ® with the stationary pointer <6>.

[§] For #2 and #3 cylinders;

.Align the TOe mark © with the stationary pointer <6>.

NOTE: _

TOC on the compression stroke can be found when the cam lobes are facing opposite one another.

• Use a feeler gauge ® to measure the valve clearance.

NOTE: _

• If the valve clearance is incorrect record the measured reading.

• Measure the valve clearance in the following sequence.

I

3-13~----------------------------~

Measuring sequence: #1 ~ #2 ~ #4 ~ #3

IIANOSJP I '~I

VALVE CLEARANCE ADJUSTMENT ~

------------------------------------------------------

lliJ 00 1800 3600 5400 7200

~--> I~+-~-+~

#1
#2
[£J
#3
#4 @Front

.Starting from the #1 cylinder when it is at TDC turn the crankshaft counterclockwise the specified amount of degrees for each cyUnder. Refer to the chart below.

lID The degrees that the crankshaft is turned counterclockwise

[£] Cylinder number

[QJ Combustion

#2 Cylinder 180 degrees
#4 Cylinder 360 degrees
#3 Cylinder 540 degrees **********************************

[Link]:

• Timing chain tensioner

• Timing chain guide (upper) CD

• Timing chain guide (exhaust side) ®

• Camshaft caps (intake and exhaust) ~.Timing chain

• Camshafts (intake and exhaust)

NOTE: __

• Refer to "ENGINE DISASSEMBLY - CYLINDER HEAD COVER, CYLINDER HEAD AND CAMSHAFTS" in CHAPTER 4.

• When removing the timing chain or camshafts, fasten a wire to the timing chain to retrieve it if it falls into the crankcase.

[Link]:

• Valve clearance

3 - 14

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•

•

**********************************

Adjustment steps:

• Remove the valve lifters CD and the pads ®.

NOTE: ___

• To prevent the pads from falling into the crankcase, cover the timing chain opening with a rag.

• Make a note of the position of each valve lifter CD and pad ® so that they can be reinstalled in their original place.

• Select the proper pad from the following chart:

Pad range Pad sizes:
25 thicknesses
1.20mm Thickness increases in
No.120 .. (0.047 in) ..
No.240 2.40mm 0.05 mm (0.02 in)
(0.094 in) increments NOTE: _

The thickness ® of each pad is indicated in hundreths of millimeters on the pad's upper surface.

• Round off the last digit of the installed pad number to the nearest increment.

Last digit of the pad Rounded value
number
00r2 0
5 DO NOT ROUND
OFF
8 10 EXAMPLE:

Installed pad number = 148 (1.48 mm) Rounded off value = 150

NOTE: ___

. Pads can only be selected in 0.05 mm ) (0.002 in) increments.

• locate the rounded value and the measured valve clearance in the pad selection table. The point where the column and row intersect is the new pad number.

3 - 15

NOTE: _

When verifying the valve clearance adjustment use the new pad number only as an approximation. It will be necessary to mea-

sure the valve clearance again and if necessary, repeat the above steps.

• Install the new pads CD and the valve lifters®.

NOTE: -----------------

• Apply molybdenum disulfide grease to

the pads.

• Lubricate the valve lifters with molybdenum disulfide oil.

• The valve lifters must turn smoothly when rotated by hand.

• Be careful to reinstall the valve lifters and the old pads in their original position .

•• Install the camshafts (exhaust and intake), the timing chain and the camshaft caps.

Bolt (camshaft ca,,):

10 Nm (1,0 m • kg, 7,2 ft· Ib)

3 - 16

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•

VALVE CLEARANCE ADJUSTMENT II~~~ I_I

INTAKE

EXHAUST

VALVE CLEARANCE (cold):

0.11 - 0.20 mm (0.004 - 0.008 in) Example: Installed is pad 150 Measured clearance is 0.24 mm (0.009

Replace pad 150 with pad 160 Pad number: (example)

Pad No. 150 = 1.50 mm (0.059 in) Pad No. 160 = 1.60 mm (0.063 in)

Always install the pad with the number facing down.

