Yzf R-7 1998

OWNER’S SERVICE MANUAL
YZF-R7
5FL-28199-E0
EC010010
YZF-R7
OWNER’S SERVICE MANUAL
1999 by Yamaha Motor Co., Ltd.
1st Edition, December 1998
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
EAU00001
INTRODUCTION
Welcome to the Yamaha world of motorcy-
cling!
As the owner of a YZF-R7, you are benefit-
ing from Yamaha’s vast experience in and
newest technology for the design and the
manufacture of high-quality products,
which have earned Yamaha a reputation for
dependability.
Please take the time to read this manual
thoroughly, so as to enjoy all your YZF-R7’s
advantages. The owner’s service manual
does not only instruct you in how to oper-
ate, inspect and basic maintain your motor-
cycle, but also in how to safeguard yourself
and others from trouble and injury.
In addition, the many tips given in this man-
ual will help to keep your motorcycle in the
best possible condition. If you have any fur-
ther questions, do not hesitate to contact
your Yamaha dealer.
The Yamaha team wishes you many safe
and pleasant rides. So, remember to put
safety first!
EC050000
TO THE NEW OWNER

This manual will provide you with a good
basic understanding of features, operation,
and basic maintenance and inspection
items of this motorcycle. Please read this
manual carefully and completely before
operating your new motorcycle. If you have
any questions regarding the operation or
maintenance of your motorcycle, please
consult your Yamaha dealer.
NOTE:
This manual should be considered a perma-
nent part of this motorcycle and should
remain with it even if the motorcycle is sub-
sequently sold.
EC060000
NOTICE
Some data in this manual may become out-
dated due to improvements made to this
model in the future. If there is any question
you have regarding this manual or your
motorcycle, please consult your Yamaha
dealer.
EC080000
HOW TO USE
THIS MANUAL
EC081000
PARTICULARLY IMPORTANT
INFORMATION
The Safety Alert Symbol means ATTEN-

TION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions
could result in severe injury or death to the
machine operator, a bystander, or a person
inspecting or repairing the motorcycle.
CAUTION:
A CAUTION indicates special precautions
that must be taken to avoid damage to the
motorcycle.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
EC082000
FINDING THE REQUIRED PAGE
1. This manual consists of eight chapters;
“General Information”, “Specifica-
tions”, “Periodic checks and adjust-
ments”, “Engine”, “Cooling system”,
“Electronic fuel injection”, “Chassis”,
“Electrical”.
2. The table of contents is at the begin-
ning of the manual. Look over the gen-
eral layout of the book before finding
the required chapter and item.
Bend the book at its edge, as shown, to
find the required fore edge symbol
mark and go to a page for required
item and description.
EC083000
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The
information has been complied to provide the mechanic with an easy to read, handy refer-
ence that contains comprehensive explanations of all disassembly, repair, assembly, and
inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and
the course of action required will follow the symbol, e.g.,
● Bearings
Pitting/Damage → Replace.
EC084002
HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.
2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is
enclosed by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of sym-
bol marks 3. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 4 accompanies the exploded diagram, providing the order of
jobs, names of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 5 are given
in addition to the exploded diagram and job instruction chart.
EB004000
1 2 SYMBOLS
The following symbols are not relevant to
SPEC every vehicle.
Symbols 1 to 9 indicate the subject of
3 4 each chapter.
CHK 1 General information
ADJ ENG 2 Specifications

3 Periodic checks and adjustments
4 Overhauling the engine
5 6 5 Cooling system
6 Electronic fuel injection
COOL EFI 7 Chassis
8 Electrical
7 8
– +
CHAS ELEC
Symbols 9 to F indicate the following.
9 0
9 Serviceable with engine mounted
0 Filling fluid
A Lubricant
B Special tool
A B C Tightening torque
D Wear limit, clearance
E Engine speed
F Electrical data
C D
T.
R.
E F
Symbols G to L in the exploded diagrams

G H I
indicate the types of lubricants and lubrica-
tion points.
E G M G Engine oil
H Gear oil
J K L I Molybdenum disulfide oil
J Wheel bearing grease
B LS M K Lithium soap base grease
L Molybdenum disulfide grease
Symbols M to N in the exploded diagrams
M N
indicate the following.
New M Apply locking agent (LOCTITE)
LT N Replace the part
INDEX
GENERAL
GEN
INFORMATION
INFO 1
SPECIFICATIONS
SPEC
2
PERIODIC CHECKS
AND CHK
ADJUSTMENTS ADJ 3
OVERHAULING
THE ENGINE ENG
4
COOLING SYSTEM
COOL
5
ELECTRONIC FUEL
INJECTION EFI
6
CHASSIS
CHAS
7
– +
ELECTRICAL
ELEC
8
EC0A0000
CONTENTS
CHAPTER 1
GENERAL INFORMATION
GIVE SAFETY THE RIGHT OF WAY ........ 1-1

DESCRIPTION ........................................... 1-2
INSTRUMENT AND CONTROL
FUNCTIONS .............................................. 1-4
OPERATION AND IMPORTANT
RIDING POINTS ...................................... 1-12
INCLUDED ACCESSORIES ..................... 1-14
MOTORCYCLE CARE AND
STORAGE ................................................ 1-15
CONSUMER INFORMATION ................. 1-17
TROUBLESHOOTING .............................. 1-18
IMPORTANT INFORMATION ................. 1-20
CHECKING THE CONNECTIONS ........... 1-22
SPECIAL TOOLS ..................................... 1-23
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS .................... 2-1

ENGINE SPECIFICATIONS ....................... 2-2
CHASSIS SPECIFICATIONS ................... 2-11
ELECTRICAL SPECIFICATIONS ............. 2-15
TIGHTENING TORQUES ........................ 2-17
LUBRICATION POINTS AND
LUBRICANT TYPES ................................ 2-22
OIL FLOW CHART ................................... 2-24
COOLANT FLOW CHART ....................... 2-25
CABLE ROUTING .................................... 2-26
CHAPTER 3
PERIODIC CHECKS AND
ADJUSTMENTS
INTRODUCTION ....................................... 3-1

PERIODIC MAINTENANCE AND
LUBRICATION INTERVALS ...................... 3-1
GENERAL MAINTENANCE AND
LUBRICATION CHART .............................. 3-2
FUEL TANK AND AIR FILTER .................. 3-4
COWLINGS ............................................... 3-6
ENGINE ..................................................... 3-9
CHASSIS ................................................. 3-36
ELECTRICAL SYSTEM ............................ 3-55
CHAPTER 4
OVERHAULING THE ENGINE
ENGINE ..................................................... 4-1

CAMSHAFTS ............................................. 4-8
CYLINDER HEAD .................................... 4-18
VALVES AND VALVE SPRINGS ............ 4-21
GENERATOR ........................................... 4-32
PICKUP COIL ........................................... 4-35
CLUTCH ................................................... 4-39
SHIFT SHAFT .......................................... 4-48
OIL PAN AND OIL PUMP ....................... 4-50
CRANKCASE ........................................... 4-56
CONNECTING RODS AND
PISTONS ................................................. 4-63
CRANKSHAFT ......................................... 4-74
TRANSMISSION ..................................... 4-79
CHAPTER 5
COOLING SYSTEM
RADIATOR AND THERMOSTAT .............. 5-1

RADIATOR AND THERMOSTAT .............. 5-3
OIL COOLER .............................................. 5-9
WATER PUMP ......................................... 5-12
CHAPTER 6
ELECTRONIC FUEL
INJECTION
ELECTRONIC FUEL INJECTION ............... 6-1
CHAPTER 7
CHASSIS
FRONT WHEEL AND BRAKE DISCS ........ 7-1

REAR WHEEL, BRAKE DISC, AND
REAR WHEEL SPROCKET ........................ 7-9
FRONT AND REAR BRAKES .................. 7-15
HYDRAULIC CLUTCH ............................. 7-43
FRONT FORK .......................................... 7-55
HANDLEBARS ......................................... 7-67
STEERING HEAD .................................... 7-72
REAR SHOCK ABSORBER
ASSEMBLY ............................................. 7-76
SWINGARM AND DRIVE CHAIN ........... 7-80
CHAPTER 8
ELECTRICAL
ELECTRICAL COMPONENTS ................... 8-1

SWITCHES ................................................ 8-2
CHECKING THE SWITCHES ..................... 8-3
CHECKING THE BULBS AND
BULB SOCKETS ........................................ 8-4
IGNITION SYSTEM ................................... 8-7
ELECTRIC STARTING SYSTEM ............. 8-12
CHARGING SYSTEM .............................. 8-16
LIGHTING SYSTEM ................................ 8-19
SIGNALING SYSTEM ............................. 8-21
COOLING SYSTEM ................................. 8-24
ELECTRONIC FUEL INJECTION
SYSTEM .................................................. 8-28
ELECTRICAL CONTROL SYSTEM ......... 8-30
GIVE SAFETY THE RIGHT OF WAY
GENERAL INFORMATION
GIVE SAFETY THE RIGHT OF WAY
Motorcycles are fascinating vehicles, which can give you an unsurpassed feeling of power and freedom. Howev-
er, they also impose certain limits, which you must accept; even the best motorcycle does not ignore the laws of
physics.
1
Regular care and maintenance are essential for preserving your motorcycle’s value and operating condition.
Moreover, what is true for the motorcycle is also true for the rider: good performance depends on being in good
shape. Riding under the influence of medication, drugs and alcohol is, of course, out of the question. Motorcycle
riders – more than car drivers – must always be at their mental and physical best. Under the influence of even
small amounts of alcohol, there is a tendency to take dangerous risks.
Protective clothing is as essential for the motorcycle rider as seat belts are for car drivers and passengers. Al-
ways wear a complete motorcycle suit (whether made of leather or tear-resistant synthetic materials with protec-
tors), sturdy boots, motorcycle gloves and a properly fitting helmet. Optimum protective wear, however, should
not encourage carelessness. Though full-coverage helmets and suits, in particular, create an illusion of total safe-
ty and protection, motorcyclists will always be vulnerable. Riders who lack critical self-control run the risk of going
too fast and are apt to take chances. This is even more dangerous in wet weather. The good motorcyclist rides
safely, predictably and defensively – avoiding all dangers, including those caused by others.
Enjoy your ride!
1-1
DESCRIPTION
DESCRIPTION
Left view
1 1 2,3 4 5 6 7 8 9
Right view
10 1112 13 14
1. Front fork compression damping force adjusting screw

2. Front fork rebound damping force adjusting screw
3. Front fork spring preload adjusting bolt
4. Air filter
5. Starter (choke) “ “
6. Shift pedal
7. Rear shock absorber spring preload adjusting ring
8. Rear shock absorber compression damping force adjusting screw
9. Rear shock absorber rebound damping force adjusting screw
10. Fuses
11. Rear brake resorvoir
12. Rear brake pedal
13. Radiator cap and coolant reservoir tank cap
14. Engine oil filter
1-2
DESCRIPTION
Controls/Instruments
1 2 3 45 6 7 8 9 10
1. Clutch lever
2. Left handlebar switches
3. Clutch reservoir
4. Digital speedometer
5. Main switch
6. Tachometer
7. Front brake reservoir
8. Right handlebar switches
9. Throttle grip
10. Front brake lever
1-3
INSTRUMENT AND CONTROL FUNCTIONS
EAU00029 EAU00040 1. Push

Main switch/Steering lock LOCK 2. Turn
The main switch controls the ignition The steering is locked in this position EW000016
and lighting systems. Its operation is and all electrical circuits are switched WARNING
described below. off. The key can be removed in this po- Never turn the key to “OFF” or
sition. To lock the steering, turn the “LOCK” when the motorcycle is
EAU00036 handlebars all the way to the left. While moving. The electrical circuits will
ON pushing the key into the main switch, be switched off which may result in
Electrical circuits are switched on. The turn it from “OFF” to “LOCK” and re- loss of control or an accident. Be
engine can be started. The key cannot move it. To release the lock, turn the sure the motorcycle is stopped be-
be removed in this position. key to “OFF” while pushing. fore turning the key to “OFF” or
EAU00038
“LOCK”.
OFF
All electrical circuits are switched off.
The key can be removed in this posi-
tion.
EAU01574 EAU00057
(Parking) Turn indicator light “ ”

The steering is locked in this posi- This indicator flashes when the turn
tion, and the taillights and auxiliary switch is moved to the left or right.
lights come on, but all other circuits
are off. The key can be removed in EAU01154
this position. Fuel indicator light “ ”

To use the parking position, first When the fuel level drops below
lock the steering, then turn the key 1. Neutral indicator light “ ” approximately 4.8 L, this light will
to “ ”. Do not use this position for 2. High beam indicator light “ ”
come on. When this light comes
3. Turn indicator light “ ”
an extended length of time as the 4. Fuel indicator light “ ” on, fill the tank at the first opportuni-
battery may discharge. EAU00056
ty. This light circuit can be checked
Indicator lights
by the procedure on page 1-7.
EAU00061
If there is a shortcircuit or disconti-
Neutral indicator light “ ” nuity at the thermistor, the fuel indi-
cator light will flash 8 times and
This indicator comes on when the
then stay off for 3 seconds repeat-
transmission is in neutral.
EAU00063 edly.
High beam indicator light “ ”
This indicator comes on when the
headlight high beam is used.
1-4
● The light will come on and symbol

NOTE:
10 12 “ ” will flash if trouble occurs in
8 14 Even if the oil is filled to the specified
a monitoring circuit. In such a
6 2 level, the indicator light may flicker
x1000r/min
case, take the motorcycle to a
when riding on a slope or during sud-
4 1 Yamaha dealer to have the self- den acceleration or deceleration, but
0
3 diagnostic systems checked. this is normal.
● The light will come on and symbol
4 “ ” will flash if the coolant tem-
1. Warning light perature is too high. The following
2. Oil level symbol “ ”
3. Coolant temperature symbol “ ”
chart shows the conditions of the
4. Engine trouble symbol “ ” indicator light, symbol and tem-
EAU01564 perature display in accordance to
Warning light coolant temperature.
This indicator light has three functions. The light circuit can be checked by the
● The light will come on and symbol procedure on page 1-6.
“ ” will flash if the engine oil EC000118
level is low. CAUTION:

If this symbol flashes, stop the en-
● Do not run the motorcycle until
gine immediately and fill it with oil
to the specified level. you know it has sufficient en-
gine oil.
● Do not run the motorcycle if the
engine is overheated.
CB-74ECB-74E
Coolant
Display Conditions What to do
temperature
Symbol is on and “LO” is

~ 39 ˚C OK. Go ahead with riding.
displayed.
C
Symbol is on and temper-

40 ˚C ~ 120 ˚C OK. Go ahead with riding.
ature is displayed.
C
Stop the motorcycle and al-
Symbol and temperature low it to idle until coolant tem-
121 ˚C ~ 139 ˚C flash. perature goes down.
C Warning light comes on. If the temperature does not
go down, stop the engine.
Symbol and message Stop the engine and allow it

140 ˚C ~ “HI” flash. to cool. Seen page 1-19 if the
C Warning light comes on. engine overheats.
Symbol and message

Ask a Yamaha dealer to in-
— “Err” flash.
spect the motorcycle.
C Warning light comes on.
1-5
Warning light circuit check

CB-75ECB-75E
Turn the main switch to “ON”.
Warning light comes on. After a few seconds: Warning light does not come on.
Warning light goes off. Warning light does not go off. Have a Yamaha dealer inspect
the electrical circuit.
Symbol “ ”, No symbol is on.

“ ”“ ” is on.
Have a Yamaha OK. Go ahead If symbol “ ” If symbol “ ” is on, check the

dealer inspect the with riding. is on, inspect the engine temperature. (See page 1-5.)
electrical circuit. oil level.
Oil level is OK. Oil level is low. If the engine is hot, If the engine
allow it to cool and see temperature is
Have a Yamaha dealer Supply “Engine overheating” normal, have a
inspect the electrical recommended in the troubleshooting Yamaha dealer
circuit. engine oil. chart on page 1-19 for inspect the
instructions. electrical circuit.
If symbol “ ” is on.
Have a Yamaha dealer

inspect the self-
diagnostic systems.
1-6
EAU01295
Fuel indicator light circuit check

CB-46ECB-69E
Turn the main switch to “ON”.
Indicator comes on. Indicator does not come

After a few seconds: on.
Indicator goes off. Indicator does not go off. Have a Yamaha dealer
Inspect the fuel level. inspect the electric
circuit.
OK. Go ahead with Fuel level is OK. Fuel level is low.

riding. Have a Yamaha Supply recommended
dealer inspect the fuel.
electric circuit.
Odometer and trip meter modes Resetting a meter

Use the trip meters to estimate how far To reset a trip odometer to 0.0, select it
you can ride on a tank of fuel. by pushing the “SELECT” button and
Use the fuel reserve trip meter to see push the “RESET” button for at least
the distance traveled from when the one second.
fuel level dropped to the reserve level. To reset the fuel reserve trip meter, se-
lect it by pushing the “SELECT” button
Selecting a mode and push the “RESET” button for at
1. Speedometer Push the “SELECT” button to change least one second. The display will re-
2. Clock, odometer
3. “SELECT” button
between the odometer mode “ODO” turn to “TRIP 1”. If you do not reset the
4. “RESET” button and the trip odometer modes “TRIP 1” fuel reserve trip meter manually, it will
EAU01601
and “TRIP 2” in the following order: automatically reset and return to “TRIP
Digital speedometer
“ODO” → “TRIP 1” → “TRIP 2” → 1” after refueling and the motorcycle
This speedometer is equipped with:
“ODO” has traveled 5 km (3.1 miles).
● an odometer
If the fuel level indicator light comes on
● two trip odometers NOTE:
the odometer display will automatically
● a fuel reserve trip meter After the fuel reserve trip meter is reset,
change to the fuel reserve trip meter
● a clock the display always returns to the “TRIP
mode “TRIP F” and start counting the
1” mode. If “TRIP 2” was being used
NOTE: distance traveled from that point. Push before the fuel reserve trip meter is re-
For UK models only: the “SELECT” button to change be- set, be sure to push the “SELECT” but-
To change the speedometer display tween the fuel odometer, trip odometer ton to change back to the “TRIP 2”
from kilometers to miles, press the “SE- and odometer modes in the following mode.
LECT” button for at least two seconds. order:
“TRIP F” → “TRIP 1” → “TRIP 2” →
“ODO” → “TRIP F”
1-7
2. When the hour digits start flash-

ing, push the “RESET” button to
set the hours. 10 12
8 14
3. Push the “SELECT” button to 1
6 x1000r/min
change the minutes.
4
4. When the minute digits start flash-
0
ing, push the “RESET” button to
set the minutes.
5. Push the “SELECT” button to start
1. Clock, odometer 1. Tachometer
2. “SELECT” button
the clock.
EAU00101
3. “RESET” button
Tachometer
Clock mode NOTE: This model is equipped with an electric
To change the display to the clock After setting the clock, be sure to push tachometer so the rider can monitor the
mode, push both the “SELECT” and the “SELECT” button before turning the engine speed and keep it within the
main switch to “OFF”, otherwise the
“RESET” buttons. ideal power range.
clock will not be set.
To change the display back to the EC000003
odometer mode, push the “RESET” CAUTION:

button.
Do not operate at 13,800 r/min and
above.
To set the clock
1. Push both the “SELECT” and
“RESET” buttons for at least two
seconds.
Diagnosis device If this occurs take your motorcycle to a

This model is equipped with a self diag- Yamaha dealer for repair.
EC000004
nosis.
Refer to “ELECTRICAL CONTROL CAUTION:
SYSTEM USER MODE” in chapter 8. To prevent engine damage, be sure
If some trouble should occur in an elec- to consult a Yamaha dealer as soon
trical circuit the tachometer will repeat- as possible if the tachometer dis-
edly display change in r/min. plays a repeated change in rpm.
1-8
EAU00134
1 Lights switch
3 Turning the lights switch to “ ”, 1
2 turns on the auxiliary light, meter lights
and taillight. Turning the lights switch to
4 “ ”, turns the headlight on also.
2
5 EAU00121
Dimmer switch
Turn the switch to “ ” for the high
1. Pass switch “PASS” 1. Engine stop switch
2. Lights switch beam and to “ ” for the low beam. 2. Start switch “ ”
3. Dimmer switch EAU00138
4. Turn signal switch
EAU00127
Engine stop switch
5. Horn switch “ ”
EAU00118 Turn signal switch The engine stop switch is a safety de-
Handlebar switches To signal a right-hand turn, push the vice for use in an emergency such as
switch to “ ”. To signal a left-hand when the motorcycle overturns or if
EAU00120 turn, push the switch to “ ”. Once trouble occurs in the throttle system.
Pass switch “PASS” Turn the switch to “ ” to start the en-
the switch is released it will return to the
Press the switch to operate the passing gine. In case of emergency, turn the
center position. To cancel the signal,
light. switch to “ ” to stop the engine.
push the switch in after it has returned
to the center position.
EAU00129
Horn switch “ ”
Press the switch to sound the horn.
EAU00143
To adjust the distance between the
Start switch “ ”
1 clutch lever and the handlebar grip,
The starter motor cranks the engine
2 turn the clutch adjusting dial while
when pushing the start switch.
pushing the lever forward. Make sure
EC000005
a the setting on the clutch lever adjusting
CAUTION: dial is aligned with the arrow mark.
See starting instructions prior to
starting the engine.
1. Lever position adjusting dial

2. Arrow mark
a. Lever distance
EAU00153
Clutch lever
The clutch lever is located on the left
handlebar. It is equipped with a clutch
lever adjusting dial and a clutch switch,
which is integrated into the ignition cir-
cuit cut-off system. (Refer to the engine
starting procedures for a description of
this system.) To disengage the clutch,
pull the clutch lever toward the handle-
bar. To engage the clutch, release the
lever. The lever should be pulled rapid-
ly and released slowly for smooth
clutch operation.
1-9
1. Shift pedal 1. Lever position adjusting dial 1. Rear brake pedal

EAU00157 2. Arrow mark EAU00162
a. Lever distance
Shift pedal EAU00161 Rear brake pedal
This motorcycle is equipped with a con- Front brake lever The rear brake pedal is on the right
stant-mesh 6-speed transmission. The front brake lever is located on the side of the motorcycle. Press down on
The shift pedal is located on the left right handlebar and is equipped with a the brake pedal to apply the rear brake.
side of the engine and is used in com- brake lever adjusting dial.
bination with the clutch when shifting. To activate the front brake, pull the le-
ver toward the handlebar.
To adjust the front brake lever position,
turn the brake lever adjusting dial while
pulling the lever forward. Make sure the
setting on the brake lever adjusting dial
is aligned with the arrow mark.
1 NOTE:
This tank cap cannot be closed unless
the key is in the lock. The key cannot
be removed if the cap is not locked
properly.
EW000023
WARNING
1. Open Be sure the cap is properly installed 1. Filler tube
EAU00172 2. Fuel level
and locked in place before riding the
Fuel tank cap motorcycle. EAU01183
To open Fuel
Insert the key and turn it 1/4 turn clock- Make sure there is sufficient fuel in the
wise. The lock will be released and the tank. Fill the fuel tank to the bottom of
cap can be opened. the filler tube as shown in the illustra-
tion.
To close EW000130
Push the tank cap into position with the WARNING

key inserted. To remove the key, turn it Do not overfill the fuel tank. Avoid
counterclockwise to the original posi- spilling fuel on the hot engine. Do
tion. not fill the fuel tank above the bot-
tom of the filler tube or it may over-
flow when the fuel heats up later and
expands.
1 - 10
EAU00185 EAU00331
CAUTION: 1 Sidestand/clutch switch

operation check
Always wipe off spilled fuel immedi- b a Check the operation of the sidestand
ately with a dry and clean soft cloth.
switch and clutch switch against the in-
Fuel may deteriorate painted surfac-
formation below.
es or plastic parts. COPY CD-11ECD-11E
EAU00191 TURN THE MAIN SWITCH TO “ON”

AND THE ENGINE STOP SWITCH TO
Recommended fuel: 1. Starter (choke) “ ” “ ”.
Premium unleaded gasoline EAU00210
with a research octane Starter (choke) “ ”

Starting a cold engine requires a richer TRANSMISSION IS IN GEAR AND
number of 95 or higher.
SIDESTAND IS UP.
Fuel tank capacity: air-fuel mixture. A separate starter cir-
Total: cuit supplies this mixture.
23 L Move in direction a to turn on the PULL IN CLUTCH LEVER AND
Reserve: starter (choke). PUSH THE START SWITCH.
4.8 L Move in direction b to turn off the
starter (choke).
ENGINE WILL START.
NOTE:
If knocking or pinging occurs, use a dif-
ferent brand of gasoline or higher oc- CLUTCH SWITCH IS OK.
tane grade.
SIDESTAND IS DOWN.
CD-11E
ENGINE WILL STALL.
SIDESTAND SWITCH IS OK.
EW000045
WARNING
If improper operation is noted, con-
sult a Yamaha dealer immediately.
1 - 11
OPERATION AND IMPORTANT RIDING POINTS
EAU00373 EAU01382*
WARNING Starting the engine

● Before riding this motorcycle, NOTE:
become thoroughly familiar This motorcycle is equipped with an ig-
with all operating controls and nition circuit cut-off system.
their functions. Consult a The engine can be started only under
Yamaha dealer regarding any one of the following conditions:
control or function that you do ● The transmission is in neutral.
not thoroughly understand. ● The sidestand is up, the transmis-
● Never start your engine or let it sion is in gear and the clutch is
run for any length of time in a disengaged.
closed area. The exhaust fumes The motorcycle must not be ridden
are poisonous and can cause when the sidestand is down.
loss of consciousness and EW000054
death within a short time. Al-
WARNING
ways operate your motorcycle
in an area with adequate venti- Before going through the following
lation. steps, check the function of the sid-
● Before starting out, always be estand switch and clutch switch.
sure the sidestand is up. Fail- (Refer to page 1-11.)
ure to retract the sidestand
completely can result in a seri-
ous accident when you try to
turn a corner.
COPY CF-28ECF-28E
TURN THE MAIN SWITCH TO “ON” AND THE

ENGINE STOP SWITCH TO “ ”.
IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND

SIDESTAND IS DOWN, SIDESTAND IS UP,
PUSH THE START SWITCH. PULL IN THE CLUTCH LEVER AND PUSH START
ENGINE WILL START. SWITCH. ENGINE WILL START.
RETRACT SIDESTAND AND PUT

TRANSMISSION IN GEAR.
MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.
1 - 12
1. Turn the main switch to “ON” and 5. After starting the engine, move
the engine stop switch to “ ”.
NOTE: the starter (choke) to the halfway
If the engine fails to start, release the
ECA00005
position.
start switch, wait a few seconds, then
CAUTION:
try again. Each attempt should be as NOTE:
The warning light and fuel indicator short as possible to preserve the bat- For maximum engine life, never accel-
light should come on for a few sec- tery. Do not crank the engine more erate hard with a cold engine!
onds and then go off. If an indicator than 10 seconds on any one attempt.
light does not go off, refer to the cor- 6. After the engine is warm, turn off
responding indicator light circuit the starter (choke) completely.
check in the “INSTRUMENT AND NOTE:
CONTROL FUNCTIONS” section. The engine is warm when it responds
normally to the throttle with the starter
2. Shift the transmission into neutral.
(choke) turned off.
NOTE:
When the transmission is in neutral, the
neutral indicator light should be on. If
the light does not come on, ask a
Yamaha dealer to inspect it.
3. Turn on the starter (choke) and

completely close the throttle grip.
4. Start the engine by pushing the
start switch.
EAU01258 EC000048
Starting a warm engine CAUTION:

The starter (choke) is not required 6 1
5 ● Do not coast for long periods
when the engine is warm.
4 with the engine off, and do not
EC000046
3
CAUTION: 2 tow the motorcycle a long dis-
N tance. Even with gears in neu-
1
See the “Engine break-in” section tral, the transmission is only
prior to operating the motorcycle for properly lubricated when the
the first time. engine is running. Inadequate
1. Shift pedal
N. Neutral lubrication may damage the
EAU00423
Shifting transmission.
● Always use the clutch when
The transmission lets you control the
changing gears. The engine,
amount of power you have available at
transmission, and driveline are
a given speed for starting, accelerating,
not designed to withstand the
climbing hills, etc. The use of the shift
shock of forced shifting and
pedal is shown in the illustration.
can be damaged by shifting
To shift into neutral, depress the shift
without using the clutch.
pedal repeatedly until it reaches the
end of its travel, then raise the pedal
slightly.
1 - 13
OPERATION AND IMPORTANT RIDING POINTS/
INCLUDED ACCESSORIES
EAU01128 EAU01329 EAU00460
Engine break-in 0 ~ 1,000 km Parking

There is never a more important period Avoid operation above 5,500 r/min. When parking the motorcycle, stop the
in the life of your motorcycle than the engine and remove the ignition key.
period between zero and 1,600 km. For 1,000 ~ 1,600 km EW000058
this reason we ask that you carefully Avoid cruising speeds in excess of WARNING
read the following material. Because 7,000 r/min.
The exhaust system is hot. Park the
EC000052
the engine is brand new, you must not motorcycle in a place where pedes-
put an excessive load on it for the first CAUTION: trians or children are not likely to
1,600 km. The various parts in the en- After 1,000 km of operation, be sure touch the motorcycle. Do not park
gine wear and polish themselves to the to replace the engine oil and oil fil- the motorcycle on a slope or soft
correct operating clearances. During ter. ground; the motorcycle may over-
this period, prolonged full throttle oper- turn.
ation, or any condition which might re-
sult in excessive heating of the engine, 1,600 km and beyond
must be avoided. Proceed with normal riding.
EC000053
CAUTION:
● Never let engine speeds enter
the red zone.
● If any engine trouble should oc-
cur during the break-in period,
consult a Yamaha dealer imme-
diately.
INCLUDED ACCESSORIES
EAU01575 EW000063
Tool kit WARNING

The tools provided in the owner’s tool
Modifications to this motorcycle not
kit are to assist you in the performance
approved by Yamaha may cause
of periodic maintenance. However,
loss of performance, and render it
some other tools such as a torque
unsafe for use. Consult a Yamaha
wrench are also necessary to perform
dealer before attempting any chang-
the maintenance correctly.
es.
The service information included in this
manual is intended to provide you, the
owner, with the necessary information
for completing some of your own pre-
ventive maintenance and minor re-
pairs.
NOTE:
If you do not have necessary tools re-
quired during a service operation, take
your motorcycle to a Yamaha dealer
for service.
1 - 14
MOTORCYCLE CARE AND STORAGE
Care Before cleaning Cleaning

The exposure of its technology makes 1. Cover up the muffler outlet with a After normal use
a motorcycle charming but also vulner- plastic bag. Remove dirt with warm water, a neutral
able. Although high-quality compo- 2. Make sure that all caps and cov- detergent and a soft clean sponge,
nents are used, they are not all rust- ers as well as all electrical cou- then rinse with plenty of clean water.
resistant. While a rusty exhaust pipe plers and connectors, including Use a tooth or bottle brush for hard-to-
may remain unnoticed on a car, it does the spark plug caps, are tightly in- reach parts. Tougher dirt and insects
look unattractive on a motorcycle. Fre- stalled. will come off more easily if the area is
quent and proper care, however, will 3. Remove extremely stubborn dirt, covered with a wet cloth for a few min-
keep your motorcycle looking good, ex- like oil burnt onto the crankcase, utes before cleaning.
tend its life and maintain its perfor- with a degreasing agent and a
mance. Moreover, the warranty states brush, but never apply such prod-
that the vehicle must be properly taken ucts onto seals, gaskets, sprock-
care of. For all these reasons, it is rec- ets, the drive chain and wheel
ommended that you observe the fol- axles. Always rinse the dirt and
lowing cleaning and storing degreaser off with water.
precautions.
ECA00010
● Do not use high-pressure ● Do not rub the frame, swingarm
CAUTION: washers or steam-jet cleaners and other similar matte metal
● Avoid using strong acidic since they cause water seep- parts with a cloth (neither one
wheel cleaners, especially on age and deterioration in the fol- dampened with solvents or
spoked wheels. If you do use lowing areas: seals (of wheel gasoline nor a dry one), as this
such products for hard-to-re- bearings, swingarm bearings, may deteriorate their finish.
move dirt, do not leave it on any forks and brakes), electric com- Wash off dirt with water only.
longer than instructed, then ponents (couplers, connectors, For hard-to-remove dirt, add a
thoroughly rinse it off with wa- instruments, switches and mild detergent and rub only
ter, immediately dry the area lights), breather hoses and lightly.
and apply a corrosion protec- vents.
tion spray. ● For motorcycles equipped with
a windshield: Do not use strong After riding in the rain, near the sea or
● Improper cleaning can damage
cleaners or hard sponges as on salt-sprayed roads
windshields, cowlings, panels
they will cause dulling or Since sea salt or salt sprayed on the
and other plastic parts. Use
scratching. Some cleaning roads in the winter are extremely corro-
only a soft, clean cloth or
compounds for plastic may sive in combination with water, carry
sponge with mild detergent and
leave scratches on the wind- out the following steps after each ride
water to clean plastic.
shield. Test the product on a in the rain, near the sea or on salt-
● Do not use any harsh chemical
small hidden part of the wind- sprayed roads. (Salt sprayed in the
products on plastic parts. Be
shield to make sure they do not winter may remain on the roads well
sure to avoid using cloths or
leave any marks. If the wind- into spring.)
sponges which have been in
contact with strong or abrasive shield is scratched, use a quali-
cleaning products, solvent or ty plastic polishing compound
thinner, fuel (gasoline), rust re- after washing.
movers or inhibitors, brake flu-
id, antifreeze or electrolyte.
1 - 15
1. Clean your motorcycle with cold After cleaning CAUTION:

water and soap after the engine 1. Dry the motorcycle with a cham-
has cooled down. ois or an absorbing cloth. Do not wax the frame, swingarm and
ECA00012
2. Immediately dry the drive chain other similar matte metal parts, as
CAUTION: and lubricate it to prevent it from this may deteriorate their finish.
rusting.
Do not use warm water since it in- 8. Let the motorcycle dry completely
3. Use a chrome polish to shine
creases the corrosive action of the before storing it or covering it.
chrome, aluminum and stainless-
salt.
steel parts, including the exhaust EWA00001
2. Be sure to apply a corrosion pro- system. (Even the thermally in-

WARNING
tection spray on all (even chrome- duced discoloring of stainless-
steel exhaust systems can be re- Make sure that there is no oil or wax
and nickel-plated) metal surfaces
moved through polishing.) on the brakes and tires. If necessary,
to prevent corrosion.
4. To prevent corrosion, it is recom- clean the brake discs and linings
mended to apply a corrosion pro- with a regular brake disc cleaner or
tection spray on all (even chrome- acetone, and wash the tires with
and nickel-plated) metal surfaces. warm water and mild soap. Then,
5. Use spray oil as a universal clean- carefully test the motorcycle for its
er to remove any remaining dirt. braking performance and cornering
6. Touch up minor paint damage behavior.
caused by stones, etc.
7. Wax all painted surfaces.
ECA00013
CAUTION: Storage Long-term

Short-term Long term storage (60 days or more) of
● Apply spray oil and wax spar- your motorcycle will require some pre-
Always store your motorcycle in a cool,
ingly and wipe off any excess. dry place and, if necessary, protect it ventive procedures to guard against
● Never apply oil or wax on rub- deterioration. After throughly cleaning
against dust with a porous cover.
ber and plastic parts, but treat ECA00014 the motorcycle, prepare for storage as
them with a suitable care prod- CAUTION: follows:
uct. 1. Drain the fuel tank.
● Avoid using abrasive polishing ● Storing the motorcycle in a
2. Remove the empty fuel tank, pour
compounds as they wear away poorly ventilated room or cov-
a cup of engine oil in the tank,
the paint. ering it with a tarp while it is still
shake the tank to coat the inner
wet will allow water and humid-
surfaces thoroughly and drain off
NOTE: ity to seep in and cause rust.
the excess oil. Reinstall the tank.
Consult a Yamaha dealer for advice on ● To prevent corrosion, avoid
3. Remove the spark plug, pour
what products to use. damp cellars, stables (because
about one tablespoon of engine
of the presence of ammonia)
oil in the spark plug hole and rein-
and areas where strong chemi-
stall the spark plug. Turn the en-
cals are stored.
gine over several times (ground
spark plug lead wires) to coat the
cylinder walls with oil.
1 - 16
MOTORCYCLE CARE AND STORAGE/
CONSUMER INFORMATION
9. Remove the battery and charge it.

WARNING
Store it in a dry place and re-
When using the starter motor to
change it once a month. Do not
crank the engine, remove the spark
store the battery in an excessively
plug wires, and ground them to pre-
warm or cold place (less than 0°C
vent sparking.
(30°F) or more than 30°C (90°F)).
4. Remove the drive chain. Thor- NOTE:
oughly clean the chain with kero- Make any necessary repairs before
sene and lubricate it. Reinstall the storing the motorcycle.
chain or store it in a plastic bag
(tied to frame for safekeeping).
5. Lubricate all control cables.
6. Block up the frame to raise both
wheels off the ground.
7. Tie a plastic bag over the exhaust
pipe outlet to prevent moisture
from entering.
8. If strong in a humid or salt-air at-
mosphere, coat all exposed metal
surfaces with a light film of oil. Do
not apply oil to any rubber parts or
the seat cover.
CONSUMER INFORMATION
EAU01040
Identification numbers record

Record the key identification number,
vehicle identification number and mod-
el label information in the spaces pro-
vided for assistance when ordering
spare parts from a Yamaha dealer or
for reference in case the vehicle is sto-
len.
1. KEY IDENTIFICATION 1. Key identification number 1. Vehicle identification number
EAU01041 EAU01043
NUMBER:
Key identification number Vehicle identification number
The key identification number is The vehicle identification number is
stamped on the key tag. Record this stamped into the steering head pipe.
number in the space provided and use Record this number in the space pro-
2. VEHICLE IDENTIFICATION it for reference when obtaining a new vided.
NUMBER: key.
NOTE:
The vehicle identification number is
used to identify your motorcycle and
may be used to register your motorcy-
cle with the licensing authority in your
3. MODEL LABEL INFORMATION: state.
1 - 17
CONSUMER INFORMATION/
TROUBLESHOOTING CHART
1. Model label
EAU01049
Model label
The model label is affixed to the loca-
tion shown in the figure. Record the in-
formation on this label in the space
provided. This information will be need-
ed to order spare parts from your
Yamaha dealer.
TROUBLESHOOTING
EW000125
WARNING
Never check the fuel system while smoking or in the vicinity of an open flame.
1. Fuel
Enough fuel. Go to compression check.
Check if there is fuel
in the fuel tank.
No fuel. Supply fuel. Engine doesn’t start, go to compression check.
2. Compression
There is compression. Go to ignition check.
Use electric starter.
Ask a Yamaha dealer to
No compression.
inspect.
3. Ignition Wipe clean with dry cloth and correct Open throttle half-way and start
Wet.
Remove spark spark gap or replace spark plugs. the engine.
plugs and
check electrodes.
Engine doesn’t start, go to battery
Dry. Ask a Yamaha dealer to inspect.
check.
4. Battery Engine turns over

Battery good.
quickly.
Use electric starter. Engine doesn’t start, ask a Yamaha
dealer to inspect.
Engine turns over Check connections or
slowly. recharge.
1 - 18
5. Engine overheating
EW000070
WARNING
Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out
under pressure, which could cause serious injury. Open the radiator cap as follows. Wait until the engine has
cooled. Remove the radiator cap stopper by removing the screw. Place a thick rag like a towel over the radiator cap
and slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it.
Ask a Yamaha dealer to inspect

Leakage.
and repair the cooling system.
Level is low, check the
cooling system for leakage.
No
Add coolant. (See NOTE.)
Wait until the Check the coolant level in the leakage.
engine has cooled. reservoir tank and/or radiator.
Restart the engine. If the engine overheats again, ask a

Level is OK.
Yamaha dealer to inspect and repair the cooling system.
NOTE:
If it is difficult to get the recommended coolant, tap water can be temporarily used, provided that it is changed to the recom-
mended coolant as soon as possible.
1 - 19
IMPORTANT INFORMATION
EB102000
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly,
remove all dirt, mud, dust, and foreign
material.
2. Use only the proper tools and cleaning

equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling, 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. During disassembly, clean all of the
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.
5. Keep all parts away from any source of
fire.
EB102010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function
and appearance, but inferior in quality.
EB102020
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace
all gaskets, seals, and O-rings. All gasket
surfaces, oil seal lips, and O-rings must
be cleaned.
2. During reassembly, properly oil all mat-
ing parts and bearings and lubricate the
oil seal lips with grease.
1 - 20
USING A DYNAMOMETER
The YZF-R7 has a carbon muffler that may
change color when exposed to high tem-
peratures. Therefore, when using a dyna-
mometer always use a fan to cool the
muffler.
EB102030
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/
plates 1 and cotter pins. After the bolt or
nut has been tightened to specification,
bend the lock washer tabs and the cotter
pin ends along a flat of the bolt or nut.
EB102040
BEARINGS AND OIL SEALS
1. Install bearings and oil seals so that the
manufacturer’s marks or numbers are
visible. When installing oil seals, lubri-
cate the oil seal lips with a light coat of
lithium soap base grease. Oil bearings
liberally when installing, if appropriate.
1 Oil seal
CAUTION:
ACHTUNG:
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
1 Bearing
EB102050
CIRCLIPS
Before reassembly, check all circlips care-
fully and replace damaged or distorted cir-
clips. Always replace piston pin clips after
one use. When installing a circlip 1, make
sure that the sharp-edged corner 2 is posi-
tioned opposite the thrust 3 that the circlip
receives.
4 Shaft
1 - 21
CHECKING THE CONNECTIONS
EB103000
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors
for stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect
several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin 1 on the terminal is flattened,
bend it up.
4. Connect:
• lead
• coupler
• connector
NOTE:
Make sure that all connections are tight.
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
• If there is no continuity, clean the termi-
nals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revital-
izer available at most part stores.
1 - 22
SPECIAL TOOLS
EB104000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly.
Use only the appropriate special tools as this will help prevent damage caused by the use of
inappropriate tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Function Illustration

Flywheel puller
90890-01080
This tool is used to remove the generator
rotor.
Rotor holding tool
90890-01235 This tool is used to hold the generator

rotor when removing or installing the gen-
erator rotor bolt or pickup coil rotor bolt.
Drive chain cutter
90890-01286
This tool is used to remove the drive
chain.
Piston pin puller
90890-01304
This tool is used to remove the piston
pins.
Radiator cap Radiator cap tester
tester Adapter
90890-01325
Adapter These tools are used to check the cooling
90890-01352 system.
Steering nut wrench
90890-01403
This tool is used to loosen or tighten the
steering stem ring nuts.
Oil filter wrench
90890-01426
This tool is needed to loosen or tighten
the oil filter cartridge.
Rod holder
90890-01434
This tool is used to support the damper
adjusting rod.
1 - 23
SPECIAL TOOLS

Rod puller Rod puller
90890-01437 Rod puller attachment
Rod puller
attachment These tools are used to pull up the front
90890-01436 fork damper rod.
Fork spring compressor
90890-01441
This tool is used to disassemble or assem-
ble the front fork legs.
Fork seal driver
90890-01442
This tool is used to install the front fork’s
oil seal and dust seal.
Pivot shaft wrench
90890-01471
This tool is used to remove or install the
engine mounting spacer bolts.
Front fork cap bolt wrench
90890-01472
front fork cap bolt.
Damper rod holder
90890-01473 This tool is used to hold the damper rod

assembly when loosening or tightening
the damper rod assembly bolt.
Micrometer (50 ~ 75 mm)
90890-03008
This tool is used to measure the piston
skirt diameter.
Cylinder bore gauge (50 ~ 100 mm)
90890-03017
This tool is used to measure the cylinder
bore.
Vacuum gauge Vacuum gauge
90890-03094 Vacuum gauge attachment
Vacuum gauge
attachment This gauge is used to synchronize the
90890-03060 throttle bodies.
1 - 24
SPECIAL TOOLS

Compression Compression gauge
gauge Adapter
90890-03081
Adapter These tools are used to measure engine
90890-04136 compression.
Pocket tester
90890-03112
This tool is used to check the electrical
system.
Pressure Pressure gauge
gauge Adapter
90890-03153
Adapter These tools are used to measure the fuel
90890-03151 pressure.
Test coupler adapter
90890-03149
control system.
Co, diagnosis switch box MO
DE
Y E UP
S/O
N
D
90890-03171 NO OW
/O N
FF

control system.
Valve spring com- Valve spring compressor
pressor Attachment
90890-04019
Attachment
90890-04108 These tools are used to remove or install
90890-04114 the valve assemblies.
Middle driven shaft Middle driven shaft bearing driver
bearing driver Mechanical seal installer
90890-04058
Mechanical seal
installer These tools are used to install the water
90890-04078 pump seal.
Clutch holding tool
90890-04086 This tool is used to hold the clutch boss

when removing or installing the clutch
boss nut.
Valve guide remover
90890-04111
valve guides.
1 - 25
SPECIAL TOOLS

Valve guide installer
90890-04112
This tool is used to install the valve
guides.
Valve guide reamer
90890-04113
This tool is used to rebore the new valve
guides.
Ignition checker
90890-06754
This tool is used to check the ignition sys-
tem components.
Mity vac
90890-06756
This tool is used to measure the vacuum
pressure.
Engine tachometer
90890-06760
This tool is used to check engine speed.

