Check the seat by performing the leakage test described in the Cylinder Head section earlier in this chapter. If fluid leaks past any of the seats, disassemble that valve assembly and repeat the lapping procedure Valve lapper until there are no leaks.
Cylinder bolt 2. Cylinder 3. Compression ring 4 Oil ring 5. Piston pin circlip 6. Piston 7. Base gasket 8. Dowel 9. Front cam chain guide Piston pin Follow the break-in procedure in Chapter Five if the cylinder block was rebored or honed, or if a new piston or piston rings were installed.
Inspection The following procedure requires the use of highly specialized and costly measuring instru- ments. Remove the cylinder head and cylinder as de- scribed in this chapter. Lightly mark the top of the piston front or rear so it can be installed in the correct cylinder during installation.
Do not drive out the piston pin. This could damage the pis- ton pin, connecting rod or piston. Remove the piston from the connecting rod and remove the remaining circlip from the piston. Dis- card both piston pin circlips. Install the second piston pin circlip Figure into the groove in the piston.
Check the piston skirt B, Figure for gall- ing and abrasion, which may have been caused by Specified distance piston seizure. If a piston shows signs of partial sei- zure bits of aluminum build-up on the piston skirt , replace the piston to reduce the possibility of engine noise and further piston seizure.
Measure the inside diameter of the piston pin bore in the piston with a small bore gauge Figure Calculate piston pin-to-piston clearance by sub- tracting the piston pin outside diameter from the piston pin bore inside diameter. If the clearance is outside the range specified in Table 2, replace the piston pin if the piston bore inside diameter is within specification.
Inspect the grooves carefully for burrs, nicks or broken and cracked lands. Recondition or replace the piston if necessary. Roll each ring around its piston groove as shown in Figure to check for binding.
Minor binding may be cleaned up with a fine-cut file. Install the oil control ring assembly into the bot- tom ring groove. Displacement cc Compression ratio 8. Service limit mm in. Valve head diameter Intake Exhaust pipe-to-manifold bolts rear cylinder — Flywheel nut — Intake manifold bolts — Oil delivery pipe banjo bolt — Primary drive nut — Rear chain guide bolt — External gearshift mechanism.
Crankcase assembly. Connecting rods. Alternator and starter clutch. Frame 8. Engine bracket lower Engine bracket upper 2. Cylinder head bracket bolt through bolt through bolt 3.
Front frame member nut 9. Upper rear engine Rear frame member bolt 4. Rear engine through bolt mounting bolt Page Removal are no longer in place. Remove the cylinder head covers from each engine from the frame. Though this is cylinder head Chapter Four.
Note that the bolt with two oil holes B, Figure 5 se cures the oil pipe to the cylinder head. Remove the removable frame member as follows: a. Remove the nuts from the upper frame mem- ber bolts Figure 13 and remove the bolts. Remove the lower frame member bolts B, Figure 3 and lift the removable frame mem- ber from the frame. Page While the engine is removed for service, check all of the frame engine mounts for cracks or other damage. If any cracks are detected, take the chassis assembly to a Yamaha dealership for further exami- nation.
Installation Install the front engine bracket as follows: 1. Install the starter, speed sensor and horn Chap- ter Nine. Route the oil level switch wire A, Figure 3 along the path noted during removal and connect the bullet connector to its harness mate. Install the right and left side covers, toolbox panel, frame neck covers and the sidestand Chapter Fourteen.
Dowel 2. Gasket 3. Wire clamp 4. Stator mounting bolt 6. Alternator cover 7. Alternator cover bolt Remove the sidestand, toolbox cover and right side cover Chapter Fourteen. Roll the boot on the toolbox panel from the elec- trical connectors. Disconnect the three-pin stator connector A, Figure 21 and the two-pin pickup coil connector B from their respective mates on the wiring harness.
Page See Chapter Nine for stator and pickup coil re- moval and inspection procedures. Sheave holder: part No. YS or Bolt 9. Timing gear 2.
One-way clutch housing Snap ring 3. One-way clutch Flywheel Bearing 5. Starter wheel gear 6. Nut Starter idler gear assembly 7. If the timing mark on the rear cam sprocket does not align with the pointer on the rear head, rotate the engine one turn clockwise. Remove the alternator cover as described in this chapter. NOTE Install the sheave holder so it sits completely flat against the flywheel.