VALVE CLEARANCE (cold):

0.21 - 0.30 mm (0.008 - 0.012 in) Example: Installed is pad 175 Measured clearance is 0.35 mm (0.014 i

Replace pad 150 with pad 185 Pad number: (example)

Pad No. 175 = 1.75 mm (0.069 in) Pad No. 185 = 1.85 mm (0.073 in)

Always install the pad with the number facing down.

IIANOSJP I'~ I

VALVE CLEARANCE ADJUSTMENT ~

-------------------------------------------------------

NOTE: _

• Refer to "ENGINE ASSEMBLY AND ADJUSTMENT -CYLINDER HEAD AND CAMSHAFTS" in CHAPTER 4.

• lubricate the 'camshaft bearings, cam

lobes and camshaft journals.

• First, install the exnaustcamsnaft.

• Align the matching marks .

• '. Rotate the crankshaft counterclockwise several turns so that the installed parts

settle into the correct position .

•

•

• Measure the valve ctearanceagain. •

• If the clearance is still incorrect, 'repeat all the clearance adjustment steps until the specified clearance is obtained.

**********************************

16.1nstall:

• All removed parts

NOTE: _

Install alt the parts in the reverse order of .• '

their removal. Note the following points.

[Link]:

• Timing chain guide (exhaust side) .,Timing chain guide (upper)

• Timing chain tensioner ..

Refer to "ENGINE ASSEMBLY AND ADJUSTMENT" in CHAPTER 4.

18.1nstall:

• Timing plug

• Crankshaft end cover (left)

Screw (crankshaft end cover): 7 Nm (0:7 m • kg, 5.1 ft ·Ib) LOCTITE@ .

3 - 18

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VALVE CLEARANCE ADJUSTMENTI 1':gS 1 **. .1

CARBURETOR SYNCHRONIZATION . _ ~._

. 19.1nstall:

• Cylinder head cover

• Spark plugs

Bolt (cylinder head cover):

10 Nm (1.0 m • kg, 7.2 ft .Ib) Spark plug:

18 Nm (1.8 m • kg, 13 ft ·Ib)

[Link]:

• Ignition coil plate

• Ignition coil

EB303010

CARBURETOR SYNCHRONIZATION

NOTE: ~ ___

Prior to synchronizing the carburetors, the valve clearance and the idling speed should be properly adjusted and the ignition timing should be checked.

[Link] the motorcycle on a level surface.

NOTE: ---

Place the motorcycle on a suitable stand. [Link]:

, • Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

Refer to "SEATS" and "FUEL TANK".

[Link]:

• Plugs (vacuum hoses) <D

3 - 19

[Link]:

• Adapters

• Vacuum gauge CD

• Engine tachometer ®

(to the #1 spark plug lead)

IIANoSJP I·oa I.

CARBURETOR SYNCHRONIZATION ~

-------------------------------------------------------

I~

•

Vacuum gauge:

YU-OS030/90S90-03094 Engine tachometer:

YU-S036-A/90S90-03113

•

[Link] the engine and let it warm up for several minutes.

[Link]:

• Engine idling speed

Out of specification ~ Adjust.

Refer to "IDLING SPEED ADJUSTMENT".

•

~ Engine idling speed:

V ~ 1,050 ... 1,150 r/min

[Link]:

• Carburetor synchronization

**********************************

Adjustment steps: •

• Synchronize carburetor #1 to carburetor i

#2 by turning the synchronizing screw CD

until both gauges 'read the same.

• Rev the engine two or three times, each time for less than a second, and check the synchronization again.

• Repeat the above steps and synchronize carburetor #4 to carburetor #3 by turning the synchronizing screw ® until both gauges read the same.

• Repeat the same steps and synchronize carburetor #2 to carburetor #3 by turning

the synchronizing screw @ until both •

gauges read the same.