Yamaha bond No. 1215
90890-85505
This bond is used to seal two mating sur-
faces (e.g., crankcase mating surfaces).
1 - 26
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard Limit
Dimensions
Overall length 2,060 mm (81.1 in) ----
Overall width 720 mm (28.3 in) ----
Overall height 1,125 mm (44.3 in) ----
Seat height 840 mm (33.1 in) ----
Wheelbase
Minimum ground clearance
1,400 mm (55.1 in)
120 mm (4.72 in)
----
----
2
Minimum turning radius 3,800 mm (150 in) ----
Weight
Wet (with oil and a full fuel tank) 207 kg (456 lb) ----
Dry (without oil and fuel) 176 kg (388 lb) ----
Maximum load (total of rider and
accessories) 317 kg (699 lb) ----
2-1
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
Item Standard Limit
Engine
Engine type Liquid-cooled, 4-stroke, DOHC ----
Displacement 749 cm3 ----
Cylinder arrangement Forward-inclined parallel 4-cylinder ----
Bore × stroke 72 × 46 mm (2.83 × 1.81 in) ----
Compression ratio 11.4:1 ----
2 Engine idling speed

Vacuum pressure at engine idling
speed
1,000 ~ 1,200 r/min
15.8 ~ 18.4 kPa
(120 ~ 140 mm Hg, 4.72 ~ 5.51 in Hg)
----
----
Standard compression pressure 157 kPa ----

(at sea level) (1.57 kgf/cm2, 22.3 psi) at 500 r/min
Fuel
Recommended fuel Premium unleaded gasoline ----
Fuel tank capacity
Total (including reserve) 23 L (20.2 Imp qt, 24.3 US qt) ----
Reserve only 4.8 L (4.22 Imp qt, 5.07 US qt) ----
Engine oil
Lubrication system Wet sump ----
Recommended oil ----
Yamalube 4 (20W40) or SAE 20W40 type

SE motor oil (40˚F/5˚C or above)
(Non-Friction modified)
Yamalube 4 (10W40) or SAE 10W40 type
SE motor oil (60˚F/15˚C or below)
Quantity
Total amount 3.6 L (3.2 Imp qt, 3.8 US qt) ----
Without oil filter cartridge 2.6 L (2.3 Imp qt, 2.7 US qt) ----
replacement
With oil filter cartridge replace- 2.8 L (2.5 Imp qt, 3.0 US qt) ----
ment
Oil pressure (hot) 40 kPa (0.4 kgf/cm2, 5.69 psi) at ----
1,100 r/min
Relief valve opening pressure 480 ~ 560 kPa ----
(4.8 ~ 5.6 kgf/cm2, 68.3 ~ 79.7 psi)
2-2
Item Standard Limit
Oil filter
Oil filter type Cartridge (paper) ----
Bypass valve opening pressure 180 ~ 220 kPa ----
(1.8 ~ 2.2 kgf/cm2, 25.6 ~ 31.3 psi)
Oil pump
Oil pump type Trochoidal ----
Inner rotor-to-outer rotor tip clear- 0.09 ~ 0.15 mm (0.004 ~ 0.006 in) ----
ance
Outer rotor-to-oil pump housing 0.03 ~ 0.08 mm (0.001 ~ 0.003 in) ----
clearance
Cooling system
Radiator capacity 2.75 L (2.42 Imp qt, 2.91 US qt)
Radiator cap opening pressure 95 ~ 125 kPa ----
(0.95 ~ 1.25 kgf/cm2, 13.1 ~ 17.8 psi)
Upper radiator core
Width 414 mm (16.3 in) ----
Height 248 mm (9.76 in) ----
Depth 24 mm (0.94 in) ----
Lower radiator core
Width 211 mm (8.31 in) ----
Height 158 mm (6.22 in) ----
Depth 24 mm (0.94 in) ----
Coolant reservoir
Capacity 0.6 L (0.53 Imp qt, 0.63 US qt) ----
Water pump
Water pump type Single-suction centrifugal pump ----
Reduction ratio 88/47 × 28/25 (2.097) ----
Maximum impeller shaft tilt ---- 0.15 mm
(0.006 in)
Starting system type Electric starter
Spark plugs
Model (manufacturer) × quantity R0256R-10 (NGK) × 4 ----
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) ----
Cylinder head
Maximum warpage ---- 0.06 mm
(0.0024 in)
2-3
Item Standard Limit
Camshafts
Drive system Chain drive (right) ----
Camshaft cap inside diameter 24.500 ~ 24.521 mm ----
(0.9646 ~ 0.9654 in)
Camshaft journal diameter 24.452 ~ 24.465 mm ----
(0.9627 ~ 0.9632 in)
Camshaft journal-to-camshaft cap 0.035 ~ 0.069 mm (0.0014 ~ 0.0027 in) ----
clearance
Intake camshaft lobe dimensions
B
Measurement A 33.36 ~ 33.46 mm (1.3134 ~ 1.3173 in) 33.31 mm
(1.3114 in)
Measurement B 24.95 ~ 25.05 mm (0.9823 ~ 0.9862 in) 24.90 mm
(0.9803 in)
Measurement C 8.31 ~ 8.51 mm (0.3272 ~ 0.3350 in) ----
Exhaust camshaft lobe dimen-
sions
B
Measurement A 33.00 ~ 33.10 mm (1.2992 ~ 1.3031 in) 32.95 mm
(1.2972 in)
Measurement B 24.986 ~ 25.086 mm 24.936 mm
(0.9837 ~ 0.9876 in) (0.9817 in)
Measurement C 7.95 ~ 8.15 mm (0.3130 ~ 0.3209 in) ----
Maximum camshaft runout ---- 0.03 mm
(0.0012 in)
2-4
Item Standard Limit
Timing chain
Model/number of links DID219FTH3/100 ----
Tensioning system Automatic ----
Valves, valve seats, valve guides
Valve clearance (cold)
Intake 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) ----
Exhaust 0.25 ~ 0.30 mm (0.0098 ~ 0.0118 in) ----
Valve dimensions
B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
Valve head diameter A

Intake 22.1 ~ 22.3 mm (0.8701 ~ 0.8780 in) ----
Exhaust 23.4 ~ 23.6 mm (0.9213 ~ 0.9291 in) ----
Valve face width B
Intake 0.54 ~ 1.57 mm (0.0213 ~ 0.0618 in) ----
Exhaust 0.88 ~ 1.87 mm (0.0346 ~ 0.0736 in) ----
Valve seat width C
Intake 0.7 ~ 0.9 mm (0.028 ~ 0.035 in) ----
Exhaust 0.7 ~ 0.9 mm (0.028 ~ 0.035 in) ----
Valve margin thickness D
Intake 0.9 ~ 1.2 mm (0.028 ~ 0.047 in) ----
Exhaust 1.0 ~ 1.3 mm (0.039 ~ 0.051 in) ----
Valve stem diameter
Intake 3.983 ~ 3.995 mm (0.1568 ~ 0.1573 in) 3.953 mm
(0.1556 in)
Exhaust 3.978 ~ 3.990 mm (0.1566 ~ 0.1571 in) 3.948 mm
(0.1544 in)
Valve guide inside diameter
Intake 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.05 mm
(0.1594 in)
Exhaust 4.000 ~ 4.012 mm (0.1575 ~ 0.1580 in) 4.05 mm
(0.1594 in)
Valve stem-to-valve guide clear-
ance
Intake 0.005 ~ 0.029 mm (0.0002 ~ 0.0011 in) 0.06 mm
(0.0024 in)
Exhaust 0.010 ~ 0.034 mm (0.0004 ~ 0.0013 in) 0.07 mm
(0.0028 in)
2-5
Item Standard Limit
Valve stem runout ---- 0.01 mm
(0.0004 in)
Valve seat width

Intake 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 1.6 mm
(0.06 in)
Exhaust 0.9 ~ 1.1 mm (0.035 ~ 0.043 in) 1.6 mm
(0.06 in)
Valve springs
Inner spring
Free length
Intake 32.35 mm (1.27 in) 30.73 mm
(1.21 in)
Exhaust 28.82 mm (1.13 in) 27.37 mm
(1.08 in)
Installed length (valve closed)
Intake 27.96 mm (1.10 in) ----
Exhaust 24.6 mm (0.97 in) ----
Compressed spring force
(installed)
Intake 101 ~ 117 N ----
(10.30 ~ 11.93 kgf, 22.7 ~ 26.3 lb)
Exhaust 106 ~ 122 N ----
(10.81 ~ 12.44 kgf, 23.8 ~ 27.4 lb)
Spring tilt
Intake ---- 2.5˚ /1.4 mm

(2.5˚/0.055 in)
Exhaust ---- 2.5˚ /1.3 mm
(2.5˚/0.051 in)
Winding direction (top view)
Intake Counter clockwise ----
Exhaust Counter clockwise ----
2-6
Item Standard Limit
Outer springs
Free length
Intake 36.42 mm (1.43 in) 34.60 mm
(1.36 in)
Exhaust 33.91 mm (1.34 in) 32.21 mm
(1.27 in)
Installed length (valve closed)
Intake 32.03 mm (1.26 in) ----
Exhaust 30.25 mm (1.19 in) ----
(installed)
Intake 230 ~ 266 N ----
(23.45 ~ 27.12 kgf, 51.7 ~ 59.8 lb)
Exhaust 286 ~ 329 N ----
(29.16 ~ 33.55 kgf, 62.3 ~ 74.0 lb)
Spring tilt
Intake ---- 2.5˚ /1.6 mm

(2.5˚/0.063 in)
Exhaust ---- 2.5˚ /1.5 mm
(2.5˚/0.059 in)
Winding direction (top view)
Intake Clockwise ----
Exhaust Clockwise ----
Cylinders
Cylinder arrangement Forward-inclined, parallel 4-cylinder ----
Bore × stroke 72 × 46 mm (2.83 × 1.81 in) ----
Compression ratio 11.4:1 ----
Bore 72.000 ~ 72.008 mm ----
(2.8346 ~ 2.8350 in)
Maximum taper ---- 0.05 mm
(0.0016 in)
Maximum out of round ---- 0.05 mm
(0.0016 in)
2-7
Item Standard Limit
Pistons
Piston-to-cylinder clearance 0.028 ~ 0.054 mm (0.0011 ~ 0.0021 in) 0.1 mm
(0.004 in)
Diameter D 71.954 ~ 71.972 mm ----
(2.8328 ~ 2.8335 in)
H
D
Height H 10 mm (0.39 in) ----
Piston pin bore (in the piston)
Diameter 17.004 ~ 17.015 mm 17.045 mm
(0.6694 ~ 0.6699 in) (0.6711 in)
Offset 0 mm (0 in) ----
Piston pins
Outside diameter 16.995 ~ 17.000 mm 16.975 mm
(0.6691 ~ 0.6693 in) (0.6683 in)
Piston pin-to-piston pin bore 0.004 ~ 0.020 mm 0.070 mm
clearance (0.00016 ~ 0.00079 in) (0.0028 in)
Piston rings
Top ring
B
T
Ring type Barrel ----

Dimensions (B × T) 0.8 × 2.7 mm (0.031 × 0.106 in) ----
End gap (installed) 0.15 ~ 0.25 mm (0.006 ~ 0.010 in) 0.50 mm
(0.020 in)
Ring side clearance 0.03 ~ 0.07 mm (0.0012 ~ 0.0028 in) 0.12 mm
(0.0047 in)
2nd ring
B
T
Ring type Taper ----

End gap (installed) 0.25 ~ 0.35 mm (0.009 ~ 0.014 in) 0.70 mm
(0.028 in)
Ring side clearance 0.02 ~ 0.06 mm (0.0008 ~ 0.0024 in) 0.12 mm
(0.0047 in)
2-8
Item Standard Limit
Oil ring
B
T

End gap (installed) 0.1 ~ 0.3 mm (0.004 ~ 0.012 in) ----
Connecting rods
Crankshaft pin-to-big end bearing 0.058 ~ 0.078 mm (0.0023 ~ 0.0031 in) ----
clearance
Bearing color code 2 = Blue, 3·4 = Black, 5·6 = Brown, ----
7·8 = Green, 9 = Yellow
Crankshaft
F
C C C
E
D
A
B
Width A 54.4 ~ 56.0 mm (2.142 ~ 2.205 in) ----
Width B 292.8 ~ 294.0 mm (11.53 ~ 11.57 in) ----
Maximum runout C 0.035 mm
(0.0014 in)
Big end side clearance D 0.16 ~ 0.26 mm (0.006 ~ 0.010 in) ----
Crankshaft journal-to-crankshaft 0.036 ~ 0.056 mm (0.0014 ~ 0.0022 in) ----
journal bearing clearance
Bearing color code 1·2 = Blue, 3·4 = Black, 5·6 = Brown, 7·8 = ----
Green, 9·10 = Yellow, 11 = Violet
Clutch
Clutch type Wet, multiple disc ----
Clutch release method Hydraulic inner push ----
Operation Left-hand operation ----
Recommended fluid Brake fluid DOT4 ----
Friction plates #1
Thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.8 mm
(0.110 in)
Plate quantity 8 ----
Friction plate #2
Thickness 3.7 ~ 3.9 mm (0.146 ~ 0.154 in) 3.6 mm
(0.142 in)
2-9
Item Standard Limit
Clutch plates
Thickness 1.5 ~ 1.7 mm (0.059 ~ 0.067 in) ----
Maximum warpage ---- 0.1 mm
(0.004 in)
Clutch springs
Free length 7.1 mm (0.280 in) ----
Spring quantity 1 spring per valve ----
Transmission
Transmission type Constant mesh, 6-speed ----
Primary reduction system Spur gear ----
Primary reduction ratio 88/47 (1.872) ----
Secondary reduction system Chain drive ----
Secondary reduction ratio 43/17 (2.529) ----
Operation Left-foot operation ----
Gear ratios
1st gear 38/17 (2.235) ----
2nd gear 36/19 (1.895) ----
3rd gear 35/21 (1.667) ----
4th gear 33/23 (1.435) ----
5th gear 31/24 (1.292) ----
6th gear 27/23 (1.174) ----
Maximum main axle runout ---- 0.08 mm
(0.003 in)
Maximum drive axle runout ---- 0.08 mm
(0.003 in)
Shifting mechanism
Shift mechanism type Shift drum ----
Maximum shift fork guide bar ---- 0.05 mm
bending (0.002 in)
Installed shift rod length 294 mm (11.57 in) ----
Air filter type Dry element ----
Fuel pump
Pump type Electrical ----
Model (manufacturer) 5FL (MITSUBISHI) ----
Output pressure 450 ~ 600 kPa ----
(4.5 ~ 6.0 kgf/cm2, 64 ~ 85 psi)
Throttle bodies
ID mark 5FL1 ----
Throttle valve #100 ----
Intake vacuum pressure 15.8 ~ 18.4 kPa ----
(120 ~ 140 mmHg, 4.72 ~ 5.51 in Hg)
Throttle cable free play (at the 3 ~ 5 mm (0.12 ~ 0.20 in) ----
flange of the throttle grip)
2 - 10
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Frame
Frame type Diamond ----
Caster angle 22.7˚ ----
Trail 95 mm (3.74 in) ----
Front wheel
Wheel type Cast wheel ----
Rim
Size 17 × MT3.50 ----
Material Aluminum ----
Wheel travel 120 mm (4.72 in) ----
Wheel runout
Maximum radial wheel runout ---- 1 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Rear wheel
Wheel type Cast wheel ----
Rim
Size 17 × MT6.00 ----
Material Aluminum ----
Wheel travel 138 mm (5.43 in) ----
Wheel runout
Maximum radial wheel runout ---- 1 mm
(0.04 in)
Maximum lateral wheel runout ---- 0.5 mm
(0.02 in)
Front tire
Tire type Tubeless ----
Size 120/70 ZR17 (58W) ----
Model (manufacturer) MTR01A (PIRELLI) ----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm2, 3.6 psi) ----
90 kg (198 lb) ~ Maximum load* 250 kPa (2.5 kg/cm2, 3.6 psi) ----
High-speed riding 250 kPa (2.5 kg/cm2, 3.6 psi) ----
* Load is the total weight of the rider
and accessories.
Minimum tire tread depth ---- 1.6 mm
(0.06 in)
2 - 11
Item Standard Limit
Rear tire
Tire type Tubeless ----
Size 180/55 ZR17 73W ----
Model (manufacturer) MTR08 (PIRELLI) ----
Tire pressure (cold)
0 ~ 90 kg (0 ~ 198 lb) 250 kPa (2.5 kg/cm2, 3.6 psi) ----
90 kg (198 lb) ~ Maximum load* 290 kPa (2.9 kg/cm2, 4.1 psi) ----
High-speed riding 250 kPa (2.5 kg/cm2, 3.6 psi) ----
* Load is the total weight of the rider
and accessories.
Minimum tire tread depth ---- 1.6 mm
(0.06 in)
Front brakes
Brake type Dual-disc brake ----
Operation Right-hand operation ----
Recommended fluid DOT 4 ----
Brake discs
Diameter × thickness 320 × 5 mm (12.6 × 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.1 mm
(0.004 in)
Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 14 mm (0.55 in) ----

Caliper cylinder inside diameter 30.2 mm (1.19 in) and 27 mm (1.06 in) ----
Rear brake
Brake type Single-disc brake ----
Operation Right-foot operation ----
Brake pedal position (from the top 31~ 36 mm (1.22 ~ 1.42 in) ----
of the brake pedal to the center of
the rider footrest bracket bolt)
Recommended fluid DOT 4 ----
Brake discs
Diameter × thickness 245 × 5 mm (9.65 × 0.20 in) ----
Minimum thickness ---- 4.5 mm
(0.18 in)
Maximum deflection ---- 0.1 mm
(0.004 in)
Brake pad lining thickness 5.5 mm (0.22 in) 0.5 mm
(0.02 in)
Master cylinder inside diameter 12.7 mm (0.5 in) ----

Caliper cylinder inside diameter 38.2 mm (1.50 in) ----
2 - 12
Item Standard Limit
Front suspension
Suspension type Telescopic fork ----
Front fork type Coil spring/oil damper ----
Front fork travel 120 mm (4.72 in) ----
Spring
Free length 240 mm (9.45 in) ----
Spacer length 127 mm (5.00 in) ----
Installed length 226 mm (8.90 in) ----
Spring rate (K1) 9.3 N/mm (0.95 kgf/mm, 53.2 lb/in)
Spring stroke (K1) 0 ~ 120 mm (0 ~ 4.72 in) ----
Optional spring available No ----
Fork oil
Recommended oil Suspension oil “01” or equivalent ----
Quantity (each front fork leg) 460 cm3 (16.2 Imp oz, 15.6 US oz) ----
Level (from the top of the outer 170 mm (6.69 in) ----
tube, with the outer tube fully
down, and without the fork
spring)
Damper adjusting rod locknut dis- 31 mm (1.22 in) ----
tance
Spring preload adjusting positions
Minimum 0 [0 mm ( 0 in)] ----
Standard 14 [14 mm (0.55 in)] ----
Maximum 18-1/2 [18.5 mm (0.73 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 17 ----
Standard* 6 ----
Maximum* 1 ----
Compression damping adjusting
positions
Minimum* 20 ----
Standard* 6 ----
Maximum* 1 ----
* from the fully turned-in position
2 - 13
Item Standard Limit
Steering
Steering bearing type Angular ball bearings ----
Rear suspension
Suspension type Swingarm (link suspension) ----
Rear shock absorber assembly Coil spring/gas-oil damper ----
type
Rear shock absorber assembly 63 mm (2.48 in) ----
travel
Spring
Free length 160 mm (6.30 in) ----
Installed length 146 mm (5.75 in) ----
Spring rate (K1) 95 N/mm (9.69 kgf/mm, 543 lb/in) ----
Spring stroke (K1) 0 ~ 63 mm (0 ~ 2.48 in) ----
Optional spring available No ----
Standard spring preload gas/air 1,200 kPa (12 kgf/cm2, 171 psi) ----
pressure
Spring preload adjusting positions
Minimum 0 [11 mm (0.43 in)] ----
Standard 6 [14 mm (0.55 in)] ----
Maximum 20 [21 mm (0.84 in)] ----
Rebound damping adjusting posi-
tions
Minimum* 50 ----
Standard* 10 ----
Maximum* 0 ----
Compression damping adjusting
positions
Minimum* 25 ----
Standard* 10 ----
Maximum* 0 ----
Swingarm
Free play (at the end of the swing-
arm)
Radial ---- 1 mm
(0.04 in)
Axial ---- 1 mm
(0.04 in)
Drive chain
Model (manufacturer) 50ZVM (DAIDO) ----
Link quantity 118 ----
Drive chain slack 40 ~ 50 mm (1.57 ~ 1.97 in) ----
Maximum ten-link section 150.1 mm (5.91 in) ----
2 - 14
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
Item Standard Limit
System voltage 12 V ----
Ignition system
Ignition system type C.D.I. ----
Ignition timing 5˚ BTDC at 1,100 r/min ----
Advanced timing 55˚ BTDC at 5,000 r/min ----
Advancer type Throttle position sensor and electrical ----
Pickup coil resistance/color 421 ~ 569 Ω / Gy–B ----
C.D.I. unit model (manufacturer) F8T19371 (MITSUBISHI) ----
Ignition coils
Model (manufacturer) F6T549 (MITSUBISHI) ----
Minimum ignition spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.16 ~ 0.21 Ω ----
Secondary coil resistance 5.0 ~ 6.8 kΩ ----
Throttle position sensor standard 4 ~ 6 kΩ ----
resistance
Charging system
System type AC magneto ----
Model (manufacturer) F4T254 (MITSUBISHI) ----
Nominal output 14 V / 22.5 A at 5,000 r/min ----
Stator coil resistance 0.38 ~ 0.46 Ω at 20˚C (68˚F) ----
Rectifier/regulator
Regulator type Semiconductor-short circuit ----
Model SH650D-11 (SHINDENGEN) ----
No-load regulated voltage 14.1 ~ 14.9 V ----
Capacity 18 A ----
Withstand voltage 200 V ----
Battery
Battery type GT9B-4 ----
Battery voltage/capacity 12V / 8AH ----
Headlight type Halogen bulb
Indicator light type × quantity LED × 5
Bulbs (voltage/wattage × quantity)
Headlight R. 12 V 60 W × 1 / L. 12 V 51 W × 1 ----
Auxiliary light 12 V 5 W × 2 ----
Tail/brake light 12 V 5 W / 21 W × 1 ----
Front turn signal light 12 V 21 W × 2 ----
Rear turn signal light 12 V 21 W × 2 ----
Meter light 12 V 1.4 W × 2 ----
2 - 15
ELECTRICAL SPECIFICATIONS SPEC
Item Standard Limit
Electric starting system
System type Constant mesh ----
Starter motor
Model (manufacturer) SM-14 (MITSUBA) ----
Power output 0.6 kW ----
Armature coil resistance 0.0015 ~ 0.0025 Ω ----
Brushes
Overall length 10 mm (0.40 in) 3.5 mm
(0.14 in)
Spring force 7.16 ~ 9.52 N ----
(730 ~ 971 gf, 25.8 ~ 34.3 oz)
Commutator resistance 0.025 ~ 0.035 Ω ----
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.7 mm (0.03 in) ----
Starter relay
Model (manufacturer) MS5F-631 (JIDECO) ----
Amperage 180 A ----
Coil resistance 4.18 ~ 4.62 Ω ----
Horn
Horn type Plain ----
Model (manufacturer) × quantity YF-12 (NIKKO) × 1 ----
Max. amperage 3A ----
Turn signal relay
Relay type Full-transistor ----
Model (manufacturer) FE246BH (DENSO) ----
Self-cancelling device built-in No ----
Turn signal blinking frequency 75 ~ 95 cycles/min. ----
Wattage 21 W × 2 + 3.4 W ----
Oil level switch model (manufac- 071380-0480 (DENSO) ----
turer)
Fuel pump relay model (manufac- G8R-30Y-J (OMRON) ----
turer)
Thermo switch model (manufac- 5EB (NIPPON THERMOSTAT) ----
turer)
Fuses (amperage × quantity)
Main fuse 30 A × 1 ----
Headlight fuse 20 A × 1 ----
Signaling system fuse 20 A × 1 ----
EFI fuse 20 A × 1 ----
ECU fuse 7.5 A × 1 ----
Radiator fan fuse 7.5 A × 1 ----
Backup fuse (odometer) 7.5 A × 1 ----
2 - 16
TIGHTENING TORQUES SPEC
EB202001
TIGHTENING TORQUES
GENERAL TIGHTENING TORQUES
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifica-
tions for special components or assemblies
are provided for each chapter of this man-
ual. To avoid warpage, tighten multi-fas-
tener assemblies in a crisscross pattern and
progressive stages until the specified tight-
ening torque is reached. Unless otherwise
specified, tightening torque specifications
require clean, dry threads. Components
should be at room temperature.
A: Width across flats

B: Thread diameter
General tightening
A B torques
(nut) (bolt)
Nm m•kg ft•lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2 - 17
ENGINE TIGHTENING TORQUES
Tightening torque
Item Fastener Thread size Q’ty Remarks
Nm m·kgf ft·lb
Spark plugs – M10 4 13 1.3 9.4
Cylinder head Nut M10 8 50 5.0 36 E
Cylinder head Cap nut M10 2 50 5.0 36 E
Cylinder head Bolt M6 2 12 1.2 8.7

Camshaft caps Bolt M6 28 10 1.0 7.2 E
Cylinder head cover Bolt M6 6 12 1.2 8.7

Oil passage check bolt Bolt M8 1 20 2.0 14
Cap bolt (timing chain tensioner) Bolt M6 1 10 1.0 7.2
Camshaft sprocket Bolt M7 4 24 2.4 17
Generator rotor Bolt M10 1 65 6.5 47 E
Pickup coil rotor Bolt M10 1 45 4.5 32 E
Water pump inlet pipe Bolt M6 1 10 1.0 7.2 LT
Water pump outlet pipe Bolt M6 1 10 1.0 7.2 LT
Oil/water pump assembly

Bolt M6 1 15 1.5 11 LT
driven sprocket
Oil pump Bolt M6 1 12 1.2 8.7
Oil cooler Bolt M20 1 63 6.3 45 E
Engine oil drain bolt – M14 1 43 4.3 31

Oil strainer housing Bolt M6 2 10 1.0 7.2 LT
Oil/water pump assembly

Bolt M6 1 12 1.2 8.7 LT
driven sprocket cover

Oil delivery pipe Bolt M6 1 10 1.0 7.2 LT
Oil filter bolt Bolt M20 1 70 7.0 50

Oil filter cartridge – M20 1 17 1.7 12 E
Exhaust pipe joints Bolt M8 8 20 2.0 14

Exhaust pipe Bolt M8 1 20 2.0 14
Exhaust pipe bracket Bolt M8 1 24 2.4 17
Exhaust pipe emission check
Bolt M6 4 10 1.0 7.2
bolts
Muffler clamp Bolt M8 1 20 2.0 14
Muffler Bolt M10 1 38 3.8 27
Muffler bracket Bolt M8 2 28 2.8 20
Crankcase (cylinder head) Stud bolt M10 10 10 1.0 7.2 E
Crankcase Bolt M9 10 32 3.2 23 E
Crankcase Bolt M6 14 12 1.2 8.7 E
Generator rotor cover Bolt M6 9 12 1.2 8.7

Clutch cover Bolt M6 9 12 1.2 8.7
Pickup coil rotor cover Bolt M6 7 12 1.2 8.7
2 - 18
Tightening torque
Item Fastener Thread size Q’ty Remarks
Nm m·kgf ft·lb
Shift shaft cover Bolt M6 6 12 1.2 8.7
Oil baffle plate Bolt M6 5 10 1.0 7.2 LT
Timing mark accessing screw – M8 1 15 1.5 11

Starter clutch Bolt M6 3 12 1.2 8.7 LT
Use a lock
Clutch boss Nut M20 1 70 7.0 50
washer.
Clutch spring Bolt M6 6 8 0.8 5.8
Use a lock
Drive sprocket Nut M18 1 70 7.0 50
washer.
Main axle bearing housing Screw M6 3 12 1.2 8.7 LT
Shift drum retainer Bolt M6 2 10 1.0 7.2 LT
Shift shaft spring stopper Bolt M8 1 22 2.2 16 LT
Shift rod locknut Nut M6 2 7 0.7 5.1

Shift arm Bolt M6 1 10 1.0 7.2
Stator coil Bolt M6 3 10 1.0 7.2 LT
Neutral switch – M10 1 20 2.0 14

Pickup coil Screw M5 2 4 0.4 2.9 LT
Thermo switch – M16 1 23 2.3 17

Camshaft sensor Bolt M6 1 10 1.0 7.2 LT
Speed sensor Bolt M6 1 10 1.0 7.2 LT
Coolant temperature sensor – M12 1 18 1.8 13

Intake air temperature sensor – M12 1 18 1.8 13
Intake air pressure sensor Screw M5 2 5 0.5 3.6 LT
Atmospheric pressure sensor Screw M5 2 5 0.5 3.6 LT
Air funnel Bolt M6 8 10 1.0 7.2 LT
Throttle body assembly Bolt M6 16 10 1.0 7.2

Injector 2 cover Bolt M5 8 8 0.8 5.8 LT
Fuel distributor Bolt M6 6 10 1.0 7.2 LT
Injector fuel pipe 1,3 and 4 Union bolt M12 3 30 3.0 22

Injector fuel pipe 2 – M12 1 30 3.0 22
Fuel hose joint pipe Bolt M5 1 6 0.6 4.3 LT
Pressure sensor bracket Bolt M5 2 8 0.8 5.8 LT
2 - 19
Crankcase tightening sequence:
2 - 20
CHASSIS TIGHTENING TORQUES
Tightening torque
Item Thread size Remarks
Nm m·kgf ft·lb
Upper bracket pinch bolts M8 26 2.6 19
Steering stem nut M28 115 11.5 85
Handlebar pinch bolts M6 13 1.3 9.4
Lower ring nut M30 9 0.9 6.5 See NOTE.
Lower bracket pinch bolts M6 11 1.1 8.0
Front brake hose union bolts M10 30 3.0 22
Front brake master cylinder M6 13 1.3 9.4
Engine mounting
Spacer bolts M16 18 1.8 13
Left front mounting bolts M10 40 4.0 29
Right front mounting bolts M10 40 4.0 29
Rear mounting bolts M10 55 5.5 40
Pinch bolts M8 17 1.7 12
Exhaust pipe bracket M8 24 2.4 17
Pivot shaft nut M18 125 12.5 90
Connecting arms M10 40 4.0 29
Relay arm and connecting arms M10 40 4.0 29
Relay arm M10 40 4.0 29
Rear shock absorber and relay arm M10 40 4.0 29
Rear shock absorber assembly M10 40 4.0 29
Fuel pump and fuel tank M5 4 0.4 2.9
Coolant reservoir and radiator M6 5 0.5 3.6
Rider footrest bracket M8 28 2.8 20
Rear master cylinder M8 23 2.3 17
Rear brake hose union bolts M10 30 3.0 22
Sidestand bracket M8 26 2.6 19
Front wheel axle M20 79 7.9 57
Rear wheel axle M24 150 15.0 110
Rear wheel axle nut M24 45 4.5 32
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 M6 18 1.8 13
Rear wheel sprocket and rear wheel
M10 69 6.9 50
drive hub
Brake caliper and bleed screw M8 6 0.6 4.3
Pinch bolt (front wheel axle) M8 23 2.3 17
HINWEIS:
NOTE:
1.First, tighten the ring nut to approximately 18 Nm (1.8 m • kg, 13 ft • lb) with a torque
wrench, then loosen the ring nut completely.
2.Retighten the ring nut to specification.
2 - 21
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB202000
LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant
Oil seal lips LS
O-rings LS
Bearings E
Crankshaft pins E
Piston surfaces E
Piston pins E
Connecting rod bolts and nuts MOLYKOTE® G-n paste

Crankshaft journals E
Camshaft lobes M
Camshaft journals M
Valve stems (intake and exhaust) M
Valve stem ends (intake and exhaust) E
Water pump impeller shaft E
Oil pump rotors (inner and outer) E
Oil pump housing E
Oil strainer E
Starter clutch idle gear inner surface E
Starter clutch assembly E
Primary driven gear E
Transmission gears (wheel and pinion) M
Main axle and drive axle M
Shift drum E
Shift forks and shift fork guide bars E
Shift shaft E
Shift shaft boss LS
Yamaha bond
Cylinder head cover mating surface
No. 1215
Yamaha bond
Cylinder head cover
No. 1215
Yamaha bond
Crankcase mating surface
No. 1215
Yamaha bond
Clutch cover (crankcase mating surface)
No. 1215
Yamaha bond
Generator rotor cover (crankcase mating surface)
No. 1215
Yamaha bond
Pickup coil rotor cover (crankcase mating surface)
No. 1215
2 - 22
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EB202010
CHASSIS LUBRICATION POINTS AND LUBRICANT TYPES
Lubrication point Lubricant

Steering bearings and bearing races (upper and lower) LS
Front wheel oil seal (right and left) LS
Rear wheel oil seal LS
Rear wheel drive hub oil seal LS
Rear wheel drive hub mating surface LS
Rear brake pedal LS
Sidestand pivoting point and metal-to-metal moving parts LS
Throttle grip inner surface LS
Brake lever pivoting point and metal-to-metal moving parts LS
Clutch lever pivoting point and metal-to-metal moving parts LS
Pivot shaft M
Connecting arm bearing (left and right) M
Spacer (relay arm and connecting arm) M
Oil seal (relay arm and connecting arm) M
2 - 23
OIL FLOW CHART SPEC
OIL FLOW CHART
Pressure feed
Timing chain area camshaft
Valve lifter Check bolt
Piston
Connecting rod
Big end bearing Crankshaft journal (#1)
Nozzle Crankshaft journal (#2, #4)
Nozzle Crankshaft journal (#3, #5)
Main gallery
Back torque limiter clutch
Starter clutch Main axle
Main axle gears
Drive axle gears Drive axle
Oil filter cartridge
Oil cooler
Relief valve
Oil pump
Oil strainer
Oil pan
Drain bolt
2 - 24
COOLANT
ELECTRICAL FLOW CHART
SPECIFICATIONS SPEC
COOLANT FLOW CHART
Thermostat assembly
Coolant reservoir
Upper radiator
Water jacket
Lower radiator
Water pump
Oil cooler
Drain bolt
2 - 25
CABLE ROUTING SPEC
CABLE ROUTING
1 Front turn signal coupler
2 Auxiliary light lead
3 Headlight lead
4 Throttle cable
5 Left handlebar switch lead
6 Clutch hose
7 Front brake hose
8 Right handlebar switch lead
9 Main switch lead
2 - 26
CABLE ROUTING SPEC
1 Rear brake switch coupler Å Fasten the coolant reservoir breather hose, thermo
2 Pickup coil lead switch lead and thermostat assembly breather hose
3 Thermo switch lead with a plastic locking tie. Do not crush the breather
4 Wire harness hoses with the plastic locking tie.
5 Rear brake switch lead ı Fasten the right handlebar switch lead with a plastic
6 Ground lead clamp.
7 Starter motor lead
2 - 27
CABLE ROUTING SPEC
1 Left handlebar switch lead 0 Horn lead
2 Starter cable A Headlight and meter sub-wire harness lead
3 Main relay B Throttle cable
4 Speed sensor C Clutch hose
5 Throttle stop screw D Wire harness (to headlight and meter sub-wire harness)
6 Sidestand switch lead E Wire harness
7 Oil level switch lead F Fuel tank overflow hose
8 Main switch lead G Water pump breather hose
9 Headlight and meter sub-wire har- H Coolant reservoir breather hose
ness coupler I Air filter case breather hose
2 - 28
CABLE ROUTING SPEC
J Fuel tank breather hose ı Fasten the starter cable and wire harness with a plastic band.
K CDI unit Ç Fasten the oil level switch lead, speed sensor lead, sidestand
L Fall detection switch switch lead and stator coil assembly lead with a plastic band.
M Fuse box Î Fasten the air filter breather hose, fuel tank overflow hose, clutch
N Relay unit hose and fuel tank breather hose with a plastic band.
‰ 20 mm (0.79 in)
Å Align the portions of the main Ï Route the sidestand switch lead behind the water pump breather
switch lead and left handle- hose.
bar switch lead marked with Ì Route the oil level switch lead to the outside of the water pump
white tape with the radiator breather hose guide.
bracket at the frame.
2 - 29
CABLE ROUTING SPEC
1 Ignition coil A ECU
2 Throttle position sensor coupler B Fuse box
3 Camshaft sensor C Fall detection switch
4 Injector 1 coupler D Starter relay
5 Starter motor E Main relay
6 Fuel tank overflow hose F Throttle stop screw cable
7 Fuel pump coupler G Fuel tank breather hose
8 Rectifier/regurator H Air filter case breather hose
9 Battery I Intake air temperature sensor coupler
0 Turn signal relay J Injector 2 sub-lead
2 - 30
CABLE ROUTING SPEC
K Pickup coil lead U Neutral switch lead
L Stator coil lead V Ground lead
M Speed sensor lead W Coolant temperature sensor coupler
N Sidestand switch lead X Throttle cable
O Oil level switch lead
P Coolant reservoir breather hose Å Route the wire harness in front of the ignition coils.
Q Wire harness ı Be sure that there is no slack in the tail/brake light lead
R Wire harness lead (to fall detection and rear turn signal leads below the rear fender panel.
switch coupler) Ç Align the portions of the wire harness, ground lead and
S Wire harness lead (to fuse box) starter motor lead marked with white tape with the lead
T Starter motor lead holder.
2 - 31
INTRODUCTION/PERIODIC MAINTENANCE AND CHK
LUBRICATION INTERVALS ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjust-
ments. If followed, these preventive maintenance procedures will ensure more reliable vehi-
cle operation, a longer service life and reduce the need for costly overhaul work. This
information applies to vehicles already in service as well as to new vehicles that are being
prepared for sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

EVERY
INITIAL 6,000 km or 12,000 km or

No. ITEM CHECKS AND MAINTENANCE JOBS 6 months 12 months
1,000 km
(whichever (whichever
comes first) comes first)
3 1
2
*
*
Fuel line
Fuel filter
• Check fuel hoses for cracks or damage.
• Replace if necessary.
• Check condition.
√
Every 50,000 km
√
• Check condition.
3 Spark plugs √ √ √
• Clean, regap or replace if necessary.
• Check valve clearance. Every 42,000 km or 42 months (whichever
4 * Valves
• Adjust if necessary. comes first)
5 Air filter element • Clean or replace if necessary. √ √
• Check operation and fluid leakage. (See NOTE on
6 Clutch page 3-2.) √ √ √
• Correct if necessary.
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
7 * Front brake √ √ √
• Correct accordingly.
• Replace brake pads if necessary.
• Check operation, fluid level and vehicle for fluid leak-
age. (See NOTE on page 3-2.)
8 * Rear brake √ √ √
• Replace brake pads if necessary.
• Check balance, runout and for damage.
9 * Wheels √ √
• Rebalance or replace if necessary.
• Check tread depth and for damage.
10 * Tires √ √
• Check air pressure.
• Check bearing for looseness or damage.
11 * Wheel bearings √ √
• Check swingarm pivoting point for play.
12 * Swingarm √ √
• Lubricate with lithium soap base grease every 24,000
km or 24 months (whichever comes first).
• Check chain slack.
• Adjust if necessary. Make sure that the rear wheel is Every 1,000 km and after washing the
13 Drive chain
properly aligned. motorcycle or riding in rain.
• Clean and lubricate.
• Check bearing play and steering for roughness.
14 * Steering bearings √ √
• Lubricate with lithium soap base grease every 24,000
3-1
PERIODIC MAINTENANCE AND LUBRICATION CHK
INTERVALS ADJ
EVERY
INITIAL 6,000 km or 12,000 km or