If necessary, lift the timing gear A, Figure 35 from the back of the flywheel. Remove each pin and spring Figure 36 from the slots in the flywheel. Installation 1. Insert a pin into each spring Figure Position the flywheel so the two marked teeth A, Figure 41 align with the Woodruff key in the crankshaft.
If either part is worn or dam aged, replace the starter clutch assembly. The one-way clutch is faulty if it fails either test. Replace the starter clutch assembly. Inspect the teeth A, Figure 48 of the starter wheel gear. Replace the gear if any teeth are worn, broken or missing. Inspect the bearing surface B, Figure 48 of the starter wheel gear for nicks or scratches. Replace the wheel gear if it shows signs of wear. If necessary, remove the oil delivery pipe mount- ing bolt C, Figure 53 at each end of the pipe, and remove the oil delivery pipe D from the crank- case.
Watch for the O-ring Figure 54 behind the fitting on each end of the pipe. Primary body 2. Oil strainer 3. Indexing pin 4. Outer rotor 5. Inner rotor 6. Secondary body 7.
Outer rotor 8. Inner rotor 9. Drive pin Pump shaft Snap ring Oil pump cover Turn the pump over and lift the primary pump body Figure 59 from the pump. NOTE This pump has two sets of rotors: a thick set that fits in the primary body and a thin set for the secondary body.
Keep each set of rotors together with its respective body. Remove the shaft Figure 67 from the pump cover. Assembly 1. Coat all parts with fresh oil prior to assembly. Install the pump shaft Figure 67 into the pump cover. The end with the holes enters from the out- board side of the cover.
Clean all parts in solvent and dry them thor- oughly with compressed air. Inspect the primary body A, Figure 68 for cracks and inspect the primary body rotors B for wear or abrasion. Inspect the strainer C, Figure 68 for tears or other damage that will allow contaminants into the pump. Page If necessary, replace the chain along with both the drive and driven sprocket. Crankcase separating tool part No. YUA or Remove the mounting screw, and lift the shift also indicate the crankcase bolt tight ening sequence.
See Figure Before removing the crankcase bolts, draw an outline of each case half on a piece of cardboard. These bolts must be reinstalled in their original locations during as sembly. Remove the two dowels A Figure 77 from the crankcase mating surface.
Remove the O-ring and its short collar B, Figure 77 from the boss beneath the crank- shaft. Remove the O-ring from the crankcase mat- ing surface above the middle drive shaft. Page Install each shift fork with the letter tools are not available, have a facing up toward the right side of the Yamaha dealership or other qualified engine.
Install the left shift fork into the countershaft 4. Page Do not add so much oil that it will drip from the bearing when the case half is turned over. Apply a light coat of Yamaha Bond No. ACC or or on equivalent sealant to the mating surface of the left crankcase half. Turn the crankcase over and install the left crankcase bolts. If there is any binding, stop and correct the cause before proceeding.
Before heating the crankcase, remove the middle drive shaft assembly and middle driven shaft as- sembly Chapter Seven. Do Puller not heat the crankcase with a torch. Connecting rod 2. Connecting rod bolt 3. Connecting rod bearing 4. Main bearing 5. Oil pump drive sprocket 6. Crankshaft 7. Nut 8. If the side clearance is still outside the specified range, replace the crankshaft. Use V-blocks and a dial gauge to check the crankshaft runout Figure If the runout ex- ceeds the specification in Table 1, replace the crankshaft.
The connecting rod must be installed so this side faces the left crankshaft end the tapered end. Install rod and cap. Be sure the weight marks Figure 99 on the side of the rod and cap align. Between to miles km of for further service. Alternator cover bolts — Connecting rod nuts — Crankcase stud 10 mm — 12 mm — Crankcase bolts 6 mm — 10 mm — Engine mounting hardware Cylinder head bracket bolts — Replace any part that is dam- Refer to Figure 1.
Oil filter cover bolt 8. Clutch cover bolt 2. Oil filter outer cover 9. Wire clamp 3. Air filter housing bracket O-ring 4. Cap bolt Clutch cover 5. Cap Gasket 6. Install the wire clamps behind the bolts A, Figure 2 noted during removal. Apply Yamaha Bond or an equivalent sealant to the threads of the two indicated bolts C, Figure 2. Oil will leak past these bolts if the threads are not sealed. Retaining wire Clutch nut 2. Clutch plate No. Lock plate 3. Clutch boss spring Clutch spring bolt 4.