Vacuum pressure at idle speed:

20,3 30,7 kPa (190 ... 230 mm Hg,

7.4S 9.055 in Hg)

NOTE:

The difference between the two carburetors

should not exceed 1.33 kPa (10 mm Hg, 0.4 in Hg).

**********************************

•

3 - 20

CARBURETOR SYNCHRONIZATION/ I ~gSI d .. I

IDLING SPEED ADJUSTMENT . _ ~ .

•

[Link]:

• Engine idling speed

Out of specification ~ Adjust.

[Link] the engine and detach the measuringequipment.

[Link]:

• Throttle cable free play

Refer to "THROTTLE CABLE ADJUSTMENT".

•

•

Free play:

3 ... 7 mm (0.12 ... 0.28 in) (at the throttle grip flange)

[Link]:

• Fuel tank

• Side panels (left and right)

• Passenger seat

• Rider seat

• Refer to "FUEL TANK" and "SEATS".

•

EB303021

IDLING SPEED ADJUSTMENT

NOTE: _

Prior to adjusting the idling speed, the carburetor synchronization should be adjusted properly, the air filter should be clean and the engine should have adequate compression.

[Link] the engine and let it warm up for

several minutes.

[Link]:

• Engine tachometer

(to the #1 spark plug lead)

•

Engine tachometer:

YU-8036-A/90890-03113

•

[Link]:

• Engine idling speed

Out of specification ~ Adjust.

•

Engine idling speed: 1,050 ... 1,150 r/min

3 - 21

IDLING SPEED ADJUSTMENT/ 1':gS 1'0} I

THROTTLE CABLE ADJUSTMENT . . ~ .

[Link]:

• Engine idling speed

**********************************

Adjustment steps:

• Turn the throttle stop screw @ in or out until the specified idling speed is obtained .

Idling speed is increased.

Turning in:

Turning out:

Idling speed is decreased.

**********************************

•

•

[Link]: •

• Throttle cable free play

Refer to "THROTTLE CABLE ADJUSTMENT".

Free play:

3,.. 7 mm (0.12,.. 0.28 in) (at the throttle grip flange)

EB303030

THROTTLE CABLE ADJUSTMENT

NOTE: _

Prior to adjusting the throttle cable free '.

play, the engine idling speed and carbure-

tor synchronization should be adjusted

properly.

[Link]:

• Throttle cable free play @ Out of specification ~ Adjust.

Free play (throttle cable): 3,.. 7 mm (0.12 .. 0.28 in) (at the throttle grip flange)

[Link]:

• Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

• Air filter case

Refer to "SEATS", "FUEL TANK" and "VALVE CLEARANCE ADJUSTMENT". [Link] back the baffle cover on the carburetor assembly.

3 - 22

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I IAN. DSJPI.~I

THROTTLE CABLE ADJUSTMENT. ~

-------------------------------------------------------

[Link]:

• Throttle cable free play

**********************************

Adjustment steps:

NOTE: _

When the motorcycle is accelerating, throttIe cable #1 <D is pulled and throttle cable #2 ® is pushed.

1st step:

• Loosen the locknut @ on throttle cable #2. .Turn the adjuster @ in or out to take up

any slack on throttle cable #2. 2nd step:

• Loosen the locknut ® on throttle cable #1.

• Turn the adjuster ® in or out until the specified free play is obtained.

Turning in:

Free play is increased.

Turning out:

Free play is decreased.

• Tighten the locknuts.

NOTE: ~ __

If the specified free play cannot be obtained on the carburetor end of the cable, use the adjuster on the handlebar end.

Additional step:

• Pull back the rubber covers on' the adjuster.

• Loosen the locknut (1) .

• Turn the adjuster ® in or out until the specified free play is obtained.

Turning in:

Free play is increased.

Turning out:

Free play is decreased.

• Tighten the locknut.

A WARNING

After adjusting, turn the handlebars to the right and to the left to ensure that this does not cause the engine idling speed to change.