No. ITEM CHECKS AND MAINTENANCE JOBS 6 months 12 months
1,000 km
(whichever (whichever
comes first) comes first)
• Make sure that all nuts, bolts and screws are properly
15 * Chassis fasteners tightened. √ √
• Tighten if necessary.
• Check operation.
16 Sidestand √ √
• Lubricate and repair if necessary.
17 * Sidestand switch √ √ √
• Check operation and for oil leakage.
18 * Front fork √ √
Rear shock • Check operation and shock absorber for oil leakage.
19 * √ √
absorber assembly • Replace shock absorber assembly if necessary.
Rear suspension
3
relay arm and con-
20 * • Lubricate with lithium soap base grease every 24,000 √ √
necting arm pivot-
ing points
• Check engine idling speed, synchronization and
Electronic fuel
21 * starter operation. √ √ √
injection system
• Adjust if necessary.
• Check oil level and vehicle for oil leakage.
22 Engine oil • Correct if necessary. √ √ √
• Change. (Warm engine before draining.)
Engine oil filter
23 • Replace. √ √
cartridge
• Check coolant level and vehicle for coolant leakage.
24 * Cooling system √ √
• Change coolant every 24,000 km 24 months (which-
ever comes first).
* Since these items require special tools, data and technical skills, they should be serviced by a
Yamaha dealer.
NOTE:
• The air filter element needs more frequent service if you are riding in unusually wet or
dusty areas.
• Hydraulic brake system
– Replace the brake fluid or clutch fluid after disassembling the master cylinder, caliper cyl-
inder or release cylinder.
– Check the brake fluid or clutch fluid level and add fluid as required.
– Replace the master cylinder, caliper cylinder and release cylinder oil seals every two
years.
– Replace the brake hoses and clutch hose every four years, or if cracked or damaged.
3-2
CHK
ADJ
3-3
CHK
FUEL TANK AND AIR FILTER ADJ
EB302010
FUEL TANK AND AIR FILTER
Order Job/Part Q’ty Remarks

Removing the fuel tank and air filter Remove the parts in the order listed.
Fuel Drain.
1 Fuel tank breather hose 1
2 Bolt 2
3 Bolt 2
4 Fuel pump coupler 1 Disconnect.
5 Fuel tank overflow hose 1
6 Fuel return hose 1 Disconnect.
7 Fuel hose 1 Disconnect.
8 Fuel tank 1
9 Air filter case cover 1
10 Air filter element 1
For installation, reverse the removal
procedure.
3-4
CHK
FUEL TANK AND AIR FILTER ADJ
REMOVAL
1. Drain:
• fuel
(completely from the fuel tank)
NOTE:
Remove the fuel tank cap and use a
pump to remove the fuel from the fuel
tank.
The fuel tank must be drained to avoid
leakage at the fuel pump outlet.
2. Disconnect:
• fuel pump coupler
• fuel hose
• fuel return hose
WARNING
WARNING
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
NOTE:
Wrap the rag over the fuel hose joints to
avoid spilling fuel.
3-5
CHK
COWLINGS ADJ
EB302020
COWLINGS

Removing the front cowling Remove the parts in the order listed.
1 Bottom cowling 1
2 Rear view mirror 2
3 Front turn signal coupler 2 Disconnect.
4 Front cowling 1
5 Windshield 1
6 Front turn signal 2
procedure.
3-6
CHK
COWLINGS ADJ

Removing the rear cowling Remove the parts in the order listed.
1 Rear fender 1
2 Rear fender panel 1
3 Tail/brake light connector 2 Disconnect.
4 Rear turn signal connector 4 Disconnect.
5 Rear cowling 1
procedure.
3-7
CHK
COWLINGS ADJ
REMOVAL
1. Remove:
• rear cowling
NOTE:
To remove the quick fastener, push its
center in with a screwdriver, then pull
the fastener out.
INSTALLATION
1. Install:
• rear cowling
NOTE:
To install the quick fastener, push its pin
so that it protrudes from the fastener
head, then insert the fastener into the
cowling and push the pin a in with a
screwdriver. Make sure that the pin is
flush with the fastener’s head.
3-8
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EB303001
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of
the valves.
NOTE:
• Valve clearance adjustment should be
made on a cold engine, at room tem-
perature.
• When the valve clearance is to be mea-
sured or adjusted, the piston must be
at top dead center (TDC) on the com-
pression stroke.
1. Remove:
• bottom cowling
• front cowling
• rear cowling
Refer to “COWLINGS”.
• fuel tank
• air filter case cover
Refer to “FUEL TANK AND AIR FIL-
TER”.
• air filter case
• throttle body assembly
Refer to “ELECTRONIC FUEL INJEC-
TION” IN CHAPTER 6.
• radiator assembly
• thermostat assembly
Refer to “RADIATOR AND THERMO-
STAT” in chapter 5.
2. Disconnect:
• camshaft sensor coupler
• ignition coil couplers
3. Remove:
• ignition coils
• spark plugs
• cylinder head cover 1
• cylinder head cover gasket
4. Remove:
1 • pickup coil lead holder 1
• pickup coil rotor cover 2
2
3-9
CHK
5. Measure:
• valve clearance
b Out of specification → Adjust.
T Valve clearance (cold)

Intake valve
H
0.20 ~ 0.25 mm
a (0.0079 ~ 0.0098 in)
Exhaust valve
0.25 ~ 0.30 mm
(0.0098 ~ 0.0119 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When piston #1 is at TDC on the com-
pression stroke, align the TDC
mark a on the pickup coil rotor with
the crankcase mating surface b.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are
turned away from each other.
c. Measure the valve clearance with a

thickness gauge 1.
NOTE:
• If the valve clearance is incorrect,
record the measured reading.
• Measure the valve clearance in the fol-
lowing sequence.
Valve clearance measuring sequence

Cylinder #1 → #2 → #4 → #3
Å Front
d. To measure the valve clearances of
the other cylinders, starting with cyl-
inder #1 at TDC, turn the crankshaft
counterclockwise as specified in the
following table.
ı Degrees that the crankshaft is turned
counterclockwise
Ç Cylinder
Î Combustion cycle
Cylinder #2 180˚
Cylinder #4 360˚
Cylinder #3 540˚
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 10
CHK
6. Remove:
• timing chain tensioner
• timing chain guide (exhaust side)
• intake camshaft caps
• exhaust camshaft caps
• timing chain
(from the camshaft sprockets)
• intake camshaft
• exhaust camshaft
NOTE:
• Refer to “CAMSHAFTS” in chapter 4.
• When removing the timing chain and
camshafts, fasten the timing chain
with a wire to retrieve it if it falls into
the crankcase.
7. Adjust:
• valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve lifter 1 and the
valve pad 2.
NOTE:
• Cover the timing chain opening with a
rag to prevent the valve pad from fall-
ing into the crankcase.
• Make a note of the position of each
valve lifter 1 and valve pad 2 so that
they can be installed in the correct
place.
b. Select the proper valve pad from the

following table.
Valve pad thick- Available valve
ness range pads
Nos. 25 thicknesses in
1.20 ~
120 ~ 0.05 mm incre-
2.40 mm
240 ments
NOTE:
• The thickness a of each valve pad is
marked in hundredths of millimeters
on the side that touches the valve
lifter.
• Since valve pads of various sizes are
originally installed, the valve pad num-
ber must be rounded in order to reach
the closest equivalent to the original.
3 - 11
CHK
c. Round off the original valve pad num-
ber according to the following table.
Last digit Rounded value

0 or 2 0
5 5
8 10
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
d. Locate the rounded number of the
original valve pad and the measured
valve clearance in the valve pad
selection table. The point where the
column and row intersect is the new
valve pad number.
NOTE:
The new valve pad number is only an
approximation. The valve clearance
must be measured again and the above
steps should be repeated if the measure-
ment is still incorrect.
e. Install the new valve pad 1 and the

valve lifter 2.
NOTE:
• Lubricate the valve pad with molybde-
num disulfide grease.
• Lubricate the valve lifter with molyb-
denum disulfide oil.
• The valve lifter must turn smoothly
when rotated by hand.
• Install the valve lifter and the valve pad
in the correct place.
f. Install the exhaust and intake cam-

shafts, timing chain and camshaft
caps.
Camshaft cap bolt

10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
NOTE:
• Refer to “CAMSHAFTS” in chapter 4.
• Lubricate the camshaft lobes and cam-
shaft journals.
• First, install the exhaust camshaft.
• Align the camshaft marks with the
camshaft cap marks.
• Turn the crankshaft counterclockwise
several full turns to seat the parts.
3 - 12
CHK
VALVE PAD SELECTION TABLE
INTAKE
ı MEASURED Å ORIGINAL VALVE PAD NUMBER
VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 ~ 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.02 ~ 0.07 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.08 ~ 0.13 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.14 ~ 0.19 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.20 ~ 0.25 Ç STANDARD CLEARANCE
0.26 ~ 0.31 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.32 ~ 0.37 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38 ~ 0.43 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.44 ~ 0.49 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.50 ~ 0.55 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.56 ~ 0.61 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.62 ~ 0.67 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68 ~ 0.73 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.74 ~ 0.79 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.80 ~ 0.85 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.86 ~ 0.91 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.92 ~ 0.97 180 185 190 195 200 205 210 215 220 225 230 235 240
0.98 ~ 1.03 185 190 195 200 205 210 215 220 225 230 235 240 Example:
1.04 ~ 1.09 190 195 200 205 210 215 220 225 230 235 240 Valve Clearance (cold)
1.10 ~ 1.15 195 200 205 210 215 220 225 230 235 240
0.20 ~ 0.25 mm (0.008 ~ 0.010 in)
1.16 ~ 1.21 200 205 210 215 220 225 230 235 240
Rounded value 150
1.22 ~ 1.27 205 210 215 220 225 230 235 240
Measured valve clearance is 0.35 mm
1.28 ~ 1.33 210 215 220 225 230 235 240
1.34 ~ 1.39 215 220 225 230 235 240
(0.014 in)
1.40 ~ 1.45 220 225 230 235 240
Replace pad 150 with pad 160
1.46 ~ 1.51 225 230 235 240 Pad No. 150 = 1.50 mm (0.060 in)
1.52 ~ 1.57 230 235 240 Pad No. 160 = 1.60 mm (0.062 in)
1.58 ~ 1.63 235 240 Always install the valve pad with the
1.64 ~ 1.69 240 number facing down.
EXHAUST
ı MEASURED Å ORIGINAL VALVE PAD NUMBER
VALVE CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00 ~ 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.01 ~ 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.07 ~ 0.12 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.13 ~ 0.18 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.19 ~ 0.24 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.25 ~ 0.30 Ç STANDARD CLEARANCE
0.31 ~ 0.36 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.37 ~ 0.42 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43 ~ 0.48 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.49 ~ 0.54 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.55 ~ 0.60 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.61 ~ 0.66 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.67 ~ 0.72 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73 ~ 0.78 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.79 ~ 0.84 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.85 ~ 0.90 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.91 ~ 0.96 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.97 ~ 1.02 180 185 190 195 200 205 210 215 220 225 230 235 240
1.03 ~ 1.08 185 190 195 200 205 210 215 220 225 230 235 240 Example:
1.09 ~ 1.14 190 195 200 205 210 215 220 225 230 235 240 Valve Clearance (cold)
1.15 ~ 1.20 195 200 205 210 215 220 225 230 235 240
0.25 ~ 0.30 mm (0.010 ~ 0.012 in)
1.21 ~ 1.26 200 205 210 215 220 225 230 235 240
Rounded value 175
1.27 ~ 1.32 205 210 215 220 225 230 235 240
Measured valve clearance is
1.33 ~ 1.38 210 215 220 225 230 235 240
1.39 ~ 1.44 215 220 225 230 235 240
0.40 mm (0.016 in)
1.45 ~ 1.50 220 225 230 235 240
Replace pad 175 with pad 185
1.51 ~ 1.56 225 230 235 240 Pad No. 175 = 1.75 mm (0.069 in)
1.57 ~ 1.62 230 235 240 Pad No. 185 = 1.85 mm (0.073 in)
1.63 ~ 1.68 235 240 Always install the valve pad with the
1.69 ~ 1.74 240 number facing down.
3 - 13
ADJUSTING THE VALVE CLEARANCE/ CHK
SYNCHRONIZING THE THROTTLE BODIES ADJ
g. Measure the valve clearance again.
h. If the valve clearance is still out of
specification, repeat all of the valve
clearance adjustment steps until the
specified clearance is obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8. Install:
• all removed parts
NOTE:
procedure. Note the following points.
SYNCHRONIZING THE THROTTLE BODIES

NOTE:
Prior to synchronizing the throttle
bodies, the valve clearance and the
engine idling speed should be properly
adjusted and the ignition timing should
be checked.
1. Stand the motorcycle on a level surface.

NOTE:
Place the motorcycle on a suitable
stand.
2. Remove:
• fuel tank
TER”.
• bottom cowling
• front cowling
3. Remove:
• bolts 1
• copper washers
3 - 14
CHK
SYNCHRONIZING THE THROTTLE BODIES ADJ
4. Install:
1 • vacuum gauge attachments
(into the bolt holes)
• vacuum gauge
(onto the vacuum gauge attachments)
2 • engine tachometer
(onto the ignition coil of cylinder #1)
a
Vacuum gauge
90890-03094
Vacuum gauge attachment
90890-03060
Engine tachometer
90890-06760
NOTE:
Disconnect the ignition coil coupler and
remove the ignition coil 1 of cylinder
#1, remove the rubber cover 2, and
wrap the engine tachometer lead sev-
eral times around section a of the igni-
tion coil. Then, install the ignition coil
and connect the ignition coil coupler.
5. Install:
• fuel tank
TER”.
6. Start the engine and let it warm up for
several minutes.
7. Measure:
• engine idling speed
Out of specification → Adjust.
Refer to “ADJUSTING THE ENGINE
IDLING SPEED”.
Engine idling speed

1,000 ~ 1,200 r/min
8. Adjust:
• throttle body synchronization
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the air screws 1 to adjust the
vacuum pressure of all throttle bodies
to specification.
NOTE:
Do not turn the synchronizing screws.
1 1
3 - 15
SYNCHRONIZING THE THROTTLE BODIES/ CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
Vacuum pressure at engine
idling speed
15.8 ~ 18.4 kPa (120 ~ 140
mm Hg, 4.72 ~ 5.51 in Hg)
NOTE:
The difference in vacuum pressure
between two throttle bodies should not
exceed 1.33 kPa (10 mm Hg, 0.4 in Hg).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Measure:
10.Stop the engine and remove the mea-
suring equipment.
11.Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play

(at the flange of the throttle
grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
ADJUSTING THE ENGINE IDLING SPEED

NOTE:
Prior to adjusting the engine idling
speed, the throttle body synchronization
should be adjusted properly, the air filter
element should be clean, and the engine
should have adequate compression.
1. Start the engine and let it warm up for

several minutes.
2. Remove:
• bottom cowling
• front cowling
3 - 16
ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
3. Install:
• engine tachometer
(onto the ignition coil of cylinder #1)
Engine tachometer
90890-06760
NOTE:
Refer to “SYNCHRONIZING THE THROT-
TLE BODIES” for the engine tachometer
installation.
4. Measure:
Engine idling speed

1,000 ~ 1,200 r/min
5. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the throttle stop screw 1 in
direction a or b until the specified
b engine idling speed is obtained.
a
Engine idling speed is
Direction a
increased.
1
Engine idling speed is
Direction b
decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Adjust:
CABLE FREE PLAY”.

grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
EB303031
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free
play, the engine idling speed and throt-
tle body synchronization should be
adjusted properly.
3 - 17
CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
1. Measure:
• throttle cable free play a

grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Remove:
• fuel tank
TER”.
• air filter case
TION” in chapter 6.
3. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a NOTE:
When the throttle is opened, the acceler-
ator cable 1 is pulled.
2 b 3 Throttle body side
a. Loosen the locknut 2 on the accelera-
tor cable.
b. Turn the adjusting bolt 3 in direction
a or b until the specified throttle
cable free play is obtained.

Direction a
is increased.
Direction b
is decreased.
c. Tighten the locknut.

NOTE:
If the specified throttle cable free play
cannot be obtained on the throttle body
side of the cable, use the adjusting nut
on the handlebar side.
3 - 18
ADJUSTING THE THROTTLE CABLE FREE PLAY/ CHK
CHECKING THE SPARK PLUGS ADJ
Handlebar side
a. Loosen the locknut 4.
b. Turn the adjusting nut 5 in direction
C c or d until the specified throttle
cable free play is obtained.

Direction c
d is increased.
4
7
5
7 Throttle cable free play
Direction d
is decreased.
c. Tighten the locknut.

WARNING
WARNING
After adjusting the throttle cable free
play, start the engine and turn the han-
dlebars to the right and to the left to
ensure that this does not cause the
engine idling speed to change.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB303040
CHECKING THE SPARK PLUGS
the spark plugs.
1. Remove:
• fuel tank
TER”.
• air filter case
2. Disconnect:
• ignition coil couplers
3. Remove:
• ignition coils
• spark plug
CAUTION:
ACHTUNG:
Before removing the spark plugs, blow
away any dirt accumulated in the spark
plug wells with compressed air to pre-
vent it from falling into the cylinders.
4. Check:
• spark plug type
Incorrect → Change.
Spark plugs
Model (manufacturer)
R0256R-10 (NGK)
3 - 19
CHECKING THE SPARK PLUGS/ CHK
MEASURING THE COMPRESSION PRESSURE ADJ
5. Check:
• electrodes 1
Damage/wear → Replace the spark
plug.
• insulator 2
Abnormal color → Replace the spark
plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire
brush)
7. Measure:
• spark plug gap a
(with a wire gauge)
Out of specification → Regap.
Spark plug gap

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
8. Install:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
NOTE:
Before installing the spark plug, clean
the spark plug and gasket surface.
EB303060
MEASURING THE COMPRESSION
PRESSURE
the cylinders.
NOTE:
Insufficient compression pressure will
result in a loss of performance.
1. Measure:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several
minutes, and then stop it.
3 - 20
CHK
3. Remove:
• fuel tank
TER”.
• air filter case
• throttle body assembly
• ignition coil
4. Remove:
• spark plug
CAUTION:
ACHTUNG:
Before removing the spark plugs, use
compressed air to blow away any dirt
accumulated in the spark plug wells to
prevent it from falling into the cylinders.
5. Install:
1 • compression gauge 1
• adapter 2
2 Compression gauge
90890-03081
Adapter
90890-04136
6. Measure:
• compression pressure
Out of specification → Refer to steps
(c) and (d).
Compression pressure (at sea

level)
Minimum
1,500 kPa
(15.0 kg/cm2, 213 psi)
Standard
1,600 kPa
(16.0 kg/cm2, 228 psi)
Maximum
1,700 kPa
(17.0 kg/cm2, 242 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the com-
pression gauge stabilizes.
3 - 21
CHK
WARNING
WARNING
To prevent sparking, ground all spark
plug leads before cranking the engine.
NOTE:
The difference in compression pressure
between cylinders should not exceed
100 kPa (1 kg/cm2, 14 psi).
c. If the compression pressure is above

the maximum specification, check the
cylinder head, valve surfaces, and
piston crown for carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below
the minimum specification, squirt a
few drops of oil into the cylinder and
measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than with- Piston wear or
out oil damage → Repair.
Piston ring(-s),
valve(-s), cylinder
Same as without head gasket or
oil piston possibly
defective →
Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• spark plug
13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
3 - 22
CHK
CHECKING THE ENGINE OIL LEVEL ADJ
EB303070
CHECKING THE ENGINE OIL LEVEL
NOTE:
• Place the motorcycle on a suitable stand.
• Make sure that the motorcycle is
upright.
2. Start the engine, let it idle for several

minutes, and then stop it.
3. Check:
• engine oil level
The engine oil level should be between
the minimum level mark a and maxi-
mum level mark b.
Below the minimum level mark → Add
the recommended engine oil to the
proper level.
Recommended oil
Refer to the chart for the
engine oil grade which is best
suited for certain atmo-
spheric temperatures.
API standard
SE or higher grade
CAUTION:
ACHTUNG:
• Engine oil also lubricates the clutch
and the wrong oil types or additives
could cause clutch slippage. There-
fore, do not add any chemical addi-
tives or use engine oils with a grade of
CD c or higher and do not use oils
labeled “ENERGY CONSERVING II” d
or higher.
• Do not allow foreign materials to
enter the crankcase.

minutes, and then turn it off.
5. Check:
NOTE:
Before checking the engine oil level,
wait a few minutes until the oil has set-
tled.
3 - 23
CHK
CHANGING THE ENGINE OIL ADJ
EB303081
CHANGING THE ENGINE OIL
1. Remove:
• bottom cowling
• front cowling
1 Refer to “COWLINGS”.
3. Place a container under the engine oil
drain bolt.
4. Remove:
• engine oil filler cap 1
• engine oil drain bolt 2
(along with the washer)
5. Drain:
• engine oil
(completely from the crankcase)
6. If the oil filter cartridge is also to be

replaced, perform the following proce-
dure.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the oil filter cartridge 1 with
an oil filter wrench 2.
Oil filter wrench

90890-01426
b. Lubricate the O-ring 3 of the new oil

filter cartridge with a thin coat of
engine oil.
CAUTION:
ACHTUNG:
Make sure that the O-ring 3 is posi-
tioned correctly in the groove of the oil
filter cartridge.
c. Tighten the new oil filter cartridge to

specification with an oil filter wrench.
Oil filter cartridge

17 Nm (1.7 m • kg, 12 ft • lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Check:
• engine oil drain bolt washer
Damage → Replace.
8. Install:
• engine oil drain bolt
43 Nm (4.3 m · kg, 31 ft • lb)
T.
R.
3 - 24
CHK
CHANGING THE ENGINE OIL ADJ
9. Fill:
• crankcase
(with the specified amount of the rec-
ommended engine oil)
Quantity
Total amount
3.6 L (3.2 lmp qt, 3.8 US qt)
Without oil filter cartridge
replacement
2.6 L (2.3 lmp qt, 2.7 US qt)
With oil filter cartridge
replacement
2.8 L (2.5 lmp qt, 3.0 US qt)
10.Install:
• engine oil filler cap
11.Start the engine, warm it up for several
12.Check:
• engine
(for engine oil leaks)
13.Check:
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
14.Check:
• engine oil pressure
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil gallery bolt 1.
b. Start the engine and keep it idling
until engine oil starts to seep from the
oil gallery bolt. If no engine oil comes
out after one minute, turn the engine
1 off so that it will not seize.
c. Check the engine oil passages, the oil
filter cartridge and the oil pump for
damage or leakage. Refer to “OIL
PAN AND OIL PUMP” in chapter 4.
d. Start the engine after solving the
problem(-s) and check the engine oil
pressure again.
e. Tighten the oil gallery bolt to
specification.
Oil gallery bolt
20 Nm (2.0 m • kg, 14 ft • lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 25
CHANGING THE ENGINE OIL/ CHK
CHECKING THE CLUTCH FLUID LEVEL ADJ
15.Install:
• front cowling
• bottom cowling
EB303100
CHECKING THE CLUTCH FLUID LEVEL
NOTE:
• Place the motorcycle on a suitable
stand.
upright.
2. Check:
• clutch fluid level
Below the minimum level mark a →
Add the recommended clutch fluid to
the proper level.
a Recommended clutch fluid

Brake fluid DOT 4
WARNING
WARNING
• Use only the designated clutch fluid.
Other fluids may cause the rubber
seals to deteriorate, causing leakage
and poor clutch performance.
• Refill with the same type of fluid. Mix-
ing fluids may result in a harmful
chemical reaction leading to poor
clutch performance.
• When refilling, be careful that water
does not enter the clutch fluid reser-
voir. Water will significantly lower the
boiling point of the fluid and could
cause vapor lock.
CAUTION:
ACHTUNG:
Clutch fluid may damage painted sur-
faces and plastic parts. Always clean up
any split fluid immediately.
NOTE:
In order to ensure a correct reading of
the clutch fluid level, make sure that the
top of the clutch fluid reservoir is hori-
zontal.
3 - 26
CHK
BLEEDING THE HYDRAULIC CLUTCH SYSTEM ADJ
BLEEDING THE HYDRAULIC CLUTCH
SYSTEM
WARNING
WARNING
Bleed the hydraulic clutch system
whenever:
• the clutch system was disassembled,
• a clutch hose was loosened, discon-
nected or replaced,
• the clutch fluid level is very low,
• clutch operation is faulty.
NOTE:
• Be careful not to spill any clutch fluid
or allow the clutch fluid reservoir to
overflow.
• When bleeding the hydraulic clutch
system, make sure that there is always
enough clutch fluid before applying
the clutch. Ignoring this precaution
could allow air to enter the hydraulic
clutch system, considerably lengthen-
ing the bleeding procedure.
• If bleeding is difficult, it may be neces-
sary to let the clutch fluid settle for a
few hours. Repeat the bleeding proce-
dure when the tiny bubbles in the hose
have disappeared.
1. Bleed:
• hydraulic clutch system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the clutch fluid reservoir to the
proper level with the recommended
clutch fluid.
b. Install the clutch fluid reservoir dia-
phragm.
c. Connect a clear plastic hose 1 tightly
to the bleed screw 2.
1 2
d. Place the other end of the hose into a
container.
e. Slowly apply the clutch several times.
f. Fully squeeze the clutch lever and
hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release
the pressure and cause the clutch lever
to contact the grip.
h. Tighten the bleed screw and then

release the clutch lever.
i. Repeat steps (e) to (h) until all of the
air bubbles have disappeared from
the clutch fluid in the plastic hose.
3 - 27
BLEEDING THE HYDRAULIC CLUTCH SYSTEM/ CHK
CLEANING THE AIR FILTER ELEMENT ADJ
j. Tighten the bleed screw to specifica-
tion.
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
T.
R.
k. Fill the clutch fluid reservoir to the
clutch fluid.
Refer to “CHECKING THE CLUTCH
FLUID LEVEL”.
WARNING
WARNING
After bleeding the hydraulic clutch sys-
tem, check the clutch operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB303130
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• fuel tank
• air filter element
TER”.
2. Clean:
Apply compressed air to the outer sur-
face of the air filter element.
3. Check:
Damage → Replace.
4. Install:
CAUTION:
ACHTUNG:
Never operate the engine without the
air filter element installed. Unfiltered air
will cause rapid wear of engine parts
and may damage the engine. Operating
the engine without the air filter element
will also affect the electronic fuel injec-
tion, leading to poor engine perfor-
mance and possible overheating.
5. Install:
• fuel tank
3 - 28 Refer to “FUEL TANK AND AIR FIL-
TER”.
CHECKING THE FUEL HOSES/ CHK
CHECKING THE CRANKCASE BREATHER HOSE ADJ
CHECKING THE FUEL HOSES
the fuel hoses.
1. Remove:
• fuel tank
TER”.
2. Check:
1 • fuel hose 1
Cracks/damage → Replace.
1 NOTE:
Drain and flush the fuel tank if abrasive
1 damage to any components of the fuel
line is evident.
1
3. Install:
• fuel tank
TER”.
EB303190
CHECKING THE CRANKCASE BREATHER
HOSE
1. Remove:
• fuel tank
TER”.
2. Check:
• crankcase breather hose 1
1
CAUTION:
ACHTUNG:
Make sure that the crankcase breather
hose is routed correctly.
3 - 29
CHECKING THE CRANKCASE BREATHER HOSE/ CHK
CHECKING THE EXHAUST SYSTEM ADJ
3. Install:
• fuel tank
TER”.
EB303200
CHECKING THE EXHAUST SYSTEM
8 The following procedure applies to all of
the exhaust pipes and gaskets.
1. Remove:
4 Refer to “RADIATOR AND THERMO-
1 2. Check:
• exhaust pipe joint 1
3 • exhaust pipe 2
5 • muffler 3
• gasket 4
6 Exhaust gas leaks → Replace.
3. Measure:
• tightening torque
2
7 Exhaust pipe joint bolt 5
20 Nm (2.0 m • kg, 14 ft • lb)
T.
R.
Muffler clamp bolt 6

20 Nm (2.0 m • kg, 14 ft • lb)
Exhaust pipe bolt 7
20 Nm (2.0 m • kg, 14 ft • lb)
Muffler bolt 8
38 Nm (3.8 m • kg, 27 ft • lb)
4. Install:
Refer to “RADIATOR AND THERMO-
3 - 30
CHK
CHECKING THE COOLANT LEVEL ADJ
EB303220
CHECKING THE COOLANT LEVEL
NOTE:
stand.
upright.
2. Remove:
• bottom cowling
• front cowling
b 3. Check:
a • coolant level
The coolant level should be between
the minimum level mark a and maxi-
mum level mark b.
Below the minimum level mark → Add
the recommended coolant to the
proper level.
CAUTION:
ACHTUNG:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However,
soft water may be used if distilled
water is not available.

5. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a
few minutes until the coolant has set-
tled.
3 - 31
CHK
CHECKING THE COOLING SYSTEM ADJ
EB303230
CHECKING THE COOLING SYSTEM
1. Remove:
• bottom cowling
• front cowling
2. Check:
• upper radiator 1
• lower radiator 2
• radiator inlet hose 3
• radiator outlet hose 4
• radiator outlet pipe 5
• radiator joint hose 6
• oil cooler 7
• oil cooler inlet hose 8
• oil cooler outlet hose 9
• water jacket joint inlet hose 0
• water pump inlet pipe A
• water pump outlet pipe B
Refer to “COOLING SYSTEM” in chap-
ter 5.
3. Install:
• front cowling
• bottom cowling
3 - 32
CHK
CHANGING THE COOLANT ADJ
EB303240
CHANGING THE COOLANT
2 1. Remove:
• bottom cowling
• front cowling
1 Refer to “COWLINGS”.
2. Remove:
• coolant reservoir bolts 1
• coolant reservoir cap 2
NOTE:
When draining the coolant from the
coolant reservoir, be sure to tilt the res-
ervoir so that coolant cannot flow
through the coolant reservoir breather
hose 3.
3. Drain:
• coolant
(from the coolant reservoir)
4. Install:
• coolant reservoir bolts
5. Remove:
• radiator cap 1
WARNING
WARNING
A hot radiator is under pressure. There-
1 fore, do not remove the radiator cap
when the engine is hot. Scalding hot
fluid and steam may be blown out,
which could cause serious injury. When
the engine has cooled, open the radiator
cap as follows:
Place a thick rag or a towel over the
radiator cap and slowly turn the radia-
tor cap counterclockwise toward the
detent to allow any residual pressure to
escape. When the hissing sound has
stopped, turn the radiator cap counter-
clockwise while pressing down on it
and then remove it.
6. Remove:
• coolant drain bolt 1
(along with the copper washer)
7. Drain:
• coolant
3 - 33
CHK
8. Check:
• copper washer 1
• coolant drain bolt 2
Damage → Replace.
9. Install:
• coolant drain bolt
7 Nm (0.7 m · kg, 5.1 ft · lb)
T.
R.
10.Fill:
• cooling system
ommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corro-
sion inhibitors for aluminum
engines
Mixing ratio
1:1 (antifreeze: water)
Quantity
Total amount
2.75 L
(2.42 lmp qt, 2.91 US qt)
Coolant reservoir capacity
0.25 L
(0.22 lmp qt, 0.26 US qt)
Handling notes for coolant

Coolant is potentially harmful and should
be handled with special care.
WARNING
WARNING
• If coolant splashes in your eyes, thor-
oughly wash them with water and
consult a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and
then with soap and water.
• If coolant is swallowed, induce vomit-
ing and get immediate medical atten-
tion.
3 - 34
CHK
CAUTION:
ACHTUNG:
• Adding water instead of coolant low-
ers the antifreeze content of the cool-
ant. If water is used instead of coolant,
check, and if necessary, correct the
antifreeze concentration of the cool-
ant.
• Use only distilled water. However,
soft water may be used if distilled
water is not available.
• If coolant comes into contact with
painted surfaces, immediately wash
them with water.
• Do not mix different types of anti-
freeze.
11.Install:
• radiator cap
12.Fill:
• coolant reservoir
(with the recommended coolant to the
maximum level mark a)
a 13.Install:
• coolant reservoir cap
14.Start the engine, warm it up for several
15.Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a
few minutes until the coolant has set-
tled.
16.Install:
• front cowling
• bottom cowling
3 - 35
CHK
ADJUSTING THE REAR BRAKE ADJ
EB304001
CHASSIS
EB304010
ADJUSTING THE REAR BRAKE
1. Measure:
• brake pedal position
(distance a from the top of the brake
a pedal to the bottom of the rider foot-
rest bracket)
Brake pedal position (from the

top of the brake pedal to the
center of the rider footrest
bracket bolt)
31 ~ 36 mm (1.22 ~ 1.42 in)
2. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjusting bolt 2 in direction
a or b until the specified brake pedal
position is obtained.
Direction a Brake pedal is raised.
Direction b Brake pedal is lowered.
WARNING
WARNING
After adjusting the brake pedal position,
check that the end of the adjusting bolt
c is visible through the hole d.
c. Tighten the locknut 1 to specifica-

tion.
Locknut
16 Nm (1.6 m • kg, 11 ft • lb)
T.
R.
WARNING
WARNING
A soft or spongy feeling in the brake
pedal can indicate the presence of air in
the brake system. Before the vehicle is
operated, the air must be removed by
bleeding the brake system. Air in the
brake system will considerably reduce
braking performance and could result in
loss of control and possibly an accident.
Therefore, check and, if necessary,
bleed the brake system.
3 - 36
ADJUSTING THE REAR BRAKE/ CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
CAUTION:
ACHTUNG:
After adjusting the brake pedal position,
make sure that there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• rear brake light switch
Refer to “ADJUSTING THE REAR
BRAKE LIGHT SWITCH”.
EB304020
CHECKING THE BRAKE FLUID LEVEL
NOTE:
stand.
upright.
Å 2. Check:
• brake fluid level
Add the recommended brake fluid to
the proper level.
Recommended brake fluid

DOT 4
Å Front brake
ı Rear brake
ı
WARNING
WARNING
• Use only the designated brake fluid.
Other brake fluids may cause the rub-
ber seals to deteriorate, causing leak-
age and poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor
brake performance.
does not enter the brake fluid reser-
boiling point of the brake fluid and
could cause vapor lock.
CAUTION:
ACHTUNG:
Brake fluid may damage painted sur-
faces and plastic parts. Therefore,
always clean up any spilt brake fluid
immediately.
NOTE:
In order to ensure a correct reading of the
3 - 37
brake fluid level, make sure that the top of
the brake fluid reservoir is horizontal.
CHECKING THE BRAKE PADS/ CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
EB304032
Å
CHECKING THE BRAKE PADS
the brake pads.
1. Operate the brake.
2. Check:
• front brake pad
• rear brake pad
Brake pad wear limit a
Wear limit reached → Replace the
brake pads as a set.
ı Refer to “FRONT AND REAR BRAKES”
in chapter 7.
Brake pad wear limit

0.5 mm (0.02 in)
Å Front brake
ı Rear brake
EB304050
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
• The rear brake light switch is operated
by movement of the brake pedal.
• The rear brake light switch is properly
adjusted when the brake light comes
on just before the braking effect starts.
1. Check:
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the main body 1 of the rear
brake light switch so that it does not
rotate and turn the adjusting nut 2 in
direction a or b until the rear brake
light comes on at the proper time.
Brake light comes on

Direction a
sooner.
Brake light comes on
Direction b
later.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 38
CHECKING THE BRAKE HOSES/ CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EB304062
CHECKING THE BRAKE HOSES
the brake hoses and brake hose clamps.
1. Check:
• brake hose 1
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose → Tighten the clamp bolt.
3. Hold the motorcycle upright and apply
the brake several times.
4. Check:
• brake hose
Brake fluid leakage → Replace the
damaged hose.
Refer to “FRONT AND REAR BRAKES”
in chapter 7.
EB304072
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
WARNING
Bleed the hydraulic brake system when-
ever:
• the brake system was disassembled,
• a brake hose was loosened, discon-
nected or replaced,
• the brake fluid level is very low,
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or
allow the brake fluid reservoir to over-
flow.
• When bleeding the hydraulic brake
system, make sure that there is always
enough brake fluid before applying the
brake. Ignoring this precaution could
allow air to enter the hydraulic brake
system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be neces-
sary to let the brake fluid settle for a
few hours. Repeat the bleeding proce-
dure when the tiny bubbles in the hose
have disappeared.
3 - 39
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
Å 1. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fill the brake fluid reservoir to the
brake fluid.
b. Install the brake fluid reservoir dia-
phragm.
c. Connect a clear plastic hose 1 tightly
to the bleed screw 2.
Å Front brake
ı ı Rear brake
d. Place the other end of the hose into a
container.
e. Slowly apply the brake several times.
f. Fully squeeze the brake lever or fully
depress the brake pedal and hold it in
position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release
the pressure and cause the brake lever
to contact the throttle grip or the brake
pedal to fully extend.
h. Tighten the bleed screw and then

release the brake lever or brake
pedal.
i. Repeat steps (e) to (h) until all of the
air bubbles have disappeared from
the brake fluid in the plastic hose.
j. Tighten the bleed screw to specifica-
tion.
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
T.
R.
k. Fill the brake fluid reservoir to the

brake fluid.
Refer to “CHECKING THE BRAKE
FLUID LEVEL”.
WARNING
WARNING
After bleeding the hydraulic brake sys-
tem, check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 40
ADJUSTING THE SHIFT PEDAL/ CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
EB304081
ADJUSTING THE SHIFT PEDAL
a
b NOTE:
The shift pedal position is determined
by the installed shift rod length a.
1 c 1. Measure:
1 • installed shift rod length a
Incorrect → Adjust.
Installed shift rod length

294 mm (11.57 in)
2. Adjust:
• installed shift rod length a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen both locknuts 1.
b. Turn the shift rod 2 in direction b or
c to obtain the correct shift pedal
position.

Direction b
decreases.
Direction c
increases.
c. Tighten both locknuts.

d. Make sure that the installed shift rod
length is within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB304092
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at
the tightest point on the chain.
CAUTION:
ACHTUNG:
A drive chain that is too tight will over-
load the engine and other vital parts,
and one that is too loose can skip and
damage the swingarm or cause an acci-
dent. Therefore, keep the drive chain
slack within the specified limits.

