NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and an d procedures inherent in motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render if unfit to use and/ or unsafe. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
PARTICULARY IMPORTANT INFORMA INFORM ATION This material is distinguished by the following notation.
EB002000
HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1 : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2 : This title indicates the section of the chapter and only appears on the first page of each section. It is located in the upper left corner of the page. 3rd title 3 : This title title indicates a sub-section that is followed by step-by-step step-by-step procedures accompanied accompanied by corresponding illustrations. EXPLODED DIAGRAMS To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each removal and disassembly section. 1. An easy-toeasy-to-see see exploded exploded diagra diagram m 4 is provided provided for removal removal and disassem disassembly bly jobs. jobs. 2. Number Numbers s 5 are given given in the the order of the jobs jobs in the the exploded exploded diagram diagram.. A number number that is enclosed enclosed by by a circle indicates a disassembly step. 3. An explanation explanation of of jobs and notes notes is present presented ed in an easy-toeasy-to-read read way way by the use of of symbol symbol marks marks 6 . The meanings of the symbol marks are given on the next page. 4. A job instruct instruction ion chart chart 7 accom accompanies panies the exploded exploded diagram, diagram, provid providing ing the order order of jobs, jobs, names names of parts, notes in jobs, etc. 5. For jobs requiri requiring ng more informa information, tion, the step-by step-by-step -step format format suppleme supplements nts 8 are given in in addition addition to the exploded diagram and the job instruction chart.
EB003000
1
GEN INFO 3
2
ILLUSTRATED SYMBOLS
SPEC
Illustrat Illust rated ed sym symbol bols s 1 to 9 are pri printed nted on top right of each page and indicate the subject of each chapter.
4
INSP ADJ 5
COOL 7
CHAS 9
TRBL SHTG
ENG 6
CARB
1 2 3 4 5 6 7 8 9
General information Specifications Periodic inspections and adjustments Engine Cooling system Carburetion Chassis Electrical Troubleshooting
8
ELEC 10
Illustrated symbols 10 to 17 are used to identify the specifications appearing in the text. 10 Can be serviced with engine mounted 11 Filling fluid 12 Lubricant
INDEX GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT ENGINE OVERHAUL
GEN INFO
1
SPEC
2
INSP ADJ
3
ENG
4
GEN INFO CHAPTER 1. GENERAL INFORMA INFO RMATION TION MOTORCYCLE IDENTIFICAT IDENTIFICATION ION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
FRAME SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
PREPARATION FOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALL REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GASKETS, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . LOCK WASHERS / PLATES AND COTTER PINS . . . . . . . . . . . . . . . . . . BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2 1-2 1-2 1-3 1-3 1-3
CHECKING OF CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 HOW TO USE THE C ONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
GEN INFO
MOTORCYCLE IDENTIFICATION
GEN INFO
EB100000
GENERAL INFORMATION MOTORCYCLE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle vehicle identi identificat fication ion number number 1 is stamped stamped into the right side of the steering head.
NOTE: The vehicle identification number is used to identify the motorcycle and may be used to register the motorcycle with a licensing authority.
EB100030
ENGINE SERIAL NUMBER The engine engine serial serial number number 1 is stamped stamped into the the
IMPORTANT INFORMATION
GEN INFO
IMPORTANT INFORMA INFORM ATION PREPARATION FOR REMOVAL PREPARATION RE MOVAL 1. Remov Remove e all dirt, dirt, mud dust, dust, and foreign foreign material material before removal and disassembly disassembly..
2. Use proper proper tools tools and cleani cleaning ng equipment. equipment. Refer to “SPECIAL TOOLS”. 3. When disassem disassembling bling the the motorcycle motorcycle keep keep mated parts together. This includes gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4. Duri During ng the motorcycle motorcycle disassemb disassembly ly,, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Kee ay f fir
IMPORTANT INFORMATION
GEN INFO
LOCK WASHERS/PLATES AND COTTER PINS 1. All loc lock k wash washers/ ers/ pla plates tes 1 and cot cotter ter pin pins s must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.
BEARINGS AND OIL SEALS 1. Instal Installl the bearing(s) bearing(s) and and oil seal(s) seal(s) with with their manufacturer’s marks or numbers facing outward. (In other word, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. 1 Oil seal
CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing
CHECKING OF CONNECTIONS
GEN INFO
CHECKING OF CONNECTIONS Dealing with stains, rust, moisture, etc. on the connector. 1. Di Disc scon onnec nect: t: Connector 2. Dry each each terminal terminal with with an air blower blower.. S
3. Connect Connect and disconnect disconnect the connector connector two or three times. 4. Pull the the lead to check check that itit will not not come off. off. 5. If the termi terminal nal comes comes off, bend up the pin pin 1 and reinsert the terminal into the connector.
6. Conn Connec ect: t: Connector S