**********************************

3 - 23

•

THROTTLE CABLE ADJUSTMENT/ II:g! I H I

SPARK PLUG INSPECTION . _ ~ .

[Link] the baffle cover over the carburetor •

assembly. [Link]:

• Air filter case

• Fuel tank

• Side panels (left and right)

• Passenger seat •

• Rider seat

Refer to "VALVE CLEARANCE ADJUSTMENT", "FUEL TANK" and "SEATS" .

•

SPARK PLUG INSPECTION [Link]:

• Spark plug caps

• Spark plugs

Before removing the spark plugs, use compressed air to blow away any dirt accumulated in the spark plug wells, to prevent the dirt from falling into the cylinders.

[Link]:

• Spark plug type Incorrect ~ Replace.

•

Standard spark plug:

DR8EA (NGK)

X24ESR-U (NIPPONDENSO)

•

3 - 24

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SPARK PLUG INSPECTIONI I':gjl ((I) I

IGNITION TIMING CHECK . . ~ .

377-000

[Link]:

• Electrode CD Wear/dam?ge -7 Replace.

• Insulator ®

Abnormal color -7 Replace.

Normal color is a medium-to-light tan

...

color. [Link]:

• Spark plug

(with a spark plug cleaner or wire brush) [Link]:

• Spark plug gap @ (with a wire gauge)

Out of specification -7 Adjust gap.

Spark plug gap:

0.6 .. 0.7 mm (0.24 .. 0.28 in)

6:1nstall:

• Spark plug

Spark plug:

18 Nm (1.8 m • kg, 13 ft ·Ib)

NOTE: __

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

EB303051

IGNITION TIMING CHECK

NOTE: __

Prior to checking the ignition timing, check all electrical connections related to the ignition system. Make sure that alfconnections are tight and free of corrosion and that all ground connections are tight.

[Link]:

• Bottom cowling (front)

• Bottom cowling

Refer to "COWLINGS".

3·25

IIANOSJP I'oa I

IGNITION TIMING CHECK ~

------------------------------------------------------

l

[Link]:

• Timing plug CD

[Link]:

• Timing light

• Enginetachometer

(to the #1 spark plug lead)

Timing light:

YM-33277 -A/90890-03141 Engine tachometer:

YU-8036-A/90890-03113

[Link]:

• Ignition timing

**********************************

Checking steps:

• Start the engine and let it warm up for several minutes. Let the engine run at the specified speed.

~ Engine idling speed:

V ~ 1,050 ... 1,150 r/min

.Check that the stationary pointer @ is within the firing range (Q) on the crankshaft web.

Incorrect firing range ~ Check the ignition system.

**********************************

NOTE: __

Ignition timing is not adjustable.

[Link]:

• Timing plug CD

3 - 26

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IIANDSJP I'~ I

COMPRESSION PRESSURE MEASUREMENT . ~

-------------------------------------------------------

EB303060

COMPRESSION PRESSURE

MEASUREMENT

NOTE: __

Insufficient compression pressure will result in a loss of performance.

[Link]:

• Valve clearance

Out of specification ~ Adjust.

Refer to "VALVE CLEARANCE ADJUSTMENT".

[Link] the engine and let it warm up for several minutes.

[Link] the engine.

[Link]:

• Spark plug caps

• Spark plugs

~--------------------

Before removing the spark plugs, use com-

pressed air to blow away any dirt accumulated in the spark plug wells to prevent the dirt from fafling into the cylinders.

[Link]:

• Compression gauge CD

Compression gauge:

YU-33223/90890-03081

[Link]:

• Compression pressure

If it exceeds the maximum pressure allowed ~ Inspect the cylinder head, valve surfaces and piston crown for carbon deposits.

If it is below the minimum pressure ~ Squirt a few drops of oil into the affected cylinder and measure again.

• Refer to the table below.