Plate seat Spring plate 5. Clutch boss Clutch spring 6. Remove the pressure plate B, Figure Remove the washer Figure 11 and the release bearing Figure 12 from pushrod No. Remove pushrod No. However, do not use a steel washer. Steel will damage the gear teeth. If a clutch holder is not available, stuff a shop cloth, copper penny, or brass washer Figure 18 between the primary drive gear and the primary driven gear on the clutch housing.
Lift the other end from the hole and remove the retaining wire from the clutch hub. Remove clutch plate No. The last item installed should be friction disc. Make sure the marked tab on each friction disc sits in the marked slots on the clutch housing as shown in Figure If necessary, remove the fric- tion discs and clutch plates. Check the inner splines Figure 30 on the clutch plates. Minor roughness can be cleaned with an oilstone or fine file.
If any one plate has excessive roughness or wear, re- place all the clutch plates as a set. They must be smooth for chatter-free operation. If there is any excessive damage, replace the compo- nents. Inspect the posts B, Figure 32 for wear or galling. If there is any excessive damage, re- place the clutch boss.
Pushrod No. O-ring 3. Adjuster 4. Push screw 5. Ball assembly 6. Housing 7. Oil seal 8. Pin 9. Clutch lever Spring 1. Remove the alternator cover as described in Chapter Five. Apply grease to the balls in the ball assembly A, Figure Lower the ball assembly A, Figure 41 onto the push screw B.
Seat the balls in the detents. Invert the assembly and install it into the housing on the inboard side of the alternator cover Figure Remove the mounting bolts A, Figure 45 , and pull the clutch adjuster cover B from the alternator cover. Disconnect the clutch cable Figure 46 from the clutch lever. Pull the clutch cable end from the port in the alternator cover. Before removing the primary drive gear, set the front cylinder to top dead center on the compression stroke, The Yamaha sheave holder part No.
YU and note the position of the timing or , or an equivalent flywheel holder, marks on the cam sprocket plate and is needed to service the primary drive gear. Remove the cylinder head and the cam chain drive assembly from the front cylinder Chapter Four. Remove the clutch as described in this chapter. Bend the ears of the lockwasher A, Figure 50 away from the primary gear nut.
Push the springs as far apart as possible. Install the cam chain drive assembly and the cylinder head as described in Chapter Four. Install the clutch as described in this chapter.
Loosen the shift lever clamp bolt B, Figure 2. Remove the footrest bracket bolts Figure 3. Locknut 2. E-clip Shift rod 3. Stopper lever spring Snap ring 4. Stopper lever Shift pedal 5. Collar XVSA models 6. Wave washer 7. Shift shaft spring XVSA models 8. Install the shift lever so the index mark A, Figure 2 on the shift shaft aligns with the slot in the shift lever. Slide the end of the shift shaft into the crankcase boss B, Figure 6 until the assembly bottoms. The arms of the shift shaft spring C, Figure 4 must straddle the post in the crankcase.
Retainer screw 6. Neutral pin 2. Shift fork shaft 7. Bearing retainer 8. Pin 20 mm 3. Shift fork shaft 9. Pin 16 mm 4. Shift fork Shift cam 5. Check the pins B, Figure 12 and shift cam ramps C for wear. Gear b. Middle drive gear Countershaft first gear Mainshaft fourth gear 3.
Countershaft fourth gear Splined washer 4. Snap ring 5. Splined washer Mainshaft second-third 6. Install fourth gear A, Figure 19 onto the mainshaft, and slide it up against first gear. Make sure the engagement dogs on the gear face away from first gear. Install a splined washer B, Figure 19 and a new snap ring C. If it is still installed, remove the middle drive gear Figure 23 from the countershaft.
Remove first gear, then remove fourth gear. Remove the snap ring and the splined washer. Remove the countershaft third gear. Install first gear Figure 30 so its flat side faces out. Install the middle drive gear Figure 23 so its splines engage those on the countershaft. Mesh both assembled transmission shafts to- gether with the middle driven gear Figure Make sure all gears mate properly.