WARNING
WARNING
Securely support the motorcycle so that
there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand
so that the rear wheel is elevated.
3 - 41
CHK
ADJUSTING THE DRIVE CHAIN SLACK ADJ
2. Rotate the rear wheel several times and
check the drive chain to locate its tight-
est point.
3. Measure:
• drive chain slack a
Drive chain slack

40 ~ 50 mm (1.57 ~ 1.97 in)
4. Adjust:
• drive chain slack
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Loosen the wheel axle nut 1 and
2
a 3 wheel axle.
b. Loosen both locknuts 2.
b c. Turn both adjusting bolts 3 in direc-

tion a or b until the specified drive
chain slack is obtained.
Drive chain slack is

Direction a
decreased.
Drive chain slack is
Direction b
increased.
NOTE:
To maintain the proper wheel align-
ment, adjust both sides evenly.
d. Tighten both locknuts.

e. Tighten the wheel axle and wheel
axle nut to specification.
Wheel axle
150 Nm
T.
R.
(15.0 m • kg, 110 ft • lb)

Wheel axle nut
45 Nm (4.5 m • kg, 32 ft • lb)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 42
LUBRICATING THE DRIVE CHAIN/ CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EB304100
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interact-
ing parts. If the drive chain is not main-
tained properly, it will wear out rapidly.
Therefore, the drive chain should be ser-
viced, especially when the motorcycle is
used in dusty areas. This motorcycle has a
drive chain with small rubber O-rings
between each side plate. Steam cleaning,
high-pressure washing, certain solvents,
and the use of a coarse brush can damage
these O-rings. Therefore, use only kerosine
to clean the drive chain. Wipe the drive
chain dry and thoroughly lubricate it with
engine oil or chain lubricant that is suitable
for O-ring chains. Do not use any other
lubricants on the drive chain since they may
contain solvents that could damage the O-
rings.
Recommended lubricant
Engine oil or chain lubricant
suitable for O-ring chains
EB304130
CHECKING AND ADJUSTING THE
STEERING HEAD
WARNING
WARNING
NOTE:
so that the front wheel is elevated.
2. Check:
• steering head
Grasp the bottom of the front fork legs
and gently rock the front fork.
Looseness/binding → Adjust the steer-
ing head.
3 - 43
CHK
3. Remove:
• bottom cowling
2 1 • front cowling
4. Remove:
• front brake fluid reservoir 1
• clutch fluid reservoir 2
5. Loosen:
• upper bracket pinch bolts 1
• handlebar pinch bolts 2
3
6. Remove:
• upper bracket bolts 3
• handlebars
2 (from the upper bracket)
1
7. Remove:
• steering stem nut 1
• washer 2
• upper bracket 3
1
3 2
8. Adjust:
• steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the lock washer 1, the upper
ring nut 2, and the rubber washer 3.
b. Loosen the lower ring nut 4 and then
tighten it to specification with a ring
nut wrench 5.
NOTE:
Set the torque wrench at a right angle to
the steering nut wrench.
Steering nut wrench

90890-01403
Lower ring nut (initial tighten-

ing torque)
T.
R.
18 Nm (1.8 m • kg, 13 ft • lb)
3 - 44
CHK
c. Loosen the lower ring nut completely,
then tighten it to specification.
WARNING
WARNING
Do not overtighten the lower ring nut.
Lower ring nut (final tightening

torque)
T.
R.
9 Nm (0.9 m • kg, 6.5 ft • lb)
d. Check the steering head for looseness
or binding by turning the front fork all
the way in both directions. If any
binding is felt, remove the lower
bracket and check the upper and
lower bearings.
Refer to “STEERING HEAD” in chap-
ter 7.
e. Install the rubber washer 3.
f. Install the upper ring nut 2.
g. Finger tighten the upper ring nut 2,
then align the slots of both ring nuts.
If necessary, hold the lower ring nut
and tighten the upper ring nut until
their slots are aligned.
h. Install the lock washer 1.
NOTE:
Make sure that the lock washer tabs a
sit correctly in the ring nut slots b.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Install:
• steering stem nut
115 Nm (11.5 m · kg, 85 ft · lb)
T.
R.
• upper bracket bolt

13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
• handlebar pinch bolt

13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
• upper bracket pinch bolt

26 Nm (2.6 m · kg, 16 ft · lb)
T.
R.
10.Measure:
• steering head tension
(with the motorcycle still on the stand)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
NOTE:
Make sure that all of the cables and
wires are properly routed.
a. Point the front wheel straight ahead.
b. Install a plastic locking tie 1 loosely
around the end of the handlebar as
shown.
3 - 45 c. Hook a spring gauge 2 onto the plas-

tic locking tie.
CHECKING AND ADJUSTING THE STEERING HEAD/ CHK
CHECKING THE FRONT FORK ADJ
d. Hold the spring gauge at a 45˚ angle
from the handlebar, pull the spring
gauge, and record the measurement
when the handlebar starts to turn.
Steering head tension

200 ~ 500 g (7.06 ~ 17.65 oz)
e. Repeat the above procedure on the

opposite handlebar.
f. If the steering head tension is out of
specification (both handlebars should
be within specification), remove the
upper bracket and loosen or tighten
the upper ring nut.
g. Reinstall the upper bracket and mea-
sure the steering head tension again
as described above.
h. Repeat the above procedure until the
steering head tension is within speci-
fication.
i. Grasp the bottom of the front fork
legs and gently rock the front fork.
Looseness or binding → Adjust the
steering head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB304141
CHECKING THE FRONT FORK
WARNING
WARNING
2. Check:
• inner tube 1
Damage/scratches → Replace.
• dust seal 2
• oil seal
Oil leakage → Replace.
3. Hold the motorcycle upright and apply
the front brake.
4. Check:
• front fork operation
Push down hard on the handlebars
several times and check if the front
fork rebounds smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 7.
3 - 46
CHK
ADJUSTING THE FRONT FORK LEGS ADJ
EB304153
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of
the front fork legs.
WARNING
WARNING
• Always adjust both front fork legs
evenly. Uneven adjustment can result
in poor handling and loss of stability.
• Securely support the motorcycle so
that there is no danger of it falling
over.
Spring preload
CAUTION:
ACHTUNG:
• Grooves are provided to indicate the
a adjustment position.
• Never go beyond the maximum or
1 minimum adjustment positions.
b
1. Adjust:
• spring preload
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting bolt 1 in direction
a or b.
Spring preload is
Direction a
increased (suspension is
(turns in)
harder).
Spring preload is
Direction b
decreased (suspension is
(turns out)
softer).
Adjusting positions
Minimum: 0 turns in direction*
Standard: 14 turns in direction*
Maximum: 18-1/2 turns in direction*
* after fully turning the adjusting
bolt in direction b
NOTE:
With each turn of the adjusting bolt, the
installed length of the fork spring is
changed by 1 mm.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 47
CHK
ADJUSTING THE FRONT FORK LEGS ADJ
Rebound damping
1
CAUTION:
ACHTUNG:
b
Never go beyond the maximum or mini-
a mum adjustment positions.
1. Adjust:
• rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting screw 1 in direc-
tion a or b.
Rebound damping is
Direction a increased (suspension is
harder).
Rebound damping is
Direction b decreased (suspension is
softer).
Adjusting positions
Minimum: 17 clicks out*
Standard: 6 clicks out*
Maximum: 1 clicks out*
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
CAUTION:
ACHTUNG:
mum adjustment positions.
1. Adjust:
• compression damping
a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 tion a or b.
b
Compression damping is
harder).
softer).
Adjusting positions
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 48
CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
EB304162
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNING
WARNING
Spring preload
CAUTION:
ACHTUNG:
1. Adjust:
a
• spring preload
NOTE:
Adjust the spring preload with the spe-
1 cial wrench and extension bar included
b in the owner’s tool kit.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting knob 1 in direc-
tion a or b.
Spring preload is
Direction a
increased (suspension is
(turns in)
harder).
Spring preload is
Direction b
decreased (suspension is
(turns out)
softer).
Adjusting positions
Minimum: 0 turns in*
Standard: 6 turns in *
Maximum: 20 turns in *
* from the fully turned-out position
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 49
CHK
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY ADJ
Rebound damping
1 CAUTION:
ACHTUNG:
b a 1. Adjust:
• rebound damping
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tion a or b.
Rebound damping is
harder).
Rebound damping is
softer).
Adjusting positions
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Compression damping
CAUTION:
ACHTUNG:
1. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Turn the adjusting screw 1 in direc-
tion a or b.
b a Compression damping is
harder).
softer).
Adjusting positions
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 50
CHK
CHECKING THE TIRES ADJ
EB304170
CHECKING THE TIRES
the tires.
1. Measure:
• tire pressure
Out of specification → Regulate.
WARNING
WARNING
• The tire pressure should only be
checked and regulated when the tire
temperature equals the ambient air
temperature.
• The tire pressure and the suspension
must be adjusted according to the
total weight (including cargo, rider,
passenger and accessories) and the
anticipated riding speed.
• Operation of an overloaded motorcy-
cle could cause tire damage, an acci-
dent or an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil
207 kg (456 lb)
and a full
fuel tank)
Maximum
317 kg (699 lb)
load*
Cold tire
Front Rear
pressure
Up to 90 kg 250 kPa 250 kPa
(198 lb) (2.5 kgf/cm2, (2.5 kgf/cm2,
load* 36 psi) 36 psi)
90 kg (198 lb) 250 kPa 290 kPa
~ maximum (2.5 kgf/cm2, (2.9 kgf/cm2,
load* 36 psi) 41 psi)
250 kPa 250 kPa
High-speed
(2.5 kgf/cm2, (2.5 kgf/cm2,
riding
36 psi) 36 psi)
* total of cargo, rider and accessories
WARNING
WARNING
It is dangerous to ride with a worn-out
tire. When the tire tread reaches the
wear limit, replace the tire immediately.
3 - 51
CHK
CHECKING THE TIRES ADJ
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth

1.6 mm (0.06 in)
1 Tire tread depth
2 Side wall
3 Wear indicator
WARNING
WARNING
Å ı • Do not use a tubeless tire on a wheel
designed only for tube tires to avoid
tire failure and personal injury from
sudden deflation.
• When using a tube tire, be sure to
install the correct tube.
• Always replace a new tube tire and a
new tube as a set.
• To avoid pinching the tube, make sure
that the wheel rim band and tube are
centered in the wheel groove.
• Patching a punctured tube is not rec-
ommended. If it is absolutely neces-
sary to do so, use great care and
replace the tube as soon as possible
with a good quality replacement.
Å Tire ı Wheel
Tube wheel Tube tire only
Tube or tubeless
Tubeless wheel
tire
• After extensive tests, the tires listed
below have been approved by
Yamaha Motor Co., Ltd. for this
model. The front and rear tires should
always be by the same manufacturer
and of the same design. No guarantee
concerning handling characteristics
can be given if a tire combination
other than one approved by Yamaha is
used on this motorcycle.
Front tire
Manufacturer Size Model
120/70 ZR17
PIRELLI MTR01A
(58W)
Rear tire
Manufacturer Size Model
180/55 ZR17
PIRELLI MTR08
(73W)
3 - 52
CHK
CHECKING THE TIRES/CHECKING THE WHEELS ADJ
WARNING
WARNING
After mounting a new tire, ride conser-
vatively for a while to become accus-
tomed to the “feel” of the new tire and
to allow the tire to seat itself properly in
the rim. Failure to do so could lead to an
accident with possible injury to the rider
or damage to the motorcycle.
NOTE:
For tires with a direction of rotation
mark 1:
• Install the tire with the mark pointing
in the direction of wheel rotation.
• Align the mark 2 with the valve instal-
lation point.
EB304180
CHECKING THE WHEELS
the wheels.
1. Check:
• wheel
Damage/out-of-round → Replace.
WARNING
WARNING
Never attempt to make any repairs to
the wheel.
NOTE:
After a tire or wheel has been changed
or replaced, always balance the wheel.
3 - 53
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS AND PEDALS/LUBRICATING THE CHK
SIDESTAND/LUBRICATING THE REAR SUSPENSION ADJ
EB304200
CHECKING AND LUBRICATING THE
CABLES
the cable sheaths and cables.
WARNING
WARNING
Damaged cable sheaths may cause the
cable to corrode and interfere with its
movement. Replace damaged cable
sheaths and cables as soon as possible.
1. Check:
• cable sheath
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Engine oil or a suitable cable
lubricant
NOTE:
Hold the cable end upright and pour a
few drops of lubricant into the cable
sheath or use a suitable lubing device.
EB304210
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-
metal moving parts of the levers and ped-
als.
Lithium soap base grease
EB304220
LUBRICATING THE SIDESTAND
metal moving parts of the sidestand.
EB304240
LUBRICATING THE REAR SUSPENSION
metal moving parts of the rear suspension.
Molybdenum disulfide grease
3 - 54
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EB305020
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
WARNING
Batteries generate explosive hydrogen
gas and contain electrolyte which is
made of poisonous and highly caustic
sulfuric acid.
Therefore, always follow these preven-
tive measures:
• Wear protective eye gear when han-
dling or working near batteries.
• Charge batteries in a well-ventilated
area.
• Keep batteries away from fire, sparks
or open flames (e.g., welding equip-
ment, lighted cigarettes).
• DO NOT SMOKE when charging or
handling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte
as it can cause severe burns or perma-
nent eye injury.
FIRST AID IN CASE OF BODILY CON-
TACT:
EXTERNAL
• Skin – Wash with water.
• Eyes – Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk
followed with milk of magnesia,
beaten egg or vegetable oil. Get
immediate medical attention.
CAUTION:
ACHTUNG:
• This is a sealed battery. Never remove
the sealing caps because the balance
between cells will not be maintained
and battery performance will deterio-
rate.
• Charging time, charging amperage
and charging voltage for an MF bat-
tery are different from those of con-
ventional batteries. The MF battery
should be charged as explained in the
charging method illustrations. If the
battery is overcharged, the electrolyte
level will drop considerably. There-
fore, take special care when charging
the battery.
3 - 55
CHK
NOTE:
Since MF batteries are sealed, it is not
possible to check the charge state of the
battery by measuring the specific gravity
of the electrolyte. Therefore, the charge of
the battery has to be checked by measur-
ing the voltage at the battery terminals.
1. Remove:
• rear cowling
• rear cowling bracket 1
• battery band 2
4 3 2. Disconnect:
• battery leads
(from the battery terminals)
2 CAUTION:
ACHTUNG:
1 First, disconnect the negative lead 3,
then the positive lead 4.
3. Remove:
• battery
4. Measure:
• battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a digital voltmeter to the bat-
tery terminals.
Tester positive probe → battery posi-

tive terminal
Tester negative probe → battery
negative terminal
NOTE:
(68 ˚F) • The charge state of an MF battery can
be checked by measuring its open-cir-
cuit voltage (i.e., the voltage when the
positive terminal is disconnected).
• No charging is necessary when the
open-circuit voltage equals or exceeds
12.8 V.
b. Check the charge of the battery, as

shown in the charts and the following
example.
Example
Open-circuit voltage = 12.0 V
Charging time = 6.5 hours
Charge of the battery = 20 ~ 30%
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 56
CHK
5. Charge:
(68 ˚F) • battery
(refer to the appropriate charging
method illustration)
WARNING
WARNING
Do not quick charge a battery.
CAUTION:
ACHTUNG:
• Never remove the MF battery sealing
caps.
• Do not use a high-rate battery charger
since it forces a high-amperage cur-
rent into the battery quickly and can
(68 ˚F) cause battery overheating and bat-
tery plate damage.
• If it is impossible to regulate the
charging current on the battery
charger, be careful not to overcharge
the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If
charging has to be done with the bat-
tery mounted on the motorcycle, dis-
connect the negative lead from the
battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the
battery charger leads are connected to
the battery.
• Before removing the battery charger
lead clips from the battery terminals,
be sure to turn off the battery charger.
• Make sure that the battery charger
lead clips are in full contact with the
battery terminal and that they are not
shorted. A corroded battery charger
lead clip may generate heat in the con-
tact area and a weak clip spring may
cause sparks.
• If the battery becomes hot to the
touch at any time during the charging
process, disconnect the battery
charger and let the battery cool before
reconnecting it. Hot batteries can
explode!
• As shown in the following illustration,
the open-circuit voltage of an MF bat-
tery stabilizes about 30 minutes after
charging has been completed. There-
fore, wait 30 minutes after charging is
completed before measuring the
open-circuit voltage.
3 - 57
CHK
Charging method using a variable-voltage charger
3 - 58
CHK
Charging method using a constant-voltage charger
3 - 59
CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSES ADJ
6. Install:
1 2 • battery
7. Connect:
• battery leads
(to the battery terminals)
3
CAUTION:
ACHTUNG:
4
First, connect the positive lead 1, then
the negative lead 2.
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
9. Lubricate:
• battery terminals
Dielectric grease
10.Install:
• battery band 3
• rear cowling bracket 4
• rear cowling
EB305040
CHECKING THE FUSES
the fuses.
CAUTION:
ACHTUNG:
To avoid a short circuit, always set the
main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• rear cowling
2. Check:
• continuity
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse
and check the continuity.
NOTE:
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”,
replace the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 60
CHK
CHECKING THE FUSES ADJ
3. Replace:
• blown fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”.
b. Install a new fuse of the correct
amperage.
c. Set the main switch to “ON” and ver-
ify if the electrical circuit is opera-
tional.
d. If the fuse immediately blows again,
check the electrical circuit.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Item Amperage Q’ty

Main fuse 30 A 1
Headlight
20 A 1
fuse
Signaling
20 A 1
system fuse
Electronic
fuel injection 20 A 1
system fuse
ECU fuse 7.5 A 1
Radiator
fan motor 7.5 A 1
fuse
Backup fuse
7.5 A 1
(odometer)
Reserve 30 A 1
Reserve 20 A 2
Reserve 7.5 A 2
WARNING
WARNING
Never use a fuse with an amperage
other than that specified. Improvising or
using a fuse with the wrong amperage
rating may cause extensive damage to
the electrical system, cause the lighting
and ignition systems to malfunction
and could possibly cause a fire.
4. Install:
• rear cowling
3 - 61
CHK
REPLACING THE HEADLIGHT BULBS ADJ
EB305051
REPLACING THE HEADLIGHT BULBS
the headlight bulbs.
1
1. Disconnect:
• headlight coupler 1
2. Remove:
• headlight bulb 1
WARNING
WARNING
1 Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
3. Install:
• headlight bulb New
Secure the new headlight bulb with
the headlight bulb holder.
CAUTION:
ACHTUNG:
Avoid touching the glass part of the
headlight bulb to keep it free from oil,
otherwise the transparency of the glass,
the life of the bulb and the luminous
flux will be adversely affected. If the
headlight bulb gets soiled, thoroughly
clean it with a cloth moistened with
alcohol or lacquer thinner.
4. Connect:
• headlight coupler
3 - 62
CHK
ADJUSTING THE HEADLIGHT BEAMS ADJ
EB305061
ADJUSTING THE HEADLIGHT BEAMS
the headlights.
1. Adjust:
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tion a or b.
Direction a Headlight beam is raised.

Headlight beam is low-
Direction b
ered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Adjust:
• headlight beam (horizontally)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
tion a or b.
Left headlight
Headlight beam moves

Direction a
to the right.
Direction b
to the left.
Right headlight

Direction a
to the left.
Direction b
to the right.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 63
ENGINE ENG
EB400011
OVERHAULING THE ENGINE

ENGINE
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
11
9
7
6
1
4
5 8
14
13 New
LT
LT
12 70 Nm (7.0 m • kg, 50 ft • Ib)
4
T.
R.
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Removing the drive sprocket Remove the parts in the order listed.
Bottom cowling and front cowling Refer to “COWLINGS” in chapter 3.
1 Locknut 2 Loosen.
2 Shift rod 1
3 Shift arm 1
4 Starter cable 1
5 Starter knob 1
6 Clutch release cylinder 1
7 Dowel pin 2
4-1
ENGINE ENG
10
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
11
9
7
6
1
4
5 8
14
13 New
LT
LT
12 70 Nm (7.0 m • kg, 50 ft • Ib)
T.
R.
4 3
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

8 Speed sensor 1
9 Drive sprocket cover 1
10 Oil seal support plate 1
11 Dowel pin 2
12 Push rod #2 1
13 Lock washer 1
14 Drive sprocket 1
procedure.
4-2
ENGINE ENG
38 Nm (3.8 m • kg, 27 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
7 New
4 (8)
5
28 Nm (2.8 m • kg, 20 ft • Ib) 6
5
T.
R.
2
2
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 14 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
T.
R.

Removing the exhaust assembly Remove the parts in the order listed.
Rear cowling Refer to “COWLINGS” in chapter 3.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in chapter 3.
Radiator assembly Refer to “RADIATOR AND THERMO-
1 Muffler 1
2 Spring 4
3 Exhaust pipe assembly 1
4 Exhaust pipe joint 1 1
7 Exhaust pipe joint gasket 4
procedure.
4-3
ENGINE ENG

Disconnecting the leads and hoses Disconnect the parts in the order listed.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FILTER
COVER” in chapter 3.
Air filter case and throttle body Refer to “ELECTRONIC FUEL INJEC-
assembly TION” in chapter 6.
Engine oil and oil filter cartridge Drain.
Refer to “CHANGING THE ENGINE
OIL” in chapter 3.
Oil cooler and thermostat assembly Refer to “OIL COOLER” and “THER-
MOSTAT ASSEMBLY” in chapter 5.
1 Battery negative lead 1
CAUTION:
ACHTUNG:
2 Battery positive lead 1
First, disconnect the negative lead,
then the positive lead.
4-4
ENGINE ENG

3 Crankcase breather hose 1
4 Ignition coil 4
5 Camshaft sensor 1
6 Starter motor lead 1 Disconnect.
7 Ground lead 1 Disconnect.
8 Starter motor 1
9 Pickup coil coupler 1 Disconnect.
10 Plastic clip 1
11 Stator coil assembly coupler 1 Disconnect.
12 Sidestand switch coupler 1
13 Oil level switch connector 1 Disconnect.
14 Neutral switch 1
For connecting, reverse the disconnec-
tion procedure.
4-5
ENGINE ENG

Removing the engine Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
1 Pinch bolt 2 Loosen.
2 Right front mounting bolt 2
3 Left front mounting bolt 2
4 Washer 2
5 Self-locking nut 2
6 Spacer bolt 2 Loosen.
7 Rear mounting bolt 2
8 Spacer 2
9 Mounting bracket 1
procedure.
4-6
ENGINE ENG
EB400700
INSTALLING THE ENGINE
1. Install:
• mounting bracket 1
• spacers 2
• rear mounting bolts 3
• washers 4
• left front mounting bolts 5
• right front mounting bolts 6
NOTE:
Do not fully tighten the bolts.
2. Tighten:
• spacer bolts 7
18 Nm (1.8 m · kg, 13 ft · lb)
T.
R.
• self-locking nut 8
55 Nm (5.5 m · kg, 40 ft · lb)
T.
R.
• left front mounting bolts
40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
• right front mounting bolt
40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
• pinch bolts 9
17 Nm (1.7 m · kg, 12 ft · lb)
T.
R.
NOTE:
• Tighten the spacer bolt 7 it to specifi-
cation with a pivot shaft wrench.
• When tightened, the spacer bolt
should be flat against the engine sur-
face.
Pivot shaft wrench

90890-01471
3. Install:
• shift arm1
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
NOTE:
Align the punch mark a in the shift shaft
with the slot in the shift arm.
4-7
CAMSHAFTS ENG
EB401000
CAMSHAFTS

Removing the cylinder head cover Remove the parts in the order listed.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Radiator assembly and thermostat Refer to “RADIATOR AND THERMO-
assembly STAT” and “THERMOSTAT ASSEM-
BLY” in chapter 5.
1 Spark plug 4
2 Cylinder head cover 1
3 Cylinder head cover gasket 1
4 Timing chain guide (top side) 1
procedure.
4-8
CAMSHAFTS ENG
EB401011

Removing the camshafts Remove the parts in the order listed.
Pickup coil rotor cover Refer to “PICKUP COIL”.
1 Timing chain tensioner 1
2 Timing chain tensioner gasket 1
3 Timing chain guide (exhaust side) 1
4 Intake camshaft cap “I” 1
5 Intake camshaft cap “R” 1
6 Intake camshaft cap “L” 1
NOTE:
7 Dowel pin 6 During removal, the dowel pins may
8 Exhaust camshaft cap “E” 1 still be connected to the camshaft
9 Exhaust camshaft cap “R” 1 caps.
10 Exhaust camshaft cap “L” 1
11 Dowel pin 6
4-9
CAMSHAFTS ENG

12 Intake camshaft 1
13 Exhaust camshaft 1
14 Intake camshaft sprocket 1
15 Exhaust camshaft sprocket 1
16 Pin 1
17 Timing chain guide (intake side) 1
procedure.
4 - 10
CAMSHAFTS ENG
EB401101
REMOVING THE CAMSHAFTS
b
1. Align:
• TDC mark on the pickup coil rotor
T (with the crankcase mating surface)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
H
a a. Turn the crankshaft clockwise.
pression stroke, align the TDC
mark a on the pickup coil rotor with
the crankcase mating surface b.
NOTE:
TDC on the compression stroke can be
found when the camshaft lobes are
turned away from each other.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• float chamber air vent hose holder
3. Remove:
4. Remove:
• camshaft caps
• dowel pins
CAUTION:
ACHTUNG:
To prevent damage to the cylinder
head, camshafts or camshaft caps,
loosen the camshaft cap bolts in stages
and in a crisscross pattern, working
from the outside in.
5. Remove:
• intake camshaft 1
• exhaust camshaft 2
NOTE:
To prevent the timing chain from falling
into the crankcase, fasten it with a
wire 3.
6. Remove:
• camshaft sprockets 1
(with the flywheel puller 2)
Flywheel puller
90890-01080
4 - 11
CAMSHAFTS ENG
EB401401
CHECKING THE CAMSHAFTS
1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• camshaft lobe dimensions a and b
Out of specification → Replace the
camshaft.
Camshaft lobe dimensions

limit
Intake camshaft
a 33.31 mm (1.3114 in)
b 24.90 mm (0.9803 in)
Exhaust camshaft
a 32.95 mm (1.2972 in)
b 24.936 mm (0.9817 in)
3. Measure:
• camshaft runout
Out of specification → Replace.
Maximum camshaft runout

0.03 mm (0.0012 in)
4. Measure:
• camshaft journal-to-camshaft cap
clearance
Out of specification → Measure the
camshaft journal diameter.
Camshaft journal-to-camshaft
cap clearance
0.035 ~ 0.069 mm
(0.0014 ~ 0.0027 in)
4 - 12
CAMSHAFTS ENG
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the camshaft into the cylinder
head (without the dowel pins and
camshaft caps).
b. Position a strip of Plastigauge® 1
onto the camshaft journal as shown.
c. Install the dowel pins and camshaft
caps.
NOTE:
• Tighten the camshaft cap bolts in
stages and in a crisscross pattern,
working from the inner caps out.
• Do not turn the camshaft when mea-
suring the camshaft journal-to-cam-
shaft cap clearance with the
Plastigauge®.
Camshaft cap bolt

10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
d. Remove the camshaft caps and then
measure the width of the Plasti-
gauge® 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• camshaft journal diameter a
camshaft.
Within specification → Replace the cylin-
der head and the camshaft caps as a set.
Camshaft journal diameter

24.452 ~ 24.465 mm
(0.9627 ~ 0.9632 in)
EB401421
CHECKING THE TIMING CHAIN,
CAMSHAFT SPROCKETS, AND TIMING
CHAIN GUIDES
the camshaft sprockets and timing chain
guides.
1. Check:
• timing chain
Damage/stiffness → Replace the tim-
ing chain and camshaft sprockets as a
4 - 13 set.
CAMSHAFTS ENG
2. Check:
• camshaft sprocket
More than 1/4 tooth wear a → Replace
the camshaft sprockets and the timing
chain as a set.
a 1/4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
3. Check:
• timing chain guide (exhaust side) 1
• timing chain guide (intake side) 2
• timing chain guide (top side) 3
Damage/wear → Replace the defective
part(-s).
EB401430
CHECKING THE TIMING CHAIN
TENSIONER
1. Check:
Cracks/damage/rough movement →
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
NOTE:
While pressing the timing chain ten-
sioner rod, wind it clockwise with a thin
screwdriver 1 until it stops.
b. Remove the screwdriver and slowly

release the timing chain tensioner
rod.
c. Make sure that the timing chain ten-
sioner rod comes out of the timing
chain tensioner housing smoothly. If
there is rough movement, replace the
timing chain tensioner.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 14
CAMSHAFTS ENG
EB401701
INSTALLING THE CAMSHAFTS
1. Install:
• timing chain guide (intake side)
2. Install:
• camshaft sprockets 1
24 Nm (2.4 m · kg, 17 ft · lb)
T.
R.
(with the flywheel puller 2)
Flywheel puller
90890-01080
3. Install:
b • exhaust camshaft
• intake camshaft
• exhaust camshaft caps
T
• intake camshaft caps

H
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Turn the crankshaft clockwise.
pression stroke, align the TDC a
mark on the pickup coil rotor with the
crankcase mating surface b.
c. Install the timing chain onto both
camshaft sprockets and then install
the camshaft sprockets onto the cam-
shafts.
CAUTION:
ACHTUNG:
Do not turn the crankshaft when install-
ing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks c on
the camshafts face up.
d. Install the exhaust and intake cam-

shaft caps.
Camshaft cap bolt

10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
NOTE:
Make sure that the punch marks c on
the camshafts are aligned with the
arrow marks d on the camshaft caps.
Out of alignment → Reinstall.
e. Remove the wire from the timing

chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 15
CAMSHAFTS ENG
4. Install:
5. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain ten-
sioner rod into the timing chain ten-
sioner housing by hand.
b. While pressing the timing chain ten-
sioner rod, wind it clockwise with a
thin screwdriver 1 until it stops.
c. With the screwdriver still inserted
into the timing chain tensioner, install
the timing chain tensioner and gasket
onto the cylinder block. Then, tighten
the timing chain tensioner bolts to the
specified torque.
WARNING
WARNING
Always use a new gasket.
NOTE:
The “UP” mark on the timing chain ten-
sioner should face up.
Timing chain tensioner bolt

10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
d. Remove the screwdriver, make sure

that the timing chain tensioner rod
releases, and tighten the cap bolt to
the specified torque.
Cap bolt
10 Nm (1.0 m • kg, 7.2 ft • lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Turn:
• crankshaft
(several turns counterclockwise)
4 - 16
CAMSHAFTS ENG
7. Check:
• TDC mark a
b Make sure that the TDC mark is
aligned with the crankcase mating sur-
face b.
• camshaft punch mark c
T
H
Make sure that the camshaft punch
a mark is aligned with the arrow mark d
on the camshaft cap.
Out of alignment → Adjust.
Refer to the installation steps above.
8. Measure:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
9. Install:
• cylinder head cover gasket
• cylinder head cover
NOTE:
• Apply bond TB1541 onto the mating
surfaces of the cylinder head cover
and cylinder head cover gasket.
• Apply bond 1215B onto the mating
surfaces of the cylinder head cover
gasket and cylinder head.
• Tighten the cylinder head cover bolts
in stages and in a crisscross pattern.
4 - 17
CYLINDER HEAD ENG
EB402000
CYLINDER HEAD

Removing the cylinder head Remove the parts in the order listed.
Engine Refer to “ENGINE”.
Intake and exhaust camshafts Refer to “CAMSHAFTS”.
1 Cylinder head 1
2 Cylinder head gasket 1
3 Dowel pin 2
procedure.
4 - 18
CYLINDER HEAD ENG
EB402102
REMOVING THE CYLINDER HEAD
1. Remove:
• cylinder head bolts
• cylinder head nuts
NOTE:
• Loosen each bolt and nut 1/2 of a turn
at a time, in stages and in a crisscross
pattern. After all of the bolts and nuts
are fully loosened, remove them.
• Loosen the bolts and nuts in decreas-
ing numerical order (refer to the num-
bers in the illustration).
EB402402
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid
damaging or scratching:
• spark plug bore threads
• valve seats
2. Check:
• cylinder head
• cylinder head water jacket
Mineral deposits/rust → Eliminate.
4 - 19
CYLINDER HEAD ENG
3. Measure:
• cylinder head warpage
Out of specification → Resurface the
cylinder head.
Maximum cylinder head

warpage
0.06 mm (0.0024 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thick-
ness gauge 2 across the cylinder
head.
b. Measure the warpage.
c. If the limited is exceeded, resurface
the cylinder head as follows.
d. Place a 400 ~ 600 grit wet sandpaper
on the surface plate and resurface the
cylinder head using a figure-eight
sanding pattern.
NOTE:
To ensure an even surface, rotate the
cylinder head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB402702
INSTALLING THE CYLINDER HEAD
1. Install:
• cylinder head
• cylinder head nut (1 ~ 10)
1st. 20 Nm (2.0 m · kg, 14 ft · lb)
2nd. 50 Nm (5.0 m · kg, 36 ft · lb)
T.
R.
• cylinder head bolt (11, 12)

12 Nm (1.2 m · kg, 8.7 ft · lb)
T.
R.
NOTE:
• Lubricate the cylinder head nuts with
engine oil.
• Tighten the cylinder head nuts and
bolts in two stages and in a crisscross
pattern.
• Tighten the nuts and bolts in numeri-
cal order (refer to the numbers in the
illustration).
4 - 20
VALVES AND VALVE SPRINGS ENG
EB403000
VALVES AND VALVE SPRINGS

Removing the valves and valve Remove the parts in the order listed.
springs
Cylinder head Refer to “CYLINDER HEAD”.
1 Intake valve lifter 12
2 Intake valve pad 12
3 Intake valve cotter 24
4 Intake valve upper spring seat 12
5 Intake outer valve spring 12
6 Intake inner valve spring 12
7 Intake valve oil seal 12
8 Intake valve lower spring seat 12
9 Intake valve 12
10 Intake valve guide 12
4 - 21

11 Exhaust valve lifter 8
12 Exhaust valve pad 8
13 Exhaust valve cotter 16
14 Exhaust valve upper spring seat 8
15 Exhaust outer valve spring 8
16 Exhaust inner valve spring 8
17 Exhaust valve oil seal 8
18 Exhaust valve lower spring seat 8
19 Exhaust valve 8
20 Exhaust valve guide 8
procedure.
4 - 22
EB403100
REMOVING THE VALVES
the valves and related components.
NOTE:
Before removing the internal parts of the
cylinder head (e.g., valves, valve
springs, valve seats), make sure that the
valves properly seal.
1. Remove:
• valve lifter 1
• valve pad 2
NOTE:
Make a note of the position of each
valve lifter and valve pad so that they
can be reinstalled in their original place.
2. Check:
• valve
(for leakage)
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat
width.
Refer to “CHECKING THE VALVE
SEATS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake
and exhaust ports.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve
seat 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 23
3. Remove:
• valve cotters 1
NOTE:
Remove the valve cotters by compress-
ing the valve spring with the valve spring
compressor 2 and attachment 3.
Valve spring compressor

90890-04019
Attachment
(for the intake valve)
90890-04114
(for the exhaust valve)
90890-04108
4. Remove:
• upper spring seat 1
• valve springs 2
• lower spring seat 3
• valve 4
• oil seal 5
NOTE:
Identify the position of each part very
carefully so that it can be reinstalled in
its original place.
EB403400
CHECKING THE VALVES AND VALVE
GUIDES
the valves and valve guides.
1. Measure:
• valve stem-to-valve guide clearance
Valve stem-to-valve guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
valve guide.
Valve stem-to-valve guide
clearance
Intake
0.005 ~ 0.029 mm
(0.0002 ~ 0.0011 in)
<Limit>: 0.06 mm (0.0024 in)
Exhaust
0.010 ~ 0.034 mm
(0.0004 ~ 0.0013 in)
<Limit>: 0.07 mm (0.0028 in)
4 - 24
2. Replace:
• valve guide
NOTE:
To ease valve guide removal and instal-
lation, and to maintain the correct fit,
heat the cylinder head to 100 ˚C (212 ˚F)
in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with a valve
guide remover 1.
b. Install the new valve guide with the
valve guide installer 2 and valve
guide remover 1.
c. After installing the valve guide, bore
the valve guide with a valve guide
reamer 3 to obtain the proper valve
stem-to-valve guide clearance.
NOTE:
After replacing the valve guide, reface
the valve seat.
Valve guide remover

Intake (4.0 mm)
90890-04111
Valve guide installer
Intake (4.0 mm)
90890-04112
Valve guide reamer
Intake
90890-04113
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger
than the body of the valve stem →
Replace the valve.
4 - 25
5. Measure:
• valve margin thickness a
valve.
Valve margin thickness

Intake
0.9 ~ 1.2 mm
(0.028 ~ 0.047 in)
Exhaust
1.0 ~ 1.3 mm
(0.039 ~ 0.051 in)
6. Measure:
• valve stem runout
valve.
NOTE:
• When installing a new valve, always
replace the valve guide.
• If the valve is removed or replaced,
always replace the oil seal.
Valve stem runout

0.01 mm (0.0004 in)
EB403410
CHECKING THE VALVE SEATS
the valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear → Replace the cylinder
head.
3. Measure:
• valve seat width a
Out of specification → Replace the cyl-
inder head.
Valve seat width

0.9 ~ 1.1 mm
(0.035 ~ 0.043 in)
<Limit>: 1.6 mm (0.06 in)
4 - 26
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye
(Dykem) b onto the valve face.
b. Install the valve into the cylinder
head.
c. Press the valve through the valve
guide and onto the valve seat to make
a clear impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face con-
tacted one another, the blueing will have
been removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
After replacing the cylinder head or
replacing the valve and valve guide, the
valve seat and valve face should be
lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a
to the valve face.
CAUTION:
ACHTUNG:
Do not let the lapping compound enter
the gap between the valve stem and the
valve guide.
b. Apply molybdenum disulfide oil onto

the valve stem.
c. Install the valve into the cylinder
head.
d. Turn the valve until the valve face and
valve seat are evenly polished, then
clean off all of the lapping compound.
NOTE:
For the best lapping results, lightly tap
the valve seat while rotating the valve
back and forth between your hands.
4 - 27
e. Apply a fine lapping compound to the
valve face and repeat the above
steps.
f. After every lapping procedure, be
sure to clean off all of the lapping
compound from the valve face and
valve seat.
g. Apply Mechanic’s blueing dye
(Dykem) b onto the valve face.
h. Install the valve into the cylinder
head.
i. Press the valve through the valve
guide and onto the valve seat to make
a clear impression.
j. Measure the valve seat width c
again. If the valve seat width is out of
specification, reface and lap the valve
seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB403420
CHECKING THE VALVE SPRINGS
the valve springs.
1. Measure:
• valve spring free length a
valve spring.
Valve spring free length

Inner spring
Intake valve spring
32.35 mm (1.27 in)
<Limit>: 30.73 mm
(1.21 in)
Exhaust valve spring
28.82 mm (1.13 in)
<Limit>: 27.37 mm
(1.08 in)
Outer spring
Intake valve spring
36.42 mm (1.43 in)
<Limit>: 34.60 mm
(1.36 in)
33.91 mm (1.34 in)
<Limit>: 32.21 mm
(1.27 in)
4 - 28
2. Measure:
• compressed spring force a
valve spring.
b Installed length
(installed)
Inner spring
Intake valve spring
10.30 ~ 11.93 kg at
27.96 mm
(22.7 ~ 26.3 lb at 1.10 in)
10.81 ~ 12.44 kg at
24.6 mm
(23.8 ~ 27.4 lb at 0.97 in)
Outer spring
Intake valve spring
23.45 ~ 27.12 kg at
32.03 mm
(51.7 ~ 59.8 lb at 1.26 in)
29.16 ~ 33.55 kg at
30.25 mm
(62.3 ~ 74.0 lb at 1.19 in)
3. Measure:
• valve spring tilt a
valve spring.
Maximum spring tilt

Inner spring
Intake valve spring
1.4 mm (0.055 in)
1.3 mm (0.051 in)
Outer spring
Intake valve spring
1.6 mm (0.063 in)
1.5 mm (0.059 in)
EB403430
CHECKING THE VALVE LIFTERS
the valve lifters.
1. Check:
• valve lifter
Damage/scratches → Replace the
valve lifters and cylinder head.
4 - 29
EB403702
INSTALLING THE VALVES
the valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem 1
• oil seal 2
(with the recommended lubricant)
Molybdenum disulfide oil
3. Install:
• oil seal 1 New
• valve 2
• lower spring seat 3
• valve springs 4
• upper spring seat 5
(into the cylinder head)
NOTE:
• Make sure that each valve is installed
in its original place.
• Install the valve spring with the larger
pitch a facing up.
b Smaller pitch
a
b
a
4 - 30
4. Install:
• valve cotters 1
NOTE:
Install the valve cotters by compressing
the valve spring with the valve spring
compressor 2 and attachment 3.
Valve spring compressor

90890-04019
Attachment
(for the intake valve spring)
9080-04114
(for the exhaust valve spring)
90890-04108
5. To secure the valve cotters 1 onto the
valve stem, lightly tap the valve tip with
a soft-face hammer.
CAUTION:
ACHTUNG:
Hitting the valve tip with excessive
force could damage the valve.
6. Lubricate:
• valve pad
Molybdenum disulfide oil
7. Install:
• valve pad
• valve lifter
NOTE:
• The valve lifter must move smoothly
when rotated with a finger.
• Each valve lifter and valve pad must be
reinstalled in its original position.
4 - 31
GENERATOR ENG
EB410000
GENERATOR

Removing the stator coil assembly Remove the parts in the order listed.
Engine oil Drain.
1 Throttle stop screw holder 1
2 Generator rotor cover 1
3 Generator rotor cover gasket 1
4 Dowel pin 2
5 Generator rotor bolt 1
6 Generator rotor 1
7 Stator coil assembly coupler 1 Disconnect.
8 Stator coil assembly lead holder 1
9 Stator coil assembly 1
procedure.
4 - 32
GENERATOR ENG
EB410110
REMOVING THE GENERATOR
1
1. Remove:
• generator rotor cover 1
NOTE:
Loosen each bolt 1/4 of a turn at a time,
After all of the bolts are fully loosened,
remove them.
2. Remove:
• generator rotor bolt 1
• washer
NOTE:
While holding the generator rotor 2
with the rotor holding tool 3, loosen the
generator rotor bolt.
Rotor holding tool

90890-01235
3. Remove:
• generator rotor 1
(with the flywheel puller 2 and rotor
holding tool 3)
Flywheel puller
90890-01080
EB410700
INSTALLING THE GENERATOR
1. Apply:
• sealant
(onto the stator coil assembly lead
grommet)

90890-85505
2. Install:
• generator rotor
• washer
• generator rotor bolt
WARNING
WARNING
Always use a new generator rotor bolt.
CAUTION:
ACHTUNG:
• Clean the tapered portion of the crank-
shaft and the generator rotor hub with
lacquer thinner.
• Lubricate the generator rotor bolt
4 - 33 threads with engine oil.
GENERATOR ENG
3. Tighten:
• generator rotor bolt 1 New
65 Nm (6.5 m · kg, 47 ft · lb)
T.
R.
NOTE:
with the rotor holding tool 3, tighten
the generator rotor bolt.
Rotor holding tool

90890-01235
4. Install:
• generator rotor cover
NOTE:
Tighten the generator rotor cover bolts
4 - 34
PICKUP COIL ENG
PICKUP COIL
45 Nm (4.5 m • kg, 32 ft • Ib)

T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)

E
T.
R.
7 4
3 New
1 2
4
LT
LT LT
(6) LT
6
5
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.
R.
15 Nm (1.5 m • kg, 11 ft • Ib)

T.
R.

Removing the pickup coil and Remove the parts in the order listed.
pickup coil rotor
Fuel tank Refer to “FUEL TANK AND AIR FIL-
TER” in chapter 3.
Engine oil Drain.
Generator rotor cover Refer to “GENERATOR”.
1 Pickup coil lead holder 1
2 Pickup coil rotor cover 1
3 Pickup coil rotor cover gasket 1
4 Dowel pin 2
4 - 35
PICKUP COIL ENG
45 Nm (4.5 m • kg, 32 ft • Ib)

T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)

E
T.
R.
7 4
3 New
1 2
4
LT
LT LT
(6) LT
6
5
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.
R.
15 Nm (1.5 m • kg, 11 ft • Ib)

T.
R.

5 Pickup coil coupler 1 Disconnect.
6 Pickup coil 1
7 Pickup coil rotor 1
procedure.
4 - 36
PICKUP COIL ENG
REMOVING THE PICKUP COIL ROTOR
1 1. Remove:
• pickup coil lead holder 1
2 • pickup coil rotor cover 2
NOTE:
remove them.
2. Remove:
• pickup coil rotor bolt 1
• washer
2 • pickup coil rotor 2
NOTE:
1 with the rotor holding tool 4, loosen the
pickup coil rotor bolt.
Rotor holding tool

90890-01235
INSTALLING THE PICKUP COIL ROTOR

1 a 1. Install:
2 • pickup coil rotor 1
• washer
• pickup coil rotor bolt
NOTE:
When installing the pickup coil rotor,
align the groove 2 in the crankshaft
sprocket with the projection a in the
pickup coil rotor.
CAUTION:
ACHTUNG:
Lubricate the pickup coil rotor bolt
threads with engine oil.
4 - 37
PICKUP COIL ENG
2. Tighten:
• pickup coil rotor bolt 1
45 Nm (4.5 m · kg, 32 ft · lb)
T.
R.
1 NOTE:
with the rotor holding tool 3, tighten
the pickup coil rotor bolt.
Rotor holding tool

90890-01235
3. Apply:
• sealant
(onto the pickup coil lead grommet)

90890-85505
4. Install:
• pickup coil rotor cover
2 • pickup coil lead holder
1 • clutch cable holder
NOTE:
• When installing the pickup coil rotor
cover, align the timing chain guide
(intake side) pin 1 of the with the hole
2 in the pickup coil rotor cover.
• Tighten the pickup coil rotor cover
bolts in stages and in a crisscross pat-
tern.
4 - 38
CLUTCH ENG
EB405000
CLUTCH

Removing the clutch cover Remove the parts in the order listed.
Engine oil Drain.
1 Clutch cover 1
2 Clutch cover gasket 1
3 Dowel pin 2
procedure.
4 - 39
CLUTCH ENG

Removing the clutch Remove the parts in the order listed.
1 Clutch spring plate retainer 1
2 Clutch spring plate 1
3 Clutch spring plate seat 1
4 Pressure plate 1
5 Push rod #1 1
6 Ball 1
7 Push rod #2 1
8 Friction plate #1 8 3.00 mm (0.12 in)
9 Clutch plate 8
10 Friction plate #2 1 3.85 mm (0.15 in)
11 Lock washer 1
12 Clutch boss 1
13 Thrust washer 1
4 - 40
CLUTCH ENG

14 Back torque limiter outer boss 1
15 Back torque limiter bearing 1
16 Back torque limiter inner boss 1
17 Thrust plate 1
18 Thrust washer 1
19 Clutch housing 1
20 Bearing 1
21 Starter clutch gear 1
22 Bearing 1
23 Starter clutch assembly 1
24 Circlip 1
25 Starter clutch idle gear 1
procedure.
4 - 41
CLUTCH ENG
EB405102
REMOVING THE CLUTCH
1. Remove:
1 • clutch cover 1
NOTE:
remove them.
2. Straighten the lock washer tab.