3 - 27

IIANOSJP I '~. I

COMPRESSION PRESSURE MEASUREMENT ~

------------------------------------------------------

Compression pressure
(with oil applied in the cylinder)
Reading Diagnosis
Higher than Worn or damaged pistons
without oil ~ Repair.
Same as Possible defective ring(s),
without oil valves, cylinder head gasket
or piston ~ Repair. Compression pressure (at sea level) Standard:

1,422 kPa (14.22 kg/cm2, 202 psi) Minimum:

1,334 kPa (13.34 kg/cm2, 190 psi) Maximum:

1,500 kPa (15.00 kg/cm2, 213 psi)

**********************************

•

•

•

Measurement steps:

• With the throttle wide open crank the

engine until the reading on the com pres- •

sion gauge stabilizes.

A WARNING

To prevent sparking, ground all of the spark plug leads before cranking the engine.

• Repeat the previous steps for the other cylinders.

NOTE: -- __

The difference in compression pressure between the highest and lowest cylinder

compression re~dings should not exceed ••

100 kPa (1 kg/cm , 14 psi).

**********************************

[Link]:

• Spark plugs

• Spark plug caps

Spark plug:

18 Nm (1.8 m • kg, 13 ft ·Ib)

3 - 28

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I'ANOSJP I·~ I

. ENGINE OIL LEVEL INSPECTION ~

-------------------------------------------------------

Engine oil
10 30 50 70'F
.A I I
K Vamalube 4 (10W30) or SAE 10W30 I
'I .A
~ KVama'Ube 4 (20W40) orSAE 2OW40!
'I I I
I SAE5W30 J
-10 0 10 20'C EB303071

ENGINE Oil lEVEL INSPECTION

[Link] the motorcycle on a level surface.

NOTE:

• When checking the oil level make sure that the motorcycle is upright.

• Place the motorcycle ona suitable stand.

[Link]: .Oillevel

Oil level should be between the maximum @ and minimum <OJ marks.

Oil level is below the minimum mark ~ Add oil up to the proper level.

Recommended oil:

Yamalube 4 or SAE 1f)W30 type SE motor oil, or SAE20W40 type SE motor oil

• Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage. .

• Do not allow foreign material to enter the crankcase.

NOTE: __

Recommended engine oil classification; API Service "SE", "SF" type or equivalent (e.g. "SF-SE", "SF-SE~CC", "SF-SE-SO" etc.).

[Link] the engine and let it warm up for

several minutes .

[Link] off the engine and check the oil level again.

NOTE: _

Before checking the oil level, wait a few minutes until the oil settles.

3 - 29

IIANOSJP I'~ I

ENGINE OIL REPLACEMENT ~

-------------------------------------------------------

• Use an oil filter wrench to tighten the new •

oil filter.

EB303081

ENGINE OIL REPLACEMENT

[Link]:

• Bottom cowling (front)

• Bottom cowling

• Side cowlings (left and right) Refer to "COWLINGS".

[Link] the engine and let it warm up for several minutes.

[Link] off the engine and place a container

under the drain bolt. [Link]:

• Oil filler cap <D

• Drain bolt ® (with the gasket)

Drain the crankcase of its oil.

[Link] the oil filter is to be replaced during this procedure, remove the following parts and reinstall them afterwards.

**********************************

Replacement steps:

• Use an oil filter wrench <D to remove the oil filter ®.

Oil filter wrench:

VU-38411/90890-01426

.Apply engine oil to the O-ring @ of the new oil filter.

Make sure that the a-ring ® is positioned correctly.

Oil filter:

17 Nm (1.7 m • kg, 12 ft ·Ib)

**********************************

3 - 30

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•

IIANOSJP I'~ I

ENGINE OIL REPLACEMENT ~

---------------------------------------------------

[Link]:

• Drain bolt

•

Drain bolt:

43 Nm (4.3 m • kg, 31 ft • Ib)

•

NOTE: _

Check the drain bolt gasket. If it is damaged; replace it.