Have these tools on hand before beginning this procedure. Bearing retainer 2. Spring retainer 3. Spring seat 4. Damper spring 5. Damper cam male 6. Damper cam female 7. Middle drive shaft nut 8. Bearing 9. Middle drive shaft shims Middle drive shaft Apply engine oil to the teeth of the middle drive shaft and install the middle drive shaft assembly into the crankcase. Turn the bearing retainer A, Figure 40 until it is in place. Inspect the internal splines on the male and fe- male sides of the damper cam.
The Yamaha universal joint holder part No. Inspect the damper spring for wear, cracks or YM or , or its equivalent, is damage. Bearing Speed sensor bracket 2. Middle driven shaft Bolt 3. Rotor 4. Collapsible collar Drive yoke 5. Collar Washer 6. O-ring Middle driven shaft nut 7. Remove the driven yoke C, Figure 46 from the drive yoke B. Hold the drive yoke with the universal joint holder A, Figure 48 and loosen the middle driven shaft nut B.
Install the universal joint holder A, Figure 48 onto the drive yoke and install the middle gear backlash band Figure 49 onto the middle drive shaft assembly. Install the bearing housing bolts A, Figure 45 They may also be damaged. Dur- NOTE ing inspection, compare measurements to the speci- During removal, label each hose and fications in the tables at the end of this chapter.
Fuel tank 6. Seat bracket bolt 2. Fuel hose 7. Passenger seat 3. Fuel tank bolt 8. Nut 4. Meter connector 5. Seat bracket 8. Raise the fuel tank bracket and support the tank. Pull the meter connector B, Figure 5 from be- neath the ignitor panel and disconnect the pin meter connector A, Figure 6 from its harness Pull the tank bracket rearward until the tank is free of the damper A, Figure 7 on each side of the frame.
Remove the fuel tank. Installation is the reverse of removal. O-ring 2. Fuel valve body 3. Clamp 4. Fuel hose 5. Valve packing 6. Valve seal 7. Lever 8. Wave washer 9. Plate Pan head screw Screw 3. Drain the fuel from the tank into a clean, sealable b. Cover bolt Surge tank base Air filter housing 2. Air filter cover Air filter housing bracket lower 3. Air filter Air filter housing duct Cylinder head 4. Remove the cover bolts A, Figure 10 and pull the air filter cover B from the housing.
Lift the air filter A, Figure 11 from the posts in the air filter housing. Loosen the clamp B, Figure 11 that secures the surge tank duct to the back of the air filter housing. Remove the plug A, Figure 15 from the drain hose on the air filter housing. Clean out accumu- lated moisture or dirt. If necessary, blow the hose clear with compressed air.
Inspect all components of the air filter housing assembly. If removed, install the cylinder head breather hose Figure 20 onto the surge tank fitting so the dots on the hose face forward. Make sure the clamp A, Figure 19 on each car- buretor duct is loose and the carburetor breather hose B faces up. At full throttle, the carburetor venturi is fully open and the needle is lifted far enough to permit the main jet to flow at full capacity.
The choke circuit is a bystarter system. If necessary, turn the pull cable adjuster C, Figure 26 to create addi- tional slack. Loosen the cable clamp screw A, Figure 27 and disconnect the choke cable end B from the choke linkage.
Route the throttle cables and choke cable along their original paths. These cables must not be twisted, kinked or pinched. Secure the cables in the holder B, Figure 7. Connect each hose to the fitting noted during removal and route the hose along its original path. Remove the cotter pin A, Figure 35 and washer. Remove the throttle arm B, Figure 35 from the throttle shaft on the front carburetor. Remove the mounting screw A, Figure 36 and lift the choke linkage B from the starter plunger on the rear carburetor.
Throttle position 1. Screw 2. Choke cable bracket sensor TPS Carburetor heater 3. Top cover 4. Spring Ground terminal 5. Needle retainer Pilot jet 6. Jet needle Spacer 7. If the carburetors were not separated, disconnect the carburetor heater wires by performing Steps in Separation in this section.
Remove the top cover as follows: a. Remove the top cover screws A, Figure When servicing the rear carburetor, remove the choke cable bracket B, Figure 41 from the top cover. Remove the carburetor heater A, Figure 48 and its washer from the bottom of the carburetor body.