3. Loosen:
• clutch boss nut 1
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, loosen the
clutch boss nut.
Clutch holding tool

90890-04086
EB405400
CHECKING THE FRICTION PLATES
the friction plates.
1. Check:
• friction plate
Damage/wear → Replace the friction
plates as a set.
2. Measure:
• friction plate thickness
Out of specification → Replace the fric-
tion plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate #1 thickness

2.9 ~ 3.1 mm
(0.114 ~ 0.122 in)
<Limit>: 2.8 mm (0.110 in)
Friction plate #2 thickness
3.7 ~ 3.9 mm
(0.146 ~ 0.154 in)
4 - 42 <Limit>: 3.6 mm (0.142 in)
CLUTCH ENG
EB405410
CHECKING THE CLUTCH PLATES
the clutch plates.
1. Check:
• clutch plate
Damage → Replace the clutch plates
as a set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness
gauge 1)
clutch plates as a set.
Maximum clutch plate

warpage
0.1 mm (0.004 in)
EB405430
CHECKING THE CLUTCH SPRING PLATE
1. Check:
• clutch spring plate
Damage → Replace.
2. Check:
• clutch spring plate seat
Damage → Replace.
EB405440
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage/pitting/wear → Deburr the
clutch housing dogs or replace the
clutch housing.
NOTE:
Pitting on the clutch housing dogs will
cause erratic clutch operation.
2. Check:
• bearing
Damage/wear → Replace the clutch
housing.
4 - 43
CLUTCH ENG
EB405450
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage/pitting/wear → Replace the
clutch boss.
NOTE:
Pitting on the clutch boss splines will
cause erratic clutch operation.
EB405460
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate 1
• bearing 2
Damage/wear → Replace.
CHECKING THE PUSH RODS AND BALL

1. Check:
• push rod #1 1
• push rod #2 2
• ball 3
Damage/wear → Replace the pull rods
and ball as a set.
2. Check:
• push rod bearing 4
CHECKING THE BACK TORQUE LIMITER

1. Check:
• back torque limiter outer boss splines
Damage/pitting/wear → Replace the
back torque limiter outer boss.
4 - 44
CLUTCH ENG
2. Check:
• back torque limiter clutch
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the back torque limiter bearing
and back torque limiter outer boss
onto the back torque limiter inner
boss and hold the back torque limiter
inner boss.
b. When turning the back torque limiter
outer boss clockwise Å, the back
torque limiter inner boss and back
torque limiter outer boss should
engage, otherwise the back torque
limiter is faulty and must be replaced.
c. When turning the back torque limiter
outer boss counterclockwise ı, it
should turn freely, otherwise the back
torque limiter is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE STARTER CLUTCH

1. Check:
• starter clutch gear
• starter clutch idle gear
Chips/pitting/roughness/wear →
Replace the defective part(-s).
2. Check:
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter clutch gear 1 onto
the starter clutch 2 and hold the
starter clutch.
b. When turning the starter clutch gear
clockwise Å, the starter clutch and
the starter clutch gear should engage,
otherwise the starter clutch is faulty
and must be replaced.
c. When turning the starter clutch gear
counterclockwise ı, it should turn
freely, otherwise the starter clutch is
faulty and must be replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 45
CLUTCH ENG
EB405703
INSTALLING THE CLUTCH
1. Install:
• clutch housing
NOTE:
• Make sure that the slots a in the
clutch housing align with the tabs b
on the oil/water pump assembly drive
sprocket.
• Make sure that the primary driven gear
teeth and primary drive gear teeth
mesh correctly.
• Make sure that the starter clutch gear
teeth and starter clutch idle gear teeth
mesh correctly.
2. Install:
• back torque limiter inner boss 1
• back torque limiter bearing 2
• back torque limiter outer boss 3
CAUTION:
ACHTUNG:
Be sure that the back torque limiter
bearing is installed facing in the correct
direction as shown.
3. Install:
• lock washer New
• clutch boss nut 1
70 Nm (7.0 m · kg, 50 ft · lb)
T.
R.
NOTE:
While holding the clutch boss 2 with
the clutch holding tool 3, tighten the
clutch boss nut.
Clutch holding tool

90890-04086
4 - 46
CLUTCH ENG
4. Bend the lock washer tab along a flat
side of the nut.
5. Lubricate:
• friction plates
• clutch plates
Engine oil
6. Install:
1 3 • friction plates 1 - 3.00 mm (0.12 in)
• clutch plates 2
• friction plate 3 - 3.85 mm (0.15 in)
NOTE:
First, install a friction plate and then
2 alternate between a clutch plate and a
friction plate.
4 - 47
SHIFT SHAFT ENG
EB408000
SHIFT SHAFT

Removing the shift shaft and stop- Remove the parts in the order listed.
per lever
Drive sprocket cover Refer to “ENGINE”.
1 Shift shaft cover 1
2 Shift shaft cover gasket 1
3 Dowel pin 2
4 Shift shaft 1
5 Shift shaft spring 1
6 Spacer 1
7 Stopper lever spring 1
8 Stopper lever 1
9 Circlip 1
10 Collar 1
11 Shift shaft spring stopper 1
procedure.
4 - 48
SHIFT SHAFT ENG
EB408401
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft 1
Bends/damage/wear → Replace.
• shift shaft spring 2
EB408410
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace the
stopper lever.
EB408703
INSTALLING THE SHIFT SHAFT
1. Install:
• shift shaft spring stopper 1
22 Nm (2.2 m · kg, 16 ft · lb)
T.
R.
• stopper lever spring 2

• stopper lever 3
NOTE:
• Apply locking agent (LOCTITE®) to the
threads of the shift shaft spring stop-
per.
• Hook the ends of the stopper lever
spring onto the stopper lever and the
crankcase boss.
• Mesh the stopper lever with the shift
drum segment assembly.
2. Install:
• shift shaft 1
• spacer
NOTE:
• Lubricate the oil seal lips with lithium
soap base grease.
• Install the end of the shift shaft spring
onto the shift shaft spring stopper 2.
4 - 49
OIL PAN AND OIL PUMP ENG
EB411000
OIL PAN AND OIL PUMP

Removing the oil pan and oil pump Remove the parts in the order listed.
Engine oil Drain.
Coolant Drain.
in chapter 3.
Radiator assembly and water pump Refer to “RADIATOR AND THERMO-
outlet pipe STAT” and “OIL COOLER” in chapter 5.
Exhaust pipe assembly Refer to “ENGINE”.
1 Oil level switch connector 1 Disconnect.
2 Oil level switch 1
3 Oil level switch lead holder 1
4 Oil pan 1
5 Oil pan gasket 1
6 Dowel pin 2
4 - 50
EB411001

7 Drain pipe 1
8 Oil strainer 1
9 Oil pipe 1
10 Oil delivery pipe 1
11 Dowel pin 1
12 Oil/water pump assembly 1
13 Relief valve assembly 1
procedure.
4 - 51
EB411003

Removing the oil pump Remove the parts in the order listed.
1 Oil/water pump assembly driven 1
sprocket
2 Washer 1
3 Oil pump housing 1
4 Bearing 1
5 Pin 2
6 Oil pump outer rotor 1
7 Oil pump inner rotor 1
8 Pin 1
procedure.
4 - 52
EB411100
REMOVING THE OIL PAN
1. Remove:
• oil level switch 1
• oil pan 2
• oil pan gasket
• dowel pins
NOTE:
remove them.
REMOVING THE OIL PUMP
1. Remove:
• oil/water pump assembly driven
sprocket
Flywheel puller
90890-01080
EB411400
CHECKING THE OIL PUMP
1. Check:
• oil/water pump assembly driven
sprocket 1
• oil pump housing 2
Cracks/damage/wear → Replace the
defective part(-s).
2. Measure:
• inner rotor-to-outer rotor tip clearance
a
• outer rotor-to-oil pump housing clear-
ance b
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner rotor-to-outer rotor tip

clearance
0.09 ~ 0.15 mm
(0.004 ~ 0.006 in)
Outer rotor-to-oil pump hous-
ing clearance
0.03 ~ 0.08 mm
(0.001 ~ 0.003 in)
4 - 53
3. Check:
• oil pump operation
Unsmooth → Repair or replace the
defective part(-s).
Refer to “WATER PUMP” in chapter 5.
EB411410
CHECKING THE RELIEF VALVE
1. Check:
• relief valve body 1
• relief valve 2
• spring 3
• O-ring 4
Damage/wear → Replace the defective
part(-s).
EB411421
CHECKING THE OIL DELIVERY PIPE AND
OIL PIPE
1. Check:
• oil delivery pipe 1
• oil pipe 2
Damage → Replace.
Obstruction → Wash and blow out
with compressed air.
EB411430
CHECKING THE OIL STRAINER
1. Check:
• oil strainer 1
Damage → Replace.
Contaminants → Clean with engine oil.
EB411701
ASSEMBLING THE OIL PUMP
1. Lubricate:
• inner rotor
• outer rotor
• impeller shaft
Engine oil
4 - 54
2. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EB411710
INSTALLING THE OIL PUMP
1. Install:
• oil pump 1
12 Nm (1.2 m · kg, 8.7 ft · lb)
T.
R.
NOTE:
Install the oil/water pump assembly
drive chain onto the oil/water pump
assembly driven sprocket.
EB411720
INSTALLING THE OIL STRAINER
1. Install:
• oil strainer 1
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
NOTE:
The arrow a on the oil strainer housing
must point towards the front of the
engine.
EB411730
INSTALLING THE OIL PAN
1. Install:
• dowel pins
• oil pan gasket New
• oil pan 1
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
• oil level switch 2

• engine oil drain bolt 3
43 Nm (4.3 m · kg, 31 ft · lb)
T.
R.
WARNING
WARNING
Always use new copper washers.
NOTE:
• Tighten the oil pan bolts in stages and
in a crisscross pattern.
• Lubricate the oil level switch O-ring
with lithium soap base grease.
4 - 55
CRANKCASE ENG
CRANKCASE

Separating the crankcase Remove the parts in the order listed.
Engine Refer to “ENGINE”.
Cylinder head Refer to “CYLINDER HEAD”.
Pickup coil and pickup coil rotor Refer to “PICKUP COIL”.
Stator coil assembly Refer to “GENERATOR”.
Clutch housing and starter clutch Refer to “CLUTCH”.
idle gear
Oil/water pump assembly Refer to “OIL PAN AND OIL PUMP”.
1 Timing chain 1
2 Oil/water pump assembly drive 1
chain guide
chain
4 - 56
CRANKCASE ENG

sprocket
5 Washer 1
6 Lower crankcase 1
7 Dowel pin 3
procedure.
4 - 57
CRANKCASE ENG

Removing the oil baffle plates and Remove the parts in the order listed.
oil filter bolt
Connecting rod assemblies Refer to “CONNECTING RODS AND
PISTONS”.
Crankshaft Refer to “CRANKSHAFT”.
Transmission Refer to “TRANSMISSION”.
1 Oil baffle plate 1
2 Oil baffle plate 1
3 Oil delivery pipe 1
4 Bearing 1
5 Upper crankcase 1
6 Oil filter bolt 1
7 Lower crankcase 1
procedure.
4 - 58
CRANKCASE ENG
EB412100
DISASSEMBLING THE CRANKCASE
1. Remove:
• crankcase bolts
NOTE:
• Loosen each bolt 1/4 of a turn at a
time, in stages and in a crisscross pat-
tern. After all of the bolts are fully loos-
ened, remove them.
• Loosen the bolts in decreasing numeri-
cal order (refer to the numbers in the
illustration).
• The numbers embossed on the crank-
case indicate the crankcase tightening
sequence.
2. Place the engine upside down.

3. Remove:
• lower crankcase
CAUTION:
ACHTUNG:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on rein-
forced portions of the crankcase, not on
the crankcase mating surfaces. Work
slowly and carefully and make sure that
the crankcase halves separate evenly.
M9 × 105 mm bolts: 1 ~ @
M8 × 60 mm bolt: K, L
M6 × 70 mm bolts: G, I, O, Q
M6 × 64 mm bolts: F, N
M6 × 60 mm bolt: M
M6 × 55 mm bolts: A ~ E
M6 × 50 mm bolt: H
M6 × 45 mm bolts: J, P, R
4. Remove:
• dowel pins
5. Remove:
• crankshaft journal lower bearing
(from the lower crankcase)
NOTE:
Identify the position of each crankshaft
journal lower bearing so that it can be
reinstalled in its original place.
4 - 59
CRANKCASE ENG
EB412420
CHECKING THE CRANKCASE
1. Thoroughly wash the crankcase halves
in a mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• upper crankcase
• lower crankcase
• oil delivery passages
Obstruction → Blow out with com-
pressed air.
EB412440
CHECKING THE BEARINGS AND OIL SEALS
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
CHECKING THE SPROCKETS AND CHAINS

1. Check:
• crankshaft sprocket
• oil/water pump assembly drive
sprocket
defective part(-s).
2. Check:
• timing chain
Damage/stiffness → Replace the tim-
ing chain and crankshaft as a set.
• oil/water pump assembly drive chain
Damage/stiffness → Replace the oil/
water pump assembly drive chain and
oil/water pump assembly drive
sprocket as a set.
4 - 60
CRANKCASE ENG
EB412743
ASSEMBLING THE CRANKCASE
1. Lubricate:
• crankshaft journal bearings
Engine oil
2. Apply:
• sealant
(onto the crankcase mating surfaces)
90890-85505
NOTE:
Do not allow any sealant to come into
contact with the oil gallery or crankshaft
journal bearings. Do not apply sealant to
within 2 ~ 3 mm (0.08 ~ 0.12 in) of the
crankshaft journal bearings.
3. Install:
• dowel pins 1
4. Install:
• crankshaft journal lower bearings
(into the lower crankcase)
NOTE:
• Align the projections a on the crank-
shaft journal lower bearings with the
notches b in the lower crankcase.
• Install each crankshaft journal lower
bearing in its original place.
5. Set the shift drum assembly and trans-

mission gears in the neutral position.
4 - 61
CRANKCASE ENG
6. Install:
• lower crankcase 1
(onto the upper crankcase 2)
CAUTION:
ACHTUNG:
Before tightening the crankcase bolts,
make sure that the transmission gears
shift correctly when the shift drum
assembly is turned by hand.
7. Install:
• crankcase bolts
NOTE:
• Lubricate the bolt threads with engine
oil.
• Install a washer on bolts 1 ~ @.
• Tighten the bolts in the tightening
sequence cast on the crankcase.
M9 × 105 mm bolts: 1 ~ @
M8 × 60 mm bolt: K, L
M6 × 70 mm bolts: G, I, O, Q
M6 × 64 mm bolts: F, N
M6 × 60 mm bolt: M
M6 × 55 mm bolts: A ~ E
M6 × 50 mm bolt: H
M6 × 45 mm bolts: J, P, R
Bolt 1 ~ @
32 Nm (3.2 m • kg, 23 ft • lb)
T.
R.
Bolt A ~ E, G ~ J, M, O ~ R
12 Nm (1.2 m • kg, 8.7 ft • lb)
Bolt F, N
14 Nm (1.4 m • kg, 10 ft • lb)
Bolt K, L
24 Nm (2.4 m • kg, 17 ft • lb)
4 - 62
CONNECTING RODS AND PISTONS ENG
EB404001
CONNECTING RODS AND PISTONS

Removing the connecting rods and Remove the parts in the order listed.
pistons
Crankcase Separate.
Refer to “CRANKCASE”.
1 Connecting rod cap 4
2 Big end lower bearing 4
3 Piston pin clip 8
4 Piston pin 4
5 Piston 4
6 Connecting rod 4
7 Big end upper bearing 4
8 Top ring 4
9 2nd ring 4
10 Oil ring 4
procedure.
4 - 63
EB412131
REMOVING THE CONNECTING RODS AND
PISTONS
the connecting rods and pistons.
1. Remove:
• connecting rod cap
• big end bearings
NOTE:
Identify the position of each big end
bearing so that it can be reinstalled in its
original place.
2. Remove:
• piston pin clips 1
• piston pin 2
• piston 3
• connecting rod 4
CAUTION:
ACHTUNG:
Do not use a hammer to drive the piston
pin out.
NOTE:
• For reference during installation, put
identification marks on the piston
crown.
• Before removing the piston pin, deburr
the piston pin clip groove and the pis-
ton pin bore area in the piston. If both
areas are deburred and the piston pin
is still difficult to remove, remove it
with the piston pin puller 4.
Piston pin puller

90890-01304
3. Remove:
• top ring
• 2nd ring
• oil ring
NOTE:
To remove a piston ring, open the end
gap with your fingers and lift the other
side of the ring over the piston crown.
4 - 64
EB404403
CHECKING THE CYLINDERS AND PISTONS
the cylinders and pistons.
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Replace the
crankcases, and the piston and piston
rings as a set.
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the
cylinder bore gauge.
NOTE:
Measure cylinder bore “C” by taking
side-to-side and front-to-back measure-
ments of the cylinder. Then, find the
average of the measurements.
Cylinder bore gauge

90890-03017
72.000 ~ 72.008 mm
Cylinder bore “C”
(2.8346 ~ 2.8350 in)
Maximum taper 0.05 mm
“T” (0.0016 in)
0.05 mm
Out of round “R”
(0.0016 in)
“C”= maximum of D1 ~ D6
“T” = maximum of D1, or D2 – maxi-
mum of D5 or D6
“R” = maximum of D1, D3 or D5 – mini-
mum of D2, D4 or D6
b. If out of specification, replace the
crankcases, and the pistons and pis-
ton rings as a set.
c. Measure piston skirt diameter “P”
with the micrometer.
Micrometer
90890-03008
a 10 mm (0.39 in) from the bottom edge
of the piston
Piston size “P”
71.954 ~ 71.972 mm
Standard
(2.8328 ~ 2.8335 in)
d. If out of specification, replace the pis-
ton and piston rings as a set.
4 - 65
e. Calculate the piston-to-cylinder clear-
ance with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.028 ~ 0.054 mm
(0.0011 ~ 0.0021 in)
<Limit>: 0.1 mm (0.004 in)
f. If out of specification, replace the

crankcases, and the pistons and pis-
ton rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB404410
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the pis-
ton and piston rings as a set.
NOTE:
Before measuring the piston ring side
clearance, eliminate any carbon depos-
its from the piston ring grooves and pis-
ton rings.
Piston ring side clearance

Top ring
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)
<Limit>: 0.12 mm (0.0047 in)
2nd ring
0.02 ~ 0.06 mm
(0.0008 ~ 0.0024 in)
<Limit>: 0.12 mm (0.0047 in)
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with
the piston crown.
a 5 mm (0.20 in)
4 - 66
3. Measure:
• piston ring end gap
ton ring.
NOTE:
The oil ring expander spacer’s end gap
cannot be measured. If the oil ring rail’s
gap is excessive, replace all three piston
rings.
Piston ring end gap

Top ring
0.15 ~ 0.25 mm
(0.006 ~ 0.010 in)
<Limit>: 0.50 mm (0.020 in)
2nd ring
0.25 ~ 0.35 mm
(0.009 ~ 0.014 in)
<Limit>: 0.70 mm (0.028 in)
Oil ring
0.1 ~ 0.3 mm
(0.004 ~ 0.012 in)
EB404421
CHECKING THE PISTON PINS
the piston pins.
1. Check:
• piston pin
Blue discoloration/grooves → Replace
the piston pin and then check the lubri-
cation system.
2. Measure:
• piston pin outside diameter a
ton pin.
Piston pin outside diameter

16.995 ~ 17.000 mm
(0.6691 ~ 0.6693 in)
<Limit>: 16.975 mm (0.6683 in)
3. Measure:
• piston pin bore diameter (in the piston)
ton pin.
Piston pin bore diameter

(in the piston)
17.004 ~ 17.015 mm
(0.6694 ~ 0.6699 in)
<Limit>: 17.045 mm (0.6711 in)
4 - 67
4. Calculate:
• piston pin-to-piston pin bore clearance
ton pin.
Piston pin-to-piston pin bore clearance =

Piston pin bore diameter (in the
piston) –
Piston pin outside diameter
Piston pin-to-piston pin bore

clearance
0.004 ~ 0.020 mm
(0.00016 ~ 0.00079 in)
<Limit>: 0.070 mm (0.0028 in)
CHECKING THE BIG END BEARINGS

1. Measure:
• crankshaft pin-to-big end bearing
clearance
Out of specification → Replace the big
end bearings.
Crankshaft pin-to-big end

bearing clearance
0.058 ~ 0.078 mm
(0.0023 ~ 0.0031 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
the connecting rods.
CAUTION:
ACHTUNG:
Do not interchange the big end bearings
and connecting rods. To obtain the cor-
rect crankshaft pin-to-big end bearing
clearance and prevent engine damage,
the big end bearings must be installed
in their original positions.
a. Clean the big end bearings, crank-
shaft pins, and bearing portions of
the connecting rods.
b. Install the big end upper bearing into
the connecting rod and the big end
lower bearing into the connecting rod
cap.
NOTE:
Align the projections a on the big end
bearings with the notches b in the con-
necting rod and connecting rod cap.
4 - 68
c. Put a piece of Plastigauge 1 on the
crankshaft pin.
d. Assemble the connecting rod halves.
NOTE:
• Do not move the connecting rod or
crankshaft until the clearance mea-
surement has been completed.
• Lubricate the bolt threads and nut
seats with MOLYKOTE® G-n paste.
• Make sure that the “Y” mark c on the
connecting rod faces towards the left
side of the crankshaft.
• Make sure that the characters d on
both the connecting rod and connect-
ing rod cap are aligned.
e. Tighten the connecting rod nuts.

Refer to “INSTALLING THE PISTONS
AND CONNECTING RODS”.
f. Remove the connecting rod and big
end bearings.
Refer to “REMOVING THE CONNECT-
ING RODS AND PISTONS”.
g. Measure the compressed Plasti-
gauge width e on the crankshaft
pin.
If the crankshaft pin-to-big end bear-
ing clearance is out of specification,
select replacement big end bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 69
2. Select:
• big end bearings (“P1”~ “P4”)
NOTE:
• The numbers stamped into the crank-
shaft web and the numbers on the
connecting rods are used to determine
the replacement big end bearing sizes.
• “P1”~“P4” refer to the bearings shown
in the crankshaft illustration.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
For example, if the connecting rod
“P1” and the crankshaft web “P1” num-
bers are “9” and “3” respectively, then
the bearing size for “P1” is:
“P1” (connecting rod) – “P1” (crank-

shaft) =
9–3=6
BIG END BEARING COLOR CODE

2 blue
3
black
4
5
brown
6
7
green
8
9 yellow
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB404704
INSTALLING THE PISTONS AND
CONNECTING RODS
the pistons and cylinders.
1. Install:
• top ring
• 2nd ring
• oil ring
NOTE:
Be sure to install the piston rings so that
the manufacturer’s marks or numbers
face up.
4 - 70
2. Install:
• piston 1
(onto the respective connecting rod 2)
• piston pin 3
• piston pin clip 4 New
NOTE:
• Apply engine oil onto the piston pin.
• Make sure that the “Y” mark a on the
connecting rod faces left when the
arrow mark b on the piston is pointing
up. Refer to the illustration.
• Reinstall each piston into its original
cylinder (numbering order starting
from the left: #1 to #4).
Å Piston head
3. Offset:
• piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
Å Intake side
4. Lubricate:
• piston
• piston rings
• cylinder
Engine oil
5. Lubricate:
• bolt threads
• nut seats
MOLYKOTE® G-n paste
CAUTION:
ACHTUNG:
MOLYKOTE “G-n” paste is a special
grease, which should not be applied to
any part other than those specified.
4 - 71
NOTE:
Apply only a thin even layer of
MOLYKOTE‚ “G-n” paste, otherwise the
correct tightening torque cannot be
achieved.
6. Lubricate:
• crankshaft pins
• connecting rod big end inner surface
Engine oil
7. Install:
1 • connecting rod assembly
(into the cylinder and onto the crank-
shaft pin)
• connecting rod cap
(onto the connecting rod)
NOTE:
• Align the projections on the big end
bearings with the notches in the con-
necting rods and connecting rod caps.
• Be sure to reinstall each big end bear-
ing in its original place.
• While compressing the piston rings
with piston ring compressor 1, install
the connecting rod assembly into the
cylinder with the other hand.
• Make sure that the “Y” marks a on the
connecting rods face towards the left
side of the crankshaft.
• Make sure that the characters b on
both the connecting rod and connect-
ing rod cap are aligned.
Piston ring compressor:

90890-05158
8. Align:
• bolt heads
(with the connecting rods)
4 - 72
9. Tighten:
• connecting rod nuts
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 • Tighten the connecting rod nuts in the
following way.
70
0.1
NOTE:
• How much the connecting rod nut is
tightened depends on how much the
connecting rod bolt stretches.
• Use a general micrometer 1 to mea-
sure the connecting rod bolts.
a. Before tightening the connecting rod
nut, measure the length of the con-
necting rod bolt with an accuracy of
three decimal places.
b. First tighten the connecting rod nut to
20 Nm (2.0 m • kg, 14 ft • lb), then up
to 40 Nm (4.0 m • kg, 29 ft • lb).
c. Measure the length of the connecting
rod bolt after tightening the connect-
ing rod nut and then calculate how
much the bolt has stretched.
d. Further tighten the connecting rod
nut until the connecting rod bolt has
stretched by between 0.170 and
0.175 mm.
CAUTION:
ACHTUNG:
If the connecting rod nut cannot eventu-
ally be tightened to about 50 Nm (5.0 m
• kg, 36 ft • lb), too much MOLYKOTE®‚
“G-n” paste may have been applied.
Loosen the connecting rod nut and
check the loosening torque. If the loos-
ening torque is less than 40 Nm (4.0 m •
kg, 29 ft • lb), too much MOLYKOTE®‚
“G-n” paste was applied. In that case,
replace the connecting rod bolt with a
new one and apply a thin uniform layer
of MOLYKOTE®‚ “G-n” paste to the
threads of the connecting rod bolt, the
contact area between the connecting
rod and the connecting rod bolt, and the
seat of the connnecting rod nut. Then,
tighten the connecting rod nut as
explained above.
WARNING
WARNING
Always replace the connecting rod bolt
with a new one if loosening the con-
necting rod nut after it was tightened.
Never use a connecting rod bolt more
than once.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 73
CRANKSHAFT ENG
EB412000
CRANKSHAFT

Removing the crankshaft assembly Remove the parts in the order listed.
Crankcase Separate.
Connecting rod caps Refer to “CONNECTING RODS AND
PISTONS”.
1 Crankshaft 1
2 Crankshaft journal lower bearing 5
3 Crankshaft journal upper bearing 5
procedure.
4 - 74
CRANKSHAFT ENG
EB412110
REMOVING THE CRANKSHAFT
1. Remove:
• crankshaft 1
• crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft
journal upper bearing so that it can be
reinstalled in its original place.
EB412403
CHECKING THE CRANKSHAFT
1. Measure:
• crankshaft runout
crankshaft.
Maximum crankshaft runout

0.035 mm (0.0014 in)
2. Check:
• crankshaft journal surfaces
• crankshaft pin surfaces
• bearing surfaces
Scratches/wear → Replace the crank-
shaft.
CHECKING THE CRANKSHAFT JOURNAL

BEARINGS
1. Measure:
• crankshaft journal-to-crankshaft jour-
nal bearing clearance
crankshaft journal bearings.
Crankshaft journal-to-crank-
shaft journal bearing clearance
0.036 ~ 0.056 mm
(0.0014 ~ 0.0022 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
CAUTION:
ACHTUNG:
Do not interchange the crankshaft jour-
nal bearings. To obtain the correct
crankshaft journal-to-crankshaft journal
bearing clearance and prevent engine
damage, the crankshaft journal bearings
must be installed in their original posi-
tions.
4 - 75
CRANKSHAFT ENG
a. Clean the crankshaft journal bearings,
crankshaft journals, and bearing por-
tions of the crankcase.
b. Place the upper crankcase upside
down on a bench.
c. Install the crankshaft journal upper
bearings 1 and the crankshaft into
the upper crankcase.
NOTE:
Align the projections a on the crank-
shaft journal upper bearings with the
notches b in the upper crankcase.
d. Put a piece of Plastigauge 2 on each

crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil
hole in the crankshaft journal.
e. Install the crankshaft journal lower

bearings into the lower crankcase and
assemble the crankcase.
NOTE:
shaft journal lower bearings with the
notches b in the lower crankcase.
• Do not move the crankshaft until the
clearance measurement has been
completed.
f. Tighten the bolts to specification in

the tightening sequence cast on the
crankcase.
Bolt 1 ~ @
32 Nm (3.2 m • kg, 23 ft • lb)
T.
R.
Bolt A ~ E, G ~ J, M, O ~ R
12 Nm (1.2 m • kg, 8.7 ft • lb)
Bolt F, N
14 Nm (1.4 m • kg, 10 ft • lb)
Bolt K, L
24 Nm (2.4 m • kg, 17 ft • lb)
NOTE:
Lubricate the crankcase bolt threads
with engine oil.
4 - 76
CRANKSHAFT ENG
g. Remove the lower crankcase and the
crankshaft journal lower bearings.
h. Measure the compressed Plasti-
gauge width c on each crankshaft
journal.
If the clearance is out of specification,
select replacement crankshaft jour-
nal bearings.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Select:
• crankshaft journal bearings (J1 ~ J5)
NOTE:
• The numbers stamped into the crank-
shaft web and the numbers stamped
into the lower crankcase are used to
determine the replacement crankshaft
journal bearing sizes.
• “J1” ~ “J5” refer to the bearings shown
in the crankshaft illustration.
• If “J1” ~ “J5” are the same, use the
same size for all of the bearings.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
For example, if the crankcase “J1” and
crankshaft web “J1” numbers are “8”
and “3” respectively, then the bearing
size for “J1” is:
Bearing size for J1:

“J1” (crankcase) – “J1” (crankshaft
web) =
8–3=5
CRANKSHAFT JOURNAL BEARING

COLOR CODE
1
blue
2
3
black
4
5
brown
6
7
green
8
9
yellow
10
11 violet
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 77
CRANKSHAFT ENG
EB412720
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft journal upper bearings
(into the upper crankcase)
NOTE:
shaft journal upper bearings with the
notches b in the upper crankcase.
• Be sure to install each crankshaft jour-
nal upper bearing in its original place.
4 - 78
TRANSMISSION ENG
EB413000
TRANSMISSION

Removing the transmission, shift Remove the parts in the order listed.
drum assembly, and shift forks
Crankcase Separate.
Stopper lever Refer to “SHIFT SHAFT”.
1 Drive axle assembly 1
2 Circlip 1
3 Oil seal 1
4 Bearing 1
5 Shift drum retainer 1
6 Shift fork guide bar 2
7 Spring 4
8 Shift fork “L” 1
9 Shift fork “R” 1
4 - 79
TRANSMISSION ENG

10 Shift drum assembly 1
11 Shift fork “C” 1
12 Main axle assembly 1
procedure.
4 - 80
TRANSMISSION ENG

Disassembling the main axle assem- Remove the parts in the order listed.
bly
1 2nd pinion gear 1
2 Toothed lock washer 1
3 Toothed lock washer retainer 1
4 6th pinion gear 1
5 Toothed spacer 1
6 Toothed washer 2
7 Circlip 2
8 3rd/4th pinion gears 1
9 5th pinion gear 1
@ Collar 1
4 - 81
TRANSMISSION ENG

A Main axle/1st pinion gear 1
B Bearing 1
C Main axle bearing housing 1
procedure.
4 - 82
TRANSMISSION ENG

Disassembling the drive axle assem- Remove the parts in the order listed.
bly
1 Washer 1
2 1st wheel gear 1
3 Spacer 1
4 5th wheel gear 1
5 Circlip 3
6 Washer 3
7 3rd wheel gear 1
8 Toothed spacer 2
9 Toothed lock washer 1
@ Toothed lock washer retainer 1
4 - 83
TRANSMISSION ENG

A 4th wheel gear 1
B 6th wheel gear 1
C 2nd wheel gear 1
D Spacer 1
E Drive axle 1
F Bearing 1
G Spacer 1
procedure.
4 - 84
TRANSMISSION ENG
EB413100
REMOVING THE TRANSMISSION
1. Remove:
• main axle assembly 1
(with the Torx wrench T30)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Insert two bolts 2 of the proper size,
as shown in the illustration, into the
main axle assembly bearing housing.
b. Tighten the bolts until they contact
the crankcase surface.
c. Continue tightening the bolts until the
main axle assembly comes free from
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB413400
CHECKING THE SHIFT FORKS
the shift forks.
1. Check:
• shift fork cam follower 1
• shift fork pawl 2
Bends/damage/scoring/wear →
Replace the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat
surface.
Bends → Replace.
WARNING
WARNING
Do not attempt to straighten a bent
shift fork guide bar.
4 - 85
TRANSMISSION ENG
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift
fork(-s) and shift fork guide bar as a
set.
EB413410
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage/scratches/wear → Replace the
shift drum assembly.
• shift drum segment 1
Damage/wear → Replace the shift
drum assembly.
• shift drum bearing 2
Damage/pitting → Replace the shift
drum assembly.
EB413422
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial
gauge 1)
main axle.
Maximum main axle runout

0.08 mm (0.003 in)
2. Measure:
• drive axle runout
(with a centering device and dial
gauge 1)
drive axle.
Maximum drive axle runout

0.08 mm (0.003 in)
3. Check:
• transmission gears
Blue discoloration/pitting/wear →
Replace the defective gear(-s).
• transmission gear dogs
Cracks/damage/rounded edges →
Replace the defective gear(-s).
4 - 86
TRANSMISSION ENG
4. Check:
• transmission gear engagement
(each pinion gear to its respective
wheel gear)
Incorrect → Reassemble the transmis-
sion axle assemblies.
5. Check:
• transmission gear movement
Rough movement → Replace the
defective part(-s).
6. Check:
• circlips
Bends/damage/looseness → Replace.
INSTALLING THE TRANSMISSION

1. Install:
• main axle assembly
• shift fork “C”
• shift drum assembly
• shift fork “R”
• shift fork “L”
• springs
• shift fork guide bars
• drive axle assembly
NOTE:
• Install the shift forks so that the
embossed marks “C”, “R”, and “L” are
facing toward the right side of the
engine.
• Carefully position the shift forks so
that they are installed correctly into the
transmission gears.
• Install shift fork “C” into the groove in
the 3rd and 4th pinion gear on the
main axle.
• Install shift fork “L” into the groove in
the 6th wheel gear and shift fork “R”
into the groove in the 5th wheel gear
on the drive axle.
• Make sure that the drive axle bearing
circlip is inserted into the grooves in
2. Check:
• transmission
Rough movement → Repair.
NOTE:
Oil each gear, shaft, and bearing thor-
oughly.
4 - 87
RADIATOR AND THERMOSTAT COOL
EB500000
COOLING SYSTEM
RADIATOR AND THERMOSTAT

Removing the radiator Remove the parts in the order listed.
Coolant Drain.
in chapter 3.
1 Coolant reservoir breather hose 1
2 Coolant reservoir hose 1
3 Coolant reservoir 1
4 Thermo switch 1
5 Thermostat assembly breather hose 1 Disconnect.
6 Water pump inlet pipe 1
7 Water pump breather hose 1
8 Radiator outlet pipe breather hose 1
9 Water pump inlet hose 1
10 Radiator outlet pipe 1
5-1

11 Radiator outlet hose 1
12 Lower radiator guard 1
13 Lower radiator 1
14 Lower radiator breather hose 1
15 Radiator joint hose 1
16 Plastic band 1
17 Oil cooler outlet hose 1 Disconnect.
18 Radiator inlet hose 1
19 Horn 1
20 Upper radiator 1
21 Radiator fan 1
22 Upper radiator bracket 2
23 Lower radiator bracket 1
procedure.
5-2
EB502000
RADIATOR AND THERMOSTAT

Removing the thermostat assembly Remove the parts in the order listed.
Rider seat and fuel tank Refer to “SEATS” and “FUEL TANK” in
chapter 3.
Air filter case and rubber cover Refer to “AIR FILTER CASE AND IGNI-
TION COIL PLATE” in chapter 3.
Carburetor assembly Refer to “CARBURETORS” in chapter 6.
Coolant Drain.
in chapter 3.
Fuel tank and air filter case cover Refer to “FUEL TANK AND AIR FIL-
Air filter case Refer to “ELECTRONIC FUEL INJEC-
1 Thermostat assembly 1
2 Thermostat assembly inlet hose 1
5-3

3 Thermostat assembly breather hose 1
4 Coolant temperature sensor 1
5 Copper washer 1
6 Plastic band 1
7 Thermostat assembly inlet pipe 1
procedure.
5-4
EB502010
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1

Disassembling the thermostat Remove the parts in the order listed.
assembly
1 Thermostat housing cover 1
2 Thermostat 1
3 Thermostat housing 1
For assembly, reverse the disassembly
procedure.
5-5
EB500010
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the
radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin,
flat-head screwdriver.
2. Check:
• radiator hoses
3. Measure:
• radiator cap opening pressure
Below the specified pressure →
Replace the radiator cap.
Radiator cap opening pressure

95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm2,
3.51 ~ 7.78 psi)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the radiator cap tester 1 and
adapter 2 onto the radiator cap 3.
Radiator cap tester

90890-01325
Adapter
90890-01352
b. Apply the specified pressure for ten

seconds and make sure that there is
no drop in pressure.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chap-
ter 8.
5-6
EB502020
CHECKING THE THERMOSTAT
1. Check:
• thermostat 1
Does not open at 71 ~ 85 ˚C (159.8 ~
185 ˚F) → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Suspend the thermostat in a con-
tainer filled with water.
b. Slowly heat the water.
c. Place a thermometer in the water.
d. While stirring the water, observe the
thermostat and thermometer’s indi-
cated temperature.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1 Thermostat
2 Thermometer
3 Water
4 Container
Å Fully closed
ı Fully open
NOTE:
If the accuracy of the thermostat is in
doubt, replace it. A faulty thermostat
could cause serious overheating or
overcooling.
2. Check:
• thermostat housing cover
• thermostat housing
EB502030
ASSEMBLING THE THERMOSTAT
2 a 1
ASSEMBLY
1. Install:
• thermostat housing 1
• thermostat 2
• thermostat housing cover
NOTE:
Install the thermostat with its breather
hole a facing up.
5-7
INSTALLING THE THERMOSTAT
ASSEMBLY AND RADIATOR
1. Fill:
• cooling system
ommended coolant)
in chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty
part.
3. Measure:
Refer to “CHECKING THE RADIATOR”.
5-8
OIL COOLER COOL
EB501000
OIL COOLER

Removing the oil cooler Remove the parts in the order listed.
Radiator assembly Refer to “RADIATOR AND THERMO-
STAT”.
Exhaust pipe assembly Refer to “ENGINE” in chapter 4.
Engine oil Drain.
1 Oil cooler outlet hose 1
2 Bolt 1
3 Gasket 1
4 Oil cooler 1
5 Oil cooler inlet hose 1
6 Water pump outlet pipe 1
7 Water jacket joint inlet hose 1
8 Water jacket joint 1
procedure.
5-9
OIL COOLER COOL
EB501010
CHECKING THE OIL COOLER
1. Check:
• oil cooler
2. Check:
• oil cooler inlet hose
• oil cooler outlet hose
3. Check:
• water jacket joint
• water jacket joint inlet hose
• water pump outlet hose
EB501020
INSTALLING THE OIL COOLER
1. Clean:
• mating surfaces of the oil cooler and
the crankcase
(with a cloth dampened with lacquer
thinner)
2. Install:
1 • O-ring New
• oil cooler 1
• gasket 2 New
3 • bolt 3 63 Nm (6.3 m · kg, 45 ft · lb)
T.
R.
NOTE:
2 • Before installing the oil cooler, lubri-
cate the oil cooler bolt and O-ring with
a a thin coat of engine oil.
b • Make sure that the O-ring is positioned
properly.
• Align the projection a on the oil
cooler with the projection b in the
crankcase.
5 - 10
OIL COOLER COOL
3. Fill:
• cooling system
ommended coolant)
in chapter 3.
• crankcase
ommended engine oil)
4. Check:
• cooling system
Leaks → Repair or replace any faulty
part.
5. Measure:
Refer to “CHECKING THE RADIATOR”.
5 - 11
WATER PUMP COOL
EB503000
WATER PUMP

Removing the impeller shaft Remove the parts in the order listed.
NOTE:
• The water pump and oil pump are
combined into one unit (oil/water
pump assembly).
• It is not necessary to remove the
impeller shaft unless the coolant
level is extremely low or coolant
leaks from the oil pan.
Oil/water pump assembly and oil Refer to “OIL PAN AND OIL PUMP” in
pump rotor chapter 4.
1 Water pump cover 1
2 O-ring 1
3 Pin 2
4 Impeller shaft (along with the impel- 1
ler)
5 - 12
WATER PUMP COOL

5 Water pump seal 1
6 Oil seal 1
7 Bearing 1
procedure.
5 - 13
WATER PUMP COOL
EB503020
DISASSEMBLING THE WATER PUMP
1. Remove:
• water pump seal 1
NOTE:
Tap out the water pump seal from the
inside of the water pump housing.
2 Water pump housing
2. Remove:
• oil seal 1
• bearing 2
NOTE:
Tap out the bearing and oil seal from the
outside of the water pump housing.
3 Water pump housing
3. Remove:
• rubber damper holder 1
• rubber damper 2
(from the impeller, with a thin, flat-
head screwdriver)
NOTE:
Do not scratch the impeller shaft.
EB503032
CHECKING THE WATER PUMP
1. Check:
• water pump housing cover 1
• water pump housing 2
• impeller 3
• rubber damper 4
• rubber damper holder 5
2. Check:
• water pump seal
• oil seal
• water pump inlet pipe
• bearing
Rough movement → Replace.
5 - 14
WATER PUMP COOL
EB503040
ASSEMBLING THE WATER PUMP
1. Install:
• oil seal 1 New
(into the water pump housing 2)
NOTE:
• Before installing the oil seal, apply tap
water or coolant onto its outer surface.
• Install the oil seal with a socket that
matches its outside diameter.
2. Install:
• water pump seal 1 New
CAUTION:
ACHTUNG:
Never lubricate the water pump seal
surface with oil or grease.
NOTE:
• Install the water pump seal with the
special tools.
• Before installing the water pump seal,
apply Yamaha bond No.1215 2 to the
water pump housing 3.
Mechanical seal installer 4

90890-04078
Middle driven shaft bearing
driver 5
90890-04058
90890-85505
Å Push down.
3. Install:
• rubber damper 1 New
• rubber damper holder 2 New
NOTE:
Before installing the rubber damper,
apply tap water or coolant onto its outer
surface.
5 - 15
WATER PUMP COOL
4. Measure:
• impeller shaft tilt
Out of specification → Repeat steps (3)
and (4).
CAUTION:
ACHTUNG:
Make sure that the rubber damper and
rubber damper holder are flush with the
impeller.
Max. impeller shaft tilt

0.15 mm (0.006 in)
1 Straightedge
2 Impeller
5 - 16
ELECTRONIC FUEL INJECTION EFI
6
Removing the injector 2 assembly Remove the parts in the order listed.
and air filter case
Air filter case cover Refer to “FUEL TANK AND AIR FIL-
1 Crankcase breather hose 1 Disconnect.
2 Fuel hose 3
3 Injector 2 sub-lead coupler 3 Disconnect.
4 Pressure sensor hose 2 Disconnect.
5 Plastic band 1
6 Injector 2 assembly 1
7 Spacer 6
8 Air funnel 4
9 Air funnel bracket 4
10 Fuel hose joint pipe 1
6-1
6
11 Intake air temperature sensor 1
12 Copper washer 1
13 Air filter case breather hose 1 Disconnect.
14 Negative pressure hose 1 Disconnect.
15 Air funnel rubber seat 4
16 Air filter case 1
procedure.
6-2
8 Nm (0.8 m • kg, 5.8 ft • Ib) (4)

T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib) 8
T.
R.
9
11 LT
LT
14
12
20 LT 11
LT
10
13
12
17
18 1
16
2
19
6
15 5
4
LT
LT 8 Nm (0.8 m • kg, 5.8 ft • Ib)
3
T.
R.