•

[Link]:

• Crankcase

Refer to "ENGINE OIL LEVEL INSPECTION".

Oil quantity:

Total amount:

3.5 L (3.2 Imp qt, 3.4 US qt) Periodic oil change:

3 L (2.6 Imp qt, 3.1 US qt) With oil filter replacement: 3.2 L (2.8 Imp qt, 3.3 US qt)

•

[Link]:

• Oil filler cap

[Link] up the engine for a few minutes, then turn it off.

[Link]:

• Engine

(for oil leaks) .Oillevel

[Link]:

• Side cowlings (left and right)

• Bottom cowling

• Bottom cowling (front) Refer to "COWLINGS".

•

•

•

3 - 31

ENGINE OIL PRESSURE INSPECTION I ':8! 1 .. 1 ENGINE OIL PRESSURE INSPECTION [Link]:

.Oillevel

Oil level low ~ Add oil to the proper level. [Link]:

• Bottom cowling (front)

• Bottom cowling

• Side cowling (right) Refer to "COWLINGS".

[Link] the engine and let it warm up. Then, stop the engine.

Ir~IIIIPJ _

Be sure to measure the oil pressure after warming-up the engine. When the engine is cold, the oil will have a higher viscosity, causing the oil pressure to increase.

[Link]:

• Main gallery bolt CD

A WARNING

The engine, muffler or engine oil may be extremely hot.

[Link]:

• Oil pressure gauge CD

• Adapter ®

Oil pressure gauge: 90890-03153 Adapter: 90890-03139

[Link]:

• The oil pressure at the following conditions:

Engine oil pressure:

350 .... 450 kPa (3.5 .... 4.5 kg/cm2, 50 .. 64 psi)

Engine speed:

, Approx. 4,000 r/min Oil temp:

Approx. 70°C (158°F)

3 - 32

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ENGINE OIL PRESSURE INSPECTIONI IINSPI"~ I CLUTCHADJUSTMENT ADJ ~

~-=;..;_._-..:;...;=--

Out of specification ~ Check the following.

Oil pressure Possible causes
• Faulty oil pump
When the oil pres- • Clogged oil filter
sure is less than the • Leaking oil pas-
specification. sage
• Broken or dam-
aged oil seal
• Leaking oil pas-
When the oil pres- sage
sure is greater than • Faulty oil filter
the specification. • Very viscous
engine oil [Link]:

• Main gallery bolt

Bolt (main gallery):

12 Nm (1.2 m • kg, 8.7 ft .Ib)

EB303091

CLUTCH ADJUSTMENT

[Link]:

• Clutch lever position

(distance @ from the handlebar grip to the clutch lever)

**********************************

Adjustment steps:

.Turn the adjuster CD while pushing the clutch lever forward until the clutch lever is in the desired position .

• Align the setting on the adjuster with the arrow mark ®.

3 - 33

CLUTCH ADJUSTMENT/ I i~gS I'~ I

CLUTCH FLUID LEVEL INSPECTION . . ~ .

Turning in: Clutch lever distance
® is the largest.
. Clutch lever distance
Turning out: ® is the smallest. .'

A WARNING

•

After adjusting the clutch lever position (distance), make sure that the pin on the clutch lever holder is firmly inserted into the hole in the adjuster.

•

**********************************

CLUTCH FLUID LEVEL INSPECTION [Link] the motorcycle on a level surface.

NOTE: _

Place the motorcycle on a suitable stand. [Link]:

• Clutch fluid level

Clutch fluid level is below the "LOWER" level line ® ~ Fill to the proper level.

l'fl>l R~c~;,,:ended fluid: •

NOTE:

In order to ensure a correct reading of the clutch fluid level, make sure that the top of the clutch reservoir (handlebar) is horizontal.

f!_~r:I _

Clutch fluid may damage painted surfaces or plastic parts. Always clean up any spilt fluid immediately.

•

A WARNING

.-Use only the designated clutch fluid.