When servicing the rear carburetor, also re- move the heater ground terminal B, Figure Remove the mounting screws A, Figure 49 and lift the float bowl B from the carburetor body.
Remove the screw A, Figure 53 and pull the valve seat B from the carburetor body. Remove the pilot jet Figure Remove the starter jet Figure 55 and spacer.
Remove the main jet Figure Install the float pin B, Figure 51 and secure it with the screw A. Install a new float bowl O-ring Figure 50 and set the float bowl onto the bottom of the carburetor B, Figure If removed, install the starter plunger B, Fig- ure Assemble the coasting enricher, if it was disas- sembled, as follows: a.
Install the coasting enricher diaphragm B, Figure 40 onto the carburetor Figure Install the spring A, Figure 40 into the cen- ter of the diaphragm.
Inspect the vacuum piston B, Figure 61 for scoring and wear. Replace it if necessary. Inspect the diaphragm on the vacuum piston for tears, cracks or other damage. Page Fuel Level If a pilot screw must Drill stop be removed, perform the procedure as described, then have a Yamaha deal Plug ership perfom the final adjustment. Page Fuel level inspection re- quires a special fuel level gauge Yamaha part No. Reinstall the carburetor assembly and re- YMA or Perform the test in the listed sequence.
Connect the positive lead of an ohmmeter to the yellow terminal Figure 77 on the sensor side of the connector and connect the negative lead to the black terminal. With the throttle fully closed, rotate the sensor body B, Figure 78 until the resistance is within the fully closed range specified in Table 2. Disconnect the four-pin harness connector from the carburetor heater relay and remove the relay.
Thermo Switch Test 1. Disconnect the two-pin thermo switch connector B, Figure 75 from its harness mate. Replace the thermo switch if the test results are not within the above specifications.
Carburetor Heater Test 1. Disconnect the electrical lead from the carbure- tor heater and remove the heater from the carbure- tor. Tie a piece of heavy string or cord to the ends of the throttle cable at the carburetor.
Starting at the choke lever, carefully pull the cable from the motorcycle, following the path of the original cable. Lubricate the new cable as described in Chap- ter Three. Untie the string from the old cable and tie it to the carburetor end of the new cable. Position the filter so its arrow points toward the fuel pump.
Check the hose clamps for damage; replace them if necessary. After installation is complete, thoroughly check for leaks. Disconnect the electrical lead from the negative battery terminal. Remove the fuel tank and surge tank as de- scribed in this chapter. Remove the frame neck cover Chapter Four- teen. Remove the starting circuit cutoff relay C, Fig- ure 75 from the mounting tang and disconnect the connector from the relay.
Vacuum hose to rear cylinder intake manifold 2. Orifice 3. AIS air filter 4. Air filter housing 5. Air cut valve 6. Reed valve 7. Housing 8. Bracket 9. AIS output hose AIS pipe to rear cylinder Remove the toolbox cover and the side cover from the left side as described in Chapter Fourteen.
Release the hose clamp Figure 96 and discon- nect the AIS pipe from its fitting on each cylinder head. Replace any component that is worn, damaged or out of specification. Fitting 2. Solenoid valve 3. Rollover valve 4. Clamp 5. Label each hose before removal so they can be easily identified during assembly.
Remove the toolbox cover and the side cover from the left side of the motorcycle. Hanger bolt 9. Exhaust manifold 2. Muffler assembly Nut 3. Muffler gasket Front exhaust pipe 4. Clamp screw Exhaust cover 5. Rear exhaust pipe Nut 6. Bolt Loosen the muffler clamp screw A, Figure on each muffler. Remove the muffler hanger bolts B, Figure Pull the muffler assembly rearward.
Separate each muffler from its respective exhaust pipe and remove the muffler assembly. After installation is complete, start the engine and make sure there are no exhaust leaks.
Correct any leak prior to riding the bike. Charging system. Ignition system. The ammeter should read less than 0. If the amperage is greater, there is a current draw on the system that will discharge the battery. Charging Voltage Test 1. Connect an engine tachometer to the spark plug lead on the No. Apply a medium-strength threadlocking compound to the threads of the stator mount- ing screws C, Figure 7 and the pickup coil mounting screws B.