Removing the injector 2 Remove the parts in the order listed.
1 Intake air pressure sensor coupler 1
2 Atmospheric pressure sensor cou- 1
pler
3 Cylinder #1 – injector 2 coupler 1
7 Pressure sensor hose 2
8 Intake air pressure sensor 1
9 Atmospheric pressure sensor 1
10 Pressure sensor bracket 1
11 Union bolt 2
12 Washer 4
6-3
8 Nm (0.8 m • kg, 5.8 ft • Ib) (4)

T.
R.
5 Nm (0.5 m • kg, 3.6 ft • Ib)
T.
R.
30 Nm (3.0 m • kg, 22 ft • Ib) 8
T.
R.
9
11 LT
LT
14
12
20 LT 11
LT
10
13
12
17
18 1
16
2
19
6
15 5
4
LT
LT 8 Nm (0.8 m • kg, 5.8 ft • Ib)
3
T.
R.

13 Injector fuel pipe 3 1
15 Injector 2 cover 8
16 Injector 2 4
17 O-ring 4
18 Seal 4
19 Seal 4
20 Fuel distributor 1
procedure.
6-4

Removing the throttle body assem- Remove the parts in the order listed.
bly
1 Fuel hose 1
2 Throttle position sensor coupler 1
7 Starter cable 1 Disconnect.
8 Throttle cable 2 Disconnect.
9 Throttle stop screw 1 Disconnect.
10 Throttle body assembly 1
11 Left plate 4
12 Right plate 4
6-5

13 Gasket 4
14 Spacer 16
procedure.
6-6

Removing the injector 1 and throttle Remove the parts in the order listed.
body
1 Negative pressure hose 1
2 Pressure regulator 1
3 Union bolt 1
4 Washer 2
7 Washer 1
8 Fuel distributor 1
9 Injector 1 4
10 O-ring 4
11 Seal 4
12 Seal 4
13 Rear connecting plate 1
6-7

14 Throttle position sensor 1
15 Throttle cable holder 1
16 Starter link lever screw 4
17 Starter link 1
18 Starter link lever 4
19 Front connecting plate 1
20 Throttle body 4
21 Starter plunger 4
22 Air screw 4
procedure.
6-8
CAUTION:
ACHTUNG:
The throttle bodies should not be disas-
sembled unnecessarily.
CHECKING THE INJECTOR

1. Check:
• injector 1
• injector 2
Damage → Replace.
CHECKING THE THROTTLE BODY

1. Check:
• throttle body
Cracks/damage → Replace the throttle
body assembly.
2. Check:
• fuel passages
Obstruction → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the throttle body in a petro-
leum-based solvent.
Do not use any caustic carburetor
cleaning solution.
b. Blow out all of passages with com-
pressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-9
CHECKING THE PRESSURE REGULATOR
1. Check:
• pressure regulator
Damage → Replace.
EAS00502
CHECKING AND ADJUSTING THE
THROTTLE POSITION SENSOR
NOTE:
Before adjusting the throttle position
sensor, the engine idling speed should
be properly adjusted.
1. Check:
• throttle position sensor
(installed on the throttle body)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the throttle position sen-
sor coupler from the throttle position
2 3 1 sensor.
b. Connect the pocket tester (Ω × 1k) to
the throttle position sensor.
Positive tester probe →

B/L Y L
blue terminal 1
Negative tester probe →
black/blue terminal 2
c. Measure the maximum throttle posi-

tion sensor resistance.
throttle position sensor.
Maximum throttle position

sensor resistance
4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F)
(blue — black/blue)
6 - 10
d. Connect the pocket tester (Ω × 1k) to

yellow terminal 3
e. While slowly opening the throttle,

check that the throttle position sensor
resistance is within the specified
range.
NOTE:
Check mainly that the resistance
changes gradually when turning the
throttle, since the readings (from closed
to wide-open throttle) may differ slightly
from those specified.
Out of specification or the resistance
changes abruptly → Go to step 2
below.
Throttle position sensor resis-

tance
(520 ~ 900 Ω) ~ (4.0 ~ 6.0 kΩ)
at 20 ˚C (68 ˚F)
(yellow — black/blue)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• throttle position sensor
2 3 1 (removed from the throttle body)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sensor.
B/L Y L b. Remove the throttle position sensor
from the throttle body.
c. Connect the pocket tester (Ω × 1k) to

blue terminal 1
6 - 11
d. Measure the maximum throttle posi-
tion sensor resistance.
Maximum throttle position

sensor resistance
4.0 ~ 6.0 kΩ at 20 ˚C (68 ˚F)
(blue — black/blue)
e. Connect the pocket tester (Ω × 1k) to


yellow terminal 3
f. While slowly opening the throttle,

check that the throttle position sensor
resistance is within the specified
range.
The resistance does not change or it
changes abruptly → Replace the
The slot is worn or broken → Replace
NOTE:
Check mainly that the resistance
changes gradually when turning the
throttle, since the readings (from closed
to wide-open throttle) may differ slightly
from those specified.

tance
0 ~ 5 ± 1.0 kΩ at 20 ˚C (68 ˚F)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 12
3. Adjust:
• throttle position sensor angle
2 3 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
sensor.
b. Connect the pocket tester (Ω × 1k) to
B/L Y L the throttle position sensor.

blue terminal 1
c. Measure the throttle position sensor

maximum resistance.
d. Calculate the throttle position sensor
maximum resistance when the throt-
tle is fully closed.
Throttle position sensor maximum

resistance (throttle is fully closed) =
Maximum resistance × (0.13 ~ 0.15)
4
Example:
If the maximum resistance = 5 kΩ, then
the throttle position sensor’s maximum
resistance when the throttle is fully
closed should be:
4 5 kΩ × (0.13 ~ 0.15) = 650 ~ 750 Ω
Lift the throttle body assembly slightly
out of the intake manifolds.
Loosen the throttle position sensor
screws 4.
Connect the pocket tester (Ω × 100) to

yellow terminal 3
e. Adjust the throttle position sensor

angle so that the measured resistance
is within the specified range.

tance
650 ~ 750 Ω
After adjusting the throttle position sen-

sor angle, tighten the throttle position
sensor screws.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 13
CHECKING THE FUEL PUMP AND
PRESSURE REGULATOR OPERATION
1. Check:
• pressure regulator operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the fuel tank and air filter
case cover.
b. Disconnect the nagative pressure
hose 1 from the pressure regulator
at the joint.
c. Disconnect the injector fuel pipe 3 2
from the fuel distributor.
d. Connect the mity vac 3 onto the neg-
ative pressure hose from the pressure
regulator.
e. Install the pressure gauge 4 and
adapter 5 with the washers and
injector fuel pipe 3 onto the fuel dis-
tributor.
Mity vac
90890-06756
Pressure gauge
90890-03153
Adapter
90890-03151
Adapter
30 Nm (3.0 m • kg, 22 ft • lb)
T.
R.
f. Install the fuel tank.

g. Start the engine.
h. Measure the fuel pressure.
Fuel pressure
250 ~ 260 kPa
(2.5 ~ 2.6 kgf/cm2,
35.6 ~ 37.0 psi)
6 - 14
i. Use the mity vac to adjust the fuel
pressure in relation to the vacuum
pressure as described below.
NOTE:
The vacuum pressure should not exceed
100 kPa (1 mmHg, 0.04 in. Hg).
Increase the vacuum pressure. →

Fuel pressure is decreased.
Decrease the vacuum pressure. →

Fuel pressure is increased.
Faulty → Replace the pressure regula-

tor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 15
FRONT WHEEL AND BRAKE DISCS CHAS
EB700002
CHASSIS
FRONT WHEEL AND BRAKE DISCS

Removing the front wheel and brake Remove the parts in the order listed.
discs
NOTE:
7
stand so that the front wheel is ele-
vated.
1 Brake hose holder (left and right) 2
2 Brake caliper (left and right) 2
3 Wheel axle pinch bolt 4 Loosen.
4 Front wheel axle 1
5 Front wheel 1
6 Collar (left and right) 2
7 Oil seal cover (left and right) 2
8 Brake disc (left and right) 2
procedure.
7-1
EB700010

Disassembling the front wheel Remove the parts in the order listed.
7 1
2
3
Oil seal (left and right)
Wheel bearing (left and right)
Spacer
2
2
1
procedure.
7-2
EB700102
REMOVING THE FRONT WHEEL
WARNING
WARNING
NOTE:
2. Remove:
• left brake caliper
• right brake caliper
NOTE:
Do not squeeze the brake lever when
removing the brake calipers.
3. Elevate:
• front wheel
NOTE:
EB700400
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
WARNING
wheel axle.
2. Check:
• tire
• front wheel
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7-3
3. Measure:
• radial wheel runout 1
• lateral wheel runout 2
Over the specified limits → Replace.
Max. radial wheel runout

1.0 mm (0.04 in)
Max. lateral wheel runout
0.5 mm (0.02 in)
4. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
5. Replace:
• wheel bearings New
• oil seals New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean the outside of the front wheel
hub.
b. Remove the oil seals 1 with a flat-
head screwdriver.
NOTE:
To prevent damaging the wheel, place a
rag 2 between the screwdriver and the
wheel surface.
c. Remove the wheel bearings 3 with a

general bearing puller.
d. Install the new wheel bearings and oil
seals in the reverse order of disas-
sembly.
CAUTION:
ACHTUNG:
Do not contact the wheel bearing center
race 4 or balls 5. Contact should be
made only with the outer race 6.
NOTE:
• First fully insert the right wheel bear-
ing, then install the spacer and finally
the left wheel bearing.
• Use a socket 7 that matches the diam-
eter of the wheel bearing outer race
and oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-4
EB700416
CHECKING THE BRAKE DISCS
the brake discs.
1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the
brake disc deflection or replace the
brake disc.
Max. brake disc deflection

Front: 0.1 mm (0.004 in)
Rear: 0.1 mm (0.004 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable
stand so that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebars to the
left or right to ensure that the front
wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle
against the brake disc surface.
e. Measure the deflection 1.5 mm
(0.06 in) below the edge of the brake
disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a
few different locations.
Min. brake disc thickness

Front: 4.5 mm (0.18 in)
Rear: 4.5 mm (0.18 in)
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt
hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages
and in a crisscross pattern.
7-5
Brake disc bolt
18 Nm (1.8 m • kg, 13 ft • lb)
LOCTITE
T.
R.
d. Measure the brake disc deflection.
e. If out of specification, repeat the
adjustment steps until the brake disc
deflection is within specification.
f. If the brake disc deflection cannot be
brought within specification, replace
the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EB700725
INSTALLING THE FRONT WHEEL
1. Lubricate:
• wheel axle
• oil seal lips
2. Install:
• brake discs
18 Nm (1.8 m · kg, 13 ft • lb)
T.
R.
NOTE:
• Apply locking agent (LOCTITE) 648 to
the threads of the brake disc bolts.
• Tighten the brake disc bolts in stages
3. Tighten:
• wheel axle 1
79 Nm (7.9 m · kg, 57 ft · lb)
T.
R.
• wheel axle pinch bolt 2

23 Nm (2.3 m · kg, 17 ft · lb)
T.
R.
1
CAUTION:
ACHTUNG:
2 Before tightening the wheel axle nut,
push down hard on the handlebars sev-
eral times and check if the front fork
rebounds smoothly.
7-6
4. Install:
• brake calipers
40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
WARNING
WARNING
Make sure that the brake hose is routed
properly.
EB700901
ADJUSTING THE FRONT WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both,
the front wheel static balance should
be adjusted.
• Adjust the front wheel static balance
with the brake discs installed.
1. Remove:
• balancing weight(-s)
2. Find:
• front wheel’s heavy spot
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the front wheel on a suitable
balancing stand.
b. Spin the front wheel.
c. When the front wheel stops, put an
“X1” mark at the bottom of the wheel.
d. Turn the front wheel 90˚ so that the
“X1” mark is positioned as shown.
e. Release the front wheel.
f. When the front wheel stops, put an
“X2” mark at the bottom of the wheel.
g. Repeat steps (a) through (d) several
times until all the marks come to rest
at the same spot.
h. The spot where all the marks come to
rest is the front wheel’s heavy spot
“X”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-7
3. Adjust:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a balancing weight 1 onto the
rim exactly opposite the heavy spot
“X”.
NOTE:
Start with the lightest weight.
b. Turn the front wheel 90˚ so that the

heavy spot is positioned as shown.
c. If the heavy spot does not stay in that
position, install a heavier weight.
d. Repeat steps (b) and (c) until the front
wheel is balanced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• front wheel static balance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the front wheel and make sure
that it stays at each position shown.
b. If the front wheel does not remain
stationary at all of the positions,
rebalance it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-8
REAR WHEEL, BRAKE DISC, AND REAR WHEEL
SPROCKET CHAS
EB701000
REAR WHEEL, BRAKE DISC, AND REAR WHEEL SPROCKET

Removing the rear wheel Remove the parts in the order listed.
NOTE:
stand so that the rear wheel is ele-
vated.
1 Brake caliper 1
2 Locknut (left and right) 2 Loosen.
3 Adjusting bolt (left and right) 2 Loosen.
4 Wheel axle nut 2
5 Washer 1
6 Rear wheel axle 1
7 Rear wheel 1
8 Brake caliper bracket 1
procedure.
7-9
SPROCKET CHAS
EB701010

Removing the brake disc and rear Remove the parts in the order listed.
wheel sprocket
1 Brake disc 1
2 Rear wheel sprocket 1
3 Oil seal cover (left and right) 2
4 Spacer (left and right) 2
5 Oil seal 1
6 Bearing 1
7 Rear wheel drive hub 1
8 Rear wheel drive hub damper 6
9 Rear wheel 1
procedure.
7 - 10
SPROCKET CHAS

Disassembling the rear wheel Remove the parts in the order listed.
1 Spacer 1
2 Bearing 1
3 Spacer 1
4 Oil seal 1
5 Circlip 1
6 Bearing 1
procedure.
7 - 11
SPROCKET CHAS
EB701100
REMOVING THE REAR WHEEL
WARNING
WARNING
NOTE:
2. Remove:
• brake caliper
NOTE:
Do not depress the brake pedal when
removing the brake caliper.
3. Remove:
• wheel axle nut
• washer
• wheel axle
• rear wheel
NOTE:
Push the rear wheel forward and
remove the drive chain from the rear
wheel sprocket.
EB701400
CHECKING THE REAR WHEEL
1. Check:
• wheel axle
• rear wheel
• wheel bearings
• oil seals
• brake disc
Refer to “FRONT WHEEL”.
2. Check:
• tire
• rear wheel
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
7 - 12
SPROCKET CHAS
3. Measure:
• radial wheel runout
• lateral wheel runout
Over the specified limits → Replace.
Max. radial wheel runout

1.0 mm (0.04 in)
Max. lateral wheel runout
0.5 mm (0.02 in)
EB701430
CHECKING THE REAR WHEEL DRIVE HUB
1. Check:
• rear wheel drive hub 1
• rear wheel drive hub dampers 2
EB701440
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• rear wheel sprocket
More than 1/4 tooth a wear → Replace
the rear wheel sprocket.
Bent teeth → Replace the rear wheel
sprocket.
b Correct
1 Drive chain roller
2 Rear wheel sprocket
2. Replace:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the self-locking nuts and the
rear wheel sprocket.
b. Clean the rear wheel drive hub with a
clean cloth, especially the surfaces
that contact the sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-lock-

ing nut
T.
R.
150 Nm (15.0 m • kg, 110 ft • lb)
NOTE:
Tighten the self-locking nuts in stages
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 13
SPROCKET CHAS
EB701710
INSTALLING THE REAR WHEEL
1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
2. Adjust:
• drive chain slack a
Drive chain slack

40 ~ 50 mm (1.57 ~ 1.97 in)
Refer to “ADJUSTING THE DRIVE

CHAIN SLACK” in chapter 3.
3. Tighten:
• wheel axle
150 Nm (15.0 m · kg, 110 ft · lb)
T.
R.
• wheel axle nut

45 Nm (4.5 m · kg, 32 ft · lb)
T.
R.
• brake caliper bolts

40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
WARNING
WARNING
Make sure that the brake hose is routed
properly.
EB701900
ADJUSTING THE REAR WHEEL STATIC
BALANCE
NOTE:
• After replacing the tire, wheel or both,
the rear wheel static balance should be
adjusted.
• Adjust the rear wheel static balance
with the brake disc and rear wheel
drive hub installed.
1. Adjust:
• rear wheel static balance
7 - 14
FRONT AND REAR BRAKES CHAS
EB702001
FRONT AND REAR BRAKES

Removing the front brake pads Remove the parts in the order listed.
The following procedure applies to
both of the front brake calipers.
1 Brake pad clip 2
2 Brake pad pin 1
3 Brake pad spring 1
4 Brake pad 2
5 Brake pad shim 2
6 Bleed screw 1
procedure.
7 - 15
EB702002

Removing the rear brake pads Remove the parts in the order listed.
1 Brake pad clip 4
2 Brake pad pin 2
4 Brake pad 2
5 Brake pad shim 2
6 Bleed screw 2
procedure.
7 - 16
EB702100
CAUTION:
ACHTUNG:
Disc brake components rarely require
disassembly.
tive measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic
brake system is disconnected, the
entire brake system must be disas-
sembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted sur-
immediately.
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for brake fluid entering the
eyes:
• Flush with water for 15 minutes and
get immediate medical attention.
EB702112
REPLACING THE FRONT BRAKE PADS
1 The following procedure applies to both
brake calipers.
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
2 or disassemble the brake caliper.
1. Remove:
• brake hose holder 1
• brake caliper 2
7 - 17
2. Remove:
• brake pad clips 1
• brake pad pin 2
• brake pad spring 3
• brake pads
(along with the brake pad shims)
3. Measure:
• brake pad wear limit a

0.5 mm (0.02 in)
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad spring
NOTE:
Always install new brake pads, brake
pad shims, and a brake pad spring as a
set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly
to the bleed screw 2. Put the other
end of the hose into an open con-
tainer.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
T.
R.
d. Install a new brake pad shim onto

each new brake pads.
e. Install new brake pads and a new
brake pad spring.
NOTE:
The arrow a on the brake pad spring
must point in the direction of disc rota-
tion.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 18
5. Install:
• brake pad pin
• brake pad clips
• brake caliper
40 Nm (4.0 m · kg, 2.9 ft · lb)
T.
R.
6. Check:
the proper level.
FLUID LEVEL” in chapter 3.
7. Check:
• brake lever operation
Soft or spongy feeling → Bleed the
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EB702113
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not
necessary to disconnect the brake hose
or disassemble the brake caliper.
1. Remove:
• brake caliper 1
2. Remove:
• brake pad clips 1
• brake pad pins 2
• brake pad spring 3
• brake pads
(along with the brake pad shims)
7 - 19
3. Measure:
• brake pad wear limit a

0.5 mm (0.02 in)
4. Install:
• brake pad shims
(onto the brake pads)
• brake pads
NOTE:
Always install new brake pads, brake
pad shims, and a brake pad spring as a
set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly
to the bleed screw 2. Put the other
end of the hose into an open con-
tainer.
b. Loosen the bleed screw and push the
brake caliper pistons into the brake
caliper with your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m • kg, 4.3 ft • lb)
T.
R.
d. Install a new brake pad shim onto

each new brake pad.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 20
5. Install:
• brake pad pins
• brake pad clips
• brake caliper
40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
6. Check:
the proper level.
7. Check:
• brake pedal operation
brake system.
7 - 21
EB702301

Removing the front brake calipers Remove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper 1
procedure.
7 - 22
EB702303

Disassembling the front brake cali- Remove the parts in the order listed.
pers
1 Brake pad clip 2
2 Brake pad pin 1
4 Brake pad 2
5 Brake caliper piston 4
6 Brake caliper piston seal 8
7 Bleed screw 1
procedure.
7 - 23
EB702304

Removing the rear brake caliper Remove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2
3 Brake hose 1
4 Brake caliper 1
procedure.
7 - 24
EB702305

Disassembling the rear brake caliper Remove the parts in the order listed.
1 Brake pad clip 4
2 Brake pad pin 2
4 Brake pad 2
5 Brake caliper piston 2
6 Brake caliper piston seal 4
7 Bleed screw 2
procedure.
7 - 25
EB702317
DISASSEMBLING THE FRONT BRAKE
CALIPERS
the brake calipers.
NOTE:
Before disassembling either brake cali-
per, drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper pistons 1
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the right side brake caliper
pistons with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side pistons from the brake cali-
per.
WARNING
WARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolts 3.
c. Remove the brake caliper piston

seals.
d. Repeat the previous steps to force out
the right side pistons from the brake
caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 26
EB702322
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper,
drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt 1
• brake hose
NOTE:
Put the end of the brake hose into a con-
tainer and pump out the brake fluid
carefully.
2. Remove:
• brake caliper piston seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Secure the right side brake caliper
piston with a piece of wood a.
b. Blow compressed air into the brake
hose joint opening b to force out the
left side piston from the brake caliper.
WARNING
WARNING
• Never try to pry out the brake caliper
pistons.
• Do not loosen the bolt 3.
c. Remove the brake caliper piston

seals.
d. Repeat the previous steps to force out
the right side piston from the brake
caliper.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 27
EB702343
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component

replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every two years
Every two years
and whenever the
Brake fluid
brake is disassem-
bled
1. Check:
Rust/scratches/wear → Replace the
brake caliper.
• brake caliper cylinders 2
Scratches/wear → Replace the brake
caliper.
Å • brake calipers
• brake fluid delivery passages
(brake caliper body)
pressed air.
WARNING
WARNING
Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.
Å Front
ı ı Rear
2. Check:
• rear brake caliper bracket 1
7 - 28
EB702376
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPERS
the brake calipers.
WARNING
WARNING
• Before installation, all internal brake
components should be cleaned and
lubricated with clean or new brake
fluid.
components as they will cause the pis-
ton seals to swell and distort.
• Whenever a brake caliper is disassem-
seals.

DOT 4
1. Install:
• brake caliper 1
(temporarily)
• copper washers New
• brake hose 2
• union bolt 3
30 Nm (3.0 m · kg, 22 ft · lb)
T.
R.
WARNING
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer
to “CABLE ROUTING”.
CAUTION:
ACHTUNG:
When installing the brake hose onto the
brake caliper 1, make sure that the
brake pipe a touches the projection b
on the brake caliper.
2. Remove:
• brake caliper
3. Install:
• brake pads
• brake caliper
40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
Refer to “REPLACING THE FRONT

BRAKE PADS”.
7 - 29
4. Fill:
• brake fluid reservoir
ommended brake fluid)

DOT 4
WARNING
WARNING
brake performance.
CAUTION:
ACHTUNG:
immediately.
5. Bleed:
• brake system
6. Check:
the proper level.
7. Check:
brake system.
7 - 30
EB702378
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
WARNING
WARNING
fluid.
components as they will cause the pis-
ton seals to swell and distort.
• Whenever a brake caliper is disassem-
seals.

DOT 4
1. Install:
• brake caliper 1
(temporarily)
• brake hose 2
• union bolt 3
30 Nm (3.0 m · kg, 22 ft · lb)
T.
R.
WARNING
WARNING
CAUTION:
ACHTUNG:
brake caliper 1, make sure that the
brake pipe a touches the projection b
on the brake caliper.
2. Remove:
• brake caliper
3. Install:
• brake pads
• brake pad springs
• brake caliper
40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
Refer to “REPLACING THE REAR

BRAKE PADS”.
7 - 31
4. Fill:

DOT 4
WARNING
WARNING
brake performance.
CAUTION:
ACHTUNG:
immediately.
5. Bleed:
• brake system
6. Check:
the proper level.
7. Check:
• brake pedal operation
brake system.
7 - 32
EB702200

Removing the front brake master Remove the parts in the order listed.
cylinder and brake fluid reservoir
Brake fluid Drain.
1 Brake fluid reservoir cap stopper 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm 1
holder
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
7 Circlip 1
8 Hose joint 1
9 Brake lever 1
10 Front brake switch connector 2 Disconnect.
11 Union bolt 1
12 Copper washer 3
7 - 33

13 Brake hose 2
14 Brake master cylinder holder 1
15 Brake master cylinder 1
16 Front brake switch 1
procedure.
7 - 34
EB702201

Disassembling the front brake mas- Remove the parts in the order listed.
ter cylinder
1 Dust boot 1
2 Circlip 1
3 Brake master cylinder kit 1
procedure.
7 - 35
EB702202

Removing the rear brake master cyl- Remove the parts in the order listed.
inder and brake fluid reservoir
Brake fluid Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir 1
5 Plastic clamp 1
6 Plastic locking tie 1
7 Brake fluid reservoir hose 1
8 Hose joint 1
9 Oil seal 1
10 Union bolt 1
11 Copper washer 2
12 Brake hose 1
procedure.
7 - 36
EB702203

Disassembling the rear brake mas- Remove the parts in the order listed.
ter cylinder
1 Brake master cylinder kit 1
procedure.
7 - 37
EB702210
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake
master cylinder, drain the brake fluid
from the entire brake system.
1. Remove:
• union bolt 1
• brake hoses 3
NOTE:
To collect any remaining brake fluid,
place a container under the master cylin-
der and the end of the brake hose.
EB702220
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
3 1. Remove:
• union bolt 1
1 • copper washers 2
• brake hose 3
NOTE:
To collect any remaining brake fluid,
2 place a container under the master cylin-
der and the end of the brake hose.
EB702243
Å CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
the brake master cylinders.
1. Check:
• brake master cylinder
Damage/scratches/wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
pressed air.
ı Å Front
ı Rear
7 - 38
Å 2. Check:
• brake master cylinder kit
Å Front
ı Rear
Å 3. Check:
• brake fluid reservoir 1
• brake fluid reservoir diaphragm 2
4. Check:
• brake hoses
EB702283
FRONT BRAKE MASTER CYLINDER
WARNING
WARNING
fluid.
components.

DOT 4
7 - 39
1. Install:
1 a • brake master cylinder 1
13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
NOTE:
• Install the brake master cylinder holder
with the “UP” mark facing up.
• Align the end of the brake master cyl-
inder holder with the punch mark a in
the right handlebar.
• First, tighten the upper bolt, then the
lower bolt.
2. Install:
• brake hose
• union bolt
30 Nm (3.0 m · kg, 22 ft · lb)
T.
R.
WARNING
WARNING
NOTE:
• While holding the brake hose, tighten
the union bolt as shown.
• Turn the handlebars to the left and to
the right to make sure that the brake
hose does not touch other parts (e.g.,
wire harness, cables, leads). Correct if
necessary.
3. Fill:

DOT 4
WARNING
WARNING
brake performance.
7 - 40
CAUTION:
ACHTUNG:
immediately.
4. Bleed:
• brake system
5. Check:
the proper level.
6. Check:
brake system.
EB702290
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
a
1. Install:
• brake hoses
• union bolt
30 Nm (3.0 m · kg, 22 ft · lb)
T.
R.
WARNING
WARNING
CAUTION:
ACHTUNG:
brake master cylinder, make sure that
the brake pipe touches the projection a
as shown.
7 - 41
2. Fill:

DOT 4
WARNING
WARNING
brake performance.
does not enter the reservoir. Water
will significantly lower the boiling
point of the brake fluid and could
cause vapor lock.
CAUTION:
ACHTUNG:
immediately.
3. Bleed:
• brake system
4. Check:
the proper level.
5. Adjust:
BRAKE” in chapter 3.
6. Adjust:
BRAKE LIGHT SWITCH” in chapter 3.
7 - 42
HYDRAULIC CLUTCH CHAS
.EAS00305
HYDRAULIC CLUTCH

Removing the clutch master cylin- Remove the parts in the order listed.
der
Clutch fluid Drain.
1 Clutch fluid reservoir cap 1
2 Clutch fluid reservoir diaphragm holder 1
3 Clutch fluid reservoir diaphragm 1
4 Clutch fluid reservoir 1
5 Clutch fluid reservoir hose 1
6 Dust seat 1
7 Circlip 1
8 Hose joint 1
9 Clutch lever 1
10 Clutch switch coupler 1
11 Union bolt 1
7 - 43

12 Copper washer 2
13 Clutch hose 1
14 Clutch master cylinder holder 1
15 Clutch master cylinder 1
16 Clutch switch 1
procedure.
7 - 44

Disassembling the clutch master Remove the parts in the order listed.
cylinder
1 Push rod 1
2 Clutch master cylinder kit 1
procedure.
7 - 45
EAS00307
CAUTION:
ACHTUNG:
Clutch components rarely require disas-
sembly.
tive measures:
• Never disassemble clutch components
unless absolutely necessary.
• If any connection on the hydraulic
clutch system is disconnected, the
entire clutch system must be disas-
sembled, drained, cleaned, properly
filled, and bled after reassembly.
• Never use solvents on internal clutch
components.
• Use only clean or new clutch fluid for
cleaning clutch components.
• Clutch fluid may damage painted sur-
always clean up any split fluid imme-
diately.
• Avoid clutch fluid coming into contact
with the eyes as it can cause serious
injury.
First aid for clutch fluid entering the
eyes:
Flush with water for 15 minutes and get
immediate medical attention.
EAS00308
CHECKING THE CLUTCH MASTER
CYLINDER
1. Check:
• clutch master cylinder
Damage/scratches/wear → Replace the
clutch master cylinder.
• clutch fluid delivery passage
(clutch master cylinder body)
pressed air.
2. Check:
• clutch master cylinder kit
7 - 46
3. Check:
• clutch fluid reservoir 1
• clutch fluid reservoir diaphragm 2
4. Check:
• clutch hose

CLUTCH MASTER CYLINDER
WARNING
WARNING
• Before installation, all internal clutch
components must be cleaned and
lubricated with clean or new clutch
fluid.
components.
Recommended clutch fluid

Brake fluid DOT 4
1. Install:
• clutch master cylinder 1
1
NOTE:
• Install the clutch master cylinder
a holder with the “UP” mark facing up.
UP
• Align the end of the clutch master cyl-
inder holder with the punch mark a in
the handlebar.
lower bolt.
7 - 47
2. Install:
• clutch hose 1
2 • union bolt 2
26 Nm (2.6 m · kg, 19 ft · lb)
T.
R.
b
WARNING
WARNING
a
Proper clutch hose routing is essential
to insure safe motorcycle operation.
1 Refer to “CABLE ROUTING”.
CAUTION:
ACHTUNG:
When installing the clutch hose onto
the clutch master cylinder, make sure
that the pipe a touches the projection
b.
3. Fill:
• clutch fluid reservoir
ommended clutch fluid)

Brake fluid DOT 4
WARNING
WARNING
Other clutch fluids may cause the rub-
age and poor clutch performance.
• Refill with the same type of clutch
fluid that is already in the system.
Mixing clutch fluids may result in a
harmful chemical reaction, leading to
poor clutch performance.
point of the clutch fluid and could
cause vapor lock.
CAUTION:
ACHTUNG:
faces or plastic parts. Therefore, always
clean up any spilt clutch fluid immedi-
ately.
7 - 48
4. Bleed:
• clutch system
CLUTCH SYSTEM” in chapter 3.
5. Check:
Below the minimum level mark a → Add
the recommended clutch fluid to the
proper level.
a Refer to “CHECKING THE CLUTCH FLUID
LEVEL” in chapter 3.
6. Check:
• clutch lever operation
clutch system.
7 - 49
EAS00311

Removing the clutch release cylin- Remove the parts in the order listed.
der
Bottom cowling Refer to “COWLINGS” in chapter 3.
Clutch fluid Drain.
1 Starter knob 1
2 Union bolt 1
3 Copper washer 2
4 Clutch hose 1
5 Clutch release cylinder assembly 1
6 Dowel pin 2
procedure.
7 - 50
EAS00312

Disassembling the clutch release Remove the parts in the order listed.
cylinder
1 Dust seal 1
2 Clutch release cylinder piston 1
3 Spring 1
4 Oil seal 1
5 Bleed screw 1
procedure.
7 - 51
EAS00313
DISASSEMBLING THE CLUTCH RELEASE
CYLINDER
1. Remove:
• dust seal 1
• clutch release cylinder piston 2
• spring 3
• oil seal 4
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the clutch
hose joint opening a to force out the
piston from the clutch release cylin-
der.
WARNING
WARNING
• Cover the clutch release cylinder with
a rag. Be careful not to get injured
when the piston is expelled from the
clutch release cylinder.
• Never try to pry out the clutch release
cylinder piston.
b. Remove the clutch release cylinder oil

seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00314
2 CHECKING THE CLUTCH RELEASE

3 CYLINDER
1. Check:
• clutch release cylinder body 1
Cracks/damage → Replace the clutch
release cylinder.
• clutch release cylinder 2
1 • clutch release cylinder piston 3
Rust/scratches/wear → Replace the
clutch release cylinder and clutch
release cylinder piston as a set.
7 - 52
EAS00315
CLUTCH RELEASE CYLINDER
WARNING
WARNING
• Before installation, all internal clutch
components must be cleaned and
lubricated with clean or new clutch
fluid.
components as they will cause the oil
seal and dust seal to swell and distort.
• Whenever a clutch release cylinder is
disassembled, replace the oil seal and
dust seal.

Brake fluid DOT 4
1. Check:
• copper washer 1 New
2 • clutch hose 2
b • union bolt 3
a 26 Nm (2.6 m · kg, 19 ft · lb)
T.
R.
3
WARNING
WARNING
1 Proper clutch hose routing is essential
to insure safe motorcycle operation.
Refer to “CABLE ROUTING”.
CAUTION:
ACHTUNG:
When installing the clutch hose onto the
clutch release cylinder, make sure that
the pipe a touches the projection b.
2. Fill:
• clutch fluid reservoir
ommended clutch fluid)

Brake fluid DOT 4
WARNING
WARNING
Other clutch fluids may cause the rub-
age and poor clutch performance.
• Refill with the same type of clutch
fluid that is already in the system.
Mixing clutch fluids may result in a
harmful chemical reaction, leading to
poor clutch performance.
7 - 53
point of the clutch fluid and could
cause vapor lock.
CAUTION:
ACHTUNG:
faces or plastic parts. Therefore, always
clean up any spilt clutch fluid immedi-
ately.
3. Bleed:
• clutch system
4. Check:
Add the recommended clutch fluid to
the proper level.
Refer to “CHECKING THE CLUTCH
a
5. Check:
• clutch lever operation
clutch system.
7 - 54
FRONT FORK CHAS
EB703001
FRONT FORK
25 Nm (2.5 m • kg, 18 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
11 Nm (1.1 m • kg, 8.0 ft • Ib) 4
T.
R.
3
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

Removing the front fork legs Remove the parts in the order listed.
both of the front fork legs.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISCS”.
1 Front fender 1
2 Upper bracket pinch bolt 1 Loosen.
3 Cap bolt 1 Loosen.
4 Handlebar pinch bolt 2
5 Lower bracket pinch bolt 3
6 Front fork leg 1
procedure.
7 - 55
FRONT FORK CHAS
EB703002

Disassembling the front fork legs Remove the parts in the order listed.
both of the front fork legs.
1 Cap bolt/O-ring 1/1
2 Straight key 1
3 Washer 1
4 Damper adjusting rod 1
5 Nut 1
6 Spring seat 1
7 Spacer 1
8 Fork spring 1
9 Outer tube 1
0 Dust seal 1
A Oil seal clip 1
B Oil seal 1
C Washer 1
7 - 56
FRONT FORK CHAS

D Damper rod assembly 1
E Inner tube 1
procedure.
7 - 57
FRONT FORK CHAS
EB703100
REMOVING THE FRONT FORK LEGS
WARNING
WARNING
NOTE:
2. Adjust:
• spring preload
NOTE:
1 Turn the adjusting bolt 1 in fully so that
it sits lightly. Refer to “ADJUSTING THE
FRONT FORK LEGS” in chapter 3.
3. Loosen:
• upper bracket pinch bolt 1
2 • cap bolt 2
(with the front fork cap bolt wrench)
Front fork cap bolt wrench:

90890-01472
• handlebar pinch bolts
1 • lower bracket pinch bolts
WARNING
WARNING
Before loosening the upper and lower
bracket pinch bolts and handlebar pinch
bolt, support the front fork leg.
4. Remove:
• front fork leg
EB703113
1 5 DISASSEMBLING THE FRONT FORK LEGS

2
3 1. Remove:
4 • cap bolt 1
(from the damper rod assembly)
• straight key
• washer
• damper adjusting rod
7 - 58
FRONT FORK CHAS
• nut 2
• spring seat 3
• spacer
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Press down on the spacer with the
fork spring compressor 4.
b. Install the rod holder 5 between the
nut 2 and the spring seat 3.