Other clutch fluids may cause the rubber seals to deteriorate, causing leakage and poor clutch performance .

• Refill with the same type of clutch fluid. •

Mixing clutch fluids may result in a harm-

ful chemical reaction leading to poor

clutch performance .

• When refilling, be careful that water does

not enter the clutch reservoir. Water will •

significantly lower the boiling point of the

clutch fluid and could cause vapor lock.

3 - 34

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•

•

•

•

AIR BLEEDING (HYDRAULIC CLUTCH SYSTEMI I':CS I_I AlA BLEEDING (HYDRAULIC CLUTCH SYSTEM)

A WARNING

Bleed the clutch system whenever:

• The system is disassembled.

• A clutch hose is loosened or removed.

• The clutch fluid level is very low.

• Clutch operation is faulty.

[Link]:

• Bottom cowling (front)

• Bottom cowling [Link]:

• Clutch system

**********************************

Air bleeding steps:

a. Fill the clutch reservoir with the proper clutch fluid.

b. Install the diaphragm. Be careful not to spill any fluid or allow the clutch reservoir to overflow.

c. Connect a clear plastic hose <D tightly to the bleed screw ®.

d. Place the other end of the hose into a container.

e. Slowly apply the clutch lever several times.

f. Pull the lever in and hold the position.

g. Loosen the bleed screw and allow the lever to travel slowly towards the handlebar.

h. Tighten the bleed screw when the lever is touching the handlebar grip, then release the lever.

i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the clutch fluid.

NOTE: ___

When bleeding the clutch system, make sure that there is always enough clutch fluid before applying the clutch lever. Ignoring this precaution could allow air to enter the clutch system, considerably lengthening the bleeding procedure.

j. Tighten the bleed screw.

Bleed screw:

6 Nm (0.6 m • kg, 4.3 ft • Ib)

3 - 35

AIR BLEEDING (HYDRAULIC CLUTCH SYSTEM)I IINSP 1(0) I AIR FILTER CLEANING ADJ ~

1-:..':'='-=-"--"':'.:...1

I·.

"

NOTE: __

If bleeding is difficult, it may be necessary to let the clutch fluid settle for a few hours. Repeat the bleeding procedure when the tiny bubbles in the clutch system have disappeared.

k. Fill the clutch reservoir up to the proper level.

Refer to "CLUTCH FLUID LEVEL INSPECTION".

A WARNING

After bleeding the clutch system, check clutch operation.

**********************************

EB303121

AIR FILTER CLEANING

[Link]:

• Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

Refer to "SEATS" and "FUEL TANK".

• Air filter case cover CD

[Link]:

• Air filter element CD [Link]:

• Air filter element Damage ~ Replace.

[Link]:

• Air filter element

Use compressed air to blow off dust from the outer surface of the element.

3 - 36

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. I

~

AIR FIL TER CLEANINGI 1':gr .. I''''1

CARBURETOR JOINT INSPECTION _ _ .~ _

[Link]:

• Air filter element

• Air filter case cover (with the gasket)

Make sure that the projection CD on the air filter case cover is securely installed into the slot ® in the air filter case.

NOTE: _

Make sure that the element is properly installed in the filter case.

1I11III-----------

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 filter element will also affeCt the carburetor tuning, leading' to poor engine performance and possible overheating.

[Link]:

• Fuel tank

• Side panels (left and right)

• Passenger seat

• Rider seat

Refer to "FUEL TANK" and "SEATS".

EB303130

CARBURETOR JOINT INSPECTION

[Link]:

• Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

Refer to "SEATS" and "FUEL TANK".

[Link]:

• Carburetor [olnts Cracks/damage -? Replace.

Refer to "CARBURETORS" in CHAPTER 6.

3 - 37

CARBURETOR JOINT INSPECTION/FUEL LINE !I:gr !.oa !