Alternator cover bolt vides longer component life and delivers a strong, tion coil and the magnetic field within the coil col- reliable spark throughout the entire range of engine lapses.
Never connect the battery backwards. If the bat- tery polarity is incorrect, the voltage regulator, al- ternator and ignitor unit will be damaged. Do not disconnect the battery while the engine is running.
Keep all connections between the various units clean and tight. Remove the fuel tank, air filter housing and surge tank as described in Chapter Eight, and the re- move the frame neck cover Chapter Fifteen. Disconnect the electrical lead from the negative battery terminal A, Figure 1. Page Before purchasing a new ignitor unit, have the system checked by a Yamaha dealership or another qualified shop. Most motorcycle dealerships will not accept returns on electrical components.
Apply a dielectric compound to the electrical connectors prior to reconnecting them. Make sure the electrical connections are free of corrosion and are completely coupled to each other. Tighten the screws securely. Install all removed items.
Case bolt Armature 2. Rear end cap Brush holder 12 Armature housing negative brush set Positive brush set 14 Gear plate 5. Planetary gear 6. Remove the front end cap D, Figure 17 from the housing and remove the locating key Figure It could come out with the end cap or it could remain in the housing.
Lift each planetary gear Figure 21 from its post in the front end cap. Remove the shims A, Figure 28 from the commutator end of the armature shaft. Record the number of shims and their locations. Store the shims in a marked plastic bag.
Pull the armature Figure 29 from the arma- ture housing. The number and or- der of the washers and shims varies. Remove the brush holder assembly Figure 32 from the armature housing. Remove the insulator A, Figure 33 from the brush holder assembly. Make sure an insulated portion of each posi- tive brush wire Figure 35 touches the brush holder.
If bare wire from the positive brush touches the brush holder, disassemble the brush holder assembly and reassemble it properly. Page 1. Pull the spring away from each brush and pull undercut is less than specification Table 1 , have the brush out of its holder.
Measure the length of the commutator serviced by a Yamaha dealership or each brush with a vernier caliper. If the length of electrical repair shop. Inspect the commutator copper bars for discolor- ation.
If a pair of bars is discolored, armature coils are grounded. Replace the starter. Measure the diameter of the commutator with a vernier caliper. Replace the starter if the commuta- tor diameter is less than the service limit specified in Undercut Table 1. Lift the starting circuit cutoff relay Figure 47 from its tang and disconnect the pin connector from the relay.
Make sure the electrical terminals are clean and pack the con- nector with dielectric grease. Replace the starting circuit cutoff relay if the ig- nition system diode fails either portion the test. Connect the ohmmeter positive test lead to the red C, Figure 52 terminal in the relay; connect the negative test lead to the black terminal D. The re- lay should have continuity. On XVS models, remove the two headlight housing bolts and remove the hous- ing from the headlight bracket.
On on XVS models, remove the headlight housing bolts and remove the housing from the headlight bracket. Shift pedal 1. Brake lever 1. Brake pedal The shift pedal is located on the left The brake lever is located at the right The brake pedal is on the right side of side of the engine and is used in com- handlebar grip.
Turn the key counterclockwise to EAU Fuel tank cap Fuel the original position, remove it, and then close the lock cover. NOTE: The fuel tank cap cannot be installed unless the key is in the lock. In addition, the key cannot be removed if the cap is not properly installed and locked.
Page Fuel Cock Always turn the fuel as well as to the exhaust system. Turn the fuel cock lever to this position if you run out of fuel while riding. Projection 1. Bolt 2. Seat holder 2. Seat bracket Rider seat To install the rider seat 1. Install the seat bracket and bolts. Install the passenger seat. The storage compartment is located on NOTE: the left side of the vehicle. Make sure that the seats are properly secured before riding.
Pull the ignitor unit panel out to the 5. To increase the spring preload and Spring preload setting: right. To decrease the spring pre- load and thereby soften the sus- Maximum hard : pension, turn the adjusting ring in Therefore, check Page 31 5.
Push the start switch. Does the engine start? The neutral switch may be defective. The motorcycle should not be ridden until checked by a Yamaha dealer. With the engine still running: 6. Move the sidestand up. Keep the clutch lever pulled. Vital components can start to deteriorate quickly and unexpectedly, even if the vehicle remains unused for example, as a result of exposure to the elements.