90890-01441
Rod holder
90890-01434
NOTE:
Use the side of the rod holder that is
marked “A”.
c. Loosen the nut.

d. Remove the cap bolt, straight key,
washer and damper adjusting rod.
e. Remove the rod holder and fork
spring compressor.
WARNING
WARNING
The fork spring is compressed.
f. Remove the nut, spring seat and

spacer.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Drain:
• fork oil
NOTE:
Stroke the damper rod 1 several times
while draining the fork oil.
3. Remove:
• outer tube
(from inner tube)
4. Remove:
• dust seal
• oil seal clip 1
• oil seal
• washer
(with a flat-head screwdriver)
7 - 59
FRONT FORK CHAS
5. Remove:
• damper rod assembly
(with the damper rod holder 1)
Damper rod holder

90890-01473
EB703401
CHECKING THE FRONT FORK LEGS
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
WARNING
WARNING
inner tube as this may dangerously
weaken it.
2. Measure:
• spring free length a
Spring free length limit

240 mm (9.45 in)
3. Check:
• damper rod 1
Obstruction → Blow out all of the oil
passages with compressed air.
CAUTION:
ACHTUNG:
• The front fork leg has a built-in
damper adjusting rod and a very
sophisticated internal construction,
which are particularly sensitive to for-
eign material.
• When disassembling and assembling
the front fork leg, do not allow any for-
eign material to enter the front fork.
7 - 60
FRONT FORK CHAS
4. Check:
• cap bolt O-ring
EB703702
ASSEMBLING THE FRONT FORK LEGS
WARNING
WARNING
• Make sure that the oil levels in both
front fork legs are equal.
• Uneven oil levels can result in poor
handling and a loss of stability.
NOTE:
• When assembling the front fork leg, be
sure to replace the following parts:
- inner tube bushing
- outer tube bushing
- oil seal
- dust seal
• Before assembling the front fork leg,
make sure that all of the components
are clean.
1. Install:
• damper rod assembly 1
CAUTION:
ACHTUNG:
Allow the damper rod assembly to slide
slowly down the inner tube 2 until it
protrudes from the bottom of the inner
tube. Be careful not to damage the inner
tube.
NOTE:
Be sure that the clip 3 is still correctly
installed.
2. Lubricate:
• inner tube’s outer surface
Yamaha fork and shock oil
M1 or equivalent
7 - 61
FRONT FORK CHAS
3. Tighten:
• damper rod assembly
48 Nm (4.8 m · kg, 35 ft · lb)
T.
R.
(with the damper rod holder 1)
Damper rod holder

90890-01473
4. Install:
• dust seal 1
• oil seal clip 2
• oil seal 3
• washer 4
CAUTION:
ACHTUNG:
Make sure that the numbered side of
the oil seal faces up.
NOTE:
• Before installing the oil seal, lubricate
its lips with lithium soap base grease.
• Lubricate the outer surface of the inner
tube with fork oil.
• Before installing the oil seal, cover the
top of the front fork leg with a plastic
bag 5 to protect the oil seal during
installation.
5. Install:
• outer tube
(onto the inner tube)
6. Install:
• washer
• oil seal 1
(with the fork seal driver 2)
Fork seal driver

90890-01442
7. Install:
• oil seal clip 1
NOTE:
Adjust the oil seal clip so that it fits into
the outer tube’s groove.
7 - 62
FRONT FORK CHAS
8. Install:
• dust seal 1
(with the fork seal driver 2)
9. Install:
• rod puller 1
• adapter 2
(onto the damper rod 3)
Rod puller
90890-01437
Adapter
90890-01436
10.Fully compress the front fork leg.
11.Fill:
• front fork leg
ommended fork oil)
Quantity (each front fork leg)

460 cm3
(16.2 Imp oz, 15.6 US oz)
Recommended oil
Yamaha fork and shock oil
01 or equivalent
CAUTION:
ACHTUNG:
• Be sure to use the recommended fork
oil. Other oils may have an adverse
effect on front fork performance.
• When disassembling and assembling
the front fork leg, do not allow any for-
eign material to enter the front fork.
12.After filling the front fork leg, slowly

stroke the damper rod 1 up and down
(at least ten times) to distribute the fork
oil.
NOTE:
Be sure to stroke the damper rod slowly
because the fork oil may spurt out.
7 - 63
FRONT FORK CHAS
13.Slowly stroke the outer tube 1 up and
down to distribute the fork oil once
more (1 stroke = about 100 mm, 3.94 in).
NOTE:
Be careful not to stroke the inner tube
over 100 mm as this will cause air to
enter. If the inner tube is stroked more
than 100 mm, repeat steps (12) and (13).
14.Before measuring the fork oil level, wait

ten minutes until the oil has settled and
the air bubbles have dispersed.
NOTE:
Be sure to bleed the front fork leg of any
residual air.
15.Measure:
• front fork leg oil level a
Out of specification → Correct.
Front fork leg oil level (from

the top of the outer tube, with
the outer tube fully down, and
without the spring)
170 mm (6.69 in)
16.Install:
• fork spring 1
6 • spacer 2
7 • spring seat 3
8 • nut 4
• damper adjusting rod 5
• washer 6
2 • straight key 7
• cap bolt 8
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5 3 1 a. Remove the rod puller and adapter.
4
b. Install the nut.
7 - 64
FRONT FORK CHAS
c. Install the fork spring, spacer, spring
seat and nut.
NOTE:
Finger tighten the nut onto the winding
at the damper rod end.
d. Install the rod puller and adapter onto

the damper rod.
Rod puller
90890-01437
Adapter
90890-01436
0
e. Press down on the spacer with the
fork spring compressor 9.
4
f. Pull up the rod puller and install the
9 rod holder 0 between the nut 4 and
the spring seat.
NOTE:
Use the side of the rod holder that is
marked “A”.

90890-01441
Rod holder
90890-01434
g. Remove the rod puller and adapter.
h. Install the damper adjusting rod,
washer, straight key and cap bolt, and
then finger tighten the cap bolt.
NOTE:
• Make sure that the spring preload
adjusting bolt at the top of cap bolt is
fully, but lightly tightened.
• Insert the cap bolt fully into the
damper rod.
i. Hold the cap bolt and tighten the nut.
Nut
25 Nm (2.5 m • kg, 18 ft • lb)
T.
R.
j. Remove the rod holder and fork

spring compressor.
WARNING
WARNING
• The fork spring is compressed.
• Always use a new cap bolt O-ring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 65
FRONT FORK CHAS
17.Install:
• outer tube
(onto the cap bolt)
NOTE:
Temporarily tighten the cap bolt.
EB703710
INSTALLING THE FRONT FORK LEGS
1. Install:
• front fork leg
Temporarily tighten the upper and
lower bracket pinch bolts.
NOTE:
Align the top of the upper bracket with
fourth groove below the cap bolt.
2. Tighten:
• lower bracket pinch bolt 1, 2, 3
11 Nm (1.1 m · kg, 8.0 ft · lb)
T.
R.
2
NOTE:
1 Tighten the lower bracket pinch bolts 1,
2 and 3 in the given order and in two
3 stages. Finally, tighten the pinch bolt 1
once more.
13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
• cap bolt
25 Nm (2.5 m · kg, 18 ft · lb)
T.
R.

26 Nm (2.6 m · kg, 19 ft · lb)
T.
R.
WARNING
WARNING
Make sure that the brake hoses are
routed properly.
3. Adjust:
• spring preload
• rebound damping
Refer to “ADJUSTING THE FRONT
FORK LEGS” in chapter 3.
7 - 66
HANDLEBARS CHAS
EB704001
HANDLEBARS
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
18
T.
T.
R.
R.
16 15
26 Nm (2.6 m • kg, 19 ft • Ib)
T.
R.
16
14
17
4
19
15 13 11
20 17 12
2
1
3
8
6
5 LS
2
LS 10
7
9
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)

4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
T.
R.

Removing the handlebars Remove the parts in the order listed.
1 Clutch switch coupler 1 Disconnect.
2 Left handlebar switch 1
3 Clutch master cylinder holder 1
5 Left grip end 1
6 Handlebar grip 1
7 Right grip end 1
8 Throttle cable housing 1
9 Throttle cable 2
10 Throttle grip 1
7 - 67
HANDLEBARS CHAS
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
18
T.
T.
R.
R.
16 15
26 Nm (2.6 m kg, 19 ft Ib)
• •
T.
R.
16
14
17
4
19
15 13 11
20 17 12
2
1
3
8
6
5 LS
2
LS 10
7
9
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)

4 Nm (0.4 m • kg, 2.9 ft • Ib)
T.
R.
T.
R.

11 Front brake switch connector 2 Disconnect.
12 Right handlebar switch 1
13 Brake master cylinder holder 1
15 Handlebar pinch bolt 4
16 Upper bracket bolt 2
17 Upper bracket pinch bolt 2
18 Steering stem nut 1
19 Upper bracket 1
20 Left handlebar 1
21 Right handlebar 1
procedure.
7 - 68
HANDLEBARS CHAS
EB704101
REMOVING THE HANDLEBARS
WARNING
WARNING
2. Remove:
• handlebar grip
NOTE:
Blow compressed air between the left
handlebar and the handlebar grip, and
gradually push the grip off the handle-
bar.
EB704401
CHECKING THE HANDLEBARS
1. Check:
• left handlebar
• right handlebar
Bends/cracks/damage → Replace.
WARNING
WARNING
Do not attempt to straighten bent han-
dlebars as this may dangerously
weaken them.
EB704704
INSTALLING THE HANDLEBARS
1. Install:
a • brake master cylinder holder 1
13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
UP
CAUTION:
ACHTUNG:
1 • Install the brake master cylinder
holder with the “UP” mark facing up.
lower bolt.
NOTE:
• Align the mating surfaces of the brake
master cylinder holder with the punch
mark a in the right handlebar.
• There should be 2 mm of clearance
between the right handlebar switch
and the brake master cylinder holder.
7 - 69
HANDLEBARS CHAS
2. Install:
• right handlebar switch 1
1 NOTE:
Align the projection a on the right han-
dlebar switch with the hole b in the
right handlebar.
a b
3. Install:
• throttle grip 1
• throttle cable housing 2
a • throttle cables
b NOTE:
Align the projection a on the throttle
cable housing with the hole b in the
right handlebar.
2
1
4. Install:
• clutch master cylinder holder 1
a CAUTION:
ACHTUNG:
• Install the clutch master cylinder
UP
holder with the “UP” mark facing up.
• First tighten the upper bolt, then the
1 lower bolt.
NOTE:
Align the slit in the clutch master cylin-
der holder with the punch mark a in the
left handlebar.
5. Install:
• left handlebar switch 1
1
a NOTE:
Align the projection a on the left han-
dlebar switch with the hole b in the left
handlebar.
b
7 - 70
HANDLEBARS CHAS
6. Install:
• handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive
onto the end of the left handlebar.
b. Slide the handlebar grip over the end
of the left handlebar.
c. Wipe off any excess rubber adhesive
with a clean rag.
WARNING
WARNING
Do not touch the handlebar grip until
the rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Adjust:
CABLE FREE PLAY” in chapter 3.
Throttle cable free play (at the

flange of the throttle grip)
3 ~ 5 mm (0.12 ~ 0.20 in)
7 - 71
STEERING HEAD CHAS
EB705001
STEERING HEAD
115 Nm (11.5 m • kg, 85 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib) 2 5
T.
R.
2
4
20 6
LS 18
16
14 8 1
17 9
10
LS 11
13
14 3
12 15
LS
18
19
19 Nm (1.9 m • kg, 13 ft • Ib)

1st. 18 Nm (1.8 kg • m, 13 ft • Ib)
T.
R.
T.
R.
2nd. 9 Nm (0.9 kg • m, 6.5 ft • Ib)

Removing the lower bracket Remove the parts in the order listed.
Front wheel Refer to “FRONT WHEEL AND BRAKE
DISCS”.
Front fork legs Refer to “FRONT FORK”.
1 Main switch coupler 2 Disconnect.
2 Upper bracket bolt 2
3 Left handlebar assembly 1
4 Right handlebar assembly 1
5 Steering stem nut 1
6 Upper bracket 1
7 Brake hose holder bolt 2
8 Lock washer 1
9 Upper ring nut 1
10 Rubber washer 1
7 - 72
STEERING HEAD CHAS
115 Nm (11.5 m • kg, 85 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib) 2 5
T.
R.
2
4
20 6
LS 18
16
14 8 1
17 9
10
LS 11
13
14 3
12 15
LS
18
19
19 Nm (1.9 m • kg, 13 ft • Ib)

1st. 18 Nm (1.8 kg • m, 13 ft • Ib)
T.
R.
T.
R.
2nd. 9 Nm (0.9 kg • m, 6.5 ft • Ib)

11 Lower ring nut 1
12 Lower bracket 1
13 Bearing cover 1
14 Bearing inner race 2
15 Upper bearing 1
16 Lower bearing 1
17 Dust seal 1
18 Bearing outer race 2
19 Upper bearing housing 1
20 Lower bearing housing 1
procedure.
7 - 73
STEERING HEAD CHAS
EB705100
REMOVING THE LOWER BRACKET
WARNING
WARNING
2. Remove:
• lower ring nut 1
(with the special tool 2)
Ring nut wrench

90890-01403
WARNING
WARNING
Securely support the lower bracket so
that there is no danger of it falling.
EB705401
CHECKING THE STEERING HEAD
1. Wash:
• bearing balls
• bearing races
Recommended cleaning solvent

Kerosine
2. Check:
• bearing balls 1
• bearing races 2
Damage/pitting → Replace.
3. Check:
• upper bracket
• lower bracket
(along with the steering stem)
7 - 74
STEERING HEAD CHAS
EB705700
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
• O-ring
• dust seat lips
• bearing cover lips
• steering stem shreads
2. Install:
• lower ring nut 1
• rubber washer 2
• upper ring nut 3
• lock washer 4
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
3. Install:
• upper bracket
NOTE:
Temporarily tighten the steering stem
nut.
4. Install:
• front fork legs
Refer to “FRONT FORK”.
NOTE:
Temporarily tighten the upper and lower
bracket pinch bolts, and handlebar pinch
bolts.
5. Tighten:
115 Nm (11.5 m · kg, 85 ft · lb)
T.
R.
• lower bracket pinch bolt

11 Nm (1.1 m · kg, 8.0 ft · lb)
T.
R.

26 Nm (2.6 m · kg, 19 ft · lb)
T.
R.
• upper bracket bolt

13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.

13 Nm (1.3 m · kg, 9.4 ft · lb)
T.
R.
7 - 75
REAR SHOCK ABSORBER ASSEMBLY CHAS
EB706000
REAR SHOCK ABSORBER ASSEMBLY

Removing the rear shock absorber Remove the parts in the order listed.
assembly
1 Bolt 1
2 Self-locking nut/bolt 1/1
5 Rear shock absorber assembly 1
7 Connecting arm 2
8 Spacer/oil seal/bearing 2/4/2
9 Sidestand 1
10 Self-locking nut/bolt/spacer 1/1/1
11 Relay arm 1
12 Spacer/oil seal/bearing 3/6/3
procedure.
7 - 76
EB706101
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNING
WARNING
This rear shock absorber and gas cylin-
der contain highly compressed nitro-
gen gas. Before handling the rear shock
absorber or gas cylinder, read and make
sure you understand the following
information. The manufacturer cannot
be held responsible for property dam-
age or personal injury that may result
from improper handling of the rear
shock absorber and gas cylinder.
• Do not tamper or attempt to open the
rear shock absorber or gas cylinder.
• Do not subject the rear shock absorber
or gas cylinder to an open flame or
any other source of high heat. High
heat can cause an explosion due to
excessive gas pressure.
• Do not deform or damage the rear
shock absorber or gas cylinder in any
way. If the rear shock absorber, gas
cylinder or both are damaged, damp-
ing performance will suffer.
EB706111
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER
Gas pressure must be released before dis-
posing of a rear shock absorber and gas cyl-
inder. To release the gas pressure, press on
the gas valve needle with a suitable tool as
shown, until all of the gas is released (the
hissing has stopped).
WARNING
WARNING
Wear eye protection to prevent eye
damage from released gas or metal
chips.
7 - 77
EB706204
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
WARNING
WARNING
NOTE:
2 2 2. Remove:
• rear shock absorber assembly lower
bolt 1
• connecting arm-to-swingarm bolt 2
NOTE:
While removing the rear shock absorber
1 assembly lower bolt, hold the swingarm
so that it does not drop down.
3. Remove:
• rear shock absorber assembly upper
bolt 1
• rear shock absorber assembly
1
NOTE:
Raise the swingarm and then remove
the rear shock absorber assembly from
between the swingarm.
EB706401
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear
shock absorber assembly.
• rear shock absorber
Gas leaks/oil leaks → Replace the rear
• spring
Damage/wear → Replace the rear
• gas cylinder
Damage/gas leaks → Replace.
• bushings
• dust seals
• bolts
Bends/damage/wear → Replace.
7 - 78
CHECKING THE RELAY ARM AND
2 1 CONNECTING ARM
1. Check:
• relay arm 1
• connecting arm 2
• bearings
2 • oil seals
• spacers
EB706701
INSTALLING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Lubricate:
• bearings
• oil seals
• spacers
2. Install:
• relay arm
• connecting arms
NOTE:
When installing the rear shock absorber
assembly, lift up the swingarm.
3. Tighten:
• relay arm-to-frame nut
40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
• relay arm-to-connecting arm nut

40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
• connecting arm-to-swingarm nut

40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
• rear shock absorber assembly upper nut

40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
• rear shock absorber assembly lower nut

40 Nm (4.0 m · kg, 29 ft · lb)
T.
R.
7 - 79
SWINGARM AND DRIVE CHAIN CHAS
EB707000
SWINGARM AND DRIVE CHAIN

Removing the swingarm and drive Remove the parts in the order listed.
chain
Drive sprocket Refer to “ENGINE” in chapter 4.
Rear wheel Refer to “REAR WHEEL, BRAKE DISC,
AND REAR WHEEL SPROCKET”.
Rear shock absorber assembly Refer to “REAR SHOCK ABSORBER
ASSEMBLY”.
1 Spacer 1
2 Adjusting bolt/locknut 2/2
3 Left drive chain puller 1
4 Right drive chain puller 1
5 Drive chain guard 1 1
7 Brake hose holder 3
8 Pivot shaft nut/washer 1/1
9 Right pivot shaft boss 1
7 - 80

10 Pivot shaft 1
11 Left pivot shaft boss 1
12 Swingarm 1
13 Spacer 2
14 Drive chain 1
16 Drive chain guide 1
17 Dust cover 2
18 Bearing 2
19 Spacer 1
20 Bearing 2
procedure.
7 - 81
EB707100
NOTE:
Before removing the drive sprocket,
drive chain, and rear wheel, measure the
drive chain slack and the length of a ten-
link section of the drive chain.
EB707111
REMOVING THE SWINGARM
WARNING
WARNING
NOTE:
2. Measure:
• swingarm side play
• swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the tightening torque of the
pivot shaft nut.
Pivot shaft nut

125 Nm (12.5 m • kg, 90 ft • lb)
T.
R.
b. Measure the swingarm side play Å

by moving the swingarm from side to
side.
c. If the swingarm side play is out of
specification, check the spacers, bear-
ings, washers, and dust covers.
Swingarm side play (at the

end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical move-

ment ı by moving the swingarm up
and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, washers, and dust
covers.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7 - 82
EB707120
REMOVING THE DRIVE CHAIN
1. Remove:
• drive chain
(with the drive chain cutter)
Drive chain cutter

90890-01286
NOTE:
Only cut the drive chain if it or the swin-
garm is to be replaced.
EB707400
CHECKING THE SWINGARM
1. Check:
• swingarm
NOTE:
If the swingarm must be replaced, the
drive chain must be cut with a drive
chain cutter.
2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
WARNING
pivot shaft.
3. Wash:
• pivot shaft
• dust covers
• spacer
• bearings
Recommended cleaning solvent

Kerosine
7 - 83
4. Check:
• dust covers
• spacer
• oil seals
• bearings
EB707410
CHECKING THE DRIVE CHAIN
1. Measure:
• ten-link section a of the drive chain
drive chain.
Max. ten-link drive chain sec-

tion
150.1 mm (5.91 in)
NOTE:
• While measuring the ten-link section,
push down on the drive chain to
increase its tension.
• Measure the length between drive
chain roller 1 and A as shown.
• Perform this measurement at two or
three different places.
2. Check:
• drive chain
Stiffness → Clean and lubricate or
replace.
3. Clean:
• drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean
cloth.
b. Put the drive chain in kerosine and
remove any remaining dirt.
7 - 84
c. Remove the drive chain from the ker-
osine and completely dry it.
CAUTION:
ACHTUNG:
This motorcycle has a drive chain with
small rubber O-rings 1 between the
drive chain side plates. Never use high-
pressure water or air, steam, gasoline,
certain solvents (e.g., benzine), or a
coarse brush to clean the drive chain.
High-pressure methods could force dirt
or water into the drive chain’s internals,
and solvents will deteriorate the O-
rings. A coarse brush can also damage
the O-rings. Therefore, use only kero-
sine to clean the drive chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• O-rings 1
Damage → Replace the drive chain.
• drive chain rollers 2
Damage/wear → Replace the drive
chain.
• drive chain side plates 3
drive chain.
5. Lubricate:
• drive chain
Engine oil or chain lubricant
suitable for O-ring chains
6. Check:
• drive sprocket
More than 1/4 tooth a wear → Replace
the drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket
7 - 85
EB707700
INSTALLING THE SWINGARM
1. Lubricate:
• bearings
• spacers
• dust covers
• pivot shaft
2. Install:
• spacers
• swingarm
• pivot shaft bosses
• pivot shaft
• washer
• pivot shaft nut
125 Nm (12.5 m · kg, 90 ft · lb)
T.
R.
3. Install:
• drive chain pullers
NOTE:
Install the drive chain pullers onto the
swingarm so that the sides stamped
“IN” face toward the inside (i.e., the rear
wheel).
4. Install:
• rear wheel
Refer to “REAR SHOCK ABSORBER
ASSEMBLY” and “REAR WHEEL”.
5. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” in chapter 3.
Drive chain slack

40 ~ 50 mm (1.57 ~ 1.97 in)
7 - 86
– +
ELECTRICAL COMPONENTS ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Wire harness B ECU M Speed sensor
2 Main switch C CDI unit N Sidestand switch
3 Front brake light switch D Fuse box O Stator coil assembly
4 Ignition coils E Fall detection switch P Oil level switch
5 Clutch switch F Starter relay Q Pickup coil
6 Throttle position sensor G Main fuse R Radiator fan
7 Intake air temperature sensor H Main relay S Horn
8 Intake air pressure sensor I Battery T Coolant temperature
9 Atmospheric pressure sensor J Rectifier/regulator sender
0 Turn signal relay K Rear brake light switch U Thermo switch
A Relay unit L Neutral switch V Camshaft sensor
8-1
– +
SWITCHES ELEC
EB801000
SWITCHES
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is
incorrect, check the wiring connections and
if necessary, replace the switch.
CAUTION:
Never insert the tester probes into the cou-
pler terminal slots 1. Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
the leads.
Pocket tester
90890-03112
NOTE:
• Before checking for continuity, set the
pocket tester to “0” and to the “Ω × 1”
range.
• When checking for continuity, switch back
b and forth between the switch positions a
few times.
R Br/L L/Y L/B The terminal connections for switches (e.g.,
ON
a main switch, engine stop switch) are shown
OFF
in an illustration similar to the one on the
left.
R Br/L The switch positions a are shown in the far
L/Y L/B left column and the switch lead colors b
are shown in the top row in the switch illus-
tration.
NOTE:
“ ” indicates a continuity of electric-
ity between switch terminals (i.e., a closed
circuit at the respective switch position).
The example illustration on the left shows
that:
There is continuity between blue/red and
red when the switch is set to “ ”.
There is continuity between blue/red and
8 blue, between brown/blue and red, and
between blue/yellow and blue/black when
the switch is set to “ON”.
8-2
– +
CHECKING THE SWITCHES ELEC
EB801010
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between
the terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace the switch.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
1 Main switch 6 Horn switch A Oil level switch

2 Light switch 7 Clutch switch B Rear brake light switch
3 Pass switch 8 Engine stop switch C Fuse
4 Dimmer switch 9 Start switch D Neutral switch
5 Turn signal switch 0 Front brake light switch E Sidestand switch
1
L/R L Br/L R L/Y L/B L/Y L/B 8 R/W R/B
P L L/R
OFF
ON R
9 L/W B
—
Br/L
G/Y Br
R/W Br
0
2 R/Y L
Br/W
R/B B
• G/Y L/W
R/Y P
L B
A
3 R/Y Y Dg Y
— Ch G
PASS B/Y L/Y
W
(BLUE)
4 Y G
7
(BLACK)
L/Y B/Y
5 Ch Br/W Dg
(BLACK)
OFF
D C B
L/Y B/Y
Sb
B
6 B P
B
—
(BROWN)
B
B
(BLUE)
8-3
– +
CHECKING THE BULBS AND BULB SOCKETS ELEC
EB801020
CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for dam-
age or wear, proper connections, and also
for continuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly con-
nect.
Incorrect continuity reading → Repair or
replace the bulb, bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are
shown in the illustration on the left.
• Bulbs A and B are used for headlights
and usually use a bulb holder which must
be detached before removing the bulb.
The majority of these bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulb C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs D and E are used for meter and
indicator lights and can be removed from
their respective socket by carefully pulling
them out.
CHECKING THE CONDITION OF THE BULBS

the bulbs.
1.Remove:
• bulb
8-4
– +
WARNING
WARNING
Since the headlight bulb gets extremely
hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
• Be sure to hold the socket firmly when
removing the bulb. Never pull the lead,
otherwise it may be pulled out of the ter-
minal in the coupler.
• Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise the transparency of the glass, the
life of the bulb and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2.Check:
• bulb (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Before checking for continuity, set the
pocket tester to “0” and to the “Ω × 1”
range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the tester positive probe to ter-
minal 1 and the tester negative probe to
terminal 2, and check the continuity.
b. Connect the tester positive probe to ter-
minal 1 and the tester negative probe to
terminal 3, and check the continuity.
c. If either of the readings indicate no conti-
nuity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-5
– +
CHECKING THE CONDITION OF THE BULB
SOCKETS
the bulb sockets.
1.Check:
• bulb socket (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
Check each bulb socket for continuity in the
same manner as described in the bulb sec-
tion; however, note the following.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If
any of the readings indicate no continu-
ity, replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE LEDs

the LEDs.
1.Check:
LED (for proper operation)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the meter assembly coupler
(meter assembly side).
b. Connect two jumper leads 1 from the
battery terminals to the respective cou-
pler terminals as shown.
WARNING
WARNING
• A wire that is used as a jumper lead must
have at least the same capacity of the
battery lead, otherwise the jumper lead
may burn.
• This check is likely to produce sparks,
therefore make sure that no flammable
gas or fluid is in the vicinity.
c. When the jumper leads are connected to

the terminals the respective LED should
illuminate.
Does not light → Replace the meter
assembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
8-6
1 Main switch T Cylinder #2-ignition coil
5 Battery U Cylinder #3-ignition coil EB802001
L/W R/B Lg L/W G W 6 MainA switch B C
V Cylinder D
#4-ignition coil
R/B L/R L/B L/R L/Y Sb B/Y B B/R
@ Y/R Br/R P/W W Br Y R/L R/L L L R R
Y W/Y Br G/W Dg R/G L G/Y G/Y L R/G Dg G/W Br W/Y Y B/L B/L B B
P Gy G R/L R/L L L R R
0 Relay unit
G L/Y B L/R W Y/B Ch Lg Lg/R Lg/R Lg Ch Y/B W L/R B L/Y G
(BLACK)
W CDI unitG/R Gy/R P/L
(BLACK) (GRAY)
(BLACK) (BLACK) (GRAY)
B R 4 WIRE HARNESS
A Diode HEADLIGHT AND METER SUB-WIRE HARNESS WIRE HARNESS SUB LEAD WIRE HARNESS
Z Neutral switch SUB LEAD WIRE HARNESS SUB LEAD
W W W R R/G B B/Y Sb L/Y
R R
(BLACK) R R R R L/W Br
L/Y
B Sidestand switch } Engine stop switch
R
A
R Br
W
2 W
R
6 L/W L/W
J ECU £ ECU fuse
3 5 L/Y
W
CIRCUIT DIAGRAM
Br K
WW B R/B R/L
Br L/W S Cylinder #1-ignition coil
W 7
B B 9 B R/L R/B
R B L/W
B B
B
WW B B
1 (BLUE) (BLUE) (GRAY)
L/Y L/B B L/Y W
B L/W B L
P L L/R L/R L 8
IGNITION SYSTEM
B L/W G/B R/L

Gy/B W/B B1 L/W B/W W/Y B2 B3 O/B L/B G/B R/B G/R Y/R
OFF
Gy B/L W/L R/Y R/W PB B2 B3 W2 Lg/R Br/R
ON R R B L Y/L Lg/Y R W1 Br G/Y Y/B Gy/R R/L G/B
Br/L Br/L Y P/W P/L G/W Br/W R/L L/R Br L/G Y/G W/G Br/G
Gy
Gy/B (BLACK) (BLACK) (GRAY)
L/R Br/L L/Y L/Y
B
M
L C W/B Gy L/B R/L
å B/L I
R R/G Gy
W L/Y L/YW/B B R/L L/B
ç B/L B/L
B B B B
Gy/B (GRAY)
B B B B
R/B R/L Br/G N
{ R/W B R/L G/W L/R W/G R/L
B R/G L/R R/G
B Br Y/G
B B R/B R/B R/L y O/B
L/G
B B | (GREEN) B B B1 B3 R/L O/B
} ~ G/W R/L R G L/W R/B
B Br R/W R/W Br z D B2 G/B
B B R/B R/W B (BLACK) (BLACK) B/L (GRAY)
Gy L/B
B B Y G/Y L/W B/L Y L Y O/B O
B L W/B Y/R Y/R C Y Y R D R/L
B (BLACK) B/L J G/R G/R C G
B
B L Br/R Br/R C Br
B1 Y Gy/R Gy/R C Gy R Y
B L D L P/W Lg/R
L/R
W B Y B B B/L P/L Y/B
B Y Br B R/L (GRAY)
B1 x Br/W W
P C P/W Br G/Y
B B Br (BLACK) G/W R R P
E B/W Y/L Y/L Y/L R G R D R/L
(BLACK) (BLACK) Br Br/W W/Y W/L W/L W/L P/B
B/L P/B P/B
§ † L D L Br B3 (BLACK) R G
Br Br/L Br/L Br P B L B B B/L Br/W B2
P C P/L Gy/B
(GRAY) R/W
(BROWN)
¢ F G R/W B/L
R/Y R/Y Q
Br Br/L R/Y Lg/Y Br
8-7
Lg/Y R/Y Lg/Y R D R/L
L/Y B/Y R/Y W1
q Br/WB1
• W2 (BLACK)
£ Br/W R Br
R/W Br/W [ (BLACK)
Br/L R/Y P \
Br L P R/Y s t u v w
L B B/L G/W (DARK GRAY)
B L
L/Y L/Y A ] H R
(DARK GRAY) PASS N Gy R D R/L
L Y Dg Dg Y
Ch G B/Y B/Y Br G/WB/L
G Ch `
B/Y L/Y (BLACK) (BLACK) L/R A R Gy
L/Y B/Y r B/W
(BLACK)
(BLUE) (BLUE) Y/B A (GRAY)
B B A a
Br G Y Ch Dg B P
L L ¶ L
R/G L/Y A X
(BLACK) (BLACK) p B/L B/W B/W B
Br P Br W A W (GRAY)
B (GRAY)
B Y b
B A W/Y A Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
G/W G/Y A Y/G W Gy/G B
L/G (BLACK)
i h c Br O/G
Y
S
d Gy
Y B B B Gy
A B
Br W/G Br/G Gy O
A e (BLACK)
Ch B L/G Y/G O/G Gy/G
Dg T
A (BLACK) (BLACK)
L Y A A f Gy/G
Ch Dg
A L B Gy/G
Ch Dg
f B
L/R G Y L/R
(BLACK)
l k U
Ch B Dg B g
IGNITION SYSTEM
Br Br L/R Lg/R A
L/R
(BLACK) (BLACK) G B
B G O/G
n m B B O/G
o G B j Y B B
R/G B L/Y W/Y G/Y W Y/B L/Y B/L (BLACK)
B Ch B B Dg (BROWN) (BLACK)
B B B B Br G/W Lg/R Lg Y Ch Dg L W/Y
V
B (BLACK) (BLACK) B B (BLACK)
Sb
Y
Sb
A
Z L/Y W/Y W L/Y
B
B/L B/L
ELEC –
+
– +
IGNITION SYSTEM ELEC
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
Check the main and ECU fuses for No good

Replace.
continuity.
OK C0NTINUITY
Check the condition of the bat- No good

Recharge or replace.
tery.
OK C0NTINUITY
No good
Check the spark plug. Re-gap or replace.
OK C0NTINUITY
OK
Measure the ignition spark gap. Ignition system is OK.
No good
Measure the ignition coil resis- No good

Replace.
tance.
OK C0NTINUITY
Measure the pickup coil resis- No good

Replace.
tance.
OK C0NTINUITY
No good
Check the main switch. Replace.
OK C0NTINUITY
No good Replace the right handlebar

Check the engine stop switch.
switch.
OK C0NTINUITY
No good
Check the neutral switch. Replace.
OK C0NTINUITY
No good
Check the diode. Replace.
OK C0NTINUITY
No good
Check the sidestand switch. Replace.
OK C0NTINUITY
No good
Check the relay unit. Replace.
OK C0NTINUITY
Check the entire ignition sys- No good

Repair or replace.
tem’s wiring.
OK C0NTINUITY
Replace the CDI unit.
8-8
– +
BAD
Replace the ECU.

NOTE:
• Before troubleshooting, remove the following part(-s):
1) fuel tank
2) air filter case
3) bottom cowling
4) front cowling
5) rear cowling
• Troubleshoot with the following special tool(-s).
Ignition checker
90890-06754
Pocket tester
90890-03112
MEASURING THE IGNITION SPARK GAP

the spark plugs.
• Disconnect the ignition coil from the spark
plug.
• Connect the ignition checker 1 as shown.
2 Ignition coil
• Set the main switch to “ON”.
• Measure the ignition spark gap a.
• Crank the engine by pushing the start
switch and gradually increase the spark
gap until a misfire occurs.
Minimum ignition spark gap

6 mm (0.24 in)
• Is there a spark and is the spark gap

within specification?
Yes → Good.
No → Measure the ignition coil resistance.
8-9
– +
MEASURING THE IGNITION COIL
1 RESISTANCE
3 the ignition coils.
• Remove the ignition coil from the cylinder
2 head.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Tester positive probe →

orange (cylinder #1) 1
gray (cylinder #2)
gray/green (cylinder #3)
orange/green (cylinder #4)
Tester negative probe → black 2
• Measure the primary coil resistance.
Primary coil resistance

0.16 ~ 0.21 Ω at 20˚C (68˚F)
• Connect the pocket tester (Ω × 1k) to the

ignition coil as shown.
• Measure the secondary coil resistance.

orange (cylinder #1) 1
gray (cylinder #2)
gray/green (cylinder #3)
orange/green (cylinder #4)
Tester negative probe →
ignition coil hole 3
Secondary coil resistance

5.0 ~ 6.8 kΩ at 20˚C (68˚F)
• Is the ignition coil OK?

Yes → Good.
No → Replace.
MEASURING THE PICKUP COIL
RESISTANCE
• Disconnect the pickup coil coupler from
the wire harness.
pickup coil coupler.
Tester positive probe → gray 1

• Measure the pickup coil resistance.
Pickup coil resistance

421 ~ 569 Ω at 20˚C (68˚ F)
(between gray and black)
• Is the pickup coil OK?

Yes → Good.
No → Replace.
8 - 10
– +
CHECKING THE DIODE
• Remove the diode from the coupler.
1 diode as shown.
• Check the diode for continuity.
L/W
2 L/Y
blue/white 1 Continu-
Tester negative probe → ity
blue/yellow 2
blue/yellow 2 No conti-
Tester negative probe → nuity
blue/white 1
NOTE:
When you switch the tester’s positive and
negative probes, the readings in the above
chart will be reversed.
• Are the tester readings correct?
Yes → Good.
No → Replace.
CHECKING THE RELAY UNIT

• Remove the relay unit from the coupler.
2 1 relay unit terminals as shown.
• Check the starting circuit cutoff relay for
continuity.
R/B Lg L/W G W
L/B L/R L/Y Sb B/Y B B/R Tester positive probe →
sky blue 1 Continu-
blue/yellow 2
blue/yellow 2 No conti-
sky blue 1
NOTE:
Yes → Good.
No → Replace.
8 - 11
EB803000
L/W R/B Lg L/W G W A B C D
G/R Gy/R P/L P Gy G R/L R/L L L R R
B R 4 WIRE HARNESS HEADLIGHT AND METER SUB-WIRE HARNESS WIRE HARNESS SUB LEAD WIRE HARNESS SUB LEAD WIRE HARNESS SUB LEAD
R R
R L/Y
A
R Br
W R
L/W L/W
2 W 3 5 6
W L/Y
CIRCUIT DIAGRAM
Br K
WW B R/B R/L
Br L/W
W 7
B B 9 B R/L R/B
R B L/W
B B
B
WW B B
L/Y L/B B L/Y W
B L/W B L
P L L/R L/R L B 8 L/W Gy/B W/B B1 L/W B/W W/Y B2 B3 O/B L/B G/B R/B G/R Y/R G/B R/L
OFF
Gy
L/R Br/L L/Y L/Y
B
M
L C W/B Gy L/B R/L
å B/L I
R R/G Gy
ç B/L B/L
B B B B
Gy/B (GRAY)
B B B B
R/B R/L Br/G N
B R/G L/R R/G
B Br Y/G
L/G
Gy L/B
ELECTRIC STARTING SYSTEM

B
B L Br/R Br/R C Br
B L D L P/W Lg/R
L/R
B Y Br B R/L (GRAY)
B1 x Br/W W
P C P/W Br G/Y
B/L P/B P/B
P C P/L Gy/B
(GRAY) R/W
(BROWN)
¢ F G R/W B/L
R/Y R/Y Q
Br Br/L R/Y Lg/Y Br R D R/L
Lg/Y R/Y Lg/Y
L/Y B/Y R/Y
8 - 12
q Br/WB1 W1
• W2 (BLACK)
£ Br/W R Br
R/W Br/W [ (BLACK)
Br/L R/Y P \
B L
L/Y L/Y A ] H R
L Y Dg Dg Y
G Ch `
L/Y B/Y r B/W
(BLACK)
B B A a
Br G Y Ch Dg B P
L L ¶ L
R/G L/Y A X
B (GRAY)
B Y b
B A W/Y A Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
L/G (BLACK)
i h c Br O/G
Y
S
d Gy
Y B B B Gy
A B
Br W/G Br/G Gy O
A e (BLACK)
Dg T
A (BLACK) (BLACK)
L Y A A f Gy/G
Ch Dg
A L B Gy/G
Ch Dg
f B
L/R G Y L/R
(BLACK)
l k U
Ch B Dg B g
ELECTRIC STARTING SYSTEM
Br Br L/R Lg/R A
L/R
(BLACK) (BLACK) G B
B G O/G
n m B B O/G
1 Main switch o
B Sidestand switch G B j Y B B
V
Sb
5 Battery J ECU
Y
Sb
6 Main fuse Z Neutral switch A
Z L/Y W/Y W L/Y
B
B/L B/L
7 Starter relay r Clutch switch
ELEC
8 Starter motor } Engine stop switch

9 Diode ~ Start switch
–
0 Relay unit £ ECU fuse

A Diode
+
– +
ELECTRIC STARTING SYSTEM ELEC
TROUBLESHOOTING
The starter motor fails to turn.
Check the main and ECU fuses for No good

Replace.
continuity.
OK C0NTINUITY

tery.
OK C0NTINUITY
No good
Check the starter motor. Repair or replace.
OK C0NTINUITY
No good
Check the relay unit. Replace.
OK C0NTINUITY
No good
Check the starter relay. Replace.
OK C0NTINUITY
No good
Check the diodes. Replace.
OK C0NTINUITY
No good
OK C0NTINUITY

Check the engine stop switch.
switch.
OK C0NTINUITY
No good
Check the neutral switch. Replace.
OK C0NTINUITY
No good
Check the sidestand switch. Replace.
OK C0NTINUITY
No good
Check the clutch switch. Replace.
OK C0NTINUITY

Check the start switch.
switch.
OK C0NTINUITY
Check the entire starting sys- No good

Repair or replace.
tem’s wiring.
8 - 13
– +
NOTE:
1) fuel tank4) bottom cowling
2) air filter case5) front cowling
3) throttle body assembly6) rear cowling
Pocket tester
90890-03112

5 2 • Disconnect the relay unit from the cou-
pler.
6 4 • Connect the pocket tester (Ω × 1) and bat-
1 tery (12 V) to the relay unit terminals as
3 shown.
R/B Lg L/W G W
L/B L/R L/Y Sb B/Y B B/R Battery positive terminal → red/black 1
Battery negative terminal →
black/yellow 2
Tester positive probe → blue/white 3
• Does the starting circuit cutoff relay have
continuity between blue/white and black?
relay unit terminals as shown.
• Check the relay unit for continuity as fol-
lows.
sky blue 5
black/yellow 2 Continu-
Tester positive probe → ity
sky blue 5
blue/yellow 6
black/yellow 2
sky blue 5 No conti-
Tester positive probe → nuity
blue/yellow 6
sky blue 5
NOTE:
Yes → Good.
No → Replace.
8 - 14
– +
CHECKING THE STARTER RELAY
• Disconnect the starter relay from the cou-
pler.
• Connect the pocket tester (Ω × 1) and bat-
tery (12 V) to the starter relay coupler as
shown.
Battery positive terminal → brown 1
Battery negative terminal →
blue/white 2
Tester positive probe → red 3
• Does the starter relay have continuity
between red and black?
Yes → Good.
No → Replace.
CHECKING THE DIODES

• Remove the diodes from the couplers.
1 diode as show.
• Check the diodes for continuity.
Br
2 L/W brown 1
blue/white 2 Continu-
Tester positive probe → ity
blue/white 3
blue/yellow 4
3
blue/white 2
L/W Tester negative probe →
4 L/Y brown 1 No conti-
Tester positive probe → nuity
blue/yellow 4
blue/white 3
NOTE:
Yes → Good.
No → Replace the defective diode(-s).
8 - 15
EB804000
R R
R L/Y
A
R Br
W R
L/W L/W
2 W 3 5 6
W L/Y
CIRCUIT DIAGRAM
Br K
WW B R/B R/L
Br L/W
W 7
B B 9 B R/L R/B
R B L/W
B B
B
WW B B
L/Y L/B B L/Y W
B L/W B L
OFF
CHARGING SYSTEM
Gy
L/R Br/L L/Y L/Y
B
M
L C W/B Gy L/B R/L
å B/L I
R R/G Gy
ç B/L B/L
B B B B
Gy/B (GRAY)
B B B B
R/B R/L Br/G N
B R/G L/R R/G
B Br Y/G
L/G
Gy L/B
B
B L Br/R Br/R C Br
B L D L P/W Lg/R
L/R
B Y Br B R/L (GRAY)
B1 x Br/W W
P C P/W Br G/Y
B/L P/B P/B
P C P/L Gy/B
(GRAY) R/W
(BROWN)
¢ F G R/W B/L
R/Y R/Y Q
Lg/Y R/Y Lg/Y
L/Y B/Y R/Y
8 - 16
q Br/WB1 W1
• W2 (BLACK)
£ Br/W R Br
R/W Br/W [ (BLACK)
Br/L R/Y P \
B L
L/Y L/Y A ] H R
L Y Dg Dg Y
G Ch `
L/Y B/Y r B/W
(BLACK)
B B A a
Br G Y Ch Dg B P
L L ¶ L
R/G L/Y A X
B (GRAY)
B Y b
B A W/Y A Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
L/G (BLACK)
i h c Br O/G
Y
S
d Gy
Y B B B Gy
A B
Br W/G Br/G Gy O
A e (BLACK)
Dg T
A (BLACK) (BLACK)
L Y A A f Gy/G
Ch Dg
A L B Gy/G
Ch Dg
f B
L/R G Y L/R
(BLACK)
l k U
Ch B Dg B g
CHARGING SYSTEM
Br Br L/R Lg/R A
L/R
(BLACK) (BLACK) G B
B G O/G
n m B B O/G
o G B j Y B B
V
Sb
Y
Sb
A
Z L/Y W/Y W L/Y
B
B/L B/L
ELEC
2 Rectifier/regulator
3 Generator
–
5 Battery
6 Main fuse
+
– +
CHARGING SYSTEM ELEC
TROUBLESHOOTING
The battery is not being charged.
Check the main fuse for continu- No good

Replace.
ity.
OK C0NTINUITY

tery.
OK C0NTINUITY
ON
Measure the charging voltage. The charging circuit is OK.
No good
Measure the stator coil assembly No good

Replace.
resistance.
OK C0NTINUITY
Check the entire charging sys- No good Repair or replace.

tem’s wiring.
OK C0NTINUITY
Replace the rectifier/regulator.