INSPECTION/CRANKCASE BREATHER HOSE INSPECTION _ _ ~ _

[Link]:

• Fuel tank

• Side panels (left and right)

• Passenger seat

• Rider seat

Refer to "FUEL TANK" and "SEATS".

EB303140

FUEL LINE INSPECTION

[Link]:

• Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

Refer to "SEATS" and "FUEL TANK".

2.1nspect:

• Fuel hoses CD Cracks/damage -7 Replace.

[Link]:

• Fuel tank

• Side panels (left and right)

• Passenger seat

• Rider seat

Refer to "FUEL TANK" and "SEATS".

EB3031S0

CRANKCASE BREATHER HOSE

INSPECTION

[Link]:

• Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

Refer to "SEATS" and "FUEL TANK".

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CRANKCASE BREATHER HOSE INSPECTIONI 1':gSI d, .1.

EXUPCABLE·ADJUSTMENT . _ ~ .

[Link]:

• Crankcase breather hose CD Cracks/damage .-.? Replace.

Loose connection .-.? Connect properly.

Make sure that the crankcase breather hose is routed correctly.

[Link]:

• Fuel tank

• Side panels (left and right)

• Passenger seat

• .Rider seat

Refer to "FUEL. TANK" and "SEATS'i.

EXUP CABLE ADJUSTMENT [Link]:

• Bottom cowling (front)

• Bottom cowling

• Rider seat

• Passenger seat

• Side panels (left and right)

• Fuel tank

Refer to "COWLINGS", "SEATS" and "FUEL TANK".

[Link]:

• EXUP valve cover CD

[Link]:

• EXUP operation

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• Disconnect the servo motor coupler CD .

• Connect the battery to the servo motor coupler.

Battery (+) lead .-.? BlackNeliow terminal ® Battery (-) lead .-.? Black/red terminal ®

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EXUP CABLE ADJUSTMENT 1':gS I_I

Perform this test immediately so that the servo motor is not damaged .

• Check the EXUP valve .

• Connect the servo motor coupler.

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[Link]:

• EXUP cable free play ®

EXUP cable free play:

1.5 mm (0.059 in) or less

[Link]:

• EXUP cable free play

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Adjusting steps: •

• Loosen both locknuts CD .

• Insert a 4 mm (1.57 in) pin through the notch of the pulley and into the hole .

• Turn both adjusters ® counterclockwise until there is no cable free play .

• Turn both adjusters 1/2 of a turn clockwise.

• Tighten both locknuts and then remove the pin.

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6.1nstall:

• EXUP valve cover

Bolt (EXUP valve cover):

10 Nm (1.0 m • kg, 7.2 ft ·Ib)

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EXUP CABLE ADJUSTMENT I II:,g~ I LC» ... 1

EXHAUST SYSTEM INSPECTION . . ~ .

7.1nstall:

• Fuel tank

• Side panels (left and right)

• Passenger seat

• Rider seat

• Bottom cowling

• Bottom cowling (front)

Refer to "FUEL TANK", "SEATS" and "COWLINGS" .

EB303160

EXHAUST SYSTEM INSPECTION

[Link]:

• Bottom cowling (front)

• Bottom cowling

• Side cowlings (left and right) Refer to "COWLINGS".

[Link]:

• Exhaust pipes CD

• Muffler ®

Cracks/damage ~ Replace.

• Gaskets ®

Exhaust gas leaks ~ Replace. [Link]:

• Tightening torque ,

Nut (exhaust pipe) @:

20 Nm (2.0 m • kg, 14 ft • Ib) Bolt (muffler and stay) @:

38 Nm (3.8 m • kg, 27 ft • Ib) Bolt (exhaust pipe and stay) @: 20 Nm (2.0 m • kg, 14 ft • Ib) Bolt (exhaust pipe and muffler) CD:

20 Nm (2.0 m • kg, ·14 ft • Ib)

[Link]:

• Side cowlings (left and right)

• Bottom cowling

• Bottom cowling (front) Refer to "COWlINGS".

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