Any damage, fluid leakage or loss of tire air pressure could have serious consequences. Page Operation And Important Riding Points Become thoroughly familiar system to enable starting, one of the Yamaha dealer check the electrical cir- with all operating controls and following conditions must be met: cuit. The transmission is in the neutral Consult a Yamaha dealer re- position. Page Starting A Warm Engine choke off. The engine trouble warning choke turned off.
Consider the following coast for long periods of time tips to reduce fuel consumption: with the engine off, and do not Turn the starter choke off as Page Engine Break-In Do not park on a slope or on soft during the engine break-in period, tle operation or any condition that might ground, otherwise the vehicle immediately have a Yamaha dealer result in engine overheating must be may overturn.
NOTE: If you do not have the tools or experi- ence required for a particular job, have a Yamaha dealer perform it for you. Page Periodic Maintenance And Lubrication Chart The annual checks must be performed every year, except if a kilometer-based maintenance is performed in- stead.
From km, repeat the maintenance intervals starting from km. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills. The panel shown needs to be removed Since heat and deposits will cause any to perform some of the maintenance spark plug to slowly erode, the spark jobs described in this chapter.
Page 44 Do not attempt to diagnose such problems yourself. Instead, have a Yamaha dealer check the vehicle. Check each spark plug for elec- trode erosion and excessive car- bon or other deposits, and replace 1. Page 46 Oil change quantity: If the oil level warning light flickers 3. In order to prevent clutch slip- 7.
Page Final Gear Oil If any 3. Install the final gear oil drain bolt, NOTE: leakage is found, have a Yamaha deal- and then tighten it to the specified The oil level should be at the brim of the er check and repair the vehicle.
Check the final gear case for oil EAU Cleaning the air filter element leakage. If oil is leaking, check for The air filter element should be cleaned the cause. Page Adjusting The Carburetors The engine should never be op- Yamaha dealer, who has the neces- periodic maintenance and lubrication erated without the air filter ele- sary professional knowledge and expe- chart. To prevent this from occurring, the valve clearance must be adjusted by a Yamaha dealer at the intervals specified in the periodic maintenance and lubrication chart.
Make sure Tire air pressure measured on cold Tires that the total weight of the cargo, rid- tires : To maximize the performance, durabil- er, passenger, and accessories 0—90 kg 0— lb : ity, and safe operation of your motor- Front: cowling, saddlebags, etc. Page Spoke Wheels Yamaha dealer check the internal regarding the specified wheels. The wheel rims should be checked for cracks, bends or warpage, and the spokes for looseness or dam- age before each ride.
If there is air in the hy- Adjusting the brake lever free draulic system, have a Yamaha play dealer bleed the system before operating the motorcycle. Air in the hydraulic system will dimin Page Adjusting The Rear Brake Light Switch If a brake pad has worn to the point that the wear indicator groove has almost disappeared, have a Yamaha dealer replace the brake pads as a set.
Rear brake light switch 2. Rear brake light switch adjusting nut 1. Minimum level mark brake fluid, otherwise the rubber denly, have a Yamaha dealer Rear brake seals may deteriorate, causing check the cause. Page Changing The Brake Fluid EAU EAU Changing the brake fluid Checking and lubricating the Checking and lubricating the Have a Yamaha dealer change the cables throttle grip and cable brake fluid at the intervals specified in The operation of all control cables and The operation of the throttle grip should Recommended lubricant: Lithium-soap-based grease all-pur- pose grease Page Checking The Front Fork Securely support the vehicle so that fork does not operate smoothly, damage and excessive oil leakage.
To check the operation 2. Hold the lower ends of the front 1. Page Checking The Wheel Bearings If there is play in the wheel hub or if the wheel does not turn smoothly, have a Yamaha dealer check the wheel bearings.
Positive battery terminal 2. Negative battery terminal The battery is located behind panel A. Page 62 To charge the battery burns. Avoid any contact with battery damage.
Have a Yamaha dealer charge the bat- skin, eyes or clothing and al- To charge a sealed-type MF tery as soon as possible if it seems to Remove the rider seat.
See page Replacing the fuses The main fuse is located under the igni- 2. Remove quick fasteners tor unit panel.
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