NOTE:
1) bottom cowling
2) front cowling
3) rear cowling
Engine tachometer
90890-06760
Pocket tester
90890-03112
8 - 17
– +
CHARGING SYSTEM ELEC
MEASURING THE CHARGING VOLTAGE
• Connect the engine tachometer to the
ignition coil of cylinder #1.
TLE BODIES” in chapter 3.
• Connect the pocket tester (DC 20V) to the
battery as shown.

battery positive terminal
battery negative terminal
• Start the engine and let it run at approxi-
mately 1,100 r/min.
• Measure the charging voltage.
Charging voltage
12 V at 1,100 r/min
NOTE:
• Make sure that the battery is fully
charged.
• When measuring, turn off the headlights
and make sure that no load is applied.
• Is the charging voltage within specifica-
tion?
Yes → OK.
No → Measure the stator coil assembly
resistance.
MEASURING THE STATOR COIL

ASSEMBLY RESISTANCES
• Disconnect the generator coupler from
the wire harness.
stator coil assembly coupler as shown.
Tester positive probe → white 1
Tester negative probe → white 2
Tester negative probe → white 3
• Measure the stator coil assembly resis-
tances.
Stator coil resistance

0.38 ~ 0.46 Ω at 20˚C (68 ˚F)
• Is the stator coil assembly OK?

Yes → OK.
No → Replace.
8 - 18
EB805000
R R
R L/Y
A
R Br
W R
L/W L/W
2 W 3 5 6
W L/Y
CIRCUIT DIAGRAM
Br K
WW B R/B R/L
Br L/W
W 7
B B 9 B R/L R/B
R B L/W
B B
B
WW B B
L/Y L/B B L/Y W
B L/W B L
LIGHTING SYSTEM
OFF
Gy
L/R Br/L L/Y L/Y
B
M
L C W/B Gy L/B R/L
å B/L I
R R/G Gy
ç B/L B/L
B B B B
Gy/B (GRAY)
B B B B
R/B R/L Br/G N
B R/G L/R R/G
B Br Y/G
L/G
Gy L/B
B
B L Br/R Br/R C Br
B L D L P/W Lg/R
L/R
B Y Br B R/L (GRAY)
B1 x Br/W W
P C P/W Br G/Y
B/L P/B P/B
P C P/L Gy/B
(GRAY) R/W
(BROWN)
¢ F G R/W B/L
R/Y R/Y Q
Lg/Y R/Y Lg/Y
R/Y
8 - 19
q L/Y B/Y Br/WB1 W1
• W2 (BLACK)
£ Br/W R Br
R/W Br/W [ (BLACK)
Br/L R/Y P \
Br L P R/Y s u
L B t v w B/L G/W (DARK GRAY)
B L
L/Y L/Y A ] H R
L Y Dg Dg Y
G Ch `
L/Y B/Y r B/W
(BLACK)
B B A a
Br G Y Ch Dg B P
L L ¶ L
R/G L/Y A X
B (GRAY)
B Y b
B A W/Y A Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
L/G (BLACK)
i h c Br O/G
Y
S
d Gy
Y B B B Gy
A B
Br W/G Br/G Gy O
A e (BLACK)
Ch 1 Main switch B L/G Y/G O/G Gy/G
Dg T
A (BLACK) (BLACK)
L Y A A f Gy/G
Ch Dg
A L 5 Battery B Gy/G
Ch Dg
f B
L/R G Y L/R
(BLACK)
l k U
Ch B Dg B g 6 Main fuse
LIGHTING SYSTEM
Br Br L/R Lg/R A
L/R
(BLACK) (BLACK) G B
B G O/G
n m B B O/G
o G B j Y B
R/G B L/Y W/Y G/Y W Y/B L/Y B/L
d High beam indicator light B
B (BLACK)
B Ch B Dg (BROWN) B B B B (BLACK) Br G/W Lg/R Lg Y Ch Dg L W/Y
V
B (BLACK) (BLACK) B B (BLACK) f Meter light
Sb
Y
Sb j Headlight
A
Z L/Y W/Y W L/Y
B
B/L B/L o Tail/brake light
ELEC
s Lights switch
t Pass switch
–
u Dimmer switch
¢ Headlight fuse
+
– +
LIGHTING SYSTEM ELEC
TROUBLESHOOTING
Any of the following fail to light: headlight, high beam indicator light, taillight, auxiliary light
or meter light.
Check the main and headlight No good Replace.

fuses for continuity.
OK C0NTINUITY

tery.
OK C0NTINUITY
No good
Check the bulbs and bulb sockets. Replace.
OK C0NTINUITY
Check the LED’s of the indicator No good

Replace the meter assembly.
light.
OK C0NTINUITY
No good
OK C0NTINUITY
No good
Check the lights switch. Replace the left handlebar switch.
OK C0NTINUITY
No good
Check the dimmer switch. Replace the left handlebar switch.
OK C0NTINUITY
No good
Check the pass switch. Replace the left handlebar switch.
OK C0NTINUITY
Check the entire lighting sys- No good

Repair or replace.
tem’s wiring.
NOTE:
1) bottom cowling
2) front cowling
3) rear cowling
Pocket tester
90890-03112
8 - 20
EB806000
R R
R L/Y
A
R Br
W R
L/W L/W
2 W 3 5 6
W L/Y
CIRCUIT DIAGRAM
Br K
WW B R/B R/L
Br L/W
W 7
B B 9 B R/L R/B
R B L/W
B B
B
WW B B
L/Y L/B B L/Y W
B L/W B L
OFF
SIGNALING SYSTEM
Gy
L/R Br/L L/Y L/Y
B
M
L C W/B Gy L/B R/L
å B/L I
R R/G Gy
ç B/L B/L
B B B B
Gy/B (GRAY)
B B B B
R/B R/L Br/G N
B R/G L/R R/G
B Br Y/G
1 Main switch L/G
Gy 5 Battery L/B
B
B L 6 Main fuse Br/R Br/R C Br
B L D L P/W Lg/R
L/R
B Y Br B R/L (GRAY)
B1 x Br/W W
P C P/W Br
0 Relay unit G/Y
B B Br (BLACK) G/W R P R
B/L P/B P/B
§ † L D L Br
Z Neutral switchB3 (BLACK) R G
P C P/L Gy/B
(GRAY) R/W
(BROWN)
¢ F G R/W B/L
R/Y R/Y
\ Fuel level indicator lightQ
Lg/Y R/Y Lg/Y
L/Y B/Y R/Y
8 - 21
q Br/WB1 W1
• ] Warning light (oil level indicator)
W2 (BLACK)
£ Br/W R Br
R/W Br/W [ (BLACK)
Br/L R/Y P \
Br L P R/Y s t u
L B v w B/L G/W (DARK GRAY)
B L
^ Neutral indicator light
L/Y L/Y A ] H R
L Y Dg Dg Y
a Tachometer
G Ch `
L/Y B/Y r B/W
(BLACK)
(BLUE) (BLUE) Y/B A b Combination meter (GRAY)
B B A a
Br G Y Ch Dg B P
L L ¶ L
R/G L/Y A X
(BLACK) (BLACK) p e Turn signal indicator light
B/L B/W B/W B
B (GRAY)
B Y b
B A W/Y A h Oil level switch Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
G/W G/Y A W Y/G Gy/G B
L/G (BLACK)
i h c i Horn Br O/G
Y
S
d Gy
Y B k Rear turn signal light (right) B B Gy
A B
Br W/G Br/G Gy O
A e (BLACK)
Dg l Rear turn signal light (left) T
A (BLACK) (BLACK)
L Y A A f Gy/G
Ch Dg
A L B Gy/G
Ch Dg
f m Front turn signal light (right) B
L/R G Y L/R
(BLACK)
l k
Ch B Dg B g
SIGNALING SYSTEM
Br Br L/R Lg/R A n Front turn signal light (left)U

L/R
(BLACK) (BLACK) G B
B G O/G
n m B B O/G
o G B j Y B o Tail/brake light B
V
B (BLACK) (BLACK) B B (BLACK) p Rear brake light switch
Sb
Y
Sb
A
v Turn signal switch
Z L/Y W/Y W L/Y
B
B/L B/L
w Horn switch
ELEC
x Turn signal relay

y Fuel pump (thermistor)
–
| Front brake light switch

† Signaling system fuse
+
– +
SIGNALING SYSTEM ELEC
TROUBLE SHOOTING
• Any of the following fail to light: turn signal light, brake light or an indicator light.
• The horn fails to sound.
Check the main and signal system fuses

continuity. No good
Replace.
OK
No good
Check the condition of the battery. Recharge or replace.
OK
No good
OK
No good
Check the entire signaling system’s wiring. Recharge or replace.
OK
Check the bulbs and No good Check the horn switch. No good Replace the
bulb sockets. Replace.
OK left handlebar
OK switch.
Check the LED’s of No good No good
Check the horn. Replace.
the indicator light. Replace.
OK
Check the brake Check the turn signal

switchs. switch.
OK No good OK No good
Replace. Replace the left
Replace the meter Replace the turn handlebar switch.
assembly. signal relay.
BAD
Check the neutral Replace the meter

switch. assembly.
OK No good
Replace.
Check the relay unit. Check the oil level

switch.
OK No good OK No good
Replace. Replace.
Replace the meter Replace the meter
assembly. assembly.
No good
Check the continuity of the thermistor in the fuel pump. Replace the fuel
pump.
OK
Replace the meter
assembly.
8 - 22
– +
SIGNALING SYSTEM ELEC
NOTE:
1) fuel tank
2) bottom cowling
3) front cowling
4) rear cowling
Pocket tester
90890-03112

• Remove the relay unit from the coupler.
2 1 relay unit terminals as shown.
• Check the starting circuit cutoff relay for
continuity.
R/B Lg L/W G W
L/B L/R L/Y Sb B/Y B B/R Tester positive probe →
sky blue 1 Continu-
blue/red 2
blue/red 2 No conti-
sky blue 1
NOTE:
Yes → Good.
No → Replace.
CHECKING THE OIL LEVEL SWITCH
• Drain the engine oil.
• Remove the oil level switch.
• Connect the pocket tester (Ω × 1) to the oil
level switch connector as shown.
• Check the oil level switch for continuity as
follows.
Tester negative probe → ground
Oil level switch float posi- Continu-
tion is upper Å. ity
1 Oil level switch float posi- No conti-

tion is lower ı. nuity
W
• Are the oil level switch readings correct?
ı Yes → Good.
W No → Replace.
Å
1
8 - 23
EB807000
R R
R L/Y
A
R Br
W R
L/W L/W
2 W 3 5 6
W L/Y
CIRCUIT DIAGRAM
Br K
WW B R/B R/L
Br L/W
W 7
B B 9 B R/L R/B
R B L/W
B B
B
WW B B
L/Y L/B B L/Y W
B L/W B L
P L L/R L/R L B 8
COOLING SYSTEM
L/W Gy/B W/B B1 L/W B/W W/Y B2 B3 O/B L/B G/B R/B G/R Y/R G/B R/L
OFF
Gy
L/R Br/L L/Y L/Y
B
M
L C W/B Gy L/B R/L
å B/L I
R R/G Gy
ç B/L B/L
B B B B
Gy/B (GRAY)
B B B B
R/B R/L Br/G N
B R/G L/R R/G
B Br Y/G
L/G
Gy L/B
B
B L Br/R Br/R C Br
B L D L P/W Lg/R
L/R
B Y Br B R/L (GRAY)
B1 x Br/W W
P C P/W Br G/Y
B/L P/B P/B
P C P/L Gy/B
(GRAY) R/W
(BROWN)
¢ F G R/W B/L
R/Y R/Y Q
Lg/Y R/Y Lg/Y
L/Y B/Y R/Y
8 - 24
q Br/WB1 W1
• W2 (BLACK)
£ Br/W R Br
R/W Br/W [ (BLACK)
Br/L R/Y P \
B L
L/Y L/Y A ] H R
L Y Dg Dg Y
G Ch `
L/Y B/Y r B/W
(BLACK)
B B A a
Br G Y Ch Dg B P
L L ¶ L
R/G L/Y A X
B (GRAY)
B Y b
B A W/Y A Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
L/G (BLACK)
i h c Br O/G
Y
S
d Gy
Y B B B Gy
A B
Br W/G Br/G Gy O
A e (BLACK)
Dg T
A (BLACK) (BLACK)
L Y A A f Gy/G
Ch Dg
A L B Gy/G
Ch Dg
f B
L/R G Y L/R
(BLACK)
l k U
Ch B Dg B g
COOLING SYSTEM
Br Br L/R Lg/R A
L/R
(BLACK) (BLACK) G B
B G O/G
n m B B O/G
o G B j Y B B
V
Sb
Y
Sb
A
1 Main switch
Z L/Y W/Y W L/Y
B
B/L B/L
5 Battery
ELEC
6 Main fuse
§ Radiator fan motor fuse
–
• Thermo switch
¶ Radiator fan motor
+
– +
COOLING SYSTEM ELEC
TROUBLESHOOTING
• The radiator fan motor fails to turn.

• The coolant temperature meter needle fails to move when the engine is warm.
Check the main and radiator fan No good

Replace.
motor fuses for continuity.
OK C0NTINUITY

tery.
OK C0NTINUITY
No good
OK C0NTINUITY
No good
Check the radiator fan motor. Replace.
OK C0NTINUITY
No good
Check the thermo switch. Replace.
OK C0NTINUITY
Check the entire cooling system’s No good

Repair or replace.
wiring.
NOTE:
1) bottom cowling
2) front cowling
3) rear cowling
Pocket tester
90890-03112
8 - 25
– +
COOLING SYSTEM ELEC
CHECKING THE THERMO SWITCH
• Remove the thermo switch from the radia-
tor.
thermo switch 1 as shown.
• Immerse the thermo switch in a container
filled with coolant 2.
NOTE:
Make sure that the thermo switch terminals
do not get wet.
• Place a thermometer 3 in the coolant.
• Slowly heat the coolant, then let it cool to
the specified temperature as indicted in
the table.
• Check the thermo switch for continuity a
the temperatures indicated in the table.
Coolant temperature
Test step Continuity
Thermo switch
0 ~ 100 ± 3˚C
1 (0 ~ 212 ± 37.4˚F)
NO
More than 105 ± 3˚C

2 (221 ± 37.4˚C)
YES
105 to 100 ˚C
3* (221 to 212 ˚F)
YES
4* Less than 100 ˚C (212 ˚F) NO

Test steps 1 & 2: Heating phase
Test steps 3* & 4*: Cooling phase
WARNING
WARNING
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
Thermo switch
23 Nm (2.3 m • kg, 17 ft • lb)
T.
R.
Three bond sealock® 10

Å The thermo switch circuit is open and the
radiator fan is off.
ı The thermo switch circuit is closed and the
radiator fan is on.
• Does the thermo switch operate properly
as described above?
Yes → OK.
No → Replace.
8 - 26
– +
ELEC
8 - 27
R R
R L/Y
A
R Br
W R
L/W L/W
2 W 3 5 6
W L/Y
CIRCUIT DIAGRAM
Br K
WW B R/B R/L
Br L/W
W 7
B B 9 B R/L R/B
R B L/W
B B
B
WW B B
L/Y L/B B L/Y W
B L/W B L
OFF
Gy
L/R Br/L L/Y L/Y
B
M
L C W/B Gy L/B R/L
å B/L I
R R/G Gy
ç B/L B/L
B B B B
Gy/B (GRAY)
B B B B
R/B R/L Br/G N
B R/G L/R R/G
B Br Y/G
L/G
Gy L/B
B
B L Br/R Br/R C Br
B L D L P/W Lg/R
L/R
B Y Br B R/L (GRAY)
B1 x Br/W W
P C P/W Br G/Y
B/L P/B P/B
P C P/L B/L Gy/B
(GRAY) R/W
(BROWN)
¢ F G R/W B/L
R/Y R/Y Q
Lg/Y R/Y Lg/Y
L/Y B/Y R/Y
8 - 28
q Br/WB1 W1
• W2 (BLACK)
£ Br/W R Br
R/W Br/W [ (BLACK)
Br/L R/Y P \
Br L P R/Y s t u v w B/L G/W
ELECTRONIC FUEL INJECTION SYSTEM
B L L B (DARK GRAY)
L/Y L/Y A ] H R
L Y Dg Dg Y
G Ch `
L/Y B/Y r B/W
(BLACK)
B B A a
Br G Y Ch Dg B P
L L ¶ L
R/G L/Y A X
B (GRAY)
B Y b
B A W/Y A Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
L/G (BLACK)
i h c Br O/G
Y
S
d Gy
Y B B B Gy
A B
Br W/G Br/G Gy O
A e (BLACK)
Dg T
A (BLACK) (BLACK)
L Y A A f Gy/G
Ch Dg
A L B Gy/G
Ch Dg
f B
L/R G Y L/R
(BLACK)
l k U
Ch B Dg B g
Br
ELECTRONIC FUEL INJECTION SYSTEM
L/R Br L/R Lg/R A

(BLACK) (BLACK) G B
B G O/G
n m B B O/G
o G B j Y B B
V
Sb
Y
Sb
A
Z L/Y W/Y W L/Y
B
B/L B/L
ELEC –
+
– +
ELECTRONIC FUEL INJECTION SYSTEM ELEC
1 Main switch
5 Battery
6 Main fuse
C Camshaft sensor
D Throttle position sensor
E Intake air pressure sensor
F Atmospheric pressure sensor
G Intake air temperature sensor
H Coolant temperature sensor
I Pickup coil
J ECU
K Cylinder #1-injector 1
L Cylinder #2-injector 1
M Cylinder #3-injector 1
N Cylinder #4-injector 1
O Cylinder #1-injector 2
P Cylinder #2-injector 2
Q Cylinder #3-injector 2
R Cylinder #4-injector 2
X Fall detection switch
Y Speed sensor
y Fuel pump
z Main relay
} Engine stop switch
å Electronic fuel injection system fuse
£ ECU fuse
TROUBLESHOOTING
The condition code is displayed by the tachometer.
Check the condition code list to

identify the faulty part. Refer to
“ELECTRICAL CONTROL SYS-
TEM”.
In diagnosis mode, select the Out of specifi-

appropriate diagnosis code to cation Check the No good
Replace.
check the operation of the faulty wiring.
part.
NOTE:
1) bottom cowling
2) front cowling
Co, diagnosis switch box

90890-03171
90890-03149
8 - 29
– +
ELECTRICAL CONTROL SYSTEM ELEC
ELECTRICAL CONTROL SYSTEM
The YZF-R7 features an electrical control system with the following modes:
• user mode
• diagnosis mode
• CO emission adjustment mode
NOTE:
The vehicle is normally in user mode. Special tools are needed to switch to a diagnosis mode
or to the CO emission adjustment mode.
USER MODE
• If a circuit is defective, setting the main switch to “ON” (without starting the engine) will
cause the corresponding condition code to be displayed by the tachometer, the warning
light to light up, and the engine trouble symbol to blink. When the engine is started, the
condition code is no longer displayed and the engine speed appears.
• Normally, when the main switch is set to “ON”, the warning light comes on for 1.4 seconds
and then goes off. The warning light also comes on while the start switch is pushed.
• When the engine is not running, the warning light flashes once every 0.16 second if the start
switch is pushed under the following conditions.
• The fall detection switch switches off the main relay.
• Ignition is cut off by the sidestand switch.
• The injector operating voltage decreases to 3 V or less, or the main relay malfunctions.
• The pickup coil is defective.
• The fall detection switch is defective.
8 - 30
– +
Tachometer display sequence (engine not running)
1 10,000 r/min for 2.0 seconds
2 First condition code (13 = intake air pressure sensor)
3 Second condition code (42 = speed sensor)
4 1st digit of condition code for 1.0 second
5 10,000 r/min for 0.5 second
6 2nd digit of condition code for 1.0 second
Revolution
(×103r/min)
10
Repeat
0 Time
5 10 (seconds)
4 6 4 6
5 5
1 2 1 3 1
Main switch is turnd on
8 - 31
– +
Condition code list
Condition
Circuit Defect(s) System response
code
11 Camshaft sensor • No incoming sig- The ECU pairs the ignition of cyl-
nal inders #1 and #4 and cylinders #2
and #3. The motorcycle can be
ridden.
12* Pickup coil • No incoming sig- The motorcycle cannot be ridden.
nal
13 Intake air pressure • Disconnected The ECU stays set to an intake air
sensor • Short-circuit pressure of 760 mm Hg (29.9 in Hg).
The motorcycle can be ridden.
14 Intake air pressure • Improper connec-
sensor hose and tion
negative pressure • Bending
hose
15 Throttle position • Disconnected The ECU stays set to a wide throt-
sensor • Short-circuit tle opening.
16 Throttle position • Locked
sensor
21 Coolant tempera- • Disconnected The ECU stays set to a coolant
ture sensor • Short-circuit temperature of 80˚C (176˚F).
22 Intake air tempera- • Disconnected The ECU stays set to an intake air
ture sensor • Short-circuit temperature of 40˚C (104˚F).
23 Atmospheric pres- • Disconnected The ECU stays set to an atmo-
sure sensor • Short-circuit spheric pressure of 760 mm Hg
(29.9 in Hg).
41 Fall detection • Disconnected The main relay stays switched off.
switch The motorcycle cannot be ridden.
42** Speed sensor • Incorrect signal The ECU stays set to 6th gear.
43*** Monitored voltage • Incorrect The ECU stays set to a monitored
voltage of 12 V.
44 ROM operation • CO emission The CO emission adjustment is
adjustment error set to 0.
NOTE:
* This condition code is also displayed in the following cases:
- when the starter switch is held down for more than 4 seconds, causing the warning
light to flash
- when the ignition circuit cut-off system stops the engine or prevents it from starting
** This condition code is also displayed when the engine is operated at 5,000 r/min for at
least 30 seconds with the rear wheel at standstill.
*** This condition code is also displayed when the engine stop switch is turned to “ ”
while riding with the transmission in gear.
8 - 32
– +
DIAGNOSIS MODE
There are two operation methods for this mode: one is performed using the CO, diagnosis
switch box, the other is performed using the test coupler adapter. With the CO, diagnosis
switch box method, the switches on the CO, diagnosis switch box are used. With the test cou-
pler adapter method, the start switch and the engine stop switch are used. The procedures for
selecting and using each method is explained below.
NOTE:
The engine cannot be started, the vehicle cannot be ridden, and no other mode can be
selected while either of the diagnosis mode operation methods is being performed.
CO, diagnosis switch box method

• Remove the bottom cowling and the front
cowling.
Refer to “COWLINGS” in chapter 3.
• Remove the protection cap 1 from the EFI
test coupler 2.
• Connect the CO, diagnosis switch box 3
to the EFI test coupler 2.
CO, diagnosis switch box

90890-03171
• Turn the main switch to “ON”.

• Turn the engine stop switch to “ ”.
• Within 4 seconds, press the following
switches on the CO, diagnosis switch box
in the order indicated to enter the diagno-
sis mode.
4 MODE switch = 1
5 UP switch = 2
6 DOWN switch = 3
1→2→1→3→1→2→1→3→1→2→
1→3
The warning light flashes when the unit has
entered the diagnosis mode.
NOTE:
Turn the main switch to “OFF” to cancel the
diagnosis mode.
8 - 33
– +
Operation after entering the diagnosis
mode
• Select a diagnosis code by holding down
the MODE switch while pressing either
the UP or DOWN switch. Refer to the diag-
nosis code list.
First, press the UP switch once to select
diagnosis code 01 or press the DOWN
switch once to select diagnosis code 31.
Afterwards, each press of the UP switch
or the DOWN switch respectively
increases or decreases the diagnosis code
number by one. If diagnosis code 00 is
selected, pressing the DOWN switch once
selects diagnosis code 31. If diagnosis
code 31 is selected, pressing the UP
switch once selects diagnosis code 00.
• Release the MODE switch to start the test
for the selected diagnosis code.
NOTE:
To select another diagnosis code, hold
down the MODE switch and press either the
UP switch or the DOWN switch.
Example:
First, select diagnosis code 29 in either of
the following ways.
• Hold down the MODE switch, press the
UP switch 29 times, and then release the
MODE switch.
DOWN switch 3 times, and then release
the MODE switch.
Next, select diagnosis code 10 in either of
the following ways.
UP switch 13 times, and then release the
MODE switch.
DOWN switch 19 times, and then release
the MODE switch.
8 - 34
– +
Test coupler adapter method
• Remove the bottom cowling and the front
cowling.
test coupler 2.
• Connect the test coupler adapter 3 to the
EFI test coupler 2.

90890-03149
• Disconnect the fuel pump coupler from

the wire harness.
• Turn the main switch to “ON”.
• Press the start switch ten times within 4
seconds to enter the diagnosis mode.
The warning light flashes when the unit
has entered the diagnosis mode.
NOTE:
diagnosis mode.
Operation after entering the diagnosis
mode
• Select a diagnosis code by pressing the
start switch. Refer to the diagnosis code
list.
First, press the start switch once to select
diagnosis code 01. Afterwards, each press
of the start switch increases the diagnosis
code number by one. If diagnosis code 31
is selected, pressing the start switch once
selects diagnosis code 00.
• Turn the engine stop switch to “ ” to
start the test for the selected diagnosis
code.
NOTE:
To select another diagnosis code, turn the
engine stop switch to “ ”, and then press
the start switch.
Example:
First, select diagnosis code 29 as follows.
• Press the start switch 29 times.
Next, select diagnosis code 10 as follows.
• Press the start switch 13 times.
8 - 35
– +
Diagnosis code list
Diagnosis Tachometer display

Inspected item System response
code (0 ~ 10,000 r/min)
00 — — —
01 Voltage The tachometer displays the volt- 0 r/min (0 V) –
age × 500. 10,000 r/min (20 V)
Example:
If the voltage is 12.5 V, the tachome-
ter displays 12.5 × 500 = 6,250 r/min.
02 Atmospheric The tachometer displays the atmo-
pressure spheric pressure sensor signal.
Example:
If the atmospheric pressure is 760
mm Hg (29.9 in Hg), the tachometer
displays 8,000 r/min.
03 Intake air pres- The tachometer displays the differ- 0 r/min (0 mm Hg)
sure ence between the minimum intake – 1,000 r/min
air pressure sensor signal and the (100 mm Hg)
atmospheric pressure sensor signal
after the main switch is turned to
“ON” in the diagnosis mode.
04 Throttle position The tachometer displays the throttle 1,300 r/min (0.68 V) –
sensor position sensor signal. 5,900 r/min (2.93 V)
05 Throttle position The tachometer displays the mini- 5,500 r/min (0.68 V) –
sensor mum throttle position sensor signal. 10,000 r/min (1.25 V)
06 Intake air temper- The tachometer displays the intake 4,800 r/min (20˚C) –
ature air temperature signal. 5,700 r/min (30˚C)
07 Coolant tempera- The tachometer displays the coolant 4,900 r/min (20˚C) –
ture temperature sensor signal. 9,200 r/min (100˚C)
08 Speed sensor The tachometer displays the speed 0–
sensor signal when the rear wheel is
rotated by hand.
09 Fall detection The tachometer displays whether 0 r/min (on), 8,000 r/
switch the fall detection switch is on or min (off) or 10,000 r/
whether it is off or disconnected. min (disconnected)
10 Sidestand switch The tachometer displays whether 0 r/min (on) or
the sidestand switch is on or off. 10,000 r/min (off)
The tachometer displays 0 r/min
when the sidestand is down (switch
on) and 10,000 r/min when the side-
stand is up (switch off).
11 — — —
8 - 36
– +
code (0 ~ 10,000 r/min)
12 Main relay CO, diagnosis switch box method
Within one second after the
MODE switch is released, the
main relay is switched on once
every second for the next five
seconds. During this time, the
warning light lights up as long as
the relay is switched on.
engine stop switch is turned to
“ ”, the main relay is switched
off, then on again. The warning
light lights up while the relay is
switched off.
13 Ignition coil for CO, diagnosis switch box method
cylinder #1 Within one second after the
MODE switch is released, the
ignition coil for the selected cylin-
der is operated once every sec-
14 Ignition coil for ond for the next five seconds.
cylinder #2 During this time, the warning
light lights up for 0.5 second
once every second.
15 Ignition coil for Test coupler adapter method
cylinder #3 Within one second after the
“ ”, the ignition coil for the
selected cylinder is operated
16 Ignition coil for once every second for the next
cylinder #4 five seconds. During this time,
the warning light lights up for 0.5
second once every second.
8 - 37
– +
code (0 ~ 10,000 r/min)
17 Injector 1 for cyl- CO, diagnosis switch box method
inder #1 Before selecting a code, discon-
nect the fuel pump coupler from
18 Injector 1 for cyl-
the wire harness.
inder #2
19 Injector 1 for cyl- MODE switch is released, the
inder #3 main relay is turned on, and the
20 Injector 1 for cyl- selected injector is operated once
inder #4 every second for the next five
seconds. During this time, the
21 Injector 2 for cyl- warning light lights up for 0.5
inder #1 second once every second.
22 Injector 2 for cyl- Test coupler adapter method
inder #2 Within one second after the
23 Injector 2 for cyl- “ ”, the selected injector is
inder #3 operated for once every second
24 Injector 2 for cyl- for the next five seconds. During
inder #4 this time, the warning light lights
up for 0.5 second once every sec-
ond.
25 ~ 28 — — —
29 Condition code The condition code of any fixed mal- Condition codes 11
record of malfunction is recorded in the ROM and – 44
functions displayed by the tachometer. Refer
to the condition code list in “USER
MODE” for details on the condition
codes.
30 ROM (Clearing Selecting this diagnosis code clears 0 r/min (no error) or
the condition the condition code record of mal- 10,000 r/min (errors)
code record) functions stored in the ROM. When the error
If an error has occurred in a sensor record is cleared, 0
signal, it was recorded in the ROM r/min is displayed.
and the tachometer displays 10,000
r/min. If no error has occurred, the
tachometer displays 0 r/min.
CO, diagnosis switch box method

Press the UP switch eight times
within four seconds to clear the con-
dition code record from the ROM.
Remove the rear cowling.
Disconnect the relay unit coupler
from the relay unit.
Press the start switch ten times
within four seconds to clear the con-
dition code record from the ROM.
31 ROM program The version number of the ROM pro-
version gram is displayed in the tachometer.
8 - 38
– +
CO EMISSION ADJUSTMENT MODE
With the CO emission adjustment mode,
the amount of fuel injected by the injector
can be adjusted.
NOTE:
Prior to adjusting the CO emission, the
throttle bodies must be properly synchro-
nized.
• Remove the bottom cowling and front
cowling.
• Remove the CO check bolts from the
exhaust pipe assembly.
2 • Install the exhaust attachment 1 and CO
tester 2 to the exhaust pipe assembly.
Exhaust attachment
90890-03134
• Attach the engine tachometer to the igni-

tion coil for cylinder #1.
TLE BODIES” in chapter 3.
Engine tachometer
90890-06760

test coupler 4.
• Connect the CO, diagnosis switch box 5
to the EFI test coupler 4.
CO, diagnosis switch box

90890-03171
• Start the engine and let it warm up for

several minutes.
Engine idling speed

1,000 ~ 1,200 r/min
8 - 39
– +
• Within 4 seconds, press the following
switches on the CO, diagnosis switch box
in the order indicated to enter the CO
emission adjustment mode.
6 MODE switch = 1
7 UP switch = 2
8 DOWN switch = 3
1→2→3→1→2→3→1→2→3→1→
2→3
The warning light flashes for 1.4 seconds
when the unit has entered the CO emission
adjustment mode. During this time, the
tachometer displays the engine idling
speed.
NOTE:
CO emission adjustment mode.
Tachometer display Selected cylinder

1,000 r/min Cylinder #1
• According to the following table, select
the cylinder to be adjusted by holding
down the MODE switch while pressing
either the UP switch or the DOWN switch.
• Release the MODE switch to start the CO
emission adjustment for the selected cyl-
inder. The warning light flashes once
every 0.5 second and the tachometer dis-
plays the engine speed.
• While watching the CO tester, press the
UP switch or DOWN switch to adjust the
CO emission.
Increase CO emis-
Press the UP switch
sion
Press the DOWN Decrease CO emis-
switch sion
NOTE:
• If the UP switch is pressed when the CO
emission has reached its maximum or if
the DOWN switch is pressed when the CO
emission has reached its minimum, the
warning light flashes once every 0.16 sec-
ond.
8 - 40
– +
• Adjust all four cylinders to specification.
Standard CO concentration
3.5 %
• To select a different cylinder, hold down

the MODE switch while pressing either
the UP switch or the DOWN switch.
8 - 41
YZF-R7 WIRING DIAGRAM
1 Main switch £ ECU fuse
2 Rectifier/regulator § Radiator fan motor fuse
3 Generator • Thermo switch
4 Backup fuse (odometer) ¶ Radiator fan motor
5 Battery
6 Main fuse
7 Starter relay
8 Starter motor COLOR CODE
9 Diode
0 Relay unit
A Diode B ............black
B Sidestand switch Br...........brown
C Camshaft sensor Ch ..........chocolate
D Throttle position sensor Dg..........dark green
E Intake air pressure sensor
F Atmospheric pressure sensor
G............green
G Intake air temperature sensor Gy..........gray
H Coolant temperature sensor L ............blue
I Pickup coil Lg ..........light green
J ECU O............orange
K Cylinder #1 - injector 1
L Cylinder #2 - injector 1
P ............pink
M Cylinder #3 - injector 1 R ............red
N Cylinder #4 - injector 1 Sb ..........sky blue
O Cylinder #1 - injector 2 W ...........white
P Cylinder #2 - injector 2 Y ............yellow
Q Cylinder #3 - injector 2
R Cylinder #4 - injector 2
B/L .........black/blue
S Cylinder #1 - ignition coil B/R.........black/red
T Cylinder #2 - ignition coil B/W .......black/white
U Cylinder #3 - ignition coil B/Y.........black/yellow
V Cylinder #4 - ignition coil Br/G .......brown/green
W CDI unit
X Fall detection switch
Br/L........brown/blue
Y Speed sensor Br/R .......brown/red
Z Neutral switch Br/W ......brown/white
[ Meter assembly G/B ........green/black
\ Fuel level indicator light G/R ........green/red
] Warning light (oil level indicator)
^ Neutral indicator light
G/W .......green/white
a Tachometer G/Y ........green/yellow
b Combination meter Gy/B ......gray/black
c Warning light (coolant temperature indicator) Gy/G ......gray/green
d High beam indicator light Gy/R ......gray/red
e Turn signal indicator light L/B .........blue/black
f Meter light L/G.........blue/green
g Warning light (engine trouble indicator) L/R .........blue/red
h Oil level switch
L/W ........blue/white
i Horn
j Headlight L/Y .........blue/yellow
k Rear turn signal light (right) Lg/R .......light green/red
l Rear turn signal light (left) Lg/Y .......light green/yellow
m Front turn signal light (right) O/B ........orange/black
n Front turn signal light (left) O/G ........orange/green
o Tail/brake light P/B .........pink/black
p Rear brake light switch P/L .........pink/blue
q Left handlebar switch P/W........pink/white
r Clutch switch R/B.........red/black
s Lights switch
t Pass switch
R/G ........red/green
u Dimmer switch R/L .........red/blue
v Turn signal switch R/W .......red/white
w Horn switch R/Y.........red/yellow
x Turn signal relay W/B .......white/black
y Fuel pump W/G .......white/green
z Main relay W/L ........white/blue
{ Right handlebar switch W/Y .......white/yellow
| Front brake light switch
} Engine stop switch Y/B.........yellow/black
~ Start switch Y/G ........yellow/green
å Electronic fuel injection system fuse Y/L .........yellow/blue
ç CYCLELOCK Y/R.........yellow/rod
† Signaling system fuse
¢ Headlight fuse
YZF-R7 WIRING DIAGRAM

@ Dg R/G L G/Y Y/R Br/R P/W W Br Y R/L R/L L L R R
Y W/Y Br G/W G/Y L R/G Dg G/W Br W/Y Y B/L B/L B B
R R
R L/Y
A
R Br
W R L/W
2 W 3 5 6 L/W
L/Y
W
Br K
WW B R/B R/L
L/W
W 7 Br
B B 9 B L/W R/L R/B

R B
B B
B
WW B B
L/Y L/B B L/Y W
P L L/R L/R L B B 8 L/W B L
L/W Gy/B W/B B1 L/W B/W W/Y B2 B3 O/B L/B G/B R/B G/R Y/R G/B R/L
OFF
Gy
L/R Br/L L/Y L/Y M
L B
å C W/B Gy L/B R/L
R
B/L
Gy
I
R/G
ç B B B B
B/L B/L
B B
Gy/B (GRAY)
B B
R/B R/L Br/G N
{ R/W B
R/G L/R R/G
R/L G/W L/R W/G R/L
B B Br Y/G
B R/B R/B R/L y O/B
B L/G
B B R/B R/W B (BLACK) (BLACK) B/L Gy L/B (GRAY)
B
B L Br/R Br/R C Br
B L D L P/W Lg/R
L/R
B B1 Y Br B R/L
x P C P/W
W Br G/Y (GRAY)
Br/W
B B Br (BLACK) E G/W R R P
B/W Y/L Y/L Y/L R G R D R/L
B/L P/B P/B
P C P/L Gy/B
(BROWN)
(GRAY) G R/W
¢ F R/Y R/Y R/W B/L Q
Lg/Y R/Y Lg/Y
• q L/Y B/Y R/Y
Br/WB1 W1
W2 (BLACK)
£ R Br
Br/L R/W Br/W Br/W
\ [ (BLACK)
R/Y P
Br L P R/Y
L B
s t u v w B/L G/W (DARK GRAY)
B L
L/Y L/Y A ] H R
L Y Dg Dg Y
Ch G B/Y B/Y Br
G Ch ` G/WB/L
R Gy
L/Y B/Y B/Y L/Y r (BLACK) (BLACK) L/R A
B/W
(BLACK)
B B
¶ Br G Y Ch Dg B P
A a
L L L
R/G L/Y A X
B (GRAY)
B B Y
A
b W/Y A Br/G O
B/L W/G Gy B O
(BROWN) (BROWN)
G/W G/Y A Y/G
L/G
W Gy/G B
(BLACK)
i h c Br O/G S
Y
d Gy
Y B B B Gy
A Br W/G Br/G B
Gy O
A e B L/G Y/G O/G Gy/G (BLACK)
Ch
Dg T
A (BLACK) (BLACK)
L Y
Ch Dg A A f Gy/G
Ch Dg A L B Gy/G
f B
L/R G Y L/R
(BLACK)
l k U
Ch B Dg B
Br L/R
g
L/R Br Lg/R A
(BLACK) (BLACK) B G
G B
O/G
n m B B O/G
o G B j Y B B
V
Sb
Y
Sb
A
B
Z L/Y W/Y W L/Y
B/L B/L
YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN
PRINTED ON RECYCLED PAPER 98 · 12 - 0.5 × 1 CR
2500 SHINGAI IWATA SHIZUOKA JAPAN

Yzf R-7 1998

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OWNER’S SERVICE MANUAL

TO THE NEW OWNER

The Safety Alert Symbol means ATTEN-

HOW TO READ DESCRIPTIONS

CHK 1 General information

ADJ ENG 2 Specifications

Symbols G to L in the exploded diagrams

GIVE SAFETY THE RIGHT OF WAY ........ 1-1

GENERAL SPECIFICATIONS .................... 2-1

INTRODUCTION ....................................... 3-1

ENGINE ..................................................... 4-1

RADIATOR AND THERMOSTAT .............. 5-1

ELECTRONIC FUEL INJECTION ............... 6-1

FRONT WHEEL AND BRAKE DISCS ........ 7-1

ELECTRICAL COMPONENTS ................... 8-1

Enjoy your ride!

1. Front fork compression damping force adjusting screw

EAU00029 EAU00040 1. Push

(Parking) Turn indicator light “ ”

this position. Fuel indicator light “ ”

● The light will come on and symbol

level is low. CAUTION:

Symbol is on and “LO” is

Symbol is on and temper-

Symbol and message Stop the engine and allow it

Symbol and message

Warning light circuit check

Turn the main switch to “ON”.

Symbol “ ”, No symbol is on.

Have a Yamaha OK. Go ahead If symbol “ ” If symbol “ ” is on, check the

Have a Yamaha dealer

Fuel indicator light circuit check

Turn the main switch to “ON”.

Indicator comes on. Indicator does not come

OK. Go ahead with Fuel level is OK. Fuel level is low.

Odometer and trip meter modes Resetting a meter

2. When the hour digits start flash-

odometer mode, push the “RESET” CAUTION:

Diagnosis device If this occurs take your motorcycle to a

1. Lever position adjusting dial

1. Shift pedal 1. Lever position adjusting dial 1. Rear brake pedal

Push the tank cap into position with the WARNING

CAUTION: 1 Sidestand/clutch switch

EAU00191 TURN THE MAIN SWITCH TO “ON”

with a research octane Starter (choke) “ ”

ENGINE WILL STALL.

SIDESTAND SWITCH IS OK.

WARNING Starting the engine

TURN THE MAIN SWITCH TO “ON” AND THE

IF TRANSMISSION IS IN NEUTRAL AND IF TRANSMISSION IS IN GEAR AND

RETRACT SIDESTAND AND PUT

MOTORCYCLE CAN BE RIDDEN. MOTORCYCLE CAN BE RIDDEN.

3. Turn on the starter (choke) and

Starting a warm engine CAUTION:

EAU01128 EAU01329 EAU00460

Engine break-in 0 ~ 1,000 km Parking

Tool kit WARNING

Care Before cleaning Cleaning

1. Clean your motorcycle with cold After cleaning CAUTION: